Site deployed combo of steel and HDPE pipes. There has been constant burst out of pipes due to very tough pipe lay out profile. The ambience at site varies from 5 deg C to almost 52 degree C, leading to material expansion and contraction. Thus constant failure of HDPE joints. needing constant maintenance, stoppage of dewatering as well.

In addition as the pumps were driven by diesel engine, there has been huge diesel fuel operational cost as well client was incurring.

SOLUTION BY RWTPL

Multiple visits by RWTPL closed into conclusion of making proposal which included heavy duty LONG COILED PIPELINE which must be suitable for constant working pressure of 21 Bar even at 50 deg C. To make the installation easy pipe of single long span was selected.
First ever break thru award was achieved when RWTPL was awarded job in 2021. Complete installation was completed within few months. The same is in operation till date without any instant of any failure.

PROJECT TAKEAWAY

Pipes were designed to be installed as an absolute vertical hanging method which is not only challenging but gives over all project benefits as below,

1. Drastically eliminating long pipe travel thru’ bench—— 180 meters of vertically hanging pipe 280 mm size of single length– In total 800 meters have been installed
2. Reduction in overall pumping head thereby saving operational cost
3. Unique nature of these pipe is to maintain low friction loss thru’ out it’s life span. Based on many global site users pipe life can cross decades of operational life.
4. As on 1/04/2025 pipes have been not a single leakage / pipe burst has occurred. Comple elimination of all pipe maintenance activities.

It is evident these pipes have greatly increased reliability of dewatering.

The post 30 Bar crush proof long coiled slurry / mine dewatering pipes in operation appeared first on Rod Wheel Technologies.

Their genuine demand was pumping system must be working non-stop, and asset usable for decades to come with least of maintenance.

DESIGN AND EXECUTION

Upon successful receipt of award entire team at RWTPL kicked into action and finalized various components of this unique pumping system as below.

• Heavy Duty High Head solid handling Mines dewatering pumping system with flow range of 4500 to 5000 GPM
• Vast head range of 95 to 200 meters head driven by custom 1140 HP motor
• Specially designed Solid handling mine dewatering NON SLAM Check Valve and Gate Valve.
• Customized modular Heavy Duty 1340 HP VV-VFD Drive system with climate control customized container, able to work in monsoon rain as well
• 400 meters of long coil PE pipeline with just two joints of high pressure operation and expecting decades of long life
• Custom steel rolled & fabricated, pressure, leak tested Pontoon able to handle dynamic loading up to 40 ton load
• Entire massive pumping system was dispatched within 3 months 10 days which any regular manufacturer may have taken at least 6 to 8m months considering magnitude of works involved

EXECUTION, COMMISSIONING WITH O&M BY RWTPL

RWTPL hand held client to assist in selection of client transformer & ACB
Completed full supervision of entire system erection and successfully commissioned entire pumping system.
Pump and pontoon was installed at deepest location in the mine sump strike length for effective dewatering without need for any shifting nor any regular manpower attendance
Pumps were delivering flow up to 1212 M3/hr at very Low 1230 rpm
Pumps can be operated all the way till 1800 rpm — Huge operational flexibility for client
Maintains volumetric efficiency close to 98% of its design rating, consumed just 323.44 to 370 KW/Hr
LONG COILED pipe having constant friction co-efficient factor impact in high energy savings
Pump was running 24×7 in the able hands of our O&M team

Conclusion:

The above system set an example of how a pontoon-mounted mines dewatering pumping system combined with flexible pump operational range along with CRUSH PROOF AND LEAK PROOF pipe can give greater benefits for client in dewatering and mines production.

The post High flow High head pumps on large scale EPC project basis with transformer, ACB, 1140 HP VFD driven mines dewatering pumps appeared first on Rod Wheel Technologies.

Recognizing gravity of developments, after critical discussion client’s CMD awarded RWTPL for emergency deployment of pump that can develop between 6000 to 8000 GPM flow.

ACTION PLAN AND SOLUTION BY RWTPL

Our site visits revealed the location may have loads of coal mine sediments, as the dewatering progresses. These may be one of reason why existing submersible pumps were getting blocked, underperforming, leading to constant repairs. Henceforth RWTPL decided to deploy High flow pumps which can handle loads of suspended particles of at least 50mm lump size

RWTPL Quickly deployed suspended solids mine dewatering pump having flow range of 1500 to 2200 m3/Hr of non stop operation

Pump was manned by competent team of RWTPL on 24×7 basis with online Video monitoring system interlinked to our HO

CONCLUSION

In a span of 45 to 60 days of net operation our high flow pump removed close to 500 Million gallon to bring mines coal yield working level.

3 of site pump could hardly match 55% of one of our pump flow out put

Our pumps were absorbing maximum power not exceeding 225 KW at any instant– Massive energy savings to the tune of 40% in comparison to existing pumps which were delivering just 55% of our output

The post High flow Dewatering with suspended solids laden coal mines – Alternate for submersible dewatering pumps appeared first on Rod Wheel Technologies.

Problem Identified

Client combined capacity of 6 pumps 950 KW, 450 KW, 400 KW, 950 KW, 660 Kw, 250 KW has consumed combinedly power 2768 KW to deliver the flow of 7239 UK GPM.

All the pumps in operation faced severe drop in Volumetric Efficiency, delivering even less than 50% of design flow.

Pump faces Continuous Mechanical breakdown, Gland Replacement, huge manpower for maintenance, continuous parts replacement.

Maintenance of Huge size transformers setup to operate client pumping system.

APPROACH AND SOLUTION BY RWTPL.

After exhaustive site study RWTPL quickly deployed pump set to deliver flow rate of 4700 to 5000 UKGPM, All within 4 to 6 weeks of award.

Upon commissioning RWTPL absorbed only 796 KW to deliver above flow range

In comparison client Pumps 6 pumps, RWTPL pumps outperformed non-stop pumping and within the span of 25 Working days water level started to recede for production

Conclusion:

• RWTPL Pumping system achieved 4875 UK GPM @ 173 meters head with just 796 KW, Where as Client’s combo of 6 pumps were delivering 7239 UK GPM with 2768 KW.
• RWTPL Pumping system saving close to 68 % power Saving per every UKGPM of water pumped
• Estimated Power Saving within 6 months of operation is close to almost 3.84 Crores (@ 6.5 Rs per Unit)
• Client was able to free up some of feeder in sub station for other purpose due to KW savings achieved from our pumps in operation thus reducing grid load
• RWTPL could assist client in drying up of water levels exposing large coal seam block for production which was never believed to be possible, paving way for hundred’s of crore of production achievement

The post High wall- High flow, high head mine dewatering appeared first on Rod Wheel Technologies.

Problem Identified

Multiple pumps deployed by client with combo of 4000 and 2000 GPM pumps were falling short not only in delivering rated flow, but also in mines water level control
Overall installed power was between 1200 to 1400 KW
Pump faces Continuous Mechanical breakdown, Gland Replacement, huge manpower for maintenance.
Frequent failure of Foot valve which demand frequent human intervention for priming, putting manpower into huge operational stress as priming could take even hours.
Coal production was the direct casualty due to regular pump’s ineffective performance with constant failures.

APPROACH AND SOLUTION BY RWTPL.

After exhaustive site study needs RWTPL has deployed single pump rated for 850 to 1000 m³/hr flow deliverable
Upon commissioning RWTPL pump achieved 945 to 1098 m3/hr driven by 400 KW motor
All existing pumps were stopped. Only one of RWTPL pump was in operation
Pumps were operated almost 24×7 between 1500 to 1825 rpm based on varying working levels of mines

CONCLUSION— (Detailed case study can be shared upon request)

RWTPL pumping system saved almost 55 to 60% of energy saving on a comparable flow of the client’s pump.
The pump operates nonstop leading to lowering of water levels significantly In spite of heavy inflow and multiple gallery open up.
Pumping up to 600 Million gallon till project completion
Effectively coal seams were exposed for blasting effectively from end of 3rd month of dewatering which was never possible with existing pumps

The post Dewatering at OC coal mine affected by flash down pour appeared first on Rod Wheel Technologies.

APPROACH AND SOLUTION BY RWTPL

After exhaustive site study needs RWTPL has deployed single pump rated for 1100 m³/hr flow deliverable. The aim was to ensure pump should be suitable for 24×7 non stop operation, absolutely reliable without any break down.

Upon commissioning RWTPL pump achieved 1057 m3/hr constantly
In comparison client Pumps 1 & 2 combined delivered just 52% of rated flow while consuming 86% of power

CONCLUSION

RWTPL pumping system operations saves almost 65 to 70% of energy on a comparable flow of the client’s pump.
This transforms to estimated savings of over 2.82 crores a year.
The pump is operating absolutely nonstop. Total elimination of mechanical failures ensuring quick dewatering progress. In addition site is manned by RWTPL team constantly.

The post 8.5MTPA KOCP – Open cast Coal mine appeared first on Rod Wheel Technologies.

RWTPL explained key salient features of our pumps mainly the elimination of foot valve & manual priming, nil shaft leakage, ability to handle slurry, handle almost 50mm of solids, drastic O&M reduction and their real life benefits. It’s much understandable that client may have been skeptical to begin with, about how our pumps would stand out. However, moment of truth came by monsoon 2021, when client got to witness successful 24×7 non stop monsoon pumping with our pumping systems. Our pumps are designed to operate unattended even in full monsoon as the need be. Having passed full two monsoon (2021 & 2022) client has benefitted with much faster access to dry the pit, conduct mine blasting. This gave them early and extra production of three months. This is considered huge achievement in mining. This was never the case earlier. As Ferro alloys plays vital role in steel production and we are humbled by our fractional contribution to enhance Indian industrial output with our EPC pumping solutions.

The post Non stop dewatering at Ferro alloy mines – Effecting early production benefit appeared first on Rod Wheel Technologies.

Precisely this is where RWTPL deployed pumping system that handles high flow (1000 m3/Hr & above) to meet above head & handle suspended solids, slurries at ease. RWTPL designed 1150 HP pumping system that needs no priming even with heavy suspended solids, designed for NON-STOP monsoon pumping. RWTPL extended an inclusive pumping solution with pontoons, VFD’s slurry valves, full system design as a comprehensive EPC pump solution provider. The entire system was greatly appreciated by client who never experienced such reliable pumping even in monsoon.

The post High flow, High head chromite slurry mine dewatering EPC solutions by RWTPL appeared first on Rod Wheel Technologies.

When we informed client our intention to replace 4 of their 150 mm pump with just one of our 200 mm pump, why on the earth they must believe us??.

Again a proven installation at an Iron ore mine, our pumps replacing 4 of regular water pumps, Not only exceeding combined flow of regular pumps by Approx 22% we also ensured non-stop operations, Client is completely relieved of jammed foot valves, priming struggled. Many times pumps encountered close between 50 to 60 mm of suspended lumps which was handled easily

Feather on the cap was when client benefitted with extra 3.02Lakh extra ore production just in 5 months of our pump operation. Absolute mine owner’s delight.

The post Iron ore mine pumping solutions from RWTPL gives 147 Crore of extra production. appeared first on Rod Wheel Technologies.

RWTPL often steps into a project when UG production is crippled with challenges. Client needed 2 of 325 HP pumps that can be installed in 4 weeks time. RWT had co-ordinated with factory to get pumps that can handle 85 mm of suspended solids & 30% solids concentration within 4 days, Pump set were commissioned on August 15th 2018. Highly symbolic date where the mines greatly got relieved of flooding, production stoppage. Seeing the slurry output gushing out at ground level discharge was the most happiest moment for client who never imagined these are possible.Since then we have crossed 4 years & going strong.

The post Chronic UG slurry mine dewatering problems and mine flooding solved permanently by RWTPL— First ever in India since 2018. appeared first on Rod Wheel Technologies.