DnD PUMPDewatering and Dredge Milestones KSB Germany 1871 – Johannes Klein, Friedrich Schanzlin and August Becker establish the company in Frankenthal. 1887 – KSB becomes a limited company. 1895 – KSB goes public. Today – One of the world's leading suppliers of pumps and valves KSB Indonesia 1993 – Established in Indonesia located in Cakung and focusing on Foundry Shareholders: - KSB Finance AG SA Luxembourg (94.06%) - KSB AG Germany (5.94%) 2010 – Opening new factory facility in Cibitung 2014 – Opening representaive workshop in KSB Group About Us KSB is one of the world’s leading manufacturers of pumps and valves, providing a range of related service offerings. 3 Company presentation It All Began with an Idea Experience since 1871 The global success story of KSB began over 140 years ago when Johannes laid the foundation for the company by inventing his “boiler feed apparatus”. Production of – Valves since 1872 – Pumps since 1873 4 Company presentation KSB Group Board of Management (from left) Dr.-Ing. Peter Buthmann Dipl.-Kfm. Werner Stegmüller 5 Company presentation KSB Group Our Corporate Culture Our internal cooperation and our contact with customers and partners is based on the values of – – – – – 6 Responsibility Trust Appreciation Professionalism Honesty Company presentation . 247.3 million Earnings (before taxes): € 119.4 million Employees: 16.On the Spot Around the World A Global Company Financial year 2013 • • • • Order intake: € 2.241.546 Global presence brings us closer to customers – production on all 5 continents KSB production sites KSB sales and service sites 7 Company presentation .2 million Sales revenue: € 2. Allight • 4/25/16 KSB secret of sucesses in retaining its market share in mining segment is the Dewatering and Dredge Pump (DnD) that is known to be highly qualified for severe mining duties.KSB Indonesia Segments & Market Shares MINING • Average number of dewatering pumpset being sold per year is between 40 to 50 sets • KSB Indonesia has been sustaining an average of 19% market share from the aforementioned proportion • There are 3 other major players in this segment throughout Indonesia including Multiflo. Agressive Mine Syaiful Anwar Water KSB Banjarmasin and Slurry Condition .e. Sykes. i. GIW (Georgia Iron Work) . . Sangat cocok untuk kondisi tambang batubara di Indonesia • The application of DnD is highly suitable for agressive mine water and slurry condition in any open pit coal mine sites • DnD features heavy duty impeller. produk berkualitas tinggi yang menggabungkan slurry pump. engine. sistem vacuum dan proteksi. liner material made from 28% high chrome • DnD is highly reliable with guaranteed durability .Featured Systems Designed by KSB Indonesia DEWATERING & DREDGE PUMP (DND) • Produk kebanggan KSB Indonesia DnD Pump. casing. Majend Sutoyo kav22 Jakarta 13630 Indonesia Open pit coal mine operation We supply Pumpset and Flow System Solution for open pit mine operation Heavy duty Slurry Pump to handling severe duty Material Gasite 28 G ( 28 % Chrome ) as std Engine Variable Speed Type (brand depend of customer choice ) Security supply of spare parts and back up services . suite D02 Jl.KSB Indonesia Cawang Kencana bldg Floor D .DnD Pumpset Feature PT. FROM AGRESSIVE WATER 4/25/16 Syaiful Anwar KSB Banjarmasin . or coal and water: clay slurry SG>1 .5-7 4/25/16 Syaiful Anwar KSB Banjarmasin . typically of fine particles of manure. cement.TO BECOME SLUDGE Definisi slurry= Campuran antara partikel air dan solid/padat. pH= 3. 5 Mampu melewatkan partikel besar diameter 9 cm Higher Shaft & Bearing Power Higher Casing Pressure Better Hydraulic Efficiency Priming System and Protection during dry running .Slurry Pump Design Consideration (Compared to Water Pump) • • • • • • • Tahan abrasive Tahan korosi PH up to =3. 5 – 4. hardness: 600 hbn/58 hrc ASTM Standard A532-87.5 Castings and machined castings Larger free passage . Class III. High-Chromium White Iron Tensile strength: 85-115 ksi Min. Type A pH levels as low as 3.® Gasite WD 28G Abrasion Resistant. DnD PumpFeatures AUTOMATIC VACUUM PRIME SYSTEM AND AUTOMATIC SHUTDOWN ENGINE Floating Ball Valve To Protect Vacuum Pump from Water Vacuum Pump operate in idle speed Of engine . vacuum time is 1-2 minutes Pully Belt drive Flow Sensor ( Probe ) Use to stop Vac Pump Clutch Non flow Sensor ( Probe ) Use to shutdown engine when flow cheases c Vacuum Pump *Standard oil * Volume Oil . Basic Centrifugal Pump A pail of water swinging in a circle centrifugal force holds the water in the pale a hole is bored at the bottom of the pale water will be thrown out the distance the water traverses and volume that flows out depends upon the velocity of the rotating pale . Working of a Centrifugal Pump Main Parts are – Impeller Volute casing . Working of a Centrifugal Pump The first resistance is created by the volute As the liquid moves in the volute towards the outlet it slows down due to increasing cross sectional area As the liquid slows down its velocity (kinetic energy) is converted into pressure . Working of a Centrifugal Pump The impeller is offset in the volute to create a close clearance between the impeller and the volute at the cut water The kinetic energy given to the liquid is proportional to the velocity at the edge of the impeller vane tip. higher will be the liquid velocity at the vane tip. A centrifugal pump neither creates pressure nor does it suck. it only provides flow. Faster the impeller rotates or bigger the impeller is. Pressure is just an indication of the amount of resistance to flow! . Pressure – Head Interconversion Head (m) = Pressure (kg/cm2) x 10 Specific Gravity . gr. 0.gr.6 kg/cm2 .0 3 kg/cm2 30 m Brine Sp.Why Head is used to measure the energy of a centrifugal pump? 30 m Kerosene Sp.4 kg/cm2 30 m Water Sp.2 3.8 2. 1. 1.gr. Why Head is used to measure the energy of a centrifugal pump? Pressure at any point in a liquid is caused by a vertical column of liquid due to its weight. Head is a measurement of the height of a liquid column that the pump could create from the kinetic energy imparted to the liquid. A given pump with a given impeller diameter and speed will raise a liquid to a certain height regardless of the weight of the liquid! . Height of this column is called Static head and is expressed in meters of liquid. Pressure is dependent on the specific gravity of a liquid but head is not. hvs ) + ( hfd + hfs ) = ( hd – hs ) + ( Pd – Ps ) x g + ( Vd2 – Vs2 ) + ( hfd + hfs ) 2xg hs = -ve. kg/m3 g = gravitational constant.Suction Velocity Head + Discharge Friction Head + Suction Friction Head ) = ( hd – hs ) + ( hps – hpd ) + ( hvd . m/s2 hf = x V2 . (loss coeff.System Resistance Curve Total System Head = Static System Head + Dynamic System Head = ( E l e v a s i ) + ( Discharge Velocity Head . if suction head suffix “s” = suction suffix “d” = discharge = density. if suction lift hs = +ve. ) 2xg Pd Vd hd hs Ps Pvp Vs Datum Level Pump Center Line . Sg Liquid Solid Conecentraion % Cv Solid Sg Sg Slurry PH Value Maximum Rock Size Allowable Barometric Pressure Area Static Head Pipe Line System Pipe Diameter Pipe Type Pipe Length Flow = M^3 / Hour Bend Pipe number System flushing. avaibility clean water . System Resistance Curve Dynamic System Head Static System Head . Operating Pump •Pompa selalu bekerja di perpotongan antara pump curve dan system curve 2 . Operating pump in different zone effects •Over capacity zone : kecepatan liquid dalam pompa sangat tinggi. •Best Operating Zone : titik operasi yang disarankan. gaya hidrolik terbesar terjadi. terjadi resirkulasi yang menyebabkan wear yang berlebih. dalam kondisi ini wear. pompa tidak boleh berada dalam kondisi ini terlalu lama. 2 . wear berlebih di casing •Shut off zone : kondisi zero flow. beban hidrolik pada impeller dan bearing tinggi. minimum wear •Reduced Capacity Zone : kecepatan liquid di pompa rendah terjadi resirkulasi dan separasi. Pump Selection to determine material pump and duty pump • Slurry type •PH •SG •Head Static •Flow •Jenis. panjang dan Diameter Pipa 3 . Vary Speed 3 .Consideration Issues 1. Expected % solid transport 5. NPSHA &NPSHR 2. Free Passage 4. Mobile Capable 6. Slurry type settling or not 3. Three basic design of Slurry Pump 3 . 6 .PT KSB INDONESIA Slurry Pump Standar ASTM A532 ANSI/HI 12.1-12. 000 m tekanan udara ≈ 10.003 atm ≈ 0.3-(Vp+Ls+Hf) • 1 atm ≈ 80.Net Positive Suction Head (NPSH) • NPSHA = 10.3 m pada suhu 25 deg C • NPSHR DnD standar ≈ 7m • NPSHR = based on curve from pump manufacturer. • NPSHA-NPSHR > 0 3 I Title of .3 m tekanan air • Vp (vapour pressure) ≈ 0. Vary NPSHA Condition . 0 m/s 3 I Title of .2 m/s • For Slurry = 3.Optimum Velocty Fluid • For Water = 1.0 – 5.5 . HANDLING MUD TO GET COAL UNDER THE MUD . 20 meter SFM Pit.Sprayer Water Vehicle Car Portable Capacity : 2500 m^3 / Jam Total length Pipe 10 Km Elevasi +/.wmv Concetration : 40 % Cv Case Mapur : Deposite Sources Capacity Target Production System and Metode ( Pumping Metode ) Equipment Selection . Capacity : 2500 m^3 / Jam Total length Pipe 10 Km Elevasi +/.20 meter Flushing Pump . Material Option for Common Slurry Application Material of Construction Part Name DnD 100 DnD 150-4H DnD 200-5HX DnD 250 Casing Gasite 28G Gasite 28G Gasite 28G Gasite 28G Suction Liner Gasite 28G Gasite 28G Gasite 28G Gasite 28G Impeller Gasite 28G Gasite 28G Gasite 29G Gasite 28G Shaft 4150 Steel 4150 Steel 4150 Steel 4150 Steel Shaft Seal Tuff Pack #100 Tuff Pack #100 Tuff Pack #100 Tuff Pack #100 Shaft Sleeve(*) Carbide Coated Steel Carbide Coated Steel Carbide Coated Steel Carbide Coated Steel Pedestal Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Bearing Housing Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Stuffing Box and Gland Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron SS304 SS304 SS304 SS304 Piping and Accs. (**) . Material Option for Mud Slurry Application Material of Construction Part Name DnD 100 DnD 150-4H DnD 200-5HX DnD 250 Casing Gasite 28G Gasite 28G Gasite 28G Gasite 28G Suction Liner Gasite 28G Gasite 28G Gasite 28G Gasite 28G Impeller Gasite 28G Gasite 28G Gasite 29G Gasite 28G Shaft 4150 Steel 4150 Steel 4150 Steel 4150 Steel Slade Packing Seal Slade Packing Seal Slade Packing Seal Slade Packing Seal SCCAP (Conforma Clad) SCCAP (Conforma Clad) SCCAP (Conforma Clad) SCCAP (Conforma Clad) Pedestal Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Bearing Housing Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Stuffing Box and Gland Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Class 40 Grey Iron Piping and Accs. SS304 SS304 SS304 SS304 Shaft Seal Shaft Sleeve . Low Head Good Sealing during submerse in to water Expensive due to submerse capability and sealing system 4 I Title of .Submersible Pump for mud slurry • • • • • • Mixer/Agitator Capability + optional cutter Up to 70% of solid More Solid more frictional losses Low NPSHR. DnD as Mud Slurry Transport Record 4 . 6 m .10”.5 m 58.12”.14” Panjang Pipa : 200 m Percentation Solid ( 5 % ) : SG = 1.Fuel Consumption Calculation DnD 200-5HX with Engine Volvo Example : Duty Pump : 900 m^3 / hours Head Static : 40 meter Pipa HDPE : 8”.9 m 92.03 Fuel Density : 860 gram / liter Size Pipa 8” 10” (ID=162) (ID=202) 12”(ID= 255) 14” (ID=287) TDH 176 m 64. 6 RPM = 1306 Eff =78% 1500 .Curve DnD 200-5HX & Engine Volvo TAD1643VE 520 Duty Point Q = 900 H = 92. Fuel Calculation Based On Pump Curve and Engine Curve • • • • • • DnD 200-5HX Engine Volvo TAD1643VE Pump Efficiency : 78 % Power Absorb of pump . engine have power enough • SFC ( specific fuel consumpt ) = 180 gram / kWh .8 liter / hour --------------------------------------- 46 .4 kW Engine Drive Safety Factor 25 % = 1.25 x 300 kW = 375 kW Engine Power : 440 kW @1300 rpm.hour ( given by curve based on Speed ) • • Rate Fuel = ( 180 grm/kW hour x 300kW / 860 grm / liter ) = 62. = SG x H x Q ( flow ) / (367 x Pump Eff) Power absorb : 299. Curve DnD 150-4H & Engine Volvo TAD1343VE . Curve DnD 100 & Engine Volvo TAD 1243VE 48 . id 4 .anwar@k sb.Thank You for Your Attention • Syaiful Anwar • Sales Engineer Mining • Rep. Banjarmasin • 0811 902 926 • syaiful.co. Trikora Banjarbaru Telp : (0511)477 0235 Fax : (0511)477 0236 .Thank You PT KSB Indonesia Rep Banjarmasin Kompleks Pertokoan Simpang Palm Blok 24 Jl.