new trends in construction of sewage pumping stations in terms...

New trends in construction of sewage pumping stations

in terms of energy savings and operational safety

Andrzej Szeroki

Business Development Wilo SE

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WILO SE

• WILO SE with headquarters in

Dortmund, Germany, is one of the leading

manufacturers of pumps and pump systems for

heating, cooling and air-conditioning technology, for

water supply and sewage and drainage.

• The pivot for all worldwide activities in Water

Management as well as the corresponding Lead

Engineering Center is in Hof/Germany.

New trends in construction of sewage pumping stations- Andrzej Szeroki

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Global Production Network – Water Management


− Dortmund, Germany

− Minden, Germany

− Oschersleben, Germany

− Hof, Germany

− Laval, France

− Pune, India

− Kolhapur, India

− Beijing, China

− Qinhuangdao, China

− Gimhae, Korea

− Thomasville, Georgia USA

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2009 2010 2011 2012 2013

(Net) Sales– Economic development of the Wilo Group

+3,7%

926,1 1,070,51,021,4 1,187,1 1,230,8 (EUR million)


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Staff – Enabling our profitable growth

2009 2010 2011 2012 2013

6,027 6,268 6,9006,708 (annual average)7,194

+4,3%


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A System expert to cover specific requests in all Market Segments.

Commercial OEMStandard

Distribution Business

Industrial Equipment

Manufacturer

General Industry

Clean Water Utility

Wastewater Utility

Residential

Building Services Water Management Industry


The Wilo Way in terms of energy saving:

Customised solutions with personal commitment.

8 New trends in construction of sewage pumping stations- Andrzej Szeroki

from planning to set-up and service

WILO SE – Water Management- Wolf-Dieter Börner


less water consumption- same lot of solids

• same lot of solids

• less water consumption

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less water consumption causes big threat to pumping station –cloging of pumps


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Solids in sewage are big challange for sewage pumps


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.

pompypompy

el

QHgρP

• free passage

• clog resistance

• efficiency, head

• power consumption


optimum > 100 mm

In pumping stations we need to use pumps with big free passage

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Vortex impeller

New Range of impeller

Closed one channel impeller Closed Solid T impeller

clog resistance

efficiency, head

clog resistance

efficiency, head

clog resistance

efficiency, head


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Wilo-EMU FA with SOLID impeller – comparison


Make/type Wilo-EMU FA 15.95E-317 + FK 202-4/27

Wilo-EMU FA 15.44W-363 + FKT 27.1-4/22

Wilo-EMU FA 15.95T-270 + FK202-4/27

Single-channel impeller Vortex impeller SOLID impeller

Starting mode direct direct direct

Running time per day 10 h 10 h 10 h

Free passage 110 mm 130 mm 78 x 105 mm

Flow capacity 80 l/s 80 l/s 80 l/s

Delivery head 15.5 m 14.5 m 15.5 m

Motor power P1.1 23 kW 35 kW 20,5 kW

Number of poles 4 4 4

Single-channel impeller Vortex impeller SOLID impeller

Acquisition costs* € 28,130 € 27,170 € 28,130

Energy costs per year € 12,592 € 19,163 € 11,224

Downtime and service costs per

year**€ 2,000 € 500 € 1,000

Total costs in 5 years*** € 101,090 € 125,485 € 89,250

* Gross list prices.** Estimate based on field test installations at € 250 per service callout. *** Energy costs calculated at a constant rate of 0.15 €/kWh.

-41%-11%

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Wilo-Pump with Ceram CT coating – comparison


Calculation: Energy savings due to Ceram CT coating

Differences in power input consumption

67.4 kW – 65.7 kW 1,7 kW

Annual operating time 365 days x 20 hrs 7300 hrs

Energy costs 0.15 €/kWh

Total energy cost saving per year 7,300h x 0.15 €/kWh x 1.7 kW € 1,862

Costs for the coating € 800,-

Payback period 157 days

Total saving of energy cost * € 1,862 × 10 years € 18,620

Comparison: Wilo-SCP 200-360HA without Ceram CT coating

with Ceram CT coating

Delivery head 31 m 31 m

Volume flow 184 l/s 184 l/s

Pump efficiency 86.9 % 89.2 %

Motor efficiency 95.6 % 95.6 %

Overall efficiency 83.1 % 85.3 %

* Energy costs calculated at a constant rate of 0.15 €/kWh.

Energy costs savings thanks

to exclusive Wilo Ceram CT

coating

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New motor generation increases efficiency by 1%


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common and new pump systems



Solids separation system - functional principle


WILO EMUport solids separation system - simple

Measurement < ball passage impeller

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FS type – tank is part of the PE-HD shaft – for max. inflow 410 m³/h


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.

pompypompy

el

QHgρP

• free passage

• clog resistance

• efficiency, head

• power consumption


Solids separation system - functional principle

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Wilo-EMUport solids separation system – reference

• Pumping station, Lauter, Germany


Conventional dry well installation with 100 mm free ball passage

Conventional dry well installation with 80 mm free ball passage

Pumps stations with solids separation system with 50 mm free ball passage

Wilo-EMU sewage pump type FA 30.78 D FA 20.98 D FA 15.99 D

Type of impeller Multi-channel impeller Multi-channel impeller Multi-channel impeller

Ball passage of pump type 100 mm 80 mm 50 mm

Power consumption at duty point P1 110 kW 98 kW 87 kW

Annual energy costs € 48,180 € 42,924 € 38,106

Extra energy costscompared to solids separation system

26 % 13 %

Energy costs savings per year* € 10,074

* At an electricity price of 0.15 €/kWh (actual electricity costs without basic fee which depends on the estimated rated output).Please note that the maintenance costs are the same for all systems, the pump wear is however much lower with the solids separation system.

Save up to€ 100,740.-

of yourenergy costsin 10 years

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Telemetric control of pumping station


http://wilo.telemetria.net.pl/login_wilo.aspxlogin: wilodemopass : wilodemo123

http://wilo.telemetria.net.pl/login_wilo.aspx












Many thanks for your attention

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