www.howden.

com

HOWDEN WATER TECHNOLOGY

TURBO COMPRESSOR SYSTEMS FOR THE WASTE WATER INDUSTRY
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A NEW BENCHMARK FOR ENERGY

EFFICIENCY AND CONTROL
PART OF THE HOWDEN GROUP, HOWDEN WATER
TECHNOLOGY IS A CENTRE OF EXCELLENCE SUPPLYING HIGH
EFFICIENCY TURBO COMPRESSOR SYSTEMS DEVELOPED TO
MEET THE SPECIFIC NEEDS OF THE WASTE WATER INDUSTRY.

HOWDEN WATER
TECHNOLOGY
SPECIALISTS IN PROVIDING
AIR SUPPLY SYSTEMS FOR THE
WATER TREATMENT INDUSTRY
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WORLD CLASS APPLICATION ENGINEERING EXPERTISE BUILT ON EXPERIENCE

Howden Water Technology (HWT) is Howden’s centre Howden has been supplying compressors to Howden turbo compressors can provide the lowest
of excellence for turbo compressors and associated waste water treatment plants for over fifty years. footprint and highest flow. The exceptional
equipment for the waste water industry. Working on By combining our high efficiency turbo compressors performance is based on a third generation high
every continent, and with companies in 16 countries, with sophisticated downstream control systems performance impeller that enables the compressor
Howden has made an enormous contribution to developed especially for water treatment, we can to operate 8-10% below the surge line during
environmental improvements within vital industries such offer the most advanced and efficient aeration normal running, giving a very high margin when
as power generation and petrochemical refining. With systems available. compared to other compressors available. The whole
over a thousand installations worldwide, Howden turbo system is governed by a modern control system
The need to minimise energy consumption, whether
compressors are the proven, reliable choice for optimal incorporating an easy-to-use human-machine
for cost or environmental reasons, has become a
performance. HWT is an invaluable source of application interface. Over the lifetime cost of the equipment,
factor of enormous significance, and the aeration
expertise as well as a supplier of complete, integrated Howden technology offers the highest cost savings
system is responsible for by far the largest proportion
aeration systems, bringing a unique combination of through a combination of energy efficiency and the
of the energy consumption in any aerobic waste
experience and flexibility to the market. reliability offered by our ‘built to last’ philosophy.
water treatment plant.
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THE POWER BEHIND THE PROCESS

OVER THE LIFE OF THE PLANT, HOWDEN TURBO COMPRESSORS ARE BY FAR THE
MOST COST EFFECTIVE TECHNOLOGY AVAILABLE. THEIR CAPITAL COST WILL QUICKLY
BE OFFSET BY LOWER ENERGY EXPENDITURE, TYPICALLY AS EARLY AS THE FIRST
12 TO 36 MONTHS OF OPERATION, LEAVING DECADES FOR THE SAVINGS TO GROW.

Howden turbo compressor technology has an at low load, the efficiency of the aeration system
installed base numbering over one thousand units is unaffected. Howden Water Technology products
worldwide. These machines typically run for decades will maintain effectiveness through the full flow
without any intervention except minimal planned range, including the key 60-80% window and
maintenance. Their robust success is a testimony dropping to as low as 40% capacity when required.
to the quality of their engineering, and their track
Every unit we supply is fitted with dual vane
record is a provable fact.
compressor regulating systems, comprising both
Howden Water Technology offers a choice of 12 variable inlet guide vanes and a variable vane diffuser
frame sizes with a capacity range of 4,000 to 140,000 system. The inlet guide vanes create a pre-rotational
m3/h, covering the most extensive duty range on the air swirl before the air reaches the impellers, adding
market. With the widest volume and pressure range significantly to the efficiency of the equipment
available, HWT can supply a product to meet any at turn-down duty, and the variable vane diffuser
demand our clients have – and with achievable is designed to control the pressure build-up at
efficiency levels exceeding 87%, Howden is the the impeller discharge while also regulating the
natural choice for water treatment plants. compressor capacity.
Our turbo compressors are designed to provide plant Prior to shipment each unit is fully factory tested.
operators with efficiency across the actual operating We offer the choice of testing to ASME PTC10-1997
range. Exceptional turndown capability is built in as or ISO 5389 specification, and supply the performance
standard to ensure that when plants are operating certificate, at the customer’s request.

1000,00 10000,00 100000,00

1200
SG105
SG92

1100
SG80
SG70
SG65
SG60
SG52
SG45
SG40

1000
SG35
SG30
SG26

900
Delta P mBar

800

700

600

500

400

300
m3/h

SG26 SG30 SG35 SG40 SG45 SG52

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Blow off valve

TURBO COMPRESSOR SYSTEM

WITH ANCILLARY EQUIPMENT

Cone diffuser-silenced
Local control panel

Motor

Inlet silencer/filter

Lube oil system

SG60 SG65 SG70 SG80 SG92 SG105

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RESPONSIVE INTEGRATED TECHNOLOGY

DESIGNING AND SPECIFYING A MODERN, ENERGY-EFFICIENT AERATION
SYSTEM IS A COMPLEX TASK, DEMANDING DETAILED KNOWLEDGE OF THE
COMPRESSION PROCESS AS WELL AS THE OPERATION AND CONTROL OF
THE AIR DISTRIBUTION SYSTEM, AND A THOROUGH UNDERSTANDING
OF THE ACTIVE SLUDGE WATER TREATMENT PROCESS.

PROVEN EFFICIENCY
Howden turbo compressors high efficiency systems have been When the capacity drops to normal operating levels,
thoroughly researched and tested to provide flexibility and however, the efficiency may fall away dramatically.
control even when plant conditions require greatly reduced Of the three technologies turbo compressors are the
capacity. Our figures relate directly to the working efficiency most efficient, approaching 87% efficiency at full capacity.
of our turbo compressors once installed and running. They will
Howden turbo compressors, with their inlet guide vanes,
be reflected in genuine energy savings.
variable vaned diffusers and enhanced impeller design,
All compressors, whether they use rotary lobe compressor have a clearly measurable advantage in maintaining excellent
(positive displacement), multi stage centrifugal compressor performance in the full operating range of 45-100% capacity.
or turbo compressor technology, are designed to work at Howden turbo compressors excel where plant conditions
peak efficiency when they are running at full capacity. dictate that compressors operate away from the design
point, giving significant operational benefits.

TURNDOWN AND RISE TO SURGE

1,2000

Surge Line
1,1000
Design Point

1,0000
Relative Head

0,9000

0,8000

0,7000 Duty Range

0,6000

0,5000
0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3
Relative Flow

IMPELLER
Howden’s third generation impeller is a core 3D high performance
impeller designed for maximum efficiency and a severe downturn
capability. By maintaining performance at operating levels far from
the surge line, it provides maximum operating stability. The S-shaped
impeller has strong backward leaning blades and every second blade
in the inducer is cut back to avoid blockages in the inducer section.
This unique aerodynamic design offers our clients maximum efficiency
VARIABLE VANE DIFFUSER across the full duty range. It also gives a head stability margin of 8-10%
The Howden variable vane diffuser system is designed to be easy from maximum duty head to surge, thus lowering vulnerability to
to access for service and maintenance to minimise down time. ambient changes and reducing down time.
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PREDICTING REAL PERFORMANCE

HOWDEN WATER The understanding that no two plants will ever operate and add ambient conditions like relative humidity
TECHNOLOGY in exactly the same conditions, and our certainty that and temperature, and variables like energy availability
IS AN INVALUABLE SOURCE we can deliver efficiencies and energy savings, led us and cost, using figures supplied by the customer.
to the development our unique modelling software.
Allowance can be made for energy price rises
OF APPLICATION EXPERTISE
This compares different types of air supply technology and maintenance over a 20-year operating period.
AS WELL AS A SUPPLIER OF within the precise parameters of the customer’s own The software is designed to precisely mirror genuine
plant. Alongside the volume and pressure of air working duties and ambient conditions, and will
COMPLETE, INTEGRATED analyse retrofits and upgrades as well as new
required, there are many other factors which affect
AIR SUPPLY SYSTEMS operation. We factor in the time the plant runs at full, installations. It gives an invaluable insight into
high average, low average and minimum capacity, savings over the equipment’s planned life.
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EFFECTIVE CONTROL
HOWDEN WATER TECHNOLOGY’S STRENGTH LIES IN OUR COMPREHENSIVE UNDERSTANDING
OF THE APPLICATION. WE BRING TOGETHER EXPERTISE IN COMPRESSOR TECHNOLOGY, DISTRIBUTED
CONTROL TECHNOLOGY AND THE DOWNSTREAM AERATION PROCESS FOR WASTE WATER
TREATMENT TO OFFER OUR CLIENTS THE VERY BEST TECHNICAL SUPPORT.

Today, single stage geared turbo compressors are • By integrating master and local control in one
the most efficient way to aerate treatment plants. panel, it removes the need for a separate Master
The technology has been brought to an extremely Control Panel and so removes the potential
advanced level, and the focus is now on highly for faults arising in a separate Programmable
efficient controls and downstream solutions that will Logic Controller.
make the overall air supply system of even higher
• It maximises energy savings through the use
value to the end user. The aim is to constantly offer
of the Most Open Valve principle, an approach
the client the optimum solution and the lowest cost
designed to prevent the compressors wasting
of ownership.
energy by creating more pressure drop in the
To ensure that the aeration system is always control valves than the plant needs at the time.
making the most effective and appropriate use
• It reduces the need for starting and stopping
of all the compressors, and thus running as efficiently
of the compressors, and reduces down time.
as possible, Howden Water Technology offers
a reliable load sharing system called Airflow • The integral Air Compressor Duty Hour Equalising
Integrated Management (AIM). Incorporated feature ensures that duty hours are shared
into the Local Control Panels, the system provides evenly across all compressors.
several advantages.

V Compressor Loop
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HWT’s BioActive Response System combines the Howden Water Technology can provide all the
energy efficient AIM system with a downstream air necessary hardware and software, and supply the
distribution system in which four control loops interact complete control system. As well as maximising
in real time to produce the minimum air flow required efficient running and thus lowers energy costs,
to efficiently treat the water in the Aeration Tanks. this gives the customer the advantage of dealing
By constantly maintaining the lowest possible Main with a single supplier.
Header air pressure, BARS prevents unnecessary
BARS also allows plant operators to build in a
energy consumption and reduces running costs.
range of special programme features to respond
The first control loop sets the dissolved oxygen level automatically when normal plant operating
set-point based on readings of the ammonium and conditions are breached. Dedicated programmes
nitrate levels in the water. The second loop uses can also be built in for procedures like normal
the dissolved oxygen level deviation from the DOL start-up, tank cleaning and backwash filter cleaning,
set-point as basis for setting the air flow set-point and special routines can be included to handle
of the air control valves. The third loop sets the main situations such as start-ups where there may be
header pressure set-point based on readings of water in the pipes (leading to danger of surge)
the most open control valve position and finally or storm water influx where high air throughput
the fourth loop controls the air flow discharged is required for a short time.
from the on-line compressors keeping a constant
main header pressure.
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FULL LIFETIME SUPPORT

EVERY TURBO COMPRESSOR WE SUPPLY, AND ALL OF ITS ASSOCIATED CONTROL AND SOFTWARE
SYSTEMS, IS BACKED BY AN UNEQUIVOCAL COMMITMENT TO LIFETIME SUPPORT. HOWDEN’S
GLOBAL NETWORK OF QUALIFIED SPECIALIST ENGINEERS MEANS THAT WE CAN OFFER A FAST
LOCAL RESPONSE VIRTUALLY ANYWHERE IN THE WORLD WHEN REQUIRED.

We maintain a full spares programme based on technological developments may make retrofits and modernization of existing plant irrespective
meticulous documentation of the equipment we or upgrades advisable. of age, location or original supplier. Our modeling
originally installed, so that every part we supply is software can provide a wealth of hard information
manufactured to specification. More importantly, RAPID RESPONSE to assist decisions about the timing and scope of
our records are a valuable resource that allows We are happy to discuss any aspect of water aeration plant modernisation. And because we are focused
us to provide reliable advice rapidly when plant technology, from consultation as systems provider solely on the needs of the industry we operate
conditions may change or other factors such as at the planning stage to advising on possible retrofits 24/7 for our clients.
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www.howden.com

Howden, founded in 1854, is the world’s leading supplier of fans,

compressors and rotary regenerative heat exchangers for a large range
of industrial applications. Whether pre-engineered or custom built for
a specific application, our products are known throughout the world
for their high levels of performance, reliability and innovation.

The combination of our product knowledge with our extensive applications

experience, gained by our engineers on sites throughout the world, allows
us to provide our customers with support from the initial project inception
right through to the end of the plant life.

For further information about Howden Water Technology, contact:

Howden Water Technology A/S

Blokken 75
DK-3460 Birkerød
Denmark

Tel: +45 45 53 62 62
Fax: +45 45 53 62 66
Email: [email protected]

©Howden Group Limited. All rights reserved. 2009

Howden and the flying H logo are registered trade marks belonging to Howden Group Limited.