Metalworking Archivi - Stella O.M.

26 May 201926 May 2019

Suction of contaminated lubricants, pumps for dense mixtures and very viscous oils.

Difficulty on extracting and aspirating contaminated lubricants.

The purpose of the application is to simplify the aspiration and replacement of contaminated lubricating mixtures in the gearboxes and drive units present in the wind turbine generators. The maintenance operations foreseen on the wind generation devices are quite frequent. Particularly difficult is the extraction of a type of lubricant which has the consistency of a fluid grease which, once its tribological properties have been exhausted, is replaced also because it contains a significant quantity of contaminating metallic microparticulate generated by the normal wear of the mechanical components.

The dense and viscous consistency of the lubricant creates various complications for maintenance purposes. The biggest problem is the difficulty in aspirating the contaminated lubricants of the gearbox. Our customer experimented different solutions to solve problem without reaching the desired efficiency levels. The different type of pumps put into the test, did not meet expectations, or proved to be ineffective or even damaged very quickly.

Also involved in the affair we were asked to offer our solution. We proposed a pump that would certainly have been the ideal solution for the suction of contaminated lubricants. A HCP 15 peristaltic pump equipped with a very compact electronic speed variation system.

The peristaltic pump, a good solution.

The small unit is particularly light and manageable, easily lifted up to the wind generator’s nacelle. Once started, the large vacuum produced by the HCP 15 peristaltic pump allows the suction of contaminated lubricants and dense mixtures with simplicity. The possibility of varying the flow rate of the pump allows to maximize the performances according to the different viscosity of the sucked lubricating fluids.

The light and compact inverter that the pump is equipped with is managed with a practical keypad with very simplified functions to be used by any operator.

The pump naturally is selfpriming capable and does not damage if it works occasionally dry. The pump do not suffer any damage generated by the presence of solid metal particulate present in the lubricating mass. The machine fully met the expectations of the customer, who with a modest investment was able to equip himself with a definitive solution, easy to use and truly effective for the aspiration of contaminated lubricants.

More information on the pump: Hose Carrier HCP 15

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22 September 201823 September 2018

Pumps for tanks cleaning

Suction and cleaning sludge wastewater.

Application: suction and cleaning of tanks containing aluminum processing sludge. In this company, aluminum semi-finished products are produced in three phases: starting from casting to obtaining billets, then many operations are carried out to obtain profiles of various shapes, and finally surface finishing steps are completed with anodization and painting of metal semi-finished product. These operations generate wastewater characterized by chemical aggressiveness and a charge of abrasive metal suspensions. The fluids are collected in tanks and the formation of sludge deriving from the heavy solid suspension precipitation to bottom of tank.

The tanks cleaning operations and the removal of wastewater are performed by submersible centrifugal pumps, but, as is often happens, the formation of thickeners creates large problems of blockage of submersible pumps making them inefficient. Normally an operator goes down into the tank in order to improve the sludge evacuation process through fluidification operations for the sediment homogenization.

This is big problem because during the emptying operations, the operator works immersed in the fluid mass at the same time as the electric pumps running. The potential risk for the operator is clearly evident (electric shock).

Safety and peristaltic pumps in tanks cleaning operations

It was proposed for the task solution , a self priming peristaltic pump hcp 40 complete with speed variator, due this, machine is perfectly adapted to variable viscosity of the sludge, The pump perform a very high suction capacity and completely isolates the operator from a potential electric shock. Insensitive to dry running, the peristaltic pump does not suffer damage resulting from the discontinuity of liquid inflow, moreover, the resistance to abrasion and chemical aggression is assured by the hose membrane perfectly compatible with the fluid. The absolute safety is guaranteed by the fact that the pump operates on the surface by introducing the only suction pipe moving it in the various points of tanks to obtain a perfect cleaning, as it would happen with a vacuum cleaner. No physical contact between mechanical or electrical parts of the pump with the pumped fluid prevents any risk.

More information on pumps: Hose Carrier HCP 40

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9 February 201715 January 2018

Pumps for transfer ceramic slip and abrasives mixtures.

Application purpose : transfer ceramic slip mixtures for lost-wax casting.

This very important company is involved in investment lost-wax casting,through this process,is possible to obtain alloy steel castings with high degree accuracy and very high final finish. The procedure involves with production of wax matrices of the product to be manufactured,then covered by ceramic slip and sand deposited in layers, by means of subsequent baths, till obtain a coating of thickness suitable for the casting operation. After removed the wax, the steel alloy will melt inside of the ceramic structure to obtain the final metal component. The ceramic slurry used in the casting operation has an abrasiveness capacity rather significant, and submits machines and plant components to a strong mechanical wear and tear.
For aspiration and transfer operations of the ceramic media, between the various pumps available in market, has been chosen by the customer, a peristaltic pump, self-priming Hose Carrier HCP 40 on two wheels kart, equipped with mechanical speed variator, complete with electrical switchboard. Purpose of the HCP 40 pump is to transfer the ceramic slurry from the preparation plant to the dip tanks. Operation that pump perform easily. Among the most important features of the pumps Hose Carrier there is the maximum resistance to mechanical wear and tear thanks to the reinforced hose with all pumps are equipped with. The pump Hose Carrier HCP 40 can run dry without damage and aspirate and transfer abrasive fluids with different viscosity by varying the speed of rotation in function of characteristics of the mixture. The electrical panel mounted on board the machine also allows to obtain quick reversal of the flow directly in line, very convenient to carry out operations of rapid emptying without the need to intervene on the pipes. The high resistance of the peristaltic hose allows to obtain long operating life, modest operating costs , The maintenance is effected by the only replacement of the worn out hose, in a few minutes, on site, without special equipment or particularly specialized manpower.

For more information on the pump Hose Carrier HCP 40

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1 January 201715 January 2018

Sulphuric acid pumping .

The purpose of the application: pumping sulphuric acid and waste products.

This company deals with the recovery of metal, plastic materials and other chemical substances for the subsequent regeneration.In a production site, there is a particular type of plant that has the aim of recovering the industrial and automotive batteries.
From the recovery cycle, will get the lead, plastics and chemicals, sulphuric acid, sodium sulfate. In one of the initial steps of the recycling process the sulphuric acid accumulated by the emptying of the batteries must be pumped. The acid is collected in tanks and is contaminated by solid substances of various types, crystal formations, particles of plastic, metallic powders, acid slurries. The result is a fluid with significant characteristics of chemical and mechanical aggression properties. The fluid must be pumped with surface pumps in order to limit any security issues, the experiences in the past with centrifugal pumps have been very disappointing, with great difficulty on priming, rapid eterioration of the sealing systems, very frequent impeller clogging, continuous machine stoppages. The company experimented the use of pneumatic diaphragm pumps, but also in this case, there were significant problems on priming and aspiration (uncertain due to wear of the valve system, in case of rupture of the membranes, it often happened that the contaminated fluid passing through the membrane deteriorated, to the air distribution device destroying it irreparably. In both cases, the centrifugal pumps and the pneumatic ones, required the complete removal of the pumps from plant for maintenance. Given that the past experiences were not certainly positive, it was not easy to convince the company to experiment a different solution with another pump not very conventional. At the end we were able to introduce into the production cycle a HCP 50 peristaltic pump in 2010. From that moment the company no longer had problems arising from the pumping of contaminated sulfuric acid. The peristaltic pump has an operating cost of three peristaltic hoses every year, without machine stops and substantial significant costs. In the course of 2016 another peristaltic pump HCP 50 has joined the existing one for further increase potential production .

More informations on : Hose Carrier HCP 5.0 pump

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6 December 201615 January 2018

Pumps Hose Carrier for suction wastewater and sludge of metal surfaces finishing process

Aspiration of varnishing sludge.

An HCP 50 peristaltic pump is responsible for suction and transfer of sludge generated by the process of regeneration of cylinders for compressed gas in a company forming part of a large industrial group, specialized in the production and trade of gas cylinders and cylinders packs for industrial use.
One of these companies in the group, takes care of the recovery and regeneration and varnishing of cylinders.

Between the processing steps is expected: the washing and the remediation of the cylinders, blasting the body, the pre-treatment operations and the final finishing with the final varnishing of the product, often with custom colors. This company works thousands of cylinders each year,in steel,aluminum,with accessories or without.

The perfect pump solution for varnishing sludge:

The HCP 50 used is a medium proportions peristaltic pump ,and must recover and transfer waste water and sludge liquids deriving from the manufacturing process. Starting from the first for arrive to last working step, the variety of liquids pumped is very wide, as well as the viscosity, but the presence of the speed variator allows to the pump a perfect adaptation to different tasks. In the wastewater there are aggressive substances, solid suspensions,residual abrasive sand, various agglomerates, there is everything, in liquid form or muddy.

The machine that can do all this work is only one, the HCP 50 peristaltic pump. With a free passage up to 50 mm in diameter, the machine performs its function in all phases, from 2007, the year which it has planted into service. It should be added that in the dead times, or when it is necessary, should also drain the varnishing sludge from the cabins tanks. The customer buy a tubular membrane spare approximately every two years. The pump goes hand in hand to various operators for their service, without problems, while always ensuring a ready effective operation, removing sludge ,at low cost.

More information on the pump : Hose Carrier HCP 5.0

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