Affordable Even at Higher Flow Rates

In many functions within the oil and fuel trade, the chemical industry, and even the meals industry, pumps that work reliably and supply excessive performance are wanted. At the same time, they should have convincingly low investment costs. With the Ecosmart diaphragm metering pump, the German Lewa GmbH has provided a cost-attractive and safe mannequin that may deal with circulate charges of up to 300 l/h for a few years. For use in applications with larger flow rates, the pump skilled from Leonberg, Germany, is now expanding its product vary with two new sizes. In addition to the LCA version, the Ecosmart will also be out there in the extra powerful LCC and LCD variations sooner or later. While the LCC mannequin can meter in extra of 264 gallons per hour, Lewa designed the LCD for a circulate price of as a lot as 528 gallons per hour. The most permissible working pressure for each fashions is 50 bar and 600 pounds respectively. The stringent use of similar elements within the Ecosmart product household retains manufacturing prices and due to this fact the final price low. At the identical time, a excessive level of safety may be assured by specializing in all important design features such because the stress aid valve or the proven sandwich diaphragm with steady monitoring. The LCC variant was made obtainable at the finish of 2021 and the LCD mannequin shall be obtainable by mid-2022.
In addition to the confirmed diaphragm metering pumps of the Ecoflow collection, Lewa has offered the cheaper Ecosmart pump for a number of years. This is especially as a result of the reality that although a dependable pump unit is required in numerous processes, on the identical time relatively low discharge pressures in the decrease two-digit vary require much less complicated pump expertise. With the Ecosmart LCA within the single pump model, nevertheless, only a move fee of beneath eighty gallons per hour was previously potential. In order to be able to supply the Ecosmart for applications with higher move charges, the engineers at Lewa began developing two extra, larger pump variants in 2019. The purpose was to scale up the Ecosmart to bigger functions with the confirmed safety level and prime quality Lewa components without significantly growing the low funding price typical for this pump sequence. This was to be achieved by a consistent modular precept within the pump series, as nicely as a strict concentrate on the important capabilities and options. The specs also demanded the usual Lewa suitability for unrestricted continuous operation over many years. Options for integrating the pumps into automated systems through analog control indicators or bus systems are additionally a matter in fact.
Lewa Ecosmart LCC3 on the test stand.
First of all, the necessities for the conveying capacity needed to be implemented constructively. Larger plunger diameters have been selected for the smaller LCC variant, in order that more than 264 gallons per hour can be conveyed instead of less than 80 gallons. In the case of the more powerful LCD model, the engineers additionally decided to extend the stroke length so that a most flow rate of 528 gallons per hour might be achieved. Both pump types can work towards a maximum operating pressure of fifty bar. As with all hydraulically actuated diaphragm metering pumps, maximum pressures are achieved with smaller plunger diameters.
Just as necessary as the performance of the pump was the operational reliability typical of Lewa familiar from different pump series. For this objective, particular person, important options such because the integrated stress safety valve or the sandwich diaphragm had been taken over from the Ecoflow models. The individually adjustable stress security valve ensures that sudden overpressure within the pump does not damage the diaphragm or pump drive. The diaphragm safety system DPS, whose essential part is a return spring for the diaphragm, also ensures that the PTFE sandwich diaphragm all the time works in the right place. It can’t be overstretched or broken during start-up. Thus, the pump is protected towards operating errors or upset operating situations. Finally, the usual diaphragm monitoring system checks the condition of the diaphragm and warns plant operators immediately 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 delicate areas with poisonous fluids. However, diaphragm monitoring isn’t used as a result of Lewa diaphragms of this collection normally obtain service lives of a quantity of 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 engaging market costs for functions with less demanding requirements and decrease operating stress. To achieve this, the design of the 2 new pump sizes needed to combine components which are as equivalent or no much less than comparable as potential in order to keep away from high manufacturing costs. In this manner, the Lewa engineers have been capable of efficiently implement the frequent components strategy that had already been practiced many instances.
Pump customers also profit from this clever modular principle, as many put on components can be used throughout pump varieties. This significantly simplifies the spare parts inventory. At the identical time, the modular principle also permits particular person adjustments to the respective utility. For example, stroke frequencies or plunger diameters can be selected individually. The foundation for that is the M900 pump head, which is already used in the LCA variant and within the Ecoflow program.
Lewa Ecosmart LCC in heated cupboard.
The pump’s flexibility also presents advantages for plant construction: It permits the Ecosmart pump to be oriented both vertically or horizontally, making it easier to combine the unit into systems with restricted or confined areas. In addition, the pump head of the brand new LCC and LCD fashions is aligned at proper angles to the plunger axis, leading to a particularly compact format. In many pumps, the pump head is on the same axis because the plunger, which regularly ends in bulky pump dimensions. The 90-degree orientation avoids this with the new fashions. This benefit is achieved by the extraordinarily compact and fully newly developed, cost-effective diaphragm drive.
In order to make sure the long service life typical of Lewa pumps, solely high-quality, strong materials are used in the LCC and LCD variations. Toxic and abrasive substances can stress the pump significantly and so a wide selection of supplies can be utilized on the moist finish, that are also successfully used in the high-pressure variants of the Ecoflow collection. Many high-quality parts from the Ecoflow sequence are additionally used for the drive models, employing the widespread components strategy. The result’s robustness and durability that’s unusual on this pump class. In addition, all Ecosmart pumps have been designed with a single oil tub, which is used for each the lubrication of the drive unit and the hydraulics of the pump head. This eliminates the extra complicated lubrication by way of two separate oil techniques and results in an easier design, which not solely facilitates operation but also reduces maintenance work.
Last however not least, the new LCC and LCD versions—like the LCA—comply with the us trade commonplace for metering pumps API 675, guaranteeing almost unlimited usage for numerous demanding processes in a extensive range of industries.
For example, when metering solvents within the chemical business, pumps are needed that on the one hand meet the best specification requirements and then again are still cost-effective. Here, the Ecosmart pump with its greater performance is prepared to meet precisely these necessities, because it has been exactly engineered for purposes in the decrease strain range up to 50 bar (600 pounds). The larger variations of the Ecosmart pump are additionally appropriate for industrial water therapy, corresponding to in seawater desalination or industrial cooling circuits. What counts right here above all is compactness and cost-effective design, which the whole Lewa Ecosmart series fulfills thanks to its progressive design principle.
Before the new pump variants can be found to prospects, a variety of extensive exams shall be carried out. They will ensure that the units also meet the high internal firm requirements for reliability and performance in operational follow. They include, on the one hand, steady load exams of as a lot as several tens of thousands of hours and, on the opposite hand, overload exams. In the latter, the pump is run constantly at as a lot as 20 p.c above maximum stress to further validate its robustness. Special tests are carried out in heated cupboards to proof that the pumps additionally perform perfectly beneath excessive ambient situations. After successful completion of all checks and final adjustments, the Ecosmart version LCC is now in the marketplace, the LCD model will observe in mid-2022.

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