Sulzer Pumps - peg-az.compeg-az.com/wp-content/uploads/2012/05/AHLSTAR-PRESENTATION.pdf · A double...

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 1/

Sulzer Pumps


AHLSTAR™ Process PumpsApplications

The AHLSTAR™ Process Pump is designed for continuous operation in industrial processes• Oil and Gas• Hydrocarbon Processing• Pulp and Paper• Power Generation• Water Transport and Distribution• Food• Basic Metals• Fertilizers• Others

Reliable • Simple • Efficient • Diverse


AHLSTAR™ Process PumpsApplications

Reliable • Simple • Efficient • Diverse

The AHLSTAR™ Process Pumps are meant for pumping all kinds of liquids from clean waters to abrasive or corrosive liquids.

Special capabilities to handle stocks of various kinds, sludges or slurries.

End suction single stage pumps• Reliable operation• Simple but versatile construction• High efficiency


AHLSTAR™ Process PumpsInterchangeability

N HydraulicsNon-clogging. Sludgescontaining big particles and long fibers.

R – Air-SeparatingExternal vacuum pump and expeller.

W HydraulicsWear-resistant. Corrosive and/or abrasive liquids.

A HydraulicsGeneral purpose. Clean, abrasive or corrosive liquids specially stocks of various kinds.

S – Self-PrimingInternal vacuum pump.


AHLSTAR™ Process PumpsDesign Features

Self-venting topcenterline casing.

Externally adjustablesideplate.

Double volute casing in larger sizes.

Impeller balancing holes and back vanes stabilize pressure in shaft seal cavity.

Optimum shaft sealing philosophy.

Simplified heavy-duty bearing unit.


AHLSTAR™ Process PumpsAPP/APT Hydraulic Design, Impellers designed for various liquids

Closed impeller• High efficiency• Clean liquids• Liquids containing

some impurities

Open impeller• High efficiency• Good throughput• Liquids containing

solid particles• Abrasive liquids• Stocks up to 8%• Solids up to 70%• Lumps in liquid

Special open impeller• High efficiency• More open passages• Liquids containing

long particles and fibers• Abrasive liquids• Stocks up to 8%• Solids up to 70%• Lumps in liquid

LowPulse impeller• High efficiency• Minimized pulsations• Dilution water forheadbox

• Stocks for headboxfeed

• Clean liquids• Stocks up to 8%


AHLSTAR™ Process PumpsNPP/NPT Hydraulic Design

Non-clogging design passes big particles and long fibers, e.g. plastic stripes.

Specially designed vane edges stay clean.

Front vanes with sideplatecutting grooves keep gap clean.

Back vanes prohibit particles from entering the seal cavity and balance axial forces.

Liquids:sludges, waste waters, effluents

Vortex impeller

Closed impeller

Cutting grooves for closed impeller


AHLSTAR™ Process PumpsWPP/WPT Hydraulic Design

Wear-resistant design resists abrasion and erosion in slurry pumping.

Smooth shapes.

Thickness in casing and impeller enlarged.

Hydraulic shapes guide particles away from casing walls.

Vortex impeller

Closed impeller

Open impeller


AHLSTAR™ Process PumpsEPP/EPT Hydraulic Design

Centerline support keeps shaft position horizontal at elevated temperatures

Spot-cooled stuffing box area to handle high temperatures

Enforced casing manages higher pressures

Hot liquid pumps have high efficiency.

Closed impeller

Open impeller


AHLSTAR™ Process PumpsStandardization

APP, ARP, ASP, EPP, NPP, NRP, NSP, WPP, WRP and WSP pumps are designed in a similar way using the same components.•246 pumps•80 casing covers•6 common bearing units•6 common shaft seal sizes•common sealing water equipment•common couplings and coupling guards

•common baseplates

Common parts shownin columns


AHLSTAR™ Process PumpsStandardization

APP/APTProcess Pump

NPP/NPTNon-Clogging Pump

WPP/WPTWear-Resistant Pump

EPP/EPTHot Liquid Pump

Low spare parts inventory through standardization.

Process reliability through tailor-made hydraulics.

Casing coverAdapter

Only 6 bearing units

StandardizationTailor-made hydraulics

RStructureAir-Separating Pump

SStructureSelf-Priming Pump


AHLSTAR™ Process PumpsOperational Limits


AHLSTAR™ Process PumpsA Performance

Head up to 160 m

Temperature max. 180 °C

Capacity up to 2000 l/s

Operating frequencies 50 or 60 Hz

Pressure up to 1.6 Mpa(depending on material and size)


AHLSTAR™ Process PumpsA Performance

Head up to 700 ft

Temperature max. 356 °F

Capacity up to 30000 USGPM


Pressure up to 230 psi(depending on material and size)


AHLSTAR™ Process PumpsN Performance

Head up to 90 m






AHLSTAR™ Process PumpsN Performance

Head up to 250 ft


Capacity up to 7000USGPM




AHLSTAR™ Process PumpsW Performance

Head up to 110 m






AHLSTAR™ Process PumpsW Performance

Head up to 360 ft






AHLSTAR™ Process PumpsE Performance

Head up to 140 m




Pressure up to 2.5 Mpa


AHLSTAR™ Process PumpsE Performance

Head up to 650 ft




Pressure up to 360 psi


AHLSTAR™ Process PumpsGas/Air in the Liquid

Gas/air gets into the liquid. AHLSTAR™ Gas Removal Pump: Stable and reliable operation

(gas content 0...40%)

Conventional Pump: Unstable operation

(gas content 0...4%)

Dissolved

Bound

Free


AHLSTAR™ Process PumpsS Self-Priming for Gas-Containing Liquids

Intended usage•self-priming•gas-containing liquids•foam

Self-priming applications

Gas/air to the inlet tank

Vacuum relief valveSealing water


AHLSTAR™ Process PumpsR Air-Separating for Gas-Containing Liquids

Intended usage•self-priming•gas-containing liquids•foam

Suitability• low speed of rotation•variable speed controlled pump

•high gas amount•separate control of vacuum pump

•separate vacuum pump not always needed

Barometric leg application


AHLSTAR™ Process PumpsShaft Seal Area

Balancing holes keep the pressure level steady at the shaft seal area.

Back vanes keep the area between the impeller and casing cover clean and reduce axial forces.

Back vanes optimizedaccording to the pumped liquid.

Controlling the shaft seal area pressure gives

• Best solutions for every application

• Reliability in operation

WPP, closed APP, open

NPP, vortex


AHLSTAR™ Process PumpsShaft Seal Liquids

W01 Non-pressurized fluid in/out• Cooling • Quench

W02 Pressurized fluid in• Flushing

W04 Pressurized non-flowing fluid in/(out)• Barrier

non-flowing

W03 Flowing pressurized fluid in/out• Barrier flowing

No fluid• Clean liquids• Light impurities• Temperature

max. 90 oC/195 oF


AHLSTAR™ Process PumpsDynamic Shaft Sealing

Operating

Dynamic Seal• Reliable operation optimize total lifetime costs• Designed for difficult applications• Simple operating principle• Reliable robust construction

Liquids• paper stock up to 8%• liquors• lime milk• waters• sugar juices• etc.

Not running



Grease• Variable speed operation• High storage towers which

are sometimes full

Double• Low pressure at suction

side during standstill

Reduced diameter• High-speed pumps• Lower power

consumption



Flushing internal (recirculation)• Clean liquids• Increased pressure

at seal cavity

Flushing external• For cleaning seal cavity

at standstills• Sometimes used with

very dirty liquids


AHLSTAR™ Process PumpsReady-Fitted Mechanical Shaft Sealing, Single

• Reliable operation• Easy assembly• Designed to be a part of

the pump• Heavy-duty design• Minimum number of parts• Compatibility with pump

materials

Typical manufacturers• John Crane Safematic• Burgmann• Huhnseal

Options• No sealing fluid• Internal or external

flushing• Grease


AHLSTAR™ Process PumpsReady-Fitted Mechanical Shaft Sealing, Single with Quench

• Reliable operation• Easy assembly• Low-pressure quench fluid• Designed to be a part of the pump• Heavy-duty design• Minimum number of parts• Compatibility with pump materials



AHLSTAR™ Process PumpsReady-Fitted Mechanical Shaft Sealing, Double

• Reliable operation• Easy assembly• High-pressure flowing barrier fluid• High-pressure non-flowing barrier

fluid, dead-end• Designed to be a part of the pump• Heavy-duty design• Minimum number of parts• Compatibility with pump materials



AHLSTAR™ Process PumpsMechanical Element Seals, Single

Metal bellows • Metal bellows allow higher temperatures• Thin materials restrict usage with

abrasive liquids

Options• No sealing fluid• Internal or external flushing• Quench• Grease

Typical manufacturers• John Crane• Burgmann


AHLSTAR™ Process PumpsMechanical Cartridge Seals

• Designed for small spaces in gland packing seal chambers

• Thin material thickness• Recommended with restrictions• Recommended for easy applications

- low speed- low temperature

Typical manufacturers• John Crane• Chesterton• Burgmann


AHLSTAR™ Process PumpsGland Packing

• Reliable operation• High maintenance costs• Traditional shaft seal design• Always leaking• Leakage lubricates sliding surfaces• Abrasion of shaft sleeve and gland packings• Easy change of gland packing ring• Split stuffing box gland

Various arrangements• No sealing fluid

- clean liquids, water• Internal flushing

- clean liquids• External flushing

- impure liquids• Barrier flowing

- impure liquids• Cooling insert

- clean liquids


AHLSTAR™ Process PumpsS Structure Shaft Sealing

Ready-fitted mechanical seals, double• Designed to be a part of the pump• With or without external flushing fluid• Quench sealing fluid• Barrier flowing or non-flowing (dead-end)

sealing fluid, pressurized

Static seal• Simple• Constant air flow from outside

Mechanical element seals, single• With or without external

flushing fluid• Metal bellows


AHLSTAR™ Process PumpsR Structure Shaft Sealing

Mechanical element seals, single• With external flushing fluid• Metal bellows allow higher temperatures

Typical manufacturers• John Crane• Burgmann

Metal bellows


AHLSTAR™ Process PumpsE Structure Shaft Sealing

Mechanical ready-fitted seals• Designed to be a part of the pump• Heavy-duty design• Minimum number of parts

Typical manufacturers• John Crane Safematic,

Burgmann, Huhnseal

Single with quench sealing fluid

Double with options• Quench sealing fluid• Barrier flowing• Temperature control fluid


AHLSTAR™ Process PumpsE Structure Shaft Sealing

Mechanical cartridge seals• Single or double with options• Quench sealing fluid• Barrier flowing• Recommended with restrictions

Gland packing• Packing/support plate• Quench sealing fluid• Temperature control

fluid

• Barrier flowing• Quench sealing

fluid


AHLSTAR™ Process PumpsBearing Unit

• Solid fixed shaft• Heavy-duty operation• Long-life bearings

• Wear-free labyrinth seals• Deflector with lipseal protects

during operation and standstills

Strong and rigid support foot


AHLSTAR™ Process PumpsBearing Unit

Different material versions• Shaft materials stainless steel

- SS2324, SS2562, Ss2328• Bearing gages of metal• Auxiliary equipment material

- traditional- stainless steel

• Frame with pump adapter of cast iron or stainless steel

Grease lubrication for temperatures up to 120 oC / 250 oF

Oil lubrication for temperatures up to 120 oC / 250 oFSight glass and oiler drilling at both sides


AHLSTAR™ Process PumpsDrillings in Pump

Emptying holes• Casing• Dynamic seal• S version casing for vacuum pump• R version stuffing box housing

Temperature measurement connections• Casing cover• Dynamic seal housing• S pump casing for vacuum pump• R pump stuffing box housing


AHLSTAR™ Process PumpsStandard Material Combinations

Other corrosion resistant cast steels available on special request.1) Avesta 654SMO is a trademark owned by Avesta Sheffield which has granted Sulzer Pumps licence to produce this material.* For W construction.


AHLSTAR™ Process PumpsMaterials, Main Parts

Think corrosion resistance. Cast iron 53

41 Duplex• standard• good for most cases

4E Martensitic• precipitation hardened stainless steel

41 / 4L / 4T / 4G / 43 / 4U / 4J• wetted parts of the same material• shaft seal frame materials same as

pump material when ready-fitted seals are used

All SS versions• adapter• bearing unit• baseplate• SS accessories in bearing unit


AHLSTAR™ Process PumpsMaterials, Auxiliary Parts

O rings• EPDM• FKM (Viton)• FFKM (in E type pump)

Gaskets• Klinger SIL C-4430• PTFE / Glass• Flexitallic Sigma 511 (in E type pump) Coupling guard

• Zinc-painted steel - standard• Aluminum - non-sparking• Stainless steel - for corrosive conditions

Shaft sealmaterials same

or better.

Corrosion resistant thinking.

Casing


AHLSTAR™ Process PumpsAssembly

Back pull-out design allows fast service.

Concrete baseplate for pump and motor.

Can also be mounted on • rubber sheet• various mounting beams• vibration dampers etc.

Baseplate for pump only • suitable for a big pump

RIGBASE baseplate, steel or concrete with 3-point fastening. Distortion free and fast installation. EPP centerline mounted.

Riser blocks allow the installation of the next frame size of motor.

Safe coupling guard is designed according to safety regulations.

Flexible coupling with spacer allows fast service.


AHLSTAR™ Process PumpsBelt Drive Counter Flanges

Shaft ends are in the same direction. Fast and easy service of V belts and pulleys.

Safe V belt guard is designed according to safety regulations.

• LowPulse• Exact guidance• O ring sealing

• Collar for general applications

• Delivery with gasket


AHLSTAR™ Process PumpsSurface Treatment

Painting• EN ISO12944• Thickness 200 µm• Epoxy max. 150 oC / 300 oF• Silicon aluminum and epoxy

above 150 oC / 300 oF• Base also available with zinc epoxy

Grinding• Interior surfaces

- Ra 6.3- Cotton ball

• Open impellers only• Sandblasting also available

WashingSpecial care is taken to ensure the cleanliness of the pump.


AHLSTAR™ Process PumpsTests and Certificates

Duty Point Performance• ISO 9906 Grade 2

NPSHr• ISO 9906 Grade 2

Pulsation• For LowPulse pumps• Guarantee values in relation

to delivered head

Certificates also available on• Material: EN10204-2.2

EN10204-3.1.B• Painting, surface finishing,

washing


AHLSTAR™ Process Pumps

Books

Customer material according to order• IOM• Specification and part list• Dimensional drawing• Characteristic curve• Sectional drawings• CE declaration of conformity• Declaration of quality• Certificates• Component documents

CD-roms

• For the total project delivery order• Several languages in IOM and

component documents• Other documentation in English

www.sulzerpumps.com

PumpFlo curve catalogues

Available at www.pump-flo.com

AutoCAD symbols

2D projections of pump and baseplate

Delivered Documentation Materials Available


AHLSTAR™ Process PumpsAHLSTAR™ Vertical Pumps

These types utilize the same hydraulic parts as AHLSTAR™ NPP/NPT and WPP/WPT (casing and impeller).

AHLSTAR™ NVP/NVT Non-Clogging Vertical Pump

AHLSTAR™ NKP/NKT, WKP/WKT Cantilever Pump


AHLSTAR™ Process PumpsAPP/APT Process Pumps, Design Features and Benefits

A double volute casing in larger AHLSTAR™ pumps reduces radial forces and shaft deflection.

The self-venting, top centerlinecasing prevents air-lock in the top of the casing.

The sideplate is adjusted externally to maintain a constant impeller clearance and continuous high efficiency.

Open, special open and closed impellers are available for a wide variety of applications.

ROTOKEY impeller mounting provides strong, reliable power transmission. It is self-locking and reverse rotation safe. ROTOKEY facilitates the installation and removal of the impeller. It is not sensitive to axial loads created during pump operation.

Simplified heavy-duty bearing unit design. Oil

or grease lubrication.

Heavy-duty shaft. Deflection at stuffing box less than 0.05 mm/0.002 in. High-strength duplex

stainless steel is standard shaft material.

Non-contacting bearing protection for the

combined advantages of labyrinth ring, deflector

and lipseal. Lipsealprotects in standstill

position.

Strong and rigid bearing support foot improves

mounting stability.

1 Jackscrews for simple disassembly.


AHLSTAR™ Process PumpsNPP/NPT Non-Clogging Pumps, Design Features and Benefits

Common spare parts with all the other AHLSTAR™ process pumps.

Smooth and symmetrical casing design reduces fiberhang-up and vibrations and gives a large passage area.


Closed or vortex impeller for long fibers and special applications.


Simplified heavy-duty bearing unit design. Oil

or grease lubrication.

Heavy-duty shaft.Deflection at stuffing

box less than 0.05 mm/0.002 in. High-

strength duplex stainless steel is

standard shaft material.


combined advantages of labyrinth ring,

deflector and lipseal.Lipseal protects in standstill position.

Strong and rigid bearing support foot improves mounting stability.



AHLSTAR™ Process PumpsWPP/WPT Wear Resistant Pumps, Design Features and Benefits

Increased wall thicknesses in impeller, casing and sideplate.

Wear resistant design. Areas of abrasion are minimized by altering the flow patterns on casing and impeller.


Backflow led smoothly towards inlet flow, not against wall, resulting in less wear.

Back and front vanes of the impeller minimize recirculationand wear.


Smooth casing design – no gouging eddies.


Strong and rigid bearing support foot improves mounting stability.

Wear and corrosion resistant materials, chromium iron and duplex stainless steels.


Heavy-duty shaft. Deflection at stuffing

box less than 0.05 mm/ 0.002 in. High-strength

duplex stainless steel is standard shaft material.


combined advantages of labyrinth ring, deflector

and lipseal. Lipsealprotects in standstill

position.


AHLSTAR™ Process PumpsEPP/EPT Hot Liquid Pumps, Design Features and Benefits

A double volute casing in larger AHLSTAR™ pumps reduces radial forces and shaft deflection. The EPP Pump is also centerline-supported.

The self-venting, top centerline casing prevents air-lock in the top of the casing.

Gland packings and mechanical seals fit into the same space.

Spot-cooled stuffing box.

Closed and open impellers are available. EPP with a closed impeller can be used for pumping clean liquids or liquids containing impurities.



Simplified heavy-duty bearing unit design. Oil or grease lubrication.

Heavy-duty shaft. Deflection at stuffing

box less than 0.05 mm/ 0.002 in. High-strength

duplex stainless steel is standard shaft material.


combined advantages of labyrinth ring,

deflector and lipseal.Lipseal protects in standstill position.

Strong and rigid bearing support foot improves

mounting stability.



AHLSTAR™ Process PumpsR – Air-Separating Pumps, Design Features and Benefits

Recirculation pipe.

Open, special open or vortex impellers are available for a wide variety of applications. Impeller type depends on the pump type.

Expeller separates the liquid from gas and pumps it back into the inlet pipe through therecirculation pipe. Degassing pipe.

Single mechanical shaft seal.


AHLSTAR™ Process PumpsS – Self-Priming Pumps, Design Features and Benefits

Open, special open or vortex impellers are available for a wide variety of applications. Impeller type depends on the pump type.

Single or double mechanical shaft seal or sealless version.

Internal vacuum pump, less equipment.

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