LEWA plunger pumps for process applications innovative sealing technology rugged and reliable compact design high hydraulic power up to 3500 bar 1
LEWA plunger pumps Triplex Kolbenpumpe G3K 160 Triplex Plunger Pump Hauptmotor Main Motor The LEWA plunger pump is the perfect solution for most applications, satisfying high hydraulic power requirements. LEWA manufactures pump packages that conform to all international, national and local standards. The packages are built to meet the needs of the customer, and to comply with project specifications. In the design, special attention is given to operability and service activities. Plunger valve assembly for high pressure pump head. LEWA plunger pumps are highperformance feed pumps that operate with volumetric precision. This is why they are used in selected processes in the oil & gas and process industries. One advantage of LEWA plunger pumps, in addition to their high hydraulic power, is that they can be designed to meet customers project specifications: Flexibility in the selection of materials Offshore design and coatings per specification Layout and delivery of auxiliary parts, such as pulsation dampers and pressure safety valves according to ASME and API standards With their high level of integrity, LEWA plunger pumps are able to fulfill the demands of difficult applications. The LEWA modular system for plunger pumps lets customers install pumps for specific applications, including applications with barrier liquids, leakage monitoring systems, cooling circuits, and heating devices. For corrosive, abrasive, and toxic fluids, LEWA recommends its proven hermetically sealed process diaphragm pumps. 2
Example oil & gas: MEG injection, G3K 80 MC, 5.2 m 3 /h, 134 bar Modular construction ensures optimal products LEWA offers the best pump for all applications. Driving power starts at 15 kw, ranging up to 600 kw, and operating pressures from 0 to 3500 bar. In all areas, LEWA plunger pumps meet the demands of your application. Of course, the pumps, designed for continuous service, fulfill all relevant international standards such as API 674 and ATEX. Integrated reduction gears allow flexible use at different drive speeds with minimum footprint area. Compact design guarantees minimal space requirements of LEWA plunger pumps. 3
LEWA gears The image shows the integrated double helical gear arrangement. For high power requirements, LEWA uses integrated double helical reduction gears for the complete range. Main advantages of double helical gears include: Silent, low axial forces, self adjusting, long bearing lifetime No need to drain oil for service Special design for the alignment of plunger and crosshead results in extremely short design Integrated double helical gear over the complete range provides for very compact design and maximum of efficiency. Minimum footprint area and low power consumption are a result of this design Thanks to the design with double helical gear, both crankshaft and pinion shaft are free of axial loads. Smooth transmission of power results in long lifetime and lower noise emissions Crankshafts are drop forged and shot-peened, which results in grain structure and reduced stress levels. Design is fatigue-resitant Integral forced feed lubrication for crosshead pins and connecting rod plain bearings, therefore no additional lubrication systems needing additional monitoring are required The gear is monitored by pressure and temperature switches. This safeguards against low oil level and overload All oil seals can be maintained from outside, securing low maintenance downtimes Vertical designs are possible upon request Cross section of LEWA gears for plunger pump 4
LEWA range of plunger pump heads Pump head type M: Pressure up to 500 bar, max. particle size 0.1 mm LEWA plunger pump heads are designed according to the latest developments. This applies in particular to the selection of materials and to the design of valves and plunger sealing. Special attention is given to ease of maintenance and maximum availability. Stuffing box packing is either pressure or spring actuated which results in extended lifetime. At the same time packing lubrication is not required Integral primary leakage return to suction is LEWA standard. No external pump or tubing is required Several options for monitoring and flushing are available For lowest downtime, access to all wearing parts is very easy and maintenance can be done without any special tools Pump head type MC: Pressure up to 440 bar, max. particle size 0.25 mm Pump head type A: Pressure up to 3500 bar, fatigue-resistant design 5
Conversion Kit designs to fi t pressures and applications Top view of conversion kits through carrier The design of the LEWA conversion kits allows for change of plunger diameter and sealing arrangement within certain limits. Therefore, flow, pressure and service requirements can be adapted easily. Easy access to the stuffing box via carrier Simple design and connection for flushing, monitoring and cooling tubing Pump head type A is free of alternating loads. Design is fatigueresistant Several options for monitoring and flushing are available Conversion kit for methanol injection (option for flushing / monitoring) Conversion kit for pump head type A high pressure application 6
Options for monitoring and flushing Barrier Fluid with Pressurized Reservoir Pressure Source N2 PG Filling Connection Sight Glass P suction Flushing PCV set @ P suction + 2 bar For selected applications, flushing, monitoring or cooling may be required. LEWA complies with project specifications or provides suitable solutions to meet customers requirements. Waste Drum Condition monitoring of stuffing box packing Barrier fluid or flushing in case of critical liquids such as methanol Save drainage of leakage through carrier P suction Flushing supply 7
Technical data Performance range graph 10000 For selection of the pump size, please refer to the performance range graph. Maximum pressure ratings for pump head types are also shown on this graph. 1000 Pumphead A G3K 550 G3K 350/400 G3K 250 G3K 100-160 G3K 80/90 100 Performance summary Pumphead M & MC Pressure up to 3500 bar Volumetric flow up to 140 m 3 /h Temperature up to 200 C Viscosity up to 2000 mpa s Pressure p [bar] 10 1 1 Flow rate Qtheo [m 3 /h] 10 100 1000 General dimensions Type L W H [mm] [mm] [mm] G3K 80/90 2000 1150 1260 G3K 100 2150 1350 1330 G3K 110/130/160 2150 1350 1330 G3K 250 2470 1540 1430 G3K 350 2700 1630 1430 G3K 400 2820 1630 1430 G3K 550 3450 2000 1610 W Dimensions shown are approx. based on maximum power (LV Motors) installed. H L 8
Typical applications Further applications:... in the oil & gas industry for methanol injection, glycol injection, waste water re-injection (well service EOR) Methanol injection Glycol injection LDHI injection Produced water Hydrostatic pressure tests Petrochemical applications, e. g. hydrocracking... in refineries, e. g. for hydrogenation 9
Partner of the customer: System responsibility from one source Engineering of pump systems Complete service From pump to system: LEWA develops and supplies solutions for the most different applications. Apart from specifically adapted process diaphragm pumps LEWA also develops and supplies complete pump systems, which can be easily and directly integrated into the complete installation. All components including control and protection installations are appropriately designed and optimized for the respective application. Computer-supported design of pipelines and pulsation dampers Vibration analysis Fluid evaluations Commissioning on-site System tests Service and maintenance contracts Worldwide service Consultation for changed operating conditions Extension and modification of existing pumps and systems Expandable system solutions Consultation at an early stage already: Fluid evaluations and computer supported pipeline calculations save money even before the actual investment has started. Instrumentation for the pump Flow adjustment via frequency inverter Interfaces to the process guiding system Online and offline condition monitoring systems for electronic control pump system (example with flow meter) FIR discharge connection PS H PS H PS H M 3~ PSL suction connection power supply f 1 f 2 pump open and closed loop control control cabinet interface to the process guiding system 10