HIGH PERFORMANCE PRESSURE SYSTEMS

INDUSTRY PRESSURE CONTROL Wash & Clean Machine Tool Filtration - - - - Boiler Feed Mixing +++ Special Requirements

Challenges: Limited space Moist environment and high temperatures TEXT Pressure spikes Large changes in flow demand No flow is an operating condition! TEXT Pressure segments: 20 Bar 40 Bar 60 Bar 80 Bar Priority: Operator time ! - Water consumption Energy consumption Flow range: Increments of 40 liters/minute = 2,4m3/h corresponds to one cleaning station or one user.

Pumps built into cabinets, portable equipment and machine centers require small physical outline due to limited space. Compactness is often a critical and primary property.

OVER SYNCHRONOUS OPERATION Selected Pump: CRE3-9 Extended I/O Card – 3 fixed speeds, Analog Output 4kW MGE motor, Reduced Fan, 6000 rpm. Factory Configured OEM pump CR5-36 1253mm Pump End Length CR3-9 393mm CRE3-9 6000rpm/4kW

OVER SYNCHRONOUS OPERATION Advantages: Small size (physical space, handling, weight, packaging, small pump) Concerns: Ball bearing life OK Shaft seal life OK NPSH !! Vibration ! Limitations on pump !!! Acceleration cavitation: ! Influence ramp time NPSH Pressure Time/sec Standard speed Over Synchronous speed Delayed pressure built up

RUN AT POWER LIMIT Makes it possible to boost the pressure at lower flows by increasing the frequency. Gives the possibility to use the motor 100 % over the full flow range. Either get more pressure or choose an undersize motor

CONTROL SYSTEM Constant pressure Constant pressure Operating a pump in regulated mode based on a pressure sensor  obtain constant pressure in the system All cleaning stations will have the same pressure, and same flow independent of number of users Effective cleaning and controlled amount of water usage Pump operation depends on system design and application requirement Important is to avoid operating against closed valve, cavitation and over pressurizing the system Systems operating with feed pump or pressurized supply line can operate with a flow switch By opening a tap or satellite lance the flow through the switch will turn on the pump and it will operate until the load is turned off and the pump can ramp down to a stop Flow switch Instead of flow switch, the built-in stop function can be used The Pump will probe the system for low flow and automatically stop when no flow is present Constant pressure By operating the pump in regulated mode based on a pressure sensor, we obtain constant pressure in the system. That means that all cleaning stations will have the same pressure, and can deliver the same flow independent of how many users are active. That means effective cleaning and controlled amount of water usage. Systems operating with feed pump or pressurized supply line can operate with a flow switch. By opening a tap or satellite lance the flow through the switch will turn on the pump and it will operate until the load is turned off and the pump can ramp down to a stop. In stead of flow switch, the built in stop function can be used provided that non return valve tank and pressure sensor is attached. The Pump will probe the system for low flow and automatically stop when no flow is present.. Stop function

Sleeve deformation due to high pressure >100Bar STOP FUNCTION Sleeve deformation due to high pressure >100Bar Damaged ball bearings Thermal expansion of the water N CRNE3-9 sleeves

PROTECTION Avoid fault! Never place a non-return valve on the suction side of the pump unless a over pressure release valve is installed! Avoid fault! Different means of pump and system protection can be installed Temperature sensor in the top of the pump A PT100 sensor placed in the top of the pump is a cheap and effective way of protecting the system from damage and scolding due to dead heading. Setup combined with Limit exceed. SAVER and HM Large has dedicated inputs for PT100/1000 Discharge pressure measurement A limit exceed on high pressure on measured discharge pressure protects from pressure damage due to dead heading. A limit exceed on low pressure can protect from cavitation due to ”run out of curve” or dry run. Pre-pressure measurement or pre-pressure switch Protect against dry run and cavitation due to low feed pressure. Dry run protection Lictec placed in the top of the pump protects against dry run and high temperature due to dead heading. SAVER FM300 I/O card has direct input for the Lictec sensor unit. Under load Detects if the pump in below minimum power consumption indicating loss of prime or air in the pump. The function is at present not accessible in all MGEs. Pump motor and drive System is protected against overload, supply failures, high ambient temperature and more by the drive. Over pressure safety valve In case of a need for a non return valve on the suction side of the pump, a safety valve must be installed for prevention of pressure damage in the system and scolding. Power limit A trimmed power limit can cut of the pump curve and make it steeper by high flow in order to avoid cavitation. Constant pressure control High speed pumps with steep curves are often prevented from over pressurizing the pump at reduced flow by constant pressure operation, even though constant pressure is not needed from a system control point of view. Diaphragm tank A small tank placed directly on the piping and as a pipe extension (shooting direction of a pressure wave) can reduce water hammer.

SPECIAL SYSTEMS 80 Bar, 17 m3/h, BMS operated at 5500 rpm by IE4 motor Supplied by 70kW VFD with 690V supply The system is used for exterior cleaning on cruise ships The system is built and sold by Lagafors AB in Sweden, supported by the Industry Segment.

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