Product training

DW Rotary lobe pump

By Product Manager Jesper Holst Rasmussen

DW PD Pumps
Definition and classification of pumps
Positve Displacement

Pumps

Reciprocal

Piston

Diaphragm

Rotary

Single Rotor

Vane Vane screw Impeller Ecentric

Ecentric casing Screw spindle Peristaltic (hose)

Multi Rotor

Rotary Lobe Gear Rotating piston Screw spindle

The most common APV pumps are in bold type in the two tables.

DW PD Pumps
The DW range Rotary Lobe Pumps for the 21st century

A development from the first Rotary Lobe Pump launched back in 1932

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Front cover Brearing, font Bearing, rear

Profiled front cover gasket

Rotor Rotor screw

Shaft, main

Shaft, auxiliary

Gear s Rotorcase

Feet Clamp ring

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Chassis Front view Rotors
Machined in one fixing Small tolerances

Inlet

Outlet

Feet

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Exploded view

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Exploded view

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Principles of operation
Expanding cavities are formed at the inlet drawing the liquid into the rotors.

Meshing of the rotors forces the fluid out of the pumping chamber.

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Slip Internal leakage
Internal leakage is fluid that travels from the high pressure side to the low pressure side of the pump. Internal leakage is present because of the slip paths between stationary and rotary parts in the product area.

Leakage

Leakage

Flow

Flow

Leakage

hVol = Volumetric efficiency = (theoretical displacement - slip) theoretical displacement

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Efficiency of the pump Slip

Slip increases proportionally with pressure

Slip increases with the cube of tolerance

Slip decreases with increasing product viscosity

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Rotor types
Tri-lobe Commonly used design, used in various applications Multi-lobe (R-pump) Used where large inlets are required or smooth flow Bi-lobe (DW-pump) Used for fluids where large particles might occur. The volumetric efficiency depends on the angle of the rotor tips Bow-tie rotor Good volumetric efficiency Disadvantage, local cavitation at high speed

Rotary piston (DW-pump) High volumetric efficiency Disadvantage, expensive production costs due to small manufacturing tolerances

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Pulsation Characteristics

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Local cavitation
Occur when the rotors move apart. This change in speed and volume pulls the media apart. Consequence of cavitation noise less output damage to the fluid vibrations

Cavitation can be minimised by reducing the internal fluid velocity optimising the rotor shape

Trilobe rotors

Rotary piston rotors

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Pulse-free performance
Patented design of rotor tips and grooves. DW pump runs without pulsation's and internal cavitation The patented grove design insures a steady, pulsation free filling and discharge of the product. The patented rotor design allows for higher rotation speed and still maintain a gentle product treatment. The pulsation free operation extend the lifetime of valves, instruments etc. significantly.

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Pulsation

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Comparison of measurements on bi-lobe and piston rotors Measurements at the pump outlet

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Rotor Types
Rotary Piston Pulsation free flow, due
to patented design Low NPSH value required No rotor timing

Versions available:

Multi-duty 110C High efficiency 110C High temperature 180C Super tight (NGA only)
Rotor material

Bi-Lobe Low internal cavitation

High pressure operation Lower cost

Stainless steel AISI 316L NGA (Non-galling Alloy)

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Rotor Types

Rotor type
MultiDuty 110 C
o

Strength

Weakness

Rapid product temperature changes up to 80C Relatively high efficiency High temperature Tolerances allow 180oC temperature shock changes up to 180oC High Efficiency High efficiency due to small o 110 C tolerances Super Tight (NGA)

Low efficiency due to large tolerances Can not withstand large shock temperature changes (ex. CIP) Expensive Non Galling Alloys necessary (75% Ni)

High efficiency also for low viscosity fluids

See Operating manual - section 6.6 All rotor types are available in NGA

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Non Galling Alloy (NGA)

NGA rotors are used where a high efficiency or minimum of slip is required. Typically where the pump is used for dosing or low viscosity applications. NGA is a soft stainless steel which do not gall (damage) the surface like conventional stainless steel.

NGA rotors can have smaller clearance than High efficiency rotors.
NGA rotors can touch the pump house or front without damaging (Galling) the house or the rotors. NGA rotors have Higher efficiency due to reduced slip.

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NPSHrequired
The NPSHreq. is significantly lower for DW pumps compared to competitor products.

Since the inlet is behind the rotors

The fluid easily flows into the pump Inlet volume is increased

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NPSHrequired
Is describing the necessary inlet pressure to avoid cavitation.
Varies from pump to pump. Depends on rotor width, inlet port diameter, rotational speed, and the fluid viscosity, temperature and vapour pressure. NPSH required for positive displacement pumps is defined as a 5% reduction in flow at constant rotational speed, viscosity and differential pressure.
Flow rate
Norm. flowrate Flowrate 5% reduction

NPSHR Inlet pressure

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Cavitation
Is evaporation of the fluid inside the pump.
Occurs when the pressure in the pump falls below the vapour pressure of the fluid. Results in: decreased volumetric efficiency noise vibrations damage to the pump, the fluid, and the system. Cavitation is avoided by keeping the inlet pressure at the pump above the necessary pressure to avoid cavitation, ie. NPSH available > NPSH required.

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EHEDG

EHEDG: European Hygienic Engineering & Design Group Hygienic pump design = compliance with EHEDG

DW Product range
Classification

Pumps are classify based on the gear size DW1 - DW7 Dimensioned based on deflection of the shaft 31 models in the pump range
Flow [l/min] 40 2200 5800 Pressure [bar] 7.5 30 7 n [rpm] 1400 600 600 Weight [kg] 18.5 700 800 Dimensions [mm] 260x218 1016x627 1119x627

DW1/003/7.5 DW7/420/30 DW7/1016/7

DW Product range

DW Product range
A broad range
DW 7/1016/07 rotary lobe pump with 8 inlet

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Standard pump
DW pump is equipped with: Single mechanical shaft seals Sic/Carbon EPDM O-rings Fittings? Rotor multi duty (lobe or piston) Motor?

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Options
The following standard options are available in the DW range: Bareshaft pump Pump with constant speed geared motor, suitable for inverter drive use. Up to 37 kW these are available with stainless steel motor shroud. Pump with geared motor with constant or manually variable speed. Pump base plate and coupling guard in stainless steel. Lobe rotors suitable for max. 110C or max.180C product temperature, in stainless steel 316L or Non Galling Alloy (NGA). Piston rotors suitable for max. 110C product temperature, in stainless steel 316L or NGA. Elastomers in EPDM, FPM (Viton) or ISOLASTTM. Single mechanical shaft seal in SiC/Carbon or SiC/SiC, flushed or non-flushed. Double mechanical shaft seal in SiC/Carbon or SiC/SiC . Single EPDM lip seal for DW1-5. Triple PTFE lip seal (confectionary) for DW1-5. Packed gland with sealing thread in PTFE impregnation, for DW1-5. Horizontal or vertical suction and discharge ports. Rectangular inlet. Cooling/heating jacket on rotor case and front cover. Pressure relief valves on DW1-5.

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Single mechanical shaft seals

Single mechanical
Carbon / silicon carbide seal: Clean fluids (not sticky or abrasive) Silicon carbide / silicon carbide seal: Abrasive, tacky (sticky) products

Single flushed mechanical - low Pressure Flush

Crystallising media in contact with the atmosphere Liquids close to their boiling point Where dry running of the seal faces may occur

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Double mechanical shaft seals
High or low Pressure flush
Product wetted end

Same as Single Flushed seal +

High temperature products Vacuum extraction Solidifying products Aseptic processes Hazardous or toxic products

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Alternative shaft seals
The packed gland:
Max. 10 Bar Abrasive slurries, viscous and aggressive products Not hygienic, not suitable for CIP.

The confectionery seal (Triple lip seal):

Max. 6 Bar Chocolate. Not suitable for CIP

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Elastomer

EPDM
Used in standard applications, not oil resistant Flourocarbon (Viton) Good heat resistance feasibility's, used in applications containing oil Perfluoroelastomers (Isolast) Used in chemical applications, resistant to most chemicals, low friction good heat resistance, excellent mechanical qualities.

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Rectangular inlet

Enlarged rectangular port for high-viscosity products. Inlet area is increased by 100 - 200% dependent on pump size.

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Rectangular inlet
New construction will be launched in August

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Thermal Jacket
Constant temperature of the liquid in a pump. The thermal jacket facilitate the heating or cooling of the pump chamber prior to product entry.

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Thermal Jacket
New construction will be launched in August

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EHEDG certified integral pressure relief valve
Protect the pump against over pressurrzation. To high pressure over a positive pump can cause the pump to fail.

Max. 30000 cP Hygienic and CIP-capable EHEDG certification (The first relief valve ever to obtain the EHEDG certificate)

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Standard Relief Valve

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Baseplate
Hygienic Aspects
Tube version TYPE 1

Folded version TYPE 2

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Motor shroud
DW pump mounted on the hygienic tubular support with shroud. The shroud protects gear and motor during washing of the eqipment.

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Pump drive (motor)

Constant speed drive = Nordgear

Speed control via Frequency converter = Nordgear Manual variable speed drive = SEW (On request)

DW Customer benefits
Wide range - 31 models Patented Rotor design All external surfaces are in Stainless steel No painted surfaces Easy to service Inlet / outlet port orientation easy to change on site Self draining when vertically ported Low NPSH required EHEDG certified / FDA approved materials / 3A certified EHEDG certified integral pressure relief valve

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Dairy
To & From Pasturisers Tank Transfer Duties To & From Heat exchangers Tanker Pumps Finished Products Products Yoghurt Products Concentrates Cream Cheese Products Butter Dairy spreads Dairy based drinks Ice cream

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Food
To & From Pasturisers To & From Heat Exchangers Bulk Transfer Tanker loading/unloading Transfer from cookers and Mixers to filling lines Evaporation Finished Products Products

Meat products Egg Products Bakeries Jams & Preservatives Baby Food Sauces & Soups Permeat Condensed Milk Confectionery Sugars & Chocolate Gelantine Glucose & Syrups

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Brewery and soft drinks
Bulk Storage Separator Feed Pasturiser Feed Dosing Tanker Loading/Unloading Filling Lines General transfer Products Beer Yeast Trub Spirits Carbonated Drinks Cider Fruit Juice & Concentrates

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Pharmaceutical and toiletries
Bulk Transfer Dosing Process Tank Supply Filling Products Shampoos Liquid soap Hand Cream & Lotions Make up Moisturizer Toothpaste Insulin Water for injection Antibiotics Ointments

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Chemical
General Transfer Tanker Loading/ Unloading Dosing Bulk Storage Products Acids Solvents Detergents Emulsions Photographic film coating Paint, Ink & Resin Oils Adhesives

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General industry
Bulk Transfer Dosing Tanker Loading/Unloading General Transfer Products Clay Coating Starch Latex Pigments Dyes Resins & Pastes Vegetable/Mineral Oils Paints