Gear Pumps for Lubricating Oil Systems. Gear Pumps KFF for Marine Fuels. Multiple Pumps / Hydraulic Manifolds. Fuel Consumption Measurement

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1 Marine Products

2 2 Marine Products Content 3 Company 4 5 Gear Pumps for Lubricating Oil Systems 6 Gear Pumps KFF for Marine Fuels 7 Valves 8 Multiple Pumps / Hydraulic Manifolds 10 Flow Meters 11 Fuel Consumption Measurement 12 Valve Position Indicators Quality Assurance 14 Customer Service 15 Sales

3 3 Company Over 100 years of experience make us stand out as a reliable partner. We are a leading manufacturer of gear pumps and flow meters. Over 300 employees at the Werdohl site and additional 85 employees in our subsidiary companies in China, USA and Hungary design, produce and sell products in both standard versions as well as special solutions tailor-made to customer wishes. These high-quality components are used for gear lubrication, for instance in wind power plants and ship gears, in dosing and mixing plants e.g. for manufacturing PU foams, and in test bench technology. The range is supplemented by products for mobile hydraulics and industrial hydraulics which are used, for example, in construction machinery, agricultural machines, in general mechanical engineering and a multitude of stationary applications. Reliability and high-quality standards are just as important a part of the corporate philosophy as fairness to customers, suppliers and employees alike Registration in the commercial register under the name Hillebrand & Kracht OHG 1971 Construction of today s company premises on a total area of over 50,000 square meters Sale through the Swedish group BAHCO through Investmentholding Industrievarden to the COMAC Group 1992 Purchase of a gear manufacturer in Hungary, now KRACHT Hidraulik Kft First certification according to DIN EN ISO 9001, KRACHT Hidraulik Kft., Budapest according to DIN EN ISO 9002 by Lloyd`s Register Quality Company 1996 KRACHT is once again in private ownership 1999 Mr. Peter Zahn becomes 100% proprietor of KRACHT GmbH Made in Germany 2003 Certification based on the ATEX Directive 2014/34/EU 2008 In New York, USA the KRACHT Corporation is founded Establishment of the subsidiary in Shanghai, China 2011 Opening of the in-house health centre on a area of approximately 300 square meters Oktober 2011 The company KRACHT has existed for 100 years 2012 In December, KRACHT was certified by the German Federal Department of Aviation (LBA) and now has the status known consignor 2015 KRACHT is certified according to AEOF 2016 Construction of the 3,500 square meter logistics center 2000 First certification according to DIN EN ISO Certificate of incorporation of today s KRACHT GmbH 2002 Mr. Heiko Zahn is appointed as Second Managing Director

4 4 Marine Products Gear Pumps for Lubricating Oil Systems Gear Lubrication Characteristics and Versions noise optimized for air containing oils (special number 197) working pressure 315 bar; ISO oils up to VG 460 version with outboard bearing for direct mounting on the gearbox and for taking radial forces (Fig. 1) with nozzle in shaft end for gear lubrication high efficiency over large ranges of speed high cold start viscosities at high idling speed possible low temperature version ambient temperature up to 40 C version in EN-GJL-250 (grey cast iron) or EN-GJS (spheroidal cast iron) with inspection certificate EN from all classification authorities upon request with SAE shaft and SAE flange (optional) optionally with flanged pressure valve / pressure relief valve / universal valve (universal valve = changing direction of rotation - consistent discharge flow) (Fig. 2) pump assembly version with electric motor (Fig. 3) Gear pump with universal valve Fig. 2 Electrically driven pump KF 3/112 Mechanically driven pump KF 3/63 Fig. 1 Gear pump assembly with pressure relief valve Fig. 3

5 5 Engine Lubrication Main Lubrication and Pre-Lubrication Pumps Gear Pumps KF Characteristics and Versions Version as pre-lubrication pump with electric drive (Fig. 1) Version as main or pre-lubrication pump with integrated pressure relief valve with electrical or mechanical drive (Fig. 2 und Fig. 3) Displacement volume according to customer requirements Pumps with outboard bearing for taking radial forces (pinion gear drive) High efficiency over large ranges of speed Noise optimized for air containing oils (special number 197) Compact version with bell housing Pump assemblies with high and premium efficiency motors Standard pumps and special pumps Displacement Δp Speed Seals Option cm³/r (standard) up to 50 bar possible /min mm²/s Rotary shaft lip-type seal Mechanical seal Magnetic coupling more than 400 special versions Pre-lubrication pump Gear pump with pressure relief valve High Pressure Gear Pumps KP Fig. 1 Displacement Δp Speed Seal cm³/r up to 315 bar possible /min mm²/s Rotary shaft lip-type seal Fig. 2 High Pressure Gear Pump KP 2 Special Pump SOP Main lubrication pump with integrated pressure control valve and driving gear Displacement Working pressure Speed Option cm³/r up to 25 bar /min Pressure control valve Fig. 3

6 6 Marine Products Gear Pumps for Marine Fuels Gear Pumps KFF for Marine Fuels Redundant gear pumps KF Characteristics and Versions For marine diesel (MDO), heavy fuel oil (HFO) and marine gas oil (MGO) (Fig. 1) Optional with magnetic coupling for a high level of operational security and a long life (Fig. 2) With inspection certificate EN from all classification authorities upon request Special execution for low viscous and low sulphur fuels Material Displacement Working pressure / Speed Seals Housing and Cover: Spheroidal cast iron EN-GJS cm³/r p max = 12 bar at 1.2 mm²/s p max = 25 bar at 12 mm²/s /min Rotary shaft lip-type seal FKM Mechanical seal FKM Magnetic coupling Fig. 1 Fuel Oil Supply Modules Fuel characteristics Lubricity HFRR-test * (according to ISO 12156) mm²/s (dependent on pressure, speed and lubricity) WSD 520 μm (meet the requirements of ISO 8217 for marine fuels) * The HFRR test acc. ISO is a recognised method for measuring the lubricity of diesel fuels. The characteristic value determined using this method is referred to as Wear Scar Diameter (WSD) and increases with decreasing lubricity. This characteristic value is stated by the fuel manufacturers and can be included when assessing the stability of components. Fuel oil supply modules are used for the supply for diesel engines and tied into fuel system between day tank and the engine. Our components: Feeder pump KF Booster pump KF Pressure relief valve SPV Gear Pump KFF with magnetic coupling (pump assembly) Fig. 2

7 7 Valves Pressure Regulation and Control Pressure Relief Directional Control Valves Pressure Valves DV The DV pressure valves are used for pressure regulation in various applications in hydraulic, lubricating oil and fuel systems. By control oil connections enables external triggering or relief. Pressure Stage Control Valve DV S Control valve, e.g. as a coupling control valve for large gears for switching between two or three pressure stages with a magnetic directional control valve. Clutch Clutch Oil Gallery Oil Gallery High Pressure Oil Cooler Low Pressure Oil Cooler Filter Filter Solenoid Valve Solenoid Valve Oil Pump Oil Pan High Pressure Setting Oil Pump Oil Pan Low Pressure Setting Pressure Valve DV Pressure Relief Valves SPV/SPVF Pressure Relief Valve SPVF Directly operated pressure relief valve For protecting of lubricating oil systems with tank connection Applicable for pretension of lubricating oil systems Applicable in ATEX areas EN-GJL-300 (GG 30) oder EN-GJS-400 (GGG 40) Pressure Control Valve DV R Pressure regulation of, e.g., lubricating oil circuits in gears and diesel engines with external hydraulic signal pressure. Filter Main Flow Oil Pump Oil Cooler Regulating Pressure Setting Oil Gallery Pilot Pressure Surplus Flow Pressure Relief Valve DV B Pressure relief valve or pressure retention valve for lubricating oil, fuel and hydraulic systems (optionally with internal magnetic 2-2 directional control valve for reduced pressure circulation). Main Flow Filter Oil Pump Oil Cooler Relief Pressure Setting Oil Gallery Relief Flow Flow rate 800 l/min Oil Pan Oil Pan Working pressure max. 120 bar Flow rate l/min mm²/s Working pressure max. 210 bar Option more than 50 versions mm²/s Directional Control Valves WL with inspection certificate according to EN Nominal Size Flow rate Working pressure Media temperature l/min 320 bar C l/min 320 bar C l/min 350 bar C l/min 350 bar C 20 (25) 700 l/min 350 bar C

8 8 Marine Products Multiple Pumps Hydraulic Manifolds Multiple Pumps Characteristics and Versions Counter rotating direction of flow possible Different sizes and types together with KRACHT pumps combinable (KF + KF / KP + KF / KP + KP) Acceptance of all classification societies Hydraulically separated Low pressure gear pump KF + Low pressure gear pump KF Low pressure gear pump KF + High pressure gear pump KP High pressure gear pump KP 2 + High pressure gear pump KP 3 Hydraulic Manifolds Versions according to customer specifications Complete hydraulic controls of clutches Purely mechanical versions possible Adjustable pressure curves Optional with manual emergency override Pressure Build-up Curves Clutch pressure P K (bar) P K 25 P K 25 Clutch pressure P K (bar) P KV2 12 P KV 7 P KV1 7 0 Pressure build-up time t 0 Pressure build-up time t Clutch pressure P K (bar) P K 25 P KV2 8 P KV1 3 Pressure build-up time t Clutch pressure P K (bar) P K 25 P KV3 12 P KV2 7 P KV1 5 Pressure build-up time t Hydraulic Manifold

9 9 Flow Meters for Control and Regulation of Fuel and Oil Systems Gear Type and Screw Type Flow Meters Gear Type Flow Meter VC Gear Type Flow Meter VCA Measuring range l/min Measuring range l/min Working pressure max. 400 bar Working pressure max. 200 bar mm²/s mm²/s Accuracy +/- 0.3% from measuring value Accuracy +/- 1% from measuring value Repeat Accuracy < 0.1 % Measuring span 1 : 250 Applicable in ATEX areas EN-GJS-400 (GGG 40) or EN-GJS-600 (GGG 60) High accuracy Fast response speed Repeat Accuracy < 0.1 % Measuring span 1 : 200 Applicable in ATEX areas Aluminium housing Threaded connections Screw Type Flow Meter SVC Measuring range Working pressure l/min max. 400 bar mm²/s Accuracy Repeat Accuracy < 0.1 % Measuring span 1 : 150 +/- 0.2% from measuring value Flow measurement with the smallest pressure drop In-line installation and SAE connections Max. foreign particle size 400 μm Applicable in ATEX areas EN-GJS-400 (GGG 40) Gear Type Flow Meter VC Gear Type Flow Meter VCA Screw Type Flow Meter SVC

10 10 Marine Products Fuel Consumption Measurement per [kg/nm] per [g/kwh] Main Engine Auxiliary Engine Display Bridge ASR 20 Mixing Tank 1 Mixing Tank 2 Screw-Type Flow Meter SVC 40 Gear Type Flow Meter VC 1 Day Tank 1 Electronics Engine Room ASR 20 Day Tank 2 Individual customer solutions on request

11 11 Valve Position Indicator Valve Position Measuring Instrument VOLUMEC VOLUTRONIC Design Gear type volume counter Gear type volume counter max. flow rate max. working pressure 02: 4 l/min 04: 7 l/min 5: 150 l/min 02 / 04: 200 bar 5: 300 bar 0.25 up to 10 l/min 160 bar Display mechanical by downstream electronic possible Current-independent display yes Current-independent position detection yes no Leakage detection yes by downstream electronic possible Reset function at slipping clutch by downstream electronic possible Calibration to actuator size by gear reducing by downstream electronic possible Flow direction must be defined A-B / B-A Error message no by downstream electronic possible Hydraulic Manifolds Description HB HB double pilot operated check valve for holding the actuator position two pressure relief valves for limiting the pressure caused by increased temperature throttle valve in port A for speed regulation of the actuator check valve for filling the piping to avoid wrong indications when temperature fluctuates check valve in P for holding the actuator position when switching parallel actuators check valve in T to avoid indicator fluctuations due to pressure pulsation one temperature pressure relief valve for limiting the pressure caused by increased temperature throttle valve in port A for speed regulation of the actuator check valve for filling the piping to avoid wrong indications when temperature fluctuates Schematic

12 12 Marine Products Quality Assurance at KRACHT Machinery Housing and Cover Manufacture The main components of our products comprise the housing and the cover. These components are manufactured in all sizes (GG-25 to GGG-40) from casts as well as from stainless steel and aluminium. The dimensional accuracy of the components in the entire material spectrum lies in the μm-range. All housings and covers are fabricated completely on our ultra-modern horizontal Mazak machining centres. The constant coolant temperature stabilization, a cooling system for the ball roller spindles and a linear system for all axes guarantees the precision. To reduce the clamping and setup times, all the machines are equipped with multi-palettes and have machine-monitoring systems for fully-automatic machining. The machining tools in use are ceramic, CBN or TIN coated, which is another characteristic feature of the high KRACHT quality. To ensure the guarantee of long-term precision, all machining centers are put through a machine capability analysis annually by our quality assurance department.

13 13 Gear Manufacture Since our components are highly complex and high requirements are placed on the quality of the workpieces, the manufacture of gearing and the external cylindrical machining pose a special challenge. We are perfectly up to the challenge. We manufacture our products on ultra-modern gear hobbing machines, generating grinding machines, profile grinders and on external cylindrical and internal cylindrical grinders. Prefabricated rotating blanks are prepared and machined on CNC-gear hobbing machines with vertical workpiece axis. The external cylindrical machining is undertaken on CNC-angular plunge-cut tables. This grinding technology is highly versatile and its enormous productivity simultaneously impressive. We are capable of grinding nearly any workpiece contours with one, single grindstone in one, single clamping restraint. After completing the external cylindrical machining, the gear sections are conclusively ground on CNC-tooth profile sharpening machines with the generation grinding method. The measuring equipment integrated in the machinery facilitates measuring all relevant tooth dimensions. That greatly reduces the setup times when setting up new machining jobs. Compliant with the housing and cover manufacturing, these machines are also put through a annual machine capability analysis by the quality assurance department. All products are put through a 100% pre-delivery inspection. Along with the functions, all working parameters are set on the test bench and can be certified according to DIN EN KRACHT GmbH, Werdohl according to DIN EN ISO 9001 according to DIN EN ISO according to ATEX 2014/34/EU KRACHT Hidraulik Kft., Budapest according to DIN EN ISO 9002

14 14 Marine Products Customer Service Fair, reliable and competent We have been developing, designing and manufacturing high-quality products for 100 years. Special solutions are implemented in close cooperation with our customers. On schedule performance and full comprehensive service are our top priorities. Latest production methods 100% pre-delivery inspection Customer On-site consulting by our product specialists Comprehensive documentation in national language After-Sales-Service

15 15 Sales International Australia Austria Belgium Canada China Czech Republic Denmark Finland France Germany Holland Hong Kong Hungary Italy Japan Korea Luxembourg Norway Poland Portugal Russia Slovakia Slovenia South Africa Spain Sweden Switzerland Turkey United Kingdom USA We are ready to support you around the world with the professional mastery of specific applications and complete solutions. A closely woven network of sales and customer specialists provide the right tools for national and international consulting and optimal customer service.

16 KRACHT GmbH Gewerbestraße Werdohl, Germany Phone Fax info@kracht.eu Web 03/2017 GB