Tag Archives: RMI Pressure Systems

RMI Pressure Systems study shows energy savings with VFD-equipped pumps

Environmental, Mining equipment, Mining services, ,

With mines looking to reduce their energy costs and carbon footprint, RMI Pressure Systems has outlined 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 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 company says.

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 RMB1.5 million (over $205,000) would result from upgrading from a full fixed speed to a full VFD system; over 15 years, this would amount to over RMB22 million (over $3 million).

The study also pointed to energy cost savings of over 10% when comparing the full fixed speed with 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%, RMI claimed.

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.

RMI Pressure Systems selecting winning pump formula at US longwall coal mines

Coal technology, Mining equipment, , , , , , , , , , ,

RMI Pressure Systems says it is making a name for itself in the US mining market, having supplied reciprocal pump solutions to leading players in the 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 Blue Creek longwall mine near Brookwood, Alabama, RMI is providing its 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 (pictured),” Punton said. “The manufacture, assembly and testing of two pump systems is planned for completion by end of the fourth (December) 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 program for the miner’s 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.

“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,” Punton said.

He highlighted that the Quinmax S500 pump at Arconic – fitted with 650 hp (485 kW) 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 to validate our pumps’ performance and reliability, as well as computational fluid dynamics to maximise the efficiency of wetted components,” he explained.

RMI on testing mining pump reliability

Mining equipment, Mining services, Water management, , , ,

Mines and industry rely on critical high pressure pump technology to keep operations safe and efficient, which makes rigorous testing of this equipment an essential part of the manufacturing process.

According to Kathryn Poke, Director of Engineering at RMI Pressure Systems, dedicated test cells in the company’s Manchester (UK) production facility support a range of technical tests to ensure final product quality.

RMI Pressure Systems specialises in the design, manufacture and application of high-pressure reciprocating pumps to global longwall mining and industrial applications. It has more than a hundred years of experience designing, manufacturing and supporting this technology, the company says. On top of a primary manufacturing facility in the UK, the company has operations in China, the US, India and Australia – supporting equipment in countries around the globe.

Poke said RMI Pressure Systems’ quality and testing regime means new equipment and components can be put through as much as two million pump cycles – over periods of up to 160 hours – to prove their integrity.

“In robust and continuous applications, such as longwall coal mining, our customers rely on our high-pressure reciprocating pumps to deliver optimal uptime and safety,” she said. “Similarly, our steel industry customers look for quality and reliability in de-scaling and forging applications.”

In these demanding and often hazardous environments, pump pressures can reach 350 to 400 bar – making any leaks or defects potentially disastrous.

She highlighted that RMI Pressure Systems’ meticulous testing regime has been critical in building the company’s quality reputation for over a century.

“Before delivery, all of our equipment is put through its paces in our test cells,” Poke explained. “These well-resourced facilities measure and record temperatures, pressures, speeds and other indicators – generating data that is carefully reviewed and analysed by our engineering team.”

The test cells run alongside the company’s manufacturing processes, which are accredited in terms ISO9001 quality standards. This ensures extended periods of testing do not compromise RMI’s production rates, with the test facility able to accommodate three RMI high pressure pumps at a time.

“This means that our customers are confident RMI equipment is ready to go when it is installed and commissioned on site,” Poke said. “There is no run-in time or bedding down to be done, so the pumps’ contribution to productivity and uptime will be immediate.”

RMI’s manufacturing quality is enhanced by its careful selection of suppliers and components – items that are also subject to cycle testing to ensure a quality finished product.

RMI Pressure Systems promotes Zhang to China aftermarkets sales role

Mining people, Water management, ,

High pressure reciprocating pump specialist RMI Pressure Systems has promoted Sabrina Zhang to the role of Director for Aftermarket Sales, Services and RMI Operations in China.

Zhang has been with Armstrong – RMI’s holding company – since 2013 and previously held the role of Senior Manager for Commercial & Aftermarket. In her new role, she will be developing RMI’s aftermarket sales and services in China, including new and rebuilt pumps, part sales and service contracts. She will also be growing the company’s field technical services, proposal generation and service execution – while coordinating with business functions such as supply chain, procurement and engineering.

“For more than 30 years, RMI has been a leader in producing premium quality emulsion pump stations and water pump stations for underground mining applications in China,” she remarked. “We are proud of being a well-known brand in China with a top-class reputation.”

She is confident that RMI will continue to satisfy existing customers and win more business, despite strong competition from local pump manufacturers in recent years.

“Customers value our quick lead times in product supply, combined with our professional upgrade and overhaul services, as well as our prompt field support response,” she said. “Importantly, our team is also implementing exciting localisation strategies to further improve our service to the market in China.”

Zhang will report directly to Joe Keenan, RMI Pressure Systems’ Global Managing Director for Industrial Fluid Flow Solutions.