DnD PUMP

Dewatering 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

worlds leading
manufacturers of
pumps and valves,
providing
a range of related
service offerings.

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

Company presentation

KSB Group

Board of
Management
(from left)
Dr.-Ing. Peter
Buthmann
Dipl.-Kfm. Werner
Stegmller

Company presentation

KSB Group

Our Corporate
Culture
Our internal
cooperation and our
contact with
customers and
partners is based on
the values of

Responsibility
Trust
Appreciation
Professionalism
Honesty

Company presentation

On the Spot Around the

World

A Global
Company
Financial year 2013

Order intake:
2,241.2 million
Sales revenue:
2,247.3 million
Earnings (before
taxes):
119.4 million
Employees:

16,546

Global presence brings us closer to customers production on all 5 continents

KSB production sites

KSB sales and service sites

Company presentation

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,
Sykes, 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, i.e. Agressive Mine
Syaiful Anwar Water
KSB Banjarmasin
and Slurry Condition

GIW (Georgia Iron Work)

Featured Systems Designed

by KSB Indonesia

DEWATERING
& DREDGE
PUMP (DND)

Produk kebanggan KSB Indonesia

DnD Pump, produk berkualitas
tinggi yang menggabungkan
slurry pump, engine, sistem
vacuum dan proteksi. 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, casing, liner material
made from 28% high chrome

DnD is highly reliable with

guaranteed durability

DnD Pumpset Feature

PT.KSB Indonesia
Cawang Kencana bldg
Floor D , suite D02
Jl.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

FROM AGRESSIVE WATER

4/25/16

Syaiful Anwar KSB Banjarmasin

TO BECOME SLUDGE
Definisi slurry= Campuran antara partikel air dan
solid/padat,
typically of fine particles of manure, cement, or coal and
water: clay slurry
SG>1 , pH= 3,5-7

4/25/16

Syaiful Anwar KSB Banjarmasin

Slurry Pump Design Consideration

(Compared to Water Pump)

Tahan abrasive
Tahan korosi PH up to =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

Gasite WD 28G
Abrasion Resistant, High-Chromium White Iron

Tensile strength: 85-115 ksi

Min. hardness: 600 hbn/58 hrc
ASTM Standard A532-87, Class III, Type A
pH levels as low as 3.5 4.5
Castings and machined castings
Larger free passage

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

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.
Faster the impeller rotates or bigger the
impeller is, higher will be the liquid
velocity at the vane tip.
A centrifugal pump neither creates pressure nor does it suck, it only
provides flow. Pressure is just an indication of the amount of resistance to
flow!

Pressure Head Interconversion

Head (m) =

Pressure (kg/cm2) x 10
Specific Gravity

Why Head is used to measure

the energy of a centrifugal pump?

30 m

Kerosene
Sp.gr. 0.8

2.4 kg/cm2

30 m

Water
Sp.gr. 1.0

3 kg/cm2

30 m

Brine
Sp.gr. 1.2

3.6 kg/cm2

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.
Height of this column is called Static head and is
expressed in meters of liquid.
Head is a measurement of the height of a liquid column
that the pump could create from the kinetic energy
imparted to the liquid.
Pressure is dependent on the specific gravity of a liquid
but head is not.
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!

System Resistance Curve

Total System Head =

Static System Head

Dynamic System Head

( E l e v a s i )

( Discharge Velocity Head

- Suction Velocity Head +
Discharge Friction Head +
Suction Friction Head )

( hd hs ) + ( hps hpd )

( hvd - hvs ) + ( hfd + hfs )

( hd hs ) + ( Pd Ps )
x g

( Vd2 Vs2 ) + ( hfd + hfs )

2xg

hs = -ve, if suction lift

hs = +ve, if suction head
suffix s = suction
suffix d = discharge
= density, kg/m3
g = gravitational constant, m/s2
hf = x V2 , (loss coeff. )
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, terjadi resirkulasi
yang menyebabkan wear yang berlebih, beban hidrolik pada impeller dan bearing
tinggi.
Best Operating Zone : titik operasi yang disarankan, minimum wear
Reduced Capacity Zone : kecepatan liquid di pompa rendah terjadi resirkulasi dan
separasi, wear berlebih di casing
Shut off zone : kondisi zero flow, pompa tidak boleh berada dalam kondisi ini terlalu
lama, dalam kondisi ini wear, gaya hidrolik terbesar terjadi.

Pump Selection to determine material pump

and duty pump
Slurry type
PH
SG
Head Static
Flow
Jenis, panjang dan Diameter Pipa

Consideration Issues
1. NPSHA &NPSHR
2. Slurry type settling or not
3. Free Passage
4. Expected % solid transport
5. Mobile Capable
6. Vary Speed

Three basic design of Slurry Pump

PT KSB INDONESIA

Slurry Pump Standar

ASTM A532
ANSI/HI 12.1-12.6

Net Positive Suction Head

(NPSH)
NPSHA = 10,3-(Vp+Ls+Hf)
1 atm 80,000 m tekanan udara 10,3 m
tekanan air
Vp (vapour pressure) 0,003 atm 0,3 m
pada suhu 25 deg C
NPSHR DnD standar 7m
NPSHR = based on curve from pump
manufacturer.
NPSHA-NPSHR > 0

I Title of

Vary NPSHA Condition

Optimum Velocty Fluid

For Water = 1,5 - 2 m/s
For Slurry = 3,0 5,0 m/s

I Title of

HANDLING MUD TO GET COAL UNDER THE MUD

Sprayer Water Vehicle Car Portable

Capacity : 2500 m^3 / Jam

Total length Pipe 10 Km
Elevasi +/- 20 meter

SFM Pit.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

Submersible Pump for mud

slurry

Mixer/Agitator Capability + optional cutter

Up to 70% of solid
More Solid more frictional losses
Low NPSHR, Low Head
Good Sealing during submerse in to water
Expensive due to submerse capability and sealing system

I Title of

DnD as Mud Slurry Transport

Record

Fuel Consumption Calculation DnD 200-5HX with Engine Volvo

Example

Duty Pump : 900 m^3 / hours

Head Static : 40 meter
Pipa HDPE : 8,10,12,14
Panjang Pipa : 200 m
Percentation Solid ( 5 % ) : SG = 1.03
Fuel Density : 860 gram / liter

Size
Pipa

8
10
(ID=162) (ID=202)

12(ID=
255)

14
(ID=287)

TDH

176 m

64,5 m

58,9 m

92,6 m

Curve DnD 200-5HX & Engine Volvo TAD1643VE

520

Duty Point
Q = 900
H = 92,6
RPM = 1306
Eff =78%

1500

Fuel Calculation Based On Pump Curve

and Engine Curve

DnD 200-5HX Engine Volvo TAD1643VE

Pump Efficiency : 78 %
Power Absorb of pump ; = SG x H x Q ( flow ) / (367 x Pump Eff)
Power absorb : 299,4 kW
Engine Drive Safety Factor 25 % = 1.25 x 300 kW = 375 kW
Engine Power : 440 kW @1300 rpm, engine have power enough

SFC ( specific fuel consumpt ) = 180 gram / kWh .hour ( given by curve based on Speed )

Rate Fuel = ( 180 grm/kW hour x 300kW / 860 grm / liter )

= 62.8 liter / hour
---------------------------------------

46

Curve DnD 150-4H & Engine Volvo TAD1343VE

Curve DnD 100 & Engine Volvo TAD 1243VE

48

Thank You for

Your Attention
Syaiful Anwar
Sales Engineer
Mining
Rep.
Banjarmasin
0811 902 926
syaiful.anwar@k
sb.co.id

Thank You

PT KSB Indonesia Rep

Banjarmasin
Kompleks Pertokoan Simpang Palm Blok 24
Jl. Trikora Banjarbaru
Telp : (0511)477 0235
Fax : (0511)477 0236