Product Presentation

Concrete Volute Pump

(CVP)

Agenda

Introduction Flowserve
Concrete Volute Pump
Comparison to VCT
Benefits
References
Summary
Installation movie

Flowserve

History
The history of Flowserve goes back to the founding of
Simpson & Dresser Pumps in 1790.

Flowserve

Over 18000 employees

Operates in over 55 countries around the world

Serving customers in over 90 countries

Flowserve

Hengelo
Founded in 1868 by
Brothers Stork

Flowserve

Served Industries
Petrochemical
Refining
Power Generation
General Industry
Irrigation & Drainage

Flowserve Hengelo Products

Service Contracts

Retrofits
Replacements coping with
existing boundary limits

History Flowserve Hengelo

The Netherlands
1868

Founded as machine company Brothers Stork & Co.

by C.T. Stork and C.C. Stork.
Mainly manufacturing steam machines and boilers.
Soon expanded with diesel engines, water turbines, pumps, etc.

1985

The several Stork departments became separate entities

i.e. steam boilers, pumps, etc.

1997

Stork Engineered Pumps aquired by BW/IP International

In June 1997 merging with Durco International.
Company name is changed into

2000

Flowserve Corporation acquires Ingersoll-Dresser Pumps

Products

API diffuser pumps

OH2 (PHL)

OH3 (PVXM)

OH5 (PVML)

Horizontal, centerline-mounted, Vertical, in-line, single-stage Vertical Close-coupled,

in-line, single-stage
single-stage overhung pumps overhung pumps with
overhung pumps
separate bearing brackets

Products

VCT

AFV

CVP

Vertical Mixed Flow

Circulating Pumps
(VOA, VSO)

Axial Flow Vertical

Pumps
(VOP)

Concrete Volute Pumps

(BSV, BCV, CVPS)

Background

Why CVP?

Background

Background

Total Area: 41,526 KM2

16,033 SQ ML
Population: 16.926.367 people
Density: 407.6/KM2
1,035,4/SQ ML
Amsterdam

Hengelo NL

Hengelo

Background

26% of The Netherlands

is below sea level
29% of The Netherlands is
sensitive to river flood

Amsterdam

55% to manage

Hengelo NL

Hengelo

Background

This is were former Stork Pompen

now
came in.
To keep the Netherlands dry

Amsterdam

Hengelo NL

Hengelo

Background

Dutch authorities demanded reliable and maintenance free pumps

to secure the western part of the Netherlands from flooding
Originated at Stork (Flowserve) in the Netherlands
First installation 1929, Pumping Station Lely
Currently over 275 pump installations worldwide

Concrete Volute Pump (CVP)

Description

Introduction

Pump types
CVPS
Open impeller
Head up to : 10 m

BSV
Semi Enclosed Impeller
Head up to: 15 m

BCV
Enclosed impeller
Head up to : 60 m

50 ft

33 ft
Flow up to: 100.000 m3/h

Flow up to: 100.000 m3/h

440000 GPM

440000 GPM

197 ft
Flow up to:

100.000 m3/h
440000 GPM

Introduction

Range chart

Design

CVP basic overview

Electric motor

Gearbox
Discharge pipe
Pull out unit
Concrete volute
Concrete suction bell
Formed suction
intake

Design

Design features
Pull-out unit
Short, sturdy shaft
Non clog impeller
Easy inspection
True pull-out design
No intermediate shaft or bearing
All bearings are anti-friction
Maintenance free shaft seal

Design

Design features
Pre-fabricated elements
Simplified site installation
No shuttering on site for pump volute
and suction bell
Reduced site installation time
Guaranteed pump performance
One civil contractor on site
Formed suction intake with simple
straight side walls

Comparison

VCT and CVP

Vertical Circulator
Deeper civil dig
Higher speed
Higher NPSHr
Minimum submerge
requirement

Pull out design is a

considerable price adder
Vibrations due to large motor
support and long pump design

Concrete volute pump

Minimum civil dig due to
formed suction intake and civil
integration
Easy accessible for
maintenance
True pull out design
Limited bearing span
Concrete volute & Sturdy
driver support eliminates
vibrations issues

Comparison

VCT and CVP

Vertical Circulator

Concrete volute pump

Maintenance interval 20.000 hrs

Maintenance interval 50.000 hrs

Spare part inventory required

No spare part inventory

High alloy steels in corrosive

applications

Corrosion free concrete is

main construction material
Highest availability and
reliability
Responsibility from suction to
discharge

Comparison

VCT and CVP

The surface area of the pump component in contact
with water will have direct consequences for the
pump price and maintenance
High alloy steel materials are much more expensive
than concrete materials

red = wetted parts of the pump

Comparison

VCT and CVP

Difference in building volume 30% (m3)

At similar pump
impeller size (1300
mm)

CVP have
50% reduction on
crane capacity
compared to VCT

Difference in digging volume 30% (m3)

Comparison

VCT and CVP

Concrete Volute Pumps

Comparison

Concrete Volute Pumps versus Vertical Metal pump

Summary, Cost Comparison

Concrete Volute pump versus Vertical metal pump
Limited suction pit depth
Limited building height
Limited Crane capacity for pump
Reduced installation time if prefabricated concrete elements are
applied
High efficiency (up to 2%)
Virtual no spares
Very low maintenance cost
Longer life time (many exceed 50 years service life)
Only a few metal parts in contact with water, so minimum
corrosion / erosion

Comparison

Cast on site and Pre-fab

Concrete Cast on site
by wooden shuttering
Engineering, production, on-site
placement and responsibility of:
Shuttering
Embedded parts
Reinforcement
Pouring of Concrete

Concrete curing time

Shuttering removal

Prefabricated Elements
Off- site prefab production
Single day prefab installation
No interference with job site
schedule
Single Flowserve responsibility,
limited interfaces
Embedded parts included and
aligned
Blast furnace slag cement
Guaranteed quality and high
accuracy shape & dimensions

Comparison

Cast on site and Pre-fab

56 days
installation time

2 days
installation time

Comparison

Cast in-situ and Pre-fab

Simplified site installation (pre-fab)
No shuttering on site for pump volute
and suction bell
Reduced site installation time
Guaranteed pump performance
One civil contractor on site
Formed suction intake with simple
straight side walls

Benefit summary
INTAKE SIDE

- No vortices
- No dead water areas

PUMP CASING

- No corrosion or erosion
- No maintenance
- No vibration

IMPELLER

- Wide operating area

PUMP SHAFT

- No contact with pumped medium

- No line shaft couplings + bushings

Added value

Mechanical design validation

Natural frequency analysis
Stress + deformation analysis
Torsional frequency analysis
Model system using:
Mass moment of inertia
Torsional stiffness's

Added value

Computational Fluid Dynamics

Impeller / volute / bowl design
Cavitation prediction
Performance calculation
Intakes
Prevent vortices
No dead water areas
Create uniform flow to impeller
Retrofit performance prediction

Added value

System engineering
Layout & calculations

Added value

Testing

Pump model test - Guaranteed performance, witnessed by customer

Intake test - Optimization of dimensions and performance
Site performance test

Added value

Testing
Growth of cavitation sheet by decreasing inlet pressure
R&D with Universities, Flowserve proprietary software

Added value

Testing
Cavitation sheets at NPSH pressure drop

Sheet
cavitation

Sheet
cavitation

Concrete Volute Pumps

Hydraulic knowledge

Prediction of sheet cavitation

Knowledge and control over performance characteristics
Optimization of dimensions and performance
Prediction of impeller / pump life

CVP v5.0 flowserve

Concrete Volute Pumps

Total cost of ownership

Concrete Volute Pumps

20 year period

30.000 m3/h at 11 m

Seawater application

Evaluate Life Cycle Cost

Energy Costs
90%

Maintenance
3%

Initial Investment
7%

Concrete Volute Pumps

20 year period

30.000 m3/h at 11 m

Seawater application

Evaluate Life Cycle Cost

Initial investment
Pumping station
Reduced building height
& pit depth

CVP 30% less

Reduced crane capacity

CVP 50% less

Pumps
Less high alloy steel
Reduced pump quantity

Concrete Volute Pumps

20 year period

30.000 m3/h at 11 m

Seawater application

Evaluate Life Cycle Cost

Maintenance cost
Less frequent overhaul
No spare part inventory
Virtually no wear
Controlled bearing conditions
Practically maintenance free seal

No corrosion
No need to disconnect piping for pull-out pump
No need to pull pump to inspect impeller

Concrete Volute Pumps

20 year period

30.000 m3/h at 11 m

Seawater application

Energy cost
CVP higher efficiency due to
Pump specific speed selection
No losses in riser tube
No losses in discharge bend

Average CVP: + 2%

Evaluate Life Cycle Cost

Concrete Volute Pumps

20 year period

30.000 m3/h at 11 m

Seawater application

Evaluate Life Cycle Cost

Savings
Initial investment savings
CVP 20% less

Maintenance cost savings

MTBM 5 to 10 years
Spare part inventory virtually zero

Energy cost savings (project example)

= 1.6%, 20 years, 4920 kW, 0.05/kWh
CVP 1,440,000.- less

References

Customer voice

References

Reliability
Pump Location
Station
1
Barrowtown Pump Station

Country
Canada

Number of
Pumps
4

Years of
Operation
29

Mechanical Pump Years of

Failures
Operation
0
116

Pump Station Westerkogge

The Netherlands

24

72

3
4
5

YC Harculo E6
Porvoo Works
Neste of Finland

The Netherlands
Finland
Finland

2
1
1

32
26
23

0
0
0

64
26
23

6
7

Gemaal Wapenveld
Oldersum

The Netherlands
Finland

4
1

16
12

0
0

64
12

8
9

Emssperrwerk
Borealis Polymers Oy

The Netherlands
Finland

3
1

12
11

0
0

36
11

10

Gemaal Wortman

The Netherlands

60

240

11

Gemaal Lovink

The Netherlands

60

120

12

Gemaal Colijn

The Netherlands

60

180

13

Gemaal de Blocq van Kuffler The Netherlands

46

184

14

Gemaal Vissering

The Netherlands

23

23

15

Power Station Delesto II

The Netherlands

16

32

16

Essent Power Station Amer8 The Netherlands

35

105

17

Essent Power Station Amer9 The Netherlands

Totals

2
41

21
506

1
1

42
1350

References

Projects
Country:
Project:

Germany
Emssperrwerk

Scope: 3x BSV 225

3x BSV 260
total cap.: 100 m3/s
at 3,6 m head
In each pillar:
Pump
Coupling
Gear unit
E-motor

References

Projects
Impression of dimensions

References

Projects

Conclusion

Summary
True pull-out design with high efficiency and many references
Smaller pumping station due to minimum civil dig and less
crane height/capacity
Prefabricated elements
Off-site production, limited interfaces
Single day installation
Embedded parts included
Guaranteed quality
Lower Capex and Opex for seawater applications
Flowserve can take responsibility from suction to discharge

Installation of CVP
Movie

Example
Plan View

CVP Pump Station Section

Motor

Gear

Volute

FSI

CVP

Discharge

Thank you
for your
interest in
our
company