When Power is Critical EN-1834-1 EN-1834-2 Reliable and powerful starting for diesel engines and generators HYDRAULIC STARTING SYSTEMS For diesel engines up to 80 litres IPU s hydraulic starting systems provide guaranteed reliability no matter how challenging or unpredictable the environment. This independent, dead-ship or black-start capability is ideal as your primary method of starting fire pumps, emergency generators and compressors. IPU s ATEX-approved starter motors provide safe starting on offshore platforms, in mines and at other hazardous locations. Manufactured from cast iron, IPU s hydraulic starter motors combine quick acceleration with high torque output for guaranteed starting in extreme temperatures, after long shut down periods and in damp and hostile conditions. Reliable IPU s hydraulic starting systems do not depend on electrical power. They can act as the primary start system for emergency systems or a secondary start system in case electrical starting fails. Convenient IPU s hydraulic starting systems are self-contained and sealed making them ideal for use in underground and dusty environments. ATEX-Approved To meet ATEX s stringent standards, IPU s hydraulic starting systems are manufactured with a cast-iron casing. A pre-engaged pinion option prevents sparking in explosive environments.
How hydraulic starting systems work Energy is stored in the form of hydraulic oil under pressure inside the accumulator. The oil is released using a foot switch, solenoid or manually-operated start valve. Once released, the oil travels to the starter motor which engages with the engine ring gear and cranks the engine. Once the engine has reached firing speed the pinion is automatically kicked back by the ring gear. The system can be recharged manually using a hand-operated pump, electrically using a hydraulic pump or even through the host machine's on-board hydraulics. Installation IPU provides a total solution not just a system. We can design to your exact specifications, build, test, install and commission your system. If space is a problem, items can be supplied loose and mounted on the engine skid. Level Sight Glass Filler Breather Starter Motor Oil Reservoir Foot Valve Pressure Gauge Hand Pump Safety Relief Valve High Pressure Filter Customer Benefits Accumulator Guaranteed start: The energy can be stored indefinitely providing the system is installed and maintained to IPU specifications. It can be quickly and easily recharged via a hand pump. Performance in all conditions: Performance is unaffected by hot or cold conditions provided the correct oil is used. Starters operate efficiently following extensive periods of shut down. Low maintenance: Hydraulic starting systems last as long as your engine. The system is totally enclosed with all internal components immersed in oil, protecting them from the adverse environmental conditions that damage electric or vane starters. Safe in hazardous areas: IPU s pre-engaged hydraulic starters meet ATEX regulations for both gas and dust environments such as offshore, marine and mining.
Additional Information ATEX-Approved ATEX regulations ensure that equipment being used in hazardous or explosive environments is safe to use. IPU s pre-engaged hydraulic starters are ATEX-approved. They offer two key technical advantages: Cast-iron casings: IPU avoids the aluminium casings used by other starter motors. Aluminium is not safe for hazardous environments due to the risk of a thermite reaction. When aluminium and iron oxide (i.e. rust) are ignited by a spark the reaction produces temperatures up to 3000 C. That would be a disaster in any explosive atmosphere. Pre-engaged mechanism: to avoid sparks, a pre-engaged starter motor waits until the pinion has engaged with the ring-gear before cranking the engine. By contrast, inertia starters move a spinning pinion onto the ring-gear. The inevitable sparks are a danger in hazardous environments. IPU s preengaged starter motors conform to ATEX EN1834-1 and 2. They are safe to use in flammable gas atmospheres and underground environments vulnerable to combustible dust. PED Certified The Pressure Equipment Directive 97/23/EC (or PED) sets out standards for the design and manufacture of pressure equipment. It covers the sale and use of equipment that contains pressures above 0.5 bar. IPU s hydraulic and air starting systems comply with the Pressure Equipment Directive. Our systems are approved by an independent Notified Body. We offer maintenance and servicing of your equipment to ensure it remains compliant. We can provide training on basic maintenance tasks that can be performed regularly by owners and operators. Certified offshore maintenance service Although our starters are rugged and designed to withstand the harshest environments, extreme conditions always take their toll. Regular inspection and servicing is essential to ensure that your starter works if disaster strikes. IPU has a dedicated service team for starting systems. We can simplify your maintenance and inspection processes. IPU s service team are offshore-certified engineers who are able to monitor, repair and maintain critical starting systems on platforms and rigs. Our experienced engineers will perform various tests on functionality and performance including pressure testing of your accumulators, oil condition testing and calibration of gauges. We can also monitor the integrity of your system and have full access to any parts your application may require.
Components Components of a hydraulic starting system Hydraulic starter motor Accumulators Hand pump Foot start valve Starter motors are available for engines up to 80 litres. Manufactured from cast iron, the unique design of the starter motors allows displacement to be easily increased. This gives greater torque and power to start larger engines or compensates for greater torque requirements in extreme environments. Accumulators range from 1 to 16 litres. Bladder accumulators are available in sizes up to 54 litres. Hand pumps can manually recharge accumulators if no hydraulic pressure system is available. The foot start valve has a simple, rugged design with a wiper seal for self cleaning. Engine pump Motor driven Combined Pneumatic recharge Suitable where there is no other source of power. The engine is used to recharge the accumulators to starting pressure. Engine driven pumps can be belt or power take off driven (PTO). Suitable where an electrical supply is present. It has the advantage of not relying on an engine to Recharge; it does so automatically when it senses a drop in pressure. Motors are available in most voltages and certifications. ATEX (hazardous area) motors are also available. Combining both systems offers a higher level of security. It can be a specific project requirement. Pneumatic recharge systems rely on an external source of compressed air to drive a hydro-pneumatic pump. The pump works on a ratio of 60:1. A pneumatic input pressure of 50 psi (3.5 bar) drives the pump to pressurise the accumulator to 3000 psi (207 bar).
Component Technical Specifications Hydraulic cranking motor Accumulator Maximum working pressure 2 MPa (3000 psi) Piston Type Bladder type Torque range From 30 Nm to 216 Nm (22 lbf.ft. to 160 lbf.ft.) Construction Certified seamless tube Forged certified steel Displacements in cc/ rev Displacements in cu.iv/rev 10, 16, 22, 28, 38, 66 Max working pressure 21 MPa (3000 psi) 21 MPa (3000 psi) 0.6, 0.95, 1.35, 1.71, 2.32, 4.0 Test Pressure 35 MPa (5000 psi) 35 MPa (5000 psi) Minimum efficiency 95% Average burst pressure 120 MPa (20000 psi) 120 MPa (20000 psi) Seals Nitrile (standard), Viton (optional) Safety factor In excess of 4:1 In excess of 4:1 Foot start valve Seals Nominal volumes in litres Nitrile (standard), Viton (optional) 1.0, 2.5, 4.0, 5.5, 7.5, 10.0, 12.0, 16.0 Nitrile (standard), Viton (optional) 10, 20, 37, 54 Maximum working pressure 21 MPa (3000 psi) Nominal volumes in usg 0.25, 0.66, 1.06, 1.50, 1.88, 2.60, 3.20, 4.20 3.0, 5.5, 10, 15 Flow rate (3/8 NPT port) Flow rate (1/2 NPT port) 75 l/min (20 usgpm) 100 l/min (26 usgpm) Part number VF (3/8 NPT port) VF8 (1/22 NPT port) Hand pump Maximum working pressure 21 MPa (3000 psi) Suction pressure 75 kpa (11 psi) Displacement 20cc/cycle (1.22 cu.in.) Part number PH20
Hydraulic Starter Motor Range M10 Hydraulic Starter The M10 hydraulic starter motor is the smallest starter motor in our range. Suitable for engines with up to 3 litres capacity, it can produce a maximum torque of 30Nm at 3000 psi (207bar). The M10 is cast iron (including the flange and pinion housing) making it suitable for all environments. The M10 is fitted with a heavy-duty inertia bendix and pinions which are machined from one cast block. This eliminates the process of pressing the pinion onto the bendix cup, a common source of system failure. The M10 s optional beryllium-copper pinion reduces the risk of sparks in hazardous environments. M16 Hydraulic Starter The M16 hydraulic starter motor produces a maximum torque of 48Nm at 3000 psi (207bar). The M16 is cast iron (including the flange and pinion housing) making it suitable for all environments and resistant to damage. The M16 is fitted with a heavy-duty inertia bendix and pinions which are machined from one cast block. This eliminates the process of pressing the pinion onto the bendix cup, a common source of system failure. The M16 s optional beryllium-copper pinion reduces the risk of sparks in hazardous environments. M22 Hydraulic Starter The M22 is a low maintenance start motor that s well-suited to use in both sub-zero and high temperature environments. It requires virtually no attention other than replacing the filter element and periodically checking the gas pre-charge and system pressure. The M22 is designed as a modular system. Spacers and pinions are common across IPU s starter ranges, as are the flanges which mount to the engine. This helps remote and offshore sites simplify stock-holding and improve interchangeability. M22 Inertia Starter Motor The M22 can suit almost any engine configuration. The flange of the standard model can be rotated to suit the engine. In special circumstances, a custom flange can be installed for particularly difficult configurations. The M22 starter motor is available as either an inertia and pre-engaged model. Although the inertia version of the M22 is not ATEX-approved it can be fitted with beryllium-copper pinions to reduce the risk of sparks. M22 Pre-engaged Starter
Hydraulic Starter Motor Range M28 Hydraulic Starter Offering more power and torque than the M22, the M28 boasts a lowmaintenance design that is ideal for extreme conditions. Maintenance is limited to replacing filters and checking gas pre-charge and system pressure. The M28 can be oriented to fit almost any engine configuration. The flange of the standard model can be rotated to suit the engine and ancillary equipment. A custom flange can be installed for difficult configurations. M28 Inertia Starter Motor The M28 is a modular system. Spacers and pinions are common with IPU s air starter ranges, as are the flanges which mount to the engine. This makes for simplified stock-holding and improved interchangeability. The M28 is available in inertia and pre-engaged versions. The M28 inertia is not approved for ATEX environments but can be fitted with beryllium-copper pinions to lower the risk of sparks. M28 Pre-engaged Starter M38 Hydraulic Starter The M38 hydraulic starter motor is capable of producing a maximum torque of 124Nm at 3000 psi (207bar). The M38 is cast iron making it suitable for hazardous and regular environments. The M38 is fitted with a heavy-duty inertia bendix and pinions which are machined from one cast block. This eliminates the process of pressing the pinion onto the bendix cup, a common source of failure. The M38 can be fitted with a steel or beryllium-copper pinion. The berylliumcopper pinion reduces the risk of sparks in hazardous environments. M66 Hydraulic Starter The M66 hydraulic starter motor is capable of producing a maximum torque of 216 Nm at 3000 psi (207 bar). The M66 is cast iron (including the flange and pinion housing), making it suitable for all environments and resistant to damage. The M66 is fitted with a heavy duty inertia bendix and pinions which are machined from one cast block. This eliminates the process of pressing the pinion onto the bendix cup, a common technique on other starter motors and a known fail-point in many applications. Depending on your application, the M66 hydraulic starter motor can be fitted with either a steel or beryllium-copper pinion. If the environment is potentially hazardous the beryllium-copper pinion helps to reduce the risk of
Technical Specifications M10 M16 M22 Weight 9.5 kg (20.9 lbs) 9.5 kg (20.9 lbs) 11 kg (24.3 lbs) Construction Cast iron (ductile iron) Cast iron (ductile iron) Cast iron (ductile iron) Max. working pressure 21 MPa (3000 psi) 21 MPa (3000 psi) 21 MPa (3000 psi) Design pressure 25 Mpa (3600 psi) 25 Mpa (3600 psi) 25 Mpa (3600 psi) Fluid media Mineral oil Mineral oil Mineral oil Viscosity range ISO 32 to 46 (SUS 140-230) ISO 32 to 46 (SUS 140-230) ISO 32 to 46 (SUS 140-230) Temperature range -40 C to +100 C (-40 F to +212 F) -40 C to +100 C (-40 F to +212 F) -40 C to +100 C (-40 F to +212 F) Speed range 0-4000 rpm 0-4000 rpm 0-4000 rpm Rotation CW - Standard (CCW - Optional) CW - Standard (CCW - Optional) CW - Standard (CCW - Optional) Duty cycle Intermittent Intermittent Intermittent Volumetric efficiency 95% (minimum) 95% (minimum) 95% (minimum) Displacement 9.98cc (0.6 cu.in.) 15.59cc (0.95 cu.in) 22.1 cc (1.35 cu.in.) Max. torque 30 Nm (22 lbf.ft.) 48 Nm (35 lbf.ft.) 66 Nm (49 lbf.ft.) Starter motor length 293mm (11.5") 293mm (11.5") 328.5mm (12.9") Starter motor diameter 89.5mm (3.5") 89.5mm (3.5") 101.5mm (4") Inlet port 3/8" NPT 3/8" NPT 3/8" NPT Outlet port 3/8" NPT 3/8" NPT 1/2" NPT
Technical Specifications M28 M38 M66 Weight 11 kg (24.3 lbs) 21.5kg (47.4 lbs) 21.5kg (47.4 lbs) Mounting Cast iron (ductile iron) Cast iron (ductile iron) Cast iron (ductile iron) Max. working pressure 21 MPa (3000 psi) 21 MPa (3000 psi) 21 MPa (3000 psi) Design pressure 25 Mpa (3600 psi) 25 Mpa (3600 psi) 25 Mpa (3600 psi) Mineral oil Mineral oil Mineral oil Mineral oil Viscosity range ISO 32 to 46 (SUS 140-230) ISO 32 to 46 (SUS 140-230) ISO 32 to 46 (SUS 140-230) Temperature range -40 C to +100 C (-40 F to +212 F) -40 C to +100 C (-40 F to +212 F) -40 C to +100 C (-40 F to +212 F) Speed range 0-4000 rpm 0-3000 rpm 0-3000 rpm Rotation CW - Standard (CCW - Optional) CW - Standard (CCW - Optional) CW - Standard (CCW - Optional) Duty cycle Intermittent Intermittent Intermittent Volumetric efficiency 95% (minimum) 95% (minimum) 95% (minimum) Displacement 28 cc (1.71 cu.in.) 38 cc (2.32 cu.in.) 66 cc (4 cu.in.) Max. torque 84 Nm (62 lbf.ft.) 124 Nm (92 lbf.ft.) 216 Nm (160 lbf.ft.) Starter motor length 328.5mm (12.9") 441mm (17.4") 441mm (17.4") Starter motor diameter 101.5mm (4") 130mm (5.1") 130mm (5.1") Inlet port 3/8" NPT SAE 12 SAE 12 Outlet port 1/2" NPT SAE 12 SAE 12
Hydraulic mini-packs Hydraulic mini-packs are a convenient way to add reliable starting to a standard engine configuration. Each mini-pack incorporates everything you need in a self-contained bolt-on unit. This includes: starter motor accumulator oil reservoir hand pump foot valve relief valve pressure gauge hoses and fittings Mini-packs can be ordered with a variety of different starter motors and accumulators to suit different engine sizes. They arrive fully assembled, piped and tested with all hoses and fittings needed to attach them to the engine. All that is required is to fit the starter motor to the engine and fix the mini-pack to a suitable surface. Mini-packs sit comfortably between bare starter motors and custom packages in IPU s range. Customers with the expertise to design and build their own starting system prefer to purchase bare starter motors (and starter motor kits) such as the M22 and M28 Customers who need a pre-configured starting system to fit precise spatial constraints or match unusual starting specifications prefer custom packages Customers without particular spatial constraints and without the expertise (or time) to build their own starting system prefer mini-packs
Custom Starting Packages IPU s enviable reputation in engine starting is built on the quality of its custom starting packages. Few of the new oil platforms, drilling rigs or mining vehicles being designed today have a regular area of free space available to house a starting system. The starting system has to fit into whatever free space is left. That s where IPU s expertise and flexibility comes to the fore. Our custom starting packages can fit into whatever space is available. A standard hydraulic starting configuration would place the accumulators next to the starter motor and engine. When there s no space available, IPU will create a custom package that places the accumulators wherever there is some space. Our design team works closely with your designers to ensure that the custom starting package integrates perfectly into the proposed platform, rig or vehicle. It will fit the available space and meet any specialised starting requirements you have: number of start attempts, cycle time, adverse environmental conditions, etc. Although every custom starting package is different, they all share one characteristic: they perfectly match their application.
Forward together 2003/372 IPU Group Engine Starting Cygnus Way, West Bromwich, B70 0XB Phone: +44 (0) 121 511 0460 Fax: +44 (0) 121 511 0401 Email: ipu@ipu.co.uk www.ipu.co.uk/starting