Hydraulic starting systemsfor diesel engines

• Hydraulic starting systems are suitable for engines up to 150 litres

• Independent or back-up start system in sub-zero conditionsor hazardous areas

Introduction

IPU hydraulic diesel engine startingsystems provide guaranteed reliability, nomatter how challenging or unpredictablethe environment. This truly independent,dead ship or black start capability is idealas your only method of starting for standby and emergency, marine and offshoregenerators.

Manufactured from aluminium or cast iron,hydraulic starter motors can be suppliedwith Beryllium Copper non-sparkingpinions eliminating potential explosion,together with remote or auto start options,electric motor driven recharge pumpsand solenoid valves.

How hydraulic starters work

The concept is to store energy inthe form of hydraulic fluid underpressure inside an accumulator.This energy is provided via amanual hand pump or a powerdriven recharge pump, which inturn can be released via a valveto turn the hydraulic starter motor.

And, because IPU Starting specialise inhelping you find the right start system forthe generator application you can be surethat the solution we provide will be morethan up to the job, however demanding.From offshore projects in hazardous areasto auxiliary marine generator sets,hydraulic power is perfect for both singleand multiple starts.

Hydraulic starting systems all comecomplete with a hand pump for manualcharging and system purging. When thesystem is pressurised it gives fast,positive cranking combined with quickacceleration and high torque outputproviding effective operation in theharshest conditions such as extremetemperatures and dampness even afterlong shutdown periods.

Hydraulic starting system components

Re-charging options

Mini pack hydraulic starting system

Suitable for engines typically up to 12 litres. These systems arewidely used in marine environments for standby emergencystarting for auxiliary generators. They come completelyassembled and supplied with hoses and a starter motor.The dimensions of the system are typically 425mm long x217mm wide x 430mm high excluding handle.

Hydrauliccranking motorStarter motors are available forengines from 1-80 litres andabove. Manufactured from castiron, the unique design of thestarter motors allows thedisplacement to be easilyincreased, to provide greatertorque and more power to startlarger engines or compensatefor greater starting torquerequirements in extreme coldenvironments.

AccumulatorsThe SC range of accumulators isfully Lloyds approved and comein sizes from 1-16 litres. Bladderaccumulators available in sizesup to 54 litres, with TUV, LloydsASME and other approvals.

Hand pumpTo manually recharge thehydraulic accumulators.

Foot start valveVF foot start valve. Simplerugged design, with wiper sealfor self cleaning, and easy torepair design.

Engine pumpSuitable in applications wherethere is no other source ofpower. The engine is thenused to recharge theaccumulators to startingpressure. Engine driven pumpscan be belt or power take offdriven (PTO).

Motor drivenSuitable in applications with anelectrical supply present withthe major advantage of notrelying on the engine torecharge as a pressure switchsenses a drop in pressure,which in turn fills theaccumulators automatically.Motors are available in mostvoltages and certifications.ATEX (hazardous area) motorsare also available as standard.

CombinedBenefit of both systems offershigher level of guarantee andmay be a specific projectrequirement.

PneumaticrechargePneumatic recharge systemsrely on an external source ofcompressed air to drive ahydro-pneumatic pump. Thehydro-pneumatic pump workson a ratio of 60:1 as standardwhich means a pneumaticinput pressure of 50 psi(3.5 bar) drives the pump toreach 3000 psi (207 bar)hydraulic oil pressure in theaccumulator.

Customer benefits

Safe in hazardous areaHydraulic starters meet ATEX regulations foroffshore projects in hazardous areas toauxiliary marine diesel engine generator sets.

Guaranteed startThe energy can be stored indefinitely providing the systemis installed and maintained to IPU specifications and can bemanually re-charged via a hand pump quickly and easily.

Performance in all conditionsPerformance of hydraulic starters is unaffected by eithervery hot or cold conditions, provided the correct viscosityof oil is used and operate efficiently following extensiveperiods of shut down.

Low maintenanceHydraulic starting systems aredesigned to last as long as your engineso why not enjoy low maintenance andreplacement costs, as well as peace ofmind? The system is totally enclosedwith all internal components immersedin oil, thus protecting it from theadverse environmental elements andconditions detrimental to electric orvane starters.

Applications

Marine applicationsMarine based systems for auxiliary, critical situations and‘dead ship’ requirements are designed to meet specificclassification systems. These societies include Lloyd’s registerof shipping, DNV, BV, GL and NK with each sharing a commonminimum standard for a hand-pumped system capable ofdelivering three starts within a 30-minute period.

Choice of accumulation certification for marine applications:• PED/CE• ASME• ASME + PED• BV• LLOYDS• DNV• NK• DPP

Offshore generator set andpump applicationsOffshore generator or pump sets require either three or six startattempts without a specific time limit. The number ofstart attempts required is based on either a customeror project based requirement, such as NFPA20.

Technical informationHydraulic cranking motorMaximum working pressure 21 Mpa (3000 psi)

Torque range From 30 Nm to 216 Nm(22 lbf.ft. to 160 lbf.ft.)

Displacements in cc/rev 10, 16, 22, 28, 38, 66

Displacements in cu.in/rev 0.6, 0.95, 1.35, 1.71, 2.32, 4.0

Minimum efficiency 95%

Seals Nitrile (standard), viton (optional)

DOWNLOAD STARTER PERFORMANCECURVES FROM OUR WEBSITE www.ipu.co.uk

Foot start valveMaximum working pressure 21 Mpa (3000 psi)

Flow rate (3/8” NPT port) 75 l/min (20 usgpm)

Flow rate (1/2” NPT port) 100 l/min (26 usgpm)

Part number VF (3/8” NPT port)

VF8 (1/2” NPT port)

Hand pumpMaximum working pressure 21 Mpa (3000 psi)

Suction pressure 75 kPa (11 psi)

Displacement 20 cc/cycle (1.22 cu.in.)

Part number PH20

Accumulators - Piston typeConstruction Certified seamless tube

Max working pressure 21 Mpa (3000 psi)

Test pressure 35 Mpa (5000 psi)

Average burst pressure 120 Mpa (20000 psi)

Safety factor In excess of 4:1

Seals Nitrile (standard), Viton (optional)

Nominal volumes in litres 1.0, 2.5, 4.0, 5.5, 7.5, 10.0, 12.0, 16.0

Nominal volumes in usg 0.25, 0.66, 1.06, 1.50, 1.88, 2.60, 3.20,4.20

Accumulators - Bladder typeConstruction Forged certified steel

Max working pressure 21 Mpa (3000 psi)

Test pressure 35 Mpa (5000 psi)

Average burst pressure 120 Mpa (20000 psi)

Safety factor In excess of 4:1

Bladder Nitrile (standard), Viton (optional)

Nominal volumes in litres 10, 20, 37, 54

Nominal volumes in usg 3.0, 5.5, 10, 15

Installation

Our aim is to provide a total solution, not just a system.We can design to your exact specifications; build, testand if required install and commission your system.And don’t worry if space is a problem, because itemscan be supplied loose and mountedin or around the engine skid.

FOR FULL INSTALLATIONDETAILS DOWNLOADOUR HYDRAULICMANUAL

FOR FULL TECHNICAL INFORMATION DOWNLOADOUR HYDRAULIC MANUAL FROM OUR WEBSITEwww.ipu.co.uk

Our starting solutions operate in some of the harshestenvironments in the world – situations where electric startingwould not offer the guarantees our customers demand.The division designs and manufactures bespoke solutionsas well as distributing from leading names in the field.

Our starting product portfolio includes:• Hydraulic starting systems• Air compressor systems• Spring starting• Nitrogen starting• Air starting

Visit our Group website www.ipu.co.ukIPU Group, Churchbridge, Oldbury,West Midlands, B69 2AS EnglandT: +44 (0) 121 511 0400 F: +44 (0) 121 511 0401E: ipu@ipu.co.uk www.ipu.co.uk

© IPU Group August 2009

2003/372

IPU GROUP Engine Starting Division

Useful contact numbers

IPU Engine Starting

David CaddickDivisional DirectorOffice: +44 (0) 121 511 0400Fax: +44 (0) 121 511 0402Mobile: +44 (0) 7831 582978Email: david.caddick@ipu.co.uk

Jon CheethamGlobal Account ManagerOffice: +33 (0) 254 726 300Mobile: +44 (0) 7825 944050Email: jon.cheetham@ipu.co.uk

Réne Sowald - Kuala Lumpar OfficeSales Account ManagerMobile: +44 (0) 7825 944048Email: rene.sowald@ipu.co.uk

No. A-29-05, Marc Service ResidenceNo. 3, Jalan Pinang50450 Kuala LumpurMalaysia

Wenkui LiaoBusiness Development - Far EastOffice: +44 (0) 121 511 0400Fax: +44 (0) 121 511 0402Mobile: +44 (0) 7826 872610Email: wenkui.liao@ipu.co.uk

Nigel HampsonGlobal Account ManagerOffice: +44 (0) 121 511 0400Fax: +44 (0) 121 511 0402Mobile: +44 (0) 7500 841263Email: nigel.hampson@ipu.co.uk