L A N D Y SC R EW PUM P S& H Y D RO POWE R SCR EWS

For all your UK aftermarket needs and supply of new products

www.ecsengineeringservices.com

L A N D Y SC R EW PUM P S

WIDE APPLICATION POSSIBILITIES

Applications for the screw pump are countless:effluent pumping stations in WWTPintermediate pumping stations in WWTPreturn sludge pumping stationshydropower screwfish-friendly screw pumps for fish passageirrigation projectsdrainage projectsreclamation of wetlandscirculation within aeration systemswild water rides in fun parksindustrial applications storm water applications

INTRODUCTION

Landustrie has a broad experience in the field ofscrew pumps and screw pump installations. Fornearly 100 years Landustrie has designed,manufactured, supplied, erected and maintainedmany types of screw pump configurations. Sincethe early eighties Landustrie has used a fullyautomated screw pump selection program whichenables the engineers to select the optimum screwpump for a particular application. The program isbased on a large number of tests, with an equalnumber of variables, in the Landustrie test facility.The accompanying calculation method has, forseveral of our orders, been approved byGermanische Lloyds. In addition, Landustrie hasdeveloped, over many years, its specific pumpknowledge base, which is continuously updated bymeans of R&D and the latest technology – forexample using Finite Element Analysis (FEA)methods. The latest range of the Landustrie screwpump also covers the hydropower screw pumps. Allthis knowledge and experience makes Landustrieone of the leading manufacturers in the world ofscrew pump installations.

PRINCIPLE OF THE SCREW PUMP

The principle of the screw pump is an inclinedtube, provided with blades, which by rotating liftthe medium to a higher level.

CROSS-SECTION Z-Z

LANDY SCREW PUMPS

Screw pumps and screw pump installations ingeneral are characterized by the following features:

open, clog-free, simple and robust constructionhigh efficiency, low maintenance, lowoperational costshighly reliable, long lifetime and virtually no wear(no spare units required)automatic adjustment of the pump capacity asa function of the incoming flowoperating in a wide range, with a capacity from10 to 11.500 l/s and lift from 0 to 12 mchanges in the capacity are easy and, ifnecessary, steplessinsensitive to supply conditions and also(because of the low rpm) no problems withcavitationcustom-made for each project

Cross-section Z-Z Chute point

Max.pumpingpoint

Touch point

Fillingpoint

D = DiameterJ = No. of flightsN = SpeedS = Pitch

L = Flight lengthH = Nominal liftF = Tension� = Inclination

SCREW PUMP TERMINOLOGY

The picture below shows the most commondefinitions regarding screw pump installations:

FISH-FRIENDLY SCREW PUMPS

The Archimedean screw pump can easily beconverted into a very fish-friendly version:

The diameter of the blades will be increasedgradually from the tube towards the outsidediameter of the screw pumpThe blades will ultimately merge with thecasing of the screw pump, in order to preventfish from becoming trapped between theblades and the casingA thicker rounded edge at the start of theblades to create pressure waves in the waterso fish will be directed into the main water flowin order to prevent contact with the blades

With these provisions the screw pump isextremely suitable to pump up water withoutdamaging fish (unharmed > 98%).

L A N D Y SC R EW PUM P S

HYDROPOWER SCREWS

Hydropower installations generate renewableenergy from flowing water resources. This couldbe from a lake, disused locks at weirs or indownstream flows. The major advantage ofhydropower is the possibility of 24 hour use.Most of the energy generated is fed back into thegrid or alternatively used on site.

Feed-in tariff regulations for renewable energyexist in most countries. Depending on the energysource, tariffs are paid on a per-kWh basis. Thismakes it worthwhile to use renewable energy. Anefficient use of water power is already achievedat a level difference of 1 m and a capacity of 500 l/s. The largest capacity and leveldifference for hydropower screw units is as muchas 15000 l/s at 10 m.

Note: energy generated from flowing waterresources gives the highest efficiency rating of allsustainable energy sources!

Benefits of hydropower screw pumps:

Highest efficiency (up to 86%)Simple installationEasy implementation in existing situations (nocivil construction work)Extremely fish-friendlyInsensitive to cloggingLow maintenance costsLong life timeImprovement of water quality24 hour energy supplyActive flow control without extra lossesPossibility to switch over to pump functionSelf-regulating to changing water flow

Hydropower screw at Windsor, UK

General Rule of Thumb Calculation of electrical power output is:

H(m) x Q(m3/s) x g(9,81m/s2) x 0.75 = P (kW)

Energy production per year:P (kW) x 8760 (hr) = (kWh/y)

lower bearing, the maintenance is limited to an annual oilchange and periodic checking of all greasing points. Allthese factors lead to very low operational costs forLandustrie screw pump installations.

HIGHLY RELIABLE, LONG LIFETIME AND HARDLYANY WEAR (NO SPARE UNITS REQUIRED)

The robust construction of the screw pump body and bothbearings, the use of standard components such as electricmotors and gearboxes at low revolutions gives the screwpump a unique reliability record. With intensive use alifetime of 20 years is normal. Even screw pumps whichhave been in operation for more than 40 years occur quiteregularly. An additional advantage of the extreme reliabilityis that no spare unit needs to be considered at designstage.

AUTOMATIC ADJUSTMENT OF THE PUMP CAPACITYAS A FUNCTION OF THE INCOMING FLOW

The capacity of the screwpump is automaticallyadjusted in the event thatthe incoming flow is lowerthan the screw pumpcapacity. When theincoming flow is greaterthan the pump capacity,the discharge will belimited to the screw pumpcapacity. Because of thisequable flow regime, ascrew pump is extremelysuitable as an effluentpump for a waste watertreatment plant, ashydraulic overloading isprevented.

Incoming flow at filling point

Incoming flow above filling point

Incoming flow below filling point

OPEN, CLOG-FREE, SIMPLE AND ROBUSTCONSTRUCTION

Depending on the medium (in most cases rawwaste water) several kinds of contamination canoccur. The screw pump has an importantadvantage: due to its open construction, screenscan be situated behind the screw pump, if required.

This results in lower civil costsof the total installation.By means of its advancedscrew pump selection program,Landustrie is capable ofselecting screw pumps which,in many cases, will have twoflights. This offers advantagesin respect of less deflectionbecause of the lower tensilestress, lower welding tension,and lower resultant forces on

the civilconstruction.This in turn willallow bigger lifts.As a standard,Landustrie, basedon nearly acentury’sexperience,allows for atensile stress of

20 N/mm2 maximum, and a maximum deflection ofL/2500. The actual stress is determined using FEA.All selected screw pumps can be supplied in eithera coated steel or stainless steel version in AISI304or AISI316. Other exotic materials are alsopossible.

HIGH EFFICIENCY, LOW MAINTENANCE, LOWOPERATIONAL COSTS

Because of contamination of the medium, theefficiency of screw pumps for this application willbe much higher than for other types of pumps.Moreover, the screw pump is ideally suited to copewith variations in the incoming flow whilst workingat a nearly constant efficiency (see under automaticadjustment of pump capacity). Also, the lowernumber of revolutions of screw pumps adds to therelatively high efficiency of the overall installation.Because the complete screw pump installation isbuilt up from an electric motor, gearbox, upper and

L A N D Y SC R EW PUM P S

Screwdiameter

(mm)

Max.speed(r.p.m.)

Capacitymax

(m3/sec.)

30°Ho

max.(mm)

Capacitymax

(m3/sec.)

Homax.(mm)

Capacitymax

(m3/sec.)

Homax.(mm)

35° 38°

300 118 0,016 2800 0,012 3200 0,011 3500450 98 0,041 4000 0,033 4600 0,029 5000600 75 0,082 4700 0,066 5400 0,059 5900800 62 0,154 5500 0,125 6300 0,0112 69001000 53 0,272 6700 0,218 7700 0,196 84001250 46 0,430 7700 0,360 8900 0,312 97001500 40 0,690 8600 0,556 10000 0,500 109001800 36 1,080 9800 0,866 11400 0,777 125002100 32 1,500 9200 1,210 10500 1,087 115002450 29 2,210 8000 1,770 9100 1,591 100002800 26 2,980 10500 2,390 12100 2,150 133003200 24 4,070 10600 3,273 12100 2,940 133003600 22 5,360 11000 4,306 12600 3,860 138004050 21 7,060 11400 5,670 13000 5,090 142004500 19 9,000 11700 7,240 13300 6,500 146005000 18 11,530 12000 9,260 13600 8,320 14900

WIDE DESIGN RANGECAPACITY FROM 10 TO 11,500 L/SLIFT FROM 0 TO 12 M

Every single screw pump is specifically designedand therefore tailor-made for each project. Thisalways gives an optimum balance betweenfunction and design, varying between capacitiesof 10 and 11,500 l/s. As regards the lift, thepossibilities are practically unlimited when screwpumps are installed in series. The adjacenttable shows an indicative overview of the mostcommon options. Also screw pump installationswith different inclinations, which were quite oftenused in the past, can be quoted on request.

Screw pumps in serial order

CHANGES IN CAPACITY ARE EASY ANDSTEPLESS IF NECESSARY

The capacity of the screw pumps is easy toadapt by simply adjusting the speed of thescrew using a multi speed motor or a variablefrequency drive (VFD). To adapt the speed of afixed speed screw, the pulleys of the V-belttransmission can be changed. In all but a fewcases the efficiency will be maintained afterchanging the speed. This characteristic is veryimportant. Most installations do not get the inputfor which they are designed. Therefore it isimportant that the input in practice will bepumped as efficiently as possible. So if theactual input deviates substantially from thedesign input the efficiency of the total installationwill not be reduced in situations where screwpumps are installed.

.

INSENSITIVE TO SUPPLY CONDITIONSAND, BECAUSE OF ITS LOW SPEED, NOPROBLEMS WITH CAVITATION

Because of the low revolutions and the nature ofthe screw pump no special demands have to bemet regarding the inlet channel of the screwpump. The screw pump is, contrary to othertypes, insensitive to supply conditions. Even athigher revolutions when critical supply conditionscould lead to cavitation, which in practice canoften occur with competing pump designs, thescrew pump maintains its efficiency levels.

Filling point

Touch point

Pump efficiency

Pump capacity

Discharge and efficiencyat various inlet levelsbelow filling point

SCREW PUMP SIZING

Many years of research and experience havegiven Landustrie the ability to select the efficientapplication for each screw pump. The optimumcombination of inclination, pitch/diameter ratio,diameter/tube ratio and number of flights willresult in substantial savings of both investmentand operational costs.

The increase in wear resistance also leads toenergy savings: a wear resistant layer betweenthe screw pump and the trough means a fixedclearance for the lifetime of the screw pumpinstallation. Increasing leak losses because ofsand, gravel and other dirt will no longer occur. Aperfect trough is essential in order to build highlyefficient screw pumps.

HIGHER EFFICIENCY

New screw pumps are often installed by using acasting mould for creating the concrete trough.The advantage of this method is that a superiorquality of concrete trough can be achieved.Also, concreting is less dependent on weatherconditions and craftsmanship.

TROUGHS

The choice of troughs presents several options.First of all there is the classic concrete trough, forwhich the screw pump itself is used to grout thetrough to its final shape, working at low speedand using a special mortar. When this specificknow-how is not available it is possible to ordereither a screw pump with a steel casting mouldwhich is removed after the concrete has beencast, leaving the correct clearance between thescrew pump and the concrete.

This can also be done with a cast-in steel (orstainless steel) trough, which will remain in theconcrete. For special applications there is alsothe option of a fully self-supporting steel troughor a completely pre-fabricated screw pump,including trough bearings and drive-unit. The lastoption has the advantage that installation time isextremely short. For smaller screw pumps, apre-fabricated pump can be installed as a tubescrew pump.

TROUGH TYPE CONCRETE CASTING MOULD STEEL (LINER) PREFABRICATED TUBE TYPE FISH FRIENDLY

Optimal clearanceWear resistantconcrete Short installation Short installation

ADVANTAGE Optimal clearance Smooth surface Easy to install time time Suitable for fish

Cheap Very easy to install Very easy to install passage

Multipurposemould

Installationexperience Slightly less Expensive Limited in

DISADVANTAGE required None efficient Slightly less diameter/Q/H Slightly more

Non-wear resistant Slightly more efficient Less efficient expensive

concrete expensive Expensive

L A N D Y SC R EW PUM P S

LOWER BEARINGS

For the lower bearings Landustrie hasthree different standard types. The mostrecent is the Landy Eco-friendly lowerbearing, with a number of specificadvantages (see the adjacent 3-D image)In the table we have compared the fourdifferent Landustrie lower bearings. Alllower bearings, of any type, only have toabsorb radial forces. The lower bearingalso absorbs the heat expansion andcontraction of the screw.

Completely enclosed unit

No maintenance and no grease costs

3-dimensional self-aligning

Corrosion-freecast iron housing

Lower investment

No spare parts required

Exchangeable withexisting bearings

No grease pump andgrease lines required

Easier to install

Eco-friendly lubricated for lifetime of the bearing

High-performance seal

Eco-friendly Conventional Heavy Duty

Lubrication Lifetime Grease Grease

Grease filling l l

Grease return line NA On request l

Maintenance required l

3D-self-aligning l l

Installation time low average average

Heavy duty l

Exchangeability with existing bearings l l

Investment low medium high

Operational costs low medium medium

Lifetime average average long

LOWER BEARING SELECTION TABLE

ECO-FRIENDLY LOWER BEARING

Wall-mountedbearing

WATER-IN-OIL DETECTION

All Landy Eco bearings can be fittedwith a water-in-oil alarm system. Thissystem gives an alarm when a certainamount of water or some otherconducting medium has polluted the oilin the bearing housing. The system canbe fitted to new bearings as well as beretrofitted to existing bearings.

UPPER BEARINGS

For the upper bearing Landustrie can offer thechoice between two different versions; awall-mounted or a foot-mounted upperbearing. The preference is normally forthe wall-mounted upper bearing, firstlybecause the forces on the civilconstruction will be better absorbed, andsecondly because an odour-tightseparation is created between the screwpump and the room in which the drive-unitis installed. Foot-mounted bearing

L A N D Y SC R EW PUM P S

DRIVE-UNIT OPTIONS

Depending on the local circumstances there is achoice of different drive-unit arrangements.Different options are shown schematically in thedrawing below. Deviations from these guidelines is,of course, possible, if so required.

TOTAL COST OF OWNERSHIP

Any screw pump installation will perform betterthan any other type of pump based on Total Costof Ownership. This is due to better efficiency over alarge working range of the screw pump, lessmaintenance and a superior life time of theinstallation.

AFTER SALES

ECS’s after sales service is the customersconnection to Landustrie not only for the supply ofspare parts but also for training and supervision. Inaddition, installation upgrades, some of which haveamazingly short payback times through savings inenergy and maintenance, can be carried out onexisting applications.

sales@ecsengineeringservices.com

01773 860001

RENOVATION OF EXISTINGINSTALLATIONS

ECS is capable of renovating any screw pumpinstallation including those supplied by othermanufacturers. Due to our vast experience we willguarantee that installations renovated by ECS willbe improved by at least 15% in terms ofoperational cost.

RESEARCH AND DEVELOPMENT

For many years Landustrie has been active inresearch to improve the screw pump even further.The most recent results are the Eco-friendly lowerbearing, which has been tested for over 10 years.In addition, the latest developments withhydropower screws have been tested in-house ona 1:1 scale, as well as the increased use of theFinite Element Analysis techniques on theLandustrie screw pump designs.

Direct drive

V-belt transmission

ECS maintenance engineers

LANDY SCREW PUMPS BECAUSE...

Besides the general characteristics of the screwpump, the Landy screw pumps are distinguished by:

In other words a first class product with

screw pump technology

Minimum tolerance on outside diameter Efficient design -

- Usually 2 flights- Limited deflection- Limited occurring tension- High efficiency

Ongoing R&D

Finite Element Analysis

Full in-house manufacturing

Totally reliable manufacturing schedulesand delivery times

Endplates- Fully watertight by means of caps

over threads of connection bolts- Fully parallel and concentric manufacture

using special lathesReinforced leading edges of flights

Manufactured with permanent lifting eyesand balancing weights

Fully qualified welders- X-ray or ultrasonic- Welding ShopApproval

Alignment of the screw

pump by machining the

bearing joint face

Coating. All required coatings areapplied professionally, and can besupplied with additional requirementsregarding sand, salt or pH.

Basic material of bearing shafts is nodularcast iron

Use of fully self-aligning bearings

Nearly 100 years experience

World-wide service with local support

Superb after-sales service

Erection with competent and experienced Landustrie mechanics. On request, we can also offer fullsupervision of installation

STATE-OF-THE-ARTSTATE-OF-THE-ART

L A N D Y SC R EW PUM P S

10-2

013

1000

UK

ECS

REFERENCES

During the nearly 100 years of their existenceLandustrie has undertaken some 7,000 screwpump projects, which are all unique in terms ofdesign and execution, varying in power from 1 to600 kW and in diameter from 10 cm to 5 meter,and in length from 50 cm to 25 m. All theseprojects have added to the vast amount ofknowledge and background information built upover the years regarding the design,manufacturing and installation of screw pumps. For every new project, you, as our customer, areusing this inexhaustible amount of experience.You will find some of our most recent projects inthe adjacent photo collage.

COVERS

On request Landustrie can cover the installationwith a modular light weight synthetic coverconstruction. Advantages are:

protection of the screw pump against thermalexpansioncreates a safe working environmentreduces the level of noise production

ECS ENGINEERING SERVICES:INSTALLATION

ECS has a great deal of experience in this fieldand is supported through its supply distributionagreement with Landustrie and is capable ofdelivering any size of project. ECS offers acomplete service from the initial site visit,through design, installation and commissioning.Design engineers will produce bespokespecifications for each individual applicationwhich will be installed by qualified andexperienced personnel to the highest standards.

REPAIR & SERVICE

ECS also offers a complete package ofmaintenance and repair services for allArchimedes type screw pumps including round-the-clock emergency breakdown cover. Forcustomers looking to maintain and improve theefficiency of existing installations, ECS has theexperience and the expertise to deliver a reliableand efficient solution for every applicationincluding hydro-power screws.ECS has a large number of field basedinstallation & service engineers with fullyequipped vehicles that can remove and repair alltypes of screw pumps.

Veneriete, The Netherlands (renovation)

Windsor, UK

Windsor, UK

ECS Engineering ServicesBrookhill RoadBrookhill Industrial EstatePinxtonNottinghamshireNG16 6NS Telephone 01773 860001Facsimile 01773 810003Email info@ecsengineeringservices.com