Ahlstar Presentation PDF

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

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

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

centerline casing. and back vanes stabilize
pressure in shaft seal
Externally adjustable cavity.
Simplified heavy-
sideplate. duty bearing unit.
Double volute casing

in larger sizes. Optimum shaft
sealing philosophy.

APP/APT Hydraulic Design, Impellers designed for various liquids
LowPulse impeller
High efficiency
Minimized pulsations
Special open impeller Dilution water for
High efficiency headbox
More open passages Stocks for headbox
Open impeller Liquids containing feed
High efficiency long particles and fibers Clean liquids
Good throughput Abrasive liquids Stocks up to 8%
Liquids containing Stocks up to 8%
Closed impeller solid particles Solids up to 70%
High efficiency Abrasive liquids Lumps in liquid
Clean liquids Stocks up to 8%
Liquids containing Solids up to 70%
some impurities Lumps in liquid

NPP/NPT Hydraulic Design
Non-clogging design passes big

particles and long fibers, e.g.
plastic stripes.
Vortex impeller
Specially designed vane edges
stay clean.
Front vanes with sideplate

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

impeller enlarged.
Hydraulic shapes guide

particles away from casing
walls. Closed impeller
Open impeller
EPP/EPT Hydraulic Design
Hot liquid pumps have high efficiency.
Centerline support
keeps shaft position
horizontal at elevated
Closed impeller
temperatures
Spot-cooled stuffing
box area to handle
high temperatures
Enforced casing Open impeller

manages higher
pressures

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

Standardization
APP/APT NPP/NPT WPP/WPT EPP/EPT

Process Non-Clogging Wear-Resistant Hot Liquid
Pump Pump Pump Pump
S R
Structure Structure
Self-Priming Air-
Pump Separating
Pump
Casing cover
Adapter
Low spare parts inventory

through standardization.
Only 6 bearing units Process reliability through

tailor-made hydraulics.
Tailor-made Standardization
hydraulics
Operational Limits

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)

A Performance
Head up to 700 ft
Temperature max. 356 F
Capacity up to 30000
USGPM
Operating
Pressure up to 230 psi

N Performance
Head up to 90 m
Operating

N Performance
Head up to 250 ft
Capacity up to 7000
USGPM
Operating

W Performance
Head up to 110 m
Operating

W Performance
Head up to 360 ft
USGPM
Operating

E Performance
Head up to 140 m
Operating

E Performance
Head up to 650 ft
USGPM
Operating

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

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

S Self-Priming for Gas-Containing Liquids
Intended usage Self-priming applications

self-priming
gas-containing liquids
foam
Gas/air to the
inlet tank
Vacuum
Sealing water relief valve

R Air-Separating for Gas-Containing Liquids
Intended usage Suitability Barometric leg application

self-priming low speed of rotation
gas-containing liquids
variable speed
foam
controlled pump
high gas amount
separate control of
vacuum pump
separate vacuum pump
not always needed

Shaft Seal Area
Balancing holes keep the pressure Controlling the shaft seal area
level steady at the shaft seal area. pressure gives
Back vanes keep the area between Best solutions for every application
the impeller and casing cover clean
and reduce axial forces. Reliability in operation
Back vanes optimized

according to the pumped
liquid.
WPP, closed APP, open
NPP, vortex
Shaft Seal Liquids
W01 Non-pressurized W02 Pressurized fluid in No fluid

fluid in/out Flushing Clean liquids
Cooling Light impurities
Quench Temperature
max. 90 oC/195 oF
W03 Flowing pressurized W04 Pressurized non-flowing

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

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

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

Flushing internal Flushing external

(recirculation) For cleaning seal cavity
Clean liquids at standstills
Increased pressure Sometimes used with
at seal cavity very dirty liquids

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 Options

John Crane Safematic No sealing fluid
Burgmann Internal or external
Huhnseal flushing
Grease

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
Typical manufacturers
John Crane Safematic
Burgmann
Huhnseal

Ready-Fitted Mechanical Shaft Sealing, Double
Reliable operation
Easy assembly
High-pressure flowing barrier fluid
High-pressure non-flowing barrier
fluid, dead-end
Designed to be a part of the pump
Heavy-duty design
Compatibility with pump materials
John Crane Safematic
Burgmann
Huhnseal

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

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

Gland Packing
Various arrangements
No sealing fluid
- clean liquids, water
Internal flushing
- clean liquids
External flushing
- impure liquids
Barrier flowing
Reliable operation
- impure liquids
High maintenance costs
Cooling insert
Traditional shaft seal design - clean liquids
Always leaking
Leakage lubricates sliding surfaces
Abrasion of shaft sleeve and gland packings
Easy change of gland packing ring
Split stuffing box gland
S Structure Shaft Sealing
Ready-fitted mechanical seals, double Mechanical element seals,
Designed to be a part of the pump single
With or without external flushing fluid With or without external
Quench sealing fluid flushing fluid
Barrier flowing or non-flowing (dead-end) Metal bellows
sealing fluid, pressurized
Static seal
Simple
Constant air flow from outside

R Structure Shaft Sealing
Mechanical element seals, single

With external flushing fluid
Metal bellows allow higher temperatures
John Crane
Burgmann
Metal bellows

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

Designed to be a part of the pump sealing fluid
Heavy-duty design
John Crane Safematic,
Burgmann, Huhnseal
Double with options

Quench sealing fluid
Barrier flowing
Temperature control fluid

E Structure Shaft Sealing
Mechanical cartridge seals Gland packing

Single or double with options Packing/support plate
Quench sealing fluid Quench sealing fluid
Barrier flowing Temperature control
Recommended with restrictions fluid
Barrier flowing
Quench sealing
fluid

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
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 Oil lubrication for temperatures
cast iron or stainless steel up to 120 oC / 250 oF
Sight glass and oiler drilling at
both sides
Grease lubrication for temperatures

up to 120 oC / 250 oF

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

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.

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

Materials, Auxiliary Parts
Corrosion resistant thinking.
O rings
EPDM
FKM (Viton)
FFKM (in E type pump) Casing
Shaft seal
Gaskets materials same
Klinger SIL C-4430 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

Assembly
Back pull-out design Safe coupling guard is Flexible coupling with
allows fast service. designed according to spacer allows fast service.
safety regulations.
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 Riser blocks allow the

concrete with 3-point fastening. installation of the next frame
Distortion free and fast installation. size of motor.
EPP centerline mounted.
Belt Drive Counter Flanges
Shaft ends are in the same direction. LowPulse

Fast and easy service of V belts and Exact guidance
pulleys. O ring sealing
Safe V belt guard is designed

according to safety regulations.
Collar for general

applications
Delivery with gasket

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.
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

Delivered Documentation Materials Available
Books www.sulzerpumps.com
Customer material according to order PumpFlo curve catalogues

IOM
Available at www.pump-flo.com
Specification and part list
Dimensional drawing AutoCAD symbols
Characteristic curve
Sectional drawings 2D projections of pump and baseplate
CE declaration of conformity
Declaration of quality
Certificates
Component documents
CD-roms
For the total project delivery order
Several languages in IOM and
component documents
Other documentation in English
AHLSTAR Vertical Pumps
These types utilize the same AHLSTAR

hydraulic parts as AHLSTAR NVP/NVT
NPP/NPT and WPP/WPT Non-Clogging
(casing and impeller). Vertical Pump
AHLSTAR NKP/NKT,
WKP/WKT Cantilever Pump

APP/APT Process Pumps, Design Features and Benefits
A double volute casing in larger Simplified heavy-duty
AHLSTAR pumps reduces radial bearing unit design. Oil
forces and shaft deflection. or grease lubrication.
The self-venting, top centerline Heavy-duty shaft.

casing prevents air-lock in the top of Deflection at stuffing box
the casing. less than 0.05 mm/0.002
in. High-strength duplex
The sideplate is adjusted externally stainless steel is
to maintain a constant impeller standard shaft material.
clearance and continuous
high efficiency. Non-contacting bearing
protection for the
Open, special open and closed combined advantages of
impellers are available for a wide labyrinth ring, deflector
variety of applications. and lipseal. Lipseal
protects in standstill
ROTOKEY impeller mounting position.
provides strong, reliable power
transmission. It is self-locking and Strong and rigid bearing
reverse rotation safe. ROTOKEY support foot improves
facilitates the installation and mounting stability.
removal of the impeller. It is not
sensitive to axial loads created 1 Jackscrews for simple
during pump operation. disassembly.

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

casing design reduces fiber Deflection at stuffing
hang-up and vibrations and box less than 0.05
gives a large passage area. mm/0.002 in. High-
strength duplex
The sideplate is adjusted stainless steel is
externally to maintain a standard shaft material.
constant impeller clearance
and continuous high efficiency. Non-contacting bearing
protection for the
Closed or vortex impeller for combined advantages
long fibers and special of labyrinth ring,
applications. deflector and lipseal.
Lipseal protects in
ROTOKEY impeller mounting standstill position.
provides strong, reliable power
transmission. It is self-locking Strong and rigid bearing support foot
and reverse rotation safe. improves mounting stability.
ROTOKEY facilitates the
installation and removal of the 1 Jackscrews for simple disassembly.
impeller. It is not sensitive to
axial loads created during
pump operation.
WPP/WPT Wear Resistant Pumps, Design Features and Benefits
Increased wall thicknesses in impeller, Smooth casing design no gouging eddies.
casing and sideplate.
Back pull-out design allows fast service.
Wear resistant design. Areas of abrasion
are minimized by altering the flow Heavy-duty shaft.
patterns on casing and impeller. Deflection at stuffing
box less than 0.05 mm/
The sideplate is adjusted externally to 0.002 in. High-strength
maintain a constant impeller clearance duplex stainless steel is
and continuous high efficiency. standard shaft material.
Backflow led smoothly towards Non-contacting bearing

inlet flow, not against wall, protection for the
resulting in less wear. combined advantages of
labyrinth ring, deflector
Back and front vanes of the and lipseal. Lipseal
impeller minimize recirculation protects in standstill
and wear. position.
ROTOKEY impeller mounting Strong and rigid bearing support foot

provides strong, reliable power improves mounting stability.
transmission. It is self-locking and
reverse rotation safe. ROTOKEY Wear and corrosion resistant materials,
facilitates the installation and removal of chromium iron and duplex stainless steels.
the impeller. It is not sensitive to axial
loads created during pump operation. 1 Jackscrews for simple disassembly.

EPP/EPT Hot Liquid Pumps, Design Features and Benefits
A double volute casing in larger Back pull-out design allows fast service.
AHLSTAR pumps reduces radial
forces and shaft deflection. The EPP Simplified heavy-duty bearing unit design.
Pump is also centerline-supported. Oil or grease lubrication.
The self-venting, top centerline casing Heavy-duty shaft.

prevents air-lock in the top of the Deflection at stuffing
casing. box less than 0.05 mm/
0.002 in. High-strength
Gland packings and mechanical duplex stainless steel is
seals fit into the same space. standard shaft material.
Spot-cooled stuffing box. Non-contacting bearing

protection for the
Closed and open impellers are combined advantages
available. EPP with a closed impeller of labyrinth ring,
can be used for pumping clean liquids deflector and lipseal.
or liquids containing impurities. Lipseal protects in
standstill position.
ROTOKEY impeller mounting provides
strong, reliable power transmission. It Strong and rigid bearing
is self-locking and reverse rotation support foot improves
safe. ROTOKEY facilitates the mounting stability.
installation and removal of the impeller.
It is not sensitive to axial loads created 1 Jackscrews for simple disassembly.
during pump operation.

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.

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.

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Sulzer Pumps

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 1

Reliable Simple Efficient Diverse

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 2

Special capabilities to handle stocks

End suction single stage pumps

Reliable Simple Efficient Diverse

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 3

Self-venting top Impeller balancing holes

Double volute casing

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 5

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 6

Non-clogging design passes big

Front vanes with sideplate

Thickness in casing and

Hydraulic shapes guide

Hot liquid pumps have high efficiency.

Enforced casing Open impeller

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 9

APP, ARP, ASP, EPP, NPP, NRP,

Common parts shown

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 10

APP/APT NPP/NPT WPP/WPT EPP/EPT

Low spare parts inventory

Only 6 bearing units Process reliability through

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 12

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 13

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 14

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 15

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Gas/air gets into the liquid. AHLSTAR Gas Removal Pump:

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 21

Intended usage Self-priming applications

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 22

Intended usage Suitability Barometric leg application

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Back vanes optimized

WPP, closed APP, open

W01 Non-pressurized W02 Pressurized fluid in No fluid

W03 Flowing pressurized W04 Pressurized non-flowing

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 25

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Flushing internal Flushing external

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Typical manufacturers Options

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Designed for small spaces in gland

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Mechanical element seals, single

V00738 en / Copyright Sulzer Pumps Finland Oy 8.2003 / 36

Mechanical ready-fitted seals Single with quench

Double with options

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Mechanical cartridge seals Gland packing