Ecopump Turbo System
Ecopump Turbo System
Paper machine vacuum system ECOPUMP TURBO SYSTEM - THE ADVANTAGES AND PRINCIPLES OF INSTALLING AND USING CAPACITY CONTROLLED VACUUM SYSTEM
CONTENTS 1. GENERAL 4 2. ECOPUMP TURBO VACUUM SYSTEM FOR A PAPER, BOARD OR PULP MACHINE 4 2.1. PRINCIPLE OF THE ECOPUMP TURBO 5 2.2. CHALLENGES IN PRODUCING VACUUM FOR PAPER MACHINE 6 2.3. LIMITATIONS OF TRADITIONAL VACUUM SYSTEMS 6 2.4. DIFFERENT PRACTISES AND TRADITIONS OF VACUUM USAGE 7 3. ECOPUMP TURBO FEATURES 811 4. MAIN BENEFITS OF ECOPUMP TURBO IN PAPER MACHINE INSTALLATIONS 12 4.1. POWER SAVING 12 4.2. WATER SAVING 13 4.3. IMPROVING SYSTEM RELIABILITY 14 4.4. SAVING IN BUILDING COST 15 4.5. REDUCING SHUTDOWN TIME IN REBUILDS 15 4.6. HEAT RECOVERY POTENTIAL 16 5. TECHNICAL DATA EP-500-S(D1) & EP 315-S(D1) 17 6. REFERENCE LIST 18 3
1. GENERAL Ecopump energy saving group has been working since 1989, with a clear target of reducing power consumption of paper machine pumping systems. Four product lines have been de- veloped to realize the great saving potential in paper produc- tion process: Ecopump Turbo vacuum systems Ecofl ow dewatering measurements Ecosep water separators Vacuum system consulting Based on the experiences on practical process optimization work, and the fact that no vacuum pumps with good controlla- bility were available on the market, Ecopump started to develop its own system. The development was done in close coop- eration with top technologists from technological universities, aerospace engineering companies and electric drive suppliers. After some years of intensive design, testing and production scale piloting, the system has found its position as the most effi cient modern vacuum system for paper machines. 2. ECOPUMP TURBO VACUUM SYSTEM FOR A PAPER, BOARD OR PULP MACHINE During years of optimiz- ing existing paper machine vacuum systems, and con- ducting dewatering trials utilizing Ecofl ow dewatering measurements, it became ob- vious that there is a need for a VACUUM SYSTEM WITH ADJUSTABLE CAPACITY. There is a great potential for power savings by eliminating excess capacity due to over dimensioning the systems are often over dimensioned due to uncertainties concern- ing new machine concept or when reserving capacity for eventual speed increase. 4 This book describes the benefi ts and working principles of ECOPUMP TURBO VACUUM SYSTEM for paper ma- chines: Power savings 500..1000 kW compared with traditional systems Water savings up to 1000 000m3/a per production line Improving system reliability Saving in installation cost Saving in building cost Saving in shutdown time Saving in maintenance cost There are examples described. The technical scope and results are based on real life projects. There are also variations in capacity need because of different running conditions new felts vs. old felts, differ- ent felt types, high grammage vs low grammage, etc. With adjustable capacity these sav- ings can be realized directly to the bottom line. Other important features are: water savings, savings in foun- dation work due to compact size and low weight, savings directly in maintenance work and parts as well as indirectly in saving maintenance shut- down time.
2.1. PRINCIPLE OF THE ECOPUMP TURBO Ecopump turbo is based on a combination of modern high-speed electric drive and high effi ciency turbo blower. The unit is driven with a fre- quency converter, which ena- bles the capacity control from zero to maximum without any limitations in operation range. Even marginal savings in vacuum capacity will result to signifi cant savings in elec- tric power. The turbo impellers are di- rectly mounted on the motor shaft, which makes the sys- tem very compact and me- chanically reliable. No gear- box or couplings are needed. The solid shaft AC motor is robust and has no resonance frequencies within the oper- ating range. Cast titanium impellers are mechanically and chemically very stable. Oil lubricated ceramic ball bearings and lightweight parts make the system easy to han- dle from maintenance point of view. Scheduled mainte- nance (bearing change) can be done on minimum during an 8-12 hours shutdown. Picture 1: Ecopump Turbo. The electric drive is included in the scope. 5
2.2. CHALLENGES IN PRODUCING VACUUM FOR PAPER MACHINE An effi cient use of vacuum system for paper machine positions face the following challenges: The vacuum system must handle todays production, but also possible speed increases in the future The vacuum need on felt conditioning is varying depending on the felt types and age of them The grammage, grade and speed varies The rising cost of power means it is not economical just to simply bleed off the extra capacity For a long time, water ring pumps have been the main way to make vacuum for paper machines. In this kind of pump, you need to rotate a water ring to get the air moving. In spite of their seemingly robust structure, there are certain limitations in use of this kind of pump. a) Poor power effi ciency; especially with low vacuums b) Limited control range; the water ring will collapse after certain point c) Need for cooling; specially with closed circulation and during summer time d) Bacteria control; specially when circulating the water => optimum circumstances for bacteria e) Heavy investment on building and foundation; heavy construction with low frequencies. Seal water is becoming ever more costly due to not only regulations but also to increasing need to control temperatures, pH and bacteria (specially with closed circulation) Availability requirements do not allow long maintenance shutdowns The air to be pumped contains water, other liquid media and solids. 2.3. LIMITATIONS OF TRADITIONAL VACUUM SYSTEMS 6 Another widely used technology, multistage blower aggregate, avoids many of the disadvantages of water ring pumps. But there are other problems related to these: a) Limited control ability; due to big size and few ag gregate installed in one system b) Complex startup procedure; risk for overloading the electrical motor c) Complex maintenance procedure; need for long shutdown when serving d) Risk of production shut down; normally no back up system. If one unit fails it is not possible to run the PM e) Heavy investment on foundation; heavy units, which are critical for vibration.
2.4. DIFFERENT PRACTISES AND TRADITIONS OF VACUUM USAGE There are some general principles in evaluating the need for vacuum capacity. A good parameter to benchmark the vacuum usage is the specifi c power consumption (kWh/ton) of the vacuum system. Of course, one value is not comparable for all. Typically, the following guidelines can be found. 1) The specifi c consumption of vacuum system is depending on the grade: typical benchmark values can be given: Pulp drying machine 20..40 kWh/ton Board machine 40..80 Linerboard machine 35..80 Fine paper 40..80 Magazine 70..120 Newsprint 70..120 Specialty papers 80..180 Tissue 100..200 Specifi c energy consumption kWh/t 200 180 160 140 120 100 80 60 40 20 0 A typical distribution of specifi c consumption is shown in the graphic below. 2) Grammage: heavier grammage requires less power per ton than lower grammage. 3) Speed: lower speed requires less power per ton than higher speed. 4) Size: Large machine capacity requires some less power per ton produced than a small machine capacity. Vacuum system specifi c consumption vs. Production, Magazine Papers 0 10 20 30 40 50 Production kWh/t Picture 2: Specifi c power consumption of vacuum system, magazine paper grades. 7 specifi c consumption kWh/t
Different working shifts can run the machines in different ways. There are some traditions and some common beliefs that some- times are based on facts, which do not exist anymore. By systematic optimization with dewatering measurement 3. ECOPUMP TURBO FEATURES During years of optimizing vacuum systems and dewatering, it become obvious that the vacuum system should have the following properties: a) Flexible capacity adjustment: the system shall fulfi ll the capacity requirements of the machine suppliers specs. But the capacity requirement of the actual running situation is often different. => ENERGY SAVING POTENTIAL b) Flexible in capacity adjustment: different grammages require different vacuum. Old felt and new felt require different vacuum capacity. => ENERGY SAVING POTENTIAL c) Effi cient pumping principle: The power should be used to move the air, not to rotate the seal water. => ENERGY SAVING POTENTIAL d) Good potential for recovering the power used in vacuum system heat. => ENERGY SAVING POTENTIAL Vacuum (kPa) 80 70 60 50 40 30 20 10 0 system and benchmark information from other machines alike, an energy effi cient running practice can be developed. Also Ecopump turbo blower can be easily automated to avoid dif- ferent running philosophy. e) Easy to adjust and fl exibility. => optimum running condition for the production Main benefi ts Ecopump turbos are specially designed for paper machine environment and for best operational economy. a) Flexible capacity adjustment with ECOPUMP TURBO: All turbos are speed controlled to enable economi- cal use from zero to max capacity. This gives freedom to design an effi cient system for different and/or varying conditions. b) Effi cient pumping principle: 3-dimensional high speed turbo impeller running variable speeds: all power is used to move air from vacuum to atmosphere. No power used to rotate water, no vacuum adjustment with speed. c) Heat recovery potential: The pumping energy is transfer- red to the air. The temperature reaches up to 160 °C, which offers good potential to use it in different stages of production. 0 1 2 3 4 5 6 7 8 9 10 Picture 3: Ecopump Turbo fl ow/vacuum range 8 Vacuum Levels and Flow Rates Air fl ow under vacuum (m³/s)
Principles in designing a vacuum system Ecopump vacuum systems are the result of practical experi- ence for evaluating the system needs, realizing the project and optimizing the running conditions. All our fi eld engineers are trained for process expertise. Some general principles in designing and operating vacuum systems can be stated. Capacity needed: capacity designed by the machine builder, capacity to be optimized at real life run situation. Ecofl ow. Controllability: how to build a system where each vacuum position can be optimized for best effi ciency and quality. Ecofl ow. Backup connections. Optimising piping design. Separator features. Tested in laboratory. Silencers to reduce the noise in the pump room, pipeline silencers and silencers for exhaust air. Picture 4: Ecopump EP315-series 9
Ecopump EP315-500-S Ecopump EP315-500-S is designed for smaller capacity, es- pecially for retrofi t installations for medium and small paper machines, where the space is limited and where production is versatile and maintenance conditions are limited. It is compact to fi t in small space available, the lightweight parts can ea- sily be handled by hand in short service shutdowns. No long shutdowns are needed. The materials are corrosion resistant: titanium impeller and stainless steel casing. Picture 5: Electric drive 10 Ecopump Turbo EP500-700-S Ecopump EP500-700-S is a heavy-duty turbo for high capacity and highest effi ciency, designed for large paper machines and for both greenfi eld and retrofi t installations. Its 3-dimensional turbo design gives top effi ciency together with good controll- ability as all Ecopump turbos. It is, although clearly larger than EP315-500-series, still compact when compared with other commercial technologies. The up-time availability and cost effi cient maintenance are valid for this series, too. The series contains altogether the following models: EP200-500-D low 200 kW, nominal 500mm impeller EP250-500-S 250 kW, two nominal 500 mm impellers in series EP315-500-S 315 kW, two nominal 500 mm impellers in series EP315-500-P low 315k W two 500 mm impellers parallel, for double fl ow, up to 40 kPa vacuum EP315-600-D 315 kW, nominal 600 mm impeller EP400-600-S 400 kW, two nominal 600 mm impellers in series EP400-700-D2 400 kW, nominal 700 mm impeller EP400-700-D1 400 kW, nominal 700 mm large impeller EP500-700-D1 500 kW, nominal 700 mm large impeller EP400-700-S 500 kW, two nominal 700 mm impellers in series Each unit is tested in Ecopump laboratory..
Lube unit Turbo blower Power supply Blower outlet Cooling air SCOPE OF DELIVERY Vacuum breaker valve Picture 7: The functional scheme of the system PI Frequency convertor DCS 11 Picture 6: The Lubrication system is extendable for multiple turbo system and is equipped with double pump for reliability. Reserve pump can be served during PM run, if needed. Drop separator FI Discharge to seal pit tank or pump Lubrication unit PI Suction position M M
4. MAIN BENEFITS OF ECOPUMP TURBO IN PAPER MACHINE INSTALLATIONS 4.1. POWER SAVING a) The main benefi t of choosing Ecopump Turbo system is power saving. But there are also other quite signifi cant reasons to go for Ecopump technology. b) Investments in reducing energy consumption are often backed by government programs. Innovative fi nancing such 4000 2000 1000 900 800 700 600 500 400 300 200 100 0 BEFORE AFTER as ESCO (= Energy Saving Company) arrangements is often available, too. Ecopump and its network will help in evaluat- ing the operation. Turbo information and energy savings kW Power consumption 12
4.2. WATER SAVING In one of Ecopump Turbo customer mills, the water comes from a distance with a pipeline. The supply is thus limited. At the time of machine rebuild, there was a need of either a) cut the fresh water consumption in the mill b) build water circulation for seal water of the liquid ring vacuum pump system. Picture 8: No seal water is needed for Ecopump Turbo. 13 After reviewing the power saving potential in vacuum system, it was concluded that Ecopump Turbo system was the best solution. The Nash pumps were removed and Ecopump Turbo System was installed in a machine rebuild. Results: a) The water consumption was cut by some 1000 000 m³/a. b) Power saving was cut down by some 500 kW, even though the speed was increased and new vacuum positions (top former) were installed on forming section.
4.3. IMPROVING SYSTEM RELIABILITY In this installation, there were originally two large multi- stage turbo blowers and one liquid ring pump in the vacuum system. Because of this confi guration, the system was vulnerable: if any of the two large turbos were down, the production would have to be stopped. At the same time, the power consump- tion was a bit high, despite the system principle (in gen- eral, turbo principle is power effi cient). Optimizing the system, and implementing a new confi g- uration shut one of the two large blowers and the liquid ring pump shut down. One Ecopump turbo was installed to serve suction press roll. By running the multistage turbo and Ecopump turbo only, the machine now is not vulner- able. The multi-stage blower can be replaced with the oth- er, now obsolete one. Also, the EP turbo can be replaced Picture 9: The overall system reliability was improved by installing one Ecopump Turbo. 14 by the multistage turbo. The water ring pump can be kept still. As a side effect, the total power was cut down by 900 kW.
4.4. SAVING IN BUILDING COST Space needed for Ecopump turbo vs. traditional pump system is far less than that for liquid ring pump system or that for multi-stage turbo system. The compact con- struction with motor and turbo integrated, it makes it possible to accommodate in very limited space. In fact, the vacuum system can be decentralized, if needed no separate pump room neces- sary. Relatively low weight reduc- es the building cost further, since no heavy foundations are needed. An even concrete fl oor is enough, if Ecopump base plate is used. Another option is to have concrete foundation for the turbo. In rebuild projects, the new 4.5. REDUCING SHUTDOWN TIME IN REBUILDS vacuum system can often be installed before dismount- ing the existing system. This way, the system rebuild can be realized practically without production shutdown. The old multistage blower was getting too old to run no spares were available. There was no room for a new unit of the same kind. Dis- By installing Ecopump system, the new system could be built parallel with the old system. Switching from old to new system was done in normal shutdown. The new system was installed and tested during normal paper machine run. The valves in connection pipes made this possible. Picture 10. Ecopump Turbo can be installed during normal production without a long shutdown 15 mounting the one and build- ing in a new one would have required a long shutdown. Building a liquid ring pump system would have required an extensive and expensive investment on seal water system.
4.6. HEAT RECOVERY POTENTIAL Recovering the energy used for pumping air, makes the energy balance superior. Practically all of the power used to generate vacuum is transformed into process air heat. In water ring pump, this heat is transferred to seal water, making it necessary to cool the water which is causing an additional cost. Eco- pump system principle enables recovering this heat: especially Picture 11: Recovering pumping power offers further energy effi ency potential. 16 in high vacuum positions this results to high temperature air, which makes recovery very feasible. It can be taken into an exchanger, to heat process water or to heat the hood supply air. In some cases, it can be blown directly to the hood. Where the heat is used, depends on the mill needs.
5. TECHNICAL DATA EP-500-S(D1) & EP 315-S(D1) Power 400/500/690 V 500 kW Production (air +20ΊC/1, 01325 bar) Serial connection (EP-500-S) 68 kPa/7,0 m³/s (EP-315-S) 60 kPa/2,5 m³/s Single impeller (EP-500-D1) 45 kPa/9,0 m³/s Cooling air (EP-315-D1) 40 kPa/2,2 m³/s Flow 0,5 m³/s /+20ΊC Filtering EU5 Frequency converter Type VACON NX Filter DUDT Voltage 400/500/690 V Main dimensions EP-500-S(D1) EP 315-S(D1) Width 1850 (1850) mm 1390 mm Height 2210 (1430) mm 1395 mm Lenght 2995 (1965) mm 2360 mm Weight 5000 (3500) kg 1500/1200 kg Process connections EP-500-S(D1) EP 315-S(D1) inlet (vacuum) DN 600 PN10 DN 300 PN10 Outlet (pressure) DN 400 PN10 DN 250 PN10 Cooling air Ψ 315 Ψ 250 Materials EP-500-S(D1) EP 315-S(D1) Blowers cast iron stainless steel Impellers cast titanium cast titanium Foundings Fe360 Fe360 Bearing units Bearings Hybrid ball Lubrication Oil Automation Bearing vibrations 2 x Transmitter Bearing temp 2 x Transmitter Coil temp 2 x Transmitter Oil fl ow 2 x Transmitter Oil level 1 x Switch Oil fi lter pressure difference 2 x Switch 17 EP-500-S EP-500-D1
6. REFERENCE LIST Arjo Wiggins SAS, Annonay PM7, France, 1 Turbo blower Drawing paper Cartiere del Polesine, S.p.A., Italy, 7 Turbo blowers Testliner Georgia Pacifi c, Cuijk, Netherlands, 2 Turbo blowers Tissue converting process Georgia Pacifi c, Nederland B.V., Netherlands, 1 Turbo blower Tissue Georgia Pacifi c, Nokia PM 7, Finland, 1 Turbo blower Tissue L.C. Paper 1881 S.A., Papelera La Confi anza, Spain, 1 Turbo blower Tissue Mayr-Melnhof Karton, Baiersbronn Frichfaserkarton BM 1, Germany, 1 Turbo blower Board M-real, Kangas PM 2, Finland, 1 Turbo blower Fine paper M-real, Kirkniemi PM 1, Finland, 1 Turbo blower LWC M-real, Kyro BM 1, Finland, 1 Turbo blower Board M-real, Lielahti, Finland, 1 Turbo blower Pulp machine M-real, Tako BM 1, Finland, 1 Turbo blower Board 18 M-real, Tako BM 3, Finland, 1 Turbo blower Board Metsδ Tissue, Mδnttδ PM 1, 1 Turbo blower Tissue Metsδ Tissue, Mδnttδ PM 7, Finland, 1 Turbo blower Tissue Stora Enso, Anjala PM 1, Finland, 1 Turbo blower Book paper Stora Enso, Enocell PM 2, Finland, 1 Turbo blower Pulp machine Stora Enso, Kaukopδδ PM 8, Finland, 1 Turbo blower Fine paper Stora Enso, Kotka PM 1, Finland, 5 Turbo blowers Laminating base paper Stora Enso, Summa PM 3, Finland, 1 Turbo blower Newsprint Stora Enso, Tainionkoski BM 5, 1 Turbo blower Board UPM- Kymmene, Kaukas PM 1, 3 Turbo blowers Pulp machine
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