Delivery of RMI Pressure System’s full fixed speed emulsion systems to a mining customer in China
With mines looking to reduce their energy costs and carbon footprint, RMI Pressure Systems has shown exactly how much can be saved by applying variable frequency drives (VFD) control technology to its pumping systems.
Specialists in high pressure reciprocated pumps, RMI Pressure Systems conducted a comparison between three of its emulsion pump sets at work in two mines in the north of Shaanxi province in China – a country where the company has provided pumping solutions for three decades. While one mine was operating a full fixed speed system (with no VFD) and a full VFD system, the second mine was operating a single VFD system. The energy consumption of these three different systems – full fixed speed, single VFD and full VFD – could therefore be compared directly.
The study showed that an upgrade from full fixed speed to either single VFD or full VFD systems would lead to considerable savings in energy costs – ranging from 10% to 20%. Using data from each mines’ SCADA system, the study considered the on-load time and off-load time of each of four RMI emulsion pumps at each underground mine site, as well as the times during which the pumps were non-operational. During on-load time, flow is sent to the roof supports, while in off-load time the flow is diverted back to the tank – as demand at the roof supports has been satisfied. An average power consumption value was calculated over 15 days for each pump system, which delivers hydraulic fluid power to critical mine roof support infrastructure.
Based on an operating condition of 24 hours a day and 365 days a year, the total kilowatts consumed per year was calculated, as well as the cost of that power – using the current cost per kilowatt of electricity. When comparing the energy consumed by the full fixed speed pumps with that consumed by the full VFD pumps, an energy cost saving of over 20% was revealed.
The study was able to reflect the annual saving, as well as savings over 15 years – the typical life span of an RMI pump – by applying a full VFD to the four emulsion pump system. Over a single year, a saving of almost ¥1,5 million (over US$205,000) would result from upgrading from a full fixed speed to a full VFD system; over 15 years, this would amount to over ¥22 million (over US$3 million).
The study also pointed to energy cost savings of over 10% when comparing the full fixed speed to the single VFD system. Similarly, if a mine upgraded from a single VFD to a full VFD system, the energy saving could be almost 12%.
Apart from the direct energy savings, the RMI VFD control technology facilitates a more sympathetic operation of the pumps by increasing the electrical current gradually as the pump starts up and overcomes inertia. By avoiding pressure spikes that jolt the equipment, VFD control technology can also reduce the maintenance required and extend the life equipment.
These energy-efficient single variable speed pumps from RMI Pressure Systems arrived recently at a mine in China, allowing significant savings in power consumption
Steelmakers worldwide have used reciprocating pumps from RMI Pressure Systems – such as this three-pump system with Quinmax S500 Series pumps – in their descaling operations to significantly reduce energy consumption.
It is turning out to be a busy year for RMI Pressure Systems in the US, with its quality reciprocal pump solutions being supplied to leading players in the minerals sector.
This includes pump systems for underground longwall mines and for industrial press applications in the aluminium segment, according to Gary Punton, RMI’s General Manager in the US. At Warrior Met Coal’s world-class Blue Creek longwall mine near Brookwood, Alabama, RMI is providing its well proven hydraulic power solution for the actuation of self-advancing roof supports.
“The design is based on our popular five-plunger Quinmax S500 high-pressure reciprocating pump,” said Punton. “The manufacture, assembly and testing of two pump systems is planned for completion by end of the fourth quarter of 2024.”
At another of Warrior Met Coal’s operations – Mine 7 East – RMI is supplying new pumps as part of an overhaul and upgrade programme for their ageing S500 units, which were first installed as early as 2011.
“We will be installing new S500 pumps on the pump systems serving the mine’s longwall equipment,” he said. “This is a testament to the longevity and reliability of our equipment, which is well referenced in the mining sector.”
In another recent contract, this time in the industrial space, RMI will be providing an additional S500 pump assembly for a press system at Arconic’s Lafayette facility in Louisiana. Arconic is a leading provider of aluminum sheet, plate and extrusions, as well as architectural products.
“We assembled and tested this S500 pump system in our Jasper facility in Alabama, and shipped it to the customer early this year for commissioning during the third quarter of the year,” said Punton.
He highlighted that the Quinmax S500 pump at Arconic – fitted with 650hp motors – provides a safe and reliable supply of high-pressure water-based fluids for both mining and heavy industrial applications. With its compact horizontal five-plunger design, this innovative pump facilitates increased crank speeds and loading.
“We use finite element analysis (FEA) to validate our pumps’ performance and reliability, as well as computational fluid dynamics (CFD) to maximise the efficiency of wetted components,” he explained.
Using RMI Pressure Systems’ reciprocating pumps for descaling – such as this three-pump system with S-Series Trimax pumps – steel plants have saved so much energy that the investment in the new pump systems pumps can be recouped within three years.
With energy efficiencies of up to 95%, reciprocating pumps from RMI Pressure Systems – such as this three-pump system with S-Series Quinmax pumps – deliver considerable savings in operating costs for steel plants’ descaling operations.
RMI Pressure Systems appointed Corey Ulrich as sales manager for North America
RMI Pressure Systems is focused on working with its industrial customers to implement optimal pump solutions
According to Joe Keenan, Global Managing Director for Industrial Fluid Flow Solutions at RMI Pressure Systems, the appointment will support the company’s ongoing growth in mining and industrial segments in the US and Canada.
“It is exciting to have Corey on board at this time, as we actively explore new markets and evolve our innovative product line-up for growth,” said Keenan. “His depth of experience and his customer service orientation is a great fit with our organisation and our ambitious plans.”
Part of the 1,200-strong international firm Armstrong Fluid Technology, RMI has a heritage in its field dating back over a century. RMI’s global presence includes wholly owned operations in the United Kingdom, China, United States and Australia; Corey will be based out of RMI’s Jasper facility in Alabama.
“Reporting to Gary Punton, our General Manager for RMI in the US, Corey will be vital resource in expanding our market position through vertical markets and potential new segments,” Keenan said. “I also look forward to his contribution in helping develop our exciting product range, including conceptual designs, component selection, prototype production, testing and certification.”
He highlighted that RMI focused on working with its industrial customers to implement optimal pumps solutions that support global sustainability goals. At the same time, it works to keep aging facilities operating – with upgrading wherever necessary – to reduce the total cost of ownership.
“Working from this strategic position, Corey will assist our customers in these industries to select the best pumps for their operations, while also ensuring the best ways to align their operations to international standards,” he explained. These benchmarks include the ISO 9001 quality standards, ISO 14001 environmental management standards, and any other national standards relevant to customer projects.
High pressure reciprocating pump specialist RMI Pump Systems has recently completed two comprehensive equipment overhauls and upgrades locally for mining customers in China.
According to Sabrina Zhang, General Manager of RMI China, a full system upgrade was just delivered to Shennan Industry’s Xiaobaodang mine, which comprised an Grade B overhaul. The system included RMI’s Quinmax emulsion pump station, Trimax water pump station and a control system. The second contract – for the Hanglaiwan mine in Shaanxi Province of China –included multiple pumps and related equipment.
Both upgrades were conducted in RMI’s MA-accredited factory and workshop in Shanghai. There have been two RMI emulsion/water systems in operation at Hanglaiwan mine, with the upgraded system having been initially installed at the mine in 2021.
According to Zhang, RMI conducted Grade A and B upgrades for Hanglaiwan on five of RMI’s Quinmax pumps, three of its S300 water pumps and one S300 high set. This followed a complete strip-down and assessment at RMI’s Shanghai facility.
“Our innovative maintenance schedules help customers to improve performance and reliability,” said Zhang. “Over a typical six-year cycle, RMI recommends three different grades of overhauls or upgrades.”
While the Grade A intervention is recommended at the end of the first and second years, the Grade B upgrade is recommended after three years – and comprises a full rebuild. Over the following two years, Grade A upgrades should again be conducted, with a Grade C upgrade – also an intensive rebuild – after the sixth year.
“Adhering to our tried-and-tested overhaul and upgrade methodology, customers can ensure that their pump systems operate consistently at peak performance,” she said.
Both contracts included the overhauling of the system’s control units. RMI’s in-house control engineer repairs the control units, and works in collaboration with subcontractors to service the MMS control boards, power units, display units, etc.
After the completion of the upgrade, the equipment was dispatched in the last week of April to the mine. The units are to be transported by 17 m truck over a distance of almost 1,700 km to the mine site.
RMI, which has been designing, manufacturing and supporting its high pressure and high volume fluid pumping stations for over a century, has served the mining sector in China for more than 30 years. The company’s certified manufacturing facility in Shanghai – owned by RMI’s holding company Armstrong Fluid Technologies – can produce and service 15 different models of high pressure pump, said Zhang. The facility has also enhanced the local availability of RMI’s genuine spare parts.
“This gives our customers in China fast access to our components – which is a cornerstone of our localisation strategy in China,” she said. “In times of emergency, parts can now be delivered to customers as quickly as three to four days. We also have technical service centres close to the main mining areas, allowing technical service engineers to reach customers within two hours.”
With the sustainability message coming through strongly once again at the recent METEC International Metallurgical Trade Fair in Düsseldorf, Germany, the steel sector continues to display confidence and pride in its key role as a driver of sustainable economic growth.
Sean Heary – Global Sales Manager, Mining and Industrial
RMI Pressure Systems’ Sean Heary was at the event, and highlighted the progress being made in developing and applying technologies that reduce the consumption of finite resources and the emission of greenhouse gases. As RMI’s, Global Sales Manager, Mining and Industrial, Heary said METEC is a valuable opportunity to meet likeminded customers and suppliers, and to contribute towards the metallurgical industry’s strategic sustainability goals.
“RMI’s century of experience in designing and manufacturing high pressure reciprocating pumps has allowed our customers to reduce their carbon footprints,” he explained. “Reciprocating pumps are energy-efficient and water-efficient at high pressures, and there are also smart components and controls that can be added to further economise on energy consumption.”
With touchpoints in the steel sector such as the descaling processes of hot rolling mills and the pressurised lubrication of hydrostatic bearings in roughing mill stands, RMI has a global spread of installations supported by local service infrastructure in key markets. The company’s manufacturing hub in Manchester, England, includes an in-house research and development capability to drive continuous innovation of its products and solutions. RMI has operations in the UK, Europe, US, China, India and Australia.
“Generating pressures as high as 350-400 bar, RMI pumps play a vital role in hydromechanical descaling, ensuring that our customers achieve the best possible prices for their steel products,” he said. “Our technology allows this kind of work to be done as efficiently as possible – conserving the use of both energy and water – while delivering optimal performance, reliability and life-span.”
Other contributions that RMI pumps are making on the environmental front include their use in the high pressure washing of air preheat heat exchangers and flue gas desulphurisation units at thermal power stations. The latter, in particular, is used to scale acid rain causing sulphur from flue gas before it is discharged into the atmosphere. RMI’s bespoke design high pressure wash units allow for the safe and efficient cleaning of these critical pieces of equipment, to allow power plants to remain highly productive and within regulation.
Platforms like the METEC exhibition provide the opportunity to engage personally with existing and prospective customers, said Heary, building relationships and sharing information about the latest technology developments. He noted that METEC was also a useful forum to meet new suppliers, which was important in growing a robust and cost-effective supply chain, especially as RMI looks to engage more local supply partners in its business.
With its modern workshop and assembly facilities in Shanghai, RMI Pressure Systems ensures customers in China of OEM-standard upgrades, commonly referred to as overhauls in the Chinese market – with an extensive stockholding of genuine spare parts to allow quick turnaround times.
Sabrina Zhang, Director for Aftermarket Sales, Services and RMI Operations in China, said that the company’s MA-certified facility was a vital part of RMI’s localisation strategy. The facility can conduct full strip-down and rebuild services, with upgraded spares and components adding wherever possible to the performance and lifespan of RMI high pressure reciprocal pumps.
She emphasised that RMI is continuously improving its components, so that customer’s pump systems can be fitted with the latest technology and material during routine maintenance. This turns a regular overhaul into an actual upgrade – contributing to product quality and longevity.
Continuous component improvements by RMI lead to routine maintenance becoming a genuine upgrade for enhanced product quality and longevity
Legacy
RMI’s Shanghai facility excels in full strip-down and rebuild services, enhancing performance and lifespan of high-pressure pumps
“With our legacy of over 30 years of supplying and supporting our pump stations in China’s underground mines, our brand has a strong reputation locally,” she explained. “Our Shanghai facility further enhances our upgrade and spares offering, ensuring uptime and productivity.”
The history of RMI goes back over a century, giving the company a unique depth of expertise in pump technology. This has allowed the company to develop innovative maintenance schedules to improve performance and reliability. Over a typical six-year cycle, RMI recommends three different grades of overhauls or upgrades: A, B and C.
“Grade A is the intervention that we recommend at the end of the first and second years, which usually aligns with the annual completion of a longwall panel,” she said. “This involves the replacement of various wet end parts, and this can be done underground, without needing to move the pump system to surface.”
Spare part kits
The consumable components that need replacing at this stage include lubrication oils, filter elements, seals, O-rings and packing. Valve chest springs, ceramic rams and unloading valve cartridges are also among the parts replaced. RMI streamlines the maintenance process by making all relevant spare parts available in dedicated kits – each designed to contain everything necessary for the specific grade of overhaul.
At the end of the third year, a Grade B upgrade is recommended, which comprises a full rebuild. This can be conducted in-house by those customers who have their own maintenance facilities and skills; alternatively, RMI undertakes this upgrade at its own workshop. RMI pump stations are delivered with training materials and detailed product manuals for owners who can conduct rebuilds in-house. Additional components replaced at this stage include con rods, ram holders and the oil pump.
“This first rebuild allows our pump systems to operate consistently at peak performance, and we then recommend annual Grade A upgrades again for the following two years,” said Zhang. “This takes the system into its sixth year, at the end of which we recommend a Grade C upgrade – also an intensive rebuild.”
Service exchange
Similar to Grade B, the Grade C intervention also includes additional aspects such as replacing the pump module and the oil cooler assembly. She highlighted that RMI can provide customers with a service exchange offering – which is particularly valuable for those customers who do not have their own replacement units. To ensure minimal downtime, RMI designs and manufactures an identical pump for the customer, ready for installation when their existing unit is removed for a rebuild.
“This saves time, and allows operations to continue without undue disruption,” she said. She noted that customers are aware of the importance of regular maintenance interventions, and are open to the advice provided by RMI’s experienced technical service engineers – who visit customer sites to track machine condition and performance.
“Our service engineers produce a detailed report after each visit, including feedback on any aspects that may need attention in the near future,” she said.
Maintenance agreements
To make full use of RMI’s support in China, some mines have signed long-term overhaul agreements for a three-year period, she noted. The arrangement means that RMI collects a customer’s pumping system from the mine and transports it to the Shanghai workshop for a full strip-down and rebuild. The customer is involved in the process, to consider the results of a technical inspection and choose between an overhaul or replacement. RMI then conducts the Grade A servicing on site after each longwall panel is completed.
“This ensures the customer of high levels of reliability and uptime for better productivity, while also controlling their capital and maintenance costs in advance,” said Zhang.
The local availability of RMI’s genuine spare parts has been considerably enhanced by the Shanghai facility, she pointed out. Quick access to components has been a cornerstone of RMI’s strategy in China, and urgent parts can now be delivered to customers within three to four days. The company’s technical service centres, located close to main mining areas, allow technical service engineers to reach customers within two hours. There are also key consumables stored at the service centres for immediate access.
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