Monthly: May

Renovations of mining machines - economic and non-economic aspects.

The Polish hard coal mining industry is in a difficult economic situation. In order to avoid losses, the management boards of mining companies are looking for ways to reduce operating costs. In this respect, the costs of renovation of machines and equipment operating in mines constitute an important item. Due to the above-mentioned difficult economic situation, purchases of new devices are limited, which necessitates the renovation of existing equipment.

The problem is important due to the difficult operating conditions in mines, as a result of which the frequency and scope of renovations are much greater compared to other types of industry. Additionally, the aspect of safety comes into play - machines operating underground in mines are not general-purpose machines, but must meet specific requirements related to, among others, the issue of work safety in an atmosphere at risk of methane or coal dust explosion. For this reason, mining machines are constructed according to special requirements and are subject to a special attestation procedure.

For the above reasons, the regulations governing the principles of repairs of machines and equipment operating in underground mining plants in force in recent years were strict. These regulations were questioned on the grounds that they limited market access for entities other than original machine manufacturers and created a risk of overpricing repair services. For this reason, these regulations have been liberalized. The Supreme Audit Office's report published a few months ago was devoted to this issue and was widely discussed in the media. Comments devoted to the report focused on the media-interesting issue of alleged lobbying by mining machinery manufacturers aimed at monopolizing the renovation market, and the liberalization of regulations was presented in these comments as a healthy tendency to open this market. In reality, the issue is much more complex and the regulations governing the manner of carrying out repairs of mining machines should be looked at not only from one point of view. When discussing the Supreme Audit Office's report, emphasis was placed on the examples cited in it of overpricing repair services by machine manufacturers taking advantage of their privileged position.

However, no attention was paid to the statement also included in the Supreme Audit Office's report that the mere reduction of prices of renovation services may not be beneficial to the economic interests of mining companies in the long run if the quality of these services is not maintained at the same time. The production and repair of mining machines of appropriate quality requires the use of appropriate technologies and expensive equipment. Garage-type companies offering renovation services do not have to include the costs of this equipment in the prices of their services, and as a result, they are able to perform renovations cheaper. In the long run, the consequences of using such services can be costly for mining companies. The costs of downtime and suspension of mining due to equipment failure may be many times higher than the costs of renovation services. The same applies to energy consumption. The devices that consume the most energy include main drainage pumps that pump water from mine undergrounds to the surface. It can be concluded that the cost of additional energy consumed by pumps as a result of improper renovation is many times higher than the cost of the renovation service itself. The benefits of reducing the prices of renovation services will only be real if the price reduction is not accompanied by a reduction in the quality of services. The NIK report points out that specifying the required quality standards when ordering renovation services and enforcing them from contractors leaves much to be desired in the Polish mining industry.

An obvious aspect is the issue of occupational safety. Polish mining boasts a system of attestation and certification of machines and equipment intended for operation in mine undergrounds, thanks to which it is one of the safest in the world, and the tragic indicator showing the number of fatalities per million tons of extracted coal is significantly lower compared to some other countries. This is a joint achievement of the mining industry itself, its scientific base and mining machinery manufacturers. Allowing companies to carry out overhauls of machines that have undergone scrupulous safety certification before putting them into service, for which the basic criterion of operation is the low price of overhaul services, creates a risk of a gap in the safety assessment system. Questions about whether machines operating underground in mines have been renovated in a way that ensures the level of safety of a new machine delivered by the manufacturer cannot be asked only during investigations aimed at explaining the causes of tragedies that cost many lives.

A less frequently noticed aspect of this case is the issue of copyright to the documentation of mining machines. These are machines produced for a niche market, sold in relatively small quantities, and at the same time, due to difficult working conditions and strict safety requirements, requiring significant expenditure on design and obtaining the required certificates. It is common practice among global manufacturers to include development costs not only in the price of a new product, but also in the costs of spare parts and renovations, so that the price of the new product is not excessive and at the same time the manufacturer can afford to invest in further development. Allowing a situation in which profits from renovations are primarily made by companies that do not incur expenditure on the development of safe mining machines, their testing and safety certification, is in fact promoting unfair competition. In the long term, this may mean that Polish producers will no longer be profitable to invest in the further development of mining machines.

Dr. Eng. Grzegorz Pakula


The article was published in 2010 on the wnp economic portal - www.wnp.pl

 

 

"Twardowski wouldn't recognize his factory" - Franciszek Sitek

158


The penultimate year of the occupation. Life in Warsaw is getting harder. More and more friends were sent to work in Germany. I managed to protect myself by taking a job in the pump factory of engineer Twardowski.

The year 1943. I started working as an apprentice. I worked for three years under the supervision of one turner. Sixty workers worked in a small factory on Grochowska Street. There were no separate production departments. However, we produced about two hundred pumps a year. The pumps were coated with graphite. It was the pinnacle of painting technique at that time. But how different they were from those we produce today!

We received castings from the previously operating foundry on Kolejowa. We worked hard. We realized that our pumps were water for Warsaw. Water that Warsaw needed so much during the Uprising. The water that, after the liberation, the inhabitants of Prague drew in buckets from the currents of the Vistula. Water, due to lack of which so many lives were lost during the occupation. Pumps manufactured by the origins of our factory are still used in waterworks today.

There are still too few industrial pumps. It was like that years ago. Our crew realizes that they are responsible for providing water to cities, for securing sugar production, and finally for increasing the power of power plants.

We produce increasingly better and more efficient pumps. These are not the units from Twardowski's factory. Their production was based on one type of casting. The pump efficiency was achieved by using rotors of different sizes and by accelerating the drive. It was much smaller than the current one. Today we produce modern pumps, based on domestic design and license.

Sixty years of operation of the factory is a huge development. But this development is recent years. Probably engineer. Twardowski would not have known the factory and construction of modern pumps.


From the article by Jerzy Wilczyński, Piękny jubileusz, "Wafapomp", 1968, no. 16 (30).

Franciszek Sitek, employee of Zakłady Mechaniczne Eng. Stefan Twardowski and the Warsaw Pump Factory in the years 1943-1977.

A systemic solution to the problem of pumps for removing the effects of flooding.

The experience of the last dozen or so years shows that the risk of flooding in our country is constant, and that subsequent floods on a local scale occur every year, and disasters on a national scale occur every few years.

Climate changes associated with the greenhouse effect contribute to an increase in the frequency of intense rainfall, as a result of which floods are becoming more frequent.

The flood that occurred in 2010 showed that despite the dedicated involvement of both rescue services and civilians in combating its effects, our country is systemically poorly prepared for floods. One manifestation of this fact is the lack of appropriate pumps for flood prevention operations. It should be noted that flood prevention exceeds human technical capabilities, as it is not possible to build and maintain a protection system that would be able to protect every place against every amount of water carried by rivers. Retention reservoirs, embankments, etc. are prepared for some statistically determined increased rainfall.

However, statistics has it that randomly there are rainfalls that exceed even the expected maximum. In such cases, protection systems turn out to be insufficient and we encounter phenomena such as overflow of retention reservoirs or ruptures of embankments. When a embankment break occurs, the amount of water flowing in is such that no pumps can contain it. The only thing that can be done is to limit the negative effects of the disaster by pumping water from the floodwaters back into the river once its level has fallen. Otherwise, floodwaters in the areas affected by the natural disaster would persist for a longer time, increasing losses. The lack of suitable pumps for this purpose has again made itself felt. The fire brigade mainly has small pumps, suitable for pumping water from basements, but not from large, flooded areas. As a result, the management of the flood control operation was forced to appeal for the provision of higher efficiency pumps to the institutions that have them, and the media reported on the supply of such pumps by neighboring countries as part of aid. This does not reflect well on the flood protection system or the ability to draw conclusions from previous floods.

It should be noted that the Polish industry has design solutions and technologies enabling the production of pumps for this purpose. The thing is that the production cycle of pumps with such parameters lasts several months, so they should be ordered well in advance and not requested when a disaster occurs. Ensuring the availability of such pumps is not only a technical and financial problem, but also an organizational and logistic one. Due to the unpredictability of when and where floods will occur, it would be uneconomical to store pumps in every flood-prone location. It is more advisable to collect them in a centralized warehouse from which they would be delivered to the flood site. However, keeping pumps that are used only occasionally and ready for the next operation requires having appropriate warehouses and qualified personnel to service them, which involves significant costs.

The Powen-Wafapomp SA Group, as the largest Polish manufacturer of industrial pumps, proposes a solution to this problem. The company declares its readiness to produce appropriate pumps and then store and service them in its own warehouses, which would keep them constantly ready for use. This would free state services from the need to have warehouses and qualified specialist staff. In the event of another flood, the pumps would be put at the disposal of emergency services. The Powen-Wafapomp SA Group has two plants: in Warsaw and Zabrze, whose location coincides with the regions most at risk of flooding. Zabrze is located in the region of the upper Vistula and Oder and relatively close to Lesser Poland and Lower Silesia, while Warsaw is located in the region of the middle and lower Vistula. As a result, pumps from our warehouses can be at the action site within a few hours.

Dr. Eng. Grzegorz Pakula

"From Lenino to Berlin" - Arseniusz Szewtsov

Arseniusz Szewtsov.


Arseniusz Shevtsov - a native of Volhynia - captured Prague, which later became his district. After demobilization, he lived in Praga. In Praga - at Twardowski's on Grochowska Street - he started working because that's where he was sent to make pumps. He remained loyal to the factory.

Arseniusz Shevtsov graduated from a technical school and started working as a mechanic at a sugar factory in Mizoch near Rivne in Volhynia. His father also worked there. The days of the borderland town, where time was marked by sugar campaigns, were busy and peaceful. He completed his military service in the 24th Uhlan Regiment. Grand Hetman of the Crown Stefan Żółkiewski in Kraśnik.

After a year, he became a corporal, and then he graduated from the Cavalry Cadet School in Grudziądz. Platoon cadet Arseniusz Szewtsov missed three consecutive sugar campaigns in his hometown of Mizocz. Before the fourth began, war broke out.

General Kutrzeba formed troops near Kutno to block the path of Nazi armored columns to Warsaw. Shevtsov was deputy platoon commander in the Podlasie Cavalry Brigade. Already on the first day of the Battle of the Bzura, they encountered the leaders of Hitler's 4th army near Gąbin. Despite the Germans' numerical advantage, there was a chance of defeating them before the main forces arrived and delaying the Nazis' march towards Warsaw. Taking advantage of the terrain, Shevtsov's platoon charged Nazi motorcycle columns several times on September 9. During one of the charges, Shevtsov's platoon came under fire from a German heavy machine gun. The first people were killed. A horse died near Szewców, and he himself was wounded in the thigh.

The cavalry, decimated during the fighting, escaped the encirclement, but the road to Warsaw was already cut off. They fought their way east and then south, fighting numerous skirmishes with the Nazis. Later, when there was no hope, cavalry units moved to the Romanian border. Shevtsov's platoon did not arrive. He laid down his arms to the Soviet Army…

Professionals were needed in Novosibirsk, so Shevtsov became a turbine mechanic in a coal mine. There was a shortage of workers in Vladivostok, so Shevtsov rode a steam locomotive, carrying wood to the port...

But soon the time of peace ended for the Soviet Union. The fighting army needed fuel tanks, so Shevtsov welded these tanks in Tashkent. Soon, however, the Wojenkomat (military reinforcement command) came to the conclusion that the tanks could be welded by someone else, not a platoon cadet of the Polish cavalry - more useful in the 1st Infantry Division formed in Sielce. Tadeusz Kościuszko.

In the camp on Oka, Shevtsov was assigned to the 5th company of the 2nd battalion of the 3rd infantry regiment and sent to Ryazan for two months, because an infantry ensign was needed more than a platoon cavalry cadet.

During the Battle of Lenino, the 3rd Regiment attacked in the second wave. After crossing the Miereja river, Shevtsov's platoon found itself in the greatest hell of fighting. Behind the village of Trygubowo, they relieved the 1st regiment and continued the attack in the main direction.

The Nazis dug tanks into the ground and conducted circular fire. Their heavy machine guns were shot at every point, and their Panzerfausts destroyed Polish light machine gun positions. German aviation supported the air defense. Wave attacks with up to thirty planes hit and stopped the attacking Poles. The pilots dropped gasoline barrels on Polish positions, which fell and howled and whistled...

They moved forward and then retreated again. They attacked and repelled attacks. And so on, meter by meter. They even fought with a rifle butt, a bayonet and a fist...

When SEPTEMBER 14, 1943 year, fortified on a nameless hill, they surrendered their section to the Soviet unit that relieved them, Ensign Shevtsov's platoon numbered one-fourth of its strength.

They crossed the Bug at dawn. They were greeted by a cannonade heading west. They did not greet their homeland with a parade march. They went west fully insured. Fighting battles, they reached the Vistula River. The 3rd Regiment was tasked with crossing the Vistula River near Karczew. They were greeted by a hail of machine gun bullets and mortar mines. Szewcow, wounded in the hand, returned to the eastern bank of the Vistula. Only those who were good swimmers returned from his shattered platoon.

They started the Prague Operation with operations along the railway line to Mińsk Mazowiecki. For two days, the battalion in which Shevtsov fought tried to cross the road behind Anin, which was defended by crossfire from artillery and machine guns. On the third day, they crossed the road and moved along the tracks towards Grochów. House by house, street by street, they drove the enemy out of Prague. They reached Pelcowizna.

Shevtsov's regiment paid a large dose of blood to capture Prague. Dozens died, hundreds were injured. After the regiments relieved the 2nd Infantry Division, the 3rd regiment was reorganized: two battalions were formed from three battalions, with a modest composition: two companies each. But at the end of September, the regiment was supplemented. Deployed in the Rembertów area, they trained newly conscripted soldiers and protected state property.

In the evening 16 Września 1945 In the same year, Szewcow's platoon crossed the Vistula at the mouth of the Pilica River. The next morning, in pursuit of the enemy, they set off through Piekuty and Piaseczno to Warsaw. In the evening January 17 they crossed Okęcie and reached Narutowicza Square. All night and the next morning January 18 they eliminated individual enemy resistance points.

January 19 paraded in Aleje Jerozolimskie in front of the president of the National Council Bolesław Bierut, General Rola-Żymierski and representatives of the Polish Workers' Party. The march route had already been demined, but not cleared of debris.

January 27 they entered liberated Bydgoszcz. Residents welcomed them solemnly on the square in front of the Frederick II monument. The monument - a symbol of pride and the shoes of Junkerism - was spontaneously destroyed by the people of Bydgoszcz in front of their eyes.

January 29 At 5:30 p.m., Szewtsov's platoon had already crossed the Polish-German border 1939 year…

1 February they attacked the village of Podgaje, defended by the 15th SS Grenadier Division composed of Latvians. Shevtsov instead commanded the 5th company of the regiment, covering the attack of the 4th company of Second Lieutenant Alfred Sofka. Together with the left wing of the group, they crossed Gwda. The right wing - cavalry units - got stuck in the river's floodplains. The SS launched an attack and surrounded the 4th company and Shevtsov's company. Shevtsov had a seventy-six-millimeter gun. The 6th company helped him. The 5th company left the encirclement with heavy losses. The 4th company fought until the last bullet, until the last grenade. The soldiers tortured in captivity did not reveal military secrets. When, after several subsequent assaults, on February 4, the regiment captured Podgaje, the bodies of thirty-two soldiers of the 4th company were found tied with barbed wire and burned alive.

In the battles for this town, 163 soldiers of the 3rd Regiment died and three hundred were wounded - including Second Lieutenant Arseniusz Szewtsov. And this was just a fortified point of resistance on the strip covering the Pomeranian Wall.

On the Pomeranian Wall they conquered Mirosławiec and Złocieniec. The names speak for themselves. They crossed the Odra and Stara Odra rivers near Siekierki...

They walked from the west along Berliner Strasse and then Charlottenburg Castle. They reached the Brandenburg Gate. From beginning to end, reserve lieutenant Arseniusz Szewtsov followed the trail of blood and glory of the Polish soldier. From Lenino to Berlin, always on the front line.


                              CC, Oficer - also production, "Wafapomp", 1976, no. 19 (135) and no. 20 (136).

Arseniusz Szewcow, employee of Zakłady Mechaniczne Eng. Stefan Twardowski and the Warsaw Pump Factory in the years 1946-1978.

 

Basic principles of selection and operation of pumps in hydrotransport installations.

1. Introduction.

Hydraulic transport of solids in pipelines is used in many industries and economies (e.g. mining, energy, mineral resources industry, food industry, chemistry, environmental protection) [1].

Without going into details, it can be said that most often (and in large masses) solids with dusty granulation (diameter of the so-called medium grain δs50 < 0 mm) and fine-grained (δs075 < 50 mm) are transported in the water stream. Thicker solids (several - several dozen mm) are transported less frequently and this usually applies to hydroexcavation and subsequent hydraulic transport of mineral aggregates, and sometimes agricultural produce.

Solids have very different shapes, regardless of size. Mixtures of dusty particles with water (called suspensions) are treated as homogeneous liquids; the velocities of liquids and solid particles during flow are virtually identical, and solid particles are distributed evenly in the flow cross-sections of pumps and pipelines. To put it simply, such suspensions can be treated as homogeneous liquids - but characterized by increased viscosity towards water, which causes a certain increase in the flow resistance of the suspensions compared to water. They are treated as non-sedimenting. Appropriate fluidity of the suspension is a condition for its ability to be pumped through pumps, transported in pipelines and spread on a flat surface. It depends on the density of solids, which should not exceed reasonable limits. Mixtures of fine-grained particles with water are two-phase heterogeneous liquids in which solid particles move slower compared to water, which causes energy losses during the flow of the mixture. Under the influence of gravity, solid particles in such mixtures fall in the pipelines (or move under the influence of centrifugal forces in the rotating channels), therefore their density in the flow sections is not uniform. A comparison of the distribution of dusty (P) and fine-grained (D) solid particles in the pipeline cross-section during the mixture flow is shown in Figure 1.

Solid particles in the mixture should remain suspended and at a certain distance (in the case of suspensions, even a very small one) from each other. This is different in the case of coarse-grained bodies, which are usually "dragged" along the bottom of the pipeline.

Fig. 1.

Fig. 1.

 

 

 

 

 

 

Since the pump efficiency and the liquid flow rate through the pipeline are measured in units of volume over time (e.g. m3 /s, m3 /h), so the parameter that most fully characterizes the composition and density of the mixture is volume concentration (volume fraction) cv solid phase in the mixture, defined by the formula where: Vs is the volume of the solid phase in the mixture, Vw is the volume of the liquid phase (water) in the mixture, and Vm is the volume of the mixture. Volume concentration cv Although it is an immeasurable quantity, its value has a significant impact on the fluidity (and therefore the "transportability") of mixtures and suspensions. It determines the degree of "occupation" of the space in which the mixture is located by solid particles.

Another parameter relating to the amount of mass contained in the mixture is mass concentration (mass fraction) cM solid phase in the mixture. The relationship between cM acv is as follows:

2

When mixtures with the same volume fraction cv solid phases contain solids that differ in density, their mass concentrations (mass fractions) cM   solid phases are different. For example, it can be said that hydromixtures with the same volume concentration cv = 0,3, which includes crushed coal (ρs = 1400 kg / m3), fly ash (ρs = 2200 kg / m3) or fine sand (ρs = 2650 kg / m3) will be characterized by mass concentrations cM 0,375, 0,485 and 0,532, respectively, which are very significantly different.

Figure 2 shows an overview of the uniform distribution of identical grains of spherical solids in the flow cross-section, in mixtures with different volume fractions cv.. It is worth noting that already when cv = 0,3, the solid particles are close to each other.

fig 2

Fig. 2.

The density of the mixture ρm depends on the volume concentration cv, determined by measurement or calculated from a simple formula, in which: ρs – is the apparent density of the solid phase (taking into account the presence of open and closed pores and caverns), and ρw – is the density of water. The apparent density of solid particles should be determined using the carrier liquid in which they will be transported (in practice, water).

3

Figure 3 shows the dependence of the density of the mixture ρm on the volume fraction of the solid phase cv, for solids with densities ρs = 1400, 2200 and 2650 kg/m3. This range includes the densities of the vast majority of solids transported hydraulically in large masses (e.g. fly ash, energy slags, post-flotation waste in copper ore mining, sand and gravel, limestone, dolomite, a significant part of waste from the process of enriching hard coal, crushed coal). The density of the mixture increases linearly as c increasesv and in practice it often exceeds 1500 kg/m3.

fig 3

Fig. 3.

2. Efficiency of the hydrotransport system.

Volumetric yield (mixture) Qm the hydrotransport system is expressed by a simple relationship,

4

where d – is the internal diameter of the transport pipeline, and vm – is the design flow rate of the mixture.

It should be remembered that the flow rates of hydromixtures in pipelines are usually significantly higher than the water flow rates, as solids should not be allowed to settle at the bottom of the pipeline. Therefore, the volumetric efficiencies of the hydrotransport system are usually relatively significant.

Mass efficiency of the M hydrotransport systemm is given by the formula:

5

or in a more extensive form – a model,

6

which shows that the mass efficiency of the hydrotransport system increases rapidly as the pipeline diameter increases, especially since the mixture flow rates increase (to avoid the deposition of solid particles).

3. Pumps in hydraulic transport systems.

Since the flow of hydromixtures in the pipeline (and their possible lifting to a higher level) requires specific work, it must be forced by the pump. In a hydraulic transport system, the pump is an active element in which energy supplied from the outside (from the driving engine) is transferred to the mixture stream.

If the mixture flows with density ρm and volumetric intensity Qm , the effective power P is transmitted in the pumpu , is the unit of weight of the mixture   (1 N) will obtain an increase in energy H (expressed in J/N, and after formal simplification of dimensions in "m") resulting from the formula:

7

and called the useful head of the pump. This name refers to the interpretation of this concept, according to which it defines the geometric height to which the pumped liquid (and therefore also the hydromixture) can be raised, but without any losses associated with it.

Effective power of the pump Pu expresses a familiar pattern

8

Transferring energy to the hydromixture is accompanied by various types of energy losses in the pump, so the power P (supplied to the pump) is greater than the useful power Pu . The pump efficiency η, defined by the formula, characterizes the efficiency of energy transfer to the pumped medium.

9

4. Selection of pumps for the hydrotransport system.

When selecting a pump for a specific hydraulic system for transporting solids, the following factors should be taken into account:

– required pump operating parameters achieved under the conditions of pumping the hydromixture,

– pump design solution appropriate for a specific hydromixture,

– expected durability of the pump's internal components.

4.1. Determining the pump operating parameters.

The necessary operating parameters of the pump at the expected operating point in the hydrotransport system should be determined as precisely as possible. With the expected volumetric efficiency of the Q systemm (identical to the pump efficiency), the energy transferred to the unit weight of the mixture in the pump must balance the geometric height Hz (to which the mixture will be lifted) and the amount of hydraulic losses ΣΔhm in the transport pipeline (also related to the unit weight of the mixture), which arise during the flow of the hydromixture. The sum is the lifting height of the hydromixture transport system (Hi), the simplest diagram of which is shown in Figure 4, and the characteristics of the hydrotransport system Hi = f(Q) is shown in Figure 5.

10

fig 4

Fig. 4.

 

Fig. 5. (Marked: M- mixture, W- water).

Fig. 5. (Marked: M- mixture, W- water).

Solids in the hydromixture leaving the impeller have a certain kinetic energy. In the case of dusty particles, this energy is transferred to the liquid almost completely, in the case of fine-grained particles - to some extent, and in the case of "coarser" particles it is completely dissipated.

 

Fig. 6. (A – fine particles, B – coarser particles).

Fig. 6. (A – fine particles, B – coarser particles).

The presence of solids in the pumped mixture therefore affects the operating parameters of the pumps, in particular the useful lifting height, efficiency and shaft power, which change in relation to the parameters achieved when pumping water.

Changes in pump parameters are characterized by the following dimensionless coefficients:

– lifting height change factor KH

11a

 

 

 

– efficiency change coefficient Kη

11b

 

K coefficient valuesH and Kη depend on the type of solids (density ρs and medium grain size δs50) and their volume fraction cv. It is also influenced by the size of the pump. K-type algebraic graphs and relationshipsH = f(Q) and Kη = f (Q) published in the literature enable approximate prediction of the impact of the presence of solids on the characteristics H = f(Q) and η = f(Q) of the pump pumping the water-solids mixture. However, they should not be treated uncritically, as they usually refer to a specific pump and specific solids. An example of such relationships quoted from [2] is shown in Figure 7. They refer to a pump with a four-blade impeller, but of unspecified size and unknown operating parameters.

 

Fig. 7. (Marked: a - fine sand 0,8-0,35 mm, coarse sand 0,3-2 mm, fine gravel 0,9-5 mm)

Fig. 7. (Marked: a – fine sand 0,8-0,35 mm, coarse sand 0,3-2 mm, fine gravel 0,9-5 mm).

Figure 8 shows an overview of the characteristics of the lifting height H - Q and efficiency η - Q of a centrifugal pump pumping mixtures with the same volume concentration, but containing solids of different grain sizes - against the background of the characteristics related to water.

Fig. 8.

Fig. 8.

When selecting a pump in a specific situation, you should first determine the lifting height of the pump installation Him under the conditions of pumping the mixture (at the required system capacity Qm), which at the expected operating point of the system must be identically equal to the useful lifting height achieved by the pump pumping the mixture (Him = HM). Required effective pump head Hm (in the conditions of pumping the mixture) cannot be directly used to select a specific pump, because pump manufacturers provide pump characteristics determined when pumping water. Therefore (after adopting reliable values ​​of the K coefficientsH and Kor), the useful lifting height H must be determinedw, which the analyzed pump would achieve by pumping water (because always Hw ≥ HM).

12

and calculate power   on the pump pumping the mixture (Pm) from the relationship:

13

To more precisely adjust the pump parameters to the required ones, it may be necessary to reduce the outer diameter of the impeller or change the rotational speed (e.g. by selecting appropriate pulleys).

Note that the K ratioH / Kη is usually close to 1 and only in the case of coarse-grained mixtures and more dense fine-grained mixtures it is lower, so the power on the pump shaft under the conditions of pumping the hydromixture increases approximately in proportion to the density ratio ρmw . The increase in power demand must be taken into account when selecting the engine (and possible belt transmissions) to drive the pump.

Selecting a pump for a specific mixture hydrotransport system is often (due to the complexity of the problem) a difficult matter and it makes sense to use the support of specialists. Reputable manufacturers of hydrotransport pumps usually have experience and knowledge in this field, and relying on the suggestions of bidders without experience is risky.

4.2. Selection of the pump design solution.

Centrifugal pumps for hydrotransport are generally single-stage, although there were multi-stage versions for special needs. Examples of design solutions for hydrotransport pumps are presented in the following figures 9 and 10 [4] and 11. The common features of these pumps are large impeller widths (which allows for the "passage" of larger solids), large collecting channels - with a constant cross-section or in the form of "incomplete" spiral, the possibility of adjusting the radial gap at the impeller inlet - which allows to reduce internal leakage at the impeller inlet, the use of elements directly in contact with the pumped mixture as relatively easily replaceable, solid bearings of the rotating unit due to the usually much higher axial and radial forces, and closure water stuffing boxes. The pump shown in Figure 10 is also equipped with a specific impeller that relieves the stuffing box, which significantly increases its durability in the case of uninterrupted water supply. This solution is intended for difficult working conditions.

Fig. 9. PH pump (Powen-Wafapomp SA Group), [4].

Fig. 9. PH pump (Powen-Wafapomp SA Group), [4].

Fig. 10. HC type pump (Powen-Wafapomp SA Group), [4].

Fig. 10. HC type pump (Powen-Wafapomp SA Group), [4].

Pumps whose internal elements are made of hard metal materials (e.g. Fig. 9 and 10) can be used to pump hydromixtures containing grains of any size. A hard material resists "cutting" - by coarser particles - especially "angular" ones - and "grinding" by fine particles. However, pumps (Fig. 11) whose internal elements are made of elastomers (rubbers, polyurethanes) are generally intended for pumping mixtures containing fine particles. An elastomer with appropriate abrasion resistance absorbs the energy of striking particles and, to some extent, causes them to bounce off the attacked surface.

fig 11

Fig. 11.

Recently, there has been a tendency to use cast steel impellers in pumps with a collecting channel and liners made of elastomer. This allows for a noticeable increase in pump efficiency.

The choice of a specific pump should be aimed primarily at achieving the longest possible operating periods between the inevitable replacements of impellers and other elements (housings, side linings), which is conditioned by the high durability of the internal elements of the pump, and this criterion is even more important than achieving slightly higher efficiency by the pump. .

It is advantageous when hydrotransport pumps have low speed (750 - 1200 (1500) rpm), because it is found that impeller wear (understood as the loss of element mass) increases approximately in proportion to the square of the rotational speed. Also, the rate of increase in the width of the radial gap sealing the rotor inlet and the wear of the stuffing box seals decreases as the rotational speed decreases.

4.3. Durability of pump components.

The impeller of the hydrotransport pump is the element subject to the fastest wear, and the places of the most intense wear are marked in Figure 12. In the case of the content of "coarse" particles in the mixture G the largest losses occur in the inlet area of ​​the rotor (inlet edges of the blades and rear rotor disc), and in the case of pumping "fine" particles D although the losses in these places are smaller, significant losses are observed at the ends of the blades, on their active side, which - when they become large enough - adversely affect the velocity distribution of the outflowing mixture, which leads to a noticeable reduction in the pump lifting height. As a result, the blades and rear disc of the rotor are thickened, especially in places of the most intense wear. The number of blades is small, z = 3 – 4 (sometimes 5), in order to maintain sufficiently large clearances at the impeller inlet and not excessively impair the suction capacity of the pump.

The bodies of collecting channels are subject to accelerated local wear in the area where the channel enters the outlet connector. as a result of "impacts" of solid bodies on the edge acting as a residual "tongue".

Rotors and replaceable metal elements (collection duct bodies and side linings) are made of cast steel containing significant amounts of alloy additives and are heat treated to increase their hardness, which requires an appropriate technological level. Replacement elements used during replacements and renovations should be of appropriate quality (ensuring appropriate durability) and for this reason it is risky to use "replacements" of undocumented quality, as it may turn out to be unprofitable. Hydromixture pumps are, for obvious reasons, inferior to water pumps in terms of efficiency, so the expected durability of their components is a decisive factor in their selection. It should also be taken into account that faster wear of the pump components leads to an extension of the period during which it operates at low efficiency.

fig 12

Fig. 12.

5. Some issues regarding the operation of pumps in hydrotransport systems.

The phenomena occurring during the flow of the hydromixture through the pump are much more complex than during the pumping of water. Therefore, you should pay attention to several circumstances that affect the proper operation of the pump, which determines the uninterrupted functioning of the hydrotransport system as a whole.

5.1. Consequences of increased factor density.

The relatively high density of the mixture increases the power consumption of the pump (and the need to use an engine with appropriate power) and increases the pressure in the pump discharge port, which is important in the event of a possible need to connect two pumps in series. Not every pump is designed to operate in conditions of significant pressure increases, so such uncertainty should be clearly explained. Care should also be taken to supply water with appropriately increased pressure to the water "lock" of the stuffing box of the second pump in the series.

5.2. Ensuring geometric inflow to the pump.

The mixture should flow to the pump from the tank (with the bottom inclined towards the inlet) to the shortest possible supply pipeline located above the pump axis (Fig. 4). Pressure in the pump inlet psm when pumping the mixture should be significantly higher compared to the situation when pumping water. At low volume concentrations of solids in mixtures (cv ≤ 0.1) the anti-cavitation surpluses are close to each other in both cases (NPSH3w ≈ NPSH3m) [5] , but even then the required ("safe") pressure in the pump inlet port when pumping a mixture must be higher due to the higher density of the mixture

14

(with NPSH3m is the anti-cavitation surplus of the pump under the conditions of pumping the mixture).

When the volume fraction of solids in mixtures and suspensions cv > 0,1, then NPSH3m, and therefore the required pressure value in the pump inlet port, increase quickly because in the inlet area of ​​the rotor solid bodies (especially those with larger granulation) are "pressed" by the force of inertia against the rear disc of the rotor (Fig. 13) [6], and their displacement causes much greater losses, and therefore a local pressure drop. However, in the case of suspensions of very fine particles, as their density increases, additional pressure losses occur due to the existence of non-Newtonian fluid characteristics in the suspension.

Therefore, ensuring an appropriate geometric inflow of the mixture to the pump is necessary.

fig 13

Fig. 13.

5.3. Pump operation at close to optimal efficiency.

The pump should permanently operate at a capacity close to optimal, i.e. close to the point of highest efficiency. Then, the bearing loads caused by the radial force acting on the rotor are relatively small, the flow in the inter-blade channels of the rotor takes place with the smallest turbulence and is most even, and the rotor wear is the slowest. Of course, the pump operation is then the most economical.

Operating the pump at increased efficiency causes increasing losses in the inlet area of ​​the impeller, and reducing efficiency during operation increases the risk of solids settling in the pipeline.

5.4. Other.

In addition to the issues mentioned above, the condition of the pump should, of course, be checked, especially the pressure in the pump discharge port, the water supply to the stuffing box, the temperature of the bearings, the vibrations of the rotating unit and the current electrical power consumption of the motor (or at least the intensity of the electrical current consumed). It is also worth remembering that the dominant influence on costs is the correct selection of the pump and its operation close to the point of maximum efficiency, and above all, avoiding pumping too dilute mixtures, because then a significant part of the energy is used to pump excessive amounts of water.

6. Ending.

Hydrotransport systems, although they contain similar elements (tanks, pumps, pipelines) and water pumping systems, operate in different conditions. Pumps must meet requirements in terms of solids throughput and durability. Tanks should be appropriately designed (slanted bottom and possibly equipped with a mixer), and pipelines and fittings should be selected appropriately. Operating parameters and values ​​characterizing the system should be determined based on the identified characteristics of the mixture or suspension and a reliable calculation methodology, and the pump selection should be made carefully.

Pumps in hydrotransport installations must perform in usually difficult conditions - primarily in terms of durability and operational reliability, and their operation requires understanding of the problems and knowledge of the supervisory team, as well as increased involvement of the staff. As a result, however, it will limit unexpected disruptions in the functioning of the system and, to some extent, also the frequency of renovations, and in the medium term it will reduce costs.

Literatura:

The literature on the issues discussed is very extensive, so due to the nature of the publication, the publication is limited only to items directly related to the issues discussed.

1.Palarski J., Hydrotransport, WNT, Warsaw, 1982

2.. Surek J., Probleme der Flüssigkeits-Feststoffgemisch – Förderung mit Kreiselpumpen, Maschinenbautechnik, Heft 9, 1972.

3. Roco NC, Wear mechanism in centrifugal slurry pumps, Journal of Science and Engineering, Vol. 46, No. 5, 1990.

4. National Forum of Producers and Users of Pumps in Mining, Lubiatów, May 6-8, 1998, (collection of materials)

5. Źiwotowskij Ł.S., Smojłowskaja Ł.A., Techniczeskaja mechanica gidrosmiesiej i primerowyje nasosy, Izd. Mashinostroyeniye, Moscow, 1986.  

6. Karielin W., Iznashiwanije łopasnych nasosov, Izd. Mashinostroyeniye, Moscow, 1973.

 

Dr. Eng. Jerzy Rokita

MSc. Zbigniew Krawczyk

 

"I was at Anders's" - Stanisław Wolski

Stanisław Wolski


Before the war, I was a civilian driver in the Border Protection Corps in Volhynia. I was mobilized 1 Września 1939 year and I took part in the fights against the Nazis. After the end of the September Campaign, I was interned in Poworsk by the Soviet army.

Period of years 1939-1941 I spent as a tractor driver in a forestry enterprise on Lake Ladoga. At the end 1941 year, as a result of an agreement between the government of General Sikorski and the Soviet Union, I was dismissed from work in connection with reporting to the Polish Army formed by General Anders. Our camp was in Tatishchev near Saratov. At spring 1942 year, on the orders of General Anders, our troops were transferred through Turkmenia to Iran. There we stopped in Tehran and then arrived at the Persian Gulf. From there we were transported by ship to Alexandria in Egypt. We started training there - we were given practice tanks. We also met with our troops who returned from Tobruk. Our colleagues from Tobruck called us "kacaps", but we lived well together and these frontline struggles taught us a lot. It's been a year already 1943.

Then we were transferred to Palestine, near Tel Aviv. There we received battle tanks - Shermans. I was the instructor (there were only six professional drivers for the entire camp). After half a year, we were sent to Iraq, where we were stationed near Mosul. It was then that I saw General Władysław Sikorski for the second time (the first time I saw him was in the USSR). He even asked me how professional officers and non-commissioned officers treat soldiers.

At spring 1944 year we went back to Alexandria, from where we sailed to Naples. The army went on a passenger ship and I went on a cargo ship. There was one soldier per vehicle to operate it. From Naples we went to Villa Val. Down 15 May we were preparing for combat action. WITH 17 in 18 the attack of Polish troops began. From eleven o'clock until one o'clock in the morning, 2800 guns of various calibers fired at Nazi positions. At five o'clock in the morning, while preparing our unit for the attack, I was deafened by the explosion of a large German shell. I regained consciousness only after four days. After leaving the field hospital, I was sent to lighter duty as an ambulance driver. I took part in the further pursuit of the Nazis. So we reached Bologna, where we had a longer stop.

The Germans surrendered. The war is over. The army began to be demobilized. I volunteered to return to the country. I took a ship to Edinburgh, Scotland. The matter of my return to the country dragged on. It was a hard winter and it wasn't until spring 1947 I returned to Gdynia by ship. Over a hundred colleagues returned from my unit with me, and the entire transport included two thousand soldiers.

For the African and Italian campaigns I received numerous decorations: the British War Medal, the Army Medal, the Cross of Valor, the African Star, the Italian Star, the War Star and others.

I came to Warsaw, where my brother lived, with whom I entered into correspondence after the end of the war. I started working as a driver at the Central Board of Red Ceramics. Then I worked in other plants. From 1958 I have been working in assembly at WFP for a year.

From the article by Bolesław Waszul, "A long way led to Poland", "Wafapomp", 1971, no. 9 (67).
         

Stanisław Wolski, employee of the Warsaw Pump Factory in 1958-1975.

"I fought for a free Poland" - Józef Pietrzak

Józef Pietrzak.


Year 1918. Kaiser Wilhelm II flees to the Netherlands. German troops are withdrawing from the fronts. Soldiers' Councils are established. Changes are felt in Greater Poland. Poles are now allowed to organize. You are allowed to organize rallies and you are allowed to talk about freedom. IN November 1918 year, as a seventeen-year-old boy, I went to Poznań and on Piekary Street I signed up at the army recruitment office - POLISH! In day 25th November, I started serving in the security company in the then fort "Priwitz". Day 26 Grudnia welcomed the city with decorations of white and red banners and eagles - in the evening, Ignacy Paderewski arrived in Poznań with a group of Allied officers, who was going to take over the rule in Warsaw. He was greeted at the station by an honorary company consisting of members of the hunting club. The orchestra played "Poland Has Not Yet Perished". We had tears of joy in our eyes.

The next day I received my first task - to deliver rifles and ammunition to Jerzyce (a district of Poznań). Our new branches were established there. In the afternoon 27 Grudnia, while in the city, I saw a procession with banners. After getting closer, it turned out that they were Germans. They shouted:

- Take down the flags!

They fired machine guns at places from which they were not taken. In the evening, an emergency was ordered in the barracks. We received one hundred bullets and hand grenades. We went out for the first action. We captured the German police headquarters and the town hall without bloodshed. Getting the mail wasn't easy. The Germans were defending themselves here and were firing machine guns from above. We had to call another company for help.

At midnight the Germans surrendered. We were connected to the entire country. Same day 27 Grudnia — an uprising against the invader has already broken out throughout Greater Poland. At the station in Poznań, we captured the entire transport of heavy weapons that had been sent from Silesia to help the German garrison in Poznań.

In the following days I participated in the capture Wilda and Sołacz (districts of Poznań), where German sappers and heavy artillery units were stationed. The Germans were surrendering. Poznań was already free.

However, in the provinces it was not so easy everywhere. German troops operated under nationalist commanders. Sometimes we had to fight hard battles with them. In February 1919 year, our battalion went to the front near the village of Grójec on the Obra River. The first company in which I served was commanded by Second Lieutenant Krauze. During the initial phase of the attack on the village, he was seriously wounded. The Germans, experienced soldiers after several years of war, better armed than our newly formed units, were on top. Many, especially on our right wing, were killed and wounded. The Germans started to surround our unit. In this situation, our commander gave the order to surrender. Sergeant Majewski hung a handkerchief on his rifle's bayonet, but the Germans only increased their fire in response. Sergeant Majewski was injured. There was no other option - we had to retreat under fire until we were completely surrounded and cut off from the nearby forest. Second Lieutenant Krauze shot himself to avoid being captured. During the retreat, a grenade injured my face. Luckily, I reached the forest, where I fainted. My friends made a makeshift dressing for me and took me to Nowa Wieś. There I was treated again and taken to the hospital in Wolsztyn. In this unequal fight against a well-armed and experienced front-line soldier, our company lost 190 killed and wounded out of a total of 250 people.

After leaving the hospital, I was assigned to the second company in... Chołbienice under the command of Second Lieutenant Kowalczyk. We joined the 7th Greater Poland Rifle Regiment.

In January 1920 In the same year we entered Chodzież, which was granted to Poland by the Treaty of Versailles. The upsurge in the fight for freedom, paid for with many sacrifices, was not wasted - it proved to those debating the treaty that these were former Polish lands that the hundred-year-long captivity and persecution of Hakata had not been able to Germanize.

If it were not for the Greater Poland Uprising, the Silesian Uprisings would not have occurred in the following years, thanks to which 1923 year, a piece of Silesia returned to the motherland. From 1925 I worked in the people's movement for a year. Initially as an instructor, and then as secretary of the district board. From the very beginning, there was a lack of people to work in the organization. We had a lot of work to do and our area of ​​operation was extensive.

During my work in the people's movement, I traveled throughout the Białystok Voivodeship. Needless to say, the working conditions were very onerous. The only means of transport available to us, activists from the area, was only a bicycle. But this did not save the situation in the event of a flood, etc.

There was discontent in the country. Both workers in the cities and peasants in the countryside were up in arms. Sanation sought to liquidate parliamentary democracy, but the elections in 1928 year, despite the terror, did not win her a majority in the Sejm. So the people's movement could act within the freedom it still had. But it only lasted until 1930 year. That year, the president dissolved the Sejm and called new elections, which were held in an atmosphere of severe terror. Brest took place, opposition deputies were imprisoned in the Brest fortress, bones were broken, and brutal torture took place. In such conditions, a parliamentary majority supporting Piłsudski's policy was elected.

The popular movement was stopped. Most of the activists emigrated. But despite all the harassment from the Sanation, the people's movement did not give up. Three organizations: the Peasant Party, "Piast" and "Wyzwolenie" merged into one organization - the People's Party. At the congress in 1935 The People's Party demanded agrarian reform without compensation and equal rights for national minorities. Massive peasant strikes began and, despite harassment, the ranks of the People's Party continued to grow.

For me personally, the peasants' strike in August was very memorable 1937 year. Mass arrests and pacifications failed to stop the peasant movement. I operated in such conditions and political situation until 1939, when the war broke out.

Thirty-three years have passed since the roar of planes and black crosses over Poland. 10 September The Germans entered Brańsk. Five difficult years of occupation began. I did not remain idle. From the very beginning, I became actively involved in underground life. In autumn 1941 year, I created a military organization under the name Peasant Guard - "Chłostra". There were many people willing to fight. Most of them were young people from the People's Party, where I was well known from the pre-war years. I started the organization from scratch. The lack of weapons was particularly noticeable. At first we only had eight hand guns and some ammunition. However, already in 1942 Last year we had 38 hand guns, four automatic rifles and ten hand grenades at our disposal. Of course, it was not much, considering that the organization numbered seventy people (three platoons).

In autumn 1942 In the same year we joined the Peasant Battalions. Colonel Franciszek Kamiński, a peasant supporter from the beginning, became the commander. We carried out various actions: from helping Soviet partisans to eliminating Nazis and informers reporting on partisan movements. The shares were not without losses. Many comrades from my unit died. With this small handful of memories, I would like to honor those comrades in arms who died for Free Poland.


From the articles by Józef Pietrzak, I took part in the Greater Poland Uprising, "Wafapomp", 1971, no. 12 (69) and From the People's Party - Peasant Chłostry to Bataliiony Chłopskich, "Wafapomp", 1972, no. 15/16 (82).

Józef Pietrzak, employee of the Warsaw Pump Factory in the years 1958-1970, collaborator of the company newspaper "Wafapomp", organizer and activist of the Circle of Pensioners and Pensioners.

Pumps of the Warsaw Pump Factory in the waterworks and sewage systems of the capital city of Warsaw.

The history of new waterworks and sewage systems in Warsaw in the period 1886-1936

118 years ago, one of the most important urban investments serving to meet the needs of the population was put into operation in Warsaw. Warsaw received new water supply facilities and the first sewage facilities. This contributed to improving the health and cultural condition of the population. Designed and constructed under the supervision of engineers William Lindley and Alfons Grotowski, the waterworks and sewage system are still examples of engineering art.

The first set of water supply devices on the raw water, clean water and used water route was the River Pump Station located in Czerniaków on the bank of the Vistula. The pumps installed there were intended to draw river water and pump it to the Filter Station for purification devices. The pumps collected water from the sedimentation tank, which was used for preliminary water purification and collection. For this purpose, 4 machine halls and 2 steam boiler halls were built. Three sets of plunger pumps powered by 3 HP steam engines manufactured by James Watt were installed in three halls. In the fourth hall, three Sulzer electropumps were installed with a capacity of 140 m1150/h and a lifting height of 3 m at a rotational speed of 42, driven by a 1480 KW engine and a supply voltage of 220 V.

One of the first machines delivered to the waterworks of the capital city of Warsaw by the company Brandel, Witoszyński i S-ka (later Inż. S. Twardowski - later Warszawska Fabryka Pomp) was a compressor manufactured in 1912.

In 1933, instead of the oldest steam pumps, three new sets of centrifugal, single-stage electropumps with a double-stream impeller were installed - fig 1, companies engineer S. Twardowski. At a pressure of 41,7 m head, the pump capacity was 1710 m3/h. The pumps operated at a speed of 1480 rpm and achieved an efficiency of 82%. They are powered by asynchronous motors with a power of 295 KW and a voltage of 5000 V.

Due to the terrain conditions in Warsaw and significant fluctuations in the water level in the Vistula, it was impossible to drain the used water directly into the Vistula by gravity. Two vertical sets of centrifugal electropumps delivered in 1935 by the company were installed in the Canal Pump Station at Dobra Street. engineer S.Twardowski.



Fig. 1. Pumps at the River Pumping Station (photo and drawing from the monograph "Waterworks and Sewerage of the Capital City of Warsaw, 1886-1936")

Fig. 1. Pumps at the River Pumping Station (photo and drawing from the monograph "Waterworks and Sewerage of the Capital City of Warsaw, 1886-1936").


Expansion of the water supply network of M. St. Warsaw.

The development of Warsaw in the post-war period resulted in the need to expand waterworks. In the 50s, eight sets of pumps were installed in the Central Waterworks at the River Pump Station. N23PBD/40-B - fig 2, produced in S. Twardowski company. These were single-stage, vertical centrifugal pumps with a double-stream impeller with a capacity of 1700 m3/h and a lifting height of 60 m at a speed of 1480 rpm, driven by a 350 KW electric motor. These pumps had a vertically divided casing with horizontally located suction and discharge ports. The installed pumps, 15 m long, have shafts composed of several sections connected with shaft couplings, mounted in rolling bearings lubricated with grease. Pumps pumped water through pipelines under Koszykowa Street to the Filter Station. Pumps of this design are still in operation today in the Main Pumping Station in Czerniaków.


Fig. 2 N23PBD/40-B pump at the River Pump Station.

Fig. 2 N23PBD/40-B pump at the River Pump Station.


The growing demand for water resulted in the need to build a new water intake for Warsaw. In 1953, construction began Basic Take Prague Waterworks the so-called Fat Kaśka. The project of capturing water from the bottom of the Vistula through horizontal, star-shaped drains under the bottom of the Vistula was a pioneering and technically complex solution. Water infiltrated by the natural sand deposit flows into the collecting well, ensuring an adequate inflow to the diagonal pumps installed there. In 1963 Warsaw Pump Factory delivered four prototype units of vertical diagonal pumps to the "Gruba Kaśka" water intake D31-P60 in a special design with a total pump length of 30 m. According to the original design assumptions, the pumps were to have the following parameters: capacity 3500 m3/h and lifting height from two stages of 72 m, which made it possible to pump infiltrated water directly into the water supply network. Ultimately, after changing the design assumptions, single-stage pumps with a lifting height of 40 m and a capacity of 3150-3500 m3/h were installed. The total capacity of the installed D31-P60 pumps is 13250 m3/h, i.e. 318 thousand. m3 of water per day. The pumps were put into operation in 1964 and for 36 years they pumped water through pipelines located under the bottom of the Vistula River to water treatment facilities.

Further development of the Praga Waterworks involves the construction of two auxiliary under-bottom bank intakes on the right side of the Vistula. Diagonal shaft pumps were installed in each 60D22 and 50D22 Warsaw Pump Factory, which pumped water in the amount of 11400 m3/h through aerators and filters into the clean water tank.

In 1986, the Northern Waterworks was launched with a water intake from the Zegrze Reservoir located 40 km from the center of Warsaw, with a production capacity of 300. m3 per day. In the first stage river pumping station, 5 WAFAPOMP units with diagonal pumps were installed 60D40 with a capacity of 3600 m3/h and a lifting height of 17 m.

Due to the considerable distance of the water intake from Warsaw, Wodociąg Północny has pumping stations of the second and third degree equipped with double-stream, horizontal pumps of the type 50B80, 50B50 and 40B75 produced by WAFAPOMP with capacities ranging from 2000 to 4200 m3/h. and lifting height 60m.

The current state of water supply installations

Currently, at the water intakes of the Warsaw Waterworks, pumps with the WAFAPOMP mark are operating in the Central Waterworks and the Northern Waterworks.

At the water intake of the Central Waterworks in Czerniaków, in addition to the already discussed vertical double-stream pumps N23PBD, 5 units with propeller pumps are installed PR37,5 from 1965, and 7 units with horizontal double-stream pumps 60B66 – fig 3, 50B63.


Fig. 3. Double-stream pump type 60B66 at the Central Waterworks station.

Fig. 3. Double-stream pump type 60B66 at the Central Waterworks station.


In second-degree pumping stations located at ul. There are 24 large pumps from the 70s in Koszykowa, these are horizontal double-stream pumps. N23BD40, 60B66 and 35B40 and 8 diagonal type pumps 60D40. The pumping stations in Ursynów use pumps of the type 35B35 and 25B32.

All basic pumps installed in the 80s, as well as additional diagonal pumps, are in operation in the Northern Waterworks 40D40 in the drainage water pumping station, and pumps 50B40 in the rinsing water pumping station.

Since 2000, the main water intake and auxiliary intakes of the Praski Waterworks have no longer had diagonal shaft pumps manufactured by the Warsaw Pump Factory. They were replaced by submersible diagonal pump units. However, 4 vertical double-stream pump units are still in operation N23PBD from 1963, pumping water from a clean water reservoir into the right-bank water supply network of Warsaw in the second stage pumping station.

To sum up, the Warsaw Waterworks has 80 large pumps installed, manufactured by the Warsaw Pump Factory, with a total capacity of 228. m3/h.

The current state of sewage installations

There are four large sewage pumping stations in Warsaw: Pompownia Żerań, Powiśle, Marymont and Saska Kępa. These pumping stations are equipped with pumping units for pumping domestic and storm water. The largest of them, the Żerań Pumping Station, has only WAFAPOMP pumps. Vertical single-stage centrifugal pumps are used to pump domestic water 50F74 with a capacity of 2500m3/h 40F64 - fig 4, with a capacity of 1500 m3/h, a total of 14 sets. These pumps, installed in dry chambers, operate with inflow into the suction port and pump into a 7-kilometer section of the pipeline to the Czajka sewage treatment plant.


Fig. 4. Pump type 40F64 in the Żerań pumping station.

Fig. 4. Pump type 40F64 in the Żerań pumping station.


Units with pumps type 60F85, with a capacity of 4000 m3/h each, they are used to pump excess water from the storm water tank to the expansion chamber from where the water flows by gravity into the Vistula. Stormwater pumps are characterized by high efficiency and relatively low lifting height. They work periodically only when there is heavy rainfall and high water levels in the river.

Pumps from the 60s are still used in the Powiśle and Saska Kępa pumping stations. 60NSC-85p i 30NSC64p both as domestic water pumps and excess water pumps. Only Warsaw pumps operate in the Saska Kępa Pumping Station, including 6 sets of propeller pumps 80P17 with a capacity of 6000m3/h. Until 1996, pumps still worked here S. Twardowski type PR37,5 from 1954.

In addition to the large canal pumping stations mentioned above, there are also 6 medium-sized pumping stations in Warsaw. Pumps from the Warszawska Fabryka Pomp type operate in the Ochota, Zacisze and Moczydło pumping stations. NSC from the 60s or type F.

The oldest centrifugal pumps with origins from the company Eng. S. Twardowski they are still used in small rainwater pumping stations in Bielany and Czerniaków; these are propeller type pumps PR 21 and PR13 from 1950.

A total of 73 large pumps manufactured by the Warsaw Pump Factory with a capacity of 167 are installed in sewage pumping stations. m3/h. This constitutes 82% of the total efficiency of pumps installed in the sewage pumping stations of the capital city. Warsaw.

Development of pump designs for municipal services

  WAFAPOMP SA maintains constant contact with users and has information regarding the correct operation of the pumps. The analysis of requests for proposals and the technical requirements contained therein determines the directions of changes taking place in the equipment of water supply and sewage pumping stations.

These are:

– full automation of pumping station operation,

– limitation of service and renovation works,

– optimal selection of pumps for the actual parameters of the pumping system,

– modernization of the pumping station to improve inflow conditions at the pumps,

– reducing noise emissions,

– use of drives with adjustable speed,

– high reliability of devices,

– use of fittings with regulating drives.

Compared to the period of construction and expansion of the Warsaw Waterworks, WAFAPOMP SA's offer for municipal services is broader and more comprehensive.

To meet the requirements of pumping station automation, we offer pumps for operation in dry chambers as well as submersible pumps with a control cabinet equipped with a specialized controller and an operator console with an LCD display. The security system enables measurement of bearing temperature and moisture in the engine compartment and oil chamber. The basic functions of the controller are to protect the pump unit against: dry running, low suction pressure, power failure. As additional equipment, a complete engine power supply system is available for direct starting, starting with a soft start or with an inverter.

In recent years, a series of submersible propeller pumps have been put into production PZ with capacities up to 4000m3/h, and the first diagonal submersible pumps were produced DZ – fig 5. The use of submersible pumps significantly reduces costs

investment in the construction of pumping stations, facilitates assembly and disassembly at the workplace, reduces the noise level. After equipping them with special pipe shafts with an outlet elbow, these pumps can be used as replacements with traditional shaft pumps.


Fig. 5. Diagonal submersible pump 15DZ17.

Fig. 5. Diagonal submersible pump 15DZ17.


In order to facilitate and reduce the work related to operation and service, as well as to increase the durability of the pump units, new construction materials were used for the sliding bushes, which enables a "dry start" of the shaft pumps. Vibration and temperature sensors are installed in the bearing housings. The pumps have maintenance-free mechanical seals.

WAFAPOMP SA produces new sewage pumps FK with the engine placed directly on the pump casing. This simplifies the work related to assembly and disassembly in the dry chamber of the pumping station. Vertical double-stream pumps have similar advantages BV intended for clean water in pumping rooms where there is no space to install horizontal pumps.

In order to improve the suction capacity, the shapes of the rotors of diagonal and propeller pumps are optimized using three-dimensional numerical computational methods as well as the results of model tests. At the same time, users are provided with design recommendations regarding the proper shape of the chambers and inlet funnels for these pumps

The factory has been producing elastomer dampers for several years PN16 DN50-600, supplied with electromechanical and pneumatic drives with full automatic control for water and sewage installations.

 MSc. Andrzej Wesołowski

The article was published in issue 4 of the "Pompy-Pompownie" magazine in 2004.


Author's comment after many years:

Our offer of pumps for waterworks and sewage pumping stations has always been impressive. Over the last 7 years, GPW SA has implemented many new maintenance-free pumps with full monitoring of operating parameters. We have new, high-efficiency diagonal pumps with specially designed stainless steel blades for shore drinking water intakes. We have also implemented a series of diagonal submersible pumps DZ intended for water intakes also from under the bottom of the Vistula. The PZ series of submersible propeller pumps already includes pumps with a capacity of up to 7000 m3/h. We have recently delivered several pumps of this design, 60PZ18 and 40PZ19, to the Warsaw Central Waterworks on Lindleya. In turn, we supplied 35B40 double-stream pumps with an efficiency of over 90% for the Northern Waterworks! Due to their very high efficiency, these pumps were also installed in the Central Waterworks. Double-stream pumps are one of our flagship products with a proven, durable, optimal design that can be operated in both horizontal and vertical configurations. We have delivered 8 35BV40 pump sets in the vertical version for the Waterworks on Czerniakowska and Brukselska Streets in Warsaw. Using proven methods of calculating the flow of double-stream pumps, we designed two more pumps: 30B70 with a lifting height of up to 180 m and 70B90 with a capacity of up to 9000 m3/h.

Our offer for sewage pumping stations includes F-type pumps with the option of being coupled to the engine via a cardan shaft or placing the engine directly on the FK-type pump.

GPW SA supplies pumps for water supply and sewage installations not only to Warsaw. The recipients are large urban agglomerations, such as Szczecin and Katowice. We participate in modernization works for the Upper Silesian Water Supply Company in Katowice. We are in the process of delivering several B and BV double-stream pumps and D-type vertical diagonal pumps.

 MSc. Andrzej Wesołowski