1) CERAMIC PLUNGER AND ITS SURFACE FINISH
Why ceramic plunger and NOT CERAMIC COATED?
Ceramic plungers are ceramic sleeves made of high grade technical ceramic. These are highly wear resistance and can achieve very high surface finish (< 0.25 Ra), resulting in very long life of plunger as well as seal (packing).
CERAMIC COATING on METAL may or may not give good life because metal and ceramic are different kind of material and ceramic coating sometimes chip off from metal resulting damage of seal, NRV, cylinder and crankshaft. So always check with other supplier that what are they providing?
How does surface finish of plunger play an important role?
PressureJet is India’s only and first high pressure triplex plunger pump manufacturing company, who is not only technologically very advanced company, but also transparency level is very high.
PressureJet offers plungers with less than 0.25 Ra value resulting in very low wear & tear and pumps run almost leak free even at very high speed. In India, probably no other manufacturer offer such advanced technology.
2) PACKING (PLUNGER SEAL)
PressureJet , an associate of world leader of electric pressure washer manufacturer, can use Parker (a German world leader in rubber product) make durable fiber impregnated Buna - N seal. Thanks to large scale manufacturering set up, it is viable to purchase large quantity from German world leader.
3) CRANK SHAFT
What is special in PressureJet’s crankshaft?
PressureJet is having Technical Collaboration with European Companies, who produces thousand of pumps per month. That is why, it is viable to use FORGED crankshaft as per our drawing. Therefore basic shape is being obtained by FORGING.
Few manufactures, sometimes misguide customers using “Forged bar” word. They use forged round bar and machine the bar as per their required shape, which is very poor / weak in strength with compare to our forged crankshaft.
4) BRASS CYLINDER (manifold)
Our Brass cylinder is forged, not casted. Again because of our high production rate, it is viable to develop Forged Liquid End (manifold / cylinder), which can withstand very high pressure and also it is more reliable than cast liquid end (cylinder).
5) HIGH SPEED
High speed pumps are prone to wear & tear and that is why I prefer low speed plunger so that I can get long trouble free life?
In our product’s context, it is absolutely WRONG. There are some manufacturers, who do not have R & D facility, so they mislead the user to sell their old technology product.
Our following questions are very simple :
- Is your car’s engine running at 1000 rpm or 3000 rpm?
- Why do you ask for 1000 rpm speed car engine?
- Do you satisfy with the today’s cars performance and engine life even though they are running at very high speed i.e. 3000 rpm.
- In 1920, automobile manufacturers manufactured engines of what speed?
- Why in those days car were of low speed engine and today high speed engine?
We hope you got the answer. However, we would like to throw more light on the issue.
As informed, the surface finish of our plunger is very high i.e. < 0.25 Ra value and we use Parker make (made in Germany) Buna-N-Seal. This enable us to reduce the wear & tear upto the highest extent, resulting in very long life of seal as well as plunger. In our case, pumps run almost at Zero leakage for months.
Other manufacturer’s plunger surface finish value is around 4 to 6 Ra. It means their plunger’s surface finish is very poor. Therefore, they cannot offer high speed pumps because high speed pump with poor surface finish will damage seal in few hours or days.
Here, the manufacturer, who does not have latest technology, take disadvantage of general belief i.e. low speed machine – more life and high speed machine – less life.
6) DIRECTLY COUPLED PUMP
Does your pump directly coupled?
As you know, belt and pulley type transmission is inefficient and having more maintenance. As we are able to produce high speed pumps, we can offer direct couple, compact & rugged pumps.
7) POWER EFFICIENCY ( MECHANICAL EFFICIENCY )
As you know, mechanical efficiency of the pump is very important parameter because the electricity bill straight way depends on the machine’s (here, pump) mechanical efficiency. Higher the mechanical efficiency, lower the electricity bill.
The equation of mechanical efficiency is as under :
- P X Q X 0.0021918 (Constant) = Theoritical hydraulic horse power (hp)
Here, P is pressure in bar and Q is flow rate in lpm
- Mechanical efficiency = Theoritical hydraulic horse power (hp) / Actual motor hp
8) SCIENTIFIC P v/s Q RATIO
The secret of effective cleaning is the ratio of pressure (bar) and flow rate (lpm) and selection of right nozzle. We have specified different range of such ratios and results obtained to understand this secret as under :
Ratio less than 5 : 1.
1. Less impact
2. Wastage of water & power
3. Ineffective cleaning
Ratio more than 15 : 1
Fogging (no impact to achieve proper Cleaning)
Ratio between 7 to 14
1. More coverage area
2. Low consumption of power, water & time
3. Fast production rate
9) THE EFFECT OF BALANCED HYDRO POWER
Hydro Power
The hydro power is the multiplication of pressure and flow rate .
Hydro Power = Pressure x Flow Rate
For proper cleaning, perfect combination of flow rate & pressure is required.
The study done with different pressure and flow rate combination has proven that the ratio of pressure (kg/cm2) / Flow Rate (lpm) must be in range of 7 to 14 to achieve proper cleaning effectiveness.
Case Study:
Case I : The pump flow is 7 lpm and pressure is 280 kg/cm2. In this case, the hydropower is 1960 and the pressure to flow rate ratio is 40:1.
Result : Fogging, no cleaning effect
Case II : The flow rate is 14 lpm and pressure is 140 kg/cm2, then also the hydro power is 1960 and the pressure to flow rate ratio is 10:1.
Result : Excellent cleaning.
Case III : The flow rate is 30 LPM and 65 kg/cm2. Hydro power is again approximate 1960 and the pressure to flow rate ratio is 2.16 : 1.
Result : Can be used, where bond between debris and object is to be cleaned, is not very strong and good amount of debris required to flush out.
Above results prove that only hydropower is not important but balanced hydropower is very important.
Now, the price difference among these three models is nothing except electric motor because the price of pump and other accessories will remain same. Therefore, final difference is hardly matters.
Most important point is power consumption. Normally, people think that 5 hp pump consumes 20 % more power than 4 hp pump. The fact is, it consumes, but also gives more pressure, which reduces the cleaning time and gives more output. Here, output is proportionally more. Therefore, it is wrong to say that 5 hp (140 kg/cm2) pump consumes more power.