High pressure technology that sets the standard

Transcription

1 High pressure technology that sets the standard High pressure plunger pumps High pressure pump units Application engineering

2 2 High pressure pumps Construction Hammelmann pumps with either 3 or 5 plungers are based upon proven, well engineered components and stand out due to their small footprint, low maintenance costs and high operational efficiency. Pump head Pump head The pump head contains the suction/ discharge valve sets. The pressurised medium produced by each individual plunger flows to a common high pressure discharge connection. The pump head valve housing is not subjected to alternating stress. Valve set Suction chamber Sealing system Plunger/Piston Suction chamber The medium is fed to the pump via a central inlet in the suction chamber. The sealing system components subjected to alternating pressures are located within the suction chamber and are completely immersed in the medium. This enclosed system offers additional safety. Bellows system Crank section Bellows system The bellows sealing system hermetically separates the medium end from the power end (crank section) preventing the ingress of fluid or gas. The standard bellows material is Viton but HNBR and PTFE versions are available for special applications. Crank section The integral speed reducer using twin helical gears arranged in herringbone configuration ensures smooth running and even power transmission without axial load to the bearings. A selection of gear ratios is available to allow the optimal choice of driver. Mechanical efficiency is in excess of 95%. The compact construction eliminates the need for an external gear box or an oversized flywheel mass.

3 High pressure pumps Sealing systems 3 High pressure seals The various plunger seal systems employed by Hammelmann enable safe and reliable, continuous duty at operating pressures up to 3800 bar. The choice of seal system used is dependant upon the pump application. Packed sealing The high pressure seal is made by packing rings. Plunger guidance is by means of a separate bush. This packed seal is particularly good when the pumped medium is abrasive or corrosive. Labyrinth sealing With this design the seal is made by a tiny amount of medium being forced downwards into the very fine cylindrical gap between the plunger and the labyrinth insert. The flow velocity and therefore the pressure decreases as the medium travels further downwards. This tiny amount of medium also acts as a component lubricant before returning to the suction chamber. Dynamic plunger sealing The dynamic plunger sealing system is used mainly for ultra high operating pressures. This design also produces very high volumetric efficiency. Packed sealing up to 1600 bar Labyrinth sealing up to 2000 bar Dynamic sealing up to 3800 bar Valves Differing valve designs are available to suit the pumped medium. Conical/Disc valves Standard design In this arrangement there is a conical valve on the discharge side and a disc valve on the suction side. Both sealing seats are in a single valve seat ring saving space and minimising dead room. Twin conical valves Special design for certain applications The discharge and suction valves are both conical.

4 4 High pressure pumps Quality features Compact construction Hammelmann pumps are renowned for producing high performance within a very small footprint. This is achieved by the compact design featuring the integral gearbox and the space saving vertical configuration. Development technology Using modern development technologies such as FEM (Finite Element Method) and CFD (Computational Fluid Dynamics) as early as the planning stage ensures the optimal design of components. Maintenance A basic design principle of Hammelmann is to ensure that the customer can service the pump quickly and easily. Maintenance therefore is carried out from above. By simply removing the valve housing you have fast, uncomplicated access to all important pump head wearing parts. The individual plunger seal sets can be quickly disconnected and be lifted out of the suction chamber for replacement or repair. During new development work comprehensive stress and long term fatigue testing is carried out. The resultant data is extensively analysed and incorporated in the component design as required. Customer specific special designs are developed in close cooperation with the client as a project with input from both parties. All oscillating forces are vertical and are absorbed by the base frame. Unwanted lateral oscillations as produced by horizontally configured pumps cannot occur. Materials All raw materials and purchased components are subjected to the stringent controls of our Quality Management System. Materials are individually selected based on component function, load and area of application. Directives and standards Hammelmann high pressure pumps are manufactured in accordance with European directives and standards. We can of course manufacture in compliance with customer s specifications. Quality control Hammelmann believe in a start to finish, unbroken flow of data from the final design stage, over the programming process including choice of tooling and selection of the machines. Hammelmann products are subjected to strict quality control procedures. All pumps are extensively tested in our modern test centre prior to delivery. Plunger speed Moderate plunger speeds limit wear of plungers and sealing elements. HDP 800 HDP 500 HDP 380 HDP 250 HDP 170 HDP 120 HDP 70 HDP 40 HDP ,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 Plunger speed m/sec

5 5 Conversion kits All Hammelmann pumps can be converted to other operational parameters (flow rate and operating pressure) with the acquisition of a conversion kit. Due to the design of the Hammelmann pump this can be carried out quickly with standard tools. If there is a regular need to change the performance of ultra high pressure pumps or pump models HDP 380 and above conversion is even faster. The pump head and the plunger seal sets form a single assembly which increases the reliability of the conversion and reduces the time required to a matter of minutes. Step 1: Disconnect the plungers Step 3: Lift out the complete medium bearing end and store. Fit the new medium bearing end in the reverse order. Step 2: Remove the pump head nuts Controls ES 2 controller Actual status data from the diesel engine is transmitted via CAN-Bus to the ES 2. All possible engine malfunctions appear as a fault code in the display with the most critical enhanced by clear text announcements. NANO-B controller (SPC) Hammelmann s exclusive ES 2 controller based on SDM technology controls the complete high pressure pump unit. The ES 2 is a microprocessor that controls diesel engine driven units and electrically powered units that are outfitted with a frequency converter. It constantly carries out complex monitoring and regulating functions whilst collecting data for the various diagnostic functions. Hammelmann control systems will continue to reflect the demands of the market place. Controls and monitors constant speed, electrically powered pump units (star delta or soft start). Pump monitoring with analogue sensors Information menu with actual unit status (bar/ C) Fault announcements in clear text NANO SPC enables special control functions and projects.

6 6 High pressure pumps Hammelmann high pressure pumps are built for continuous duty within their stated performance parameters. Refer to the individual pump data sheets for the crankshaft speeds, average plunger speeds, plunger diameters and power ratings. HDP 20: up to 18,5 kw up to 3500 bar, up to 103 l/min HDP 40: up to 37 kw up to 3800 bar, up to 155 l/min HDP 70: up to 70 kw up to 3800 bar, up to 246 l/min HDP 120: up to 120 kw up to 3800 bar, up to 326 l/min HDP 170: up to 170 kw up to 3800 bar, up to 460 l/min HDP 250: up to 250 kw up to 3800 bar, up to 766 l/min HDP 380: up to 380 kw up to 3000 bar, up to 841 l/min HDP 500: up to 500 kw up to 3000 bar, up to 1058 l/min HDP 800: up to 800 kw up to 3000 bar, up to 2100 l/min Mining industry pump HDP 250 L: up to 250 kw up to 3000 bar, up to 766 l/min Sewer cleaning pump HDP 146: up to 135 kw up to 230 bar, up to 462 l/min Sewer cleaning pump HDP 196: up to 180 kw up to 210 bar, up to 605 l/min

7 High pressure pump units 7 The pumps are configured as complete units to meet the requirements of the many varied industrial applications. Stationary unit with electric motor and controller Extra compact electric unit for on board ship applications Stationary unit with frequency converter for a jet cutting table or for pressurised coolant/lube feed In plant trailer mounted electrically powered unit with control cabinet Transportable unit with extra strength base and frame for deep mining applications Stationary unit with electric motor Stationary unit with diesel engine Diesel unit with V-belt drive Road going diesel unit Built into 10 and 20 containers or special sizes Built into a truck Built into a BDF swap body container

8 8 Application engineering Accessories and systems Standard High pressure hoses are cut and assembled with end fittings in house and in accordance with certified procedures High pressure water blasting guns with various activation and control mechanisms Round and flat jet nozzle inserts in a variety of sizes, shapes and materials Bypass key switch Surface cleaning/preparation Bypass foot switch and mechanical, electro/mechanical foot valves in various designs Protective clothing and safety accessories Rotorjets for use with high pressure blasting guns and lances Pneumatically powered Rotorjet with a selection of nozzle holders Mechanically deployed Rotorjets for special cleaning systems Hydraulically or electrically powered Rotorjets Spray bars for various applications Multiple Rotorjets, electrically powered

9 9 Surface cleaning/preparation Aquablast surface blasters with and without direct vacuuming Spiderjet attaches to the work surface by the same vacuum power that collects the waste and waste water Dockmaster semiautomatic blasting vehicle for surface preparation on ship hulls Dockboy semi-automatic tracked vehicle for surface preparation on hull bottoms and other metal surfaces Tank cleaning The water jet velocity entrains abrasive to form a water/abrasive jet to strip and roughen metals Hand rail cleaner removes rust and old coatings down to bare metal prior to recoating Aquamat 3 D tank cleaning heads remove soft and hard deposits from the internal surfaces of tank walls Nozzle arms for tank cleaning heads with a range of formats, leverage angles and lengths Protective cages and fittings for tank cleaning heads Hose reels Aquarex systems for deploying tank cleaning heads to internally clean a variety of tank and vessel designs

10 10 Application engineering Accessories and systems Heat exchanger cleaning Rigid and flexible lances Nozzles with multiple bores for heat exchanger bundle tube internal cleaning Turbojets with fast spinning bore sections Pipemaster system with rotating lances for semiautomatic heat exchanger cleaning Positioning and safety device for working with manually deployed lances Rotating hose reel for cleaning vertical and horizontal heat exchangers Pipe and sewer cleaning Reversible nozzles can be switched from push to pull either manually or remotely Rotorjets to remove hard deposits Cleaning nozzles for large sewers Nozzle holder designs for rotating hose reels 3 D pipe cleaners Oil industry down hole cleaners with radial and push nozzles at the front and pull nozzles at the rear

11 11 Water hydraulics Pneumatically actuated pressure regulating valve for smooth adjustment of pump operating pressure Changeover valves divide the total flow of the pump equally or unequally between a number of blasting tools Pressure maintaining valves, non return valves and safety valves Solenoid valves open and close various blasting tools Flow diverter (splitter) nozzles reduce excess operating pressure flow to ambient pressure Rotary joints can be outfitted with various blasting tools Oil hydraulically driven rotary joints Pneumatically driven rotary joints Electrically driven rotary joints Abrasive cutting A water jet entrains the abrasive inside the cutting head housing Focussing nozzle, guide piece and water nozzle inserts for cutting heads Nozzle carrier with guide rail for flat surfaces and tensioning device for cutting pipes

12 Service Service centre A product is only as good as the service the manufacturer provides. Hammelmann is known internationally for reliable and fast customer service. Training Professional instruction of operational personnel is extremely important. Learning by doing in realistic situations will enable personnel to retain the knowledge they gain. Technology centre By simulating the production process and carrying out individual tests the necessary performance parameters are defined, recorded and evaluated to arrive at a practical proposal. Flexible, competent and experienced staff are always ready to carry out servicing and repair works. Logistic centre With our logistic centre we can offer our customers a very fast spare parts service. Around different active parts can be accessed within a short time span. Based on the participant s needs and their existing knowledge we provide practical and theoretical training covering the following subjects: Safety Proper operating procedures Maintenance and repair Basics of application technology High pressure pumps Accessories and systems For your own testing we provide you with an applications engineer and a technician plus various water tools and a range of inspection instruments, rotary joints and special nozzles. Hammelmann Maschinenfabrik GmbH Oelde headquarters and plant Member of INTERPUMP GROUP As a business operating in a global market and with subsidiary companies in the USA, Brazil, China, Australia and Spain plus around 40 international partners Hammelmann provide a worldwide service. Zum Sundern Oelde Germany Telephone , Telefax mail@hammelmann.de Hammelmann products are manufactured using the most modern machines available today. Strength in depth manufacturing capability enables maximum flexibility in producing high quality products. 10/10 Copyright of Hammelmann Maschinenfabrik GmbH, Oelde, Germany. Subject to modification.

13 3000 bar UHP water blasting systems for surface preparation in ship building and ship repair Hammelmann ultra high pressure water blasting systems operate at pressures up to 3000 bar without any abrasive additives. Using water eliminates the harmful and often damaging side effects produced by dry abrasive blasting such as airborne dust, chemical/ thermal pollution and surface ingrained residual blasting materials. It is the healthy, environmentally friendly method of surface preparation. The energy of the high velocity water jets blasts into the pores in the metal surface flushing out solid foreign matter and non water soluble pollutants such as oil and grease. Remaining chloride levels are at least 5 times lower than in a grit blasted surface and the substrate profile remains intact ensuring good adhesion of the new coating and greatly reducing the risk of future paint film defects. The amount of waste produced is far less than that produced by dry blasting. It is only the waste water, old paint, marine growth and rust which is easily collected for separation and disposal. Water can be treated for disposal or recycling. Shrouding the work area is not necessary. Water will not harm nearby seaworthy equipment and machinery as is often the case with ingress of flying grit particles nor is there any unhealthy dust to distress yard personnel. Substrates prepared by Hammelmann systems meet the quality requirements set by international paint manufacturers and standards authorities for the application of new coatings. The water pressure necessary depends upon the condition of the existing surface layer(s), the type of coating to be applied and the substrate quality necessary for the successful application of that coating. Economic, ecological removal of TBT coatings Old paint Red epoxy Rust shop primer These illustrations are extracts from HEMPEL S reference handbook of NACE/ SSPC standards showing substrate grades with the original surface conditions at the top. Hochdrucksysteme nach Maß

14 Semi automatic UHP systems Semi automatic UHP metal surface preparation systems are capable of producing a range of surface finishes from washed, swept, selectively removed coating(s) right through to blank metal. The traverse speed over the surface and the stand off distance between jetting nozzles and the surface are adjustable to enable optimum working efficiency. Dockmaster The Dockmaster is specifically designed for cleaning, rust removal and coating removal from ship hulls. The waste water and removed solids are vacuumed to an on board treatment plant where the solids and water are separated with the solids collected in an interchangeable filter module for further disposal. The system is outfitted with an integral Aquajet 40 Ultra High Pressure pump unit producing 72 l/min. at 2800 bar operating pressure and at the touch of a button 85 l/min. at 2500 bar. The high energy water jets concentrate blasting over a working width of 850 mm and dependent upon the quality of surface finish required achieve removal rates between 100 and 300 m 2 /h. The self propelled vehicle has a turntable mounted telescopic jib with a work arm mounted at the tip carrying an Aquablast surface blasting unit. Working height 0.5 m to 28 m. The design of the swivelling work arm is such that overhead deployment of the Aquablast is possible from a minimum height of 3.5 m. Photo courtesy of Blohm+Voss Repair GmbH

15 SpiderJet 3000 The remotely controlled SpiderJet 3000 attaches to the work surface by vacuum force. It can blast while traversing both vertically and horizontally in either direction on flat and on curved surfaces and can also operate overhead. ML 3000 The ML 3000 is mounted to man lifts, dock arms and other access devices. It has a working width of 400 mm and can be traversed either vertically or horizontally achieving blasting rates of up to 50 m 2 /h dependent upon the surface being treated. Two powerful pneumatic motors drive the wheels of this extremely manoeuvrable unit enabling surface blasting rates of up to 70 m 2 /h to be achieved from a working width of 375 mm. A gas damped telescopic section automatically maintains the blasting head against the work surface and the waste water and removed waste can be vacuumed away from the surface for collection and disposal. Waste water and waste materials are directly vacuumed away from the work surface. A twin cable arrester and permanent vacuum force monitoring coupled to automatic pump pressure shut down ensure safe operation. Dockboy The Dockboy is a modern blasting head carrier vehicle designed for use in dry docks. Its low height enables it to be deployed for hull bottom blasting and work at a height of up to 2600 mm. In addition to bottom blasting with an Aquablast mounted on the carrier device it can be outfitted with ancillary tools either on the carrier or on mounting adapters to convert it to dock bottom or ship deck work.

16 Manual UHP water blasting tools The efficiency of manual water blasting tools is very dependent upon the operator. They are normally employed for special small surface area blasting tasks. Hand held guns fitted with water driven Rotorjets or with pneumatically driven specialist nozzle carrier heads are particularly useful for working in restricted access areas or for intensive spot blasting. The hand held Aquablast is the ideal tool for flat vertical surface treatment. It has a working width of 140 mm. Flexibility of deployment and ease of handling make the manual UHP gun the universally accepted blasting tool. Repair yard and on board applications Marine growth removal from bilge keels, propellers etc. Spot blasting on hulls above and below the water line Rust and coating removal in ballast tanks, holds and bunkers Blast cleaning and coating removal, superstructures, decks, deck machinery, anchor chains etc. Dry dock clean up and maintenance The manually deployed horizontal surface version has a working width of 215 mm. Both can be outfitted for direct waste vacuuming. New build applications Removing burnt primer and slag from welds Pollutant (grease, dirt etc.) removal Cold cutting Pump units The heart of any high pressure cleaning or ultra high pressure blasting system is the pump unit. Hammelmann Aquajet pump units are available in power ratings from 70 to 550 kw in stationary or mobile format and with sound damping covers if required. They can also be mounted in a range of heavy duty containers particularly suitable for the dockyard environment. Copyright of Hammelmann Maschinenfabrik GmbH, Oelde, Germany. Subject to Modification. Hammelmann Maschinenfabrik GmbH P.O. Box D Oelde Phone ( ) 76-0 Zum Sundern Germany Fax ( ) mail@hammelmann.de Internet: HAM Stu e