High pressure technology that sets the standard

High pressure pumps

Ultra high pressurepumps

Pump units

Quality The most modern developmenttechniques e.g.FEM Analysis areused during the design phase toachieve optimal component configuration. Our computer controlled workshop ensures constant dimensional accuracy.Hammelmann components andproducts are subjected to stringentquality control procedures. Allpumps, pump units and accessoriesare tested under maximum load in our modern test facility beforedelivery.

Hammelmann works in accordancewith and is certified to the DIN ENISO 9001 quality management stan-dard.

Water qualityA clean medium is an advantage forall high pressure pumps. Abrasivematerials in the water will shorten thelifetime of valves, valve seats andwater jetting tools. An advantage ofthe dynamic plunger seal with labyrinth insert is that each stroke ofthe plunger washes away abrasiveparticles.

Vertical pump configurationOur three and five cylinder highpressure pumps are mounted verti-cally. This offers certain advantages:

• The crosshead and plungerweights are neutralised within thesealing system, effectively reducingwear on all oscillating components.

• Automatic air venting is ensuredwhich greatly decreases the possibility of cavitation.

• Enables construction of very compact units with all importantcomponents accessible from allaround the pump. This simplifiesmaintenance works. • The ability to position the pump

completely within the frameworkreduces the width of units furtherenhancing compactness.

• Linearly aligned forces of gravitybetween the pump and the dieselengine reduce vibration.

FEM Analysis of HDP 230 crankshaft

High and ultra high pressure pumps

Water supplyA complete water supply systemcomprises header tank, boost pumpand fine filter to compensate thevarying on site supply conditions.Cooling water and bypass water arereturned to the header tank. Advan-tages: lower water consumption,drainage lines are eliminated.

The header tank, boost pump and bypass line are all made fromnonrusting materials.

Practical ancillary components

Boost pumpThe boost pump in combination withthe header tank ensures that optimaloperating conditions exist for the high pressure pump. Theboosters are belt driven on dieselpowered units and by independentE-motor on electrically poweredunits.

System status monitoringMonitoring water and oil pressuresprevents possible pump damage bycavitation or lack of oil. Water tem-perature, filter differential pressure,max. operating pressure and drivemotor/engine condition can also be monitored. The unit shuts downimmediately preset limits are reached.

Electronic speed regulation for dieselpowered unitsWhen the required working pressureis entered into the control computerthe engine speed will automaticallyadjust to achieve it. When the pumpor jetting tool switches to bypass theengine speed automatically drops toidling. This cuts down wear andsaves on fuel costs. Hose reels

Manual or hydraulically poweredhose reels store hose neatly andease the work on site. Hose can bewound off and on when pressurised.

For the many various applicationspumps are combined with systemsto form self contained units. Ourstandard range includes stationaryunits with diesel or electric drive andmobile units for either on site orpublic road use.

High and ultra high pressure units

Compactness, a strongly construc-ted frame and good access to components are the basic designprinciples.

Diesel unit base frames have spacesaving integral fuel tanks.

Hammelmann electrically driven unitsincorporate NEMA specificationmotors and control components.Motor control options include softstart and VFD starters to latestcontrol technology.Electric motors and controls are optionally available in explosionproof design.

The vertically acting forcesof gravity allow the unit tobe deployed without needfor special foundations oranchors.

Electric or diesel powered units canbe supplied with sound dampenedcovers or built into containers. Dueto its compactness even a 5 cylinderhigh pressure pump with a 310 HPdiesel engine will fit neatly into a 10 ft. container.

Crank section• The crank sections‘ calculations

are made employing the “Finiteelement method” resulting in desi-gns that ensure a long working lifeunder continuous load.

• An integral speed reducer usingtwin helical gears arranged inherringbone configuration ensuressmooth running and even powertransmission without axial load tothe bearings. A selection of gearratios is available to allow theoptimal choice of driver.

• Low noise level.

Strong, compact crank sections built for continuous duty

Conversion kitsAll Hammelmann high and ultra highpressure pumps can be convertedwith ease to different pressure/flowrate combinations.

• The high reliability forged crank-shaft is supported by bearingslocated between the connectingrods so that the bearing load isspread evenly.

Pressurised lubricationsystem• All moving parts are subjected to

force fed lubrication.

• The pressurised circulating oillubrication system protects thehigh pressure pump even underextreme operating conditions suchas inclined working, continualchanges in demand and very highor very low ambient/medium tem-peratures.

• A micro oil filter positioned in thepressurised line keeps the oilsupply clean minimising wear oncomponents and lengtheningservice intervals.

• An integral oil cooler controlstemperature.

Pressure regulating valvesManually or pneumatically actuatedpressure regulating and bypassvalves set the maximum operatingpressure and enable the use of dryshut off valves in the pressure lines.When switched to bypass the medium flows without pressure towaste or to tank.

Operation of an eccentric lever onmanually actuated valves results inimmediate pressure relief which is asubstantial safety advantage.

Electropneumatically controlledvalves can be fitted with a solenoidto automate the bypass switchingfunction.

Proven design - minimal components - high reliability

Pump head• The pump head with antechamber

is designed for high reliability. Theminimal number of components,especially seals, are clear evidenceof this.

• The valve housing is not subjectedto alternating stress. This specialdesign eliminates the risk of fatiguecracking and keeps pressureloaded surfaces to an absoluteminimum resulting in a correspon-dingly reduced force.

• Parts subjected to constant loa-ding and unloading are rotationallysymmetrical and have surfacestreated to prevent metal fatigue.Long life and reliability are featuresof Hammelmann pump headcomponents.

Sealing systemsThe sealing systems can be mat-ched to differing pumping duties. Inaddition to three standard typesspecial designs are available forabrasive, agressive and temperaturesensitive mediums.Each individual cylinder is immersedin the medium providing the advan-tage of automatically balancing thetemperature to prevent overheating.

Eventual leakage is retained withinthe suction chamber. High pressuremedium cannot under any circum-stances escape the chamber whichis only sealed against suction pressure.

Friction free plunger sealThe patented* Hammelmann frictionfree plunger assembly has NO seals and NO packings in thehigh pressure area. This noncontact-ing sealing system is a metalliclabyrinth design with controlledclearances for minimum leak andmaximum pressure drop. This designis well proven to provide extendedservice lifetimes and allow for long intervals between scheduledmaintenance.

* Patented in Germany and othercountries.

During the pressure stroke a smallquantity of the medium flowsthrough the slight gap between theplunger and the sleeve liner.

Circumferential grooves are evenlyspaced along the length of the sleeve liner forming the labyrinth. The grooves fill with medium gradually reducing in pressure downthe length of the liner providing a cushion to centralize the plunger.

This controlled leakage of mediumalso acts as a lubricant betweenplunger and liner before flowing backinto the suction chamber at suctionpressure.

Pressurised mediumSuction mediumSealsPressure loaded componentsPlunger

MediumSealsPress. loaded componentsPlunger

Dynamic plunger sealThis further development of the lowwear labyrinth seal features a unique,replaceable labyrinth insert. Theinsert is subjected to dynamic forcewhich maintains the seal between itand the plunger.This metal to metal seal is particu-larly suitable for high and ultra highpressures. The small sealing areareduces friction on the plunger and combines good mechanicalefficiency with very high volumetricefficiency.The special characteristics of thisdesign are the minimal number of components and the ease ofassembly.

Uniflow piston sealassemblyAs with all Hammelmann sealassemblies the Uniflow system isalways immersed in the medium.The medium passes to the pressurechamber through the hollow plun-gers which ensures an absolutelyeven fluid transportation in bothupward and downward strokes ofthe plungers. Acceleration of the liquid column iseliminated resulting in low suctionpulsation. The ceramic coated plungers aresealed either by packings or the lowwear labyrinth system.The Uniflow sealing system is espe-cially suitable for pumping highvolumes.

Sealed bypackings

Sealed by labyrinth system

Labyrinth insertSealsPress. loaded componentsPlunger

Labyrinth insertSealsPressure loaded componentsPlunger

Select pressure or r.p.m.control

Adjust minimum pressure

Remote control /Radio remote control

Select „Pressure step“

Fault display in clear text

Limit max. pressure

Function menus

Choice of operational mode to suit the jobto be done

Ensures constant quality of work by auto-matically compensating tool wear

Start, Stop, Increase pressure, Decreasepressure and other commands available atthe jetting area

Enables one pump to be used with one ormore performance conversion kits

Provides detailed information on faultsreducing down time

Precise monitoring. No need to check overpressure safety elements after overpressure cut out

Allows checking of various unit functionswithout having to start and run the pump unit

ES1 features and their applicationsControlsUtilising electronics makes life easier.Diesel powered units are controlledby an ES1 computer which can beprogrammed to display data in 12different languages. It takes over allcontrol and monitoring functionskeeping the operator fully informedvia a user friendly menu.The control signals are given eitherby a jetting tool fitted with a controlcable or by radio remote control.

By using a mechanical bypass jettingtool it is possible to work

• without control cable

• without valves or tumble boxes.

Pneumatic control hoses are absolu-tely not necessary. Hammelmannbypass tools enable flexible workingregardless if you are only 60 or up to1600 ft away from the pump unit.

Functional electronics

NANO-PLC control and monitoringof electrically powered high pressurepump units.

An alternative to the ES1 computerfor use with mechanical bypasstools. The control and monitoringfunctions are reduced to the minimum necessary.

Hammelmann Corp.600 Progress RoadDayton, Ohio 45449PHONE: 937-859-8777FAX: 937-859-9188e-mail: mail@hammelmann.comhttp://www.hammelmann.com

© Copyright of Hammelmann Maschinenfabrik GmbH, Oelde, Germany. Subject to modification.

HAM 35-1, 0-4-02 Stu US

DIN EN ISO 900109 100 6463

Flush fitting cabinet for enclosed units

Umbilical cable connection to pump unit

Start and control functions available tooperator with cover/container closed

Enables positioning of ES1 anywhere on,inside, outside or remotely from pump unit