What is Direct In-Line pumping ? What are the advantages ?
The principle of direct in-line pumping is to pump directly from the gravity flow according to variations in water stream flow . This eliminates all the drawbacks of a retention tank : dangerous gases (H2S), odors, sand and grease accumulation, equipment corrosion, structural erosion and clogged floaters. This process reduces costs in number of different ways :
• 100% savings on regular operational cleaning costs
• Reduced construction and investment costs, with a shallower pit and often less surface area taken up.
• Reduced maintenance costs as equipment is kept dry and not in contact with polluted effluent and gases, ease of access, and designed with sustainable materials and few moving parts. With no oil pan and protected from dry running, the DIP System is very forgiving of incorrect manuevers, and its wearing parts are inexpensive.
• Reduced safety risk for operating personnel due to shallower structures and equipment that operates in a healthy environment.
Disadvantages of direct in-line pumping ?
Just one! Sand, present in all networks in greater or lesser concentration, is also pumped directly, unlike immersed systems within which it decants. Result : The sealed system has been continually redesigned and improved to overcome this drawback, at low replacement cost and without requiring external spraying normally required for mechanical parts, which are unable to operate dry. In the early years, this "disadvantage" was not insignificant, but today it is no longer an issue.
How much direct in-line pumping capacity do you require ?
For separate sewage systems, based on 150l/day/resident and 18 hours operation per day for 1 motor unit. Limits on the number of start-ups, drawdown volumes and values fixed at 50 Hz are no longer relevant, as peak coefficients can be handled up to 60 Hz when required. Example : 1000 Eq. Inhab. x 150 l/d = 150 000l/d > 150m3/18h = 8.33m3/h average instant availability. S.I.D.E INDUSTRIE guarantees capacities calculated on such flows, backed up by figures from its design and engineering department.
Example compared to the usual calculation for immersed systems : 150m3/24h x K.peak 2,5= 15,62m3/h in batches. That's nearly double! Our regional managers are available to answer any questions you may have and to help you draw up an Assessment Questionnaire, also available online at www.side-industrie.com .
For combined or rainwater networks, it is assessed using peak flow as with other pumping systems, but with 2 motor units in service to avoid aversizing all too often the cause of operational problems.
And if the system is in continuous operation ? Or it starts up too often ?
The system starts up, regulates and stops in line with the effluent input volume. Below approx. 10% of its capacity (a value set when put into service) it stops completely. The number of start-ups is not a problem as each motor can switch on and off 150 times an hour without reaching peak current and therefore without overheating.
The vortex is said to have poor hydraulic output compared to channel impellers. How does the DIP perform in terms of energy consumption ?
That's correct, the DIP Vortex effect acts like an open hydraulic coupler, a "torque transmitter" which provides diphasic pumping, unblockability, etc., but is therefore an intermediate impeller, consuming additional energy compared to a channel impeller (20% to 25%). In the case of the DIP, however pumping from the water stream intake and absorbed power adjusted at the input flow are enough in itself to compensate for this loss. Accordingly, consumption is virtually identical. This is just one example of energy savings with modulated pumping.
What are the risks of blockage ? Is upstream creening necessary ? Are towelettes a problem ?
The DIP has absolutely nothing to fear from domestic towelettes and similar hygiene products which have become such a problem in recent years, as completely free flow sections have always been designed into the DIP system and direct in-line pumping does not include a storage area where such products are able to build up. There is no need to provide any screening systems.
In addition, all DIPs have motor torque control and automatic reverse, enabling them to tackle and reduce the volume of towelettes passing through during pumping (see videos).
In combined or rainwater networks, sometimes large unseemly objects pass through accidentally, and for this reason the DIP intake body is fitted with a service hatch.
Is there any risk from accumulated grease of fibres upstream ?
No, because, when put into service, our technicians fine-tune the factory settings so that the operating range matches that of the flow; there can therefore be no accumulations upstream, just maximum flow trace as you can see here :
What happens to sand and grit that can come from a gravity network ?
Sand is transported away in the flow and larger pieces of grit are caught in the rear part of the body, designed for this purpose, where they can be removed via the service hatch. If the network is really full of stones and gravel, it might be useful to fit a trap in the upstream inspection chamber for example.
What happens if there is a power cut ?
The same as with other systems - pumping stops! The only difference is that the return to full service begins 1 to 3 m³/h earlier than with a submersed unit (depending on size), which doesn't represent a great deal more security. For critical networks, an automatic start-up generator set is the best solution, especially as the DIP doesn't need a current surge on start-up, the generator therefore cannot be sized without incurring extra costs. Otherwise, the maintenance-free and fuel-free solution is a safety cover upstream, installed in the selected water stream.
What happens if the measuring sensor breaks down ?
The control system ensures emergency pumping by automatically switching the Master Pump to fallback mode at a pre-programmed fixed speed and displays an alarm on the screen. This degraded mode can last for up to 150 hrs, around one week, to allow for the changing of the sensor.
What should you do if one of the motors breaks down ? What action should be taken ?
If a fault has been identified but not resolved by the automatic fault management system, the control system automatically switches over to the other pump in the unit. To remove the motor unit for service, just a few minutes downtime is required, or even none at all if the DIP is in version C (suction valves for each pump). There are only 4 to 12 nuts to be loosened for the larger models. A plate is supplied with each system to seal the seating location of the removed motor. Intervention is therefore straightforward and is performed in complete safety.
How do you know the level of outlet flow ? Can I use an electromagnetic flowmeter ?
You can use a classic electromagnetic spool-piece flowmeter for a DIP upstream of a purification station where diphasic pumping (presence of air) is not required. However, for a network unit where the injection of air is used, we suggest an adapted electromagnetic meter, not requiring straight lengths, which provides an instant flow measurement on a signal of 4/20mA and an m³ counter. This information can be read from the screen of the SIDE ALC variators and recopied to remote management devices. Contact us for sizing in accordance with the nominal discharge diameter.
How to ensure sufficent speed for automatic cleaning during discharge ?
Regarding automatic cleaning, we must first consider the full requirements of this rule, introduced to avoid sedimentation in the discharge from batch pumping, during pump downtime, namely during filling phases: the flow speed in the discharge pipe must reach a minimum of 0.7m/s at least once every 24 hrs.
With direct in-line pumping, there is no filling time that exceeds 3 hours, as there is no retention volume. Sedimentation is therefore greatly reduced, espcecially as adjustable speed changes and full speed start-ups with the DIP system promote anti-sedimentation. Experience gained from over 1500 DIP pumps since 2003 shows that with regulated pumping at variable speed, an average speed of 0.4m/s dos not pose any problems.
Why are speed variators systematically included ? What function do they perform and can I use a different make ?
The DIP system can function without a speed variator, in maximum degraded mode, in the event of a major problem with the control cabinet for example, for up to 150 hours, but without operational control or energy consumption control. Apart from this extreme case, it is always linked up with one automatic variator per motor, giving it real virtual intelligence (see ALC automation functions) especially developped for the system in collaboration with Vacon France. Torque control, energy savings, fault management, communication and safety have been integrated into every DIP system unlike any other product on the market. 24/7 free telephone assistance and stock availibility in France and abroad also guarantee peace of mind for the users of our variable speed systems.
What about water hammer problems with this system ?
Water hammer effect during normal operation can be completely eliminated as long as the variators are functional. For those caused by a full power cut while the DIP is in maximum peak pumping mode, a temporary effect may be produced where the return wave could be dangerous. In such cases an air inlet valve provides good protection, to be sized according to the installation profile and performance levels. Contact us on a case by case basis.
How do you manage the high point of a discharge ? And reduced flow ?
With the sophisticated DIP speed variation system, such instances are managed by temporary speed increases in the case of high points and controlled braking in the case of reduced flow, without encountering any particular difficulties. you must however verify that the type of discharge pipe selected is strong enough in low pressure areas (locking gaskets, electro-welded gaskets, etc.). Contact us for further information.
A patented system, does this mean that there are no competitors ?
Not at all ! There are several competitor systems and, as S.I.D.E Industrie is not involved in the tender market, competition between the various companies offering in-line pumping remains diverse and fierce.
I am not comfortable with change, is any technical assistance available ?
Of course ! we provide you with support from the design stage right up to the moment it is put into service, and we provide a 24/7 helpline service free of charge to give users of our systems peace of mind regarding their smooth operation. On request, we also offer subscription to a remote factory service, for those who have GSM-GPRS coverage.
Contact us for more information.
Where is the DIP system manufactured ? Where can I obtain spare parts ?
In France, at the Villemer manufacturing site, south of Paris. All units are inspected, tested and spare parts maintained at each delivery headquarters. Only the motor units from Germany and from USA for NEMA specifications, and the converters from Finland are sourced externally from established partners.
Why a stainless steel tank, they're very expensive ! What are the benefits ?
Between concrete and composites, stainless steel tanks have all the advantages :
• 100% waterproofing achieved though welding the joints of the various elements and the inlet/oulet pipes. Non porous, with no fragile tank adaptors.
• Resistance to external pressure, ground movements, poor backfilling, impacts during installation, and any direct stress caused when pouring the upper concrete slab for underground installations.
• It's ecological, designed with non-oil based products.
• It's economical in terms of weight, for both transport and installation. Will not degrade over time and also enables any furture modifications to be made.
What sort of warranty does the tank have ?
S.I.D.E. Industrie guarantees the Sidinox tanks for 25 years against holes caused by rust.
Isn't there a risk of corrosion caused by soil acidity ?
None at all ! The admissible pH level for contact with the stainless steel from which tanks and connectors are made is much higher than that of the soil (between 4 and 9).
If the unit is on the coast and there's a risk of sea water getting in, what should we do ?
We have a construction model made out of 316L stainless steel, and even one made out of Super Duplex stainless steel with 25% chromium, called "marine grade" stainless steel.
When installing within the water table or at the edge of a body of water, what should you do ?
Use the appropriate concrete ballasting. All tanks are fitted with an extended soleplate and special anchoring holes.
Why do you say "Ready-to-Connect", it's a prefabricated unit, isn't it ?
Ready-to-Connect means that all internal equipment is installed, fixed and ready to operate as soon as the SIDINOX is delivered. You only really need to set up the control cabinet and connect the inlet and outlet pipes and the unattached cables.