Industrial Diesel Incorporated TECHNICAL SPECIFICATION 1000 HP Acid Pumper (Unit # 1345) 11000000 H HO OR RS SE EP PO OW WE ER RH HIIG GH HP PR RE ES SS SU UR RE EP PU UM MP P TTR RA AIILLE ER R TRAILER MOUNTED HIGH PRESSURE PUMP UNIT INTRODUCTION: This specification covers the minimum requirements of design, fabrication and testing of a Trailer Mounted High Pressure Pump Unit; this unit shall be trailer mounted and suitable for use in industrial and in-plant type environments. This high-pressure pump unit shall be suitable for many types of high pressure pumping with various fluids used for industrial water blasting and high pressure cleaning applications. This unit is locally & remotely operated with a digital pump control system. The unit shall be capable of operating in temperature ranges of 0 to 120 F. DESCRIPTION: Major components to include: Trailer, Radiator Engine, Transmission, Pump Low Pressure Tank & Plumbing System High Pressure Plumbing System (Customer Supplied) Control Panel/ Enclosure For Unit Operation This unit is equipped with one (1) Cummins QSK19 diesel engine rated 1090 BHP (+/-5% based on ambient conditions). The engine shall drive a Western Roughrider 1000 triplex pump via an Allison powershift transmission system.
OVERALL PERFORMANCE: While delivering full horsepower in any speed range of the deck engine in any gear, and without exceeding the pump ratings, there shall be no components that will vibrate with excessive amplitudes in resonance with the forcing vibrations of the engine or pump. Also, there shall be no excessive rotational vibrations of the engine, transmission, or pump due to transmitted torque and the flexibility of the trailer and mounting systems. The unit shall be capable of operating during prolonged pumping operations. The approximate physical dimensions of this unit are as follows: Overall Length - 38-6 Width - 8-2 Height - 13-6 Weight - 56,800 Lbs. (estimated) EQUIPMENT SPECIFICATIONS: POWER SYSTEM DIESEL ENGINE: Mounted on the trailer chassis will be a Cummins model QSK19 1090 BHP, two-stroke diesel engine. Engine rating: 1090 BHP @ 2100 RPM Heavy Duty air-filter system, dual stage, dry, element service indicators Fuel filters (Primary & secondary) Flywheel and flywheel housing (SAE #1), for use with Allison transmission Lifting eyes Manifold exhaust Oil filter and dipstick Oil pan Pumps, fuel & lubricating, fuel transfer, lubricating oil Pumps, jacket water Support, front trunnion Thermostats and housing Turbo chargers Vibration dampener Exhaust system, dual industrial grade silencers with rain caps Shutoff group electrical Torque converter flex plate drive connection Alternator (minimum 12 VDC) with dedicated battery bank Hydraulic starter system (Requires customer supplied wet kit on tractor) or 12V electric starter Emergency shutdown system
COOLING SYSTEM RADIATOR: A vertical mounted radiator system with horizontal air discharge will be installed on the unit that includes an engine-driven fan assembly, a surge tank, a water drain valve, a core guard. This radiator is designed to perform at ambient temperatures of 110 F and include the following auxiliary cooling systems Transmission oil cooler (tube & shell) Triplex pump power-end lube oil cooler (air to oil) Hydraulic oil cooler (air to oil) POWERTRAIN SYSTEM TRANSMISSION: An Allison CLT6061 transmission shall be mounted on the rear of the engine and complete with: 680 series torque converter w/ manual hydraulic lockup 1880 series output flange (or equivalent) Integral transmission filter Fill tube Lube oil site glass Gear ratios as follows: First 4.00 : 1 Second 2.68 : 1 Third 2.01 : 1 Forth 1.35 : 1 Fifth 1.00 : 1 Sixth 0.67 : 1 (blocked) Reverse N/A The transmission control shall be connected electrically to the triplex pump over pressure indicator and will, in over pressure situations, set the transmission to neutral and the engine throttle to idle. The transmission range selector will need to be reset to neutral position and the engine throttle will need to be reset to the idle position to reactivate the system control. DRIVE LINE: This unit shall be equipped with Spicer 1880 (or equivalent) driveline with heavy-duty universal joints connecting the transmission to the triplex pump. Installation of the driveline shall not exceed the manufacturer s maximum recommended angle and include the following: One (1) driveline guard, perforated metal One (1) safety driveline loop w/ removable cap
HYDRAULIC SYSTEM: A fixed displacement, gear type hydraulic pump for triplex pump power end lube oil is installed on the transmission driven PTO at engine speed. The pump will be complete with the following items: One (1) lube oil regulating relief valve, mounted at triplex pump One (1) inline pressure type lube oil filter Hydraulic reservoir system including: Internal baffles Carbon steel construction Cleanout cover Sight level gauge Breather cap Suction strainer Hydraulic hoses and fittings PUMP SYSTEM TRIPLEX PUMP: Installed is a Western Roughrider 1000 triplex pump with Gardner Denver 4 triplex fluid end The triplex pump includes the following features: Complete power end assembly Complete fluid end w/ integral suction manifold Single 2 FIG 1502 gauge connection installed on fluid end Steel 6 suction manifold 2 FIG 1502 discharge connection facing the front and rear of the unit 2 FIG 1502 discharge manifold (customer supplied) 8 stroke length Plunger packing lubrication system: Beka-Max grease type, 12 VDC Plunger sizes 4.0 (Or customer specified) LOW PRESSURE FLUID HANDLING SYSTEM SUCTION PIPING: Included shall be a suction manifold piping system mounted to the pump and terminated at the back of the trailer. All piping connections will be secured and supported to the trailer frame. This manifold shall include: One (1) 6 suction manifold One (1) 4 FIG 200 Male sub and cap
FLUID HANDLING SYSTEM: BOOST PUMP SYSTEM Included is a suction boost/ transfer pump system built as an integral part of the suction manifold system. The system is complete with the following: Open loop variable speed pump/motor drive system to provide power to drive the centrifugal boost/ transfer pump One (1) Mission 4 x 3 x 11 centrifugal pump One (1) 4 x 6 suction manifold system complete with cross over line and pump isolation for manifold & fluid end clean water flush Six (6) Fig. 200 hose connections complete with manual butterfly valves, two (2) on each side of machine Two (2) at the rear Manual hydraulic boost pump control (locally mounted on unit). Analog boost pressure monitoring via manual gauge and hydraulic pressure sensor RECIRCULATING / MIXING PUMP SYSTEM Included is a Recirculating / Mix tank & pump system built as an integral part of the suction manifold system. The system will be complete with the following: One (1) Twin 750 Gallon (1500 Gallon total) Acid storage/mix tank system, steel w/ internal acid resistant coating (Tnemec 120 or comparable) Open loop variable speed pump/motor drive system to provide power to drive the centrifugal Recirculating/ Fluid mixing pump One (1) Mission 4 x 3 x 11 centrifugal pump One (1) 4 x 6 suction manifold system complete with cross over line and pump isolation for manifold & fluid end clean water flush Six (6) Fig. 200 hose connections complete with manual butterfly valves, two (2) on each side of machine Two (2) at the rear Hydraulic recirculating / mix pump with electronic control ½ Barrel Mixing Tank w/ access lid and drain valve HIGH PRESSURE DISCHARGE PIPING: Note: Customer to supply all high-pressure iron
CONTROL & INSTRUMENTATION SYSTEM CONSOLE MOUNTED SYSTEM INTERCONNECT ENCLOSURE: The digital TRICON pump control system includes a locally mounted console with stainless steel interconnect enclosure mounted to the chassis. The engine/transmission/pump gauge display is for monitoring operating conditions of the engine, transmission and pump during normal operations in real-time. The local operator s control panel utilizes manual electric and air control switches for managing the operation of the engine, transmission and butterfly valve functions. System gages include: Engine RPM Engine hours Engine coolant temperature Engine oil pressure Transmission range w/ torque converter lockup status Transmission oil temperature Transmission oil main pressure Pump lube oil temperature Pump lube oil pressure Pump rate (BBL/Min) Pump rate totalizer (BBLs) Pump discharge pressure Over pressure trip setting (Manual) Hydraulic oil pressure Hydraulic oil temperature Other operator controls include- Engine OFF / RUN / START switch Engine throttle control (rotary control) Engine EMERGENCY KILL switch Transmission UP / DOWN rotary range selector switch Control system OFF / ON switch Work lights OFF / ON switch Pump plunger lube system ON / OFF switch
Additional features included on local machine frame Battery disconnect switch OPTIONAL EQUIPMENT (Price adder applies) REMOTE DAS SUITCASE The remote IntuiDaq digital operator pump data monitoring & acquisition system with hard wired & wireless data output system is installed in a weather-tight rugged suitcase enclosure for remote monitoring of the unit up to 300 away. The remote operator s display suitcase utilizes a 6 x 9 color display module to provide intuitive viewing of all major component operating run data as well as additional sensor feedback information. System data include: Pump discharge pressure (0-15,000 PSI) Pump discharge rate (BBL/Min) (turbine style flow meter) Pump discharge rate totalizer (BBLs) Pump discharge pressure Over pressure trip setting via Martin Decker manual gage Additional screens are available for component specific run data and sensor calibration Main Operator s screen (as listed above) Sensor calibration screen Over pressure trip/indication screen Alternate screen All wiring penetrations are routed into the enclosure via environmentally sealed twist-lock Mil spec connectors and cables with molded strain relief protection. Included is One (1) 200 remote control data cable w/ twist-lock cable connector. All instruments, switches, controls, etc. are clearly labeled in English. ADDITIONAL ITEMS: The Triplex pump shall include (1) 2 1502 gauge connection to utilize the supplied O - 15,000 PSI, FIG. Viatran pressure transducer which is connected to the TRICON pump control and IntuiDaq and displayed on the remote control screen for over pressure monitoring. Available Options: This control system is available with a quick connect twist-lock data connection for feeding running data to the data van for real time monitoring. Unit mounted remote cable reel
UNITIZATION AND COMPLETION DESCRIPTION The above unit shall be fully assembled, unitized, and completed to the customer s specifications. Note: If these items are already detailed above, they shall not be duplicated. This shall include the following items: Installation of all other electrical systems Installation of all hydraulic systems All steel and miscellaneous fittings to complete the unit All labor to complete unit Finish Coatings & Trim Level 1 (standard) o Oxide primer coat and Urethane finish coat to customer s one-color specifications.