Sulzer Pumps

ABS Submersible Sewage Pump XFP

Advancednewthinking
thatredefines
pumpefficiency

The Heart of Your Process

 Pumps and Impellers for World-Class Savings
The ABS submersible sewage pump
XFP was the first pump with a sub-
mersible motor meeting the premium-
efficiency IE3 standard. Today it still
leads the field for reliability and energy
performance, thanks especially to
new advances in the Contrablock
Plus impeller technology, specifically
engineered to handle today’s tough
wastewater.
With its premium-efficiency IE3 motor
(in accordance with the IEC 60034-30
standard), the ABS submersible
sewage pump XFP sets a new stand-
ard for the wastewater industry. Yet the
motor is only one of its many remark-
able characteristics. The pump is a
complete, highly engineered package
whose design takes into account all
aspects of wastewater handling.
Optimal Lifecycle Economy
No other wastewater pump lives up to
the efficiency and reliability of the ABS
submersible sewage pump XFP. Avail-
able in a complete range of models,
it provides nothing less than optimal
lifecycle economy.
2
Key advantages of the ABS submers- than ever due to reduced water con-
ible sewage pump XFP include: sumption and tougher solid mate-
rials, you can be assured of fewer
• Greater energy savings
blockage- related service calls. This
The ABS submersible sewage
is because Contrablock Plus impel-
pump XFP offers substantial energy
lers are the most advanced on
savings, with a lower operating
the market, and because they are
cost and reduced carbon footprint
designed to handle today’s challeng-
as a result.
ing wastewater.
• Long-term reliability
• Future-proof design
The advantages of the IE3 motor,
The ABS submersible sewage pump
combined with stronger bearings
XFP exceeds existing and planned
and the most blockage-resistant
worldwide legislation regarding
impellers on the market, make the
equipment efficiency. With its out-
ABS submersible sewage pump
standing energy performance and
XFP a smart choice for all waste-
high reliability, you can be confident
water applications, including those
of meeting both today’s and tomor-
requiring extended operation. The
row’s needs and regulations.
pump reduces not only energy
costs and maintenance, but also the • Sustainability in manufacturing
risk of overflows and breakdowns. and operation
Efficient manufacturing, a long
• Excellent rag handling
design life, low maintenance and
The Contrablock Plus impeller
opportunities for ongoing optimi-
series – now with a new genera-
zation make the ABS submersible
tion of multi-vane models – gives
sewage pump XFP a forward-
the ABS submersible sewage pump
thinking solution. Throughout its
XFP exceptional blockage resist-
lifetime, it contributes to a reduced
ance. Despite the fact that today’s
carbon footprint and reduced
wastewater is more difficult to pump
cost of operation.
Presenting the Multi-Vane Contrablock Plus
The Contrablock Plus series of impel-
lers provides excellent hydraulic
efficiency while greatly increasing
the reliability of the ABS submers-
ible sewage pump XFP. Developed
through a combination of advanced
modeling with computational fluid
dynamics (CFD) and extensive testing,
Contrablock Plus impellers provide
free solids passage of at least
75 mm (3 inches) through the impeller.
In addition, they pass the vast major-
ity of fibrous material using the impel-
ler vane rather than relying on the
cutting action provided by the impel-
ler’s bottom-plate interface.
TheABSEffeXRevolutioncontinues
Part of the ABS EffeX
Revolution
This makes Contrablock Plus impel-
The ABS EffeX Revolution is an
lers far less reliant on precision
ongoing effort from Sulzer Pumps
adjustments of the bottom plate and
to push the boundaries of waste-
sharpened impeller edges than com-
water technology, especially in
peting designs.
the area of energy efficiency.
Encompassing the whole chain
Today the Contrablock Plus series
from design to manufacturing,
includes multi-vane as well as single-
it has resulted in the most inno-
vane models. This means their unique
vative and resource-conserving
blockage resistance is now availa-
solutions on the market.
ble for pumps from 1.3 kW (1.8 HP) /
DN80 (3 inch) all the way up to 400 kW
The revolution began in 2009 with
(536 HP) / DN400 (16 inch).
the launch of the ABS submers-
ible sewage pump XFP. Since
then, it has expanded to comprise
a complete range of world-class
wastewater products. Their energy
savings, reduced carbon footprint
and high reliability contribute to
efficient processes and satisfy the
growing demands placed on the
wastewater industry.
3
 Greater Energy Savings
The impact of energy management for
your pumping equipment is twofold.
First, it lowers your energy-related
operating costs, which is critical as
energy prices increase. Second, it
has a direct and important role in
reducing the carbon footprint of your
organization.
A Total Approach to Energy
When considering the energy con-
sumption of pumping equipment, cal-
culations must be based on the total
efficiency of the pump. This includes
not only the efficiency of the hydrau-
lics, but also that of the motor.
4
Motor efficiency
Total efficiency
Pump efficiency
To achieve the best result, both of
these efficiencies have to be opti-
mized. Even the best hydraulic effi-
ciency means little if the hydraulics
are mounted on a submersible motor
with substandard efficiency.
The Highest Motor Efficiency
Throughout the range, the ABS sub-
mersible sewage pump XFP utilizes
premium-efficiency IE3 motors.
Designed and tested according to IEC
60034-30, they ensure the best motor
efficiency available. (The motors also
meet NEMA Premium standards for
efficiency.) This is a major reason
why the ABS submersible sewage
pump XFP can offer such remarkable
energy savings.
Using a premium-efficiency motor is
the best way to influence the balance
between reliability and energy con-
sumption. This is because it improves
the pump’s total efficiency without
adversely affecting the pump’s poten-
tial for blockage.
Sulzer Pumps was the first company in
the world to offer submersible motors
meeting the premium-efficiency IE3
standard – not only in pumps, but in
other products as well.
Premium hydraulics to match
When it comes to hydraulics, tra-
ditional thinking has dictated com-
promises between efficiency, rag
handling, and free solids passage.
However, through computational fluid
dynamics (CFD) modeling and exten-
sive testing on today’s wastewater,
Sulzer Pumps has arrived at a no-
compromise solution.
The Contrablock Plus impellers uti-
lized by the ABS submersible sewage
pump XFP offer some of the market’s
highest hydraulic efficiencies, yet they
also give the pump the best blockage
resistance of any wastewater pump
on the market. This is accomplished
through advanced impeller design
and the incorporation of a minimum
free solids passage size of 75 mm
(3 inches) through the impeller.
 Stainless steel ABS XFP motor
lifting bail

Plug-and-Play cable
entry system

Silicon carbide ABS XFP total

mechanical seals efficiency

ABS Sealminder
system

ANSI/DIN slotted
flange

Contrablock Plus
impeller system

seal protection
system

Adjustable wear
plate

5
 Long-Term Reliability
Ensuring reliability begins with under-
standing the application. Pumping
wastewater involves pumping not only
liquid, but also abrasives, fibrous rag-
like material and other solids. Whether
the pump operates continuously or
starts and stops frequently, the pump
motor, bearings and hydraulics must
stand up to high loads, high wear,
poor cooling conditions and the gen-
erally harsh environment of waste­
water pumping stations.
Both Cooler and Stronger
The reliability of the ABS submersible
sewage pump XFP starts with its
premium-efficiency IE3 motor. The
motor has the major advantage of
lower operating temperatures (NEMA
Class A temperature rise) and the
resulting reduced need for cooling.
This considerably improves the
environment for the motor bear-
ings and reduces the thermal load
on the stator, leading to significantly
increased component life. In the
smaller pump models (PE1 and PE2)
up to 10.5 kW (14 HP), the motor
6
can be run in dry-well pumping sta-
tions without any supplemental cool-
ing at all. All larger pump models
(PE3 to PE6) can be installed in dry
well by using an optional closed-loop
cooling system, transferring the heat
losses of the motor via a water-water
heat exchanger to the wastewater
pumped.
Add to this an increased bearing
design life, reduced shaft deflection
and increased shaft-fatigue safety
factors, and you have a highly robust
submersible motor design.
Optimized for Life
In terms of hydraulic reliability, the
key is blockage and wear resistance,
combined with easy service features
that allow the operator to maintain
ideal operating conditions. Our new
Contrablock Plus impeller designs
provide both. In addition to their
excellent solids handling, the impel-
lers have a bottom plate that is easily
adjusted externally, without having to
disassemble the pump.
This ensures that the operator can
easily maintain operating efficiency
and reliability throughout the pump
lifetime.
The Sum of the Parts
The many advances inside the ABS
submersible sewage pump XFP make
it a reliable and complete package.
Together, they ensure:
• Reduced risk of pollution and fines
from overflows
• Reduced risk of interruptions in
customer services
• Reduced costs for breakdowns
and unscheduled maintenance
• Reduced tankering costs
• Reduced maintenance costs
• Improved overall efficiency in the
operation of pumping systems
 Excellent Rag Handling
Over 60% of breakdowns related to
wastewater pumps are the result of
blockage. From year to year, reduced
water consumption and changing
personal hygiene habits have stead-
ily increased rag-handling difficulties
within municipal wastewater collec-
tion, such as the attachment of sand
and other abrasives to the self-adhe-
sive strips of sanitary items. With
Contrablock Plus impellers, there is
finally a way to stay problem-free.
Designing Away Blockage
The ABS submersible sewage pump
XFP makes use of a completely new
impeller concept called Contrablock
Plus. Built on the principles of the
original ABS Contrablock, which has
proven reliable since its introduction in
1967, it raises the bar for rag handling
and high efficiency beyond anything
else on the market today.
8
Contrablock Plus impellers have a
minimum of 75 mm (3 inches) free
solids passage through the impel-
ler, which is groundbreaking in itself
for an impeller with such excep-
tional hydraulic efficiency. Even more
impressive, the shape of the impeller
is designed to let 80% of the enter-
ing fibrous material pass the impel-
ler vane – without relying on a cutting
action. Only the remaining 20% of
solids are handled by the natural cut-
ting action of the impeller’s bottom-
plate interface.
Since fibrous items are often loaded
with sand and grit, this focus on the
impeller vane dramatically reduces
wear on the bottom plate. As a result,
Contrablock Plus impellers are far less
dependent on precision bottom-plate
adjustment and sharpened impeller
edges for solids handling than com-
peting impeller designs.
From Single-Vane to Multi-Vane
The single-vane Contrablock Plus
impeller was launched with introduc-
tion of the ABS submersible sewage
pump XFP in 2009. At that time,
it represented more than 5000 hours
of laboratory blockage-resistance test-
ing, field testing, wastewater analysis,
design benchmarking and optimiza-
tion with computational fluid dynam-
ics (CFD).
Today, after countless new hours of
research, simulation and testing, Con-
trablock Plus impellers are now avail-
able in completely new two- and
three-vane designs. These multi-vane
models are like nothing seen before,
and at first glance they resemble a
mixed-flow impeller. Yet they deliver the
same perfect balance of high perfor-
mance and blockage resistance as the
single-vane models introduced in 2009.
A Full Series
With the addition of multi-vane impel-
lers, the Contrablock Plus series
extends from 1.3 kW (1.8 HP) / DN80
(3 inch) up to 400 kW (536 HP) /
DN400 (16 inch) models of the ABS
submersible sewage pump XFP. All of
the impellers are open, and all feature
an adjustable bottom plate that lets the
operator easily maintain efficiency and
reliability throughout the pump lifetime.
Future-Proof and Sustainable Pumping
As demands change and regulations
grow stricter, you need a pump that
continues to deliver. Like other prod-
ucts from Sulzer Pumps, the ABS
submersible sewage pump XFP is
designed for long-term benefits.
Future-Proof Design
Wastewater will likely continue evolving
as it has in the past decade. Decreas-
ing water consumption and changes
in personal hygiene habits will lead to
even greater rag content and higher
solids concentrations. At the same
time, legislation, standards and other
incentives will continue pushing for
higher-efficiency products and for
expanded utilization of explosion-proof
classifications for added safety.
With its exceptional efficiency and reli- This is why we offer easy mainte-
ability, the ABS submersible sewage nance and adjustment features that
pump XFP goes well beyond the prolong component life and enhance
global standards for wastewater col- ongoing operation.
lection. It exceeds the requirements of
current and pending legislation. Combined with the highest efficiency,
all this gives the ABS submers-
Sustainability in Manufacturing ible sewage pump XFP the lowest
and Operation resource and energy consumption –
Sulzer Pumps strives for sustainabil- and the smallest carbon footprint –
ity in our business and in yours. This from start to finish.
means looking far ahead to reduce
environmental impact, from manufac-
turing to lifetime operation.
One aspect of this is conserving
resources, which includes giving
products a long design life. Another
is ensuring performance over time.
9
 Delivering World-Class Performance
The ABS submersible sewage pump
XFP is part of a complete, world-class
product range from Sulzer Pumps.
Gathered under the ABS EffeX name,
the range embodies our unique drive
to define the leading edge of waste­
water technology.
Leading Wastewater Innovation
Sulzer Pumps is a wastewater special-
ist with outstanding customer relations
and extensive application expertise. As
the only supplier on the market with a
complete range of premium-efficiency
wastewater equipment, we lead the
way in solving the challenges faced by
municipal, industrial, commercial, and
domestic end-users.
10
Our ABS product brand is synony-
mous with innovation and well-proven
solutions for wastewater collection
and treatment. Nothing makes this
clearer than the ABS EffeX range.
The ABS EffeX Revolution
The ABS EffeX range targets legisla-
tive demands to reduce energy use
and carbon footprint. Yet it also meets
fast-changing needs within waste-
water collection and treatment. In
addition to using premium-efficiency
motors, we address the causes of
blockage and the effects of reduced
water consumption and changing per-
sonal hygiene habits.
Balancing these concerns is what
keeps costs low and service levels high.
The ABS EffeX range provides the most
efficient, reliable operation possible –
which gives you full peace of mind.
The World-Class Range of
Wastewater Products
The ABS Effex range from Sulzer
Pumps is a complete portfolio of prod-
ucts designed to cover all key aspects
of wastewater transport and treatment.
It includes:
• Submersible sewage pumps
• Submersible mixers
• Submersible flow boosters
• Turbocompressors
• Modular pump control systems
All of these products employ premium-
efficiency motors (IE3 or equivalent), as
well as innovative features that ensure
efficiency and reliability.
Service Globally and Locally
Sulzer Pumps is a strong global
organization, represented worldwide
with a strong local presence.
We offer a complete Service Program,
covering everything from on-site
repair to full service maintenance con-
tracts with alarm management and
24-hour breakdown services.
In addition, we have a sophisticated
stocking system with international hub
locations and on-hand stocks of key
products. This ensures products are
rapidly and reliably available whenever
they are needed on site.
 wastewater treatment plant stormwater
retention basin

domestic & commercial

inlet pumping stations wastewater

Network
pumping
terminal pumping stations stations

terminal pumping stations

Network Network Network
pumping pumping pumping
stations stations stations

Network Network
pumping pumping
stations stations

flood protection Network

pumping stations pumping
stations

Pressurized Pressurized Pressurized

system system system

Pressurized Pressurized Pressurized

system system system

terminal pumping stations

Network Network
pumping pumping
stations stations

Network
pumping
stations

11
Combined Strength for Unmatched Expertise

ABS, associated with innovation and well proven solu- with extensive application expertise in solving wastewater
tions for wastewater handling and dewatering, is a prod- and dewatering challenges is the foundation of this strong
uct brand of Sulzer. Strong customer service combined global brand. For more information, visit www.sulzer.com

www.sulzer.com

E10145 en (1) 09.2012, Copyright © Sulzer Pumps

This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please, contact us for a description of the warranties and
guarantees offered with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice.