Sulzer Pumps

AHLSTAR™ Process Pumps

The Heart of Your Process

 Sulzer Pumps

Sulzer Pumps is a leading global sup-

plier of reliable products and innova-
tive pumping solutions for end users.
Our active research and development,
detailed process and application
knowledge together with a comprehen-
sive understanding of market demands
keeps us consistently at the leading
edge of technical development. Our
global network of modern manufactur-
ing and packaging facilities together
with sales offices, service centers and
representatives located close to major
markets provide fast responses to
customer needs.

Sulzer Pumps has a long history of

providing innovative pumping solutions
to business partners in the following
industries:
• Oil and Gas
• Hydrocarbon Processing
• Pulp and Paper
• Power Generation
• General Industry
• Chemical Process Industry
• Water and Wastewater

A Reputation for Excellence

Sulzer Pumps has earned its reputation Through having our own foundries, we 18001 certified. Each and every pump
for providing advanced pumping solu- are able to ensure optimum pump ma- is rigorously tested before shipment,
tions that meet the critical demands of terial selection for each particular ap- and regardless of where in the world
our customers and business partners. plication. Our 14 manufacturing plants our pumps are made, the commitment
Attention to detail and an insistence on are strategically located throughout the to quality is unrelenting.
quality are paramount to all phases of world, and our production processes
our operations. are ISO 9002, ISO 14001 and OHSAS

2
Lifetime Service Solutions for the AHLSTAR™ Pump

High pumping performance comes as

a result of the availability, reliability and
quality of the correct pump. Genuine
spare parts and proper maintenance
ensure the high performance of AHL-
STAR™ process pumps in complex
production operations.

We support our customers with an

extensive range of pumping services,
from spare parts to remote monitor-
ing. Additionally we offer various types
of service agreements in which spare
parts and service solutions can be
combined.

PumpsOnline Spare Parts Solutions Service Solutions

Customers can benefit from our new We offer an exchange unit service To maintain and improve the high
eBusiness solution, Pumps Online. This and newly developed service kits for performance of AHLSTAR™ process
enables instant online access to prod- all AHLSTAR™ process pumps. This pumps, customers can select from a
uct documentation, electronic ordering enables fast and easy servicing and wide range of available service solu-
of spare parts and installed pump base reduces downtime. tions. All service work is carried out
at the mill. by qualified, experienced technicians
using state-of-the-art equipment.

3
 Expanded AHLSTAR™ Process Pumps – Features and Benefits

A double volute casing in larger AHLSTAR™

pumps reduces radial forces and shaft deflec-
tion.

The self-venting, top centerline casing prevents

air lock in the top of the casing.

The sideplate is adjusted externally to maintain

a constant impeller clearance and continuous
high efficiency.

ROTOKEY impeller mounting provides strong,

reliable power transmission. It is self-locking
and reverse rotation safe. ROTOKEY facilitates
the installation and removal of the impeller. It is
not sensitive to axial loads created during pump
operation.

A-Hydraulics
Designed for pumping clean, abrasive
or corrosive liquids especially stocks of
various kinds.

A wide selection of shaft seals is available to meet

the needs of each specific application. Dynamic
seals and ready fitted mechanical seals suit all
requirements.

N-Hydraulics W-Hydraulics
Non-clogging process pumps are the Wear-resistant pumps guarantee reli-
right solutions when the liquid contains able pumping when the liquid is very
large or long particles. corrosive and/or abrasive.

4
Self-Priming S Bearing Unit
Self-priming pumps with an internal Simplified heavy-duty bearing unit
vacuum pump are designed for self- design ensures reliability.
priming purposes and to pump gas-
containing liquids. Grease Lubrication
Temperature of pumped liquid
max. 120oC

Oil Lubrication
Temperature of pumped liquid
max. 180oC (EPP 210oC)

Heavy-duty shaft. Deflection at stuffing

box less than 0.05 mm. High strength
duplex stainless steel is standard shaft
material.

Non-contacting bearing protection for

the combined advantages of labyrinth
ring, deflector and lipseal. Lipseal pro-
tects in standstill position.

Strong and rigid bearing support foot

improves mounting stability and main-
tains solid support.

Jackscrews for simple

disassembly.

Air-Separating R Others
Air-separating pumps with an external AHLSTAR™ hydraulics are also utilized
vacuum pump are particularly applica- in NVP non-clogging vertical process
ble for pumping gas-containing liquids. pumps and NKP/WKP non-clogging
cantilever pumps.

EPP hot liquid pumps for industrial

processes where the system pressure
is high and pressure or temperature
strokes occur.

5
 Standardization

AHLSTAR™ Interchangeability of Main Parts

Volute Casing Bearing All AHLSTAR™ pumps have the same

Pump type Impeller Adapter basic design using the same compo-
casing cover unit
nents.
APP
• 246 pumps
ARP • 80 casing covers
• 6 common bearing units
ASP • 6 common shaft seal sizes
• common sealing water equipment
EPP • common coupling and coupling
guard
NPP • common baseplates

NRP
__P
NSP P metric dimensioning
P basic horizontal pump,
WPP S self-priming and
R air-separating construction
WRP A, N, W and E indicate the
basic hydraulics
WSP

Common parts shown in the columns.

Hydraulic Design

The AHLSTAR™ product line offers a The back vanes of the impeller keep The impeller hub design ensures a
wide range of hydraulic sizes to guar- the area between the impeller and the smooth flow and helps to avoid spin-
antee minimum power consumption. casing cover clean, and reduce the ning and plugging.
Pump hydraulics, casings and impellers axial load on the bearings.
are designed to optimize fluid han- The reverse sides of same size impel-
dling capabilities. Stocks are pumped Balance holes in the impeller are used lers on the APP, NPP and WPP pumps
like water. Particles in sludges do not to stabilize the pressure in the seal are of equal dimensions. It is possible,
accumulate in the pump, or slurries chamber. The balance holes can be therefore, to use the same casing cov-
are effectively channeled so as not to plugged to optimize the shaft seal ers for all impellers. This reduces the
cause wear. environment, should the application number of spare parts required.
demand it.

6
An Impeller Tailored to Each Liquid

Closed Impeller Open Impeller Special Open Impeller

is used for pumping clean liquids or is designed for liquids containing solid is suitable for liquids containing larger
liquids containing some impurities. particles, abrasive liquids or stock up solid particles and long fibers, abrasive
to 8 % consistency. liquids or stock up to 8 % consistency.
For pump types:
APP For pump types: For pump types:
EPP APP APP
ARP ARP
ASP ASP
EPP

Low Pulse Impeller Non-Clogging Closed Impeller Vortex Impeller

is designed and manufactured to mini- is used for sludges or slurries contain- is suitable for liquids containing large or
mize pressure pulsations. ing large solid particles. long solid particles or abrasive liquids.

For pump type: For pump types: For pump types:

APP NPP NPP
NRP NRP
NSP NSP
WPP
WRP
WSP

Wear-Resistant Closed Impeller Wear-Resistant Open Impeller

is used for pumping both erosive and is suitable for liquids with larger solid
corrosive liquids or slurries containing particles and long fibers, abrasive liq-
solid particles. uids or stock up to 8 % consistency.

For pump types: For pump types:

WPP WPP
WRP WRP
WSP WSP

7
 Gas Handling Systems

AHLSTAR™ Gas Removal Pumps for The Effect of Gas Content in The Effect of Weakly Bound Gas
Various Applications Conventional Centrifugal Pumps Content in the AHLSTAR™ Gas
The patented AHLSTAR™ self-priming • Almost all impeller types can oper- Removal Pump
gas removal pumps are designed ate with a gas content of below 4 %. • Pump operation is stable.
to pump liquids containing gas, and However, the capacity and head will • For weakly bound gases, the abso-
for use where the inlet pipe is empty. be reduced. lute maximum value is 40 %.
These are situations where conven- • At a gas content level of above 4 %, • For strongly bound gases it is up to
tional centrifugal pumps fail. the duty point remains approximately 70 %.
10...100 % from BEP (Best Efficiency
With standard centrifugal pumps, Point).
gas bubbles which are formed in the Pumping is unstable since the duty
impeller eye impair pumping. With the point varies heavily and excessive over-
AHLSTAR™ pump, these gas bubbles dimensioning of the pump becomes
are removed by an internal or external necessary.
vacuum pump, or through sufficient
inlet pressure. By removing the gas
bubbles from the impeller, the opera-
tion of the pump system is stabilized
and efficiency is greatly increased.

Head 4% 0% Conventional pump has

3% 2% 1% unstable operation with
a gas content of 0...4 %
Capacity

BEP
40 %

30 % 20 % 10 % AHLSTAR™ gas removal

Head
0%
pump has stable operation
with a gas content of 0...40 %
Capacity

Self-priming application Gas-containing liquid pumping Water separator application

8
Shaft Sealing

Dynamic Seal Mechanical Seals Gland Packings

The Dynamic Seal is specially designed Various mechanical seal configurations A gland packing with external flush-
for fibrous liquids such as paper stock are available. For difficult applications ing prevents the pumped liquid from
and other difficult liquids. The Dynamic “ready-fitted” seals are especially precipitating into the sealing housing.
Seal requires no external sealing water. recommended. For extremely corrosive The flushing liquid is mixed with the
It is essentially maintenance-free and applications, a ready-fitted seal can be pumped liquid. Alternatively the exter-
offers outstanding reliability. selected with the same exact construc- nal flushing has an outlet connection.
tion material as the pump casing itself.

Additional Options for the Dynamic Seal

The well-proven and highly successful Dynamic Seal can be modified to have addi-
tional properties. With these properties we are able to expand its operational limits.
The pump can operate under a light vacuum or even over liquid boiling point.

9
 Materials

Standard material combinations Nominal chemical composition %

Stainless steel design C max. Cr Ni Mo Cu N
Duplex SS ASTM A890 Grade 3A 41 0.06 24.0-27.0 4.0-6.0 1.75-2.50 - 0.15-0.25
ASTM A890 Grade 1B 4L 0.04 24.5-26.5 4.75-6.00 1.75-2.25 2.75-3.25 -
ASTM A890 Grade 5A 4T 0.03 24.0-26.0 6.0-8.0 4.0-5.0 - 0.10-0.30
Austenitic SS ASTM A743 Grade CF-8 4C 0.08 18.0-21.0 8.0-11.0 - - -
ASTM A743 Grade CG-3M 4G 0.03 18.0-21.0 9.0-13.0 3.0-4.0 - -
ASTM A743 Grade CN-7M 43 0.07 19.0-22.0 27.5-30.5 2.0-3.0 3.0-4.0 -
AVESTA 654 SMO 1)
4U 0.025 23.0-25.0 21.0-23.0 7.1-7.5 0.3-0.7 0.45-0.55
Martensitic SS ASTM A747 Grade CB7Cu-2 4E 0.07 14.0-15.5 4.5-5.5 - 2.5-3.2 -
Other design C max. Cr Ni Mo Cu N
Nickel alloy A494CW-6M 4J 0.07 17.0-20.0 balance 17.0-20.0 - -
Cast iron design C Cr Ni Mo Cu Si
Cast iron ASTM A48 CL 35 B 53 3.1-3.4 - - - 0.5-1.0 1.5-2.1
Chromium iron 2)
A532 IIIA 5B 2.0-3.3 23.0-30.0 2.5 max. 3.0 max. 1.2 max. 1.5 max.
Material alternatives for other parts
Gasket material Klinger SIL C-4430 83 Used in temperature range -40...+160°C and pH 2-12
PTFE/Glass 84 Used in temperature range -190...+240°C and pH 0-14
O-ring material EPDM 92 Used in temperature range -50...+150°C
FKM 96 Used in temperature range -20...+210°C

Other corrosion resistant cast steels available on special request.

1)
AVESTA 654SMO is a trademark owned by Outokumpu Stainless which has granted Sulzer Pumps licence to produce this material.
2)
For W construction (5B/4E).

Corrosion Resistant Thinking

To ensure maximum reliability against • All stainless steel structures for ex-
corrosion we offer material selection tremely corrosive situations. All parts
options from our own steel foundries. including the adapter and bearing
• All parts in contact with the pumped unit are made of stainless steel.
liquid can be produced from the • Additionally, stainless steel can be
same construction material as the selected for the bearing unit auxiliary
pump casing. Materials available for equipment to give longer operating
this option are 41, 4L, 4T, 4G, 43, 4U life in corrosive environments.
and 4J.

10
Main Dimensions A
~L DN2

AHLSTAR™ Series
Dimensions EN 22858:1993 (ISO 2858:1975)
up to size 44-200 DN1 H

Design EN ISO 5199:2002 H1

Flange drilling Several flange drilling options
according to valid standards
B2

Weight Weight
Size DN1 DN2 B2 1) H 1) L 1) A H1 Size DN1 DN2 B2 1) H 1) L 1) A H1
kg 2) kg 2)
A 11-32 50 32 500 480 1240 80 300 125 E 31-65 100 65 755 780 1790 140 465 390
11-40 65 40 500 480 1260 100 300 125 31-100 150 100 795 820 1830 160 465 400
s 11-50 80 50 630 540 1330 100 340 160 s 32-100 150 100 875 965 1910 175 555 480
e 21-65 100 65 630 640 1580 100 415 230 e 41-150 200 150 940 1000 2010 195 590 530
r 21-80 125 80 630 665 1600 125 415 240 r 41-200 250 200 1010 1105 2070 200 640 600
i 22-32 50 32 630 620 1490 100 395 230 i 42-150 200 150 1010 1100 2100 195 640 600

e 22-40 65 40 630 670 1710 100 445 250 e 42-200 250 200 1050 1155 2520 200 640 650
22-50 80 50 630 640 1600 125 415 235 42-250 300 250 1150 1230 2640 220 657 760
s s
22-65 100 65 720 730 1820 125 480 275 43-100 150 100 1010 1100 2040 175 640 660
22-80 125 80 720 760 1820 125 480 280 43-150 200 150 1050 1150 2510 195 640 690
23-40 65 40 630 740 1700 125 460 280 52-350 400 350 1600 1950 3160 355 1100 2560
23-50 80 50 720 800 2020 125 520 350 53-100 200 100 1200 1240 2870 195 740 1000
31-100 125 100 730 835 2290 140 555 420 53-200 250 200 1200 1305 2870 220 740 1030
31-125 150 125 730 910 2290 140 555 430 53-250 300 250 1200 1360 2870 220 740 1100
31-150 200 150 630 840 1670 160 465 340 53-300 350 300 1350 1420 3040 220 800 1300
32-65 100 65 730 835 2270 125 555 420 54-300 350 400 1480 1590 3080 270 870 1550
32-80 125 80 730 870 2270 125 555 410 54-500 500 500 1600 1980 3180 355 1100 2960
32-100 125 100 730 915 2400 140 600 480 55-300 400 300 1480 1620 3090 270 870 200
32-125 150 125 730 955 2400 140 600 500 61-500 500 500 1800 2260 3260 400 1200 3550
33-100 125 100 720 820 1780 140 465 370
33-125 150 125 720 900 1860 140 500 400 N 21-50 80 50 720 680 1820 125 480 260
41-200 250 200 730 980 2100 200 530 510 21-80 100 80 720 705 1865 160 480 270
41-300 300 300 730 1175 2150 225 615 630 s 22-50 80 50 720 705 1830 125 480 275
42-150 200 150 730 930 2100 160 530 460 e 22-80 100 80 630 715 1785 160 465 260
42-200 250 200 730 980 2100 180 530 500 r 31-100 150 100 720 745 1835 180 465 310
43-250 300 250 830 1175 2600 225 615 660 i 32-80 100 80 720 760 1875 160 480 335
43-300 350 300 880 1365 2700 250 735 870 e 32-100 150 100 730 870 2365 180 555 440
44-150 200 150 830 1005 2350 160 555 570 33-80 100 80 730 910 2140 160 555 480
s
44-200 250 200 880 1175 2650 180 675 740 33-100 150 100 730 910 2355 180 555 480
51-250 300 250 880 1295 2850 200 735 840 42-150 200 150 880 1070 2710 200 670 680
51-300 350 300 1160 1440 2900 250 770 1060 42-200 200 200 880 1120 2710 210 670 720
52-350 400 350 880 1645 2900 280 845 1190 44-150 200 150 880 1070 2710 200 670 710
52-400 400 400 1160 1770 2900 280 920 1420 44-200 200 200 880 1125 2710 210 675 740
53-100 200 100 880 1185 2700 180 685 740 53-250 250 250 1160 1370 2950 240 770 1125
53-150 250 150 880 1185 2800 180 685 780
53-200 250 200 1160 1330 2800 180 770 1000 W 22-32 80 50 630 640 1600 125 415 265
53-250 300 250 1160 1400 2850 200 770 1060 22-50 80 50 630 640 1600 125 415 265
53-300 350 300 1160 1590 3100 250 920 1110 s 23-50 80 50 720 800 2020 125 520 390
54-400 500 400 1160 1850 3000 355 1000 1600 e 32-80 125 80 730 870 2270 125 555 460
54-500 500 500 1160 2000 3000 355 1000 1780 r 32-100 125 100 730 915 2400 140 600 535
55-100 200 100 1160 1330 2850 250 770 1130 i 32-125 150 125 730 955 2420 160 600 555
55-200 300 200 1160 1415 2820 200 785 1250 e 33-100 125 100 720 820 1780 140 465 435
55-250 300 250 1160 1495 2850 225 785 1330 44-150 200 150 830 1005 2350 160 555 655
s
55-300 400 300 1160 1645 2870 250 845 1410 44-200 250 200 880 1175 2650 180 675 840
61-500 500 500 1340 2100 3180 400 1100 2350 53-100 200 100 880 1185 2700 180 685 845
61-600 600 600 1340 2280 3180 420 1100 2350 53-150 250 150 880 1185 2800 180 685 895
62-400 500 400 1340 1960 3135 355 1010 2020 53-200 250 200 1160 1330 2800 200 770 1150
53-250 300 250 1160 1400 2850 225 770 1230
1)
Max. dimension for the largest IEC motor required in standard operation. 54-400 500 400 1160 1850 3000 355 1000 1910
2)
With the largest steel baseplate and coupling but without motor. 55-300 400 300 1160 1645 2870 250 845 1700
AHLSTAR™ is available with both metric and US standard dimensions
61-600 600 600 1340 2280 3180 420 1100 3185
with compatible fasteners and fittings.
NOTE! Dimensions not to be used for construction.

11
 Design Features and Installation Advantage

Various options are available for paint- Back pull-out design facilitates fast and Flexible coupling with spacer for quick
ing the pump. easy access when servicing the pump. service.

Grinding of the pump interior and Safety coupling guard is designed ac-
special cleaning offered for specific cording to stringent safety regulations.
applications where surface quality or
cleanliness is essential.

RIGBASE baseplates are of steel Removable adjusting screws permit Riser blocks allow the installation of the
or concrete with 3–point fastening. fast and simple alignment of the cou- next frame size of motor.
Distortion-free and easy to install. pling.
EPP centerline mounted.

Foundation Screws

Grouted Welded A smaller pump and motor

can be installed with
adjustable support feet

12
Baseplates

Steel Baseplate Concrete Baseplate Belt Drive

A steel baseplate for pump and motor The concrete baseplate can be mount- Belt drive construction is also available.
grouted at site. A short baseplate is ed on rubber sheeting, various mount-
also available. ing beams, vibration dampers, etc.

Sealing Water Equipment

The concept for sealing water equip-

ment meets all the requirements A A

demanded by the pumped liquid or the FI FI

shaft seal. All general pumping solu-

tions can be covered by just four differ-
ent options. Special materials to take
into account corrosive environments
ensure reliable operation in extreme
circumstances.

Non-pressurized Pressurized
Fluid in/out Fluid in

PI A PI A

FI FI

Flowing pressurized Non-flowing pressurized

Fluid in/out Fluid in (out)

13
 Wide Hydraulic Coverage

A-Performance Head H (m)

Head up to 160 m 200

Temperature max. 180oC 150

Capacity up to 2000 l/s 100

Operating frequency 50 or 60 Hz 80

Pressure up to 1.6 MPa, 60

depending on material and size 40

20

10
8
6

2
1 2 4 6 8 10 20 40 60 80 100 200 400 6008001000 2000
Capacity Q (l/s)

E-Performance Head H (m)

Head up to 140 m 200

150
Temperature max. 210oC
Capacity up to 1700 l/s 100
80
Operating frequency 50 or 60 Hz 60
Pressure up to 2.5 MPa
40

20

10
8
6

2 4 6 8 10 20 40 60 80 100 200 400 600 8001000 2000

Capacity Q (l/s)

14
N-Performance Head H (m)
Head up to 90 m 200
Temperature max. 180oC 150
Capacity up to 550 l/s 100
Operating frequency 50 or 60 Hz 80
Pressure up to 1.6 MPa, 60

depending on material and size 40

20

10
8
6

1
1 2 6 6 8 10 20 40 60 80 100 200 400 600 8001000 2000
Capacity Q (l/s)

W-Performance Head H (m)

Head up to 110 m 120

Temperature max. 180oC 100

Capacity up to 2000 l/s 80

Operating frequency 50 or 60 Hz 60
Pressure up to 1.6 MPa,
depending on material and size 40

20

10

5
2 4 6 8 10 20 40 60 80 100 200 400 600 8001000 2000
Capacity Q (l/s)

15
www.sulzerpumps.com

E00545 en (8) 12.2009 (1000), Copyright © Sulzer Pumps

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.