No noise hydraulic pumps - Deutsche Messe AGdonar.messe.de/.../windmill-presentation-eng-326266.pdf · 2016-12-15 · Settima® Meccanica s.r.l. Phone: +39 0523 3650 FAX: +39 0523

Settima® Meccanica s.r.l. Phone: +39 0523 3650 FAX: +39 0523 557623

Email: [email protected] www.settima.it

Windmill

No noise hydraulic pumps No noise hydraulic pumps Windmill Presentation

mailto:[email protected]

http://www.settima.it/


http://www.settima.it/applications/windmill.asp



Windmill

SMT16B

SMT8B

SFO SMAPI (API676) FOTP

The ideal Settima three screw and gear pumps for the Wind Power Industry are…

Settima Meccanica designs and manufactures hydraulic screw pumps and helical rotors pumps. Our specialization is the production of no-noise, low-vibration pumps. Settima pumps are fit for use in every hydraulic application and in many kind of systems. They are positive displacement rotary pumps. Moving parts are kept to a minimum. There is only a rolling action between the drive screw and the idler ones, without oil encapsulation and trapping. The rolling action eliminates noise and vibrations.

2VHL Continuum® no-noise, compact size

SMT SMAT (for USA market) no-noise, medium size Fluid Types: mineral oils, synthetic fluid or emulsions, bunker oils, furnace oils, ecologic fluids, fuel oils Outlet Pressure: up to 100 bar Inlet Pressure: from -0,7 bar to 3 bar Flows: from 4 to 1.220 L/min Shaft Speed: from 500 to 3.600 rpm Acoustic Emissions: from 52 to 68 dB (A) at 2.950 rpm Temperature Range: from -50°C to +300°C

Fluid Types: mineral oils, synthetic oils Outlet Pressure: from 0 to 15 bar Inlet Pressure: from -0,5 bar to 1,5 bar Flows: from 15 to 80 L/min at 1.450 rpm Shaft Speed: from 500 to 1.750 rpm Acoustic Emissions: from 55 to 63 dB (A) at 1.750 rpm Temperature Range: from -20°C to +150°C

Continuum®

SM

SMTU

SMT 2VHL Continuum®







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1

Where technology matters Possible applications of Settima pumps on Wind Turbines

1. Oil and water cooling units.

2. Gear box lube and filtration systems.

3. Hydraulic units:

Nearly half of the utility grade wind turbines currently in service depend on hydraulic pitch and yaw controls. Many of the others use electric pitch and yaw controls but may incorporate the use of hydraulics for braking or utilize a forced lubrication system. 2 3

Did you know? The Windmill application is a very demanding one for the hydraulic pumps industry. Since maintenance costs are very high and turbines can be quite difficult to reach, they must run unattended for more than 5 years of continuous operations; thus, it is expected from all parts to run without maintenance, all year round, with a Medium Time Before Failure (MTBF) in excess of 100.000 hours. To this end, all parts and components manufacturers must guarantee a lifetime of more than 20 years in extremely harsh conditions.

Main advantages of Settima pumps for Wind Mills: - Light weight - Compactness - Low noise operation - Low pulsation operation - Reliability







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Settima pumps for Wind Turbines Gear Box lubrication

Thanks to their powerful suction capability, Settima pumps for wind turbines lubrication systems can be both submersed and dry, differently from the competitors, that need forcedly a submersed installation. Installation Options - Settima pumps can be installed: • To an electric motor, (see picture A), • Mechanically driven (see picture B) by the gearbox shaft.

Settima products portfolio also includes pumps able to handle reverse rotation of the gearbox shaft, thus conveying flow in the same direction, independently of the input shaft sense of rotation. Usually, by inverting the sense of rotation of the input shaft, also the pump flow direction is inverted, but Settima mechanically driven pumps are able to maintain the same suction and pressure direction, regardless from the gearbox shaft sense of rotation. These characteristics enable the usage of Settima pumps in any application in which a reversed flow is not permitted.

For example, during wind turbines idle (for lack of wind, maintenance operations…), when the gearbox reverses its shaft sense of rotation, Settima pumps keep the flow direction always the same, providing long life service, with no interruption.

A

B







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EU standard models US standard models Models 20 – 25 – 32 – 40 – 45 – 55 – 60 –

70 – 80 – 90 20 – 25 – 32 – 40 – 45 – 55 – 60 – 70

– 80 – 90 Motor connection (male shaft type) ISO 3019/2 SAE

Motor connection (AC Type pumps)

IEC standard (for direct coupling with motor)

NEMA standard (for direct coupling with motor)

Ports BSPP – SAE 3000 NPT Flow From 4 to 1.220 L/min From 1 to 1.800 GPM (at 1.750 rpm) Shaft rotation Clockwise (from shaft end), suitable also for counter clockwise rotation Shaft speed From 200 to 3.600 rpm (contact Settima for speed below 1000 and over 1.800) Outlet pressure Up to 100 bar Inlet pressure Min. -0.7 bar max. 3 bar Fluids Mineral oils, synthetic fluid or emulsions, bunker oils,

furnace oils, ecologic fluids, fuel oils (HFO, MDO, LFO, MGO) Viscosity From 2 up to 100.000 cSt (always contact Settima) Seal NBR, FKM, EPDM, mechanical seals (silicon/tungsten carbide high performance,

heavy duty), magnetic coupling Noise From 52 up to 68 db(A) at 2.950 rpm Body Aluminium / Hard anodic oxidation on request (according to military rules

UNI7796) to avoid corrosion Screw set Steel for primary screw, cast iron for secondary screws / Core hardened steel

screws, surface treated screws on request Environment temperature From -50° up to +60°C Fluid temperature From -50°up to +300°C

SMT & SMAT

Did you know? Settima SMT is one of the most versatile products from Settima range of three-screw pumps. The SMT pump is able to manage high-pressures, and therefore it can be utilized for an unrivalled (except for its low-pressure counterpart, the SMT16B) wide range of high-stress applications in very demanding fields, like wind power industry, high-pressure tool machines or marine, without compromising the reliability and the long life-span of the pump itself.







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• green: SN screw profile The oil bubbles in air foam are smoothly transported such that the new profile enables no noise, very low pulsation and high internal lubrication also in presence of air emulsion

• red: non-SN screw profile

• SMT16B (AC or male shaft) • Installation: below oil level • Suction capability: medium • Pressure: up to 40 bar • Pressure pulsation: deltaP < 3%

• SMT SN (AC or male shaft) • Installation: above or below oil level • Suction capability: high • Pressure: up to 80 bar • Pressure pulsation: deltaP < 1%

Screw profile technology







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9

0 50 100 150 200 250 300 350 400 450

m

l/min

NPSHr SMT

NPSHr 16B S4

NPSHd

SMT SN characteristics

• Body up to 80 bar

• High suction capabilities • The diagram below show generic

calculations for ISO VG320 cSt oil • Blu line: NPSH requested by SMT SN • Yellow line: simulation of a NPSH

available from oil line • You can install ABOVE OIL LEVEL,

making free the design decision (our competitor manufacturing gear pump cannot do that)

• Lower point of cavitation start-up

• Low noise and high performance with air into the oil







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Models 47 - 55 Motor connections (male shaft type only)

NEC SAE 3000

Installation position Dry or submerged, foot installation Ports SAE 3000, ANSI 150 Flows from 40 up to 230 L/min (at 1.500 rpm) Shaft rotation Clockwise (from shaft end) for counter clockwise please contact Settima Shaft speed From 150 to 3.600 rpm Outlet pressure Up to 40 bar Inlet pressure From 0,8 to 3 bar Fluids Mineral oil, synthetic oil, emulsions, heavy oils Viscosity From 7 to 100.000 cSt Seals Rotary shaft lip-type (Standard NBR, FKM/PTFE for high temperature and

special fluids) Acoustic emissions From 52 up to 63 db(A) at 2.950 rpm Body, Flange GJL 250 cast iron with lamellar graphite Gear set High strength hardened steel Temperature range From -50° to 150° C Filtration Suction filter: from 100 µm

Fixing screws Inox or nichel steel to avoid corrosion

2VHL Continuum®

Did you know? Settima 2VHL CONTINUUM ® is one of the most durable pumps on the market. With its body made of cast iron, and its helical rotors manufactured with high-strenght hardened steel, the 2VHL CONTINUUM ® can easily manage a fluid viscosity of 100.000 cSt in the most extreme conditions, without shortening its lifespan. The 2VHL CONTINUUM ® has become the pump of choice for difficult installations, like inside windmills in the open sea.







Windmill

In the 2VHL Continuum® pump the transport flow is perpendicular to the axes like in the classic gear pumps, but the especially studied profile does not trap any volume while the profiles have a helical course. In the Continuum® rotors there is just a single point of contact between the profiles. There is so no encapsulated volume between the profiles and this completely eliminates the need for pockets on the axial thrust washer and any noise linked to that problem. The helical course makes a gentle transmission of movemenet and minimization of the pulsation possible. This lead to eliminate any vibration with no dispersion of energy.

2 VHL Continuum® screw profile technology

2VHL Continuum® main characteristics

• Special Helical rotors eliminate pulsation ensuring a continuous flow of the fluid.

• This ensure a longer life time to the system filter.

• No pulsation equal to no vibration to give longer life time to the complete system.

• Possibility to handle very high viscosity fluids.

• Pressure: up to 25 bar (peak 40 bar) • High volumetric efficiency • High efficiency also at very low

revolution • Same external dimensions as the most

used pump systems • Better price than the direct competitors.

Did you know? Settima 2VHL CONTINUUM is one of the most durable pumps on the market. The 2VHL CONTINUUM has therefore become the pump of choice for difficult and demanding installations, like inside windmills on the open sea, where its reliability and resistance to stress can truly be taken advantage of to a full extent!







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-0,4

-0,3

-0,2

-0,1

0

0,1

0,2

0,3

0,4

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9 9,5

Re

lati

ve p

ress

ure

pu

lsat

ion

(b

ar)

Time (msec)

Environment: 100bar - 40 cSt - 1.500 rpm Continuum

External silence gear

Internal gear

A look at a pulsation-rate comparison between Continuum® and its competitors…

Up to 20% energy saving! Less noise, less costs, more efficiency!

Silence saves money

®







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A look at a noise emission comparison between Continuum® and its competitors…


Silence saves money

GR 28 GR 33-38

GR 47-55 GR 72







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TECHNOLOGY SIZE CC FLOWRATE (@1450rpm)

MAX PRESSURE FLOW MEDIA

Continuum® Helical Rotors

GR47 28→63 40→93

25 bar (peak: 40)

Mineral oils , synthetic oils,

heavy oils, emulsions

GR55 75→160 100→230

A look at the 2VHL Continuum® application sectors…

The revolutionary silent way to replace gear, vane and screw pumps

Power Generation • Filtration and cooling for turbines,

compressors, gear boxes, transmissions,bearings, shafts.

• Turbines and compressors lubrication. Marine • Oil filtration. • Cooling. • Recirculation.

Silence saves money


Industrial • Filtration and cooling Wind Energy • Lubrication • Filtration • Cooling for gear boxes, transmissions,

bearings, shafts.







Windmill

Settima SMT&SMAT Settima 2VHL Continuum® Gear pump (Kracht, Richmeier…)

Lightness = = =

Pressure range + = =

Customization flexibility + + -

Low noise / Low pulsation operations + + -

Compactness = = =

Cost efficency (components & installation) = + -

Pump efficency + + -

Installation above oil level (flexible positioning) + + -

The competition

Reference list – Up & running • Vestas: 2Mw, cooling • Made: 1.5Mw, cooling / lube • Vernier: 1.5Mw, cooling • Gamesa: 2Mw, cooling • Yu-sung: N/A, cooling / lube / filtration • Hansen Transmission: lube / filtration

• Mitsubishi: pitch control cooling system • Acciona: lube / filtration • Gamesa: 4.5Mw, cooling / lube / filtration • Siemens: 2.3Mw, cooling / lube / filtration • Vestas: 3Mw, cooling / lube / filtration







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• Custom design and integration with other components is available as per customer request

• Best fit and integration friendly system Example with SMT SN pump: • Sub-system supply:

1. Motor pump unit already assembled 2. Bell-housings and couplings 3. Valve block 4. Fixing plate according to customer requirements 5. Hoses and flanges

We support your integration needs

1

2

3

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MAGNETIC COUPLING seal

SEAL MATERIALS Stainless steel, Hastelloy, PEEK, ceramic

FLUIDS MANAGED All standard oils, fuels, emulsion and fluids, plus all fluids unsuited for use with

NBR/Viton/EPDM/PTFE lip seals or with mechanical seal materials

TEMPERATURE RANGE Up to +130° C standard, up to 300° C with ceramic seal

ORDER CODE Ask SETTIMA: tell us the specifics of your installation, our engineers will provide you a solution!

MAGNETIC COUPLING SEALS

SETTIMA SMT pumps can be equipped, upon request, with a Magnetic Coupling seal. Magnetic coupling are high technology seals, with extremely high reliability and high performances, guaranteed to be absolutely totally leakage free. SETTIMA can provide this seal alone, or with an already perfectly compatible bellhouse. SETTIMA engineers study very carefully every customer’s single specific installation, and they can offer him with a complete solution, from the motor pump unit, to the correct magnetic seal and the compatible bellhouse, everything tested and ready to use.







Windmill

SMT16B – cooling, filtration and lube oil

SMTU – USA lifts and freight elevators

FLOWMETERS – high-pressure, high-precision flow measurement

SMT8B – compact cooling and filtration

SFO – shipyards diesel oil handling

SMT – high-pressure industrial, lube and tool machines

SMAPI (API676) – wide range of marine and industrial applications

FOTP – high-reliability boiler ignition/feeding marine application

SM – lifts and freight elevators CONTINUUM® – high-pressure, no-noise fluid power applications

2VHL CONTINUUM® – low-pressure no-noise lube oil services

MAGNETIC COUPLING – seal-less option for no medium leakage

Settima full complement of products:

Engineering and certification are a resource for our customers. If some certification is not available today, it could be available soon: ask Settima and we will answer.

SLN – in-line plants for cooling, filtration, lube and fuel oil

ENERGY SAVING SYSTEMS – currently in R&D, available soon!

TWO-SCREW PUMP – innovative project currently in R&D!





Documents

No noise hydraulic pumps - Deutsche Messe AGdonar.messe.de/.../windmill-presentation-eng-326266.pdf · 2016-12-15 · Settima® Meccanica s.r.l. Phone: +39 0523 3650 FAX: +39 0523