DESCRIPTION OF THE TECHNOLOGICAL CONTAINER:
Design of the insulated 6m container:
- Container with ISO corners.
- Container made of standard steel S235, insulated with mineral wool (ORSTECH).
- Floor load capacity of 500kg/m2, with a total maximum load of 1000 kg.
- Handling of the container using the upper ISO corners at a 60° angle.
- Insulated stainless steel (AISI 316) chequer plate floor in the area of the high-pressure pump (approximately 4x2.3m) with a 100mm rim serving as a containment tray.
- Additional equipment: fan, air conditioning unit, electric heaters, lighting, socket distribution boards.
DESCRIPTION OF THE HIGH-PRESSURE PUMP UNIT AQVT:
1. High-pressure pump:
The core of the technological container is a horizontal high-pressure triplex pump, AQL 56 - 50 - XL, equipped with temperature monitoring of the lubricating fluid.
All parts of the pump that come into contact with the pumped fluid are made of corrosion-resistant material.
The plungers' surface is coated with a wear-resistant layer based on tungsten carbide.
High-pressure seal with automatic spring-adjusted wear compensation.
Check seal with lubrication and oil flushing using a dosing pump.
2. Electric motor with belt drive:
The high-pressure pump is driven by a 30 kW electric motor via a belt drive.
3. Assembly:
The high-pressure injection unit is mounted on a common frame welded from U-profiles. The pump frame is bolted to the container floor using flexible mountings. The pump is driven from the motor by a gear belt with a gear ratio of 1:2.86. The pulleys and belt are located under a cover.
4. Suction pipeline:
- Centric shut-off valve with position sensor between stainless steel flanges DN65 PN16.
- 2x high-capacity coarse filters.
- Suction pressure sensor 0-10 bar with a separating diaphragm.
- Control pressure gauge with a separating diaphragm 0-16 bar.
- Rubber compensator DN65 PN16.
- Flow meter Endress + Hauser Promag P 100, DN 15 with output to PLC.
- Connection between suction and high-pressure pump with stainless steel piping.
- Vertical flange DN65 PN16 as the termination point of the supply.
5. Discharge pipeline:
- Stainless steel piping DN50 PN160.
- Stainless steel compensator with a 4-liter bag.
- Shut-off high-pressure valve DN50 PN160 with end position sensors.
- Manual wheel valve control.
- Safety valve with discharge directed to the suction branch.
- Pressure transmitter 0-160 bar with a separating diaphragm.
- Control pressure gauge 0-250 bar with a separating diaphragm.
- Connection between discharge and high-pressure pump with high-pressure hose.
- Vertical flange DN50 PN160 as the termination point of the supply.
6. Waste pipeline:
- Stainless steel 1" piping.
- Discharge of the high-pressure branch through a ball valve PN160 (pressure relief of the high-pressure branch).
- Discharge of the suction branch through a ball valve PN16 (pressure relief of the suction branch).
- The waste branch will be sealed with a plug allowing pressure relief during servicing.
7. Electrical control system of the technology:
The control system of the unit will be located behind a partition separating the mechanical and electrical sections of the container. All control elements, except for the speed controller, will be housed in two electrical distribution panels (Schrack) with dimensions of 600 x 400 x 1800.
- Allen Bradley control system with a 7" touchscreen PLC panel.
- Visualization of all fault and operational states on the control system panel.
- ABB speed controller 30kW.
- Control buttons for decreasing and increasing the speed.
- On/off switch for control voltage, central stop button.
DESCRIPTION AND FUNCTION OF THE UNIT:
After turning on the main circuit breaker and bringing the electrical system into operation, the system enters a standby mode and waits for operational conditions to be met. Upon opening the suction and discharge valves, when the supply pump is started, the VT pump will be flooded with water. The suction pressure gradually increases, and when the minimum pressure switch is activated, the main unit motor is started.
According to the selected mode, the unit can operate in the following modes:
- Motor speed control based on the desired flow rate (automatic flow priority mode)
- Motor speed control based on the desired pressure (automatic pressure priority mode)
- Motor speed control based on set speed (manual mode)
Monitoring of unit status and safety:
During operation, the system continuously evaluates the following unit conditions. In case of a fault, the unit is shut down and the system displays the corresponding malfunction on the PLC unit display. The system automatically checks for:
- Closure of the suction valve
- Drop in suction pressure below the minimum value
- Exceeding the maximum allowable pressure at the pump discharge
- Closure of the discharge valve
- Exceeding the maximum temperature of the bearing water or components in contact with the pumped bearing water
- Drop in control voltage
- Speed controller malfunction
- Overheating of the main motor windings
