Overview
Faced with a complex challenge on the HS2 project, the client required a bespoke solution for pumping bentonite across various points on the site. They needed amid-range pump capable of high flow rates at low running pressures to handlethe long distances involved, all while maintaining system integrity. Afterapproaching EuroFlo Fluid Handling, the two teams collaborated to createa tailored solution using Grindex Matador submersible pumps, which not only met the specific requirements but also provided numerous operational benefits.
The Challenge
Theclient's existing setup used diesel surface-mounted pumps that required constant monitoring and refuelling, had a large footprint, and posed significant operational inefficiencies. Their primary challenge was to find a pump solution that could recirculate, mix, and distribute bentonite through10-bar rated Bauer-style pipework, ensuring the system would remain intact even if flow was reduced to zero.
Furthermore,they needed pumps with high flow rates and low pressure to manage the long distances and prevent pipe bursts. Another key consideration was the wear on the equipment caused by recycling bentonite, which posed concerns for the longevity and reliability of the system.
The EuroFlo Solution
EuroFlo worked closely with the client to design a custom solution using Grindex Matador submersible pumps mounted on bespoke stands with special fittings, allowing them to be used without submersion in bentonite. Additional features included:
- Flushing Points: Installed to keep the pumps clean when not in use, significantly reducing downtime for cleaning.
- Variable Speed Drives: These were introduced to regulate the pump speeds, optimising performance across different sections of the site.
- Energy Efficiency: The custom design reduced the motor size from 30kW to 18kW, resulting in considerable energysavings.
Throughtrials, it was confirmed that the pumps could handle the unique requirements of the project while offering a more efficient, lower-maintenance alternative to the diesel surface-mounted pumps.
Results and Benefits
- Reduced Footprint and Maintenance:
The submersible design and compact footprint of the pumps significantly reduced the space required, while the fully encased units meant minimal maintenance was needed throughout the 6-month trial period. The pumps also proved to be low maintenance even when handling abrasive materials like bentonite. - Improved Efficiency:
By using variable speed drives and optimising the motor size, energy consumption was dramatically reduced. The pumps performed exceptionally well, with a higher pumping head than the previous diesel alternatives, allowing for greater reach across the site. - Simplified Operations:
The ability to flush the pumps easily when not in use improved operational ease. The risk of wear due to recycled bentonite was also far lower than expected, with minimal degradation over the trial period. - Environmental Benefits:
The replacement of diesel pumps with electric submersible pumps removed the need for constant refuelling and monitoring, contributing to the project's environmental goals by reducing reliance on fossil fuels. - Customisation and Support:
EuroFlo provided full customisation to meet the project’s specific needs at every stage, from modifying pump stands to adjusting speed settings. The customer reported high satisfaction with the ongoing support and collaboration, noting that feedback was incorporated throughout the project to deliver the best possible outcome.
Customer Testimonial
"On approaching EuroFlo with an alternative solution to our pumpneeds, we developed a bespoke solution using their Grindex Matador submersible pumps. The customised stands, special fittings, and flushing points all allowed us to use the pumps without submersion in bentonite, and the variable speed drives gave us the flexibility we needed. Overall, the solution reduced our footprint, improved efficiency, and eliminated the need for diesel pumps. I would recommend EuroFlo's pumps to others and have already taken on several more for different applications."
– Steve Wilson, BKJV Superintendent
Future Plans
Aftera successful six-month trial, the client has since purchased additional unitsand is looking at expanding the use of EuroFlo's pumps across different applications. With their endorsement, they have also referred others to EuroFlo, further solidifying the partnership.
Conclusion
The bespoke solution provided by EuroFlo Fluid Handling demonstrates how customisation and collaboration can lead to significant operational and environmental benefits in complex infrastructure projects. By focusing on efficiency, reliability, and reducing the carbon footprint, EuroFlo has successfully supported the client’s specific application needs, leading to continued use and future expansion.
