TAIFUN® from idea to product

WERNERT - PUMPEN GMBH

Until now: two drivers for seal-less centrifugal pumps

• magnetic coupling

• asynchronous canned motor

Magnetic coupling - advantages

• no energy losses due to synchronous* driving principle when using non-metallic isolation shells.

• larger radial gaps don’t increase energy loss, lead only to necessity of stronger magnets.

• design of non-metallic pumps possible.

*outer and inner rotor show same speed

Magnetic coupling - disadvantages

broken isolation shell:

fluid contaminates atmosphere

= simple safety.

wasteful:- 4 roller bearings

- 1 asynchronous driver- 1 synchronous driver

Space requirement.

Canned motor pump - advantages

broken isolation shell:

fluid remains in the outer safety barrier

compacteconomical:

- 1 asynchronous driver

Canned motor pump - disadvantages

• energy losses due to asynchronous* driving principle ( eddy currents! )

• larger radial gaps ( required for SiC or PFA ) lead to higher energy losses = less efficiency.

• Heating up of the rotor does not allow using thermoplastics like PFA.

• Fluid is heated up.

*outer and inner rotor do not show same speed = slip

Forget this...

The way to TAIFUN

.... and the second skin for

improved safety.

Coils around theisolation shell...

Wow, that’s a lot of stuff....and this.

TAIFUN - the idea

The outer coils produce a rotating magnetic field for the inner rotor, which behaves like it would do in a magnetic coupled pump.

Designing non-metallic canned motor pumps becomes possible.

Excursus: electric coils

Coils, which are passed by electric current, will generate a magnetic field.

Alternating current will generate an alternating magnetic field.

Excursus: rotating magnetic field

Driving scheme TAIFUN

3 groups of coils:black,yellow, green.

All coils of same colour areparallel connected.

The coil groups are delta connected.

Simulation of a 60° turn

Starting point: full positive phase at coil 1

End point: full negative phase at coil 1+ -

Calculating the supply frequency

In one frequency’s half-period the rotor turns 60°.

Then a full period will lead to a 120° turn. For a full 360° turn 3 periods of the frequency are needed.

At 3000 rpm the system will need 9000 periods per minute, that is equal to 9000/ 60 s = 150 Hz.

Such frequencies need to be generated by a frequency converter.

Advantages of the TAIFUN concept

• Synchronous driver– no eddy-current losses and heating-up of

the rotor and the fluid.– excellent efficiency.– allows large radial gaps for non-metallics.

• Integrated driver– double hermetically tight.– compact design. – minimised mechanical losses.

Dimensions:Conventional vs. TAIFUN

Same scale

Same size50-32-200

Comparable electric motor15 kW

Disadvantage of the TAIFUN concept

• Needs to be operated with frequency converter– price of converter about Euro 2000,-– installation of converter and special cabling

But - operating a pump with frequency converter results in a lot of benefits:

Advantages of using frequency converters• Speed of pump is variable:

– Flow control by varying the speed • mostly energy efficient = money.• no throttle valves needed = money.• uncertainty of head calculation tolerated = no trouble.

– Impeller diameter keeps constant. Pump can replace any other of that type directly.

– Choice of design speed is free, e.g. 4375 rpm

• Converters intelligence is raising:– Today: Integrated power control– In future: Diagnostics and trend analyses.

Conditions: 7 Cent/kWh - Efficiency 45% - density of water

Example:Saving 1,0 bar plants throttling at 25 m³/h with TAIFUN pays back 4.300,- Euro in 5 years.

Prototypes test run on 7.5.1999

The developing team.

32 - 200 with integrated13 kW - synchronous driver....

...in exact sizing to

ISO 2858

Presentation at ACHEMA 2000

ATEX tests on 2./3. Juli 2001

Measuring the maximum surface temperatures

ATEX tests on 2./3. Juli 2001Dry run test

The Ax-lock designblocks the rotor after

approx. 30 sec , without damaging further parts. Spare part costs:

€ 245,-

Absolut tight without damaging

the inner savety zone

First TAIFUN in operation (3.8.2001)

BASF Pigment, Besigheim, Germany

Technical data TAIFUN 32-200

• Chemical pump to ISO 2858, size 50-32-200• No design variations• Fixed impeller diameter: 140 mm• Maximum driver torque: 25 Nm• Maximum fluid temperature: 150 °C (302°F)• Max. environmental temperature: 40 °C (104°F)• Integrated 13 kW driver certified to

II 2 G EEx de IIC T3-T6 ( PTB 01 ATEX 1094 )

Hydraulics TAIFUN 32 -200

• High speed = Low torque = less required magnetic mass and better hydraulic efficiency

• n = 1000 - 5000 rpm

• Q = 1 - 35 m³/h

• H = 5 - 80 m

• 3D - impeller for best inlet flow conditions

• NPSHmax < 3 m

• Etatotal,max = 45%

Performance curvesTAIFUN 32-200

Stator

Driver (Stator):

• „Forbidden zone“: assembly only by licensed electricians/ for opening special-tool required

• bearings not part of this zone

Outer cover

Outer cover:• Additional

O-Rings in case that the bearing zone breaks

• GGG 40.3 and steel

Outer and inner cover

• Flat seals EURO-GYLON blue

• PFA-lining• sleeves out

of siliconcarbide, not part of the bearings

Inner cover:

Rotor withbearings

• Magnets out of Samarium Cobalt

• Hollow shaft with PFA-lining

• impeller and adaptation piece out of massive PTFE

• O-Rings out of FFKM (Perfluorine-elastomer)

• rotating bearings out of siliconcarbide

Rotor:

General view

TAIFUN®

• Static bearings out of carbonised PTFE

• internal flushing with about 350 l/h

• not part of the inner cover

Bearings:

TAIFUN - your plant standard

• Highest safety standard, due to two independent hermetically tight zones.

• Handles all corrosive and/ or toxic liquids up to 150 °C

• Only few sizes without variations and with fixed impeller diameter.

• Local flow conditions are adapted by energy saving speed control.

• Take it from stock, put it in place, start.

The end.