The SABS, in conjunction with KSB Pumps and Valves, has tested a massive V16 diesel motor, which produces 1 350 kW of raw power, one of the most impressive pump sets to be assembled on South African soil in recent times.
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Because of the critical nature of an application required to suppress toxic gases in an emergency, engineers took the unusual step of pre-testing the complete pump set to ensure the unit performed exactly as required. In this instance, even KSB’s own world-class testing facilities in Germiston were deemed too small to deal with the size and power of the set, which required the use of the SABS’ larger facilities in Pretoria.
KSB contract manager, Geoff Havenga, explained the set – comprising heavyweight KSB RDLO 400-935 A pump, V16 Quad-Turbo Mitsubishi motor and David Brown-manufactured gearbox – was part of Sasol’s Natref Hydrofluoric Acid Cloud Mitigation project and was required to rapidly produce spray water to ‘knock down’ any gas cloud that might form in an emergency spill. As a result, the pump set needed to be ultra-reliable and ready to spark into action in an instant to pump approximately 770 litres of water per second at a head pressure of 13 Bar.
“The test was unusual in that components are usually tested individually and again on commissioning. This time, however, the units were tested separately, the pump in Germany pre its delivery to South Africa, the diesel engine by Mitsubishi in France and the gearbox by David Brown in Benoni. Owing to the nature of the project, further tests were required of the entire unit including capacity, head, power, efficiency and net positive suction of the pump to ensure further conformity with specifications,” said KSB’s test field manager, Norman Taylor.
“KSB usually performs these tests on its own equipment, but this time the size of the motor was a limiting factor and required us to use the SABS facility. Here, testing was done under the supervision of the customer, KSB and SABS personnel. The process ran for four hours before successfully meeting all specifications and requirements.
“These kinds of string tests are done to ensure the entire unit works correctly, taking into account the diesel motor is required to produce 1 015 kW of power to handle the required absorb-power necessary to produce the 2 800 m³ of water needed per hour. You can only imagine the forces at play when you consider this power is generated at 1 500 rpm and reduced through a reduction gearbox to 1 000, which is the optimum range of the KSB RDLO 400-935 A pump,” adds Taylor.
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Havenga continues, “With the unit weighing in at 32 tons, it is impressive that we have facilities in South Africa where our customers can witness the performance of the equipment they have purchased; in this instance by Worley Consulting Engineers on behalf of Sasol.
“The pump is operated in high volume applications in raw and potable water industries and is capable of reliably pumping high volumes on a continual basis. Well known for its reliable operation, it was deemed as ideal for this critical operation,” Havenga concludes.
