Overview -...
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Overview Diesel Engine Applications Confidential, Colfax Corp
Transcript of Overview -...
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
