Overview

Diesel Engine Applications

Confidential, Colfax Corp

Colfax- Global Footprint

Colfax Corporation is a publically held company, headquartered

in Fulton Maryland. The corporation currently has 14 principal

manufacturing facilities in 8 countries. Colfax Fluid Handling

manufactures pumps, fluid control valves, and pumping

systems.

Colfax Corporation is a public company

headquarters in Fulton Maryland, with global

manufacturing facilities. The Colfax Fluid

Handling group is focused on pumps &

pumping systems, and has its headquarters in

Monroe, North Carolina.

Examples- Pump Manufacturing Facilities

IMO AB

Stockholm, Sweden

Allweiler

Bottrop, Germany

Allweiler

Radolfzell, Germany

Houttuin

Utrecht, Netherlands

Imo Pump & Zenith Pumps

Monroe, NC

Imo Pump

Columbia, KY

Warren Pump

Warren, MA

Colfax Pump

Wuxi, China

Tushaco

Daman, and Vapi India

Examples of The Wide Variety of Pump Types

• Three screw pumps

• Two screw pumps

• Crescent internal gear pumps

• External gear pumps

– Single Stream

– Multi-Stream

• Gerotor pumps

• Shuttle Block Piston Pumps

• Plunger style piston pumps

• Centrifugal pumps

• Propeller pumps

• Macerator pumps

• Progressive cavity pumps

• Peristaltic pumps

• Integrated pressure and flow control valves

Markets Served

•Power Generation

•Oil & Gas

•Commercial Marine

•Navy

•Hydrocarbon & Chemical

Process Industry

•Water & Wastewater

•General Industrial

•Machine Tool

•Diesel Engine

•Mobile Equipment

•Pulp & Paper

•Hydraulic Lift

•Pharmaceutical

Markets Served

Systems & Systems Integration

Diesel Engine Capabilities

Types- Crescent Internal Gear

3-Screw

2-Screw

Gerotor

External Gear

Smart pump/motor/controller systems

Fuels, Lube Oils, Refrigerants and Urea Water, Seawater and Coolant

Servo Hydraulic

Typically- Centrifugal, Single or Dual Flow

Typically- Crescent Internal Gear

Freon Pump

Imo/CIG

• Bottom Cycle High Pressure Freon Pump-

Capture waste heat and convert to

mechanical or electrical power

HOW THE CIG PUMP OPERATES

Ring Gear

Pinion Gear

Stationary

Crescent

Suction Zone

or Inlet Cavity-

shown by

dashed lines

Pressure Zone or

Discharge Cavity-

shown by dashed

lines

Shaft Rotating

Clockwise

CIG PUMP PRODUCT FEATURES

Long life & durability

Low airborne noise

Low pressure ripple

Low contamination sensitivity

Excellent suction lift

Wide viscosity range

Crescent Internal Gear Pumping Element

SUCTION

ZONE DISCHARGE

ZONE

STATIONARY

CRESCENT

PINION GEAR RING GEAR

FLUID

CAVITIES

PUMP TYPE COMPARISON

TYPICAL OUTPUT PRESSURE RIPPLE AS A

% OF MEAN OUTLET PRESSURES

PATENTED

INTERNAL GEAR

PROFILE DESIGN

PROVIDES FOR

MINIMAL TRAPPED

FLUID VOLUME.

CIG PRESSURE RIPPLE

PRESSURE ZONE SUCTION ZONE

EXTRA LARGE SUCTION

AND PRESSURE ZONES

AXIAL

PISTON

EXTERNAL

GEAR CIG

MEAN PRESSURE

RIPPLE (PSI) 3000 2000 4500

P-P RIPPLE (PSI) 480 290 28

RIPPLE

(% OF MEAN) 16% 14.5% .62%

TYPICAL PERFORMANCE DATA

50

60

70

80

90

100

110

120

0 10 25 50 100 125 150 200

INPUT POWER (HP @ 1750 RPM)

db

(A)

@ 3

FE

ET

CONVENTIONAL PISTON,

VANE, AND EXTERNAL

GEAR PUMPS

QUIET LINE T-FRAME ELECTRIC MOTORS

CIG AIRBORNE NOISE

CIG SERIES PRODUCTS

LUBRICITY COMPARISON

FUEL OR FLUID GRADE API GRAVITY SPECIFIC

GRAVITY

KINEMATIC

VISCOSITY

(CST @ 104 degrees F)

BOCLE GRADE

(Fuel Lubricity)

#1-D Diesel (ASTM D975) 48 – 34 .788 to .855 1.3 to 2.4 1200 to 3000

#2-D Diesel (ASTM D975) 40 – 24 .825 to .910 1.9 to 4.1 1900 to 4500

#2-Fuel Oil (ASTM D396) 30 Min. .876 2.0 to 3.6 4600

Jet A & A1 (ASTM D1655) 51-37 .775 to .840 1.7 Max. 1600

Jet-B (ASTM D1655) 57 – 45 .751 to .802 0.75 <1000

#1 & #2-K Kerosene (ASTM D3699) 50 – 35 .780 to .850 1.0 to 1.9 >1500

JP-4 (MIL-J-5624) 57 – 45 .751 to .802 0.7 <1000

JP-5 (MIL-J-5624) 48 – 36 .788 to .845 1.7 max. 2200 to 3000

JP-8 (MIL-T-83133) 51 – 37 .755 to .840 1.7 Max. (*) 2200 to 3000

MIL-C-7024B Type II Reference Fuel 57 – 45 .765 to .775 0.7 <1000

R245fa (Refrigerant) NA 1.28 0.25 <1000

OMEGA RATING TEST

SUPPLY

TANK

BLENDER

METERED CONTAMINATION

PUMP TESTED

FILTER

P T

TEMPERATURE PRESSURE

GATE VALVE

P

OMEGA RATING CHART

CIG PUMP OMEGA VALUE 1.036

CIG PUMP PRODUCT FEATURES

Long life & durability

Low airborne noise

Low pressure ripple

Low contamination sensitivity

Excellent suction lift

Wide viscosity range

3-SCREW SERIES PUMP CUTTING EDGE TECHNOLOGY

IDLER ROTOR

POWER ROTOR

IDLER ROTOR

Options-

External or Internal Mounting

External Lube Pump

Internal Lube Pump

3-SCREW SERIES PRODUCT FEATURES

•Design Simplicity

•Long Life & High Durability

•Low Noise

•Low Pressure Ripple

•Low Contamination Sensitivity

•Excellent Suction Lift

•Excellent Scavenge

Performance at high viscosities

•High Speed Capability

•Low Horsepower

Consumption

•Versatile Mounting & Porting

•Complete Range of Sizes

•Flows rates from 1 to 2400

GPM

3-SCREW PRODUCT

Power

Rotor

Equal opposing pressures

Equal opposing

pressures

Idler

Rotors

Flow

Power Rotor

Balance Piston

Idler Rotor

Balance Piston

Clockwise Rotation

IDLER ROTOR

FLUID FILM

FLUID FILM

IDLER ROTOR

DRIVE SCREW OR POWER ROTOR

DIRECTION

OF ROTATION

ROTOR HOUSING OR CASE

PUMP TYPE AXIAL PISTON EXTERNAL GEAR 3 SCREW

Mean Pressure (BAR) 12 12 12

PP Ripple (BAR) 1.74 0.34

Ripple (% OF MEAN) 16 14.5

TYPICAL OUTPUT PRESSURE RIPPLES AS % OF MEAN OUTLET PRESSURES

Fluid Captured in One 3-Screw

Pump Closure or Wrap. It is Formed

by the Intermeshing of the Power

and the Two Idler Rotors in the

Surrounding Housing.

2.8

1.92

TYPICAL AIRBORNE NOISE VERSUS INPUT HORSEPOWER

CONVENTIONAL VANE AND EXTERNAL

GEAR PUMPS

TYPICAL 3-SCREW PUMP

INPUT HORSEPOWER

AIR

BO

RN

E N

OIS

E (

db

(A)

@ 1

mete

r

3-Screw pump at any input speed

100

90

80

70

60

50

40

10 20 30 40

Low Noise Levels

OMEGA RATING TEST

SUPPLY TANK

BLENDER METERED CONTAMINATION

PUMP TESTED

FILTER

P P T

TEMPERATURE PRESSURE

GATE VALVE

0

10

20

30

40

50

60

70

80

90

100

1 10 100

OMEGA VALUE

P

E

R

C

E

N

T

O

F

P

U

M

P

S

B

E

T

T

E

R

3-SCREW PUMP OMEGA VALUE 1.0005

3-SCREW PUMP RANKS BETTER THAN

99% OF THE PUMPS TESTED

OMEGA RATING CHART

7% ENTRAINED AIR

PULSATION (Developing Solutions to Meet Demanding Customer Requirements)

0

50

100

150

200

250

300

350

800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900

Engine Speed (rpm)

Pre

ss

ure

(p

si) BEFORE AFTER

SINGLE CLOSURE 3-SCREW PUMP DATA

WITH 5 TO 7 PERCENT ENTRAINED AIR

(Patent Pending)

Figure M

Typical Sizes

Fluid Viscosity 8.8 cSt

Inlet Pressure 0.57 BAR-abs

SIMILAR DESIGNS

Pump Type: 3EI-400D 3JK-400 3JK-400D A-3JK-400C A3JK-400D I-A3JK-437D A-3JIC-630M 3JK-800J CL-3JKC-800JK CL-3JK-1000JK

ROTATION (B=

REVERSING)

CCW CW CCW CW CCW CCW CW CW B B

ROTOR LEAD 2D 2D 2D 2D 2D 2D 1.75D 1.5D 1.5D 1.5D

OUTLINE DRAWING SDD-10134 SDD-10134 SDD-10134 SDD-11971 SDD-11971 SDD-11163 SD-5567 SCS-5051

POWER ROTOR STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL

IDLER ROTORS IRON IRON IRON IRON IRON IRON IRON IRON IRON IRON

HOUSING IRON IRON IRON IRON IRON IRON BRONZE BRONZE BRONZE BRONZE

MAX. SPEED (RPM) 2100 1800 1800 2410 2410 1800 1150 1500 1500 1200

MAX. DISCHARGE

PRESSURE- PSIG

(BAR)

75 (5.2) 75 (5.2) 75 (5.2) 75 (5.2) 75 (5.2) 80 (5.5) 125 (8.6) 80 (5.5) 80 (5.5) 140 (9.7)

NOMINAL FLOW -GPM

(L/M)

500 (1893) 417 (1578) 417 (1578) 560 (2120) 560 (2120) 550 (2082) 882 (3339) 2109 (7983) 2109 (7983) 3237 (12253)

0 – 5 0 – 10 0 – 20 0 – 30 0 – 40 0 – 50 0 – 60 0 – 70 0 – 80

90 %

100 %

60 %

70 %

80 %

105 %

0 30 60 90 120 150 180 210 240 270

3-Screw pump, internal ball

bearing, at 100 BAR, 2900

RPM, fluid temperature

650C

Crescent Internal Gear

(CIG) pump, 125 BAR,

1500 RPM, fluid

temperature 37.50C

External Gear pump with

axial compensation at 210

BAR, 2000 RPM, fluid

temperature 650C

Vane pump, with axial

compensation at 155 BAR,

1800 RPM, fluid

temperature 650C

Radial Piston pump, slotted

hydrostatic unloading

cylinders at 210 BAR, 1500

RPM, fluid temperature

650C

Axial Piston pump, beveled

graphite or nodular iron

swash plate, at 210 BAR,

1800 RPM, fluid

temperature 650C

Test Duration Time in Minutes

Pump Ingested AC fine test dust of various fractional sizes (Microns), at a concentration of 300 milligrams per liter

PUMP OUTPUT FLOW DECAY VERSUS TIME AND FLUID CONTAMINATION

End of flow reduction with 60 micron

Q0 Initial flow rates measured at 2 hours of run time on clean fluid at indicated discharge pressure.

Q delivered flow measured at 30 minutes with various fractional sizes of contamination at original discharge pressure.

RWTH Aachen (Technical University)

EXTERNAL GEAR PRODUCT FOR DIESEL ENGINES

SUCTION

ZONE DISCHARGE

ZONE

EXTERNAL GEAR PRODUCT FEATURES

Design simplicity

Wide viscosity range

Ideal for small axial profile applications

Multi-segment pump capability

GEROTOR PRODUCT FOR DIESEL ENGINES

RING GEAR

SUCTION ZONE

PINION GEAR

DRIVE SHAFT

HYDRODYNAMIC LIFT

PRESSURE ZONE

HYDRODYNAMIC LIFT

GEROTOR PRODUCT FOR DIESEL ENGINES

GEROTOR PRODUCT FOR DIESEL ENGINES

GEROTOR PRODUCT FEATURES

Design simplicity

Flow direction can remain constant regardless of drive shaft direction

Wide viscosity range

Ideal for pre-lube and low pressure applications

2-SCREW PUMPS FOR DIESEL ENGINES

2-SCREW PUMPS FOR DIESEL ENGINES

TWO SCREW PUMP PRODUCT FEATURES

Excellent suction lift at high flow volumes.

Can be designed in single and double flow configurations

Wide viscosity range

Ideal for high-volume applications

SINGLE OR DUPLEX CENTRIFUGAL PUMPS FOR DIESEL ENGINES

Sea Water Pump

Seewasser-pumpe

Fresh-Water Pump

Motarwasser-Pumpe

Attached Mounted Centrifugal-Pumps

Application

Fresh- and sea water cooling

pump for internal combustion

engine, and sometimes simultaneous for

additional water supply on the ship.

Attachment on the engine

bloc, directly driven by control

gear box from the diesel engine

SINGLE OR DUPLEX CENTRIFUGAL PUMPS FOR DIESEL ENGINES

Performance Range

On customer demand

Flow rate:10 m3/h up to 550 m3/h

(44 to 2422 GPM)

Delivery head: to 120 m (394 ft)

Technology Development

COMPUTER MODELING

AIRBORNE, FLUID-BORNE AND STRUCTURE-BORNE NOISE

ANALYSIS

PULSATION (Developing Solutions to Meet Demanding Customer Requirements)

0

50

100

150

200

250

300

350

800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900

Engine Speed (rpm)

Pre

ss

ure

(p

si) BEFORE AFTER

SINGLE CLOSURE 3-SCREW PUMP DATA WITH 5 TO

17 PERCENT ENTRAINED AIR

(Patent Pending)

Figure M

MODAL ANALYSIS CAPABILITY

• Provides the ability to analyze physical shapes to determine the vibration effects under rapid stress cycles.

• Allows us the ability to model the impact of vibration on the product components and pumping systems supplied.

• Ability to measure transfer functions, and frequency response.

METALLURGICAL LAB

Photo Micro-graphs,

Photo Macro-graphs,

Radiography,

Magnetic Particle,

Dye Penetrant,

Brinell & Rockwell Hardness,

Sclieroscope,

Chemical Properties and

Magnetic Permeability.

Root cause analytical failure

mode analysis.

Durability and Quality

assurance.

MODERN PRODUCTION METHODS

Modern Inspection Equipment & Techniques

Colfax Business Systems Business Processes Methods and Procedures

(Manufacturing and Office)

Toyota Production System

TPS

Origins of Colfax Business System

Jacobs Production System

JPS

Danaher Production System

DPS

Danaher Business System

DBS

Colfax Business System

CBS

Business Model

Project Dissemination

• Dedicated Champions for Production, Engineering,

Maintenance and Quality.

• Business System- Colfax Business System

• Policy Deployment/ Tracking & Measurement

Establish

Organizational Vision

Self Diagnosis

IMPLEMENTATION

REVIEW

CBS Tools

Catchball

Critical

Step

PLANNING Strategic Planning / Develop 3-5

Year Breakthrough Objectives

Develop Annual Objectives

Implement Annual Objectives

Deploy Annual Objectives

Root Cause Countermeasures

Monthly Review

Annual Review

7 Phase Policy Deployment Process

Quality

Dedicated quality team.

ISO:TS/16949 standards.

• QS9000 or ISO9001 certified sub-suppliers meeting PPAP requirements with quarterly data reviews.

• Colfax Business System/Policy Deployment Tracking & Measurement

• Cross functional sub-supplier assessment teams

• Driven toward continuous improvement in manufacturing processes, field reliability, and quality performance to reduce total cost of ownership