In many applications in the oil and gas trade, the chemical business, and even the meals trade, pumps that work reliably and provide excessive performance are wanted. At the same time, they must have convincingly low funding costs. With the Ecosmart diaphragm metering pump, the German Lewa GmbH has provided a cost-attractive and protected mannequin that can handle circulate rates of as a lot as 300 l/h for a couple of years. For use in functions with larger flow rates, the pump expert from Leonberg, Germany, is now increasing its product vary with two new sizes. In addition to the LCA version, the Ecosmart will also be out there within the extra highly effective LCC and LCD variations in the future. While the LCC mannequin can meter in extra of 264 gallons per hour, Lewa designed the LCD for a move rate of up to 528 gallons per hour. The most permissible operating pressure for both models is 50 bar and 600 kilos respectively. The stringent use of similar parts throughout the Ecosmart product family keeps manufacturing prices and subsequently the final value low. At the identical time, a excessive level of safety could be assured by focusing on all important design options such as the stress reduction valve or the confirmed sandwich diaphragm with steady monitoring. The LCC variant was made available at the finish of 2021 and the LCD model might be obtainable by mid-2022.
In addition to the confirmed diaphragm metering pumps of the Ecoflow collection, Lewa has offered the inexpensive Ecosmart pump for several years. This is especially as a outcome of the fact that though a dependable pump unit is required in quite a few processes, at the same time relatively low discharge pressures within the decrease two-digit vary require much less advanced pump expertise. With the Ecosmart LCA in the single pump version, nonetheless, only a move fee of below 80 gallons per hour was previously attainable. In order to have the ability to supply the Ecosmart for applications with greater flow rates, the engineers at Lewa began growing two further, larger pump variants in 2019. The goal was to scale up the Ecosmart to larger purposes with the confirmed safety degree and top quality Lewa components without considerably growing the low investment value typical for this pump collection. This was to be achieved by a consistent modular precept within the pump series, in addition to a strict concentrate on the important functions and options. The specifications also demanded the similar old Lewa suitability for unrestricted steady operation over many years. Options for integrating the pumps into automated techniques through analog control alerts or bus systems are additionally a matter in fact.
Lewa Ecosmart LCC3 on the test stand.
ADJUSTMENT OF PLUNGER DIAMETER AND STROKE ENABLE MORE FLOW
First of all, the necessities for the conveying capacity had to be carried out constructively. Larger plunger diameters were selected for the smaller LCC variant, in order that more than 264 gallons per hour could be conveyed as a substitute of lower than eighty gallons. In the case of the extra powerful LCD version, the engineers also decided to extend the stroke length so that a maximum flow fee of 528 gallons per hour could probably be achieved. Both pump varieties can work against a most operating strain of fifty bar. As with all hydraulically actuated diaphragm metering pumps, most pressures are achieved with smaller plunger diameters.
Just as essential because the efficiency of the pump was the operational reliability typical of Lewa acquainted from other pump collection. For this objective, particular person, essential features such as the integrated strain safety valve or the sandwich diaphragm have been taken over from the Ecoflow fashions. The individually adjustable stress security valve ensures that sudden overpressure within the pump does not harm the diaphragm or pump drive. The diaphragm safety system DPS, whose important element is a return spring for the diaphragm, additionally ensures that the PTFE sandwich diaphragm at all times works in the proper place. It cannot be overstretched or damaged during start-up. Thus, the pump is protected towards operating errors or upset working conditions. Finally, the standard diaphragm monitoring system checks the situation of the diaphragm and warns plant operators instantly if there might be any injury. This reliably prevents cross-contamination between the pump and the piping system and ensures operational safety at all times, especially in sensitive areas with toxic fluids. However, diaphragm monitoring is rarely used because Lewa diaphragms of this series usually obtain service lives of several years – even underneath full load and continuous operation.
A key level was to keep production prices within an identical range to the small LCA variant, thereby creating enticing market prices for functions with less demanding necessities and lower working pressure. To do so, pressure gauge octa of the two new pump sizes wanted to integrate parts that are as similar or at least related as attainable in order to keep away from excessive manufacturing prices. In this manner, the Lewa engineers had been able to efficiently implement the common parts strategy that had already been practiced many instances.
Pump users additionally profit from this clever modular principle, as many wear parts can be utilized across pump sorts. This significantly simplifies the spare parts stock. At the same time, the modular precept additionally allows individual changes to the respective utility. For example, stroke frequencies or plunger diameters may be chosen individually. The foundation for this is the M900 pump head, which is already used within the LCA variant and in the Ecoflow program.
Lewa Ecosmart LCC in heated cabinet.
GOOD INTEGRABILITY FOR PLANT CONSTRUCTION COMPANIES
The pump’s flexibility additionally presents benefits for plant construction: It allows the Ecosmart pump to be oriented either vertically or horizontally, making it easier to combine the unit into methods with restricted or confined spaces. In addition, the pump head of the brand new LCC and LCD models is aligned at proper angles to the plunger axis, resulting in a very compact format. In many pumps, the pump head is on the same axis because the plunger, which often ends in bulky pump dimensions. The 90-degree orientation avoids this with the brand new fashions. This benefit is achieved by the extremely compact and fully newly developed, cost-effective diaphragm drive.
In order to make sure the lengthy service life typical of Lewa pumps, solely high-quality, strong supplies are used within the LCC and LCD versions. Toxic and abrasive substances can stress the pump significantly and so a selection of materials can be used on the wet end, which are additionally efficiently used within the high-pressure variants of the Ecoflow sequence. Many high-quality elements from the Ecoflow sequence are also used for the drive items, using the widespread elements technique. The result’s robustness and sturdiness that is uncommon on this pump class. In addition, all Ecosmart pumps have been designed with a single oil tub, which is used for both the lubrication of the drive unit and the hydraulics of the pump head. This eliminates the more complicated lubrication through two separate oil methods and ends in a much less complicated design, which not solely facilitates operation but also reduces maintenance work.
Last however not least, the brand new LCC and LCD versions—like the LCA—comply with the us trade standard for metering pumps API 675, ensuring nearly limitless utilization for numerous demanding processes in a variety of industries.
USE IN THE CHEMICAL INDUSTRY
For instance, when metering solvents in the chemical trade, pumps are wanted that on the one hand meet the very best specification requirements and then again are still cost-effective. Here, the Ecosmart pump with its higher performance is in a position to meet exactly these requirements, as it has been exactly engineered for applications in the decrease pressure range as much as 50 bar (600 pounds). The bigger variations of the Ecosmart pump are additionally appropriate for industrial water therapy, similar to in seawater desalination or industrial cooling circuits. What counts right here above all is compactness and cost-effective design, which the entire Lewa Ecosmart sequence fulfills due to its progressive design principle.
Before the new pump variants can be found to clients, a variety of extensive tests shall be carried out. They will be sure that the models also meet the high inside firm requirements for reliability and performance in operational follow. They embrace, on the one hand, continuous load exams of up to a number of tens of hundreds of hours and, however, overload checks. In the latter, the pump is run continuously at up to 20 percent above maximum pressure to additional validate its robustness. Special tests are carried out in heated cabinets to proof that the pumps additionally perform completely under excessive ambient conditions. After successful completion of all exams and final changes, the Ecosmart version LCC is now on the market, the LCD mannequin will comply with in mid-2022.
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