Product brochure - Wilo-EMUport solids separation system

Wilo-EMUport solids separation system.
Product brochure.

2
Pumpen Intelligenz.

Wilo is synonymous throughout the
world with the tradition of first-class
German engineering. Wilo pumps and
systems set new standards in terms
of technical performance and
efficiency for municipal water and
sewage management. Sewage
disposal currently plays a major
role with regard to protection of the
environment and maintenance of
resources. Continuous challenges
such as increasing solid contents
in sewage, which hinder operating
conditions for systems, require
new and innovative solutions to
constantly improve the processes
and the corresponding products.
One innovation in the field of sewage
disposal is the Wilo-EMUport solids
separation system. The solids separation
system is distinguished from
conventional sewage disposal systems
by its energy efficient function,
extremely durable, corrosionresistant
PE-HD components and
low life cycle costs. Far-sighted?
We call it Pumpen Intelligenz.
3

4
Intelligent sewage disposal.
2
1
3
4

1 2
Wilo-DrainLift
M 2/8
Wilo-DrainLift
FTS MG 750
3
5
Wilo-EMUport FTS FS
with PE-HD sump
4
Wilo-EMUport FTS FG
in fixed structures
5
Wilo-DrainLift
WS 830
5

Pumping stations – an overview.
Solids separation system –
The premium solution for sewage pumping.
Wilo provides the right solution for all
your sewage disposal requirements.
Based on an extensive product range,
pumping stations can be individually
planned and assembled. Whether in
a prefabricated, concrete or plastic
sump – Wilo will work out the most
economic solution for you.
Wet well installation
With wet well installation, costs are
saved above all by the simple construction.
The pumps stand directly
in the sewage and can be assembled
without having to climb into the sump
by using a self-coupling system.
Dry well installation
With the dry well installation version,
the sewage is collected unfiltered in
a reservoir. The pumps are located
outside the reservoir. This means that
maintenance work on the pumps can
be carried out conveniently without
coming into contact with the sewage.
Dry well installation is suitable for
uncritical sewage with a low solids
content.
Solids separation system
This innovative Wilo technology
separates the solids from the sewage
and holds them back in separate
solids tanks upstream of the pumps.
Only prepurified sewage comes into
direct contact with the pumps on
the way to the combined collection
space. Once the coarse solids have
been eliminated from the sewage
using this technique, the sewage is
transported by the dry well pumps
and pumped out into the collection
tank. On the way to the outgoing
pressure pipeline, the sewage flows
through the solids separation tank,
pressing the solids out into the
pressure pipeline. Sewage and solids
remain in the system. The pumps
remain dry due to their location
outside the tank. This allows
maintenance work on the pumps
to be carried out conveniently and
hygienically.
Wet well installation
• Pumps stand in the fluid
• Usually without operating building
• Cost-effective due to simple
construction
Dry well installation
• Pumps do not stand in the fluid
• Technology accessible at all times
• Simple and hygienic maintenance
Solids separation system
• Pumps do not stand in the fluid
• Unrestricted function thanks to
double-pump station
• Optimised plugging immunity
• Maximum level of hygiene
7

The Wilo-EMUport solids separation system.
Innovative technology for cost-cutting
operation.
From a technological and economical
viewpoint, completely preassembled
pumping stations with Wilo-EMUport
solids separation systems are the best
choice for drainage for entire localities
or larger industrial and commercial
complexes via conventional gravityflow
drainage systems.
Economical:
Thanks to their small free ball passage.
Since only prepurified sewage without
coarse solids flows through the pump
hydraulics, the free ball passage of
the pumps can be designed to be
considerably smaller than in traditional
systems, so that the pumps are significantly
more efficient. This leads to
significant savings on energy and thus
on operating costs.
Operational reliability:
Thanks to optimised plugging immunity
The solids are held back in the solids
separation tank and pumped directly
into the pressure pipeline during each
pumping sequence, without coming
directly into contact with the pump.
This prevents plugging and immensely
increases realiability and operational
safety. Since the inside of the pump
is protected from contact with coarse
solids, its service life is also significantly
prolonged. The result: fewer breakdowns
and less servicing, and much
more efficient operation.
Long service life:
Thanks to PE-HD components
Wilo-EMUport products have to
function reliably for long periods of
time under difficult environmental
influences. This can only be achieved
by using high-quality materials. For
this reason, a large proportion of the
material is made of polyethylene
(PE-HD) which, according to a study in
the city of Göttingen, has a resistance
of approx. 70–100 years. The material
is made exclusively of hydrogen and
carbon, and contains non-poisonous
colourings. For manufacturing and
processing, PE-HD is completely
environmentally friendly and can be
recycled up to seven times without
suffering a reduction in quality.
Easy to maintain:
Thanks to dry well installation.
The pumps are always dry and clean.
This makes maintenance much more
pleasant, hygienic and efficient, as all
of the mechanical components can be
accessed quickly and easily from the
outside.
"Non-stop“:
Thanks to individual blocking
The Wilo-EMUport solids separation
system is a double-pump station
which uses two pumps in alternation.
Each pump is assigned its own solids
separation tank which can be individually
blocked off. This means there
are no interruptions to operation
during maintenance and repair work.
Economical
• More efficient due to smaller pump
free ball passages
• Increased pump service life
• Non-stop operation due to individual
blocking
Long service life
• 10-year guarantee on all PE-HD
components
• Environmentally-friendly material,
corrosion-resistant and recyclable
Operational reliability and easy maintenance
• Optimised plugging immunity
• Dry, clean and odour-free
• Hygienic assembly and maintenance
conditions
9

10
Schematic diagram of function.
1
2
Pump ON Pump OFF
3
4
4
5
8
I 6
II
I
II
Pumping sequence
Filling sequence
1
2
3
4
5
6
7
8
7
Inlet
Distribution tank
Shut-off ball
Separation flaps
Solids separation tank
Collection reservoir
Pressure pipeline
Ventilation and exhaust

Function of the Wilo-EMUport solids
separation system.
Technology that sets standards.
With the solids separation system,
the inflowing sewage flows into the
distribution tank and from there into
the open solids separation tank.
The solids are kept back here. Only
prepurified sewage is now able to
pass through the pump into the large,
combined collection reservoir.
While the collection reservoir is filled,
the water level in the solids separation
tank rises. The shut-off ball automatically
closes the inlet.
Now, pumping starts when the correct
level has been reached. The pump
pumps in the reverse direction.
The sewage flows through the solids
separation tank and thus conveys the
"filtered-out" solids into the outgoing
pressure pipe.
Then, the entire solids separation system
is flushed and cleaned. Pumping is
stopped again when the correct level
has been reached. The shut-off ball
drops, leaving the path free for a new
filling sequence. During this pumping
sequence, the sewage is pumped into
the other solids separation tank.
Advantages of the solids separation
system:
• Uses pumps with free ball passage
< 80 mm, thus reducing fuel requirements
and operating costs while
increasing efficiency
• Hygienic conditions for maintenance
and assembly work
• Pump room is dry, clean and odourless
• Less wear, since the solids are not
pumped by the hydraulic unit
• Submersible sewage pump with
adjusted impeller and protection
class IP 68 (submersible)
• No corrosion problems, no effect
from the formation of hydrogen
sulphide
Filling process
• Inflowing sewage flows into the solids
separation reservoir
• Solids are held back
• Prepurified sewage continues into the
combined collection reservoir
Reservoir filled
• Collection reservoir filled
• Shut-off ball automatically closes the
inlet
• Pumping sequence begins
Pumping sequence
• Pump pumps in the reverse direction
• Sewage flows through the solids
separation tank, pumping the solids
into the outgoing pressure pipeline
11

12
Intelligent energy cost saving.
Maximum efficiency.
Energy costs [€]
700.000
600.000
500.000
400.000
300.000
200.000
Example
Sewage pumping station in Lauter,
Germany
2
100.000
1
2
0
0 1 2 3 4 5 6 7 8 9 10
Years
Conventional
dry well installation
with free ball passage 100 mm
Up to
€ 87,310.00 Euro*
in 10 years.
Conventional
dry well installation
with free ball passage 80 mm
dry well installation
with 100 mm free ball passage
dry well installation
with 80 mm free ball passage
solids separation system
profit zone
solids separation system
vs. dry well installation
with 100 mm free ball passage
profit zone
solids separation system
vs. dry well installation
with 80 mm free ball passage
1
payback time**
solids separation system
vs. dry well installation
with 100 mm free ball passage
payback time**
solids separation system
vs. dry well installation
with 80 mm free ball passage
**for additional investment
needs
Pumping station
with solids separation system
with free ball passage 50 mm
Wilo-EMU sewage pump type FA 30.78 D FA 20.98 D FA 15.99 D
Impeller type Multi-channel impeller Multi-channel impeller Multi-channel impeller
Free ball passage of pump type [mm] 100 80 50
Power requirements at duty point P1 [kW] 110 98 87
Annual energy costs [€] 41,756.00 37,201.00 33,025.00
Extra energy costs [%]
compared to solids separation system
26% 13%
*At an energy cost of 0.13 €/kWh (actual energy costs without basic fees, charged according to the specified rated power)
Please note that maintenance costs are the same for all systems. However, pump wear is much lower for the solids separation system.

Amortisation and life cycle costs.
Long-term economic efficiency.
Maximum efficiency.
How economical a pumping station
actually is can only be seen when
all additional costs are considered.
Investment costs alone are only the
tip of the iceberg. Much more decisive
are the life cycle costs that arise during
a long pump life.
Only solids separation systems can use
pumps with small free ball passages
which lead to a higher degree of
efficiency and lower energy costs.
The example calculations for the
pumping station in Lauter, in the
German Ore Mountains, show the
enormous savings which are possible.
Renew your pumping station.
With the retrofit system, Wilo offers
you the most economical solution for
reconstructing old pumping stations.
Our experienced employees take the
exact dimension of the existing
installation on site, including all inlets
and pipe outlets. This data can then
be used together with individual
customer requirements to plan and
produce a new pumping station
together with all the necessary
equipment.
Once the old installation has been
dismantled, a new base is constructed
using sand and concrete. The new
Wilo-EMUport pumping station is
then inserted into the base. Next,
the connections are re-established,
meaning the new system can usually
be commissioned the same day, before
any necessary filling and surface work
is carried out. Using this method, the
amount of sewage which is pumped
out or repumped is restricted to a
minimum, or sometimes eliminated
completely.
Life cycle costs
• LCC analysis is an especially efficient
method for monitoring total costs
• For new systems or also for optimising
existing installations
Reference installation in Lauter, Germany
• Wilo-EMUport pumping station with
solids separation system
• Innovative Wilo technology allows
enormous savings on energy costs –
up to € 87,310 in 10 years
Retrofit system
• Economical renewal of pumping
stations
• Reconstruction in one day
13

Expert support.
From planning to maintenance.
Consulting and planning
Optimum solutions come from
objective-oriented planning. Our
employees are here for you and will
draw up an exact assessment of what
you require. The cheapest duty point
of a pump is the key factor in deciding
whether to install a pumping station
with or without a solids separation
system.
This requires a longitudinal section of
the planned pipe and a decision as to
whether to construct a closed system
without ventilation and exhaust or
half-closed system with ventilation
and exhaust.
If all the basic parameters and planning
data are available, we will make a
hydraulic calculation, contrasting all
the systems in order to find the most
economical solution for you. Using
modern software, we calculate all the
relevant measurements for you such as
delivery head, head loss, volume flow,
flow velocity, Reynolds number etc.,
from the flow calculations in impellers,
housings, inlet constructions and
pressure pipes to pipe calculations.
Installation and assembly
The installation and the complete
assembly for the pumping station are
performed by qualified construction
personnel with many years of experience.
Wilo takes personal supervision
on site as a given, right up to commissioning.
Wilo customer service
At Wilo, we have a long tradition of
customer support. A major component
of our partnership philosophy is our
own customer service, which is unique
in the market.
52 Wilo customer service technicians
are available with their practical
support 365 days a year, all across
Germany. In addition, we have all
common spare parts in stock and
we are able to deliver within 24 hours,
if required.
Consulting and planning
• Individual planning and configuration
Installation and assembly
• Expert installation and assembly of all
system parts in co-operation with the
customer on-site
Wilo customer service
• Maintenance of the solids separation
system and switching systems by Wilo
customer service
15

Technology and service.
From system technology to accessories.
Pumping stations from Wilo can be
reconfigured to meet individual
requirements on their processing and
performance functions. We produce
within a standard programm:
from the mini-system for the smallest
volumes (inlet pipes up to 10 m³/h) to
systems with delivery heads of up to
80 m and inflows of up to 600 m³/h.
What is more, Wilo also supplies
customer-specific switching systems
and operating buildings.
Submersible sewage pumps
The numerous combinations of fluids
and solids in our sewage place many
different demands on a pump solution.
The Wilo-EMU FA series offers an
extensive portfolio for a wide range
of applications. Through the perfect
combination of modern submersible
motor technology, high-quality
treated hydraulic components and the
solvent-free two-component Ceram
coating, Wilo-EMU sewage pumps
guarantee long-term safe operation –
even for the most demanding fluids.
Switching systems
Modern pumping systems require
electrical/electronic components
to control the mechanical parts such
as the pumps and slide valves. Wilo
supplies customer-specific, preassembled
switching systems and control
systems. The range of functions of the
switching systems and control systems
stretches from simple pump control to
complex remote control systems.
Operating buildings
Large pumps installed in soil often
require an operating structure. Wilo
offers various preassembled operating
buildings. From the size of the structure
to the colour of the roof brick, there
are a wide range of options available
for you to customise your building.
The operating building is delivered by
lorry to the site and placed in its final
position with the aid of a mobile crane.
Sewage pumps
• Operational reliability thanks to
high-quality materials and technical
components
Switching systems
• Standing cabinets for the entire
electrical system
• Safe housing for highly delicate
electronics
• Simple and safe
Operating buildings
• Sturdy design
• Short construction time
• Weathering and break-in protection
17

Usedom – Island of sun.
Reliable sewage disposal –
even in the high season.
About 15 years ago,
work began on the island of Usedom
to renew the sewage system step by
step. For economic reasons, the
supervisory association relied heavily
on pressure drainage. Wilo-EMUport
supplied the pumps stations with
solids separation systems for this
system.
High demands on the sewage structure.
With an area of 373 km² (plus 72 km²
on the Polish side), Usedom, in the
district of Eastern Pomerania, is
Germany's second biggest island.
Although very sparsely populated on
the German side with 31,000 inhabitants
(approx. 83 inhabitants/km²),
its infrastructure needs to meet the
seasonal demands of high numbers
of guests, particularly in summer.
On average, around 40 per cent more
sewage is produced at this time of
year. Measurements of the inflow
amounts in the major treatment
plant in Swinemünde show inflows of
between 3,500 and 4,500 m³ per day
on the German side in the summer
months. Out of season, the figures
are usually 2,500 to 3,000 m³ per day.
Due to this, both the sewer system and
the pumping stations must be designed
to cope with the maximum amount
of sewage. However, the maximum
inflow amount is very hard to calculate,
as the numbers of guests increase year
upon year. In addition to this, the
quantity of sewage also changes
depending on the usage behaviour of
the inhabitants and tourists.
Demanding system planning.
As there are no concrete figures for the
influencing factors, the long-term
measurements recorded at the beginning
of renewal work on the Usedom
sewage system were taken at different
collection points.
This at least gave the association
guideline figures for calculating
the capacity of the systems. These
surveys and the figures on the average
consumption of water per head served
as the basis from which Wilo-EMUport
developed tailor-made solutions for
the pressure drainage on Usedom.
All the pumps stations were individually
planned and designed for the projected
inflow quantities and the calculated
inflow depth. Then, of course, they
were fitted with a Wilo-EMUport solids
separation system.
The large range of Wilo-EMU sewage
pumps from pump specialist WILO SE
allows customers to choose the pump
they need from pumps designed for
the pumping requirements in question.
Transport
• The eighth pumps station leaves the
factory in Minden.
Assembly
• Installing the PE-HD collection
reservoir in the sump
Commissioning
• Checking the system after the first
test run
19

Wilo – International (Subsidiaries)
Argentina
WILO SALMSON
Argentina S.A.
C1295ABI Ciudad
Autónoma de Buenos Aires
T+ 54 11 4361 5929
info@salmson.com.ar
Austria
WILO Pumpen
Österreich GmbH
1230 Wien
T +43 507 507-0
office@wilo.at
Azerbaijan
WILO Caspian LLC
1065 Baku
T +994 12 5962372
info@wilo.az
Belarus
WILO Bel OOO
220035 Minsk
T +375 17 2503393
wilobel@wilo.by
Belgium
WILO SA/NV
1083 Ganshoren
T +32 2 4823333
info@wilo.be
Bulgaria
WILO Bulgaria Ltd.
1125 Sofia
T +359 2 9701970
info@wilo.bg
Canada
WILO Canada Inc.
Calgary, Alberta T2A 5L4
T +1 403 2769456
bill.lowe@wilo-na.com
China
WILO China Ltd.
101300 Beijing
T +86 10 80493900
wilobj@wilo.com.cn
Wilo – International (Representation offices)
Algeria
Bad Ezzouar, Dar El Beida
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Armenia
375001 Yerevan
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info@wilo.am
Croatia
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Denmark
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Estonia
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Finland
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02330 Espoo
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France
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Great Britain
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DE14 2WJ Burton-
Upon-Trent
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sales@wilo.co.uk
Greece
WILO Hellas AG
14569 Anixi (Attika)
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Bosnia and Herzegovina
71000 Sarajevo
T +387 33 714510
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Georgia
0179 Tbilisi
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Subject to technical changes without prior notice.
Hungary
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(Budapest)
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Ireland
WILO Engineering Ltd.
Limerick
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Borromeo (Milano)
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WILO Pumps Ltd.
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Gyeongnam
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Latvia
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Lebanon
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Lebanon
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wsl@cyberia.net.lb
Macedonia
1000 Skopje
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Mexico
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Lithuania
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The Netherlands
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Norway
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0975 Oslo
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Poland
WILO Polska Sp. z.o.o.
05-090 Raszyn
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Portugal
Bombas Wilo-Salmson
Portugal Lda.
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Romania
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077040 Com. Chiajna
Jud. Ilfov
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Russia
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Saudi Arabia
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Riyadh 11465
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Ulaanbaatar
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Serbia and Montenegro
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11000 Beograd
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office@wilo.co.yu
Slovakia
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Slovenia
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South Africa
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salmson.co.za
Spain
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28806 Alcalá de Henares
(Madrid)
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wilo.iberica@wilo.es
Sweden
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35246 Växjö
T +46 470 727600
wilo@wilo.se
Switzerland
EMB Pumpen AG
4310 Rheinfelden
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info@emb-pumpen.ch
Tajikistan
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WILO SE
Nortkirchenstraße 100
44263 Dortmund
Germany
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F +49 231 4102-7363
wilo@wilo.com
www.wilo.com
WILO EMUPORT GmbH
Zechenstr. 54
32429 Minden
Germany
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F +49 571 5055079
info@emuport.de
www.wilo.com
Taiwan
WILO-EMU Taiwan Co. Ltd.
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wiloemutaiwan.com.tw
Turkey
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San. ve Tic. A.S¸.
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Ukraina
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Vietnam
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USA
WILO-EMU USA LLC
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Georgia 31792
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USA
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mike.easterley@
wilo-na.com
Uzbekistan
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info@wilo.uz
June 2009