Minimising cost of ownershipfor sewage & sludge pumpsthe truecosts

Energy

Purchase

Maintenance

Energy

Purchase

Maintenance

Unscheduled65%

6%

4%

25%

73%

15%

12%

The purchasing decision has a huge implication on the end user who will pay the bills for the next 20+ years. If the decision is based on the simplistic LCC model the costs of unblocking pumps and the loss of output when running partially blocked are largely ignored. Even worse, of course, is to purchase on price alone. The question that must be answered is “Does the purchaser have the authority to embed costs that could be 10 to 20 times the cost of the pump to be paid for by the end user?”

HIDROSTAL .. minimising the cost of pump ownership...Life Cycle Costing [LCC] analysis is a method of determining the total cost of ownership of a pump. Typically these costs are taken to include purchase price, energy use and scheduled maintenance over the life time of the pump which could typically be 15 - 20 years. These are the most obvious costs, and are easy to quantify and track

But it doesn’t tell the whole story ...

Energy

Purchase

Maintenance

Energy

Purchase

Maintenance

Unscheduled65%

6%

4%

25%

73%

15%

12%

Pumps which block have three additional costs ...

• Reduction in efficiency when running partially blocked

• Loss of output when run partially blocked (longer running hours)

• Cost of unblocking pump

“Estimated cost of maintenance in the UK is £800-£1000 million”UK Pump Centre

The purchase decision determines the cost of ownership ...

Often overlooked are the energy costs arising from loss of efficiency due to blockages or wear during the life time of the pump and the resulting costs of unscheduled maintenance. Quite often the value of lost output, the incurring energy costs and costs of unscheduled maintenance will dwarf all the other elements

High efficiency is important but should never be attained at the cost of compromising on the pump’s ability to handle gross solids, rags and fibre, so increasing the likelihood of blocking and resulting in the need for unscheduled maintenance.

Costs of a 6kW sewage pump [a typical network pump] suffering from blockages

The real costs of maintenanceA common mistake is to assume that maintenance costs apply purely to routine maintenance and spare parts. The reality is that unscheduled maintenance, caused by blocked or partially blocked pumps and premature failure or leaks at mechanical seals, can incur the greater costs. The impact of flooding, environmental issues, loss of output and consequential damages can have a detrimental effect on the company’s brand as well as expenditure!

The key to a successful installation is to select the most appropriate pump for the task, a pump that is ‘Fit for Purpose’ with high efficiencies and that will operate free of blockages. This will reduce

energy consumption and keep maintenance costs to a minimum.

Typical material removed from a 300mm conventional sewage pump

Energy

Purchase

Maintenance

Energy

Purchase

Maintenance

Unscheduled65%

6%

4%

25%

73%

15%

12%

Energy

Purchase

Maintenance

Energy

Purchase

Maintenance

Unscheduled65%

6%

4%

25%

73%

15%

12%

Energy is recognised as the dominant issue ...

Runs continuously free of blockages

Lack of ragging and blockages extend the period before maintenance is required which reduces spares and increases plant availability

Screw Centrifugal Pumps

The Hidrostal screw centrifugal impeller pumps have been designed with two essential features:

• Large free/ball passages to handle solid objects Function of impeller ball passage

• Ability to handle rags and fibrous material without blockage of the impeller Function of blade geometry at impeller inlet.

Submersible/immersible pumps

Close couple end suction pumps

Screw centrifugal pumps have large free passages

No loss of output from leakage at the pedestal coupling; all Hidrostal submersible pumps are fitted with a rubber seal rather than relying on metal to metal contact

Pump sealed against pedestalContinuously monitoring the total pump condition will identify faults and minimise any consequential repair

and nuisance costs

For Return Activated Sludge - The gentle handling characteristics of the screw impeller doesn’t damage the floc, improving the quality of the effluent in the sewage treatment process and saving money!!

Hidrostal Pumps are efficient while still ‘fit for purpose’The aim at Hidrostal is to build pumps that are reliable, have high efficiencies, and most importantly, are ‘fit for purpose’ so keeping unscheduled maintenance to a minimum.

The unique Hidrostal screw centrifugal impellers are specifically designed to handle large solids, rags and fibres whilst still maintaining broad efficiencies over their operating range. By axially extending the impeller without compromising the hydraulic design we have been able to produce a pump that will run continuously free of blockages.

Maintaining a flexible coupling and direct mounted motor guarantees alignment and

simplifies maintenance

Bo Foot for vertical pumps gives easy installation and good access to service connection

Seal in coupling

Horizontal versions can be pulled out on a trolley which forms part of the base plate

Screw centrifugal pumps are the "MUST HAVE" for reliable sludge and raw sewage pumping

www.hidrostal.co.uk

WHY HIDROSTAL SCREW CENTRIFUGAL PUMPS MINIMISE LIFE CYCLE COSTS

FEATURE BENEFITSHigh quality product High degree of reliabilityHigh pump efficiency Reduced energy consumption hence reduced running costsExternally adjustable liner provides a means of restoring pump efficiency and flow during routine maintenanceRange of material options Resists wear, maintains efficiency, prevents corrosion problemsScrew centrifugal impeller Special blade geometry ensures rags and fibre pass freely through the pump

Pumps for every purpose...

Canister pumps Prerostal™ - Flow matching

Self priming diesel driven pump sets End Suction pumps

Dry Installed Immersible pumps with flywheels

All with the unique Hidrostal screw centrifugal impeller designed to eliminate blockages and reduce life cycle costs

++ plus ++Technical support from experienced field sales

engineers & office based sales/applications engineers

• Design & engineering skills• Pump selection• On-going support and consultancy• Pump repair and maintenance

Designed with application and ease of maintenance in mind• The best possible environment is provided for mechanical seals so that seals can deliver full life time

potential• Bearing clearances are controlled and stiffened to reduce shaft deflection• Large submersible/immersible motors can be re-greased in the field thereby extending bearing life• Belt drives enable optimum performance particularly valid on sludge pumping installations where sludge

characteristics can vary from initial design• Immersible motors allow sump draw down for cleaning• Choice of installation, wet or dry, horizontal or vertical all with the famous Hidrostal screw centrifugal

impeller• Oil jacket with forced circulation for efficient cooling of immersible motor (no contact with sewage being

pumped)

Hidrostal Limited, 4 & 5 The Galloway Centre, Hambridge Lane, Newbury RG14 5TL, EnglandTel: +44 1635 550440 | Fax: +44 1635 550140 | Email: sales@hidrostal.co.uk