Economy of scale – KAMAT has developed the first quintuplex (five-cylinder) pumps with a rating of 530 or 800 kW on the basis of the thoroughly redesigned triplex pumps (photo: KAMAT)

KAMAT has now developed the first quintuplex pumps ready for series production on the basis of the redesigned triplex plunger pumps for pressures up to 3500 bar. The operator is thus in a position to generate large volume flows with one single, well controllable pump. This brings clear benefits in terms of costs and efficiency.

The (water) hydraulic systems in various high-pressure plunger pump applications, including those for longwall roof supports in the mining industry and descaling systems in the steel industry, are getting larger and larger. As a consequence, the operators are using multiple large triplex pumps given that the volume flow of these pumps is limited by design and for reasons of the high pressures involved. And the cylinder size is limited by cavitation which implies that it only makes sense to produce triplex pumps with ratings of “only” about 400 kW.

KAMAT has now taken the next step and developed, on the basis of the thoroughly redesigned triplex pumps, the first quintuplex (five-cylinder) pumps with a rating of 530 or 800 kW and the capability to reliably deliver distinctly larger volume flows than triplex pumps.

The advantages for the operator result from the “economy of scale”: A large pump is working far more cost-effectively than two or three smaller ones, and clearly needs less space – an important argument in most modernization projects.

A lot of detailed design work was, however, required to transfer the basic concept of the triplex design to the quintuplex pump. The crankshaft, for example, is supported by multiple bearings, and the crossheads are oil spray lubricated rather than splash lubricated so that sufficient lubrication of the centre crossheads is ensured as well.

KAMAT nevertheless managed to keep spare parts stocking economical through the use of many parts which are common to the triplex pumps. The housing was developed and optimised by KAMAT in close collaboration with the IFAS Institute at the Ruhr University Bochum who also simulated the thermal load of the pumps and carried out the respective optimisations.

The quintuplex pumps furthermore offer the same advantages as the redesigned triplex pumps. They operate at extremely low-noise and low-vibration levels and are capable of working at full operating pressure over a speed range of 10 to 100% in conjunction with speed-controlled drives. Thus they can ideally be adapted to the respective volume flow requirements. The flow rate is not controlled through unloading valves in on/off technique but through an electronically controlled speed regulation of the pump. As a result, wear is significantly reduced since the pump, the pipes and the valves are subjected to far less load.

The first 530-kW quintuplex pump was quickly followed by an 800-kW model. The two versions are already produced in series, and the operators benefit from significant cost savings in terms of energy consumption and maintenance and service bills: Three 800-kW pumps – one each as a master, slave and standby unit which is the common constellation – are able to generate even very large volume flows at pressures up to 3500 bar at highly economical rates.

And the next development stage is already under preparation: In the medium term, KAMAT will add a quintuplex pump with a rating of 1200 kW to the portfolio.

Tags: KAMAT