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A new look at moving water in the digital age
34
Product focus
WORLD PUMPS
January 2018
Ambitious pumping concept
A new look at moving water in the digital age T
here are many technologies available to move water. However, only a few get to deliver high efficiency level when all factors of an application are analyzed. A new amphibious pumping concept from HIGRA looks to meet the new global demands, saving energy, making the operation easier and integrating to the new industrial revolution of digital distance monitoring and information.
The new world’s demands on natural resources preservation, competitive installation and operational costs, as well as remote control and monitoring, are leading manufacturers of equipment to direct the research and development of new products towards innovation fitting such requirements. When it comes to the reduced water reservoirs and compromised springs, the water harvesting is many times presented as a villain, even though it has been taking a more and more important role for irrigation, industrial and water supply purposes.
Figure 1. The amphibious pump concept.
www.worldpumps.com
Besides using high volumes of water, pumping stations are also target for critics due to need of being located near to riverbanks, creeks, barrages or dams, requiring landfill, deforestation, construction of canals and even deviations in the course of the rivers, in order to meet the technical requirements to install the existing conventional pumps.
The amphibious concept
The market has been constantly looking for pumping solutions that might offer low installation cost, low energy consumption and that bring flexibility to adapt the pumping stations to the installation site.
Using the centrifugal pumping concept with closed or semi-open impellers with radial, mixed or axial flow, the amphibious pump has been developed with the ability to operate inside and out of water, which means it works totally or partially submersed or
Ever since 2001 the amphibious pumping concept has been applied to the water, industry, irrigation and mining markets, offering high hydro energetic efficiency associated to strength and versatility to install and operate.
totally out of water, with negative or positive suction pressures. The amphibious pump is a monoblock equipment where motor and pump are a single body with no need for couplings between the parts. For being an equipment with inflow and outflow axially aligned and equipped with connection flanges, the amphibious concept multiplies flow rates or pressures when installed in parallel or series modulation, allowing one pump to be installed directly after another, when necessary. The amphibious characteristic is a result of the pump design, where the water flux that comes in through the suction frame goes throughout the centrifugal pumping system that supplies energy to the fluid and is conducted towards the outlet frame through an annular chamber existing between the pump external frame and the electric motor, which is inside the pumping flux (Figure 1). The fluid path throughout the motor assures great thermal exchange and cooling levels higher than the ones offered by forced ventilation, usually used in conventional motors and that makes the motor work at its
Product focus WORLD PUMPS
January 2018
high performance, eliminating losses with energy conversion or cavitation issues. This way, the amphibious pump global performance is one of the highest in the market, since combines high hydraulic efficiency, generating significant energy savings when compared to other technologies.
Versatility Figure 2. Simulation of radial pump showing the discharge flux lines and their speeds.
maximum efficiency constantly, regardless of the external ambient temperature conditions. For this reason, it is possible to safely explore higher powers in small size motors. Besides the external cooling, the motor is internally filled with water. The winding is built with spirals of coated wires that assures insulation and allows rewinding process. Taking advantage from the benefits of the internal cooling with water, the complete mechanical system is lubricated with this same fluid, using the concept of hydrodynamic sliding bearings to absorb all radial and axial loads generated by the turbo machine. For not using conventional bearings, the set becomes more robust and durable, with no need for additional lubrication. To work with high pressures and/ or deep submergences, the amphibious pump has a filter to equalize the pressure, which is
mounted directly to the motor set. Its function is balancing pressures inside and external to the motor, resulting equal pressures and avoiding efforts in the sealing components.
Energy saving Only high efficiency turbo machines are able to save energy. There are basically two factors to be allied for that: electric and hydraulic efficiencies. As previously mentioned, the amphibious pumps operate with high efficiency electric motors independently of the external scenario, since they work under forced cooling regimen all the time. Besides that, the whole pumping system is designed using state-ofthe-art software of computational simulation through finite volumes for turbo machines (CFD – Computational Fluid Dynamics). The association of high technology and a qualified engineering team results impellers and diffusers with
Figure 3. Floating system of raw water harvesting in a water concessionaire.
One of the main advantages of the amphibious concept is the versatility it offers to engineers and planners when designing pumping systems. For being mono-block and having hydrodynamic bearings the amphibious pump offers a wide range of installations and uses, fitting the application place, not the other way around, and reducing the costs with execution and infrastructure drastically. The amphibious pumps might be installed in horizontal, vertical or inclined positions, totally or partially submersed or out of water, in different ways: • totally submersed over rails • partially submersed held by the discharge flange • with positive pressure outdoor • with negative suction • as booster connected to the pipeline • modulated in series with a submersed unit and another one out of water • under or over floating systems
Advantages The possibility to work inside and
out of water brings an important advantage regarding NPSH (Net Pressure Suction Head) and the disrespect to its limits, which is cavitation. The damages to an installation operating under conditions that cause cavitation are many and include increase of energy consumption and permanent damages to impellers, diffusers and bearings. This way, preventing cavitation reduces significantly costs with the system operation and maintenance. The amphibious pump might be installed submersed under the spring’s normal level condition, foreseeing reduction of water level in the drying period – the situation when the pump works out of water. It might also be installed suctioning considering the required NPSH limits for each impeller. In this same situation, a conventional pump would need to be periodically displaced to fit the water level variation. The costs involved in the pump station construction might be elevated, mainly if the installation is located near to flooded regions or riverbanks, where the land is not firm and staking, landfill and deforestation are necessary. Amphibious pumps do not demand shelters. Simple wooden supports, rails or even the piping are enough to support the pump, reducing the civil work cost and environmental impact. The whole infrastructure is reduced, making the starting process shorter. For being mono-block, the amphibious pump makes installation and operation even easier,
Figure 4. Harvesting for irrigation over rails.
www.worldpumps.com
35
36
Product focus
WORLD PUMPS
January 2018
Figure 5. Irrigation system pressurization installed outdoor and directly on the ground.
Figure 6. Dewatering in open pit mine with booster system and pumps connected directly one after another.
Figure 7. Automated potable water distribution remotely controlled.
Figure 8. Raw water harvesting with minimum environmental impact.
with no need to align motor and pump, unlike conventional turbo machines. Shaft couplings or protectors are not used. The absence of exposed rotating parts eliminates the risk of mechanical accidents near the pump.
inside the pump to the ambient, reaching figures not over 60 dB, which is extremely low when compared to conventional pumps and allowing operation in urban centers with no need to build external acoustic insulations.
Besides, the electric motors and the whole dynamic system are designed to operate in a wide speed range through the use of variable speed drivers, giving the user the possibility to adjust and change the operational condition and save energy during the operation. Inner sensors do the distance monitoring of the equipment and components behavior, generating information to the planning and
www.worldpumps.com
maintenance personnel and, consequently, extending the equipment availability in operation. Users embracing digital operational plants are able to integrate this sensing process to their existing one, in order to control the equipment remotely.
Environmental benefits The easy and simple installation and operation presented by the amphibious pumps reduce the environmental impact to a minimum. Besides that, the water layer formed between the motor and the pump frame during the pumping process works as an acoustic insulation, with a very low transmission of sound from
Another extremely important fact is the low energy consumption, considering it is a high efficiency turbo machine. The electric energy, mostly generated from nonrenewable sources or sources that generate high environmental impact, has its consumption optimized.
Conclusion The competitiveness existing in every market demands the manufacturers to use high performance
machines, processes and professionals. There are many technologies available in the market to the ones who need to move water, no matter if it is a water supply station, mining dewatering, steel or paper industry or irrigation system. However, only a few technologies get to deliver high efficiency level when all factors of an application are analyzed. This new amphibious pumping concept meets the new global demands, saving energy, making the operation easier and integrating to the new industrial revolution of digital distance monitoring and information.
•
www.higrapumps.com
Product focus
WORLD PUMPS
January 2018
Ambitious pumping concept
A new look at moving water in the digital age T
here are many technologies available to move water. However, only a few get to deliver high efficiency level when all factors of an application are analyzed. A new amphibious pumping concept from HIGRA looks to meet the new global demands, saving energy, making the operation easier and integrating to the new industrial revolution of digital distance monitoring and information.
The new world’s demands on natural resources preservation, competitive installation and operational costs, as well as remote control and monitoring, are leading manufacturers of equipment to direct the research and development of new products towards innovation fitting such requirements. When it comes to the reduced water reservoirs and compromised springs, the water harvesting is many times presented as a villain, even though it has been taking a more and more important role for irrigation, industrial and water supply purposes.
Figure 1. The amphibious pump concept.
www.worldpumps.com
Besides using high volumes of water, pumping stations are also target for critics due to need of being located near to riverbanks, creeks, barrages or dams, requiring landfill, deforestation, construction of canals and even deviations in the course of the rivers, in order to meet the technical requirements to install the existing conventional pumps.
The amphibious concept
The market has been constantly looking for pumping solutions that might offer low installation cost, low energy consumption and that bring flexibility to adapt the pumping stations to the installation site.
Using the centrifugal pumping concept with closed or semi-open impellers with radial, mixed or axial flow, the amphibious pump has been developed with the ability to operate inside and out of water, which means it works totally or partially submersed or
Ever since 2001 the amphibious pumping concept has been applied to the water, industry, irrigation and mining markets, offering high hydro energetic efficiency associated to strength and versatility to install and operate.
totally out of water, with negative or positive suction pressures. The amphibious pump is a monoblock equipment where motor and pump are a single body with no need for couplings between the parts. For being an equipment with inflow and outflow axially aligned and equipped with connection flanges, the amphibious concept multiplies flow rates or pressures when installed in parallel or series modulation, allowing one pump to be installed directly after another, when necessary. The amphibious characteristic is a result of the pump design, where the water flux that comes in through the suction frame goes throughout the centrifugal pumping system that supplies energy to the fluid and is conducted towards the outlet frame through an annular chamber existing between the pump external frame and the electric motor, which is inside the pumping flux (Figure 1). The fluid path throughout the motor assures great thermal exchange and cooling levels higher than the ones offered by forced ventilation, usually used in conventional motors and that makes the motor work at its
Product focus WORLD PUMPS
January 2018
high performance, eliminating losses with energy conversion or cavitation issues. This way, the amphibious pump global performance is one of the highest in the market, since combines high hydraulic efficiency, generating significant energy savings when compared to other technologies.
Versatility Figure 2. Simulation of radial pump showing the discharge flux lines and their speeds.
maximum efficiency constantly, regardless of the external ambient temperature conditions. For this reason, it is possible to safely explore higher powers in small size motors. Besides the external cooling, the motor is internally filled with water. The winding is built with spirals of coated wires that assures insulation and allows rewinding process. Taking advantage from the benefits of the internal cooling with water, the complete mechanical system is lubricated with this same fluid, using the concept of hydrodynamic sliding bearings to absorb all radial and axial loads generated by the turbo machine. For not using conventional bearings, the set becomes more robust and durable, with no need for additional lubrication. To work with high pressures and/ or deep submergences, the amphibious pump has a filter to equalize the pressure, which is
mounted directly to the motor set. Its function is balancing pressures inside and external to the motor, resulting equal pressures and avoiding efforts in the sealing components.
Energy saving Only high efficiency turbo machines are able to save energy. There are basically two factors to be allied for that: electric and hydraulic efficiencies. As previously mentioned, the amphibious pumps operate with high efficiency electric motors independently of the external scenario, since they work under forced cooling regimen all the time. Besides that, the whole pumping system is designed using state-ofthe-art software of computational simulation through finite volumes for turbo machines (CFD – Computational Fluid Dynamics). The association of high technology and a qualified engineering team results impellers and diffusers with
Figure 3. Floating system of raw water harvesting in a water concessionaire.
One of the main advantages of the amphibious concept is the versatility it offers to engineers and planners when designing pumping systems. For being mono-block and having hydrodynamic bearings the amphibious pump offers a wide range of installations and uses, fitting the application place, not the other way around, and reducing the costs with execution and infrastructure drastically. The amphibious pumps might be installed in horizontal, vertical or inclined positions, totally or partially submersed or out of water, in different ways: • totally submersed over rails • partially submersed held by the discharge flange • with positive pressure outdoor • with negative suction • as booster connected to the pipeline • modulated in series with a submersed unit and another one out of water • under or over floating systems
Advantages The possibility to work inside and
out of water brings an important advantage regarding NPSH (Net Pressure Suction Head) and the disrespect to its limits, which is cavitation. The damages to an installation operating under conditions that cause cavitation are many and include increase of energy consumption and permanent damages to impellers, diffusers and bearings. This way, preventing cavitation reduces significantly costs with the system operation and maintenance. The amphibious pump might be installed submersed under the spring’s normal level condition, foreseeing reduction of water level in the drying period – the situation when the pump works out of water. It might also be installed suctioning considering the required NPSH limits for each impeller. In this same situation, a conventional pump would need to be periodically displaced to fit the water level variation. The costs involved in the pump station construction might be elevated, mainly if the installation is located near to flooded regions or riverbanks, where the land is not firm and staking, landfill and deforestation are necessary. Amphibious pumps do not demand shelters. Simple wooden supports, rails or even the piping are enough to support the pump, reducing the civil work cost and environmental impact. The whole infrastructure is reduced, making the starting process shorter. For being mono-block, the amphibious pump makes installation and operation even easier,
Figure 4. Harvesting for irrigation over rails.
www.worldpumps.com
35
36
Product focus
WORLD PUMPS
January 2018
Figure 5. Irrigation system pressurization installed outdoor and directly on the ground.
Figure 6. Dewatering in open pit mine with booster system and pumps connected directly one after another.
Figure 7. Automated potable water distribution remotely controlled.
Figure 8. Raw water harvesting with minimum environmental impact.
with no need to align motor and pump, unlike conventional turbo machines. Shaft couplings or protectors are not used. The absence of exposed rotating parts eliminates the risk of mechanical accidents near the pump.
inside the pump to the ambient, reaching figures not over 60 dB, which is extremely low when compared to conventional pumps and allowing operation in urban centers with no need to build external acoustic insulations.
Besides, the electric motors and the whole dynamic system are designed to operate in a wide speed range through the use of variable speed drivers, giving the user the possibility to adjust and change the operational condition and save energy during the operation. Inner sensors do the distance monitoring of the equipment and components behavior, generating information to the planning and
www.worldpumps.com
maintenance personnel and, consequently, extending the equipment availability in operation. Users embracing digital operational plants are able to integrate this sensing process to their existing one, in order to control the equipment remotely.
Environmental benefits The easy and simple installation and operation presented by the amphibious pumps reduce the environmental impact to a minimum. Besides that, the water layer formed between the motor and the pump frame during the pumping process works as an acoustic insulation, with a very low transmission of sound from
Another extremely important fact is the low energy consumption, considering it is a high efficiency turbo machine. The electric energy, mostly generated from nonrenewable sources or sources that generate high environmental impact, has its consumption optimized.
Conclusion The competitiveness existing in every market demands the manufacturers to use high performance
machines, processes and professionals. There are many technologies available in the market to the ones who need to move water, no matter if it is a water supply station, mining dewatering, steel or paper industry or irrigation system. However, only a few technologies get to deliver high efficiency level when all factors of an application are analyzed. This new amphibious pumping concept meets the new global demands, saving energy, making the operation easier and integrating to the new industrial revolution of digital distance monitoring and information.
•
www.higrapumps.com