Affordable Even at Higher Flow Rates

In many purposes within the oil and fuel industry, the chemical trade, and even the food business, pumps that work reliably and supply high performance are wanted. At the same time, they should have convincingly low funding prices. With the Ecosmart diaphragm metering pump, the German Lewa GmbH has offered a cost-attractive and safe model that may deal with circulate rates of as a lot as 300 l/h for many years. For use in applications with larger circulate charges, the pump professional from Leonberg, Germany, is now expanding its product range with two new sizes. In addition to the LCA model, the Ecosmart may even be available in the extra powerful LCC and LCD variations sooner or later. While the LCC model can meter in excess of 264 gallons per hour, Lewa designed the LCD for a circulate fee of up to 528 gallons per hour. The maximum permissible operating strain for each fashions is 50 bar and 600 kilos respectively. The stringent use of similar components inside the Ecosmart product family keeps manufacturing costs and due to this fact the ultimate value low. At the identical time, a high stage of security could be assured by specializing in all essential design options such as the stress reduction valve or the proven sandwich diaphragm with steady monitoring. The LCC variant was made available on the end of 2021 and the LCD model will be out there by mid-2022.
In addition to the proven diaphragm metering pumps of the Ecoflow series, Lewa has provided the less expensive Ecosmart pump for several years. This is mainly as a outcome of the truth that though a reliable pump unit is required in quite a few processes, at the similar time comparatively low discharge pressures in the lower two-digit range require much less advanced pump know-how. With weksler ea14 within the single pump model, nevertheless, only a flow price of under eighty gallons per hour was beforehand potential. In order to have the power to offer the Ecosmart for purposes with greater flow rates, the engineers at Lewa began developing two additional, larger pump variants in 2019. The goal was to scale up the Ecosmart to bigger functions with the proven safety level and high quality Lewa components without considerably rising the low investment cost typical for this pump sequence. This was to be achieved by a constant modular principle within the pump series, as nicely as a strict give attention to the important features and options. The specs also demanded the same old Lewa suitability for unrestricted continuous operation over many years. Options for integrating the pumps into automated methods through analog control alerts or bus methods are also a matter in fact.
Lewa Ecosmart LCC3 on the take a look at stand.
First of all, the necessities for the conveying capability had to be implemented constructively. Larger plunger diameters were chosen for the smaller LCC variant, so that greater than 264 gallons per hour can be conveyed instead of lower than eighty gallons. In the case of the extra powerful LCD model, the engineers additionally decided to increase the stroke size so that a maximum flow fee of 528 gallons per hour could 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 because the efficiency of the pump was the operational reliability typical of Lewa familiar from different pump series. For this purpose, particular person, important options such as the built-in stress safety valve or the sandwich diaphragm were taken over from the Ecoflow models. The individually adjustable pressure security valve ensures that sudden overpressure in the pump doesn’t damage the diaphragm or pump drive. The diaphragm protection system DPS, whose important part is a return spring for the diaphragm, additionally ensures that the PTFE sandwich diaphragm always works in the best place. It can’t be overstretched or broken throughout start-up. Thus, the pump is protected towards working errors or upset operating conditions. Finally, the usual diaphragm monitoring system checks the condition of the diaphragm and warns plant operators instantly if there might be any damage. This reliably prevents cross-contamination between the pump and the piping system and ensures operational safety at all times, particularly in delicate areas with toxic fluids. However, diaphragm monitoring is never used as a result of Lewa diaphragms of this sequence often obtain service lives of several years – even beneath full load and continuous operation.
A key point was to maintain manufacturing prices within a similar vary to the small LCA variant, thereby creating attractive market costs for applications with less demanding necessities and lower operating pressure. To do so, the design of the 2 new pump sizes needed to integrate elements that are as identical or a minimal of comparable as possible so as to avoid excessive manufacturing prices. In this fashion, the Lewa engineers have been able to successfully implement the widespread elements strategy that had already been practiced many occasions.
Pump customers also benefit from this intelligent modular principle, as many wear components can be utilized throughout pump types. This considerably simplifies the spare components stock. At the identical time, the modular precept additionally allows individual changes to the respective software. For example, stroke frequencies or plunger diameters can be chosen individually. The foundation for this is the M900 pump head, which is already used within the LCA variant and in the Ecoflow program.
Lewa Ecosmart LCC in heated cupboard.
The pump’s flexibility additionally offers advantages for plant building: It permits the Ecosmart pump to be oriented either vertically or horizontally, making it simpler to integrate the unit into systems with limited or confined spaces. In addition, the pump head of the brand new LCC and LCD fashions is aligned at right angles to the plunger axis, resulting in a particularly compact format. In many pumps, the pump head is on the identical axis because the plunger, which often results in cumbersome pump dimensions. The 90-degree orientation avoids this with the new fashions. This benefit is achieved by the extremely compact and fully newly developed, cost-effective diaphragm drive.
In order to make sure the lengthy service life typical of Lewa pumps, solely high-quality, robust supplies are used in the LCC and LCD versions. Toxic and abrasive substances can stress the pump significantly and so quite lots of materials can be used on the moist finish, which are additionally successfully used within the high-pressure variants of the Ecoflow sequence. Many high-quality components from the Ecoflow collection are also used for the drive models, using the common parts technique. The result’s robustness and durability that’s uncommon in this pump class. In addition, all Ecosmart pumps have been designed with a single oil bathtub, which is used for both the lubrication of the drive unit and the hydraulics of the pump head. This eliminates the more complex lubrication via two separate oil methods and results in an easier design, which not only facilitates operation but additionally reduces maintenance work.
Last however not least, the new LCC and LCD versions—like the LCA—comply with the U.S. trade normal for metering pumps API 675, guaranteeing nearly limitless usage for numerous demanding processes in a variety of industries.
For example, when metering solvents in the chemical trade, pumps are needed that on the one hand meet the very best specification requirements and however are nonetheless cost-effective. Here, the Ecosmart pump with its greater efficiency is prepared to meet precisely these necessities, as it has been exactly engineered for applications within the lower strain vary as much as 50 bar (600 pounds). The bigger variations of the Ecosmart pump are additionally suitable for industrial water remedy, corresponding to in seawater desalination or industrial cooling circuits. What counts here above all is compactness and cost-effective design, which the entire Lewa Ecosmart series fulfills thanks to its progressive design precept.
Before the model new pump variants are available to customers, numerous in depth checks shall be carried out. They will make sure that the models also meet the high inner company requirements for reliability and performance in operational follow. They embody, on the one hand, steady load exams of as a lot as several tens of thousands of hours and, however, overload exams. In the latter, the pump is run repeatedly at up to 20 p.c above maximum stress to further validate its robustness. Special tests are carried out in heated cabinets to proof that the pumps additionally perform perfectly underneath extreme ambient circumstances. After successful completion of all checks and last changes, the Ecosmart version LCC is now on the market, the LCD mannequin will follow in mid-2022.

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