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AHLSTARUP – The Newest Member of the Sulzer Stock Pumping Family

Sulzer Pumps has more than 110 years of experience in providing innovative and technically supe-rior pumping and mixing solutions to the pulp and paper industry. During this time we have enjoyed close cooperation with the world’s leading pulp and paper producers, machinery suppliers and engineer-ing companies.

Unrivalled Experience in the Pulp and Paper Industry

The result has been that we have attained a deep and thorough understanding of pulp and paper processes, which in turn has enabled us to design and develop innovative, reliable and effective pumping and mixing solutions. Our profi ciency in this fi eld has given us a leading technical position that is globally acknowledged.

Through our commitment to understanding the processes and specifi c needs of our customers, we have consistently been on the leading edge in providing techni-cally advanced pumping solutions to this industry. This essential process know-how is supported by state-of-the-art technology, exten-sive and highly advanced research and development facilities, and our own foundries to ensure optimum pump material selection for each particular application.

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Designed for the lower end (0 to 8 %) of the consistency range, the AHLSTARUP A-series represents a major break-through in terms of energy effi ciency and reliability. The potential for real operating cost savings is substantial, thanks to the many groundbreaking innovations that have been incorporated into this latest addition to Sulzer’s stock pumping concept.

The following concepts are innovations that have been developed and utilized to ensure optimal performance.

AHLSTARUP* - the New Frontier in Stock Pumping Effi ciency

* AHLSTARUP is a trademark of Sulzer Pumps

1. Sulzer EnerSave™ Impeller (A-series)

2. Sulzer WaterLess™ Shaft Seal Concept

3. Sulzer Selfprime & Degas™ Concept

4. Sulzer Bearing Unit Concept

5. Sulzer Environmental Concept

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Stock Pumping Concept

MC® range

Semi-MC™ range

Low consistency range

MC® rangeMCE™

LCE™

KCE™

AHLSTARUP

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Sulzer EnerSave™ Impeller

New A Hydraulics. For the pump-ing of clean, abrasive and erosive liquids and especially stocks of various kinds.

Real Innovations… True Benefi ts… Better Performance

for sealing liquid in a double mechanical seal has been mini-mized. Other sealing options are also available.

Sulzer Selfprime & Degas™ Concept

Degassing and self-priming pumps are designed for the pumping of liquids which contain much air or gas and for applications where the inlet pipe is occasionally empty.

Sulzer Bearing Unit Concept

• Grease lubrication - max. tem- perature of the pumped liquid 120°C. • Oil lubrication - max. temperature of the pumped liquid 180°C.

Sulzer Environmental Concept

Saving more than just money.

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Sulzer WaterLess™ Shaft Seal Concept

Shaft sealing without external sealing liquid.The pump can be fi tted with two types of shaft seals which do not need sealing liquid: dynamic seal or single mechanical seal. The need

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Sulzer’s expertise in hydraulics is the result of years of stock pump-ing experience. We employ sys-tematic and constant compilation and analysis of hydraulic data, and the very latest computing methods - all of which have been utilized in developing the pumping hydraulics for the AHLSTARUP A-series.

The innovative and effi cient Sulzer EnerSave™ Impeller is designed specifi cally for the needs of the pulp and paper industry.

• High effi ciency over a wide performance range results in lower energy consumption.• Larger performance range and optimum hydraulic coverage

The AHLSTARUP Series (A, N and W pumps)

Dimensions: EN 22858:1993 (ISO 2858:1975)Design: EN ISO 5199:2002Pressure: To 1.6 MPa depending upon material and size.Flange drilling: Several options according to valid standards.Frequency: 50 Hz and 60 Hz

Sulzer EnerSave™ Impeller

means reduced total energy consumption.• Externally adjustable side plate (pat. pending) maintains constant savings on energy consumption.• Excellent suction capability and low NPSHr over a wide perfor- mance range means that the pump can be used at low inlet heads.• The strong, rigid design and smooth hydraulic shape means reduced wear and longer working life.• The self-locking ROTOKEY impeller mounting provides strong and reliable power trans- mission. It also facilitates the easy installation and removal of the impeller.

N Hydraulics

The non-clogging AHLSTARUP N-series pumps are intended for pumping liquids containing large or long solid particles. In applications where normal stock and process pumps cannot operate in a reli-able or stable manner because of abrasive particles and/or clogging problems, the N-series pumps pro-vide an effective solution.

W Hydraulics

The AHLSTARUP W-series pumps feature specially designed wear-resistant hydraulics with materials that can withstand the most abra-sive and erosive pumping applica-tions. These include the pumping of lime milk and mud, and coating pigments.

AHLSTARUP pumps Other AHLSTAR pumps

The concept includes the following shaft seal solutions, all of which save external sealing liquid.• Dynamic seal – no external sealing liquid• Single mechanical seal – no external sealing liquid• Double mechanical seal – minimized need for external sealing liquid

Sulzer WaterLess™ Shaft Seal Concept

Sulzer Dynamic Seal

• No external sealing liquid needed• No sealing liquid piping or instruments required• No leakage• No sealing liquid treatment costs for clean water production and wastewater treatment• Fast and easy installation with no measuring needed• Seal guard provides greater safety

It is estimated that the majority of pumping problems come as a result of shaft seal failures. This has a heavy impact on the lifetime costs of the pump.

In the new AHLSTARUP series of pumps, these costs are minimized. To achieve this, particular attention has been paid to the shaft seal-ing and to the control of fl ow and

pressure in the sealing area (pat. pending). The result is a depend-able shaft-sealing concept that is more reliable and stable throughout the entire performance range.

Sulzer Pumps has been develop-ing and utilizing dynamic seals for pulp and paper industry pumps for almost 20 years. The dynamic seal employed in the AHLSTARUP

pumps is the culmination of this work and experience. This non-contact seal solution is practically maintenance-free. It also features a new and innovative static seal

that provides a level of reliability at standstill previously unattainable in dynamic seals (pat. pending).

Sulzer WaterLess™ Mechanical Seals

Amongst the many important features of the AHLSTARUP series of pumps is our own, WaterLess™ mechanical seal that has been inte-grated into the casing cover of the pump (pat.pending). As a result of correct fl ow and pressure control in the sealing area, the dry running of a single mechanical seal and gland packing has been eliminated.

Other Sealing Solutions

Gland packing is also available if needed. This is an optional sealing that often needs external sealing liquid.

• Increased reliability means lower operating costs• Fast, easy installation and mainte- nance with no measuring needed• Seal guard provides greater safety• Innovative sealing liquid control equipment for double mechanical seal saves more than 90 percent of the sealing liquid required by conventional equipment

Gas, in most cases air, is inevitably present in liquids being pumped and is a constant cause of pump-ing disturbances. Sulzer’s exten-sive expertise and experience in pioneering solutions to these gas-related pumping problems, lies behind this new degassing concept.

The AHLSTARUP pumps incorpo-rate this concept and deal effec-tively with the pumping of liquids containing air or gas (Fig. 1 and 2), as well as with situations where

Sulzer Selfprime & Degas™ Concept

the inlet pipe is occasionally empty (Fig. 3). Conventional centrifugal pumps tend to fail in such applica-tions because of the disturbance caused by gas bubbles accumulat-ing at the impeller eye.

The AHLSTARUP pumps have an internal or external vacuum pump to remove these gas bubbles, or they are removed as a result of suffi cient inlet pressure. This effec-tively eliminates instability within the pumping system and process.

Gas removal pump eliminates fl uc-tuations in pressure and fl ow for stable operation• The need for environmentally harmful antifoaming agents is greatly reduced.

Internal vacuum pump provides self-priming and gas removing capability• The pump can replace a mainte- nance-demanding vertical pump or submersible pump.• Easy maintenance because of its dry mounted horizontal design.

Fig. 1 Fig. 2 Fig. 3

Sulzer Bearing Unit Concept

The long-standing ability of Sulzer Pumps to provide innovative solu-tions and technically advanced designs for pulp and paper industry pumps is further enhanced by the Bearing Unit Concept incorporated into the new AHLSTARUP series. This concept provides a sturdy and reliable bearing unit that offers longer working life and numerous other benefi ts.

• Strong oversized bearing arrangement.• Excellent sealing of the bearing housing covers prevents water from entering and eliminates the need for a separate defl ector. • No wear is applied to the shaft.• Duplex stainless steel shaft pro- vides rigidity and minimal defl ec- tion (less than 0.05 mm) at the shaft seal area.

• Sturdy bearing support foot pro- vides solid mounting and prevents changes in coupling alignment. • Quick and easy installation minimizes downtime.

Duplex ASTM A890 Grade 3A 41

ASTM A890 Grade 1B 4L

ASTM A890 Grade 5A 4T

Austenitic AVESTA 654 SMO1) 4U

Martensitic ASTM A747 Grade CB7Cu-2 4E

Stainless Steel Design Sulzer Code

Cast Iron Design Sulzer Code

Cast Iron ASTM A48 CL 35 B 53

Chromium Iron* A532 IIIA 5B

1) AVESTA 654SMO is a trademark owned by Outokumpu Stainless which has granted Sulzer Pumps licence to produce this material.* For W Hydraulics

Other corrosion resistant cast steels available on special request.

Pump Materials

Environmental considerations have always been of importance to Sulzer Pumps in the design and development of the company’s pumping and mixing solutions. These same considerations are an integral feature of the AHLSTA-RUP series of pumps, which are designed to be effective throughout the pumps’ entire life cycle.

Sulzer Environmental Concept

For example, the standard shaft seals need no external sealing liquid whatsoever. The seals are protected with guards from splash, and potential leaks are catered for with a drip pan. All rotating parts are protected against contact, and thanks to the effective sealing of the bearing unit, lubricant cannot escape nor can water mix with the lubricant.

• All our factories work in accor- dance with the quality manage- ment system and environmental management system. EN ISO 14001:1996 certifi cation was awarded to the foundry as early as 1998, followed by an environ- mental award in 2002.• All relevant directives and standards pertaining to legisla- tion and product safety are strictly adhered to.

Lifetime Service Solutions for the AHLSTARUP Pump

The signifi cant performance improvements featured in the new AHLSTARUP series, together with the innovative design features, offer extended lifetime, higher availability and easy maintainabil-ity. Furthermore, the back pullout construction and highly modular structure of the AHLSTARUP series mean that current pumps can be easily upgraded to achieve, for example, increased capacity or reduced energy consumption.

When maintenance of the AHL-STARUP pump is necessary, the use of original spare parts ensure high availability and perfor-mance. Spare part needs for this series of pumps are low however, thanks to the compact but sturdy structure and the best-in-class interchangeability of the parts. This also provides easy optimization of spare part inventories.

We support our pump users with a full range of pumping services, ranging from installation services to troubleshooting and remote moni-toring. Additionally, our innovative service concepts such as the Exchange Unit service program, Service Kits, and the Optimized Inventory Concept (InvO), together with our Extranet based PumsOn-line eBusiness solution, provide extra pump maintenance effi cien-cies.

All factors infl uencing the life cycle costs (LCC) of the pump have been taken into consideration when designing the AHLSTARUP series. These include items such as pump selection and energy costs, purchase, installation, operation, maintenance and disposal.

Through the development of new concepts for the impeller, shaft sealing, degassing, the bearing unit and environmental considerations,

Minimized Pump Life Cycle Costs

it is now possible to offer true LCC savings. By signifi cantly reducing energy consumption, eliminat-ing sealing liquid, by simplifying installation and maintenance requirements and through overall improved reliability, a fundamental impact on LCC has been achieved. The AHLSTARUP series from Sulzer Pumps is a breakthrough achieve-ment that benefi ts pulp and paper processes everywhere.

Check our worldwide offi ces at www.sulzerpumps.com

E00624 en 5.2005 (3000), Copyright © Sulzer Pumps Finland Oy

This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice.

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