Presentation Sulzer

Sulzer Pumps
V00738 en / Copyright Sulzer Pumps Finland Oy
8.2003 / 1
AHLSTAR Process Pumps

Applications
The AHLSTAR Process Pump is
designed for continuous operation in
industrial processes
Oil and Gas
Hydrocarbon Processing
Pulp and Paper
Power Generation
Water Transport and Distribution
Food
Basic Metals
Fertilizers
Others
Reliable Simple Efficient Diverse
8.2003 / 2

Applications
The AHLSTAR Process Pumps
are meant for pumping all kinds of
liquids from clean waters to abrasive
or corrosive liquids.
Special capabilities to handle stocks
of various kinds, sludges or slurries.
End suction single stage pumps
Reliable operation
Simple but versatile construction
High efficiency
Reliable Simple Efficient Diverse

8.2003 / 3

Interchangeability
R Air-Separating
External vacuum
pump and expeller.
N Hydraulics
Non-clogging. Sludges
containing big particles
and long fibers.
W Hydraulics
Wear-resistant.
Corrosive and/or
abrasive liquids.
A Hydraulics
General purpose. Clean,
abrasive or corrosive
liquids specially stocks of
various kinds.
S Self-Priming
Internal vacuum
pump.
8.2003 / 4

Design Features
Self-venting top
centerline casing.
Externally adjustable
sideplate.
Double volute casing

in larger sizes.
Impeller balancing holes

and back vanes stabilize
pressure in shaft seal
cavity.
Simplified heavyduty bearing unit.
Optimum shaft
sealing philosophy.
8.2003 / 5

APP/APT Hydraulic Design, Impellers designed for various liquids
Closed impeller
High efficiency
Clean liquids
Liquids containing
some impurities
Open impeller
High efficiency
Good throughput
Liquids containing
solid particles
Abrasive liquids
Stocks up to 8%
Solids up to 70%
Lumps in liquid
Special open impeller

High efficiency
More open passages
Liquids containing
long particles and fibers
Abrasive liquids
Stocks up to 8%
Solids up to 70%
Lumps in liquid
LowPulse impeller
High efficiency
Minimized pulsations
Dilution water for
headbox
Stocks for headbox
feed
Clean liquids
Stocks up to 8%
8.2003 / 6

NPP/NPT Hydraulic Design
Non-clogging design passes big
particles and long fibers, e.g.
plastic stripes.
Specially designed vane edges
stay clean.
Front vanes with sideplate
cutting grooves keep
gap clean.
Vortex impeller
Closed impeller
Back vanes prohibit

particles from entering
the seal cavity and balance
axial forces.
Liquids:
sludges, waste waters, effluents
Cutting grooves for

closed impeller
8.2003 / 7

WPP/WPT Hydraulic Design
Wear-resistant design
resists abrasion and
erosion in slurry pumping.
Smooth shapes.
Vortex impeller
Thickness in casing and

impeller enlarged.
Hydraulic shapes guide
particles away from casing
walls.
Closed impeller
Open impeller
8.2003 / 8

EPP/EPT Hydraulic Design
Hot liquid pumps have high efficiency.
Centerline support
keeps shaft position
horizontal at elevated
temperatures
Closed impeller
Spot-cooled stuffing
box area to handle
high temperatures
Enforced casing
manages higher
pressures
Open impeller
8.2003 / 9

Standardization
APP, ARP, ASP, EPP, NPP, NRP,
NSP, WPP, WRP and WSP pumps
are designed in a similar way using
the same components.
246 pumps
80 casing covers
6 common bearing units
6 common shaft seal sizes
common sealing water equipment
common couplings and coupling
guards
common baseplates
Common parts shown
in columns
8.2003 / 10

Standardization
APP/APT
Process
Pump
NPP/NPT
Non-Clogging
Pump
WPP/WPT
Wear-Resistant
Pump
EPP/EPT
Hot Liquid
Pump
S
Structure
Self-Priming
Pump
R
Structure
AirSeparating
Pump
Casing cover
Adapter
Low spare parts inventory

through standardization.
Only 6 bearing units
Tailor-made
hydraulics
Process reliability through

tailor-made hydraulics.
Standardization
8.2003 / 11

Operational Limits
8.2003 / 12

A Performance
Head
up to 160 m
Temperature max. 180 C

Capacity
up to 2000 l/s
Operating
frequencies
50 or 60 Hz
Pressure
up to 1.6 Mpa
(depending on material and size)
8.2003 / 13

A Performance
Head
up to 700 ft
Temperature max. 356 F

Capacity
up to 30000
USGPM
Operating
frequencies
50 or 60 Hz
Pressure
up to 230 psi
8.2003 / 14

N Performance
Head
up to 90 m

Capacity
up to 550 l/s
Operating
frequencies
50 or 60 Hz
Pressure
up to 1.6 Mpa
8.2003 / 15

N Performance
Head
up to 250 ft

Capacity
up to 7000
USGPM
Operating
frequencies
50 or 60 Hz
Pressure
up to 230 psi
8.2003 / 16

W Performance
Head
up to 110 m

Capacity
up to 2000 l/s
Operating
frequencies
50 or 60 Hz
Pressure
up to 1.6 Mpa
8.2003 / 17

W Performance
Head
up to 360 ft

Capacity
up to 30000
USGPM
Operating
frequencies
50 or 60 Hz
Pressure
up to 230 psi
8.2003 / 18

E Performance
Head
up to 140 m

Capacity
up to 1700 l/s
Operating
frequencies
50 or 60 Hz
Pressure
up to 2.5 Mpa
8.2003 / 19

E Performance
Head
up to 650 ft

Capacity
up to 21000
USGPM
Operating
frequencies
50 or 60 Hz
Pressure
up to 360 psi
8.2003 / 20

Gas/Air in the Liquid
Gas/air gets into the liquid.
Dissolved
AHLSTAR Gas Removal Pump:

Stable and reliable operation
(gas content 0...40%)
Bound
Conventional Pump:
Unstable operation
(gas content 0...4%)
Free
8.2003 / 21

S Self-Priming for Gas-Containing Liquids
Self-priming applications
Intended usage
self-priming
gas-containing liquids
foam
Gas/air to the
inlet tank
Sealing water
Vacuum
relief valve
8.2003 / 22

R Air-Separating for Gas-Containing Liquids
Intended usage
self-priming
gas-containing liquids
foam
Barometric leg application
Suitability
low speed of rotation
variable speed
controlled pump
high gas amount
separate control of
vacuum pump
separate vacuum pump
not always needed
8.2003 / 23

Shaft Seal Area
Balancing holes keep the pressure
level steady at the shaft seal area.
Controlling the shaft seal area

pressure gives
Back vanes keep the area between

the impeller and casing cover clean
and reduce axial forces.
Best solutions for every application

Reliability in operation
Back vanes optimized

according to the pumped
liquid.
APP, open
WPP, closed
NPP, vortex
8.2003 / 24

Shaft Seal Liquids
W01 Non-pressurized
fluid in/out
Cooling
Quench
W03 Flowing pressurized

fluid in/out
Barrier flowing
W02 Pressurized fluid in

Flushing
No fluid
Clean liquids
Light impurities
Temperature
max. 90 oC/195 oF
W04 Pressurized non-flowing

fluid in/(out)
Barrier
non-flowing
8.2003 / 25

Dynamic Shaft Sealing
Dynamic Seal
Reliable operation optimize total lifetime costs
Designed for difficult applications
Simple operating principle
Reliable robust construction
Liquids
paper stock up to 8%
liquors
lime milk
Not running
waters
sugar juices
etc.
Operating
8.2003 / 26

Grease
Variable speed operation
High storage towers which
are sometimes full
Reduced diameter
High-speed pumps
Lower power
consumption
Double
Low pressure at suction
side during standstill
8.2003 / 27

Flushing internal
(recirculation)
Clean liquids
Increased pressure
at seal cavity
Flushing external
For cleaning seal cavity
at standstills
Sometimes used with
very dirty liquids
8.2003 / 28

Ready-Fitted Mechanical Shaft Sealing, Single
Reliable operation
Easy assembly
Designed to be a part of
the pump
Heavy-duty design
Minimum number of parts
Compatibility with pump
materials
Typical manufacturers
John Crane Safematic
Burgmann
Huhnseal
Options
No sealing fluid
Internal or external
flushing
Grease
8.2003 / 29

Ready-Fitted Mechanical Shaft Sealing, Single with Quench
Reliable operation
Easy assembly
Low-pressure quench fluid
Designed to be a part of the pump
Heavy-duty design
Compatibility with pump materials
Burgmann
Huhnseal
8.2003 / 30

Ready-Fitted Mechanical Shaft Sealing, Double
Reliable operation
Easy assembly
High-pressure flowing barrier fluid
High-pressure non-flowing barrier
fluid, dead-end
Heavy-duty design
Compatibility with pump materials
Burgmann
Huhnseal
8.2003 / 31

Mechanical Element Seals, Single
Metal bellows
Metal bellows allow higher temperatures
Thin materials restrict usage with
abrasive liquids
Options
No sealing fluid
Internal or external flushing
Quench
Grease
John Crane
Burgmann
8.2003 / 32

Mechanical Cartridge Seals
Designed for small spaces in gland
packing seal chambers
Thin material thickness
Recommended with restrictions
Recommended for easy applications
- low speed
- low temperature
John Crane
Chesterton
Burgmann
8.2003 / 33

Gland Packing
Reliable operation
High maintenance costs
Traditional shaft seal design
Always leaking
Leakage lubricates sliding surfaces
Abrasion of shaft sleeve and gland packings
Easy change of gland packing ring
Split stuffing box gland
Various arrangements
No sealing fluid
- clean liquids, water
Internal flushing
- clean liquids
External flushing
- impure liquids
Barrier flowing
- impure liquids
Cooling insert
- clean liquids
8.2003 / 34

S Structure Shaft Sealing
Ready-fitted mechanical seals, double
With or without external flushing fluid
Quench sealing fluid
Barrier flowing or non-flowing (dead-end)
sealing fluid, pressurized
Mechanical element seals,

single
With or without external
flushing fluid
Metal bellows
Static seal
Simple
Constant air flow from outside
8.2003 / 35

R Structure Shaft Sealing
Mechanical element seals, single
With external flushing fluid
Metal bellows allow higher temperatures
John Crane
Burgmann
Metal bellows
8.2003 / 36

E Structure Shaft Sealing
Mechanical ready-fitted seals
Heavy-duty design
Single with quench

sealing fluid
John Crane Safematic,
Burgmann, Huhnseal
Double with options

Barrier flowing
Temperature control fluid
8.2003 / 37

E Structure Shaft Sealing
Mechanical cartridge seals
Single or double with options
Barrier flowing
Recommended with restrictions
Gland packing
Packing/support plate
Temperature control
fluid
Barrier flowing
Quench sealing
fluid
8.2003 / 38

Bearing Unit
Solid fixed shaft
Heavy-duty operation
Long-life bearings
Strong and rigid

support foot
Wear-free labyrinth seals
Deflector with lipseal protects
during operation and standstills
8.2003 / 39

Bearing Unit
Different material versions
Shaft materials stainless steel
- SS2324, SS2562, Ss2328
Bearing gages of metal
Auxiliary equipment material
- traditional
- stainless steel
Frame with pump adapter of
cast iron or stainless steel
Oil lubrication for temperatures

up to 120 oC / 250 oF
Sight glass and oiler drilling at
both sides
Grease lubrication for temperatures

up to 120 oC / 250 oF
8.2003 / 40

Drillings in Pump
Emptying holes
Casing
Dynamic seal
S version casing for vacuum pump
R version stuffing box housing
Temperature measurement connections
Casing cover
Dynamic seal housing
S pump casing for vacuum pump
R pump stuffing box housing
8.2003 / 41

Standard Material Combinations
Other corrosion resistant cast steels available on special request.

1) Avesta 654SMO is a trademark owned by Avesta Sheffield which has granted Sulzer Pumps licence to produce this material.
* For W construction.
8.2003 / 42

Materials, Main Parts
Think corrosion resistance.
Cast iron 53
41 Duplex
standard
good for most cases
4E Martensitic
precipitation hardened stainless steel
41 / 4L / 4T / 4G / 43 / 4U / 4J
wetted parts of the same material
shaft seal frame materials same as
pump material when ready-fitted seals
are used
All SS versions
adapter
bearing unit
baseplate
SS accessories in bearing unit
8.2003 / 43

Materials, Auxiliary Parts
O rings
Corrosion resistant thinking.
EPDM
FKM (Viton)
FFKM (in E type pump)
Gaskets
Klinger SIL C-4430
Casing
Shaft seal
materials same
or better.
PTFE / Glass
Flexitallic Sigma 511
(in E type pump)
Coupling guard
Zinc-painted steel - standard
Aluminum - non-sparking
Stainless steel - for corrosive conditions
8.2003 / 44

Assembly
Back pull-out design
allows fast service.
Safe coupling guard is

designed according to
safety regulations.
Flexible coupling with

spacer allows fast service.
Concrete baseplate for

pump and motor.
Can also be mounted on
rubber sheet
various mounting beams
vibration dampers etc.
Baseplate for pump only
suitable for a big pump
RIGBASE baseplate, steel or

concrete with 3-point fastening.
Distortion free and fast installation.
EPP centerline mounted.
Riser blocks allow the

installation of the next frame
size of motor.
8.2003 / 45

Belt Drive
Shaft ends are in the same direction.
Fast and easy service of V belts and
pulleys.
Counter Flanges
LowPulse
Exact guidance
O ring sealing
Safe V belt guard is designed

according to safety regulations.
Collar for general

applications
Delivery with gasket
8.2003 / 46

Surface Treatment
Painting
EN ISO12944
Thickness 200 m
Epoxy max. 150 oC / 300 oF
Silicon aluminum and epoxy
above 150 oC / 300 oF
Base also available with zinc epoxy
Grinding
Interior surfaces
- Ra 6.3
- Cotton ball
Open impellers only
Sandblasting also available
Washing
Special care is taken to ensure
the cleanliness of the pump.
8.2003 / 47

Tests and Certificates
Duty Point Performance
ISO 9906 Grade 2
NPSHr
ISO 9906 Grade 2
Pulsation
For LowPulse pumps
Guarantee values in relation
to delivered head
Certificates also available on
Material:
EN10204-2.2
EN10204-3.1.B
Painting, surface finishing,
washing
8.2003 / 48

Delivered Documentation Materials Available
Books
Customer material according to order
IOM
Specification and part list
Dimensional drawing
Characteristic curve
Sectional drawings
CE declaration of conformity
Declaration of quality
Certificates
Component documents
www.sulzerpumps.com
PumpFlo curve catalogues
Available at www.pump-flo.com
AutoCAD symbols
2D projections of pump and baseplate
CD-roms
For the total project delivery order
Several languages in IOM and
component documents
Other documentation in English
8.2003 / 49

AHLSTAR Vertical Pumps
These types utilize the same
hydraulic parts as AHLSTAR
NPP/NPT and WPP/WPT
(casing and impeller).
AHLSTAR
NVP/NVT
Non-Clogging
Vertical Pump
AHLSTAR NKP/NKT,
WKP/WKT Cantilever Pump
8.2003 / 50

APP/APT Process Pumps, Design Features and Benefits
A double volute casing in larger
AHLSTAR pumps reduces radial
forces and shaft deflection.
The self-venting, top centerline
casing prevents air-lock in the top of
the casing.
The sideplate is adjusted externally
to maintain a constant impeller
clearance and continuous
high efficiency.
Open, special open and closed
impellers are available for a wide
variety of applications.
ROTOKEY impeller mounting
provides strong, reliable power
transmission. It is self-locking and
reverse rotation safe. ROTOKEY
facilitates the installation and
removal of the impeller. It is not
sensitive to axial loads created
during pump operation.
Simplified heavy-duty
bearing unit design. Oil
or grease lubrication.
Heavy-duty shaft.
Deflection at stuffing box
less than 0.05 mm/0.002
in. High-strength duplex
stainless steel is
standard shaft material.
Non-contacting bearing
protection for the
combined advantages of
labyrinth ring, deflector
and lipseal. Lipseal
protects in standstill
position.
Strong and rigid bearing
support foot improves
mounting stability.
1 Jackscrews for simple
disassembly.
8.2003 / 51

NPP/NPT Non-Clogging Pumps, Design Features and Benefits
Common spare parts with all
the other AHLSTAR process
pumps.
Simplified heavy-duty
bearing unit design. Oil
or grease lubrication.
Smooth and symmetrical

casing design reduces fiber
hang-up and vibrations and
gives a large passage area.
Heavy-duty shaft.
Deflection at stuffing
box less than 0.05
mm/0.002 in. Highstrength duplex
stainless steel is
The sideplate is adjusted

externally to maintain a
constant impeller clearance
and continuous high efficiency.
Closed or vortex impeller for
long fibers and special
applications.
transmission. It is self-locking
and reverse rotation safe.
ROTOKEY facilitates the
installation and removal of the
impeller. It is not sensitive to
axial loads created during
pump operation.
protection for the
combined advantages
of labyrinth ring,
deflector and lipseal.
Lipseal protects in
standstill position.
Strong and rigid bearing support foot
improves mounting stability.
1 Jackscrews for simple disassembly.
8.2003 / 52

WPP/WPT Wear Resistant Pumps, Design Features and Benefits
Increased wall thicknesses in impeller,
casing and sideplate.
Smooth casing design no gouging eddies.

Back pull-out design allows fast service.
Wear resistant design. Areas of abrasion

are minimized by altering the flow
patterns on casing and impeller.
The sideplate is adjusted externally to
maintain a constant impeller clearance
and continuous high efficiency.
Backflow led smoothly towards
inlet flow, not against wall,
resulting in less wear.
Back and front vanes of the
impeller minimize recirculation
and wear.
transmission. It is self-locking and
reverse rotation safe. ROTOKEY
facilitates the installation and removal of
the impeller. It is not sensitive to axial
loads created during pump operation.
Heavy-duty shaft.
box less than 0.05 mm/
0.002 in. High-strength
duplex stainless steel is
protection for the
combined advantages of
labyrinth ring, deflector
and lipseal. Lipseal
protects in standstill
position.
Strong and rigid bearing support foot
improves mounting stability.
Wear and corrosion resistant materials,
chromium iron and duplex stainless steels.
8.2003 / 53

EPP/EPT Hot Liquid Pumps, Design Features and Benefits
A double volute casing in larger
AHLSTAR pumps reduces radial
forces and shaft deflection. The EPP
Pump is also centerline-supported.
The self-venting, top centerline casing
prevents air-lock in the top of the
casing.
Gland packings and mechanical
seals fit into the same space.
Spot-cooled stuffing box.
Closed and open impellers are
available. EPP with a closed impeller
can be used for pumping clean liquids
or liquids containing impurities.
ROTOKEY impeller mounting provides
strong, reliable power transmission. It
is self-locking and reverse rotation
safe. ROTOKEY facilitates the
installation and removal of the impeller.
It is not sensitive to axial loads created
during pump operation.
Back pull-out design allows fast service.

Simplified heavy-duty bearing unit design.
Oil or grease lubrication.
Heavy-duty shaft.
box less than 0.05 mm/
0.002 in. High-strength
duplex stainless steel is
protection for the
combined advantages
of labyrinth ring,
deflector and lipseal.
Lipseal protects in
standstill position.
Strong and rigid bearing
support foot improves
mounting stability.
8.2003 / 54

R Air-Separating Pumps, Design Features and Benefits
Recirculation pipe.
Open, special open
or vortex impellers are
available for a wide variety
of applications.
Impeller type depends
on the pump type.
Expeller separates the liquid
from gas and pumps it back
into the inlet pipe through the
recirculation pipe.
Degassing pipe.
Single mechanical
shaft seal.
8.2003 / 55

S Self-Priming Pumps, Design Features and Benefits
Open, special open or
vortex impellers are
available for a wide
variety of applications.
Impeller type depends on
the pump type.
Single or double mechanical

shaft seal or sealless version.
Internal vacuum pump,
less equipment.
8.2003 / 56

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Sulzer Pumps

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

AHLSTAR Process Pumps

Reliable Simple Efficient Diverse

AHLSTAR Process Pumps

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Double volute casing

Impeller balancing holes

AHLSTAR Process Pumps

Special open impeller

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Back vanes prohibit

Cutting grooves for

AHLSTAR Process Pumps

Thickness in casing and

AHLSTAR Process Pumps

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Low spare parts inventory

Process reliability through

AHLSTAR Process Pumps

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 180 C

(depending on material and size)

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 356 F

(depending on material and size)

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 180 C

(depending on material and size)

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 356 F

(depending on material and size)

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 180 C

(depending on material and size)

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 356 F

(depending on material and size)

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 210 C

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

Temperature max. 410 F

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

AHLSTAR Gas Removal Pump:

V00738 en / Copyright Sulzer Pumps Finland Oy

AHLSTAR Process Pumps

AHLSTAR Process Pumps

Barometric leg application

V00738 en / Copyright Sulzer Pumps Finland Oy