PUMP AND MIXER SPECIALISTIN WATER AND WASTE INDUSTRY

Head Office

Manufacturing

Unit

Sales Office

ABS has sales and service

representation in more than 100 countries the world over.

World-Wide Partnership

C PUMPS INTERNATIONAL´s W&W DISTRIBUTOR

Main office

Distributors

Manufacturingunits

Turnover 2000 300 M EUR *

No. of Employees 2,192

Sales Units 35

Manufacturing Units 5

ProductsPumps, Mixers, Agitators and Aerators

ABS Group Key Data

* 277 M USD 2,537 MSEK

Water & Waste

Sales per Market Segment1999

Process IndustryBuilding & Construction

14%31%

55%

HISTORY

Water & Waste Products

Mixers and Agitators

ABS / NOPOL® AERATION SYSTEMS

NOPOL® DISC DIFFUSER SYSTEMS

The experience gained over 25 years together with easily installable and long lasting parts as well as reliable and tailored solutions explain the worldwide success of the NOPOL® DDS aeration systems

NOPOL® O.K.I AERATOR/MIXER

Efficient mixing, non-clogging, operational flexibility and easy installation are the key features of the NOPOL®

O.K.I. Aerator/mixer. Due to this it is the premium choice for all demanding aeration applications.

ABS self aspirating aerators

Efficient mixing, non-clogging, operational flexibility and easy installation are the key features of the ABS® TA Aerator/mixer. Due to this it is the premium choice for all demanding aeration applications. For small need of oxygen.

Inlet Structure with ArchimedianScrew

ABS replaced the screw

Raw Sewage

Activated Sludge Tanks (Biological Treatment)

• Nitrification

• Denitrification

• Phosphate Elimination

Activated Sludge(organic)

Digester (Biological Treatment)

Digester Sludge

ABS SCABA® Agitator

Thermophilic Fresh Sludge

What You Don’t See Is What You Get

Initial Cost

and Purchase Price...

Installation and Commissioning

Energy Costs

Operating Costs

Maintenance Costs

Decommissioning

Environmental Costs

Down Time and Loss of Production

All Other Costs...

The Life Cycle Cost Equation

Cic Initial Costs and Purchase Price

Cin Installation and Commissioning Cost

Ce Energy Costs

Co Operating Costs

Cm Maintenance and Repair Costs

Cs Down Time and Loss of Production

Cenv Environmental Costs

Cd Cd Decommissioning Costs

LCC = Cic + Cin + Ce + Co + Cm + Cs + Cenv + Cd

The ABS Web Site

www.abspumps.com

AVAILABLE SOFTWARE FROM ABS:

• ABSEL (pump selection and friction loss calculation)• MixSel (mixer selection)• AutoCad drawing program• AerSel (aerator selection program)• EPM (full documentation of all ABS products)

ABS CAD INTEGRATED TO AUTOCAD:

PIRANHASubmersible macerating pumps

Piranha Range

PIRANHA SHREDDING SYSTEM

Shredding Ring

Shredding Rotor

Suction

ShearingMaceration

THE SHREDDING SYSTEMWORKS IN 3 PHASES

Performance Curves 50 Hz

Pipe Diameter

CONVENTIONAL

PIRANHA

TRENCH SIZE

SMALL PIPELINES REQUIRESSMALLER AND CHEAPERMACHINES DURING INSTALLATION

SMALL PIPELINES REQUIRESSMALLER AND CHEAPERMACHINES DURING INSTALLATION

CHEAP INSTALLATION

VERY HIGH HEADS!!!!

• Synconta L/S• WAGE House• WAGE 900• WAGE 1200• WAGE 1500• WAGE 2000• WAGE 2500

PUMPING STATIONS

Conical bottom

WAGE FEATURES:

• Made of GRP (Glasfiber Reinforced Plastic)• Safety screen• Rounded bottom shape• Flow damper on the inlet• Conical shape, the strongest possible• No need for extra reinforcement• Only pre-made concrete plate• Always taylor made to fits the customers demands!• Possible to re-install

P1P8

P3

P4

P6

P2

P5 P7

Where would you use Lifting Stations ?

New software for Piranha Pressure systems - PAWS

FRDRY INSTALLED SEWAGE PUMPS

WATER TREATMENT PLANT OF SOPHIA

What do installations look like

Pump below water level

FR 150/150-32

Installation PossibilitiesClosed coupled version

Horizontal

with or without base plate

Vertical

with base and suction elbow

Installation Possibilities Possibilities

Spacer coupled version

Horizontal

with or without base plate

Installation Possibilities Possibilities

Vertical with Tri-pod for motor

Space saving

With suction elbow incorporating hand hole cover

Installation Possibilities

Conventional long shaft

Pump on base with suction elbow

Universal jointed shaft

Guard as protection

Pump below water level

What do installations look like

Pump above water level

What do installations look like

Automatic evacuation system

EcoPrimeEcoPrime

Q-H coverage

50 Hz

Automatic evacuation system

EcoPrimeEcoPrime

EcoPrime function

Plug the hose to the priming valve and check at the manometer how large suction pressure EcoPrime creates

Check that the filter is closed

Check the pressure from the compressor is set to 6 bar

BackgroundNew demands on working environment has pushed the development further introducing a new type of dry installed pumps

FR pumps with eco-prime installed in Värnamo Sweden

EcoPrime main components

Compressor

Priming valve

Level guard

Priming program located in PLC in Pump main cabinet together with level relay

Pressure switch

Main cabinetPressure

pipe

Pumping station

Helleviksstrand 1999Helleviksstrand 1999

2 FR 80/80-262 FR 80/80-26

Installation

Maintenance and supervision simple due to dry installation

AFP

the core of theW&W program

AFP Range

Fixed Wet Installation

Fixed Dry Installation, horizontalFixed Dry Installation, vertical

Transportable Applications

AFP Pumps for every Application

Disadvantagesof other

Guiderail and"Guide-wire"-

systems

Reinforced and Suspended Single Guiderail Systemfor Deep Shafts

Single guide rail video

ABS SINGLE Guide rail system:

• Discharge from DN 80 to DN 800• Delivery from 20 l/s to 3,200 l/s• Head from 1 to 75 m• Power from 1.3 kW to 1,000 kW• Weight from 80 kg to 10,500 kg

AFP Key Values

AFP DesignationsAFP 1041.2 - M30/4 - 11.EX

1 2 3 4 5 6 7 8 9

1 PUMP SERIES AFP, AS, Piranha...

2 DISCHARGE DN / 10

3 HYDRAULIC 3 = Vortex, 4 = CB

4 IMPELLER .1, .2, .3…

5 MOTOR TYPE AFP = M, AS = S

6 MOTOR POWER kW x 10

7 No. OF POLES 2, 4, 6, 8…

8 MOTOR SIZE

9 MOTOR VERSION STD/EX

Vortex Impeller

ClosedChannel Impeller

ContraBlock

Two Channel ContraBlock

AFP HYDRAULICS

CBContraBlock

since35 yearsSuccess

Patented Anti Clogging System

ContraBlock = CB

United States Patent No. 3,447,475Title: Centrifugal PumpFiling date Jan 9, 1967Patented June 3, 1969Inventor: Albert Blum

ContraBlock™ SystemThe ContraBlock™ System functions by means of the combined effects of the various components :

1

2

3

4

Open single channel impeller with sloped deflector edge at the impeller blade,

adjustable bottom plate with sharp spiral shearing edges,

large suction inlet with wave shaped tearing edges and

coarsely toothed shearing ring on the upper side of the impeller

ContraBlock Advantages

• Big opening in the inlet

• Large solids passages

• Often 1 vane impeller

• Patented ABS design

• More than 30 years use

• Blockage free operation

• Ideal for use in sewage

• Can maintain efficiency

VORTEX / CONTRA BLOCK

Vortex ContraBlock

CBHydraulic CB 1 CB 2

Standard pump.

ABS ContraBlockTM adjusted annually

Ef fi

cien

cy,

Higher hydraulic efficiency over time

AFP “CHOPPER” PUMP

FOR HEAVY DUTY APPLICATIONS!!!

When the going gets tough ! - the CHOPPER gets going !.

Chopper Features

• Special hardened impeller and cutter plate – impeller is GGG60, flame hardened and oil quenched to 45-

55 Rockwell to a depth 0.5-3mm – wear plate GG30, hardened in salt bath and cooled in oil,

hardness 50-55 Rockwell

• Choice of DN 100, DN 150 discharge

Agriculture Wood industry

Food processingFood processing

AFP...

AFP Product Advantages

Insulation Class FEEx and FM

Stainless SteelShafts

Monitoring Devices

Reliability by automatic seal and temperature monitoring - around the clock

Thermal sensors- Stator (3 off) as standard- Lower Bearing option for M4 & M5- Upper Bearing option for M4 & M5

Moisture sensors- Oil Chamber as standard- Lower Motor Chamber option for M4 & M5- Connection Chamber option for M4 & M5

Silicon Carbide Mechanical Sealssince 15 years a standard for all ABS Submersible Pumps

for sewage, drainage and construction applications

high abrasion resistanceexcellent hardness 2500 HV v.s. 1500 HV of Tungsten Carbide

excellent heat transfer high thermal shock resistance

excellent chemical resistance range: ph 2 to 10

bi- directionalno glue-, solder- or shrink - jointsbellow - design shelters shaft area

STANDARD SEALS!

Protected against fibrous materialspinningaround the shaft

Monitoring:why ?!

- to avoid larger damage of pump and motor

- to give an early, preventive indication of wear, missing lubrication, etc

- to give indication for service, just when it is due: not to frequent, not to early, not to late

- to have the pump on an optimum availability

Reasons for High Temperature

- loss of one phase about doubles temperature rise in one coil of the stator

- voltage drop by 5 % increase stator temperature by 12 %

- voltage unbalance of 2 % can cause temperature rise of up to 30 % in one coil

- frequency increase to 52 instead of 50 Hz (VFD or genset) can cause a temperature rise of 12 %

- cooling problems may occur, by blockage, locked air and alike

TCS (THERMO CONTROL) - SYSTEM

Thermal sensors in every phase of the stator give a timely warning or switch off the pump automatically before the allowable temperature limit e.g. due to overloading, medium being too hot, dry running,or other problem sources has been exceeded.

Sensor for Temperature MonitoringBimetallic Switches „Klixons“

Temperature

ResistanceConnection into motor control: Take care not to exceed the allowable switching current;

can be fitted directly into the control circuit.

Application: Standard

Function: Temperature switch using the Bimetallic principle which snaps open at a rated temperature.

Sensors for Temperature Monitoring

Operating Principle of Thermo Contacts

Motor winding Thermo-sensorStandard: Thermo Contact

Upper and lower BearingStandard for AFP M 6 to M12Standard: Thermo Contacts

Thermo Contact (also called “Klixon”)

Bi-metallic switch that opens when temp goes up and closes when it goes down.Can break a high current

Have moving parts and not accuratebut cheap and not so easy to destroyduring testing

N.C. at temperature lower than e.g.110 deg. C

N.O. at temperature higher than e.g.140 deg. C

Contact loads:

DI (SEAL MONITORING) - SYSTEM

DI sensors in the electronic seal monitoring system recognise the ingress of moisture into the oil chamber via the shaft seal.

The DI sensors give an early warning that moisture has entered and by means of a timely inspection prevent the failure of the unit.

Operating Principle of DI - Sensor

Moisture Sensor (in oil Standard)

An electrode gives a signal that must be connected to a relay to give an alarm.Can also be connected to a relay for stopping pump or give voltage free alarm to say PLC.

ABS - relais have integratedspecial filters against radio noise

Comparator relay

Set reference for ABS Di is 50 k

Sensor

Alarm LampCan be substituted by an auxiliary relay

Seal Monitoring

“Di”- Moduleas built since 25 years

Floating Contact Relaiswith integrated time delay for connecting 2 Di - Modules

The Multivoltage - Design

M 1 to M 5Volts

440435430425420415410405

400395390385380375370365

360

+ 10 %

- 10 %

50 Hz

Volts399

380

361

+ 5 %

- 5 %

Volts436

415

394

+ 5 %

- 5 %

400 Volts + - 10 % includes: 380 Volts + - 5 % and 415 Volts + - 5 % the same stator is also used for 60 Hz: 460 Volts + - 10 % (415 to 505 Volts)

AFP 8000

AFP 8002

CLEANING OF

PUMPING STATIONS

For Cost-Effective Mixing

Turbo flush video

TURBO FLUSH FOR CLEANING OF PUMPING STATIONS:

VUP

Old Conventional Longshaft Propeller Pumps vs.

VUP Submersible DesignCONVENTIONAL

Bearing exposed to medium

complicated to service, sump has to be emptied

permanent discharge of grease into medium

SUBMERSIBLE

compact unit

easy to maintain, sump need not to be emptied

VUP Range

300- 7100 kg1.2 - 4.5 m7.5 - 650 kW

Performance Range VUPH[m]20,0

10,0

7,0

5,0

3,0

2,0

1,0

0,5

50 Hz

VUP 0400 - 1200

200 300 500 1000 2000 3000 5000

Q[l/s]

Flow Formation VUP

nq = 290 to 330 min -1

3 blade and 4 blade

VUP Unique Design Features

Replacement of the wear ring without detaching the

impeller

Adjustment of the blade inclination to fit customers need without any additional machining of the impeller.

Large AFL`s and VUP`shave a Planetary Gearbox

Performance Field VUP 1202M5000/4-92

2000 2500 3000 3500 4000 4500

11

10

9

8

7

6

5

4

3

2

1

Htot [m]

Q[l/s]

13.75

i = 3i = 3.5i = 4

10.10

19.23

VUP Axial Flow Pumps4-pole motors with gearboxes

PROS:non wicking elastomer cable grommet• optimum efficiency can be matched to duty

point • good efficiency including gearbox

motor 94 to 95%

gearbox 97 to 98%

total about 92 to 93%• good power factor (cos phi)

about 0.83• needs only normal switchgear and

power factor correction• slim motors, small column-pipe diameters• low frictional losses of water pumped along

motor• no radial load on motorshaft by planetary gear

or hydraulic• no axial thrust on motorshaft• low in weight 5280 kg

CONS:• more rotating parts

Values from following examples:

VUP 1201 M 3000/4-81 G3,6

direct drive, 14-pole

CONS:• drive speed is fixed

optimum of efficiency cannot be varied

• no good efficiency

motor 90.5%

• bad power factor

about 0.59• big, uneconomical electrical switchgear

• big diameter of motor, wide column pipes needed

• high frictional losses of water along motor• full radial load on motorshaft

• full axial load on motorshaft• heavier 6900 kg

PROS:• less rotating parts

VUP 1201 M 3000/14-95

VUP: Limits of Application

all Axial Flow Pumps have an unstable operating range leftfrom part of curve shown ! This area is called “Rumor Area”

•never use VUP`s in area left from end of curve shown

•when using variable frequency drives, limit minimum frequency such, that unstable part of curve is not touching system curve

•never start VUP`s against closed valve

Full Performance Curve of a Typical Axial Flow Pump

0 1000 2000 3000 4000 5000 6000 7000

10

9

8

7

6

5

4

3

2

1

0

Q[l/s]

H[m]

H

Usable AreaRumor Area

VUP Pumpshave excelent

NPSH - valuesthanks to their spherical hub, all propeller pumps with conical hub have worse NPSH!

VUP: always with power reserve !

• Propeller pumps have an increasing power demand

with increasing head (in contrary to radial pumps)

• Propeller pumps have small discharge heads: small mistakes in determining static head give relatively

high additional power demands (3 m, mistake of 0.3 m in

static head makes an additional power demand of 10 %)

• Propeller pumps have large deliveries: small misjudgements in frictional factors make relatively

large differences in frictional losses (2 m head, 2.6 m/s in pipe: k = 0.66 instead of 0.6 give 5 % higher power demand)

Comments on Vortex - Formation

AVS Anti-Vortex SystemBy making use of optimized pump sump dimen-sions (relationship of width to length), minimum wall distances and a profiled inflow chamber, all detrimental swirl and vortex formation is avoided. The dimensions are calculated precisely for every pump. Contact your ABS representative with your requirements.

AVS Anti-Vortex SystemAn end to the basic problems of inflow chambers for axial and semi-axial pumps - vortex and swirl formation.

VUP FEATURESSUMMERY

• Available with gearbox• Adjustable vanes• High efficiency• Anti vortex design of inlet chamber• Simple installation

PUMPING STATION ZOHOR

PUMPING STATION ZOHOR

PUMPING STATION ZOHOR

PUMPING STATION ZOHOR

AFL

Archimedian Screw vs. Submersible

lifting station for waste water treatment works1800 l/s to 8 m

Old fashioned solution

Old fashioned solution

Archimedian Screw:2.5 m diameter

ABS solution

AFL 1202 M 2000-12

Archimedian Screw v.s. Submersibleexample (up to scale) 2500 l/s 8m

Submersible pumps always fit into existing archimedian screw - installations!

Screw 4.8 m dia 2 x AFP 6001eta = 83 %

Archimedian Screw v.s. Submersible AFP 6001 3 x 1300 l/s (eta = 83%) Screws 1m diam. 2 x 200 l/s (eta = ?)

AFL Range

414 - 6070 kg1.3 - 4 m15 - 650 kW

Flow Formation AFL

mixed flownq = 100 to 130 min -

1

AFL Impeller

Performance Range AFL

100 200 300 500 1000 2000 3000

H[m]

Q[l/s]

AFL 0600

AFL 0700

AFL 0800

AFL 1200

80

30

20

10

7

5

3

2

1

0,5

50 Hz

VUP Installation Proposalswith Steel - pipe and Non- Return Valve

the standard solution

VUP Installation ProposalsWith Steel Pipe and free Overflow

Low investment, high safety, but energy consuming,if outer water level has relatively big variation (e.g.:tide)

VUP Installation ProposalsWith Non- Return Valve and

Manifold

the pumping station disappears below a road

VUP Installation ProposalsWith Siphon and Pipe Ventilation

Safe and energy saving,if elevation of outer waterlevel has high variation

with Discharge Elbow

Proposal for VUP Pipe Cover

VUP Installation ProposalsWith Concrete Riser Main and Weir Crest

Low investment, high safety, but energyconsumption, if outer water level hasrelatively variation (e.g. : tide)

Z 22Double suction

Split Casing Pump Series Z22Split Casing Pump Series Z22

High EfficiencyHigh Efficiency

Reliable ConstructionReliable Construction

Wide Capacity Range Wide Capacity Range

Low NPSH RequirementLow NPSH Requirement

A

For Cost-Effective Pumping

Split Casing Pump Series Z22Split Casing Pump Series Z22The pump casing is protected by replaceable wear rings

On gland packing versions,there are sleeves alsooutside the shaft seals

The double volute reduces radial forces on the impeller and consequently the bearing loads

The top casing half caneasily be removed forinspection or service

Double-suction impellers have lower NPSH requirements

All sizes are availablewith mechanical sealsand most withgland packings

A

For Cost-Effective Pumping

Water supply Romania eff 92%, Russian motor

Split Casing Pumps Series Z22Split Casing Pumps Series Z22Fan pumps must meet highFan pumps must meet highdemands for smooth flowdemands for smooth flowwith low pressure pulsationwith low pressure pulsationto make the paper perfect. to make the paper perfect.

This Z22 900/800-90 feeds aThis Z22 900/800-90 feeds apaper machine in thepaper machine in theKemsley Mill of NewKemsley Mill of NewThames Paper Co in theThames Paper Co in thesouth of England. The south of England. The capacity is 7400 m3/h andcapacity is 7400 m3/h andthe drive power 630 kW.the drive power 630 kW.

A

For Cost-Effective Pumping

Split Casing Pumps Series Z22Split Casing Pumps Series Z22

Q-HQ-H

A

For Cost-Effective Pumping

FAN Pump Series Z22FAN Pump Series Z22

FAN Pump OptionsFAN Pump Options

Low Pulse ImpellerLow Pulse Impeller

Inside Polishing Inside Polishing

Lap FlangesLap Flanges

Double Driven Ends Double Driven Ends

Inclined Position Inclined Position

A

For Cost-Effective Pumping

JUMBODrainage pumps

Draining of temporary sumps at constructions sites

JUMBO® 12 DKS

JUMBO® 12 DKS

Dewatering at construction sites

surface coating flanged outlet

JUMBO® 24Bilge Pumps on ships

JUMBO®54NDWell point Dewatering

JUMBO®54NDDewatering in narrow spaces

Mining (Gold, In Africa)

JUMBO® 205

Mining

JUMBO® 405

Floating dock (Ship repair)

JUMBO® 604

Construction (Power Station, Tarragona)

Road Works

JUMBO® 604

Features (Marketing) optimal cooling due to outlet

position and cooling jacket slim design plug in start modular system adjustable wear parts in rubber double mechanical seals wear resistant impellers

Jumbo 12-84Professional Contractor Pump

Jumbo 12-84Professional Contractor Pump

H

Q

HD version

LD version

ND version

Features (Marketing)

Optimal cooling due to outlet position and cooling jacket

Various discharge orientation

Robust design with cooling jacket in aluminium

Adjustable wear parts in rubber

Double mechanical seals with seal probe in oil casing

Easy to convert from ND to HD or vice versa

Jumbo 205-604Professional Contractor Pump

Jumbo 205-604Professional Contractor Pump H

Q

HD version

ND version

Common featuresMechanical seals

Same seals for Jumbo 24-84 and Jumbo S24-S84

secondary seal Same Cartridge seal on

Jumbo 205 and 405 Primary and secondary seal in

one unit Easy to dismantle and

assemble

Primary seal

Built in on DOL started Jumbo 12-205 and Jumbo S24-S84

Plug-in start possible Thermal sensors ensures dry running protection

Common featuresDOL starter & Protection (overheating)

Strainer for low level pumping

Using a bottom suction adapter Available on Jumbo 12-24 Easy to add by replacing bottom

plate

Connection for series pumpingTwo or more pumps

Available on

all standard Jumbo pumps Jumbo 12-44

by replacing bottom plate Jumbo 54-84

by replacing bottom plate

and outer casing Jumbo 205-604

by rebuilding bottom part of pump

Zinc AnodesFor Cathodic Protection

Available for all Jumbo pumps

Mounted on aluminiumparts on top and bottom of pump

Easy to add and to replace on pump

Available as assembly kits

Surface coating- for additional protection

Available for all Jumbo pumps

Environmental friendly 3-layer surface coating

Offering extremely good corrosion resistance

PURE - Lining(Polyurethane wear parts)

For handling of highly abrasive liquids

A feature to offer when required

Offering extremely good corrosion resistance

Available partsDiffusers for Jumbo 24, 44, 54 & 84Wear ring for Jumbo 205HD

Electronic surveillance system

Prevents automatic restart of the pump

Stops the pump when phase failure occurs

Prevents start of the pump when phase sequence is incorrect (wrong rotation)

Starter boxes JP

Available for DOL started pumpswith float switch as standard

Available for star-delta started pumps with overload relay as standard ( float switch as option)

THE END