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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
compact
economical:
- 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 the
isolation 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 are
parallel
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 size
50-32-200
Comparable
electric motor
15 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 integrated
13 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 2001
Dry run test
The Ax-lock design
blocks 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 curves
TAIFUN 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 with
bearings
• 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.

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Taifun_E

  • 1. TAIFUN® from idea to product WERNERT - PUMPEN GMBH
  • 2. Until now: two drivers for seal-less centrifugal pumps • magnetic coupling • asynchronous canned motor
  • 3. 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
  • 4. Magnetic coupling - disadvantages broken isolation shell: fluid contaminates atmosphere = simple safety. wasteful: - 4 roller bearings - 1 asynchronous driver - 1 synchronous driver Space requirement.
  • 5. Canned motor pump - advantages broken isolation shell: fluid remains in the outer safety barrier compact economical: - 1 asynchronous driver
  • 6. 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
  • 7. Forget this... The way to TAIFUN .... and the second skin for improved safety. Coils around the isolation shell... Wow, that’s a lot of stuff....and this.
  • 8. 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.
  • 9. Excursus: electric coils Coils, which are passed by electric current, will generate a magnetic field. Alternating current will generate an alternating magnetic field.
  • 11. Driving scheme TAIFUN 3 groups of coils: black, yellow, green. All coils of same colour are parallel connected. The coil groups are delta connected.
  • 12. Simulation of a 60° turn Starting point: full positive phase at coil 1 End point: full negative phase at coil 1+ -
  • 13. 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.
  • 14. 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.
  • 15. Dimensions: Conventional vs. TAIFUN Same scale Same size 50-32-200 Comparable electric motor 15 kW
  • 16. 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:
  • 17. 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.
  • 18. 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.
  • 19. Prototypes test run on 7.5.1999
  • 21. 32 - 200 with integrated 13 kW - synchronous driver.... ...in exact sizing to ISO 2858
  • 23. ATEX tests on 2./3. Juli 2001 Measuring the maximum surface temperatures
  • 24. ATEX tests on 2./3. Juli 2001 Dry run test The Ax-lock design blocks the rotor after approx. 30 sec , without damaging further parts. Spare part costs: € 245,- Absolut tight without damaging the inner savety zone
  • 25. First TAIFUN in operation (3.8.2001) BASF Pigment, Besigheim, Germany
  • 26. 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 )
  • 27. 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%
  • 29. Stator Driver (Stator): • „Forbidden zone“: assembly only by licensed electricians/ for opening special-tool required • bearings not part of this zone
  • 30. Outer cover Outer cover: • Additional O- Rings in case that the bearing zone breaks • GGG 40.3 and steel
  • 31. Outer and inner cover • Flat seals EURO-GYLON blue • PFA-lining • sleeves out of siliconcarbide, not part of the bearings Inner cover:
  • 32. Rotor with bearings • 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:
  • 33. General view TAIFUN® • Static bearings out of carbonised PTFE • internal flushing with about 350 l/h • not part of the inner cover Bearings:
  • 34. 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.