Affordable Even at Higher Flow Rates

In many purposes within the oil and gas industry, the chemical business, or even the meals trade, pumps that work reliably and provide high performance are wanted. At the identical time, they should have convincingly low investment costs. With the Ecosmart diaphragm metering pump, the German Lewa GmbH has supplied a cost-attractive and safe mannequin that can handle move charges of up to 300 l/h for many years. For use in purposes with larger move rates, the pump professional from Leonberg, Germany, is now increasing its product vary with two new sizes. In addition to the LCA version, the Ecosmart may also be available in the extra highly effective LCC and LCD versions in the future. While the LCC model can meter in extra of 264 gallons per hour, Lewa designed the LCD for a circulate fee of up to 528 gallons per hour. The maximum permissible working pressure for each models is 50 bar and 600 pounds respectively. The stringent use of similar components within the Ecosmart product family retains production costs and subsequently the final worth low. At the identical time, a excessive level of security could be guaranteed by focusing on all essential design features such as the strain relief valve or the proven sandwich diaphragm with continuous monitoring. The LCC variant was made obtainable on the finish of 2021 and the LCD model shall be available by mid-2022.
In addition to the proven diaphragm metering pumps of the Ecoflow sequence, Lewa has provided the less expensive Ecosmart pump for several years. This is especially due to the reality that although a reliable pump unit is required in numerous processes, on the identical time relatively low discharge pressures within the lower two-digit range require less complicated pump expertise. With the Ecosmart LCA in the single pump version, nonetheless, only a flow fee of below 80 gallons per hour was beforehand attainable. In order to have the flexibility to provide the Ecosmart for purposes with higher flow rates, the engineers at Lewa began creating two extra, larger pump variants in 2019. The goal was to scale up the Ecosmart to bigger purposes with the confirmed security stage and prime quality Lewa elements without significantly growing the low funding cost typical for this pump series. pressure gauge was to be achieved by a consistent modular principle within the pump sequence, as properly as a strict focus on the important functions and features. The specifications also demanded the similar old Lewa suitability for unrestricted continuous operation over a few years. Options for integrating the pumps into automated techniques by way of analog management signals or bus methods are also a matter after all.
Lewa Ecosmart LCC3 on the check stand.

First of all, the necessities for the conveying capability had to be implemented constructively. Larger plunger diameters had been selected for the smaller LCC variant, so that greater than 264 gallons per hour could be conveyed instead of less than 80 gallons. In the case of the more highly effective LCD version, the engineers also decided to increase the stroke size so that a most move fee of 528 gallons per hour could be achieved. Both pump varieties can work in opposition to a most operating stress of 50 bar. As with all hydraulically actuated diaphragm metering pumps, maximum pressures are achieved with smaller plunger diameters.
Just as essential because the efficiency of the pump was the operational reliability typical of Lewa acquainted from other pump collection. For this function, individual, important options such because the integrated pressure safety valve or the sandwich diaphragm were taken over from the Ecoflow models. The individually adjustable strain safety valve ensures that sudden overpressure in the pump does not 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 at all times works in the proper place. It can’t be overstretched or damaged during start-up. Thus, the pump is protected in opposition to operating errors or upset working situations. Finally, the usual diaphragm monitoring system checks the condition of the diaphragm and warns plant operators instantly if there is any injury. This reliably prevents cross-contamination between the pump and the piping system and ensures operational safety always, especially in delicate areas with poisonous fluids. However, diaphragm monitoring is never used because Lewa diaphragms of this sequence normally obtain service lives of several years – even under full load and steady operation.
A key point was to maintain production prices within an identical vary to the small LCA variant, thereby creating enticing market prices for applications with less demanding requirements and decrease operating pressure. To achieve this, the design of the two new pump sizes wanted to integrate elements that are as similar or no less than comparable as attainable so as to avoid high manufacturing costs. In this way, the Lewa engineers were in a position to successfully implement the common parts strategy that had already been practiced many instances.
Pump customers also benefit from this intelligent modular principle, as many put on elements can be utilized across pump types. This significantly simplifies the spare elements stock. At the same time, the modular principle additionally permits particular person changes to the respective utility. For instance, stroke frequencies or plunger diameters may be selected individually. The basis for that is the M900 pump head, which is already used within the LCA variant and in the Ecoflow program.
Lewa Ecosmart LCC in heated cabinet.

The pump’s flexibility additionally presents benefits for plant construction: It allows the Ecosmart pump to be oriented either vertically or horizontally, making it simpler to integrate the unit into techniques with limited or confined areas. In addition, the pump head of the new LCC and LCD models is aligned at right angles to the plunger axis, resulting in a particularly compact format. In many pumps, the pump head is on the same axis because the plunger, which often results in bulky pump dimensions. The 90-degree orientation avoids this with the brand new models. 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, sturdy 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 wet end, that are also successfully used in the high-pressure variants of the Ecoflow collection. Many high-quality parts from the Ecoflow collection are also used for the drive models, employing the frequent components technique. The result’s robustness and durability that is uncommon on this pump class. In addition, all Ecosmart pumps have been designed with a single oil bath, which is used for each the lubrication of the drive unit and the hydraulics of the pump head. This eliminates the more complicated lubrication via two separate oil techniques and results in a simpler design, which not solely facilitates operation but in addition reduces maintenance work.
Last but not least, the model new LCC and LCD versions—like the LCA—comply with the united states industry standard for metering pumps API 675, guaranteeing nearly unlimited usage for numerous demanding processes in a broad range of industries.

For instance, when metering solvents in the chemical business, pumps are needed that on the one hand meet the highest specification necessities and however are still cost-effective. Here, the Ecosmart pump with its larger efficiency is prepared to meet precisely these necessities, as it has been precisely engineered for purposes in the decrease pressure vary as a lot as 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 here above all is compactness and cost-effective design, which the complete Lewa Ecosmart series fulfills because of its revolutionary design precept.
Before the model new pump variants are available to clients, numerous extensive tests will be carried out. They will be positive that the models also meet the excessive internal company necessities for reliability and efficiency in operational practice. They embody, on the one hand, continuous load checks of as much as a quantity of tens of hundreds of hours and, however, overload exams. In the latter, the pump is run continuously at up to 20 % above maximum strain to further validate its robustness. Special checks are carried out in heated cupboards to proof that the pumps additionally perform completely under extreme ambient circumstances. After successful completion of all checks and final adjustments, the Ecosmart version LCC is now on the market, the LCD model will follow in mid-2022.

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