Case Study: Bespoke Pump Solution for HS2 Project
Over view
On the HS2 project, the client required a custom pump solution to mix, recirculate, and distribute bentonite across various points on site. The solution needed to maintain high flow rates at low pressures over long distances, while ensuring system integrity. EuroFlo Fluid Handling collaborated with the client to create a tailored solution using Grindex Matador submersible pumps, delivering operational improvements and making a significant contribution to carbon reduction by eliminating the reliance on diesel-powered pumps and achieving zero emissions.
The Challenge
The client’s original setup relied on a combination of diesel surface-mounted and large 30kw electric pumps, which required constant monitoring and refuelling, occupied excessive space, and introduced operational inefficiencies. In addition to concerns about increased carbon emissions from diesel use, the client needed a solution that could handle bentonite circulation efficiently through 10-bar rated Bauer-style pipework without the risk of bursting, while also managing long distances and minimizing wear from bentonite recycling. Their goal was to not only improve operational efficiency but also significantly reduce the project’s carbon footprint.
The EuroFlo Solution
EuroFlo worked closely with the client to design a custom solution using Grindex Matador submersible pumps mounted on bespoke stands with special fittings, allowing them to be used without submersion in bentonite. Additional features included:
Flushing Points: Installed to keep the pumps clean when not in use, significantly reducing downtime for cleaning.
- Variable Speed Drives: These were introduced to regulate the pump speeds, optimising performance across different sections of the site.
- Energy Efficiency: The custom design reduced the motor size from 30kW to 18kW, resulting in considerable energy savings.
Through trials, it was confirmed that the pumps could handle the unique requirements of the project while offering a more efficient, lower-maintenance alternative to the diesel surface-mounted pumps.
Results and Benefits
1. Reduced Footprint and Maintenance: The submersible design and compact footprint of the pumps significantly reduced the space required, while the fully encased units meant minimal maintenance was needed throughout the 6-month trial period. The pumps also proved to be low maintenance even when handling abrasive materials like bentonite.
2. Improved Efficiency: By using variable speed drives and optimising the motor size, energy consumption was dramatically reduced. The pumps performed exceptionally well, with a higher pumping head than the previous diesel and large electric alternatives, allowing for greater reach across the site.
3. Simplified Operations: The ability to flush the pumps easily when not in use improved operational ease. The risk of wear due to recycled bentonite was also far lower than expected, with minimal degradation over the trial period.
4. Environmental Benefits: The replacement of diesel pumps with electric submersible pumps removed the need for constant refuelling and monitoring, contributing to the project’s environmental goals by reducing reliance on fossil fuels.
5. Customisation and Support: EuroFlo provided full customisation to meet the project’s specific needs at every stage, from modifying pump stands to adjusting speed settings. The customer reported high satisfaction with the ongoing support and collaboration, noting that feedback was incorporated throughout the project to deliver the best possible outcome.
Conclusion
EuroFlo Fluid Handling’s bespoke solution delivered significant operational and environmental benefits for the HS2 project. By focusing on efficiency, reliability, and most importantly, achieving zero emissions through the replacement of diesel with electric pumps, EuroFlo provided a solution that exceeded expectations, leading to continued use and future growth in the partnership.