+61 (0)2 4903 8900
Quick Quote/ Contact Us

If you would like to discuss a project or receive a quote for any of our industry leading products and services please fill in the form below.

Hose Down Pump

Date: 16th April 2008

Project: BHP Site @CHPP

Test Results: Adjustable Speed Control – MagnaDrive’s A.S.D Coupling

Application: Hose Down Pump

1.0 Introduction

The Magnadrive Adjustable Speed Drive Coupling (ASD) was installed on the Hose Down Pump at South Walker Creek CHPP on the 4th October 2007. The installation included extending the motor mounting rails, installation of the actuator bracket, coupling and actuator, motor and pump axial and radial alignment and adjustment of the actuator linkage. Electrical works included installation of additional cables, pressure transducer, and configuration changes to the SCADA and PLC systems. The whole process was completed within a 12 hour scheduled maintenance day.

Prior to the installation of the new coupling, the 3/2 AH Warman slurry pump ran at a constant 2950 rpm with a pressure sustaining valve diverting excess water needs back to the clarified water tank. Motor load was consistently above 31kW. With the installation of the ASD coupling, the sustaining valve was removed and the pump speed is now controlled by the ASD coupling which in turn is controlled by water demand. As motor load is proportional to pump speed 3 (if pump speed is halved there is an eight fold reduction in power demand) any reduction in pump RPM is going to provide energy conservation.

hose down

2.0 Results

A series of readings taken over the last two months has shown significantly lower energy consumption when compared with the recordings taken on the fixed speed pump in August 2006. Based on this data, it is expected that this pump will consume ~ 120MWh per annum less than it would have in 2006. Broadly speaking this could amount to a $12,000 per annum electricity cost saving, this will depend on energy & maximum demand tariff charges.

In the original purchase justification I estimated a payback period of less than five years. The actual results suggest a payback period of less than 3 years.

Date 02/08/06 28/03/08 29/03/08 14/04/08
Average Pump Speed (RPM) 2950 1740 1670 1750
Average Motor Input Power (kW) 31.8 17.9 16.6 17.4
Total Energy Consumed / Day (kWh) 764.7 431.1 398.7 418.6
Estimated Energy Consumed / Annum (kWh) 273,528 154,188 142,603 149,725

hose down charts

   All Case Studies

Case Studies

Water Cannon Repair Learn More Water Cannon Repair

Integrated Reliability Solutions were approached by one of the Hunter Valley coal mines to inspect and come up with a suitable repair for the leaking water cannons. On inspection of the water cannon, it was noted that a number of components had worn due to lack of lubrication which allowed the water to leak when not in use.

Breather and Sampling Point Audit - Nth Queensland Learn More Breather and Sampling Point Audit - Nth Queensland

Glencore site Collinsville CHPP had requested that we undertake an audit on their current Breather and Sampling Points, to identify opportunities to improve the cleanliness of the air entering the compartments, oil and the accuracy and process of taking oil samples. 

MagnaDrive saves Plant Feed Conveyor Learn More MagnaDrive saves Plant Feed Conveyor

On the 4th of November 2007, the plant feed conveyor failed to start after the operator attempted to restart operations following a plant stoppage.

MagnaDrive Coupling Vibration Success Learn More MagnaDrive Coupling Vibration Success

Nothwestern U.S. Forest Products Company uses MagnaDrive MagnaGuard Econimizer to eliminate vibration.

MagnaDrive Coupling Screw Pump Learn More MagnaDrive Coupling Screw Pump

City of Eugene, Oregon – Wastewater Division – MagnaDrive Magnetic Coupling on Archimedean Screw Pump

MagnaDrive Coupling Chilled Water Pump Learn More MagnaDrive Coupling Chilled Water Pump

Washington Mutual Tower in Seattle, Washington Replaces Flexible Coupling with MagnaDrive ASD

MagnaDrive Coupling Air Preheater Learn More MagnaDrive Coupling Air Preheater

Minnesota Power was experiencing vibration problems on their Air Pre-Heaters. In an effort to correct this problem, Minnesota Power implemented a preventative maintenance procedure that required all couplings to be re-greased during every outage.

Hose Down Pump Learn More Hose Down Pump

The Magnadrive Adjustable Speed Drive Coupling (ASD) was installed on the Hose Down Pump at South Walker Creek CHPP on the 4th October 2007.

Bearing Skidding Learn More Bearing Skidding

Over the last three years IRS has been monitoring motor bearings displaying various stages of fatigue.

Electric Motor Bearing Defects Learn More Electric Motor Bearing Defects

The site was experiencing a high frequency of electric motor bearing faults. Condition monitoring reports had identified specific motors as manifesting bearing defects and had suggested that a “lack of lubricant” was a significant factor contributing to the defects.

Grease Contamination Learn More Grease Contamination

Over the course of several months, site maintenance personnel observed that lubrication system components were failing at a rate higher then what would normally be expected.

Get in touch to discuss your specific needs. Call now!

+61 (0)2 4903 8900
or Contact Us