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.
Wich pumps for water sampling can ensure maximum suction?
Our customer operates in geological and environmental inspections. Among the most common main activities, there is an intense water monitoring activities carried out using appropriate sampling pumps for surveys in plant facilities and chemicals production sites. The most common operation in monitoring is sampling and analysis of process and ground water. One of the most critical aspects, it is precisely the collecting of groundwater that must be handled by special monitoring wells arranged in order. The most important feature that should have a pump for this function is a high suction capacity, especially in case the sampling is practiced from the ground surface with self priming pump. A pump capable of developing very high suction capability is absolutely needed.
Use of surface self priming pumps is generally the system most used and preferred where applicable. This system is the fastest and cheapest way to operate on wells with a static level up to less than 10 metres depth.
Only long-lasting textile fiber reinforced peristaltic hose with large elastic memory produce the maximum suction effect needed for a monitoring pump.
There are several manufacturers of sampling and monitoring pumps, but all available products make use of single-component or mono-extruded peristaltic tube. This type of component, although it can provide a substantial vacuum, but difficult in practice, ensures effective functionality at depths greater than 6 meters, because of the tendency to remain compressed due to vacuum effect, and lack of elastic memory tipically present on non reinforced tube type.
A sampling peristaltic pump that arrives at great depth
For the construction of its own analysis unit, our customer wanted an HCP 20 peristaltic pump that, unlike ordinary sampling pumps, uses reinforced hoses with textile fibers between the various layers of rubber. This type of hose maintain a very high elastic memory and permanently guarantee a great vacuum up to 95% with the advantage of suction capability up to 9.5 meters above ground level. An important average of 3.5 meters more than conventional similar pumps. From an operational point of view, this is already a notable advantage, but it is also added the much longer life of the fiber-reinforced textile peristaltic hose, greatly simplifying the operational monitoring activity and moving far in the time the replacement of peristaltic hose.
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.
Hazardous and aggressive fluids in open areas or without electricity – this is the solution.
How a lightweight and versatile self-priming engine driven pump can expand the operational possibilities in the field of ecological recovery, our customer works in the environmental field for the recovery and treatment of wastewater and hazardous fluids arising from industrial processes, already owner of a self-priming electric peristaltic pump Hose Carrier intended to operate for the same purpose, presented us with the need to possess a self-priming petrol engine driven peristaltic pump for new incoming duties.
Starting from a 35 HCP pump ideal for performance and size, we have created a transmission equipped with a gearbox selected to operate with the speed typical of the current fast petrol engines, combined with a special joint able to power allow the start of the engine without dragging load of the pump. once the engine is started, just act on the accelerator to engage the pump and obtain at the same time a change of rpm that allows the pump Hose Carrier to adapt for different fluids viscosity.
A single self-priming engine driven pump is suitable for all common hazardous fluids.
The possibility to set up tubular membranes in different compounds makes it possible to extend the pump’s compatibility with most fluids and wastewater destined to be recovered by the company for subsequent treatment: the entire group has been set up in a steel tube cage equipped with folding handles and lifting eyes so as to guarantee adequate protection for the pump during the “abrupt” operational use needs, the result is a perfect heavy duty practical unit.
For the past three years, this self-priming engine driven pump has been making its operational contribution to the company’s objectives, making it possible to further expand the range of services offered by the company: maintenance and management costs are so low that it has not yet been necessary to replace any of the various tubular membranes of first delivery.
100,000 cps, up to this value can reach viscosity of fluids that our customer, operating in the food sector, must transfer seasonally from reactor to containers prepared for the following Machining. The operation was carried out by flexible impeller pumps with very disappointing results and very high operating costs. The transfer of normal or viscous products, obviously ,did not generate problems, but as the viscosity raise, difficulty, inefficiencies, and high management costs grew fast. The company reached a level that was no longer sustainable. The increasing viscosity of products generated great discontinuity of suction flow to the pumps, often causing destruction of the rubber impellers and mechanical seals of all the pumps available. Viscous and dense fluids = problems.
This is the fact, without any consideration for the long process pumping times, combined with cleaning, restoring and continuous maintenance time spent for the various pumps involved . The company technical manager finally decide to seek a rational solution to solve the issue, he exposed the problem to several pump producers, proposing them a sample of the most difficult viscous product to verify the transferability. No one proposed a solution, 100000 cps are a limit for almost everyone. We made our own tests with our peristaltic pumps. After that we have realized that we could definitely eliminate the high viscosity transfering problems of this company.
The right solution for very viscous and dense fluids.
Now, a peristaltic HCP 50 pump equipped with special accessories has replaced the previous pumps in the suction and transfer operations. Our peristaltic pump is equipped with additional vacuum system and Inverter panel for the management of the speed variation. The possibility to change the speed allows the adaptation of the pumping capacity to the characteristics of most of the less problematic fluids. With the few high viscosity fluids, increased vacuum system allows to obtain the suction efficiency required, needed to work with high viscous products (up to 100000 cps).
The pump capability of realizing a vacuum up to 95% and the ability to keep it stable even with different speeds allows the HCP 50 peristaltic pump to satisfy the customer’s requirements for high viscosity fluids. Low operating cost and effectiveness in operation have consolidated the trust of our customer to our peristaltic pumps. We can expect the introduction of some other machine in future