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The market for sea water desalination plants is growing, and with it the demand for bigger and bigger pumps. In future, the Düchting machine factory can measure exactly the capacity of its single and multiple-stage centrifugal pumps in large dimensions. The test stand for this has been fitted out by the electric motor specialist EMZ with an individually modified 4,000 Kw drive.

When Elektro-Maschinen-Zentrale GmbH (EMZ) develops solutions tailored to customers, the end result is that “every motor is unique“, says Frank Scherlack, technician responsible for large drives and for this project. Nonetheless, EMZ also regards the custom-made products for the machine and plant construction sector ordered from Düchting as interesting challenges for electric motor experts.

For the participants on both sides have to accept three high thresholds for the demanding expansion of the pump test stand to 4,000 Kw:

For the direct connection to the 10 Kv municipal electricity supply, no excessive starting current may be produced when the motor is switched on. For this reason, instead of a cage motor, EMZ has chosen for this application a slip ring motor available from ABB, with a carbon brush lifting and short circuit device.

The electricity provider’s exact conditions with regard to the narrow threshold values concerning the transient start-up current in terms of milliseconds must be adhered to and proven. On the basis of calculations made by the College of South Westphalia, a special-dimensioned three-phase current –liquid starter will be developed. With its moment regulation and delayed short-circuit protection activation, it fulfils all requirements.

The customer’s third requirement has resulted in comprehensive mechanical modifications:
Whereas the motor is normally intended for a single direction of rotation, Düchting would like to be able to use the test stand to test various pumps, and therefore also motors with both directions of rotation. The amount of cooling air required for converting the cooling system and the pressure loss will be determined by the EMZ testing facility in Recklinghausen. The team is basing itself on these measurements when fitting the motor with additional radial blowers which will be installed ion them
modified hood of the water cooler.

“This has been an enormous project with great challenges even for us here at Düchting “, admits Sascha Lahnstein, engineering manager, when inspecting the test stand at the Witten-based machine factory. But EMZ has developed and implemented “an elegant solution“ – from the first presentation, via delivery, all the way to the launch of the motor and starter in Witten. “Enquiries from our clients inspired us to search for ideas on an expansion n of capacity long ago, but the
solutions currently available require a large amount of space and a high price,“he explains. “Now, the facility is set up in such a way that space and costs are but a fraction of what they were.“

Various quality pumps for sea water desalination plants already occupy a considerable share of business at Düchting. According to a forecast by the Organization for Economic Cooperation and Development (OECD), world demand for water desalination is going to increase by ten percent per year. “Several large orders have encouraged us to expand this sphere of competence. And judging from the enquires, we expect in future, the same quantity of water may be desalinated by fewer but
larger centrifugal pumps“, says Sascha Lahnstein, looking ahead to future success. The technology is in demand, especially in rich countries that lie sufficiently close to the sea but are considered to have a water shortage. The Arab Emirates already obtain 100 percent of their drinking water from desalination plants, and Israel obtains half of its fresh water requirements from them.

“With this measure we are now reaching markets from which we were virtually barred due to the absence of testing possibilities,“ stresses managing director Dr.Ing. Carsten Düchting. Thus, the expansion of the test stand by EMZ also underscores “our quality requirement to test each pump in
detail prior to shipment, in order to offer our customers reliable and functional solutions,“ says the boss of the machine factory in Witten.

With test runs for the first big pumps, Düchting has already benefited from the expansion of the test stand. A customer in Iran is receiving a total of six aggregates, consisting of a pump, turbine and motor. The pumps handle 1,500 cubic metres of water per second at a pressure of less than 65 bar and a centrifugal force of 90 degree rediversion. The pumps, each with a capacity of 3,000 kilowatts, form parts of a combination of plants each measuring 9 by 2.5 metres and weighing 16.,5 tonnes.
The heavyweights are taken on a 5,000 km. journey by truck and delivered to the client.

Almost 30 kilometres separate the corporate headquarters of Düchting pumps in the southeast and EMZ in the north west of the Ruhr region. Those ignorant of the branch might consider the former to be “regular customers” of the latter, but in fact, due to long years of cooperation, they are more of a cooperative partnership offering solutions.

In view of the demanding project that has been tackled jointly, the qualified commercial engineer and EMZ managing director Stefan Beese puts it this way: “We are proud of such fruitful cooperation, Once again this project serves as a reference of how, in competence and co-production, extraordinary requirements lead to extraordinary solutions. The solutions to this demanding task by way of motor modifications, tailored to individual requirements, pose great benefit to both sides and represent a successful transformation.“

Cement plant, Algeria

Recklinghausen, 14 September 2017

The EMZ team delivered a motor to an Algerian cement plant as a one-to-one replacement for a slip ring motor with plain bearings. The construction size and foot dimension were adjusted with the aid of a base frame. The motor, delivered in parts, was assembled by the EMZ workshop team.

The lubrication facility required for the hydrostatic plain bearings, as well as the pipelines, were punctually provided with the support of regional partners.

In conclusion, the plain bearing machine, including the lubrication facility, were successfully tested in EMZ’s own test facility.

Split ring motor:

Manufacturer: EMZ | Capacity: 3,700 kW | Voltage: 5,500 V | Frequency: 50Hz Revolutions: 743 rpm | Protection type IP 23 | Coolant type: IC 01

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