Sanitation | COPASA Cataguases/MG

The largest sanitation company in Minas Gerais, Copasa, has chosen HIGRA products to significantly improve services at its Cataguases plant. At the site, benefits such as a 90% increase in flow rate; low maintenance costs; a reduction in noise levels; major gains in energy efficiency; the complete elimination of equipment burnout caused by floods (thanks to the HIGRA amphibious system) and a constant reduction in corrective maintenance (avoiding system stoppages that jeopardized supply to the city) are already making a difference. The first pump was installed at the beginning of 2013 and the third in March, as well as the backup equipment. “As soon as the installation was complete, the entire old system could be deactivated and the advantages could be seen in practice,” says HIGRA director Silvino Geremia, highlighting a phrase uttered by one of the Copasa workers. “He said… where’s the noise? I can’t believe it, 25 years working here and I never imagined this was possible.”

Hydro-Energy Efficiency

Old Scenario

-Horizontal Centrifugal Pump
-Motor power of 200CV (147kW)
-Flow per pump of 198m³/h (55 l/s)
-Pumping pressure of 95mca
-Hydro-energy index of 0.743 kW/m³/h
-Monthly Electricity Cost R$110,223.00 (R$0.26 kWh)
-Annual Electricity Cost R$1,322,680.00

Current Scenario

-HIGRA R2-360/200B amphibious pump
-Engine power of 200CV (147kW)
-Flow per pump of 396m³/h (110 l/s)
-Pumping pressure of 95mca
-Hydro-energy index of 0.372 kW/m³/h
-Monthly Cost of Electricity R$
55,111.68 (R$ 0.26 kWh)
-Annual Electricity Cost R$
661.340,00
Result
-Acquisition of 4 pumps gaining up to 90%
more flow in the system.
-Direct consumption reduction of 50%.
-Investment in the 4 pumps R$ 450.000,00
-Monthly savings of R$ 55,111.68
-Annual savings of R$ 661,340.00
-Return on investment in 8 months

BEFORE

04 horizontal motor pump sets, 200 hp, operating in parallel, suctioning the wells and recharging them to the WTP, at a flow rate of Q=220 l/s;

Average monthly electricity costs in 2012: R$111,000.00/month.

Constant burnout of motors and transformers;

Poor motor pump sets;

Frequent maintenance on pumps, motors, QCMs and transformers;

Team on constant alert;

Absorption of up to 30% of the maintenance team’s time, with an average cost in 2012: R$18,000.00/month;

Frequent flooding at the unit, caused by the Pomba River;

Damage to motor control panels;

Great difficulty in carrying out routine and emergency maintenance;

Poor working conditions, with major electrical, mechanical, ergonomic and noise risks.

AFTER

Installation of 04 amphibious motor pump sets, two operating and 02 in hot reserve, 200 hp of power per pump, with an individual capacity of 100 l/s, for a total flow of Q= 400 l/s;

Improved performance of motor-pump sets leads to a significant reduction in electricity consumption: R$ 59,000.00/month;

Reduced maintenance costs at the unit;

Greater personnel and operational security;

Greater availability of staff to meet electromechanical maintenance demands at the DT;

Electricity substation and control panel and QCM room, above flood level;

Normal operation of the unit in flood situations;

City water supply guaranteed.