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Headoffice: Marflex b.v. Oud-Beijerland, The Netherlands
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Marflex Holding b.v., which is based near Rotterdam, The Netherlands, is the parent company of the Marflex group of companies world-wide. Founded in 1980, the company has specialised itself in many fields related to the maritime branch. Beginning 80’s, Marflex specialised itself in producing hydraulic driven portable submersible pumps and generator sets for sales and rental. Apart from the production of above mentioned equipment Marflex also established a repair service center in the field of repairing a wide range of cargo pumps and hydraulic systems. Due to these activities Marflex built up during the 80’s a high level of know how concerning cargo pumps/hydraulic systems and its problems onboard of tanker ships world-wide. This expertise was the basis for starting to create a complete new and unique Deepwell pump design during 1986/1987. In 1988 Marflex sold the first complete Deepwell pumping system to a major Dutch tanker operator. With subsidiaries in Singapore and Houston and a world-wide network of sales representatives, Marflex is today in the position to offer her customers a professional and reliable service world-wide.
From the start Marflex has always promoted and applied the hydraulic-drive principle for her cargo pumps thanks to the advantage of variable-speed control and the non-overload characteristics of a hydraulic motor. However, the availability of sophisticated and class-approved ‘explosion proof’ electric motors and ‘static frequency converters’ and also the fact that shipowners in Europe became more and more reluctant to install hydraulic systems onboard their newbuildings, changed this philosophy. For the above-mentioned reasons Marflex started the development of a total new pump design in 1986.
The new pump design is based upon the modern technologies available nowadays and the presence of existing knowledge and experience of todays used cargo pumping systems. As a result of the great demand for double-hull stainless steel chemical tankers on the Dutch market Marflex introduced the new designed Marflex Deepwell pump in 1987. In close cooperation with the local tanker operators, Marflex introduced a Deepwell pump with a unique oillubricated drive shaft. Marflex sells her cargo pumping systems all over the world ever since.
The Marflex Deepwell Pump
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Already for many years various well-known pump manufacturers have produced Deepwell pumps for chemical and product tankers with a socalled cargo lubricated drive shaft. The operational disadvantages of such a design are well-known in the shipping industry.
As the new Marflex Deepwell pump needed to be driven by an electric motor we first had to develop a ‘non cargo lubricated drive shaft’. The development has resulted in a unique ‘oil lubricated shaft’ running in a separate supporting pipe. The service life of an ‘oil lubricated shaft arrangement’ is more than 10.000 running hours and is based upon the service life of the bearings in the electric motor. The 10.000 running hours are normally sufficient to last the service life (20-25 years) of a sea-going vessel. To explain the Marflex Deepwell pump in details we like to divide the total pump in three sections: • Deck arrangement • Pipe stack • Pumphead
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The Marflex Deepwell pump can be driven by an explosion-proof and class-approved electric motor or a hydraulic motor. However, since the introduction of this new design in 1987, 95% of all, by Marflex installed, Deepwell pumps are electrically driven for the following reasons:
Advantages of electrically-driven Deepwell pumps compared to hydraulically-driven Deepwell or submerged pumps: • Total system efficiency approximately 20% higher; • Low noise level; • Easy to install thanks to the electrical wiring instead of a complicated hydraulic piping system (commissioning will be reduced to a real minimum); • Simple and robust AC motor; • Clean system (no hydraulic oil leakages); • Reduced maintenance. The speed of the electrically driven Marflex Deepwell pumps can be controlled in several ways: One-speed electric motor • Suitable for tankers which carry products with a small specific gravity range, like the so-called product tankers. Two-speed electric motors • This is not really practical due to the fact that the Marflex Deepwell pump is single-stage pump; • Can be considered only for tank cleaning or cargo circulation purposes.
Variable speed control by means of a ‘static frequency converter’ We like to mention the following advantages of a ‘static frequency converter’ system:
1. Power • High efficiency; • Energy consumption according to actual need; • E-motors and consequently generators do not need to be over-dimensioned for products with a high viscosity and/or specific gravity; • Soft start (no inrush peaks): less frequent start-up of generators.
2. Control • Independent control of each Deepwell pump; • Accurate, variable control; • Low mechanical wear; • Low cavitation; • Programmable for specific pumping requirements: - minimized discharging time; - minimum cavitation; - liquid level; - specific gravity; • Connection to cargo-monitoring or machinery automation system.
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The design of the Marflex Deepwell Pump is based upon a drive shaft which is separated from the cargo. The pump stack consists of two pipes; one is the discharge pipe and the other is the enclosure for the intermediate drive shaft, the shaft bearings and lubricating oil.
As the shaft is not exposed to the cargo the following advantages are obvious: • The material of the intermediate drive shaft is 42CrMo4V which is a heat treatable steel. If the shaft should be exposed to the cargo, AISI 316L steel is required which is not the ideal material for a Deepwell Pump. • As the shaft is oil lubricated the pump never runs ‘dry’ during stripping and tank cleaning operations. - No explosion danger resulting from overheating of intermediate shaft bearings. - Extended life time of the shaft bearings (approx. 10.000 running hours).
• Because the intermediate pump shaft and bearings are oil-lubricated, the pump can run on relative high speeds. This results in a single stage Deepwell Pump. The shaft bearings of the Marflex Deepwell pump are made of Railko® material, held within a Viton® or Kalrez® flexible member.
Advantages of the Marflex intermediate shaft design: • No shaft-alignment problems; • Fixed coupling between the shaft of the drive motor on deck and the intermediate drive shaft; • Thanks to the oil-lubricated intermediate shaft bearings the servicelife of the intermediate shaft bearings will be quite extensive. The length of the pipestack has no restrictions. However, after every 6 meters of pipestack an intermediate shaft support will be installed (see drawing page 8). This support consists of a ball bearing which takes the axial load of each shaft length of 6 meters only. Axial thrust/load from the impeller will be taken only by the pump shaft bearings and not transmitted to the intermediate shaft (bearings) due to the spline connection between the pump shaft and intermediate pump shaft.
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The Marflex Deepwell pump is designed in such a way that the total pump head can be disconnected from the pipestack, which makes maintenance very easy.
A so-called ‘spline’ connection between the intermediate drive shaft and the pump shaft in the pumphead makes it possible to disconnect the pumphead from the pipe stack by lowering the pumphead by approximately 30 mm. The maximum space between the suction side of the pumphead and the bottom of the pump well is 40 mm. 1. The pump shaft This shaft is made of 32CrNiMo6V steel which can be considered as a very highgrade material and excellent to serve as a pump shaft. Like the intermediate drive shaft, the material of the pump shaft is not made of AISI 316L because the pump shaft is not exposed to the cargo but oil-lubricated.
2. Seal arrangement The Marflex Deepwell pump is standard delivered with a special-seal arrangement to segregate the cargo from the lubricating oil and vice-versa. This seal design exists already for more than 20 years and has proven to be a simple and reliable seal for all chemicals and mineral-oil products. The seal arrangement is built up as follows: a. Primary oil seal: this is a Viton® lipseal running on a hard-chromium SS sleeve. b. Secondary cargo seal: this is a Teflon® lipseal running on a silicon carbide sleeve. c. Secondary oil seal: this is a Teflon® lipseal running on a silicon carbide sleeve. d. Primary cargo seal: this is a Teflon® lipseal running on a silicon carbide sleeve.
The Marflex Deepwell pump is completely built from hot-rolled and forged materials except the pump impeller. The standard material specification is DIN 1.4435 which is a 316L quality with a minimum molybdenum content of 2,5%. All seals and O-rings in contact with the cargo are Teflon® or Kalrez®. Thanks to the applie materials the Marflex Deepwell pump is fully chemical-resistant and suitable to handle cargoes with a temperature up to 180 °C.
Between the two secondary seals is an atmospheric drainage chamber. This chamber is called the ‘cofferdam’, which is acting as a safety barrier between the oil seals and the cargo seals. Any leakage that might occur will be collected in the cofferdam. The cofferdam is connected to the main deck by means of two purge lines. By purging the cofferdam with air or nitrogen the contents of the cofferdam can be blown out and collected on deck. By following a regular purging routine the condition of the seals is constantly monitored.
The advantages of such a seal arrangement are: • Double protection with an atmospheric drainage chamber between the cargo and lubrication-oil side. • Proven to be reliable and simple. • Easy replacement by ship’s crew (low cost). • Seal condition can be monitored from main deck side. Note: Especially for abrasive, solidifying or polymerising cargoes or cargoes with a temperature above 100 °C, Marflex has developed in close cooperation with Nippon Pillar Japan a special ‘knife’ seal.
On request, the Marflex Deepwell pump can be also produced of highergrade materials such as ‘duplex’ to fulfil the customer’s requirements.
INERT GAS / AIR UNDER PRESSURE FLEXIBLE HOSE
OUTLET STRIPPING CARGO PIPE
MAIN CARGO PIPE STRIPPING CARGO PIPE
When the cargo tank is empty the cargo stripping valve has to be opened and the main cargo valve to be closed. The remaining cargo left in the main cargo pipe is purged by means of inert gas or air via the stripping pipe into the cargo line on deck. During the purging/stripping procedure the pump should be kept running (the impeller acts as a dynamic footvalve) until the cargo pipe has been purged empty. This procedure will guarantee an absolute minimum of remaining cargo in the pump well. Present and future IMO rules are achieved.
STRIPPING CARGO PIPE
CARGO STRIPPING VALVE FLEXIBLE HOSE OPEN SNAP-ON-COUPLING MAIN CARGO VALVE CLOSED OPEN
MAIN CARGO PIPE OPTIONAL: DIRECTLY TO MANIFOLD
INERT GAS / AIR UNDER PRESSURE
Type of Pump MDP- 100 MDP- 125 MDP- 150 MDP- 200 MDP- 250 MDP- 300
Remaining quantity of cargo after stripping 12 ltr. 20 ltr. 30 ltr. 30 ltr. 50 ltr. 50 ltr.
These stripping results are based upon a proper pump well design and minimum clearance between pump and pump well bottom.
Pump performance curves
30 20 30 40 50 100 200 300 400 500 1000 2000
= subsidiaries = representatives
Marflex b.v. Postal / visit address: Louis Pasteurstraat 12 3261 LZ Oud-Beijerland The Netherlands Tel.: +31 186 89 02 00 Fax: +31 186 89 02 99 E-mail: email@example.com Website: www.marflex.com
SUBSIDIARIES: Marflex repair Postal / visit address: Langeweg 1 3214 LJ Zuidland The Netherlands Tel.: +31 181 45 88 00 Fax: +31 181 45 88 09 E-mail: firstname.lastname@example.org Website: www.marflex.com
Marflex Asia Pte. Ltd. Postal / visit address: No. 50 Raffles Place Level 37, Singapore Land Tower Singapore 048623 Tel.: +65 861 55 53 Fax: +65 861 41 98 E-mail: email@example.com Website: www.marflex.com
Marflex Moscow Marflex Tanker Services b.v. Postal / visit address: Langeweg 1 3214 LJ Zuidland The Netherlands Tel.: +31 181 45 88 10 Fax: +31 181 45 88 19 E-mail: firstname.lastname@example.org Website: www.marflex.com Postal / visit address: Building 1, Nikoloyamskaya 49 Flat no. 414 109004 Moscow Russia Tel. / fax: +007 095 912 35 01 Website: www.marflex.com
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