Stainless Steel Awards 2008

Innovation Category

Winner : Hazleton Pumps
Product: High voltage flameproof submersible pump

Hazleton Pumps has earned this year’s Innovation Award at the Stainless Steel Awards for a world-first in pump technology. Hazleton’s Hippo High Voltage Flameproof Submersible Pump is the answer to the mining industry’s need for a submersible pump that operates using a high voltage power supply and is able to pump liquids that contain solids. The Hippo’s effectiveness has piqued international interest and is a testament to the excellence of South African engineering and design.

Flooding is a major problem in the mining industry as it causes unsafe working conditions and loss of production. Twelve hours of downtime can cost a mine up to R3 million. The availability of a pump that is capable of pumping large amounts of acidic liquids quickly, while being totally submerged, would radically reduce downtime and safety risks. The available submersible pumps were unable to solve the flooding problem; in addition to only operating on low voltage power supplies (525v), they cannot pump liquids containing acid, and solid particles. The Hippo, which was manufactured in collaboration with Alstom Motors, is able to pump large volumes of acidic liquids containing solids, on a power supply of 1 100 volts, at a rate of 1 200 litres per second. The pump was designed be used in harsh, corrosive environments. The manufacturers discovered that a stainless steel alloy (CD-4MCu) could withstand the corrosion and wear that occurs when pumping most acidic slurries. As a result, all pump parts that come into contact with acidic water are made from CD-4MCu duplex stainless steel.

After the first Hippo pump was successfully put into service at Maroela Platinum Mine in 2005, two pumps were exported to Canada in 2006. Hazleton is currently processing an order for a pump to be sent to the Oil Sands region in Alberta, Canada; the second largest oil reserve in the world. There, the pump will be used to pump corrosive sand slurry.

The benefits of the Hippo High Voltage Flameproof Submersible Pump are explicitly stated in the products impressive name. Firstly, the Hippo operates on a high voltage power supply (1100v), which is readily available in most mines. This reduces the size of the pump and eliminates the need for the expensive electrical equipment necessary when low voltage pumps are used.

Secondly, since the pump is likely to be submerged in potentially explosive locations, the Hippo is required to comply with international flameproof requirements.

The pump’s housing compartment was rigorously tested at the SABS explosion proof department to ensure that it complies with these requirements. This means that the Hippo is safe to use in environments that contain methane gas and acidic liquids. Thirdly, the pump can be totally submerged in the product that it is required to pump. Plunging high voltage equipment into liquid is a potentially dangerous exercise. To prevent liquid from entering the pump’s electric machinery a double shaft sealing system in parallel is used. If the first sealing system is compromised, an alarm is activated and the pump is removed before the second sealing system fails. The Hippo is operated using an electrical control panel, which is located at a safe site, kilometres away from the volatile pumping location. The Hippo can also serve to reduce the environmental damage caused by mines. Many coal mines channel their run-off acidic water into dams, where the water is allowed to evaporate. Heavy rainfall may cause these dams to overflow and this would result in ground and river pollution.

The Hippo can be used to pump this acidic water to a safer location. The Hippo is an environmentally responsible product. All parts are reusable and no harmful substances are used in the manufacturing process. Considerable thought towards safety was incorporated into the design of the Hippo pump. In addition to meeting international flameproof requirements, the pump has been fitted with sensors which act as an early warning system should vital components be compromised. Temperature and vibration monitors have been fitted to the pump bearings and electric windings. In the event that any of these components overheat, the power supply to the pump will be automatically cut off. The housing, which encloses the windings, is filled with oil and the oil acts as a coolant. This also allows the pump to run dry without incurring damage.

The pump must be easily moved from one location to the next. To facilitate mobility, the manufacturers have designed the pump to be self-supporting and they have fitted the structure with eyebolts so that it can be easily moved using a crane. Like the semi-aquatic mammal that it is named after, the Hippo High Voltage Submersible Pump has proved to be rugged and strong. Hazleton Pump’s attention to detail during the design process has resulted in an innovative product that perfectly meets its market’s needs.