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
• 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
• Easy assembly
• Low-pressure quench fluid
• Designed to be a part of the pump
• Compatibility with pump materials
Typical manufacturers
• John Crane Safematic
• Burgmann
• Huhnseal

Ready-Fitted Mechanical Shaft Sealing, Double
• Easy assembly
• High-pressure flowing barrier fluid
• High-pressure non-flowing barrier
fluid, dead-end
• Designed to be a part of the pump
• 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
- 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
• 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 µm
• 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

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 16

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 17

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 18

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 19

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 20

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

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 23

Back vanes optimized

WPP, closed APP, open

W01 Non-pressurized W02 Pressurized fluid in No fluid

W03 Flowing pressurized W04 Pressurized non-flowing

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V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 27

Flushing internal Flushing external

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Typical manufacturers Options

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V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 32

• Designed for small spaces in gland

V00738 en / Copyright © Sulzer Pumps Finland Oy 8.2003 / 33

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Mechanical element seals, single

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Mechanical ready-fitted seals Single with quench

Double with options

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Mechanical cartridge seals Gland packing