| YEARBOOK 2015 | 21st VOLUME

Postvertriebsstück 30878

Entgelt bezahlt

ingenieur verlag nagelUhlandstraße 1D-72631 AichtalGERMANY

PUMPS AND SYSTEMSMADE IN EUROPE

Abel, Germany

Affetti, Italy

Bungartz, Germany

Dickow, Germany

Flotronic, United Kingdom

Flux, Germany

HNP Mikrosysteme, Germany

ITT Bornemann, Germany

Klaus Union, Germany

Knoll, Germany

KSB, Germany

KTR, Germany

Leistritz, Germany

Lewa, Germany

Motive, Italy

ProMinent, Germany

SAER, Italy

Schmalenberger, Germany

Seko, Italy

Schroeder, Germany

Sera, Germany

Uraca, Germany

Wilo, Germany

GlobalATEX zone I inside a twin screw pumpATEX zone I inside

a twin screw pumpITT Bornmann presents this

new feature at Achema – page 18

www.delta-p-online.com

www.pumps-directory.com

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PUMPTECHNOLOGY

Delta p – The international MAGAZINE ofGlobalCONTENTS

p Global 2015 – 21ST YEAR

Abel, GermanyElectromechanical diaphragm pump in PVC production plant . . . . . . . . . . . . . . 4

Affetti, ItalyThermoplastic and Fiberglass pumps for corrosive liquids . . . . . . . . . . . . . . . . . 6

Bungartz, GermanySpecial centrifugal pump with high intrinsic safety . . . . . . . . . . . . . . . . . . . . . . 8

Dickow, Germany/Tuthill, USASealless Magnetic Coupled Gear Pumps . . . . . . . . . . . . . . . . . . . . . . . 11

Flotronic, UKNew E Series’ achieves the EHEDG seal of approval . . . . . . . . . . . . . . . . . . . . 12

Flux, GermanyExplosion-proof drum emptying system for materials just capable of flowing . . . . 14

HNPM, GermanyPump for liquid coating materials . . . . . . 17

ITT Bornemann, GermanyATEX zone I inside a twin screw pump . . 18

Klaus Union, Germany“Plug & Pump“ – A New Generation of Double Volute Twin Screw Pumps . . . . 20

Knoll, GermanyIndividual solutions from the progressing cavity pump toolbox . . . . . . . . . . . . . . . . 26

KSB, GermanyNew canned motor pumps for chemical and process engineering applications . . . 28

KTR, GermanyPump coupling optimizing safety and service life . . . . . . . . . . . . . . . . . . . . . . . . 30

p Global 2015

Leistritz, GermanyNew screw pump for API applications . . 36

Lewa, GermanyFrom the rugged process diaphragm pump to the high-precision micro- metering pump . . . . . . . . . . . . . . . . . . . . . 38

Motive, Italy Neo WiFi Inverters . . . . . . . . . . . . . . . . . 40

ProMinent, GermanyNew standards in accuracy and reliability with the new solenoid driven metering pump . . . . . . . . . . . . . . . . . . . . . 41

SAER, Italy The importance of energy saving . . . . . . 44

Schmalenberger, GermanyStepping up the pressure with self-priming centrifugal pumps . . . . . . . . . 46

Seko, Italy More than 40 years in metering and dosing . . . . . . . . . . . . . . . . . . . . . . . . 48

Schroeder Valves, GermanyA valve for high pressures and all load conditions . . . . . . . . . . . . . . . . . . . . . 52

Sera, Germany From baking trays to dosing specialist . . . 53

Uraca, GermanyEfficient marathon runners . . . . . . . . . . . . 54

Wilo, Germany Cost-neutral modernisation secure water supply in Jordan . . . . . . . . . . . . . . . 55

3

p Global 20154

Electromechanical diaphragm pump in a PVC plant

ABELGERMANY

Electromechanical diaphragm pumps

are used for pumping polyvinyl

chloride dispersions. A total of nine

electromechanical diaphragm pumps

as well as two piston diaphragm

pumps are operating in the Europe’s

largest fully integrated polyvinyl

chloride (PVC) production plant is

located in the north of the German

Ruhr region.

The pumps transport flamm able

PVC dispersion with vinyl chloride

content of 5 to 10 % from chemi-

cal reactors into buffer containers.

Originally, the reactor pressure of

ca. 6 to 8 bar was used to transport

the PVC dispersions into the buffer

container. Due to the use of the elec-

tromechanical diaphragm pumps

(EM) whose original pumping pres-

sure is 0.5 bar, the time for emptying

the reactor has been clearly reduced.

This makes it possible to fill the

reactor faster.

Special constructions

The pumps are equipped with

an intelligent diaphragm pulsation

dampeners (iMPD). This special con-

struction has proven to be useful

where minimal residual pulsation

needs to be achieved when pumping

pressures fluctuate. The iMPD auto-

matically adjusts the charge to the

pumping pressure, so that dampening

occurs in a much wider pressure range

with consistently reliable results.

In a different area of the plant,

a piston diaphragm pump of the

CM series (l Fig. 2) has been in

continuous operation for loading a

dryer plant since 2011. This pump is

also made from stainless steel and is

ATEX compatible. The pump trans-

ports hot PVC dispersions of tem-

peratures up to 70 °C and with a

content of solid matter of 40 to 55 %

to a spray dryer. Operating pressures

between 8 and 20 bar are necessary

due to various quality requirements.

Therefore, the pump is equipped

with two conventional diaphragm

pulsation dampeners with different

pre-charge settings.

www.abel.de

Achema: Hall 8.0, H47

mFig. 1 Electromechanical diaphragm pumps in operation.

kFig. 2 Piston diaphragm pump of the CM series

Knows what’s happening... before it even happens.X-tremely clever: the new gamma/ X

METERING

MEASUREMENT & CONTROL

TREATMENT

DISINFECTION

IMPLEMENTATION

Pressure too high or air in the dispensing head? The new gamma/ X automatically detects potential issues – and fi xes them before they can actually turn into problems.

www.prominent.com/gammaX

X Solenoid-driven diaphragm metering pump for 2 to 45 l/h at back-pressure from 25 to 2 bar

X Intelligent control electronicsX Without failure-prone sensorsX Integrated timer for timer-controlled

meteringX Cavitation detectionX Automatic venting system

June 15 – 19 ACHEMA Hall 8.0 Booth J 94

p Global 20156

Thermoplastic and Fiberglass pumps for corrosive liquids

p Global 2015l6

AFFETTIITALY

Thermoplastic and Fiberglass pumps for corrosive liquids

Luca Pacioni

Pumping corrosive liquids pre-

sents many problems, not least in

respect to the material type and

sealing arrangement required.

Affetti Pumps manufactures a full

range of thermoplastic and fiber-

glass (FRP) pumps that are avail-

able in both horizontal and vertical

arrangements and comply with the

required ANSI or ISO standard.

Born in the mid Sixties as man-

ufacturing company of industrial

plants dedicated to containment

and conveying of corrosive liquids,

throughout the last thirty years Affet-

ti Pumps has gained a top speciali-

zation in the realization of pumps

in thermoplastic and FRP material

dedicated to the chemical, sea water,

pharmaceutical, alimentary, gal-

vanic, metallurgy, paper, tanning,

automotive, and water treatment

industries. The company,

based in Castellanza

(VA), preserves total control over

production ensuring for itself pro-

ductive processes upstream and

downstream; design, assembly, fin-

ish, setting up and final testing. In

these last 5 years the company has

obtained good results in terms of

turnover and increased capabilities

and the forecasting is for a signifi-

cant growing, sustained by serious

and important investments.

ANSI/ASME B73.1 pumps

In the last years the company

has presented the line of fiberglass

pumps (Vitrum line l Fig. 1) stand-

ardized ANSI/ASME B73.1 dedicated

to

l desalinization,

l electro-chlorination plants,

l chemical industries and

l aquariums.

The Vitrum line is now the first

product in terms of turnover and

Affetti is forecasting a concrete

growth in the near future for this

product.

The presence of impurities and

sand in sea water makes it neces-

sary to use a material featuring not

only chemical resistance but excel-

lent resistance to abra-

sion. The Series CFG

horizontal centrifugal

coupling pumps are de-

signed according to ANSI/

ASME B73.1, presenting new

features and innovations to be

more competitive and reliable: no-

screwing impeller, separated shaft

sleeve from the impeller, shaft and

base adjustment system are just few

examples. CFM close coupled hori-

zontal centrifugal pumps with ANSI/

ASME B73.1 suction and discharge

out-lets, presents strong and resist-

ant construction.

qFig. 1

p Global 2015 7

AFFETTIITALY

www.affetti.com

Achema: Hall 9.0, B26

of support and documentation and

not least the importance to supply

a product 100 % in accordance with

the client specification.

moplastic solid (PP-PVDF-

PEHD-PVC-PTFE), the seals

are molded in elastomer

(EDPM-FPM-FFKM).

Affetti’s portfolio

also includes magnet-

ic coupling cen-

trifugal pumps

MMB-N/MMB-

E (in self prim-

ing version MSP-

N/E), volumetric

self priming

pumps series VMA

and VGA, enbloc

centrifugal pumps CMO

and CGO with support

and coupling joint, vertical

centrifugal pumps of the series CMV,

CLV, CGV, CGV-N and the recent CGV-S

(cantilever).

The company is able to custom-

ize each product according to the

customers’ needs. The experience

made with the EPC companies in

the last years has permitted to the

company to understand the need

Pump casing are made in Solid

FRP with high thickness to ensure

optimal mechanical strength and

chemical resistance. Fiberglass

pumps can be proposed in alterna-

tive to thermoplastic ones also with

more competitive prices and fast

deliveries.

DIN EN 22858 ISO 2858 pumps

Not only FRP but also thermo-

plastic (PP, PVDF, PE-UHMW, PVC and

PTFE) are available materials. CGD ar-

moured pumps (l Fig. 2), normal-

ized to DIN EN 22858 ISO 2858, are

developd for

l high flow rates and

l heavy-duty tasks.

Proposed with flow rates from

20 to 1,000 m³/h, these pumps with

horizontal axis and mechanical seal

are suitable for installation in pro-

cess plants thanks to the presence of

components with large sections; the

internal parts are made from ther-

Many years of experience coupled with state-of-the-art technologies enable the

to set technological standards!

Many years of experience coupled withstate-of-the-art technologies enable the state-of-the-art

o set technological standardsds!!t

100% C O AT I N G M E A N S 0% C O R R O S I O N !

We have invested a big deal in the anti-corrosion pump:

2,000,000 EUR development costs, 5,500 days of development,

1,500 test facility measurements, 400 foundry models. All to achieve one aim: 100% corrosions protection in pool water.

Herborner Pumpen – number 1 concerning swimming pool pumps.

HERBORNER PUMPENTECHNIK GmbH & Co KG | Littau 3–5 | 35745 Herborn, GermanyTelephone: +49 (0) 27 72 / 933-0 | Fax: +49 (0) 27 72 / 933-100 | info@herborner-pumpen.de | www.herborner-pumpen.de

qFig. 2

p Global 20158

BUNGARTZGERMANY

Typical cases of damage when using centrifugal pumps include the

dry running of the seal and bearing unit. Other malfunctions through

operating error, cavitation, vibrations or difficult pumping media may

cause unplanned stoppages and production loss. In order to prevent such

malfunctions, diagnosis and early detection systems are used. Bungartz

has proven for years that no additional expenditure is required with their

special centrifugal pumps.

of centrifugal pumps are diverse. Of-

ten, the malfunctions are already set

in stone due to the pump selection.

Other than selection and alignment

errors, such damaging vibrations,

operating errors can also be identi-

fied as a cause. For example, these

may be insufficient ventilation,

wrong directional rotation of the

pump, spout drag or closed sealing

systems.

Avoidance of expensive securing and monitoring equipment

In practice, there are various

approaches for minimising the risk

of centrifugal pumps failing. These

include a redundant design and suf-

ficient stockpiling of spare parts. In

addition, companies invest in com-

prehensive operating manuals and

ongoing personnel training. Recent

times have seen an increase in meas-

uring and control technology with

(remote) monitoring, protecting and

controlling components. Measuring

points are installed, gas sensors or

dry-running protection signals are

used and additional components

such as filters, check valves or vortex

breakes are installed. However, this

does not take into consideration that

the additional protection, intended

for reducing the failure rate, can

itself easily contribute to malfunc-

tions and failures. Experts estimate

this to be the cause of up to 50 %

of the problems. At the same time,

an increased expenditure has to be

taken into consideration during the

planning process: Depending on the

size, up to 10,000 Euros per signal

have to be taken into account for the

calculation. (costs for procurement,

integration, repair, maintenance and

documentation, etc.)

Safe, even under difficult conditions

Solid, gaseous and corrosive

media is processed under difficult

conditions in the petrochemical and

chemical industry. The given provi-

sions and legal regulations (e. g.

Germany’s Technical Instructions on

Air Quality Control (TA Luft)) have to

be complied with. The pump manu-

facturer Bungartz is a specialist in

these areas. These robust centrifugal

pumps with high intrinsic safety are

used for pumping extreme media

such as hot sulphuric acid, fertiliser

solid mixtures, mineral oil concen-

trates or materials such as titanium

tetrachloride and ammonium ni-

trate. “The term ‘intrinsic safety’

originates from the field of electri-

cal equipment,” explains Dipl.-Ing.

Sadko Meusel, Sales Engineer at

Bungartz. (l Fig. 1) Even the de-

sign has to ensure that no hazard-

ous situations can arise even in the

case of operating errors. Applied

to pumps, the design again serves

as prerequisite for making external

monitoring systems obsolete. During

his technical presentations, Meusel

explains the use of the special cen-

Special centrifugal

A wrongly designed pump, a

performance outside of the working

point, which can also lead to cavita-

tion formation – causes for failures

m

Fig. 1 Sadko Meusel

Special centrifugal

p Global 2015 9

BUNGARTZGERMANY

for the proven horizontal pumps. Ba-

sically, this seal consists of distinc-

tive vanes on the impeller rear side.

Thus, the pumping medium is car-

ried away from the shaft gap transi-

tion protecting the downstream shaft

seal system. The physical conditions

guarantee a sealed pump, which is

completely independent from the

downstream sealing (mechanical

seal, magnetic seal, lip seal, etc.).

The chemical pump MPCH-

DryRun (l Fig. 2) is also known

for its high availability. In the case

of this hermetically sealed magnet-

coupled pump, bearing and mag-

netic drive do not come into contact

with the pumping medium. This

allows a liquid-independent utilisa-

tion. The labyrinth zone between

the impeller rear side and the shaft

bearing is free of product and filled

with sealing gas, ensuring a ther-

mal barrier with a high temperature

trifugal pumps and reports on the

experiences which plant managers

and pump experts have with the in-

trinsically safe pumps. “Install and

forget,” was a comment made by

an experienced professional. One of

many statements, which times and

times again surprise seminar partici-

pants, due to the long maintenance

intervals and long service lives of the

special pumps.

Increasing availa-bility, saving control technology, reducing costs

Since the company was found-

ed, intrinsic safety of the Bungartz

pumps has always been based on

the intelligent application of physi-

cal principles. One of those is the hy-

drodynamic shaft seal originally de-

veloped by Bungartz, which is iconic

pump with high p

Fig. 2 The chemical pump MPCHDryRun

intrinsic safety gradient and a low bearing tempera-

ture. The grease-lubricated rolling

bearings with a minimum service

life of 32,000 hours do not require

any monitoring or maintenance over

this period. Further advantages are

that the system is ATEX-compliant,

suitable for melting, safe against

blockages and operating error (e. g.

insufficient ventilation). The other-

wise normal signals and controlled

systems are omitted.

One unique property is the self-

regulating behaviour, which is de-

fined as special physics. The centrif-

ugal pumps from the V-AN (AN stands

for abnormal) series (l Fig. 3) work

without suction capacity. They au-

tomatically adapt to changing feed

rates. Here is the principle in simpli-

fied terms: When a medium flows

into a vessel, the liquid level rises

until the inflow and outflow of the

vessel balance out — without any

mFig. 3 The self-regulating

V-AN-type centrifugal pump

pump with high

intrinsic safety

phase (no pits, scaffold-

ing, buffer tanks).

The contact-

free hydrodynamic

shaft seal with seal

expeller and the

idle state sealing

controlled by cen-

trifugal force make

the large circulation

pumps (1,200 m3/h)

of the type M-UMOR

(l Fig. 4) intrinsi-

cally safe in their

entirety. These

pumps (one pump

has been running since 1948!) are

particularly suitable for solids and

are utilised worldwide, e. g. for

pumping ammonium nitrate.

www.bungartz.de

Achema: Hall 8.0, C1

type of mechanical or electrical regu-

lation equipment. All pumps are self-

ventilating as well as safe to run dry

and reliable. They do not require any

kind of controlling (see p Info-Plus)

The self-regulating pumps are

often used for emptying tankers.

They ensure a complete emptying

without applying additional pres-

sure. When emptying from the top,

this can even be used for heavy me-

dia up to a density of 2.4 kg/dm³.

The V-AN series is also in demand

for usage with gaseous or boiling

media. They are ideal for separa-

tion processes with fluctuating feed

rates, because the pumps indepen-

dently adapt to changing volume

flows. The otherwise normal addi-

tional equipment, such as Min/Max

switching system, rotation speed

control through frequency converter

or volume flow measurement, can

be foregone completely. Significant

investment costs can be saved, if

the pumps were taken into consid-

eration early enough in the planning

This animation demonstrates

the principle of self-ventilating

pumps.

p Info-Plus

BUNGARTZGERMANY

lFig. 4 The large circulation pumps of the type M-UMOR

p Global 2015 11

plant and personnel safety, especial-

ly when handling toxic, explosive or

other dangerous liquids which react

on contact with the atmosphere. For

all these services the containment

shell replaces the single or double

acting mechanical seals with exter-

nal fluid reservoirs and the neces-

sary control equipment.

GML/GMB-pumps therefore of-

fer benefits to the chemical, petro-

chemical and allied industries, and

protect the environment. The pump

handles everything from bulk trans-

fer, chocolate and asphalt, to high-

temperature fluids and chemical

processing. The pump is approved

for hazardous areas (ATEX) and suit-

able for liquids which are dangerous

for the environment.

Robust pump design together

with tough and strong materials

make the pump last longer. The ro-

tor and idler gears are made of tough

materials, which can handle the

stresses of high viscosity operation.

No need for steel rotor upgrade. Pat-

ented lubrication method extends

overall life by reducing friction.

The single elements of the

multipolar magnetic coupling are

manufactured of permanent magnet

material “Cobalt Samarium” with

unlimited lifetime. The magnets in

the driven rotor are completely en-

capsulated, not in contact with liq-

uid. Power is transmitted to the her-

metically sealed liquid end by a bank

of external magnets. Inner and outer

magnet rings are locked together by

magnetic forces and work as a syn-

chronous coupling. The containment

shell is a one piece deepdraw design

without additional welds.

www.dickow.de

Achema: Hall 8.0, D54

Sealless Magnetic Coupled Gear

PumpsThe new GML/GMB gear pump com-

bines

l the Dickow magnet coupling

design

l with Tuthill gear pump

engineering

Dickow has more than 30 years

and Tuthill more than 80 years of ex-

perience—the result is a new pump

that offers high performance and

reliability.

Magnetic driven GML/GMB-

pumps are designed to improve

mThe gear pump type GML

DICKOW, TUTHILLGERMANY, USA

p See us in Frankfurt Hall 8.0, Booth L94

p Global 201512

New E Series’ achieves the EHEDG seal of approval

our customers are increasingly

seeking conformance with the high

standards required,” says Flotron-

ic’s Managing Director, Jane Waite.

“Being authorised to display the

EHEDG logo confirms the new ‘E’

series pump’s credibility and gives

our customers peace of mind.”

www.flotronicpumps.co.uk

Achema: Hall 9.0, C82

suction pressure challenges result-

ing from SIP systems, bulk tanks

with head pressure of more than

0.5 Bar, re-circulation and thermal

expansion can all be met by the ‘E’

Series.”

Flotronic designed the ‘E’ Se-

ries for markets at home and abroad

where independent hygiene ac-

creditation is growing in importance.

“While EHEDG accreditation is not

necessarily a statutory requirement,

an electro-polished overall finish.

Cleanability is also assisted by the

incorporation of a support stand

whereby the pump can be inverted

for full draining.

“The ‘E’ series pump passed

EHEDG’s tests with flying colours,”

says Flotronic’s Chief Engineer,

Peter Wheal, “confirming that the

pump meets EHEDG standards for

sanitary product transfer. Other

features, including a diaphragm

rupture detection system with in-

stant pump shut-down alarm facil-

ity and BS, DIN and ISO hygienic

connection options, all help to keep

product contamination free and to

ensure that hygienic standards are

not compromised.”

“A unique feature of the Flo-

tronic ‘E’ Series pump is that the

diaphragms are reinforced as

standard,” Peter continues. “The

reinforcing plates add support to

the diaphragms and ensure that the

pumps can withstand CIP pressures

in the suction line of up to 5 Bar

with no diaphragm damage. Other

Flotronic Pumps Limited, the UK-

based specialist manufacturer of

air-operated double diaphragm

pumps, having already secured 3-A

Sanitary Standards, Inc (3-A SSI)

approval for their recently launched

‘H’ series pump, have now achieved

the European Hygienic Engineering

& Design Group (EHEDG) accredita-

tion for their new E Series pump.

The new E Series pump has

been specifically designed for the

Food and Beverage industry and

other processes where product con-

tamination must be avoided. The

pump’s features include Flotronic’s

established and unique ‘One-Nut’

pump design which allows swift dia-

phragm access without disconnect-

ing process pipework. The internal

surfaces of the E Series pump can

be effectively ‘cleaned in place’ or,

alternatively, easy dismantling can

be carried out for cleaning and in-

spection. Cleaning is aided by the

provision of polished wetted sur-

FLOTRONICUNITED KINGDOM

More information about pump + systems on

l www.delta-p-online.comand the global pump search machine

l www.pumps-directory.com

Our technology. Your success.Pumps Valves Service

ACHEMA – Solutions from a single source for the chemical industry

Get the answers to all of your questions from KSB, the only full-range supplier for pumps, valves and service. We look forward to welcoming you to ACHEMA 2015 from 15 to 19 June. Visit us at stand H14 in hall 8 to benefit from competent and comprehensive consultancy on all services throughout the entire life cycle of your equipment. Learn how we can optimise your life cycle costs, achieve maximum operating reliability and secure the availability of the systems you operate. Find out about our all-in solutions and other fascinating highlights for the chemical industry. Whatever you need. From a single source.

For more information, please visit www.ksb.com/achema

We look forward to seeing you at ACHEMA in Frankfurtfrom 15 to 19 June 2015Hall 8, Stand H14

p Global 201514

World premiere: Explosion-proof drum emptying system for materials just capable of flowing

FLUXGERMANY

The Viscoflux / Viscoflux mobile drum emptying system, espe-cially for pumping highly viscous, paste-like and non-free-flow-

ing materials from the widest variety of drums, has been part of the Flux-Geräte company’s offering for years. Following 2013’s presen-tation of the “Viscoflux lite” system variant, a version for materials just capable of flowing, Flux is now presenting the explosion-proof, PTB approved “Viscoflux lite Ex” version (l Fig. 1) in a world pre-mier at Achema. With this version, after only a year of development work, the supplier is meeting the demands of many operators for an explosion-proof version for emptying drums

l of the widest variety of flammable materials – namely zone 0/1,

l likewise for non-flammable materials which must be pumped in zone 1.

interested parties, such as those from

the paint and varnish industry, are in-

terested in our modular system. How-

ever, they often face the challenge of

needing to use it in zone 1 and/or to

pump flammable materials out of the

drum, namely from zone 0/1. This

gave us the impetus to develop the

explosion-proof version of the Visco-

flux lite, which is now available.”

This explosion-proof drum emp-

tying system is designed like the

non-explosion-proof version and,

after earthing the individual l

“The response to the launch of our

Viscoflux lite device version was ex-

traordinarily positive. The system,

which was developed to remove ma-

terials just capable of flowing from

ISO drums with lids,” says Dr. Jörg

Dassow, Sales Manager at Flux, “op-

erates with an eccentric worm-drive

pump. A vacuum is created in the

drum, so that the follower plate of the

system moves down and wipes the

drum wall. This makes it possible to

achieve complete emptying, down to

less than 1% residual volume. Many

mFig. 1 Viscoflux lite Ex consists of few components – all designed

for explosion-proof use. It is quickly installed and easily transported. It can be used in zone 1 and also pumps the widest variety of flammable materials just capable of flowing from zone 0/1.

World premiere: Explosion-proof drum emptying system for materials just capable of flowing

Discover the Sulzer Partnership

Visit us at ACHEMA in Frankfurt, hall 8 booth A71 and at Power-Gen Europe in Amsterdam, booth 1L47.

Sulzer provides complete pumping sys-tems and service solutions with leading-edge technologies backed by our long-standing expertise in engineering and innovation.

Dedicated teams of experts work closely with you to develop the right solu-

Our customized and innovative ser-

to reduce maintenance time and cost, and

pumps and compressors.Contact us to discover your ideal

pumping and service solution.

www.sulzer.com

p Global 201516

FLUXGERMANY

supply it upon request,” says Büh-

nert. Müller provides an important

note on the topic of potential equali-

sation: “All components must be

earthed outside of an explosion zone

before being joined together. The

operator always specifies the zone

areas.”

Wide variety of applications in zones 0 and 1

Flux thus provides a drum emp-

tying system which can be used in

zone 1. For example, highly viscous

materials just capable of flowing can

be pumped out of the drum directly

in zone 1 of a production system.

At the same time, a wide variety

of flammable materials just capable

of flowing can also be pumped with

this system. Drums with resins, sof-

tening agents or other flammable

materials—the drum interior is zone

0—can be emptied with it easily.

“Our new explosion-proof sys-

tem can be used in the widest variety

of industrial areas,” says Bühnert.

“For example, it can also be used in

production areas in the chemicals

and pharmaceuticals industry in

which solvent vapours make explo-

sion proof necessary. Wherever there

is a zone 1, the explosion-proof

version of Viscoflux lite can now be

used. For example, it now allows us

to provide a solution which enables

pumping lubricants out of the drum

into a plant, directly in this zone.”

www.flux-pumpen.de

Achema: Hall 8.0, E10

have additionally produced

the opening in the follower

plate for the pump tube from

a conductive polyethylene.

This safely prevents impact

sparks from occurring in any

case when inserting the pipe

and in case of contact with

the follower plate.”

The pump centring

plate in the explosion-proof

system is likewise made

from conductive, black poly-

ethylene and has a connec-

tion for earthing wire. In ad-

dition, the handles, arrestor

hook and other attachment

parts also produced from

stainless steel here. The

hose for the compressed air supply,

which serves to loosen the follower

plate from the drum floor, is likewise

implemented in a conductive mate-

rial. The explosion-proof eccentric

worm-drive pump used in the system

has a pipe diameter of 50 mm.

Flux uses proven explosion-

proof motors to drive the new ex-

plosion-proof system. All additional

components of the drum emptying

system which follow on the pressure

side of the pump and which must be

electrically conductive, such as hos-

es and flow meters, are available in

the Flux portfolio in explosion-proof

versions and can be used for the new

system.

“Many operators have their

own potential equalisation or

earthing systems in their plants.

For that reason, we offer Viscoflux

lite in the explosion-proof version

without earthing cable, but of course

highest priority. We assume that

there will be companies in which

the explosion-proof as well as the

non-explosion-proof system will be

operated. For that reason, our design

measures have ensured that the fol-

lower plate and process seal cannot

be combined between the explosion-

proof and non-explosion-proof ver-

sion, for example. In addition, the

explosion-proof follower plate has

stainless steel grips and, of course, a

connection for earthing wire.”

Gerd Müller, Viscoflux develop-

er, adds: “The process seal currently

consists of static dissipative FKM. We

are working on additional conductive

elastomer versions in order to make

the follower plate seal compatible

with as many rising media as possi-

ble. In order to consistently conform

to explosion proof requirements, we

components, can be installed and

operated in just a few steps:

1 Open the drum,

2 put the stainless steel follower

plate with process seal onto the

medium,

3 place the pump centring beam

onto the drum edge and lock it,

4 insert the pump into the

centring,

5 install the hose pipe,

6 put the motor on and connect it,

7 start the motor to begin

emptying.

Focus on operator safety

Helga Bühnert, Flux product

manager, points out a very important

aspect of the explosion-proof ver-

sion: “Safety of the operator is Flux’s

mFig. 2 Drums without inliner are emptied down to less than 1 % residue.

Pump for liquid coating materials

In coating technology a homogene-

ous distribution of the coating ma-

terial is one of the most important

points. An exact coating is required

for a stable and defined modifica-

tion of physical, electrical or chemi-

cal properties of materials. Varia-

tions occurring due to inadequate

technology can lead to a significant

zles or slot dies. The micro annular

gear pump mzr-6305 fulfils these

sensitive metering and dosing tasks.

The micro annular gear pump

mzr-6305 meets the requirements

for exact dosing of liquids with low

and high viscosities. This pump of-

fers a highly precise volume flow

from 0.024 to 144 ml/min. By the 10

to 11 tooth ratio of the rotor set, the

already extremely low pulsation of

mzr-pumps has been further

reduced many times.

HNPMGERMANY

www.gather-industrie.de

kupplung@gather-industrie.de

Phone: +49 2058 89381-23

Pump Technology

Dosing Technology

Coupling Technology

Flat-face Coupling For water, solvent, acids, bases and more

• Temperature range from –80 °C to +325 °C

• DN4 to DN65

Visit us at

ACHEMA 2015

Frankfurt, 15.–19.06.2015

Hall 8.0, Stand H41

Mini-Turbine Pumps Dosing Gear PumpsTube-Hose Quick-Disconnect Couplings

lack of quality in production. These

quality problems can be avoided

by the application of high precision

pump technology to deliver the liq-

uid coating material, for example,

for a exact feeding of spraying noz-

The coating technology is just

one of many fields of application in

mechanical and plant engineering

for the new pump.

www.hnp-mikrosysteme.de

Achema: Hall 8.0, J95

News, facts, developments about

pumps + systemswww.delta-p-

online.com

p Global 201518

ATEX zone I inside a twin screw pump

Our manufacturing focusses nowa-

days on the twin-screw pumps.

A superior command of tech-

nology in nearly all areas of appli-

cation has made ITT Bornemann a

worldwide leader in its field. Sales

offices and subsidiaries worldwide

ensure that there is immediate and

professional support throughout all

phases of the production process

ranging from detailed advice ex-

tending to tailor-made engineering

and finally including reliable main-

tenance of the installed pumps and

systems. Efficiency, reliability and a

high level of availability are the most

important features that distinguish

Bornemann pumps and systems.

www.bornemann.com

Achema: Hall 8.0, E63

these special application pumps the

most famous advantages are still ap-

plicable. Best suction capabilities,

transferring fluids of varying viscosi-

ties or flow. Even under extreme con-

ditions this pump can resist and it is

still reliable. Long lifetime and cost

effectiveness over the whole product

life cycle are further features.

ITT Bornemann from Obern-

kirchen, Germany, has a long history

of success. Since the company was

founded in 1853, our goal has been

to respond to markets with products

and solutions that are technologi-

cally outstanding and cost-effective.

From that point on, Bornemann has

been setting the pace. In 1934, for

example, it patented the Twin-Screw

Pump with external bearings. In

the 1960s, the development of the

triple-screw pump and the Progres-

sive Cavity Pump led to more inno-

vative solutions, and in the 1980s,

Bornemann multiphase pumps cre-

ated commercial opportunities that

had been previously unthinkable.

factures of mechanical or electrical

equipment need to produce in ac-

cordance to 94/9/EG ATEX 95 direc-

tives.

Today ITT Bornemann twin screw

pumps are used to handle flamma-

ble fluid across all industries where

mixtures of liquid, gas and oxygen

from the atmosphere can occur. In

the past the pumps were already cer-

tified for installation and operation

in Zone 1 or 2, but a Zone inside of

the pump was excluded. Therefor ad-

ditional measurement and devices

were required to avoid dry running or

provide inertisation inside. For that

reason priming and stripping phases

in loading or offloading applications

were sometimes critical to handle.

The manufacturer now invented

a procedure to manufacture Twin

Screw Pumps which can be installed

in these processes which avoid the

above mentioned restrictions. From

now on it is possible to deliver this

twin-screw pump in any applica-

tion where Zone 1 Category 2 is de-

manded by the customer without any

division between inside or outside of

the pump. As an added value highly

sophisticated process measurement

and control equipment for dry run-

ning protection or nitrogen recip-

rocation is not needed any more.

This is another important advantage

which shows ITT Bornemann innova-

tive steps into the future. Even with

Twin screw pumps are self-priming

positive displacement pumps with

external timing gears and bearings.

Manufactured in over 80 sizes, their

design provides excellent suction

performance and eliminates all met-

al-to-metal contact within the pump.

They can handle virtually any fluid,

regardless of viscosity, homogeneity,

lubricity or abrasiveness e. g.

l seawater,

l bitumen,

l molasses,

l lime,

l acid,

l caustic soda,

l polymer solution or

l hydrocarbons.

Today companies in Europe and

other countries which need to act

according to European legislation

have to consider the ATEX directive.

In accordance with the European

directive 1999/92/EG companies

have to define areas where an explo-

sive atmosphere could occur. Those

plants and sites are for example tank

farms, chemistry plants or other pro-

duction facilities which handle with

potential explosive fluids.

For those companies this direc-

tive regulates how the certain areas

and zones within this site shall be

defined and classified. Regarding

those classified areas companies

have to use certified machinery and

electrical devices. And even manu-

ITT BORNEMANN

GERMANY

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p Global 201520

KLAUS UNIONGERMANY

Hans-Jürgen Schöner

A new “Plug & Pump” Design has

been successfully introduced

by Klaus Union GmbH & Co. KG for

Double Volute Twin Screw Pumps

built in accordance with the re-

quirements of API 676, 3rd Edition.

Founded in 1946, Klaus Union

GmbH & Co. KG is a pump and valve

manufacturer located in Bochum,

Germany. The delivery portfolio in-

cludes Magnetic Driven Centrifugal

Pumps, where the company is a

globally leading supplier, Double

Volute Twin Screw Pumps, Valves

and Fittings for all types of indus-

tries.

Applications

Double Volute Twin Screw

Pumps, which have been introduced

to the industries in the first half of

the last century, gained increased

acceptance during the past 30 years.

Incorperating all the advantages of

positive displacement pumps, they

gained more and more acceptance

as a solution for highly sophisticated

pumping applications. Their capabil-

ity of handling products with chang-

ing viscosities at good efficiencies

and a wide speed range make them

an ideal pump for e. g. tank storage

applications. For applications in the

Chemical & Petrochemical indus-

tries, the pumps can be delivered in

various materials ranging from Cast

Steel, Stainless Steel and Duplex

or Super Duplex Steel, vari-

ous Specials Alloys as Hast-

eloy, Monel or Alloy 20 and

even Titanium. Initially, the pumps

have been designed to handle clean

liquids with a neglectible solids

content. Today, with various highly

wear resistant coating materi-

als available, the

“Plug & Pump“ – A Ne

nFig. 2 Rotor Set of a

Double Volute Twin Screw Pump

of Double Volute Twin p

Fig. 1 Cut-a-way of a Conventional Double Volute

Twin Screw Pump

p Global 2015 21

ment Facility. They make separation and treatment

facilities at the well site and separate flowlines for

oil, gas and water obsolete. With the help of Mul-

tiphase Pumps, matured fields can longer produce

with reduced requirement for artificial lift (e. g. gas

injection) or abandoned wells or well clusters can

be revived. Even gas slugs of 100 % can be toler-

ated for certain period of time if a Liquid Control

System (LCS) is installed. Such a system provides

a minimum flow rate, generally approx. 3.0 % of

pumps can handle considerable amounts of sol-

ids without suffering from excessive wear. Sensi-

tive liquids are handled with low shear and almost

no pulsation. All Klaus Union Double Volute Twin

Screw Pumps are self priming up to 8.5 mWc.

Last but not least, Double Volute Twin Screw

Pumps have entered and conquered a very spe-

cial market segment — Multiphase Pumping. With

their ability to handle high gas fractions (GVF), the

pumps are particularly suited for applications on

either Greenfields or Brownfields. Klaus Union

Multiphase Pumps handle the entire untreated

flow from particular wells or well clusters and

transfer the Multiphase Fluid to a Central Treat-

w Generation

mFig. 3 Exploded View of a Double Volute

Twin Screw Pump in “Plug & Pump” Cartridge Design

the total pump flow, in

order to form a liquid

seal between the pump

rotors and the pump cas-

ing insert (liner). This liquid

seal guarantees uninter-

rupted gas compression even

when the well flow does not supply

any liquid phase. Multiphase Pumps are usually

supplied as complete systems with electric mo-

tors or combustion engines, variable speed drives

(VFD), control equipment, piping, valves and ex-

tensive instrumentation which makes them the

Screw PumpsMade in Switzerland

Lowest operating cost and highest availability withfast and easy maintenance.Heavy duty 24/7 design,up to 800 L/min [200 gpm]and 600 kW drive power.Unique membrane-like technology without con-ventional seal packing, ideal for pumping all kindof waters, other non-lubricating liquids or fluidswith abrasive particles.

high

pistonpressure

pumps

HYDROWATT AG CH-8200 Schaf fhausen / Switzerlandwww.hydrowatt.com

visit us at booth 3A48

Düsseldorf, Germany16-20 June 2015

KLAUS UNIONGERMANY

p Global 201522

chanical seals can be provided. It is

possible to use either component

seals or cartridge seals following the

requirements of API 682. The seal

materials are selected to match the

particular operating parameters.

Seal flushing systems meeting the

requirements of API 682, can be

furnished.

The Plug & Pump Cartridge Design

Double Volute Twin Screw

Pumps find applications in almost

any type of industry. However, due to

their special advantages described

above, many pumps find their du-

ties on oilfields around the world.

Many of those locations are in very

remote areas, e. g. deserts, artic

environments, jungles or offshore

The drive torque is transmitted

from the drive rotor to the idler ro-

tor by means of herringbone timing

gears. These guarantee a noise re-

duced operation as well as an easy

adjustment of the pump rotors after

overhauls. The rotors are carried in

heavy duty spherical roller bearings,

which are designed to exceed the

L10 requirements of 25,000 h. Both,

timing gears and bearings are oil

lubricated. The ample sized bearing

and gear covers with large cooling

fins guarantee sufficient heat dissi-

pation. For heavy duty applications,

forced feed lubrication systems can

be provided.

The pumps are sealed by four

mechanical seals (two seals for each

rotor). Depending on the actual op-

erating conditions, single or double

acting, unbalanced or balanced me-

either side to be conveyed and pres-

surized within the axially moving

cavities of the screw packages. The

flow is discharged through the outlet

port in the pump center. This design

makes the pump for 100 % hydrauli-

cally balanced, hence, thrust bear-

ings are not required. Klaus Union

rotors are made from single piece

bar stock. Different screw geom-

etries are available which offer high

efficiencies along with considerable

power savings for selected applica-

tions. All pump rotors are designed

with an exceptionally short distance

between the bearings and a large

core diameter to minimize the shaft

deflection and hence, to prevent

any contact between the rotors and

pump liner at any design condition of

a particular pump.

top product of all screw pump ap-

plications. Double Volute Twin Screw

Pumps in Multiphase applications

can also considerably contribute to

a cleaner environment. With their

ability to handle liquid/gas mixtures

they can prevent the need of releas-

ing greenhouse gases into the at-

mosphere by venting or flaring.

Design Features

Conventional Double Volute

Twin Screw Pumps consist of a pump

casing, a liner which is either inte-

grated or interchangeable and two

pump rotors. Each pump rotor has

two screw packages with similar

pitch but a different pumping direc-

tion. The well flow enters the pump

through the inlet port and splits to

KLAUS UNIONGERMANY

qFig. 4 Placement of the Cartridge on the Installation Tool

pFig. 5 Cartridge Half Way Installed

Roten s.r.l. - Via Ortica, 6 - 20134 - Milano Tel. +39 02 76110157 r.a. - Fax +39 02 7385445 www.roten.it - info@roten.it

MILANO 1945

NOI SOSTENIAMO IL FAI - FONDO AMBIENTE ITALIANO

p Global 201524

rFig. 6 Cartridge Completely Installed

pFig. 7 Cartridge on Installation Tool

KLAUS UNIONGERMANY

The “Plug & Pump” Cartridge

Design is available as a standard for

all types and sizes of Klaus Union’s

Twin Screw Pumps Series.

Conclusion

The new Klaus Union “Plug &

Pump” Cartridge Execution marks a

substantial progress in the develop-

ment of a new generation of Double

Volute Twin Screw Pumps. Especially

for installations in harsh environ-

ments, but not limited to, the user’s

benefit from several advantages:

l Quick and easy disassembly

and re-assembly of a pump

l Very short downtime of the

pump unit

l Less production losses during

overhauls and maintenance

shut-downs

l Easy overhaul of the cartridge

unit in the local workshop

l Considerable savings in over-

haul costs

www.klaus-union.com

Achema: Hall 8.0, B80

tion and discharge pipework stay

in place. Only the coupling must be

re-installed and aligned after the

change of cartridges.

The optional installation tool is

consisting of sliding rails running on

antifriction bearings. It allows easy

installation of the cartridge on site in

horizontal position.

The removed cartridge can be re-

furbished with genuine spare parts at

the operator’s workshop or returned

to the factory for inspection.

liner and the rotors comes ready as-

sembled with the mechanical seals,

the bearings, the casing covers and

the timing gears as a ready to oper-

ate “Plug & Pump” Cartridge Unit.

Instead of a time consuming

disassembly of the pump during

overhauls on the jobsite, the entire

cartride can be pulled and replaced

by a new one. The new cartridge is

fitted in following sequences:

During overhaul, the pump cas-

ing, the drive motor and the suc-

platforms. With limited resources of

near-by workshops, skilled labour

and transport, overhauls and repairs

are always a special and time con-

suming challenge.

The new Klaus Union “Plug &

Pump” Design (patend pending) of-

fers a completely new approach to

overhaul and maintenance of Double

Volute Twin Screw Pumps. Contrary to

the conventional Double Volute Twin

Screw Pump Design, the hydraulic

part of the pump consisting of the

FELUWA Pumpen GmbH | GERMANY | info@feluwa.de | www.feluwa.com

YOUR Business – OUR TechnologyMULTISAFE Double Hose-Diaphragm Pumps Handling of abrasive, aggressive and toxic mediaFlow rate up to 1000 m3/h Pressure up to 500 bar

| Reactor, Autoclave, Filter Press and Gasifier Feeding

| Tailings Transfer

| Fly and Bottom Ash Disposal

| Pipeline Transportation

| Wet Oxidation

| Dewatering

Engineered and Made in Germany

Vi

sit u

sJune 15-19, GermanyHall 8.0 | Booth G94

p Global 201526

KNOLLGERMANY

The German pump naufacturer Knoll

will make the modular MX progress-

ing cavity pump toolbox the focus of

its presentation at Achema. The MX

toolbox enables the combination

of the various main components,

including

l pump sets,

l drive variants,

l seal designs, and

l suction housing shapes

across all model series. The wide

variety of the MX pumps thus ena-

bles a precise adjustment of the

pump to the specific requirements of

the task at hand.

In addition, thanks to the easy

replacement of the pump set (rotor

and stator), the delivery rate and

delivery pressure can be adjusted

quickly and economically to current

needs even after the fact. The cur-

rent toolbox system includes the

following:

l Drive variants: servo geared

motor, three-phase geared

motor, geared motor in aseptic

model, Atex drives for Zones 1

and 2

l Seal variants: single or double

hygiene axial face seal with or

without sealing pressure, elas-

tomer bellows axial face seal,

rotary shaft seal and packing

gland optional with flushing

l Housing variants: suction

housing compliant with DIN

11864, DIN 32676, DIN 11851

or EN 1092-1, suction hous-

ing with extended diameter,

rectangular hopper, as well as

with cleaning ports and double

jacket

l Joint variants: cardan joint or

joint with conveyor feed worm

for hopper

l Various pump sets

l Pressure joint variants:

DIN 32676, DIN 11851,

DIN 118654, EN 1092-1 tan-

gential or centric run-out.

This variety of variants for the

initial design and retrofitting of

installed MX pumps will be demon-

strated on a pillar in the Knoll booth

(Hall 9.0, booth E33) at Achema; the

various main components can be

twisted onto one another.

With EvenWall® the prerequisites for high pressures are provided

Knoll MX progressing cavity

pumps are equipped with stators

with EvenWall® technology. Here, in

contrast to cylindrical models, the

metallic stator jacket is adjusted to

the inner contour of the elastomer

and provided with an even elastomer

wall thickness. Depending on the

pump set size, this can be between

4 and 12 mm. This results in

l significantly improved pressure

stability,

l less backflow,

l longer service life,

l better efficiency,

l less shearing of the product,

l better suction behavior and

l the possibility of allowing a

greater temperature fluctuation,

such as due to CIP cleaning,

without change of the rotor.

Helge Kopczak, department

manager at Knoll for the MX and KTSV

pumps, says about these properties:

“EvenWall® is the high-end solution

for stator design. Precisely in the

Individual solutions from the progressing cavity pump toolbox

p Global 2015 27

KNOLLGERMANY

Dry interface allows access to the seal

Völksen continues: “We

have also implemented the

easy-to-loosen interface be-

tween suction housing and rotor

unit between the bearing seat and

suction housing. This ‘dry’ interface

is a unique selling property that

distinguishes our pumps. Thus, if a

pump requires service, the MX op-

erator can easily separate the pump

between the suction housing and

bearing seat; the suction housing

remains unchanged in the process.

The easy pulling away of the bear-

ing seat with geared motor provides

access to the seal without having

to loosen the suction or pressure

side of our pumps. This increases

process reliability and minimizes

downtimes.”

In addition to this module tool-

box for the MX progressing cavity

pumps, Knoll will also display the

KTSV screw pump at Achema. “This

is the KTS screw pump that Knoll has

developed and optimized for pro-

cess-technical applications — hence

the ‘V’. It is used for a wide variety

of products with viscosities from 1

to 2,000,000 mPas. We adjust these

screw pumps individually to the op-

erator’s requirements, so that these

pumps are optimized precisely for

the application in question,” accord-

ing to Schönenberger.

www.knoll-mb.de

Achema: Hall 9.0, E33

rate or the delivery pressure

as needed. The delivery rate of

these Knoll pump sets covers a deliv-

ery range for this single pump model

series from 100 to 5600 l/h with

maximum pressure of up to 40 bar.

The modification can be made

easily and without special tools

thanks to a special interface be-

tween suction housing and the rotor-

stator unit. “Each pump set is adapt-

ed to the suction housing via module

rings. This is the prerequisite for the

after-the-fact pump set change,” ac-

cording to Gustav Schönenberger,

Design Team Manager for progress-

ing cavity and screw pumps. “With

our pumps, the bearing housing is

identical across various configura-

tions. Thus the mounting for the

shaft seal is always the same. This

allows a truly slim spare parts inven-

tory. Our concept also leaves open

the option for replacing an unheated

with a heated pump set. Even if the

operator would like to build a com-

pletely heated pump after the fact,

he can replace the suction housing

with one that can be heated.”

“If the viscosity of a medium

changes a lot in a process, the

pump must be adjusted for this, for

the speed must suit the viscosity.

This is also possible quickly, easily,

and economically with our pumps,

thanks to a replacement of the pump

set,” concludes Völksen.

pletely redesigned and re-procured.

According to Reiner Völksen,

Sales Team Leader at Knoll for the

MX model series with a focal point

on the design of pumps, “The deci-

sive advantage of our MX progress-

ing cavity pump model series is that

you can retrofit our pumps with a

few components and movements.

Regardless of whether you want to

adjust the delivery rate or pressure,

with our pumps it is possible to do

this just by changing the pump set.

For example, you can double the

delivery rate of an MX20 by chang-

ing the pump set 25/10 to the larger

rotor diameter 30/10 with the same

speed. The significant advantage is

that the shaft seal always remains

the same and you do not need to

make any detailed changes. Thus,

this toolbox concept presents a great

advantage when it comes to spare

parts supply.”

“It is therefore possible for

operators to adjust to the changed

parameters with a very simple ad-

justment of the pump set.” Völksen

continues: “A current example from

one of our customers is the adjust-

ment of MX pumps in filling systems

for cleaning products. Thanks to the

easy replacement of the pump set,

the delivery rates were adjusted to

changed package sizes.”

For the MX20 progressing cavity

pump, for example, there are nine

pump set sizes, which allow the

pump operator to adjust the delivery

high-pressure range, this stator of-

fers outstanding advantages. With it,

we can achieve 10 bar per pressure

stage and we are thus well above the

4 to 6 bar commonly available on the

market. With multi-stage construc-

tion, MX progressing cavity pumps

achieve pressures up to 80 bar. In

addition, the tolerances can be ac-

commodated more precisely. In con-

trast to the harsh applications for

progressing cavity pumps, such as

wastewater treatment and bio gas,

media with large foreign bodies are

rare in the chemical, pharmaceuti-

cal, cosmetics, and food industries

and in the manufacturing of colors

and paints. Here, we are ideally po-

sitioned with the EvenWall® technol-

ogy as standard equipment. Even for

high-viscosity media, which require

high pressures in the pipelines, our

MX pumps with the EvenWall® sta-

tor offer the advantage that, thanks

to the high delivery pressure, they

are built much more compactly than

other solutions, some of which have

multiple stages.”

Easy adjustment to changed process parameters

Product change, recipe ad-

justments, process optimization,

changed initial materials — there are

many reasons why the parameters

and thus usually also the require-

ments of the pumps present change

in a process. If you change the re-

quired delivery rate and/or the pres-

sure, the pump must often be com-

p Global 201528

KSBGERMANY

Achema 2015 will see KSB show-

case totally leak-free canned motor

pumps from the Ecochem Non-Seal

range designed to transport haz-

ardous, aggressive, flammable and

explosive fluids. The pumps are

also capable of handling toxic and

extremely hot or cold media as well

as volatile or valuable liquids.

This new type series combines

KSB’s MegaCPK — a standardised

chemical pump successfully em-

ployed for years in process engineer-

ing — with ground-breaking canned

motors built by Japanese coopera-

tion partner Nikkiso. The pumps’ di-

mensions comply with ISO 2858 and

meet the requirements of the DIN/

EN/ISO 15783 and API 685 stand-

ards, with economic operation being

ensured via a new energy-optimised

electric motor design. The low-noise

motor features a corrosion-

resistant can made of Has-

telloy (2.4610).

The new type series

will be available in four

standard variants featur-

ing one design each for

standard chemical ap-

plications, heat transfer

fluids, polymerising or

ferrite-containing fluids

and a special variant for

low-boiling fluids and liq-

uefied gases.

The pump sets have been

designed to meet the require-

ments of explosion protection class

II 2 G c Ex de IIC to ATEX, TR and

IEC Ex and temperature classes

T1 to T5, and can handle fluids

at temperatures from — 40 °C to

+ 400 °C as standard. The maximum

head is 236 m and the maximum

flow rate 690 m3/h, while product-

lubricated plain bearings made of

pure silicon carbide or a silicon-car-

bide-graphite compound allow the

bearing configuration to be optimally

matched to the pump’s operation

and the fluid handled.

If required, the pump casing

can also be heated to avoid a block-

age developing due to fluid cooling

and becoming viscous or solid in

the event of standstill. The motors

are rated up to 75 kW, and with 16

different motor sizes available, the

drive can be precisely tailored to de-

mand. Thanks to the motor bearings’

modular design, the number of parts

requiring storage can be reduced,

cutting warehousing costs.

An E-Monitor available on op-

tion monitors the axial and radial

condition of the bearings, and its

integrated direction-of-rotation indi-

cator eliminates the need for phase

rotation measurements during com-

missioning. As canned motor pumps

operate very quietly, the built-in

operating status indicator provides

a very useful function, especially in

loud environments. Power is sup-

plied to the E-Monitor via the mo-

tor’s terminal box so that no external

cabling is required.

www.ksb.com

Achema: Hall 8.0, H14

New canned motor pumps for chemical and process engineering applications

p Global 201530

Pump coupling opti KTR

GERMANY

On the occasion of Achema 2015 in Frankfurt KTR will not only present

a wide range of solutions for pump couplings, but mainly two solu-

tions which were specifically developed for chemistry and petrochemistry:

l The torsionally flexible shaft couplings for explosion-proof

applications which reliably prevent, as the name ‚Rotex Non Sparking’

implicates, sparks in case of wear of the damping element and

l a simple procedure when replacing the coupling to maintain

compliance.

For pump operators this will mean a significant surplus of safety and a

considerable gain with the service life of pumps, seals and bearings.

We spoke about those items as well as other innovations and further

developments with KTR’s specialists André Artmann and Michael Brüning.

tive nylon coating for metal compo-

nents preventing any kind of static

charging. As a result it is ideally

suitable for hazardous locations and

definitely KTR’s highlight presented

at the Achema 2015. This new ‚Rotex

Non Sparking’ coupling

l is failsafe and maintenance-free

with hazardous locations

l can be operated even with wear

of the elastomer spider

l prevents any generation of sparks

reliably subject to the material

combination metal/nylon.

To ensure the latter, the nylon

coating is highly resistant so that it

is able to continue to transmit the

torque even with total wear of the

elastomer spider installed. Thus, if

the spline of the counter hub supports

the nylon-coated hubs, the pump

driven in this way can be operated

over a certain while without problems

and without any danger of sparking,

even if damping is missing in this

case. Consequently the maintenance

of such pump can be postponed to a

later date without hesitation.

Michael Brüning (l Fig. 2),

KTR Product Manager of flexible cou-

plings, comments on the technical

details: „We have coated the metal

hubs of this coupling with conduc-

tive, highly stiff nylon adapted to the

cam geometry of the Rotex coupling.

In this way it is prevented that steel

strikes against steel if wear is gener-

ated. Moreover, the injection-mould-

ing of the cam geometry provides us

with the option of producing many

other coupling types, for example

with reduced hub for very compact

designs. Customized and shaft-hub-

connections for specific applications

can be realized in this way, too.“

The combination of standard

Rotex components with non-spark-

ing components allows to realize a

wide range of couplings for applica-

Pump coupling opti

Torsionally flexible couplings

type Rotex are characterized by small

dimensions, low weight and a low

flywheel mass while transmitting

high torques. The accurate, all over

machining has a beneficial influ-

ence on the running properties while

increasing the service life of the

coupling considerably. These cou-

plings ensure a torsional vibration-

damping power transmission and

compensate for shocks generated by

motors with irregular operation.

For the new torsionally flex-

ible coupling ‚Rotex Non Sparking’

(l Fig. 1), KTR developed a conduc-

mFig. 1 The new explosion-protected Rotex Non Sparking

in a single-cardanic design with the hub coated on both sides

kFig. 3 With this double-

cardanic Rotex Non Sparking the spacer is coated

p Global 2015 31

service life mizing safety and

KTRGERMANY

tions following the ATEX standard,

comprising the following standard

types, as an example:

l single-cardanic with hub coated

on one or both sides (l Fig. 1)

l double-cardanic with coated

hubs or coated spacer (l Fig. 3)

for large shaft displacements

with low restoring forces al-

lowing for an easy assembly of

standard shell hubs, too.

Compliance is maintained with retrofitting of coupling

With existing systems many

pump operators are afraid of retro-

fitting the pump drive with an inno-

vative coupling solution like, for ex-

ample, the new Rotex Non Sparking,

since this would affect the system’s

compliance. However, according to

the European Machinery Directive

modifications of the original configu-

ration are permissible provided that

a hazard analysis is performed.

André Artmann (l Fig. 4) ex-

plains as follows: „Some pump op-

erators actually perform such risk

analysis if they cannot think of anoth-

er option to get a grip on permanent

bad actors. However, the bureau cratic

burden has often prevented such

retrofitting up to now. That is why we

searched for a way to simplify this

mizing safety and Fig. 2

Michael Brüning, KTR Product Manager

service life

p Global 201532

innovative solutions in a close coop-

eration with excellent support. „Our

strength is the individual solution we

develop in cooperation with our cus-

tomers“, Brüning explains. „In 2014

we moved a big step ahead in manu-

facturing. Today we are in a position

to separate casted components for

couplings with high process reli-

ability. For that purpose we adapted

a procedure which is used success-

fully in the automobile industry, for

example big end bearings. The result

is Rotex S-H with split hubs.“

This coupling which will also be

introduced at the Achema is made

of low-cost cast iron and the hubs

are purposefully separated into

two halves mechanically and with

high process reliability by „crack-

ing“ (l Fig. 5). This results in an

uneven surface with a positive lock-

ing fit ensuring an accurate fit of

the two halves when they are joined

to gether. The contoured, uneven

fracture surfaces ensure the ideal

centring of the hub halves.

Since the hub is split, the

coupling is easy to assemble and

disassemble. „The step towards the

split coupling hub made of cast iron

makes the product pricewise unbeat-

able“, Brüning comments. „Already

in the first year after launching we

could gain many new customers

for this coupling. Particularly for

maintainers this split hub which is

mounted radially in a simple way is

actually a solution of their problems.

The components do not have to be

put apart any longer. This benefit is

even used as a sales argument by

the pump manufacturers.“ l

for all our couplings so that pump

operators are offered the perfect so-

lution for those systems which stand

out by damages of bearing or sealing

again and again, while the fear of a

loss of compliance has prevented an

optimization so far.“

The world’s first split coupling with positive locking

In KTR more than 60 engineers

are working exclusively in develop-

ment and engineering to provide

specifically pump manufacturers

would definitely not make sense to

change the coupling. „If we switch to

a double-cardanic coupling, for ex-

ample,“ Artmann explains, „we will

mostly reach smaller dimensions,

the displacement figures can be

increased, the service life is longer

which means that we can record a

minimized risk in this way. We offer

this risk analysis as a service free

of charge to our customers. This al-

lows the pump operators to retrofit

to safe pump drives with a minimum

of expenses. Compliance is main-

tained which is certified and re-

corded. We can provide this service

hazard analysis in cooperation with

Shell Germany via a form which will

allow us to perform this analysis on

behalf of the pump operators. For that

purpose we made Bureau Veritas, one

of the leading companies in the range

of compliance testing and certifica-

tions assess and confirm this hazard

analysis.“

Features of a coupling which

are relevant for operation and as-

sembly are compared with each

other and an analysis is made if the

risk is minimized, maintaining the

risk either at the same or a higher

level. For the two latter cases it

KTRGERMANY

Fig. 4

required as a service free of

charge to our customers“,

André Artmann, specialist for pump cou-plings and now Sales Manager of Northern

Europe and South Asia, explains.

„This allows the pump operators

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Achema 2015

15.-19. June 2015

in Frankfurt am Main

hall 8.0, stand C27

VISIT US

p Global 201534

KTRGERMANY

chemical pumps will be displayed at

Achema 2015.

www.ktr.com

Achema: Hall 9.0, C4

four screws with no need to shift

motor or pump. Two more sizes of

this coupling (l Fig. 6) specifi-

cally for pump drives of standardized

These couplings have mainly

been developed for the use in

pumps and compressors, thus for

applications in chemistry. That is

why KTR had the couplings certified

in accordance with the ATEX directive

94/9/EC.

Part of the special features of

BoWex GT is the simplified assem-

bly: The coupling sleeve is separated

into two absolutely identic shells

which can easily and quickly be dis-

assembled after having unscrewed

Maintenance-free curved-tooth gear coupling

On the occasion of Achema

2012 KTR presented the curved-

tooth gear couplings type BoWex GT

for the first time. This coupling is

characterized, among others, by a

high ease of assembly and thanks

to its double-cardanic design by the

ability to compensate for big dis-

placements. Moreover, this pump

coupling is almost free from restor-

ing forces allowing for a positive

locking torque transmission both

with axial, radial and angular shaft

misalignment. Since BoWex GT op-

erates free from constraints due to

the curved-tooth gear principle even

with radial displacements prevent-

ing edge pressure with angular/

radial displacement, the coupling

minimizes the loads affecting the

bearings and seals in the drive train.

This has a positive effect on the life

cycle cost balance of the overall

system.

nents as well as cooling systems. With its extraordinarily wide product

portfolio the company provides for solutions for a large number of indus-

tries, for example

l Pumps and compressors

l Construction machinery industry

l Agricultural and forestry

engineering

l Machine tools

In less than eight years the specialists located in Rheine, Westphalia

managed to make the business of couplings for pumps and compressors

the second biggest one within the company. The basis of this success are

General Managing Director of KTR and previously CEO of KSB AG, and

André Artmann, specialist for pump couplings and today Sales Manager of

Northern Europe and South Asia. They managed to create an understand-

ing with pump manufacturers, pump operators and service companies

within the supply chain, while they in fact correspond to the character of

A-components. Since the right coupling decides on failures of seals and

bearings, standstill periods, thus have a high share in life cycle costs.

C-components corresponding to the character of A-components

l Materials-handling technology

l Hydraulics

l Wind power technology

l Railway and traffic engineering

l Marine technology

mFig. 5 The Rotex S-H couplings with split hubs are made of cast iron and the hubs are separated

into two halves with a high process reliability by cracking. The uneven surface generated in this way is the ideal positive locking fit.

nFig. 6 „In every single cardan point of BoWex GT the radial displacement is converted into an angular displacement,“

Artmann explains. „In this way shear forces which often damaged bearings and/or seals are eliminated. If these couplings are

used, the service life of adjacent components will automatically rise.“

Schmalenberger GmbH + Co. KGD-72013 TübingenPhone.: +49(0)7071-7008-0info@schmalenberger.dewww.schmalenberger.de

INTELLIGENT CONTROL CLEVER PRODUCTIONTop class pump technology:

Self priming pump concepts

Compact construction

ISI-System: IE3 motors + frequency convertor

PumpControl

Our Sales pleased to advise you:

NETWORKED PUMP TECHNOLOGY:

Visit us:ACHEMA 2015Hall 9 · Booth B 53

Pump technology of the fu

ture

We are ready:Industry4.0

Lise-Meitner-Allee 20D-25436 Tornesch/HamburgTel.: + 49 (0) 4120 706590Fax: + 49 (0) 4120 7065949 sales@witte-pumps.de

www.witte-pumps.de

Leading Gear Pump Technology since 1984

Lise-Meitner-Allee 20D-25436 Tornesch/Hamburg

Tel.: + 49 (0) 4120 706590

Fax: + 49 (0) 4120 7065949

info@witte-pumps.de

www.witte-pumps.de

Gear Pumps for transfer and metering in the chemical processing industry.

WITTE CHEM - Gear Pump Series

Special design for chemical applications

and well suited for use with corrosive or

The multitude of available materials for the

core components like gears and bearings of

the WITTE building block system guarantee

Spec.displacement

volume:: 0,2 cm3/rev

up to 12.000 cm3/rev

Viscosity: up to 1.000.000 mPas

Temperature: up to 580 °F

Suction pressure: Vacuum up to 215 psig

Intermediate sizes with narrower gears for

high-pressure applications are also available.

VISIT US ON ACHEMA

Hall 8, Booth F 36

Scan for

more information

about CHEM Series

ABEL GmbH & Co. KGAbel-Twiete 1 • 21514 Büchen Tel.+49 (41 55) 818 - 0 www.abel.com • mail@abel.de

Membrane PumpsSolids Handling PumpsHigh Pressure PumpsMarine Pumps

Energy saving pumping solutions for the chemical industry.ABEL can make your conveying process

pump technologies. Stop by our booth at the ACHEMA for your FREE Energy Savings Report and let ABEL show you the map to savings.

Gold Rush with ABEL: We help you Mine the Gold in your Process.

Hall 8 / Booth H47

p Global 201536

for API applications

New screw pump LEISTRITZ

GERMANY

New screw pump

Peter Bader

With the recently released L3MA se-

ries of triple screw pumps German

Leistritz Pumpen GmbH presents a

new series of pumps designed to

comply with API 676 3rd Edition.

API 676 — Positive Displacement

Pumps — Rotary, 3rd Edition, Nov.

2009, is a standard put forth by

the American Petroleum Institute. It

covers the minimum requirements

for rotary positive displacement

pumps for use in the oil & gas,

petro chemical, and chemical indus-

tries.

Triple screw pumps are self-

priming rotating positive displace-

ment pumps suited to handle various

oil types and other liquids with a min-

imum lubricating quality. The design

simplicity makes these screw pumps

intrinsically reliable and efficient.

Only three moving parts — a driving

spindle and two idler spindles—ro-

tate inside a casing with close toler-

ances, so forming sealed chambers

and provoking the axial displacement

of the fluid. The idler spindles rotate

without contact with the driving spin-

dle because of the fluid itself. The

accurate hydraulic balance and the

special profile of the screw thread

guarantee a continuous flow with

for API applications

mFig. 1 3D Graphic of the new L3MA Pump

lFig. 2 The L3MA built

in a lube oil skid.

LEISTRITZGERMANY

minimum pulsations and turbulence, resulting in

extremely low noise levels even at high rotational

speed.

The L3MA Features

The new pump has no separate steel casing

with an internal liner for the screw spindles to

run in. A new spindle material makes it possible

to have the spindles run directly in a steel cas-

ing and avoids an expensive construction with a

coating in a separate liner.

Only three static seals, executed as O-ring

seals instead of flat gaskets, are used. This

eliminates the risk of leakage due to insufficient

compressed flat gaskets. A single balanced act-

ing mechanical seal has been chosen as shaft

seal which proved itself in thousands of appli-

cations. A cartridge seal can be provided as an

option.

Suction and discharge flanges are accord-

ing to ANSI B 16.5 class 300 lbs. The L3MA

pump series is available in 12 different frame

sizes with defined rotor pitch angles. The maxi-

mum operating conditions of the pump are de-

fined with a max. flow rate of 276 m3/h, a dif-

ferential pressure of 20 barg and max. speed of

3600 rpm. A minimum viscosity of the pumping

fluid should be around 10 cSt to secure always

the required lubrication.

www.leistritz.com

Achema: Hall 8.0, F93

l No special internal coatings required

l Axial inlet for ease of piping

l Single bearing

l Single mechanical seal subjected only to

suction pressure, API 682 cartridge

l Seal optional

l Hydro-dynamically balanced rotors —

no thrust bearing required

l Quiet operation — no pulsations

l Low fluid shear

l High reliability/long service life/

low maintenance

l Low NPSH requirement

l Handles entrained gases

(advantage vs. centrifugal)

l High volumetric efficiency

Further technical highlights are

THE ENDURERSFOR EXTREME DUTY POWER TRANSMISSION:OUR ZERO MAINTENANCE DISC PACK COUPLINGS.

THE COUPLING.RW-COUPLINGS.COM

p Global 201538

LEWAGERMANY

With two current developments that could hardly differ more, Lewa GmbH,

a pump and system manufacturer based in Leonberg, Germany, reinforces

its reputation as a leading supplier of metering and process diaphragm

pumps: The Intellilab (l Fig. 1), a laboratory pump specially made for

technical centers, enables new processes and products to be developed

safely and reliably at pressures up to 500 bar. The hermetically sealed high-

pressure micro-metering pump is equipped with the latest drive and control

technology and has been available since January 2015. Unlike the Intellilab,

which enables reproducible metering of even the smallest quantities, the

G3M (l Fig. 2) is a robust workhorse for use in the chemical industry or

on offshore platforms. In addition to the triplex drive unit, which has been

on the market for about a year, Lewa is currently working on developing a

suitable line of pump heads. Initial orders have already been received for

both products.

the fluid is hermetically blocked

against atmosphere and the dis-

placement hydraulic system. Leak-

ages to the outside and the fluid

coming into contact with air are elim-

inated by the hydraulically coupled

metal diaphragm, which is particu-

larly well suited for metering small

flows. The pressure stiff hydraulic

actuation and the intelligent control

of the pump also keep the impact of

the pressure on the metered flow to

a minimum.

The special operation of the ser-

vomotor allows the pump in the table

housing to be capable of generating

low-pulsation volume flows. At a dis-

charge pressure of up to 500 bar, flow

rates between 10 and 500 ml/h at an

accuracy of ±1 percent are possible.

In automatic mode, the pump can be

controlled from a DCS via an analog

signal (0/4–20 mA). A new interface

is also well matched to the special

requirements in high-pressure labo-

ratories. In combination with various

closed-loop control structures, the

fluid kinematics can be adapted to

the requirements of the process and

the profile of the metered flow can be

modeled in nearly any way. In doing

so, the stroke volume (for example)

can be filled with the conveyed me-

dium, which is then gradually and

continuously displaced. Metered flow

profiles can also be programmed and

run in a controlled manner. The in-

put and visualization are carried out

via a color touchpad with intuitive

usability.

From the rugged process diaphragm pump to the high-precision micro-metering pump

The Intellilab is a logical evolu-

tion of the K3 and K5 micro-metering

pumps. The tried-and-true technol-

ogy was retained and enhanced by

adding the latest drive and control

technology, Lewa Intellidrive. This

technology controls the drive-side

angle speed dynamically during

operation. Unlike piston pumps,

which can also operate under high

operating pressure, the hermetically

sealed micro-metering pump is not

subjected to natural leakage. This

is an advantage, particularly when it

involves dangerous substances, not

even a tiny drop of which may escape

outside.

The Intellilab is primarily used

for accurate and reproducible meter-

ing in high-pressure synthesis and

hydration processes and within the

framework of mini-plants, because

mFig. 1 At a discharge pressure of up to 500 bar, flow rates

between 10 and 500 ml/h at an accuracy of ± 1 percent are possible. Various closed-loop control structures allow the fluid kinematics to be adapted to the requirements of the process and the profile

of the metered flow can be modeled in nearly any way.

p Global 2015 39

LEWAGERMANY

that regulates the change of the mo-

tor RPM, the number of strokes per

minute and thus the flow rate. Be-

cause all components are designed

for continuous duty, trouble-free

operation over 40,000 h is possi-

ble. Lewa drive technology has been

used for decades in such widely dif-

fering climate zones as the Arctic,

the tropics and desert regions.

New pump head family for all common applications

To fit the G3M, which can man-

age a maximum pressure of 750 bar

and a flow rate of approximately

50 m³/h, Lewa is also currently work-

ing on pump heads for every conceiv-

able application. The development

is based on existing and proven

technologies. The objective is to be

able to offer a complete series of

pump heads by the end of the year,

which can be matched perfectly to

the respective specific application.

Even high-pressure applications will

be possible with the M800 pump

heads, because the heads on the

G3M are designed for up to 750 bar.

For this year, Lewa also wants to of-

fer a synchronization of up to three

G3M pumps—as it is already possi-

ble for the other triplex models. The

objective is to reduce the pulsation

of the pumped liquid.

www.lewa.de

Achema: Hall 8.0, C62

piece, solid and triple-throw crank

shaft that requires only two roller

bearings. To attain better damping

of the swelling load, the bearings of

the connecting rods are designed as

friction bearing. Because an external

lubricating oil supply would be too

susceptible to problems, Lewa tri-

plex drive units lubricate the moving

parts via an oil bath or splash lubri-

cation.

As with other Lewa triplex drive

units, the primary applications of

the G3M are in the oil and gas indus-

try as well as the chemical process

industry. The chief application in

the oil and gas industry is injecting

monoethylene glycol and methanol.

In the process industry, a wide va-

riety of pumping tasks in pressure

ranges between 40 and 750 bar can

be managed with ease, including

vinyl acetate, slurry in wet oxidation

or high-pressure metering of liquid

ammonia. The flow rate can be con-

trolled using a frequency converter

The highly explosive gas re-

quired an absolutely leakproof spe-

cial design that withstands both low

temperatures and high pressure,

especially considering the transport

ships are dry docked for mainte-

nance only once every five years. In

implementing this solution, Lewa

relied on its experiences in the de-

velopment of the sister models.

The G3M is an intermediate size

with a stroke length of 120 mm. It

combines the positive features of the

other types. At a rod force of 125 kN,

a maximum output of 200 kW is at-

tained. Like all other models, the

newcomer to the portfolio features

a constant stroke length and is

designed with an integrated heavy-

duty worm gear. The monoblock drive

element housing with flanged-on

electric motor allows a design with

a minimum number of bearings and

sealings. A highly compact machine

is the result. The perfect phase offset

of the pistons is ensured by a one-

Rugged and compact design for trouble-free operation for over 40,000 h

The G3M, a heavy-duty, medi-

um-sized triplex drive unit, was origi-

nally developed to bring re-liquefied

boil-off gases to a high pressure

level, rendering these gases usable

for the engine of the LNG tanker. This

option is of interest not only because

the engine efficiency is much higher

compared to heavy fuel oil (HFO), but

also because environmental impact

can be drastically reduced by its use.

For example, NOx values are reduced

by 85 percent and SOx values are

even reduced by 100 percent.

kFig. 2 The G3M, a triplex drive unit made by Germany-based plant manufacturer Lewa, has a robust and low-maintenance intermediate size. This year, the manufacturer plans to add

a matching pump head series to the product line.

Motor-inverter makes it possible

The ErP directive allows the combi-

nation of IE2 motors with inverters

as an alternative to IE3 premium

efficiency motors. The purpose of

an integrated motor-inverter is to

save time and reduce costs in sup-

plementary material (wires and

racks mainly), study, installation,

programming and testing of the mo-

tor and inverter system, as well

as the dangers due to errors

associated with these

operations.

Therefore Motive developed the

patented, easy to program, easy

to use inverter with additional

analogic switch and knob,

IP65, with removable keypad,

remotable wireless, powered

by induction when placed in

its housing on the motor or

by lithium rechargeable bat-

teries. This inverter is designed

as a user-friendly turnkey inte-

grated system, with all parts,

motor, inverter and control

designed for outdoor use, and

with standard remote control.

The manufacturers of pumps

can thus offer a finished “plug-in”

product, without delegating risky

and costly installations to pump us-

ers. These need only to insert the

plug, wherever it is installed, and

decide if they want to bring the key-

pad with them.

www.motive.it

MOTIVEITALY

Frankfurt am Main · 15 – 19 June 2015

Be informed. Be inspired. Be there.

➢ World Forum and Leading Show for the Process Industries

➢ 3,800 Exhibitors from 50 Countries

➢ 170,000 Attendees from 100 Countries

www.achema.de

p Global 2015 41

with the new solenoid driven metering pump

New standards in accuracy and reliability

PROMINENTGERMANY

New standards in accuracy and reliability

with the new solenoid driven metering pump

The German manufacturer ProMinent developed a new metering pump for metering between 2 l/h and 45 l/h at a back pressure of 25 bar to 2 bar. As the successor to the solenoid driven metering

pump gamma/ L, it features a modern design with new electronics and many new functions. In particu-lar it offers a precise, low-wear solenoid drive, predictive control technology and intuitive operation. The gamma/ X independently ensures a smooth metering process at any time, massively improving the efficiency and accuracy of the capacity.

The gamma/ X is the first meter-

ing pump in its class to be driven

by a cleverly controlled solenoid. Its

innovative control technology gives

the new pump an important advan-

tage over conventional technologies.

Its model-based solenoid control

detects pressure variations and

protects the system against over-

pressure without the use of addi-

tional sensors. The stroke length can

be electronically set at between 0 and

100 %. Continuous metering charac-

teristics in the form of an elongated

metering stroke are beneficial with

volume-proportional metering of a

chemical into a primary flow, as they

ensure good mixing and there is no

need for a static mixer in the primary

flow. For the customer this means in-

novation in metering and production

processes.

Easy installation

Users benefit even at the instal-

lation stage: a standard tool is used

to fix the new solenoid driven me-

tering pump to the mounting plate.

There are also virtually no restric-

tions in terms of installation and

42 p Global 2015

PROMINENTGERMANY

ous scrolling through the various

operating layers, enabling intuitive

operation and programming of the

new gamma/ X: the capacity can be

quickly and simply adjusted in litres

per hour.

Stroke, stroke rate and meter-

ing profile are all freely parameter-

isable. A pressure display provides

information about the existing pres-

sure levels by the operator glancing

briefly at the screen. The three-level

LED status display on the front of

the unit is easy to read from a dis-

tance and from all angles, clearly

indicating the current operating

status, thereby guaranteeing an

overview of the current operating

status at any time.

Increase effective-ness, reduce costs

When in operation, the new

solenoid driven metering pump

gamma/ X detects varying pressure

levels, and fully automatically and

precisely adjusts its metering be-

haviour to the prevailing conditions.

Automatic bleeding optimises the

metering result when metering is

affected by gas bubbles pro-

duced by gaseous media. The pump

also adjusts its metering behaviour

with high-viscosity media. The intel-

ligent control technology works fully

automatically to ensure a smooth

metering process, enabling produc-

tivity and product quality to be in-

creased. And its service module also

indicates when the pump occasion-

ally needs maintenance.

Hydraulic deviations detected without the need of sensors

Its innovative control technology

gives the new pump an important

advantage over conventional tech-

nologies: its sophisticated solenoid

control detects hydraulic deviations

that can have an adverse effect on

the metering task. Overpressure,

ruptured discharge lines or negative

pressure and gas in the dosing head

are all detected without the need for

an additional sensor in the dosing

head.

The gamma/ X shows the cur-

rent pressure on its display. In the

event that the pump exceeds or

undershoots pre-set limit

values, an alarm be-

comes visible in the

display, which can

be transmitted via

positioning, as the status LED can

be easily read from all angles. The

clearly arranged pin configuration

prevents incorrect assignment. Op-

erating elements, simply accessible

from the front, as well as clear mes-

sages on the large display guarantee

fast maintenance.

Intuitively operated

The gamma/ X is fitted with a

large illuminated graphic display

with plain text in a number of lan-

guages. Parameters can be quickly

adjusted using the newly developed

Click Wheel. Four keys ensure fast

access without the need for labori-

p Global 2015 43

PROMINENTGERMANY

excessively strong pulsations of the incompressible

metering liquid. The gamma/ X masters all these ap-

plications with aplomb. If low-pulsation or continu-

ous metering is called for, the compression stroke

can be performed correspondingly slowly on the

gamma/ X due to the controlled solenoid drive.

www.prominent.com

Achema: Hall 8.0, J64

The stroke length can be electronically set at

between 0 and 100 %. Continuous metering charac-

teristics in the form of an elongated metering stroke

are beneficial with volume-proportional metering of

a chemical into a primary flow, as they ensure good

mixing and there is no need for a static mixer in the

primary flow. Low-pulsation metering characteris-

tics can also be necessary with rigid metering lines,

to prevent damage to the pipework or the pump by

relays or the bus interface, thereby preventing

damage through early detection and shut-down

of the system and pump.

Safety without the need for additional components

The integral pressure monitor is a reliable

back-up system for the existing manometer and

pressure relief valve. Showing the pressure on

the display simplifies commissioning, monitor-

ing and troubleshooting.

The three-level LED status display on the

front of the unit is easy to read from a distance

and from all angles, clearly indicating the cur-

rent operating status and guaranteeing fast

and clear detection — regardless of the instal-

lation location — from any position. There are

therefore virtually no restrictions in terms of

installation and positioning.

The optional diaphragm rupture sen-

sor guarantees additional safety and triggers

an alarm, resulting in the metering pump

switching off in the event of a simultaneous

fault indication.

Higher product quality through seamless metering processes

Its model-based solenoid control detects

varying pressure levels and fully automatically

and precisely adjusts its metering behaviour to

the prevailing conditions. Automatic bleeding

optimises the metering result when metering

is affected by gas bubbles produced by gase-

ous media. The solenoid driven metering pump

gamma/ X can protect the system from over-

pressure, as it detects all pressure deviations.

The operating range extends from 1 ml/h

to 45 l/h, the adjustment range is 1:2,000 and

reproducibility of accuracy is +/– 2 %.

Dickow Pumpen KGSiemensstraße 22, D-84478 WaldkraiburgPhone 08638/602-0, Fax 08638/602-200E-Mail: verkauf@dickow.de · export@dickow.deInternet: http://www.dickow.de

The new GML Gear Pump withMagnet Coupling and TuthillGlobal Gear combines decades ofexperience and offers unparalleledperformance and reliability.

June 15 - 19 Hall 8 / D54

New ProductNew Product

44 p Global 2015

energy saving

The importance ofThe importance ofSAERITALY

SAER, with more than 60 years of

experience in water field, invests

more than 6 % of his annual turno-

ver in R&D whose aim is to reduce

wastage of water and energy and

enhance productivity. The company

offer pumps with a complete range

of operating options, variable speed

running for applications such as

l general irrigation,

l water intake and distribution,

l drinking purposes,

l agriculture,

l industry,

l HVAC,

l power generation,

l municipalities,

l mining,

l off shore,

l naval groundwater supply,

l pivot feeds, etc.

Water has to be treated accord-

ing to its final use. SAER pumps are

constructed for extended operation

in the toughest environments from

corrosion-resistant Duplex or AISI

316 Stainless Steel or Bronze Marine

as appropriate — and customization

isn’t a problem: recently the com-

pany inaugurated a new Division

for Big Projects where the qualified

staff is able to drive in the selec-

tion of tailored solutions. All styles

can be customized to suit the exact

application with the warranty of

100 % Italian origin and quality. Over

2,000 types of pumps are made in

5 metallurgies, with one of the best

delivery time on the market: the

average, doesn’t matter the size of

the pump, is 10 working days.

The range includes SKD Split

casing pumps (up to 5,000 m³/h),

TM multistage pumps (up to

64 bar), NCBK end suction pumps

(2,500 m³/h max flow) submers-

ible, monoblock and residential

pumps, booster sets and surface

mFig. 1 Installation of a 14 inches submersible pump and motor.

energy saving

nFig. 2 SAER end suction pumps.

SAERITALY

supply. Due to its enduring

magnet motor and its inverter

driver, the SL Solar System

ensures even water distribution

to all areas, even where there is

little or no power supply.

l T-One exclusive electronic pres-

surization system with innova-

tive technology maintaining a

consistent delivery of pressure,

regardless of the demanded

flow, ENERGY SAVING because

of its automatic regulation.

Pump systems can also be

supplied with a dry run protection

system, to avoid damage to pumps

from loss of prime situations.

SAER is also provided with two

state of the art testing room for the

test of pumps and motors, both sur-

face and submersibles. All the pro-

duction is tested inside the facilities

and also third part witnessed tests

are performed, with international

certifications bodies too.

www.saer.it

and submersible motors up to

400 HP.

The Italian manufacturer has

further increased it’s huge range of

pumps and motors. Efficient, save

and quality technology: these are

the keywords for further innovations

totally made in Italy:

l Latest series of submersible

pumps from 6” up to 12” at

highest efficiency, series VS,

available in Stainless Steel

AISI 316, Bronze marine,

Carbon steel and DUPLEX. With

such a choice the applications

are wides: Oil&Gas, mining,

agriculture, civil, industrial etc.

l range of surface motors from

7.5 kW to 55 kW 2-pole and

4-pole with IE3 efficiency levels,

both for monoblock pumps and

normalized.

l With a view to achieve sustain-

able growth, SAER has devel-

oped SL Solar, the ultimate

solar powered system for water

Pumps and Valves - Experience, Responsibility, Passion.

www.klaus-union.com

made in Germany

Vogelsang & Benning Prozeßdatentechnik GmbH

Tel. + 49 (0) 2 32 75 47-0www.vogelsangbenning.de

Hansastraße 92D-44866 Bochum

We supply test systems for:

• Centrifugal pumps• Displacement pumps• Submersible pumps• Compressors• Booster stations

Test systems for the pump industry

Pumps for nearly any application – each one requiresa special testing system

ww

w.ic

d-m

arke

ting.

de

p Global 201546

SCHMALENBERGERGERMANY

Stepping up the pressure with self-priming centrifugal pumps

Dietmar Rogg

Among the outstanding properties

of these self-priming pump series is

the capacity for sucking in contami-

nated oils and emulsions with high

air content. Now Schmalenberger is

presenting several more additions

to its existing range of these ultra-

efficient pumps.

A completely new concept is

represented by the multi-stage self-

priming KSP centrifugal pump. Up to

now this pump series was designed

just for use with low pressures and

large flows. As a result of its variable

modular system, the KSP can now

cover the higher hydraulic ranges

of up to 10 bar pressure, as well as

handling lower flows of 20–160 l/

min. The manufacturer has achieved

this by a combination of different

pump hydraulics and the multistage

configuration within a single unit.

This extends the range for use in

industrial applications, making it

perfectly suitable for supply to filter

systems and pumping of coolant

fluids in the machine industry. The

high hydraulic efficiency of this

pump series guarantees highly effi-

cient energy consumption.

In order to meet international

conditions and the various associ-

ated energy requirements (e. g. of

the IE3 class), the series of self-

priming pumps has now been ex-

panded with the addition of a new

docking module. This offers the pos-

sibility of installing standard mo-

tors of various international manu-

facturers. Here Schmalenberger is

responding to extended customers

requirements, so that not only Eu-

ropean but also American and Chi-

nese standards of efficiency can be

complied with — without however

any compromises being made in

terms of the versatility of the prod-

uct series.

And Schmalenberger has taken

another step forward with its SMK

pump. This model can be supplied

together with an innovative ISI (Inte-

grated Simple Inverter) system. The

SMK is also capable of pumping liq-

uid and gas mixtures with an air ra-

tio of 15 %, works in slurping mode

and is self-priming for up to 3 m.

Ideally it should be installed above

medium level. Due to the open ge-

ometry of the impeller, it can handle

solids up to a size of 5 mm. The SMK

is made of corrosion-resistant and

highly durable plastic. With its low

weight and compact design, the

pump is easy to install. Further ben-

efits are low noise level and reduced

vibrations. The SMK can handle

flows up to 55 m³/h, with a pressure

of 1.7 bar.

The ISI system is a high-tech

motor control system, characterised

by a space-saving design of both mo-

tor and inverter. The electronic com-

ponents are built into a robust die-

cast aluminium housing. Notable

benefits are the ease of installation

p Global 2015 47

SCHMALENBERGERGERMANY

with or without a display screen. For

example, the SMK’s integrated field

bus interface (ProfiNet, Profibus,

CAN Open) means that it can easily

be linked to various automated sys-

tems. Additional product-integrated

analogue and digital interfaces are

available upon request.

www.schmalenberger.de

Achema: Hall 9.0, B53

motors of past decades, to the per-

manent magnet motors that are in

demand today and even the reluc-

tance motors that stand for the fu-

ture. Due to its streamlined design,

the entire ISI system can hardly be

distinguished from the traditional

and familiar electrical motor. The ISI

controls include interfaces and func-

tions for the processing of standard

signals and can be supplied either

bly. The integrated inverter software

is designed to handle both current

and future motor systems — from

the tried and tested asynchronous

and ease of operation, based on an

intuitive operating interface, whose

robust buttons enable the pump set-

tings to be adjusted swiftly and relia-

n

The SMK pump with an innovative Integrated Simple Inverter

www.ktr.com

Thanks to new material and production technologies the fail-safe ROTEX® Non Sparking can continue to operate if the spider has worn off with no danger of sparking, ensuring a carefree operation in hazardous locations.

More safety for hazardous locationsHall 9.0 Booth C4

ti

In this YouTube movie you will get

details about a self-priming sewage

pumps for clean and polluted

liquids or media with gaseous

inclusions. Fields of application:

coolant supply, environmental protection technology,

surface technic, water supply and -filtration.

p Info-Plus

p Global 201548

More than 40 ye SEKOITALY

Established in 1976, Seko S.p.A.

is a leading manufacturer of

metering pumps and dosing sys-

tems. His long activity allowed Seko

to acquire a vast experience

in diversified applications

and reliable solutions for

the dosage and injection

of chemicals, maintaining

an efficient control of the

related process parameters.

Today Seko is an Interna-

tional Group operating with

three business units each one

designing and man-

ufacturing selected prod-

uct lines for dedicated markets

with different applications on

customer specifications.

Process & System

Seko P&S business unit

was born in 2002 after the merge

between Seko Italia S.p.A. and Bono

Exacta S.p.A. active in the oil & gas

industry since 1958. This operation

has expanded the product range,

its expertise and has immediately

given the “entry pass” to the oil &

gas market.

This business unit currently de-

signs, produces and supplies pumps

and systems to oil & gas, energy,

chemical and petrochemical, food

& beverage, ceramic, pharmaceuti-

cal, paper and textile industries. It

is able to provide a qualified support

on commissioning and start-up on

pumps and systems, an assistance

for maintenance activities and spe-

cific “on job” trainings for End-Users.

The product range is composed of

l plunger metering pumps,

l mechanical diaphragm meter-

ing pumps and

l hydraulic diaphragm metering

pumps.

Seko P&S provide even chemi-

cal injection packages completely

designed and manufactured under

customer specifications (l Fig. 1).

To be closed to the Middle Easter

End-Users a specific site is located

in UAE.

Main products of the P&S unit

are

l plunger and

l hydraulic double diaphragm

metering pumps Nexa Series

(l Fig. 2).

Designed according to the API

675 standards, this series is char-

acterized by flexibility and modular-

ity of combining different metering

units, even on site. The specific

design tailored on customer speci-

fications is our “daily job”. The

compliance with ATEX European

Directive makes SEKO pumps suit-

able for being installed in classified

areas.

Seko P&S is ready to introduce

a new high pressure pump — the

BN pump’s model is an extension of

Nexa series working at a discharge

pressures up to 350 bar gauge.

Designed according to API 674

Standards, Triplex series has spe-

and

rFig. 1

Chemical Injection package

p Global 2015 49

SEKOITALY ars in metering

allows these pumps to be installed

in hazardous areas.

The mechanical diaphragm and

plunger pumps Exacta series with

spring return mechanism are a solu-

tion for industrial application where

chemicals have to be pumped l

is designed according to the API 675

Standards. This pump is suitable for

those applications requiring high ac-

curacy. The possibility of construction

with various materials allows these

metering pumps to satisfy every ap-

plication where safe and reliable

dosage is a must. Their compliance

with the ATEX European Directive

qFig. 2 Nexa Series—

API 675 plunger and hydraulic double diaphragm

metering pump

dosingcific design of the mechanism which

allows the pump to operate at a very

low speed without forced lubrication

where a slow plunger motion

is required e.g. to avoid cavi-

tation when pumping viscous

liquids, hot products or liquids

have a low vapor pressure.

The pump can be designed to

be remotely or automatically

controlled to meet the process

needs.

The hydraulic diaphragm

metering pumps Nyva series

50 p Global 2015

Cleaning & Hygiene

Seko C&H business unit

occupies a prominent position

in the global market for cleaning

and hygiene solutions. The company

is the world’s largest manufacturer

of peristaltic pumps for commercial

laundry and ware washing applica-

tions. Seko C&H is the market leader

for integrated pumps in commercial

dishwashers, with market share of

over 80 % in Europe.

The blue peristaltic pumps

from the PR series are now consid-

ered an international standard and

have gradually come to epitomize

peristaltic pumps in general. Dosing

systems from the Smart series are

used in machines with a capacity

up to 100 kg. Motor-driven

pumps such as those from

Spring series are used in

larger machines and tun-

nel systems.

www.seko-group.com

Achema: Hall 8.0, J63

cal and physical parameters

in industrial processes. The

instruments are completed by

sensors and accessories ena-

bling them to be installed in

any application.

l Swimming pool dosing sys-

tems

driven pumps features a high

level of reliability and accuracy

guaranteeing excellent quality.

Three sizes of mechanism and

a wide selection of models with

different performances allow

the user to find the appropriate

solution for almost any ap-

plication.

l Measure and control instru-

ments for monitoring chemi-

safely. Its low maintenance cost is

one of the main reasons to choose

these models.

Water & Industry

Seko W&I business unit of-

fers a complete range of products

for measuring and monitoring the

chemical and physical properties of

water. A whole range of accessories,

such as tanks, stirrers, water meters

and level probes, complete an ideal

installation. W&I currently supplies

its products for the treatment of pri-

mary water, waste waters, industrial

processes, swimming pools, cooling

towers, agriculture, fertilizing and irri-

gation. Main products of W&I unit are:

l Solenoid dosing pumps: The

construction technology and

the great chemical compat-

ibility of the components make

these pumps extremely precise

and versatile. Thanks to their

microprocessor-based electron-

ics, they adapt easily to any

dosing requirement.

l Motor driven pumps: The

spring return range of motor

SEKOITALY

nFig. 4 Nyva Series—API 675 hydraulic

diaphragm metering pump

rFig. 3 Triplex Series—API 674

three plunger reciprocating pump

LEISTRITZ PUMPEN GMBH

The Screw of Archimedes

L3 Triple Screw Pump

L4 Twin Screw Pump - Double Volute

L2 Twin Screw Pump - Single Volute

Markets & Industries

L5 Five Screw Pump

Tradition meets Innovation

Leistritz Pumpen GmbHMarkgrafenstrasse 29-39 | D-90459 NurembergPhone: +49 (0)911/4306 - 0 | Fax: +49 (0)911/4306 - 490E-Mail: pumps@leistritz.com | www.leistritz.com

Capacity max.: up to 22,000 GPM (up to 5,000 m3/h)

Differential Pressure max.: up to 4,060 psi (up to 280 bar)

Leistritz Screw Pumps and Systems

Leistritz Pumpen GmbH, with its headquarters in Nuremberg/Germany, has been producing Screw Pumps since 1924. Latest Technology in combination with strictly controlled quality is the basis for the globally

Leistritz serves all kind of markets and applications.

Please visit us at ACHEMAHall 8 / Stand F93

BUNGARTZMASTERPIECES

SEAL OF TRUTH

Representing the groundbreaking special centrifugal pumps from the Bungartz collection, series production

As a leading representative from the era of long-lasting creations, we present the horizontal centrifugal pump M-UMOR. Its hydrodynamic seal shines thanks to its complete safety. Possible explosions are nipped in the bud, so it‘s perfect for abrasive and volatile media. A magnificent acquisition!

More under 0211 57 79 05 - 0 and: www.bungartz.de/masterpieces6

Visit us at ACHEMA 2015, Hall 8, Stand C 1

p See us in Frankfurt Hall 8.0, Booth L94

p Global 201552

SCHROEDERGERMANY

A valve for high pressures and all load conditions

Schroeder Valves has developed a

new automatic recirculation valve

for high and very high pressures.

To to ensure the highest degree of

quality and functionality, the com-

pany is currently constructing a test

stand for pressures up to 400 bar.

Schroeder Valves has devel-

oped a new automatic recirculation

valve for high and extremely high

pressures, which also works reli-

ably under highly fluctuating load

conditions: the SHP-series auto-

matic recirculation valve. With the

innovation, the specialist in pump

protection valves is responding to

the requirements of its customers,

primarily from the field of power

plant and plant construction and the

offshore industry.

“The SHP takes the general

development of higher pressures

and temperatures and the in-

creased energy-efficiency require-

ments into account,” explained

Axel Mücher, managing partner

at Schroeder Valves. “Alongside

this, the changing way in which

plants work was also taken into

consideration in the development

of the SHP. Special load sequence

power plants, such as modern com-

bined cycle power plants and coal-

fired power plants, are operated at

partial load for a large proportion

of their operating time, on account

of the increasing high proportion of

regenerative energy generation and

highly fluctuating load conditions.”

The SHP is the ideal minimum

flow device for these conditions:

Thanks to multi-stage pressure re-

lease control over the entire mini-

mum quantity range, wear is mini-

mised — even in the case of long-term

partial load operation. The particu-

larly wear-critical area near to the

bypass closing point in the bypass is

automatically overdriven by the con-

trol characteristics, without the range

of movement of the equipment being

limited. The shut-off for the bypass

function and the pressure reduc-

tion function are clearly separated

in terms of location. Furthermore,

the shut-off element for the bypass

has no throttle function whatsoever.

Thus, the seal of the bypass is not

affected should limited wear occur to

the pressure-reducing components

during operating time. The radiation

of the sealing surfaces, which can

ultimately lead to the total failure

of the sealing function, is safely

avoided. Furthermore, the seal seat

is located in the direction of flow,

upstream from the flow-regulating

fittings and thus in the area of high

static pressure, and consequently

far removed from the cavity-suscep-

tible pressure level at the end of the

throttle section.

Schroeder Valves has each valve

undergo a 100 % pressure and func-

tionality testing prior to delivery. To

ensure this also with the SHP, the

company is currently adding to their

flow test center a test stand for pres-

sures up to 400 bar.

The SHP builds on exist-

ing Schroeder Valves

technology. The

company already

has years of op-

erational experience

with almost all of the

effective principles and as-

semblies used. As such this can

be considered ‘Proven Equipment’.

The individual system components

have simply been modified and in-

novatively combined, as such that

they enhance the dependable and

low-wear area of application of the

existing technology to meet the in-

creased requirements. Thus, the

new SHP-series automatic recircula-

tion valve enables and promotes the

energy-efficient operation of modern

power plant facilities.

www.schroeder-valves.com

Achema: Hall 9.0, E59

The Schroeder High Pressure Valve

(SHP) is an automatic recirculation

valve for high and extremely high

pressures, which also works reliably

under highly fluctuating load conditions.

See more details in this video.

p Info-Plus

p Global 2015 53

is able to offer complete dosing sys-

tems, including control technology

for automated work processes.

In the seventies, another impor-

tant milestone in the dosing indus-

try was the development of the KKV

pump (Klotz Kaltverweil method) for

textile dyeing, which was so success-

ful that it continues to be used by

the textile industry all over the world

today, now updated with state-of-

the-art technology.

sera’s latest technical achieve-

ments include the following pumps

which were exhibited at this year’s

Achema:

l The new sera iStep diaphragm

dosing pump, which combines

an intelligent drive concept with

the accuracy of a diaphragm

dosing pump and thus sets new

standards in terms of accuracy

and reliability.

l The new ecoBlue solenoid dia-

phragm dosing pump, which

offers more than quality and

reliability, is economical from the

start and covers simple solutions

in the area of chemical dosing.

l The new sera R509.1 distin-

guishes itself with a highly ac-

curate dosing capability even for

high flow rates with high counter

pressures and is used, for exam-

ple, for the addition of additives

in the petrochemical industry.

www.sera-web.com

Achema: Hall 8.0, K63

From baking trays to dosing specialistCommitted to tradition, the name

sera (Seybert & Rahier) has stood for

quality, innovation, competence, reli-

ability, efficiency and flexibility since

it was established in May 1945. After

initially manufacturing household

utensils (baking trays, pots, ladles,

cake tins and smokers) and repairing

agricultural machinery, the range was

expanded to include more technically

sophisticated products, such as dry

sterilizers, multifunctional chemical

devices and the sera magnetic car

lamp. sera responded quickly to the

chemical industry’s rising demand

for dosing and feeding pumps for

acids and was already producing the

first acid pump for Farbwerke Hoechst

in July 1948. sera employee Martin

Hergt’s design principle of the dou-

ble diaphragm pump was patented

in 1950 and is nowadays a globally

recognized technology. This success

proved right for the young business

and from now on it focused on the

development and production of oscil-

lating positive displacement pumps.

In 1958 sera transferred the

design principle of the oscillating

displacement machines to oil-free

compression and pumping of gases

and built the first metal diaphragm

compressor. This laid the foundation

for the division which continues to be

successful to this day — nowadays

as an independent company — sera

ComPress. With more options for

producing tanks, valves and miscel-

laneous fittings now available, sera

SERAGERMANY

engineering for a better world

GEA Tuchenhagen GmbHAm Industriepark 2 – 10, 21514 Büchen, GermanyPhone +49 4155 49-0, sales.geatuchenhagen@gea.comwww.gea.com

GEA Tuchenhagen offers a complete portfolio of normal and self-priming centrifugal pumps – exactly tailored to your needs.

Lowest energy and detergent con sumptionGentle product handling Flow rates from 1 m³/h to 210 m³/hEHEDG certifi ed

Future conveyingHygienic pumps –optimized for effi ciency

p Global 201554

Efficient marathon runners

URACAGERMANY

These high pressure pumps are de-

signed in compliance with API 674

for pumping toxic and flammable

fluids at continuous operation. The

particular advantage of these pumps

is the high and constant volumetric

efficiency allowing economical op-

eration, independent from flow rate

and operating pressure.

The reciprocating pump series

cover a power range

l up to 1,300 kW

l for maximum capacities of

300 m³/h and

l operating pressures of

3,000 bar.

Plunger pumps for the oil & gas

and petrochemical industry can be

used for a variety of applications.

Uraca pumps meet the demands

of typical up and downstream

application features, whether as

hydrostatic test pressure pumps for

pipelines and well service or as in-

jection pumps for salt water, glycol,

methanol and supercritical CO2 and

for wash water and catalysts in the

cracking process.

Process pumps at fluid tempera-

tures of up to 350 °C used for the

gasification process of oil residues

(IGCC) and the coal to liquid process

(coal liquefaction) have long proved

their excellent marathon condi-

tions—25,000 operating hours be-

tween service intervals are not an

exception.

Long-standing life and reliability

are based on an exact design and siz-

ing of pump and components. Uraca

uses pulsation dampers subject to

the reflection principle, so-called

resonators. The dampers are without

internals, which means that they are

maintenance-free, thus exceeding

customer’s expectations by far.

www.uraca.com

Achema: Hall 8.0, E38

kFig. 1 Typical high pressure

injection pump unit with maintenance-free pulsation

dampers as used in oil & gas industry

lFig. 2 High pressure pump

unit P5-96 for coal liquefaction

This YouTube movie describes the

function of a high pressure plunger

pump using a 3D animated model.

It shows an insight into the

mechanics and hydraulics of a

positive displacement pump, starting with the rotation of

the crankshaft and the implementation into an oscillat-

ing motion up to the action of the suction and discharge

valves.

p Info-Plus

This movie describes the functiona -

lity of positioning devices for the

tank cleaning heads for the internal

cleaning of containers and vessels

with high pressure water. Several

positioning systems with varying degrees of automation

are presented.

p Info-Plus

A refurbishment project with German participation in Jordan is aiming at modernizing and thus securing the water

supply for the city of Madaba. One-third of the project fi-nancing was provided by the GIZ (German Society for Inter-national Cooperation) with two-thirds coming from future cost savings. This is made possible by the deployment of efficient pumps from the Dortmund company, Wilo, at the Wala and Libb pump stations.

to be poor. Developing a modern

and futureproof yet affordable water

supply system there calls for innova-

tive solutions. Just how this may be

structured and financed is demon-

strated by the Wala-Libb project, in

which the Dortmund pump manufac-

turer, Wilo, is involved.

Steep wadis hamper infrastructural link-up

Wala and Libb are located in the

mountain region of eastern Jordan,

close to Madaba, the ancient “City of

Mosaics”. l

For many people in Jordan, hav-

ing adequate drinking water is not

something they can take for granted

because the country’s geographi-

cal conditions make extraction im-

mensely difficult. Furthermore, the

country has barely any natural re-

sources and is therefore considered

WILOGERMANY

55p Global 2015

kFig. 1 Foundations and

technology are clearly attacked in the pumping station Wala. Leaks cause water outlet and

corrosion damages. In the past, some of the splitcase and ring

section pumps have been replaced in such a way that the

pipe routing is now unfavourable. The efficiency of the technically

outdated equipment is not higher than 50 to 30 per cent.

The planned modernisation will provide modern pumps

with an efficiency of 75 per cent.

Cost-neutral modernisation

secure water supply in Jordan

Cost-neutral modernisation

secure water supply in Jordan

p Global 201556

There, around 30 kilometres south

of the country’s capital city, Amman,

the landscape is riven by steep-

walled valleys. These so-called

wadis, engraved by riverbeds bear-

ing water only after strong rainfalls,

dissect the tableland on which the

majority of settlements are located.

“That is precisely the problem,” says

Dr. Amer Mokbel, Wilo’s Sales Area

Manager Gulf. “The differences in

altitude between the Jordan Valley

and the tableland can be as much

as 1,400 metres and the ground-

water — the only source of water

in the area — lies very deep in the

WILOGERMANY

earth. Conveying this life-giving

water to the people on the table-

land is therefore a very complicated

matter.”

Altitude of al-together 700 metres overcome to secure water supply

The elevated city of Madaba

is also affected by this difficulty.

Two stages are required in order to

raise the drinking water extracted

at a depth of 250 metres up to the

city. The pump station in Wala, lo-

cated in the valley, transports the

water halfway up the slope to the

Libb pump station from where it is

then conveyed to Madaba. In doing

this, the supply system overcomes

an altitude of 460 metres. “In past

years, outdated, inefficient and

increasingly dilapidated technical

equipment had been causing still

more problems,” Dr. Amer Mokbel

reports. “It was therefore urgently

necessary to upgrade the pumps in

order to ensure that the people of

Madaba were adequately and reli-

ably supplied with water. However,

the Jordan water authority was un-

able to finance this project.” Work-

ing together, three project partners

came up with a way of undertaking

the 440,000 euro upgrade without

equity capital.

Energy saving finances construction project

The financing concept foresees

that one-third of the entire amount

will be provided by the GIZ (Deutsche

Gesellschaft für internationale Zu-

sammenarbeit) from its fund for

Development Partnerships with the

57p Global 2015

spent one year assisting staff at Jor-

dan’s central workshop to draw up

new work plans, optimise processes,

and set up a quality management

system in line with modern stand-

ards. To make these results sustain-

able, the workshop employees were

given comprehensive training. Given

the good working relationship, the

Jordanian Ministry of Water and Ir-

rigation, and the Water Authority

Jordan registered the Dortmund com-

pany as a reliable project partner.

High efficiency helps cut CO2 and costs

Wilo had another opportunity

to work in Jordan in 2009 when the

Water Authority Jordan, which is

responsible for the operation of all

water plant, sought manufacturers

of high-efficiency pumps as part of

a pilot project in conjunction with the

a volume flow of 1400 m³/h. The

aim is to provide Madaba with 7 to

9 million cubic metres of water per

annum.

Quality manage-ment for the central workshop

Wala-Libb is already the third

project that Wilo is undertaking in

Jordan. The company’s good links

with the country were formed in

2006 when the GIZ was looking for

a manufacturer of pressure shroud

pumps as a cooperation partner for

a lengthier assignment in Jordan.

The idea was that repair and servic-

ing plans would be drawn up for all

pumps owned by the state, which

were looked after by the country’s

central workshop. Owing to its long-

standing experience in this area,

Wilo was awarded the contract: Em-

ployees from the German company

project financeable. “Wilo provided

pre-financing of the construction

work for three years,” Dr. Amer Mok-

bel explains. The pump producer is

acting here as a partner of the Jor-

danian consulting engineering main

contractor, Engicon, which handles

many public-sector construction

projects in the water sector. “Engi-

con receives part of the returns from

the energy savings and reimburses

Wilo’s outlay on a six-monthly ba-

sis.” In this way the financing is to

be paid off within three years under

the terms of the contract signed in

December 2013.

The new pumps—high-performing, robust and reliable

The delivery of the pumps,

their installation and their commis-

sioning will take place in April. The

Wala pump station will receive four

pumps, and a further four will be

installed in Libb. Wilo will not only

be delivering the pumps, but will

also oversee their installation and

the start of operations. Furthermore,

employees of the central workshop

in Zarqa—which services and repairs

all of the country’s pumps—will be

trained on the new models. It is not

only their high performance and ef-

ficiency that sets these pumps apart:

because of their robust construction

they can also work reliably under

difficult operating and unfavour-

able climatic conditions. At Wala and

Libb the pumps with output of 315

kilowatts and a maximum delivery

height of 232 metres, will produce

WILOGERMANY

Private Sector. The operator — the

Jordanian water supply company,

Miyahuna — will cover the remaining

two-thirds, solely from the savings

achieved through the efficient opera-

tion of the upgraded plant. This cal-

culation works out thanks to pumps

from manufacturer, Wilo, which use

highly efficient technology. These

modern pump models have an ef-

ficiency factor of up to 75 per cent,

thus far outstripping the old equip-

ment which achieved a factor of 30

to 50 per cent. The resulting reduc-

tion in energy consumption and op-

erating costs makes the high-tech

nFig. 2 The pylons are the first thing that catches ones eye when

overlooking the pumping station in Libb. They guarantee the energy supply of the pumps. The planned modernisation and the utilisation of

efficient Wilo pumps will reduce the electricity consumption of the station significantly. The savings contribute significantly to

financing the renovation measures.

p Global 201558

tions should be completed before

summer so that Madaba’s supply is

secure during the hot season.

www.wilo.com

rity, “even though it is also possible

to finance better quality acquisi-

tions, as Wala-Libb proves.” The

modernisation of the two pump sta-

as “a successful combination of busi-

ness, ecology and help for self-help”

(June 17, 2012).

Quality can be financed as well

The current project in Wala-Libb

continues this excellent working

relationship. “For us it is important

not only to deliver the pumps, but

also to work on achieving an exact

fit for the given use,” says Dr. Amer

Mokbel. “At Wilo we understand

energy efficiency, the responsible

treatment of resources and the

environment, and the development

of innovative concepts. We use this

specialist knowledge to help our

clients find and implement custom-

ised and optimised solutions.” The

Syrian expert also has a personal in-

terest in projects such as Wala-Libb:

“Quality pays for itself. I would like

this to be more broadly recognised

in the countries of the Middle East.”

He says that, too often, people opt

for cheap products that break down

quickly and jeopardize supply secu-

GIZ. The object of the project was to

save energy and reduce CO2 emis-

sions. As Jordan’s biggest consumer

of electricity, the authority, which

uses 15 per cent of the country’s

electricity with its pump operations,

has a very special interest in making

Jordan’s water management system

more eco-friendly and less expen-

sive. The main focus here was on ob-

solete pumps which, in many cases,

had an efficiency factor of only 20 per

cent. Within the scope of the Interna-

tional Climate Protection Initiative,

launched by the Federal Ministry for

the Environment, Nature Conserva-

tion, Building and Nuclear Safety, the

authority contracted Wilo to modern-

ize the Ebquoreyeh pump station.

The manufacturer succeeded in ex-

ceeding the specified targets: Since

then 40 per cent of the electricity

previously required for operation is

now being saved, thanks to the high

efficiency of the Wilo pumps. After

just one year the investment costs of

300,000 euros had been amortised.

The news paper, Westdeutsche Allge-

meine Zeitung, described the project

(DPPs) is one of two strategies with which the GIZ (Deutsche Gesells-

chaft für internationale Zusammenarbeit) is aiming to improve coop-

eration between the private sector, the public sector and civil society

in developing and emerging countries in Africa and Asia. The other

strategy approaches this objective via structure-building capacity

development. The two procedures complement each other: Apart from

the concrete objectives of the respective projects, the Development

Partnerships are also intended to serve as implementation and learn-

ing examples for public-private dialog, and to stimulate ideas.

Development Partnerships with the Private Sector

WILOGERMANY

mFig. 3 The pumps in the pumping station Libb are

controlled via these switch cabinets. It has to be tested whether they can be used in the modernised system.

m

Fig. 4 Dr. Amer Mokbel is Wilo Sales Area Manager for the Gulf area.

The native Syrian takes care of projects in the Middle East from the German company site in Hof.

59p Global 2015

MASTHEADp Global

p Global is the worldwide partner magazine of the Unique German Pump Magazine p.It concentrates exclusively on pump technology, techniques for transporting and dosing of liquids, fluids and gas as well as their applications

Publisher Rüdiger Nagel

Editorial department Rüdiger Nagel Phone + 49 71 27 / 5 66 09 ruediger.nagel@pumps-directory.com

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Circulation 6.000 copies

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