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Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(71685,2955,'_content_blocks_0_description','field_6170d8cd9800c'),(71686,2955,'content_blocks_0_images_0_image','2950'),(71687,2955,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(71688,2955,'content_blocks_0_images_0_header','Seperation Cut'),(71689,2955,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(71690,2955,'content_blocks_0_images_0_description',''),(71691,2955,'_content_blocks_0_images_0_description','field_6170d90398010'),(71692,2955,'content_blocks_0_images_1_image','2951'),(71693,2955,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(71694,2955,'content_blocks_0_images_1_header','Through Cut'),(71695,2955,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(71696,2955,'content_blocks_0_images_1_description',''),(71697,2955,'_content_blocks_0_images_1_description','field_6170d90398010'),(71698,2955,'content_blocks_0_images_2_image','2952'),(71699,2955,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(71700,2955,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(71701,2955,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(71702,2955,'content_blocks_0_images_2_description',''),(71703,2955,'_content_blocks_0_images_2_description','field_6170d90398010'),(71704,2955,'content_blocks_0_images_3_image','2953'),(71705,2955,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(71706,2955,'content_blocks_0_images_3_header','Good Finish'),(71707,2955,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(71708,2955,'content_blocks_0_images_3_description',''),(71709,2955,'_content_blocks_0_images_3_description','field_6170d90398010'),(71710,2955,'content_blocks_0_images_4_image','2954'),(71711,2955,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(71712,2955,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(71713,2955,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(71714,2955,'content_blocks_0_images_4_description',''),(71715,2955,'_content_blocks_0_images_4_description','field_6170d90398010'),(71716,2955,'content_blocks_0_images','5'),(71717,2955,'_content_blocks_0_images','field_6170d8df9800d'),(71718,2955,'content_blocks_1_header','Pump Specification'),(71719,2955,'_content_blocks_1_header','field_6170d8ba9800b'),(71720,2955,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(71721,2955,'_content_blocks_1_description','field_6170d8cd9800c'),(71722,2955,'content_blocks_1_images_0_image',''),(71723,2955,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(71724,2955,'content_blocks_1_images_0_header','Need Table here'),(71725,2955,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(71726,2955,'content_blocks_1_images_0_description',''),(71727,2955,'_content_blocks_1_images_0_description','field_6170d90398010'),(71728,2955,'content_blocks_1_images','1'),(71729,2955,'_content_blocks_1_images','field_6170d8df9800d'),(71730,2955,'content_blocks_2_header','Horsepower, pressure and water output'),(71731,2955,'_content_blocks_2_header','field_6170d8ba9800b'),(71732,2955,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(71733,2955,'_content_blocks_2_description','field_6170d8cd9800c'),(71734,2955,'content_blocks_2_images',''),(71735,2955,'_content_blocks_2_images','field_6170d8df9800d'),(71736,2955,'content_blocks_3_header','Horsepower'),(71737,2955,'_content_blocks_3_header','field_6170d8ba9800b'),(71738,2955,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(71739,2955,'_content_blocks_3_description','field_6170d8cd9800c'),(71740,2955,'content_blocks_3_images_0_image','2849'),(71741,2955,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(71742,2955,'content_blocks_3_images_0_header',''),(71743,2955,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(71744,2955,'content_blocks_3_images_0_description',''),(71745,2955,'_content_blocks_3_images_0_description','field_6170d90398010'),(71746,2955,'content_blocks_3_images','1'),(71747,2955,'_content_blocks_3_images','field_6170d8df9800d'),(71748,2955,'content_blocks_4_header',''),(71749,2955,'_content_blocks_4_header','field_6170d8ba9800b'),(71750,2955,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(71751,2955,'_content_blocks_4_description','field_6170d8cd9800c'),(71752,2955,'content_blocks_4_images_0_image','2850'),(71753,2955,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(71754,2955,'content_blocks_4_images_0_header',''),(71755,2955,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(71756,2955,'content_blocks_4_images_0_description',''),(71757,2955,'_content_blocks_4_images_0_description','field_6170d90398010'),(71758,2955,'content_blocks_4_images_1_image',''),(71759,2955,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(71760,2955,'content_blocks_4_images_1_header','Need Image'),(71761,2955,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(71762,2955,'content_blocks_4_images_1_description',''),(71763,2955,'_content_blocks_4_images_1_description','field_6170d90398010'),(71764,2955,'content_blocks_4_images','2'),(71765,2955,'_content_blocks_4_images','field_6170d8df9800d'),(71766,2955,'content_blocks_5_header',''),(71767,2955,'_content_blocks_5_header','field_6170d8ba9800b'),(71768,2955,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n\r\nWhat percentage of pumps in use today are intensifier as opposed to direct drive?\r\nWhat percentage of new machines being sold today have intensifier pumps versus direct drive?\r\nHow many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?\r\nHow many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?\r\nWhat are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?\r\nHow much downtime is involved to replace consumable and spare parts on each style pump?'),(71769,2955,'_content_blocks_5_description','field_6170d8cd9800c'),(71770,2955,'content_blocks_5_images',''),(71771,2955,'_content_blocks_5_images','field_6170d8df9800d'),(71772,2955,'content_blocks','6'),(71773,2955,'_content_blocks','field_6170d8ac9800a'),(71774,2955,'menu','11'),(71775,2955,'_menu','field_6170d9e059837'),(71776,2955,'display_left_column','1'),(71777,2955,'_display_left_column','field_613563c4d424b'),(71778,2955,'contact_left_heading',''),(71779,2955,'_contact_left_heading','field_60c249d645c99'),(71780,2955,'contact_left_copy',''),(71781,2955,'_contact_left_copy','field_60c24a0845c9c'),(71782,2955,'display_right_column','1'),(71783,2955,'_display_right_column','field_613563f4d424c'),(71784,2955,'contact_right_heading',''),(71785,2955,'_contact_right_heading','field_60c249e945c9a'),(71786,2955,'contact_right_copy',''),(71787,2955,'_contact_right_copy','field_60c249f845c9b'),(71788,2955,'contact_right_cta',''),(71789,2955,'_contact_right_cta','field_60c24a1945c9d'),(71791,2848,'content_blocks_6_header','Pressure'),(71792,2848,'_content_blocks_6_header','field_6170d8ba9800b'),(71793,2848,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(71794,2848,'_content_blocks_6_description','field_6170d8cd9800c'),(71795,2848,'content_blocks_6_images','1'),(71796,2848,'_content_blocks_6_images','field_6170d8df9800d'),(71797,2956,'hero_gallery',''),(71798,2956,'_hero_gallery','field_60c23d554e4a3'),(71799,2956,'hero_banner',''),(71800,2956,'_hero_banner','field_6170dbe179470'),(71801,2956,'page_title','Nozzle and Orifice'),(71802,2956,'_page_title','field_6170d88998008'),(71803,2956,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(71804,2956,'_page_description','field_6170d89398009'),(71805,2956,'content_blocks_0_header','Desired edge quality'),(71806,2956,'_content_blocks_0_header','field_6170d8ba9800b'),(71807,2956,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(71808,2956,'_content_blocks_0_description','field_6170d8cd9800c'),(71809,2956,'content_blocks_0_images_0_image','2950'),(71810,2956,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(71811,2956,'content_blocks_0_images_0_header','Seperation Cut'),(71812,2956,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(71813,2956,'content_blocks_0_images_0_description',''),(71814,2956,'_content_blocks_0_images_0_description','field_6170d90398010'),(71815,2956,'content_blocks_0_images_1_image','2951'),(71816,2956,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(71817,2956,'content_blocks_0_images_1_header','Through Cut'),(71818,2956,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(71819,2956,'content_blocks_0_images_1_description',''),(71820,2956,'_content_blocks_0_images_1_description','field_6170d90398010'),(71821,2956,'content_blocks_0_images_2_image','2952'),(71822,2956,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(71823,2956,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(71824,2956,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(71825,2956,'content_blocks_0_images_2_description',''),(71826,2956,'_content_blocks_0_images_2_description','field_6170d90398010'),(71827,2956,'content_blocks_0_images_3_image','2953'),(71828,2956,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(71829,2956,'content_blocks_0_images_3_header','Good Finish'),(71830,2956,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(71831,2956,'content_blocks_0_images_3_description',''),(71832,2956,'_content_blocks_0_images_3_description','field_6170d90398010'),(71833,2956,'content_blocks_0_images_4_image','2954'),(71834,2956,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(71835,2956,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(71836,2956,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(71837,2956,'content_blocks_0_images_4_description',''),(71838,2956,'_content_blocks_0_images_4_description','field_6170d90398010'),(71839,2956,'content_blocks_0_images','5'),(71840,2956,'_content_blocks_0_images','field_6170d8df9800d'),(71841,2956,'content_blocks_1_header','Pump Specification'),(71842,2956,'_content_blocks_1_header','field_6170d8ba9800b'),(71843,2956,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(71844,2956,'_content_blocks_1_description','field_6170d8cd9800c'),(71845,2956,'content_blocks_1_images_0_image',''),(71846,2956,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(71847,2956,'content_blocks_1_images_0_header','Need Table here'),(71848,2956,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(71849,2956,'content_blocks_1_images_0_description',''),(71850,2956,'_content_blocks_1_images_0_description','field_6170d90398010'),(71851,2956,'content_blocks_1_images','1'),(71852,2956,'_content_blocks_1_images','field_6170d8df9800d'),(71853,2956,'content_blocks_2_header','Horsepower, pressure and water output'),(71854,2956,'_content_blocks_2_header','field_6170d8ba9800b'),(71855,2956,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(71856,2956,'_content_blocks_2_description','field_6170d8cd9800c'),(71857,2956,'content_blocks_2_images',''),(71858,2956,'_content_blocks_2_images','field_6170d8df9800d'),(71859,2956,'content_blocks_3_header','Horsepower'),(71860,2956,'_content_blocks_3_header','field_6170d8ba9800b'),(71861,2956,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(71862,2956,'_content_blocks_3_description','field_6170d8cd9800c'),(71863,2956,'content_blocks_3_images_0_image','2849'),(71864,2956,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(71865,2956,'content_blocks_3_images_0_header',''),(71866,2956,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(71867,2956,'content_blocks_3_images_0_description',''),(71868,2956,'_content_blocks_3_images_0_description','field_6170d90398010'),(71869,2956,'content_blocks_3_images','1'),(71870,2956,'_content_blocks_3_images','field_6170d8df9800d'),(71871,2956,'content_blocks_4_header',''),(71872,2956,'_content_blocks_4_header','field_6170d8ba9800b'),(71873,2956,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(71874,2956,'_content_blocks_4_description','field_6170d8cd9800c'),(71875,2956,'content_blocks_4_images_0_image','2850'),(71876,2956,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(71877,2956,'content_blocks_4_images_0_header',''),(71878,2956,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(71879,2956,'content_blocks_4_images_0_description',''),(71880,2956,'_content_blocks_4_images_0_description','field_6170d90398010'),(71881,2956,'content_blocks_4_images_1_image',''),(71882,2956,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(71883,2956,'content_blocks_4_images_1_header','Need Image'),(71884,2956,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(71885,2956,'content_blocks_4_images_1_description',''),(71886,2956,'_content_blocks_4_images_1_description','field_6170d90398010'),(71887,2956,'content_blocks_4_images','2'),(71888,2956,'_content_blocks_4_images','field_6170d8df9800d'),(71889,2956,'content_blocks_5_header',''),(71890,2956,'_content_blocks_5_header','field_6170d8ba9800b'),(71891,2956,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(71892,2956,'_content_blocks_5_description','field_6170d8cd9800c'),(71893,2956,'content_blocks_5_images',''),(71894,2956,'_content_blocks_5_images','field_6170d8df9800d'),(71895,2956,'content_blocks','7'),(71896,2956,'_content_blocks','field_6170d8ac9800a'),(71897,2956,'menu','11'),(71898,2956,'_menu','field_6170d9e059837'),(71899,2956,'display_left_column','1'),(71900,2956,'_display_left_column','field_613563c4d424b'),(71901,2956,'contact_left_heading',''),(71902,2956,'_contact_left_heading','field_60c249d645c99'),(71903,2956,'contact_left_copy',''),(71904,2956,'_contact_left_copy','field_60c24a0845c9c'),(71905,2956,'display_right_column','1'),(71906,2956,'_display_right_column','field_613563f4d424c'),(71907,2956,'contact_right_heading',''),(71908,2956,'_contact_right_heading','field_60c249e945c9a'),(71909,2956,'contact_right_copy',''),(71910,2956,'_contact_right_copy','field_60c249f845c9b'),(71911,2956,'contact_right_cta',''),(71912,2956,'_contact_right_cta','field_60c24a1945c9d'),(71913,2956,'content_blocks_6_header',''),(71914,2956,'_content_blocks_6_header','field_6170d8ba9800b'),(71915,2956,'content_blocks_6_description',''),(71916,2956,'_content_blocks_6_description','field_6170d8cd9800c'),(71917,2956,'content_blocks_6_images',''),(71918,2956,'_content_blocks_6_images','field_6170d8df9800d'),(71922,2958,'_wp_attached_file','2021/11/pressureChart.jpg'),(71923,2958,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:600;s:6:\"height\";i:417;s:4:\"file\";s:25:\"2021/11/pressureChart.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(71924,2958,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(71925,2848,'content_blocks_6_images_0_image','2958'),(71926,2848,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(71927,2848,'content_blocks_6_images_0_header',''),(71928,2848,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(71929,2848,'content_blocks_6_images_0_description',''),(71930,2848,'_content_blocks_6_images_0_description','field_6170d90398010'),(71931,2848,'content_blocks_7_header','Water Output'),(71932,2848,'_content_blocks_7_header','field_6170d8ba9800b'),(71933,2848,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(71934,2848,'_content_blocks_7_description','field_6170d8cd9800c'),(71935,2848,'content_blocks_7_images',''),(71936,2848,'_content_blocks_7_images','field_6170d8df9800d'),(71937,2848,'content_blocks_8_header','Orifice selection – The scientific way'),(71938,2848,'_content_blocks_8_header','field_6170d8ba9800b'),(71939,2848,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(71940,2848,'_content_blocks_8_description','field_6170d8cd9800c'),(71941,2848,'content_blocks_8_images','1'),(71942,2848,'_content_blocks_8_images','field_6170d8df9800d'),(71943,2959,'hero_gallery',''),(71944,2959,'_hero_gallery','field_60c23d554e4a3'),(71945,2959,'hero_banner',''),(71946,2959,'_hero_banner','field_6170dbe179470'),(71947,2959,'page_title','Nozzle and Orifice'),(71948,2959,'_page_title','field_6170d88998008'),(71949,2959,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(71950,2959,'_page_description','field_6170d89398009'),(71951,2959,'content_blocks_0_header','Desired edge quality'),(71952,2959,'_content_blocks_0_header','field_6170d8ba9800b'),(71953,2959,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(71954,2959,'_content_blocks_0_description','field_6170d8cd9800c'),(71955,2959,'content_blocks_0_images_0_image','2950'),(71956,2959,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(71957,2959,'content_blocks_0_images_0_header','Seperation Cut'),(71958,2959,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(71959,2959,'content_blocks_0_images_0_description',''),(71960,2959,'_content_blocks_0_images_0_description','field_6170d90398010'),(71961,2959,'content_blocks_0_images_1_image','2951'),(71962,2959,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(71963,2959,'content_blocks_0_images_1_header','Through Cut'),(71964,2959,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(71965,2959,'content_blocks_0_images_1_description',''),(71966,2959,'_content_blocks_0_images_1_description','field_6170d90398010'),(71967,2959,'content_blocks_0_images_2_image','2952'),(71968,2959,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(71969,2959,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(71970,2959,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(71971,2959,'content_blocks_0_images_2_description',''),(71972,2959,'_content_blocks_0_images_2_description','field_6170d90398010'),(71973,2959,'content_blocks_0_images_3_image','2953'),(71974,2959,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(71975,2959,'content_blocks_0_images_3_header','Good Finish'),(71976,2959,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(71977,2959,'content_blocks_0_images_3_description',''),(71978,2959,'_content_blocks_0_images_3_description','field_6170d90398010'),(71979,2959,'content_blocks_0_images_4_image','2954'),(71980,2959,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(71981,2959,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(71982,2959,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(71983,2959,'content_blocks_0_images_4_description',''),(71984,2959,'_content_blocks_0_images_4_description','field_6170d90398010'),(71985,2959,'content_blocks_0_images','5'),(71986,2959,'_content_blocks_0_images','field_6170d8df9800d'),(71987,2959,'content_blocks_1_header','Pump Specification'),(71988,2959,'_content_blocks_1_header','field_6170d8ba9800b'),(71989,2959,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(71990,2959,'_content_blocks_1_description','field_6170d8cd9800c'),(71991,2959,'content_blocks_1_images_0_image',''),(71992,2959,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(71993,2959,'content_blocks_1_images_0_header','Need Table here'),(71994,2959,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(71995,2959,'content_blocks_1_images_0_description',''),(71996,2959,'_content_blocks_1_images_0_description','field_6170d90398010'),(71997,2959,'content_blocks_1_images','1'),(71998,2959,'_content_blocks_1_images','field_6170d8df9800d'),(71999,2959,'content_blocks_2_header','Horsepower, pressure and water output'),(72000,2959,'_content_blocks_2_header','field_6170d8ba9800b'),(72001,2959,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(72002,2959,'_content_blocks_2_description','field_6170d8cd9800c'),(72003,2959,'content_blocks_2_images',''),(72004,2959,'_content_blocks_2_images','field_6170d8df9800d'),(72005,2959,'content_blocks_3_header','Horsepower'),(72006,2959,'_content_blocks_3_header','field_6170d8ba9800b'),(72007,2959,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(72008,2959,'_content_blocks_3_description','field_6170d8cd9800c'),(72009,2959,'content_blocks_3_images_0_image','2849'),(72010,2959,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(72011,2959,'content_blocks_3_images_0_header',''),(72012,2959,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(72013,2959,'content_blocks_3_images_0_description',''),(72014,2959,'_content_blocks_3_images_0_description','field_6170d90398010'),(72015,2959,'content_blocks_3_images','1'),(72016,2959,'_content_blocks_3_images','field_6170d8df9800d'),(72017,2959,'content_blocks_4_header',''),(72018,2959,'_content_blocks_4_header','field_6170d8ba9800b'),(72019,2959,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(72020,2959,'_content_blocks_4_description','field_6170d8cd9800c'),(72021,2959,'content_blocks_4_images_0_image','2850'),(72022,2959,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(72023,2959,'content_blocks_4_images_0_header',''),(72024,2959,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(72025,2959,'content_blocks_4_images_0_description',''),(72026,2959,'_content_blocks_4_images_0_description','field_6170d90398010'),(72027,2959,'content_blocks_4_images_1_image',''),(72028,2959,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(72029,2959,'content_blocks_4_images_1_header','Need Image'),(72030,2959,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(72031,2959,'content_blocks_4_images_1_description',''),(72032,2959,'_content_blocks_4_images_1_description','field_6170d90398010'),(72033,2959,'content_blocks_4_images','2'),(72034,2959,'_content_blocks_4_images','field_6170d8df9800d'),(72035,2959,'content_blocks_5_header',''),(72036,2959,'_content_blocks_5_header','field_6170d8ba9800b'),(72037,2959,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(72038,2959,'_content_blocks_5_description','field_6170d8cd9800c'),(72039,2959,'content_blocks_5_images',''),(72040,2959,'_content_blocks_5_images','field_6170d8df9800d'),(72041,2959,'content_blocks','9'),(72042,2959,'_content_blocks','field_6170d8ac9800a'),(72043,2959,'menu','11'),(72044,2959,'_menu','field_6170d9e059837'),(72045,2959,'display_left_column','1'),(72046,2959,'_display_left_column','field_613563c4d424b'),(72047,2959,'contact_left_heading',''),(72048,2959,'_contact_left_heading','field_60c249d645c99'),(72049,2959,'contact_left_copy',''),(72050,2959,'_contact_left_copy','field_60c24a0845c9c'),(72051,2959,'display_right_column','1'),(72052,2959,'_display_right_column','field_613563f4d424c'),(72053,2959,'contact_right_heading',''),(72054,2959,'_contact_right_heading','field_60c249e945c9a'),(72055,2959,'contact_right_copy',''),(72056,2959,'_contact_right_copy','field_60c249f845c9b'),(72057,2959,'contact_right_cta',''),(72058,2959,'_contact_right_cta','field_60c24a1945c9d'),(72059,2959,'content_blocks_6_header','Pressure'),(72060,2959,'_content_blocks_6_header','field_6170d8ba9800b'),(72061,2959,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(72062,2959,'_content_blocks_6_description','field_6170d8cd9800c'),(72063,2959,'content_blocks_6_images','1'),(72064,2959,'_content_blocks_6_images','field_6170d8df9800d'),(72065,2959,'content_blocks_6_images_0_image','2958'),(72066,2959,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(72067,2959,'content_blocks_6_images_0_header',''),(72068,2959,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(72069,2959,'content_blocks_6_images_0_description',''),(72070,2959,'_content_blocks_6_images_0_description','field_6170d90398010'),(72071,2959,'content_blocks_7_header','Water Output'),(72072,2959,'_content_blocks_7_header','field_6170d8ba9800b'),(72073,2959,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(72074,2959,'_content_blocks_7_description','field_6170d8cd9800c'),(72075,2959,'content_blocks_7_images',''),(72076,2959,'_content_blocks_7_images','field_6170d8df9800d'),(72077,2959,'content_blocks_8_header','Orifice selection – The scientific way'),(72078,2959,'_content_blocks_8_header','field_6170d8ba9800b'),(72079,2959,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(72080,2959,'_content_blocks_8_description','field_6170d8cd9800c'),(72081,2959,'content_blocks_8_images',''),(72082,2959,'_content_blocks_8_images','field_6170d8df9800d'),(72084,2960,'_wp_attached_file','2021/11/Waterjet-University_Nozzle-n-Orifice-Pump-Selection-Chart.jpg'),(72085,2960,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:640;s:6:\"height\";i:404;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Nozzle-n-Orifice-Pump-Selection-Chart.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72086,2961,'_wp_attached_file','2021/11/Waterjet-University_Nozzle-n-Orifice-Abrasive-Amount-and-Cutting-Speed-Chart.jpg'),(72087,2961,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:617;s:6:\"height\";i:343;s:4:\"file\";s:88:\"2021/11/Waterjet-University_Nozzle-n-Orifice-Abrasive-Amount-and-Cutting-Speed-Chart.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72088,2962,'_wp_attached_file','2021/11/Waterjet-University_Nozzle-n-Orifice-Nozzle-Combination-Chart-2.jpg'),(72089,2962,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:630;s:6:\"height\";i:418;s:4:\"file\";s:75:\"2021/11/Waterjet-University_Nozzle-n-Orifice-Nozzle-Combination-Chart-2.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72090,2963,'_wp_attached_file','2021/11/abrasive-amount-chart-4.jpg'),(72091,2963,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:600;s:6:\"height\";i:351;s:4:\"file\";s:35:\"2021/11/abrasive-amount-chart-4.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72092,2963,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72093,2962,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72094,2961,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72095,2960,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72096,2848,'content_blocks_8_images_0_image',''),(72097,2848,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(72098,2848,'content_blocks_8_images_0_header','chart needed here'),(72099,2848,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(72100,2848,'content_blocks_8_images_0_description',''),(72101,2848,'_content_blocks_8_images_0_description','field_6170d90398010'),(72102,2848,'content_blocks_9_header','Running Two Cutting Heads'),(72103,2848,'_content_blocks_9_header','field_6170d8ba9800b'),(72104,2848,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(72105,2848,'_content_blocks_9_description','field_6170d8cd9800c'),(72106,2848,'content_blocks_9_images',''),(72107,2848,'_content_blocks_9_images','field_6170d8df9800d'),(72108,2848,'content_blocks_10_header','Orifice selection – the easy way'),(72109,2848,'_content_blocks_10_header','field_6170d8ba9800b'),(72110,2848,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(72111,2848,'_content_blocks_10_description','field_6170d8cd9800c'),(72112,2848,'content_blocks_10_images_0_image',''),(72113,2848,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(72114,2848,'content_blocks_10_images_0_header','insert table'),(72115,2848,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(72116,2848,'content_blocks_10_images_0_description',''),(72117,2848,'_content_blocks_10_images_0_description','field_6170d90398010'),(72118,2848,'content_blocks_10_images','1'),(72119,2848,'_content_blocks_10_images','field_6170d8df9800d'),(72120,2848,'content_blocks_11_header','General pump selection guidelines'),(72121,2848,'_content_blocks_11_header','field_6170d8ba9800b'),(72122,2848,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(72123,2848,'_content_blocks_11_description','field_6170d8cd9800c'),(72124,2848,'content_blocks_11_images_0_image','2960'),(72125,2848,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(72126,2848,'content_blocks_11_images_0_header',''),(72127,2848,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(72128,2848,'content_blocks_11_images_0_description',''),(72129,2848,'_content_blocks_11_images_0_description','field_6170d90398010'),(72130,2848,'content_blocks_11_images','1'),(72131,2848,'_content_blocks_11_images','field_6170d8df9800d'),(72132,2848,'content_blocks_12_header','Abrasive nozzle selection'),(72133,2848,'_content_blocks_12_header','field_6170d8ba9800b'),(72134,2848,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(72135,2848,'_content_blocks_12_description','field_6170d8cd9800c'),(72136,2848,'content_blocks_12_images_0_image',''),(72137,2848,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(72138,2848,'content_blocks_12_images_0_header','insert chart'),(72139,2848,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(72140,2848,'content_blocks_12_images_0_description',''),(72141,2848,'_content_blocks_12_images_0_description','field_6170d90398010'),(72142,2848,'content_blocks_12_images','1'),(72143,2848,'_content_blocks_12_images','field_6170d8df9800d'),(72144,2848,'content_blocks_13_header','Abrasive amount and cutting speeds'),(72145,2848,'_content_blocks_13_header','field_6170d8ba9800b'),(72146,2848,'content_blocks_13_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.\r\n\r\n<img class=\"size-medium wp-image-6973 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/closeup-of-waterjet-cutting-head-300x225.jpg\" alt=\"closeup-of-waterjet-cutting-head\" width=\"450\" />\r\n\r\n&nbsp;\r\n\r\nAs abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\n<img class=\"size-full wp-image-2961 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/11/Waterjet-University_Nozzle-n-Orifice-Abrasive-Amount-and-Cutting-Speed-Chart.jpg\" alt=\"Waterjet University_Nozzle n Orifice Abrasive Amount and Cutting Speed Chart\" width=\"617\" height=\"343\" />\r\n\r\n&nbsp;\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(72147,2848,'_content_blocks_13_description','field_6170d8cd9800c'),(72160,2848,'content_blocks_13_images',''),(72161,2848,'_content_blocks_13_images','field_6170d8df9800d'),(72162,2848,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(72163,2848,'_content_blocks_14_header','field_6170d8ba9800b'),(72164,2848,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.\r\n\r\n<img class=\"size-medium wp-image-6977 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/nozzle-and-orifice-abrasive-amount-chart-2-300x172.jpg\" alt=\"nozzle and orifice - abrasive-amount-chart-2\" width=\"630\" />\r\n\r\n&nbsp;\r\n\r\nSmaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.\r\n\r\n<img class=\"size-full wp-image-2962 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/11/Waterjet-University_Nozzle-n-Orifice-Nozzle-Combination-Chart-2.jpg\" alt=\"Waterjet University_Nozzle n Orifice Nozzle Combination Chart 2\" width=\"630\" height=\"418\" />\r\n\r\n&nbsp;\r\n\r\nIn the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).\r\n\r\n<img class=\"size-full wp-image-2963 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/11/abrasive-amount-chart-4.jpg\" alt=\"\" width=\"600\" height=\"351\" />'),(72165,2848,'_content_blocks_14_description','field_6170d8cd9800c'),(72184,2848,'content_blocks_14_images',''),(72185,2848,'_content_blocks_14_images','field_6170d8df9800d'),(72186,2964,'hero_gallery',''),(72187,2964,'_hero_gallery','field_60c23d554e4a3'),(72188,2964,'hero_banner',''),(72189,2964,'_hero_banner','field_6170dbe179470'),(72190,2964,'page_title','Nozzle and Orifice'),(72191,2964,'_page_title','field_6170d88998008'),(72192,2964,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(72193,2964,'_page_description','field_6170d89398009'),(72194,2964,'content_blocks_0_header','Desired edge quality'),(72195,2964,'_content_blocks_0_header','field_6170d8ba9800b'),(72196,2964,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(72197,2964,'_content_blocks_0_description','field_6170d8cd9800c'),(72198,2964,'content_blocks_0_images_0_image','2950'),(72199,2964,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(72200,2964,'content_blocks_0_images_0_header','Seperation Cut'),(72201,2964,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(72202,2964,'content_blocks_0_images_0_description',''),(72203,2964,'_content_blocks_0_images_0_description','field_6170d90398010'),(72204,2964,'content_blocks_0_images_1_image','2951'),(72205,2964,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(72206,2964,'content_blocks_0_images_1_header','Through Cut'),(72207,2964,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(72208,2964,'content_blocks_0_images_1_description',''),(72209,2964,'_content_blocks_0_images_1_description','field_6170d90398010'),(72210,2964,'content_blocks_0_images_2_image','2952'),(72211,2964,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(72212,2964,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(72213,2964,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(72214,2964,'content_blocks_0_images_2_description',''),(72215,2964,'_content_blocks_0_images_2_description','field_6170d90398010'),(72216,2964,'content_blocks_0_images_3_image','2953'),(72217,2964,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(72218,2964,'content_blocks_0_images_3_header','Good Finish'),(72219,2964,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(72220,2964,'content_blocks_0_images_3_description',''),(72221,2964,'_content_blocks_0_images_3_description','field_6170d90398010'),(72222,2964,'content_blocks_0_images_4_image','2954'),(72223,2964,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(72224,2964,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(72225,2964,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(72226,2964,'content_blocks_0_images_4_description',''),(72227,2964,'_content_blocks_0_images_4_description','field_6170d90398010'),(72228,2964,'content_blocks_0_images','5'),(72229,2964,'_content_blocks_0_images','field_6170d8df9800d'),(72230,2964,'content_blocks_1_header','Pump Specification'),(72231,2964,'_content_blocks_1_header','field_6170d8ba9800b'),(72232,2964,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(72233,2964,'_content_blocks_1_description','field_6170d8cd9800c'),(72234,2964,'content_blocks_1_images_0_image',''),(72235,2964,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(72236,2964,'content_blocks_1_images_0_header','Need Table here'),(72237,2964,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(72238,2964,'content_blocks_1_images_0_description',''),(72239,2964,'_content_blocks_1_images_0_description','field_6170d90398010'),(72240,2964,'content_blocks_1_images','1'),(72241,2964,'_content_blocks_1_images','field_6170d8df9800d'),(72242,2964,'content_blocks_2_header','Horsepower, pressure and water output'),(72243,2964,'_content_blocks_2_header','field_6170d8ba9800b'),(72244,2964,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(72245,2964,'_content_blocks_2_description','field_6170d8cd9800c'),(72246,2964,'content_blocks_2_images',''),(72247,2964,'_content_blocks_2_images','field_6170d8df9800d'),(72248,2964,'content_blocks_3_header','Horsepower'),(72249,2964,'_content_blocks_3_header','field_6170d8ba9800b'),(72250,2964,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(72251,2964,'_content_blocks_3_description','field_6170d8cd9800c'),(72252,2964,'content_blocks_3_images_0_image','2849'),(72253,2964,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(72254,2964,'content_blocks_3_images_0_header',''),(72255,2964,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(72256,2964,'content_blocks_3_images_0_description',''),(72257,2964,'_content_blocks_3_images_0_description','field_6170d90398010'),(72258,2964,'content_blocks_3_images','1'),(72259,2964,'_content_blocks_3_images','field_6170d8df9800d'),(72260,2964,'content_blocks_4_header',''),(72261,2964,'_content_blocks_4_header','field_6170d8ba9800b'),(72262,2964,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(72263,2964,'_content_blocks_4_description','field_6170d8cd9800c'),(72264,2964,'content_blocks_4_images_0_image','2850'),(72265,2964,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(72266,2964,'content_blocks_4_images_0_header',''),(72267,2964,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(72268,2964,'content_blocks_4_images_0_description',''),(72269,2964,'_content_blocks_4_images_0_description','field_6170d90398010'),(72270,2964,'content_blocks_4_images_1_image',''),(72271,2964,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(72272,2964,'content_blocks_4_images_1_header','Need Image'),(72273,2964,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(72274,2964,'content_blocks_4_images_1_description',''),(72275,2964,'_content_blocks_4_images_1_description','field_6170d90398010'),(72276,2964,'content_blocks_4_images','2'),(72277,2964,'_content_blocks_4_images','field_6170d8df9800d'),(72278,2964,'content_blocks_5_header',''),(72279,2964,'_content_blocks_5_header','field_6170d8ba9800b'),(72280,2964,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(72281,2964,'_content_blocks_5_description','field_6170d8cd9800c'),(72282,2964,'content_blocks_5_images',''),(72283,2964,'_content_blocks_5_images','field_6170d8df9800d'),(72284,2964,'content_blocks','15'),(72285,2964,'_content_blocks','field_6170d8ac9800a'),(72286,2964,'menu','11'),(72287,2964,'_menu','field_6170d9e059837'),(72288,2964,'display_left_column','1'),(72289,2964,'_display_left_column','field_613563c4d424b'),(72290,2964,'contact_left_heading',''),(72291,2964,'_contact_left_heading','field_60c249d645c99'),(72292,2964,'contact_left_copy',''),(72293,2964,'_contact_left_copy','field_60c24a0845c9c'),(72294,2964,'display_right_column','1'),(72295,2964,'_display_right_column','field_613563f4d424c'),(72296,2964,'contact_right_heading',''),(72297,2964,'_contact_right_heading','field_60c249e945c9a'),(72298,2964,'contact_right_copy',''),(72299,2964,'_contact_right_copy','field_60c249f845c9b'),(72300,2964,'contact_right_cta',''),(72301,2964,'_contact_right_cta','field_60c24a1945c9d'),(72302,2964,'content_blocks_6_header','Pressure'),(72303,2964,'_content_blocks_6_header','field_6170d8ba9800b'),(72304,2964,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(72305,2964,'_content_blocks_6_description','field_6170d8cd9800c'),(72306,2964,'content_blocks_6_images','1'),(72307,2964,'_content_blocks_6_images','field_6170d8df9800d'),(72308,2964,'content_blocks_6_images_0_image','2958'),(72309,2964,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(72310,2964,'content_blocks_6_images_0_header',''),(72311,2964,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(72312,2964,'content_blocks_6_images_0_description',''),(72313,2964,'_content_blocks_6_images_0_description','field_6170d90398010'),(72314,2964,'content_blocks_7_header','Water Output'),(72315,2964,'_content_blocks_7_header','field_6170d8ba9800b'),(72316,2964,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(72317,2964,'_content_blocks_7_description','field_6170d8cd9800c'),(72318,2964,'content_blocks_7_images',''),(72319,2964,'_content_blocks_7_images','field_6170d8df9800d'),(72320,2964,'content_blocks_8_header','Orifice selection – The scientific way'),(72321,2964,'_content_blocks_8_header','field_6170d8ba9800b'),(72322,2964,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(72323,2964,'_content_blocks_8_description','field_6170d8cd9800c'),(72324,2964,'content_blocks_8_images','1'),(72325,2964,'_content_blocks_8_images','field_6170d8df9800d'),(72326,2964,'content_blocks_8_images_0_image',''),(72327,2964,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(72328,2964,'content_blocks_8_images_0_header','chart needed here'),(72329,2964,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(72330,2964,'content_blocks_8_images_0_description',''),(72331,2964,'_content_blocks_8_images_0_description','field_6170d90398010'),(72332,2964,'content_blocks_9_header','Running Two Cutting Heads'),(72333,2964,'_content_blocks_9_header','field_6170d8ba9800b'),(72334,2964,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(72335,2964,'_content_blocks_9_description','field_6170d8cd9800c'),(72336,2964,'content_blocks_9_images',''),(72337,2964,'_content_blocks_9_images','field_6170d8df9800d'),(72338,2964,'content_blocks_10_header','Orifice selection – the easy way'),(72339,2964,'_content_blocks_10_header','field_6170d8ba9800b'),(72340,2964,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(72341,2964,'_content_blocks_10_description','field_6170d8cd9800c'),(72342,2964,'content_blocks_10_images_0_image',''),(72343,2964,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(72344,2964,'content_blocks_10_images_0_header','insert table'),(72345,2964,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(72346,2964,'content_blocks_10_images_0_description',''),(72347,2964,'_content_blocks_10_images_0_description','field_6170d90398010'),(72348,2964,'content_blocks_10_images','1'),(72349,2964,'_content_blocks_10_images','field_6170d8df9800d'),(72350,2964,'content_blocks_11_header','General pump selection guidelines'),(72351,2964,'_content_blocks_11_header','field_6170d8ba9800b'),(72352,2964,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(72353,2964,'_content_blocks_11_description','field_6170d8cd9800c'),(72354,2964,'content_blocks_11_images_0_image','2960'),(72355,2964,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(72356,2964,'content_blocks_11_images_0_header',''),(72357,2964,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(72358,2964,'content_blocks_11_images_0_description',''),(72359,2964,'_content_blocks_11_images_0_description','field_6170d90398010'),(72360,2964,'content_blocks_11_images','1'),(72361,2964,'_content_blocks_11_images','field_6170d8df9800d'),(72362,2964,'content_blocks_12_header','Abrasive nozzle selection'),(72363,2964,'_content_blocks_12_header','field_6170d8ba9800b'),(72364,2964,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(72365,2964,'_content_blocks_12_description','field_6170d8cd9800c'),(72366,2964,'content_blocks_12_images_0_image',''),(72367,2964,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(72368,2964,'content_blocks_12_images_0_header','insert chart'),(72369,2964,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(72370,2964,'content_blocks_12_images_0_description',''),(72371,2964,'_content_blocks_12_images_0_description','field_6170d90398010'),(72372,2964,'content_blocks_12_images','1'),(72373,2964,'_content_blocks_12_images','field_6170d8df9800d'),(72374,2964,'content_blocks_13_header','Abrasive amount and cutting speeds'),(72375,2964,'_content_blocks_13_header','field_6170d8ba9800b'),(72376,2964,'content_blocks_13_description','As abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(72377,2964,'_content_blocks_13_description','field_6170d8cd9800c'),(72378,2964,'content_blocks_13_images_0_image','2830'),(72379,2964,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(72380,2964,'content_blocks_13_images_0_header',''),(72381,2964,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(72382,2964,'content_blocks_13_images_0_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.'),(72383,2964,'_content_blocks_13_images_0_description','field_6170d90398010'),(72384,2964,'content_blocks_13_images_1_image','2961'),(72385,2964,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(72386,2964,'content_blocks_13_images_1_header',''),(72387,2964,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(72388,2964,'content_blocks_13_images_1_description',''),(72389,2964,'_content_blocks_13_images_1_description','field_6170d90398010'),(72390,2964,'content_blocks_13_images','2'),(72391,2964,'_content_blocks_13_images','field_6170d8df9800d'),(72392,2964,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(72393,2964,'_content_blocks_14_header','field_6170d8ba9800b'),(72394,2964,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.'),(72395,2964,'_content_blocks_14_description','field_6170d8cd9800c'),(72396,2964,'content_blocks_14_images_0_image','2961'),(72397,2964,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(72398,2964,'content_blocks_14_images_0_header',''),(72399,2964,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(72400,2964,'content_blocks_14_images_0_description','Smaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.'),(72401,2964,'_content_blocks_14_images_0_description','field_6170d90398010'),(72402,2964,'content_blocks_14_images_1_image','2962'),(72403,2964,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(72404,2964,'content_blocks_14_images_1_header',''),(72405,2964,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(72406,2964,'content_blocks_14_images_1_description','In the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).'),(72407,2964,'_content_blocks_14_images_1_description','field_6170d90398010'),(72408,2964,'content_blocks_14_images_2_image','2963'),(72409,2964,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(72410,2964,'content_blocks_14_images_2_header',''),(72411,2964,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(72412,2964,'content_blocks_14_images_2_description',''),(72413,2964,'_content_blocks_14_images_2_description','field_6170d90398010'),(72414,2964,'content_blocks_14_images','3'),(72415,2964,'_content_blocks_14_images','field_6170d8df9800d'),(72417,2965,'_wp_attached_file','2021/11/Waterjet-University_Nozzle-n-Orifice-Cutting-Speed-Calculator.jpg'),(72418,2965,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:500;s:6:\"height\";i:464;s:4:\"file\";s:73:\"2021/11/Waterjet-University_Nozzle-n-Orifice-Cutting-Speed-Calculator.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72419,2966,'_wp_attached_file','2021/11/Waterjet-University_Nozzle-n-Orifice-Feed-Rate-Calculator.jpg'),(72420,2966,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:505;s:6:\"height\";i:175;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Nozzle-n-Orifice-Feed-Rate-Calculator.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72421,2967,'_wp_attached_file','2021/11/Waterjet-University_Nozzle-n-Orifice-Feed-Rate-Calculator-2.jpg'),(72422,2967,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:505;s:6:\"height\";i:118;s:4:\"file\";s:71:\"2021/11/Waterjet-University_Nozzle-n-Orifice-Feed-Rate-Calculator-2.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72423,2967,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72424,2966,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72425,2965,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(72426,2848,'content_blocks_15_header','Nozzle wear'),(72427,2848,'_content_blocks_15_header','field_6170d8ba9800b'),(72428,2848,'content_blocks_15_description','As the abrasive nozzle wears, the diameter of the abrasive waterjet stream increases. The diameter increases by approximately 0.0001” per hour of cutting. Power per square inch is reduced. Therefore, the feed rate must be reduced in order to maintain the same edge finish, or the quality of the edge will deteriorate.'),(72429,2848,'_content_blocks_15_description','field_6170d8cd9800c'),(72430,2848,'content_blocks_15_images',''),(72431,2848,'_content_blocks_15_images','field_6170d8df9800d'),(72432,2848,'content_blocks_16_header','Cutting speed calculators'),(72433,2848,'_content_blocks_16_header','field_6170d8ba9800b'),(72434,2848,'content_blocks_16_description','Various waterjet feed rate calculators are available online. With these calculators, you can play around with the various parameters to see how cutting speed and cost per inch are affected. Below is an example of one such calculator.\r\n\r\nWith all of these calculators, it is more important to focus on cost per inch (or foot, or meter), rather than cost per hour. Focusing on cost per foot takes into account the diminishing returns discussed in the previous section.\r\n\r\nAnother thing to keep in mind is that these calculators are only showing straight line cutting speeds. Depending upon part geometry, piercing times, machine design and more, actual part cutting times can vary significantly from just taking the total linear inches of cutting in a part and dividing that number by the inches per minute shown in a calculator. The calculators are useful though in at least getting an idea of speeds and costs.'),(72435,2848,'_content_blocks_16_description','field_6170d8cd9800c'),(72436,2848,'content_blocks_16_images_0_image','2965'),(72437,2848,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(72438,2848,'content_blocks_16_images_0_header',''),(72439,2848,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(72440,2848,'content_blocks_16_images_0_description',''),(72441,2848,'_content_blocks_16_images_0_description','field_6170d90398010'),(72442,2848,'content_blocks_16_images','1'),(72443,2848,'_content_blocks_16_images','field_6170d8df9800d'),(72444,2848,'content_blocks_17_header','Machinability Index'),(72445,2848,'_content_blocks_17_header','field_6170d8ba9800b'),(72446,2848,'content_blocks_17_description','The Machinability Index shown in most waterjet feed rate calculators defines the relative cutting rates of different materials. Materials with higher numbers cut proportionately faster than lower numbers. Mild steel has a baseline value of one. Stainless steel at 0.9 would indicate that it cuts about 10% slower than mild steel to achieve similar edge quality and tolerance results.\r\n\r\nIf you know the machinability indexes of two materials, you can estimate fairly easily a good cutting speed of one material from the other. We know that the Machinability Index of stainless steel is 0.9 and below we see that Aluminum’s Machinability Index is 2.9. You know that ½” stainless cuts at 5.5 ipm for the edge quality you want. You want to know the speed for ½” Aluminum. Divide the machinability of Aluminum by the machinability of stainless. 2.9 ÷ 0.9 = 3.2. Multiply the cutting speed for Stainless by 3.2 for the cutting speed in the same thickness of Aluminum. 5.5 ipm x 3.2 = 17.6 ipm. Therefore, 17.6 ipm would be a good place to start for ½” Aluminum.'),(72447,2848,'_content_blocks_17_description','field_6170d8cd9800c'),(72448,2848,'content_blocks_17_images_0_image','2966'),(72449,2848,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(72450,2848,'content_blocks_17_images_0_header',''),(72451,2848,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(72452,2848,'content_blocks_17_images_0_description',''),(72453,2848,'_content_blocks_17_images_0_description','field_6170d90398010'),(72454,2848,'content_blocks_17_images_1_image','2967'),(72455,2848,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(72456,2848,'content_blocks_17_images_1_header',''),(72457,2848,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(72458,2848,'content_blocks_17_images_1_description',''),(72459,2848,'_content_blocks_17_images_1_description','field_6170d90398010'),(72460,2848,'content_blocks_17_images','2'),(72461,2848,'_content_blocks_17_images','field_6170d8df9800d'),(72462,2848,'content_blocks_18_header','Summary'),(72463,2848,'_content_blocks_18_header','field_6170d8ba9800b'),(72464,2848,'content_blocks_18_description','In this chapter we looked at the three critical specifications of a high pressure pump: horsepower, pressure and water output. We reviewed how to figure out what size orifice to use based upon these pump specifications and how many cutting heads are being used. We covered the productivity increases and cost savings of using two smaller orifices versus one large orifice. Additionally, abrasive nozzle diameter selection was discussed in terms of the ratio to the orifice being used. Finally, we looked at waterjet feed rate calculators and how Machinability Indices can be used to extrapolate the cutting speed of one material from a different material.'),(72465,2848,'_content_blocks_18_description','field_6170d8cd9800c'),(72466,2848,'content_blocks_18_images',''),(72467,2848,'_content_blocks_18_images','field_6170d8df9800d'),(72468,2968,'hero_gallery',''),(72469,2968,'_hero_gallery','field_60c23d554e4a3'),(72470,2968,'hero_banner',''),(72471,2968,'_hero_banner','field_6170dbe179470'),(72472,2968,'page_title','Nozzle and Orifice'),(72473,2968,'_page_title','field_6170d88998008'),(72474,2968,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(72475,2968,'_page_description','field_6170d89398009'),(72476,2968,'content_blocks_0_header','Desired edge quality'),(72477,2968,'_content_blocks_0_header','field_6170d8ba9800b'),(72478,2968,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(72479,2968,'_content_blocks_0_description','field_6170d8cd9800c'),(72480,2968,'content_blocks_0_images_0_image','2950'),(72481,2968,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(72482,2968,'content_blocks_0_images_0_header','Seperation Cut'),(72483,2968,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(72484,2968,'content_blocks_0_images_0_description',''),(72485,2968,'_content_blocks_0_images_0_description','field_6170d90398010'),(72486,2968,'content_blocks_0_images_1_image','2951'),(72487,2968,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(72488,2968,'content_blocks_0_images_1_header','Through Cut'),(72489,2968,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(72490,2968,'content_blocks_0_images_1_description',''),(72491,2968,'_content_blocks_0_images_1_description','field_6170d90398010'),(72492,2968,'content_blocks_0_images_2_image','2952'),(72493,2968,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(72494,2968,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(72495,2968,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(72496,2968,'content_blocks_0_images_2_description',''),(72497,2968,'_content_blocks_0_images_2_description','field_6170d90398010'),(72498,2968,'content_blocks_0_images_3_image','2953'),(72499,2968,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(72500,2968,'content_blocks_0_images_3_header','Good Finish'),(72501,2968,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(72502,2968,'content_blocks_0_images_3_description',''),(72503,2968,'_content_blocks_0_images_3_description','field_6170d90398010'),(72504,2968,'content_blocks_0_images_4_image','2954'),(72505,2968,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(72506,2968,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(72507,2968,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(72508,2968,'content_blocks_0_images_4_description',''),(72509,2968,'_content_blocks_0_images_4_description','field_6170d90398010'),(72510,2968,'content_blocks_0_images','5'),(72511,2968,'_content_blocks_0_images','field_6170d8df9800d'),(72512,2968,'content_blocks_1_header','Pump Specification'),(72513,2968,'_content_blocks_1_header','field_6170d8ba9800b'),(72514,2968,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(72515,2968,'_content_blocks_1_description','field_6170d8cd9800c'),(72516,2968,'content_blocks_1_images_0_image',''),(72517,2968,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(72518,2968,'content_blocks_1_images_0_header','Need Table here'),(72519,2968,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(72520,2968,'content_blocks_1_images_0_description',''),(72521,2968,'_content_blocks_1_images_0_description','field_6170d90398010'),(72522,2968,'content_blocks_1_images','1'),(72523,2968,'_content_blocks_1_images','field_6170d8df9800d'),(72524,2968,'content_blocks_2_header','Horsepower, pressure and water output'),(72525,2968,'_content_blocks_2_header','field_6170d8ba9800b'),(72526,2968,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(72527,2968,'_content_blocks_2_description','field_6170d8cd9800c'),(72528,2968,'content_blocks_2_images',''),(72529,2968,'_content_blocks_2_images','field_6170d8df9800d'),(72530,2968,'content_blocks_3_header','Horsepower'),(72531,2968,'_content_blocks_3_header','field_6170d8ba9800b'),(72532,2968,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(72533,2968,'_content_blocks_3_description','field_6170d8cd9800c'),(72534,2968,'content_blocks_3_images_0_image','2849'),(72535,2968,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(72536,2968,'content_blocks_3_images_0_header',''),(72537,2968,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(72538,2968,'content_blocks_3_images_0_description',''),(72539,2968,'_content_blocks_3_images_0_description','field_6170d90398010'),(72540,2968,'content_blocks_3_images','1'),(72541,2968,'_content_blocks_3_images','field_6170d8df9800d'),(72542,2968,'content_blocks_4_header',''),(72543,2968,'_content_blocks_4_header','field_6170d8ba9800b'),(72544,2968,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(72545,2968,'_content_blocks_4_description','field_6170d8cd9800c'),(72546,2968,'content_blocks_4_images_0_image','2850'),(72547,2968,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(72548,2968,'content_blocks_4_images_0_header',''),(72549,2968,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(72550,2968,'content_blocks_4_images_0_description',''),(72551,2968,'_content_blocks_4_images_0_description','field_6170d90398010'),(72552,2968,'content_blocks_4_images_1_image',''),(72553,2968,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(72554,2968,'content_blocks_4_images_1_header','Need Image'),(72555,2968,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(72556,2968,'content_blocks_4_images_1_description',''),(72557,2968,'_content_blocks_4_images_1_description','field_6170d90398010'),(72558,2968,'content_blocks_4_images','2'),(72559,2968,'_content_blocks_4_images','field_6170d8df9800d'),(72560,2968,'content_blocks_5_header',''),(72561,2968,'_content_blocks_5_header','field_6170d8ba9800b'),(72562,2968,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(72563,2968,'_content_blocks_5_description','field_6170d8cd9800c'),(72564,2968,'content_blocks_5_images',''),(72565,2968,'_content_blocks_5_images','field_6170d8df9800d'),(72566,2968,'content_blocks','19'),(72567,2968,'_content_blocks','field_6170d8ac9800a'),(72568,2968,'menu','11'),(72569,2968,'_menu','field_6170d9e059837'),(72570,2968,'display_left_column','1'),(72571,2968,'_display_left_column','field_613563c4d424b'),(72572,2968,'contact_left_heading',''),(72573,2968,'_contact_left_heading','field_60c249d645c99'),(72574,2968,'contact_left_copy',''),(72575,2968,'_contact_left_copy','field_60c24a0845c9c'),(72576,2968,'display_right_column','1'),(72577,2968,'_display_right_column','field_613563f4d424c'),(72578,2968,'contact_right_heading',''),(72579,2968,'_contact_right_heading','field_60c249e945c9a'),(72580,2968,'contact_right_copy',''),(72581,2968,'_contact_right_copy','field_60c249f845c9b'),(72582,2968,'contact_right_cta',''),(72583,2968,'_contact_right_cta','field_60c24a1945c9d'),(72584,2968,'content_blocks_6_header','Pressure'),(72585,2968,'_content_blocks_6_header','field_6170d8ba9800b'),(72586,2968,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(72587,2968,'_content_blocks_6_description','field_6170d8cd9800c'),(72588,2968,'content_blocks_6_images','1'),(72589,2968,'_content_blocks_6_images','field_6170d8df9800d'),(72590,2968,'content_blocks_6_images_0_image','2958'),(72591,2968,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(72592,2968,'content_blocks_6_images_0_header',''),(72593,2968,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(72594,2968,'content_blocks_6_images_0_description',''),(72595,2968,'_content_blocks_6_images_0_description','field_6170d90398010'),(72596,2968,'content_blocks_7_header','Water Output'),(72597,2968,'_content_blocks_7_header','field_6170d8ba9800b'),(72598,2968,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(72599,2968,'_content_blocks_7_description','field_6170d8cd9800c'),(72600,2968,'content_blocks_7_images',''),(72601,2968,'_content_blocks_7_images','field_6170d8df9800d'),(72602,2968,'content_blocks_8_header','Orifice selection – The scientific way'),(72603,2968,'_content_blocks_8_header','field_6170d8ba9800b'),(72604,2968,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(72605,2968,'_content_blocks_8_description','field_6170d8cd9800c'),(72606,2968,'content_blocks_8_images','1'),(72607,2968,'_content_blocks_8_images','field_6170d8df9800d'),(72608,2968,'content_blocks_8_images_0_image',''),(72609,2968,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(72610,2968,'content_blocks_8_images_0_header','chart needed here'),(72611,2968,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(72612,2968,'content_blocks_8_images_0_description',''),(72613,2968,'_content_blocks_8_images_0_description','field_6170d90398010'),(72614,2968,'content_blocks_9_header','Running Two Cutting Heads'),(72615,2968,'_content_blocks_9_header','field_6170d8ba9800b'),(72616,2968,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(72617,2968,'_content_blocks_9_description','field_6170d8cd9800c'),(72618,2968,'content_blocks_9_images',''),(72619,2968,'_content_blocks_9_images','field_6170d8df9800d'),(72620,2968,'content_blocks_10_header','Orifice selection – the easy way'),(72621,2968,'_content_blocks_10_header','field_6170d8ba9800b'),(72622,2968,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(72623,2968,'_content_blocks_10_description','field_6170d8cd9800c'),(72624,2968,'content_blocks_10_images_0_image',''),(72625,2968,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(72626,2968,'content_blocks_10_images_0_header','insert table'),(72627,2968,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(72628,2968,'content_blocks_10_images_0_description',''),(72629,2968,'_content_blocks_10_images_0_description','field_6170d90398010'),(72630,2968,'content_blocks_10_images','1'),(72631,2968,'_content_blocks_10_images','field_6170d8df9800d'),(72632,2968,'content_blocks_11_header','General pump selection guidelines'),(72633,2968,'_content_blocks_11_header','field_6170d8ba9800b'),(72634,2968,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(72635,2968,'_content_blocks_11_description','field_6170d8cd9800c'),(72636,2968,'content_blocks_11_images_0_image','2960'),(72637,2968,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(72638,2968,'content_blocks_11_images_0_header',''),(72639,2968,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(72640,2968,'content_blocks_11_images_0_description',''),(72641,2968,'_content_blocks_11_images_0_description','field_6170d90398010'),(72642,2968,'content_blocks_11_images','1'),(72643,2968,'_content_blocks_11_images','field_6170d8df9800d'),(72644,2968,'content_blocks_12_header','Abrasive nozzle selection'),(72645,2968,'_content_blocks_12_header','field_6170d8ba9800b'),(72646,2968,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(72647,2968,'_content_blocks_12_description','field_6170d8cd9800c'),(72648,2968,'content_blocks_12_images_0_image',''),(72649,2968,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(72650,2968,'content_blocks_12_images_0_header','insert chart'),(72651,2968,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(72652,2968,'content_blocks_12_images_0_description',''),(72653,2968,'_content_blocks_12_images_0_description','field_6170d90398010'),(72654,2968,'content_blocks_12_images','1'),(72655,2968,'_content_blocks_12_images','field_6170d8df9800d'),(72656,2968,'content_blocks_13_header','Abrasive amount and cutting speeds'),(72657,2968,'_content_blocks_13_header','field_6170d8ba9800b'),(72658,2968,'content_blocks_13_description','As abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(72659,2968,'_content_blocks_13_description','field_6170d8cd9800c'),(72660,2968,'content_blocks_13_images_0_image','2830'),(72661,2968,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(72662,2968,'content_blocks_13_images_0_header',''),(72663,2968,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(72664,2968,'content_blocks_13_images_0_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.'),(72665,2968,'_content_blocks_13_images_0_description','field_6170d90398010'),(72666,2968,'content_blocks_13_images_1_image','2961'),(72667,2968,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(72668,2968,'content_blocks_13_images_1_header',''),(72669,2968,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(72670,2968,'content_blocks_13_images_1_description',''),(72671,2968,'_content_blocks_13_images_1_description','field_6170d90398010'),(72672,2968,'content_blocks_13_images','2'),(72673,2968,'_content_blocks_13_images','field_6170d8df9800d'),(72674,2968,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(72675,2968,'_content_blocks_14_header','field_6170d8ba9800b'),(72676,2968,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.'),(72677,2968,'_content_blocks_14_description','field_6170d8cd9800c'),(72678,2968,'content_blocks_14_images_0_image','2961'),(72679,2968,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(72680,2968,'content_blocks_14_images_0_header',''),(72681,2968,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(72682,2968,'content_blocks_14_images_0_description','Smaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.'),(72683,2968,'_content_blocks_14_images_0_description','field_6170d90398010'),(72684,2968,'content_blocks_14_images_1_image','2962'),(72685,2968,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(72686,2968,'content_blocks_14_images_1_header',''),(72687,2968,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(72688,2968,'content_blocks_14_images_1_description','In the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).'),(72689,2968,'_content_blocks_14_images_1_description','field_6170d90398010'),(72690,2968,'content_blocks_14_images_2_image','2963'),(72691,2968,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(72692,2968,'content_blocks_14_images_2_header',''),(72693,2968,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(72694,2968,'content_blocks_14_images_2_description',''),(72695,2968,'_content_blocks_14_images_2_description','field_6170d90398010'),(72696,2968,'content_blocks_14_images','3'),(72697,2968,'_content_blocks_14_images','field_6170d8df9800d'),(72698,2968,'content_blocks_15_header','Nozzle wear'),(72699,2968,'_content_blocks_15_header','field_6170d8ba9800b'),(72700,2968,'content_blocks_15_description','As the abrasive nozzle wears, the diameter of the abrasive waterjet stream increases. The diameter increases by approximately 0.0001” per hour of cutting. Power per square inch is reduced. Therefore, the feed rate must be reduced in order to maintain the same edge finish, or the quality of the edge will deteriorate.'),(72701,2968,'_content_blocks_15_description','field_6170d8cd9800c'),(72702,2968,'content_blocks_15_images',''),(72703,2968,'_content_blocks_15_images','field_6170d8df9800d'),(72704,2968,'content_blocks_16_header','Cutting speed calculators'),(72705,2968,'_content_blocks_16_header','field_6170d8ba9800b'),(72706,2968,'content_blocks_16_description','Various waterjet feed rate calculators are available online. With these calculators, you can play around with the various parameters to see how cutting speed and cost per inch are affected. Below is an example of one such calculator.\r\n\r\nWith all of these calculators, it is more important to focus on cost per inch (or foot, or meter), rather than cost per hour. Focusing on cost per foot takes into account the diminishing returns discussed in the previous section.\r\n\r\nAnother thing to keep in mind is that these calculators are only showing straight line cutting speeds. Depending upon part geometry, piercing times, machine design and more, actual part cutting times can vary significantly from just taking the total linear inches of cutting in a part and dividing that number by the inches per minute shown in a calculator. The calculators are useful though in at least getting an idea of speeds and costs.'),(72707,2968,'_content_blocks_16_description','field_6170d8cd9800c'),(72708,2968,'content_blocks_16_images_0_image','2965'),(72709,2968,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(72710,2968,'content_blocks_16_images_0_header',''),(72711,2968,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(72712,2968,'content_blocks_16_images_0_description',''),(72713,2968,'_content_blocks_16_images_0_description','field_6170d90398010'),(72714,2968,'content_blocks_16_images','1'),(72715,2968,'_content_blocks_16_images','field_6170d8df9800d'),(72716,2968,'content_blocks_17_header','Machinability Index'),(72717,2968,'_content_blocks_17_header','field_6170d8ba9800b'),(72718,2968,'content_blocks_17_description','The Machinability Index shown in most waterjet feed rate calculators defines the relative cutting rates of different materials. Materials with higher numbers cut proportionately faster than lower numbers. Mild steel has a baseline value of one. Stainless steel at 0.9 would indicate that it cuts about 10% slower than mild steel to achieve similar edge quality and tolerance results.\r\n\r\nIf you know the machinability indexes of two materials, you can estimate fairly easily a good cutting speed of one material from the other. We know that the Machinability Index of stainless steel is 0.9 and below we see that Aluminum’s Machinability Index is 2.9. You know that ½” stainless cuts at 5.5 ipm for the edge quality you want. You want to know the speed for ½” Aluminum. Divide the machinability of Aluminum by the machinability of stainless. 2.9 ÷ 0.9 = 3.2. Multiply the cutting speed for Stainless by 3.2 for the cutting speed in the same thickness of Aluminum. 5.5 ipm x 3.2 = 17.6 ipm. Therefore, 17.6 ipm would be a good place to start for ½” Aluminum.'),(72719,2968,'_content_blocks_17_description','field_6170d8cd9800c'),(72720,2968,'content_blocks_17_images_0_image','2966'),(72721,2968,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(72722,2968,'content_blocks_17_images_0_header',''),(72723,2968,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(72724,2968,'content_blocks_17_images_0_description',''),(72725,2968,'_content_blocks_17_images_0_description','field_6170d90398010'),(72726,2968,'content_blocks_17_images_1_image','2967'),(72727,2968,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(72728,2968,'content_blocks_17_images_1_header',''),(72729,2968,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(72730,2968,'content_blocks_17_images_1_description',''),(72731,2968,'_content_blocks_17_images_1_description','field_6170d90398010'),(72732,2968,'content_blocks_17_images','2'),(72733,2968,'_content_blocks_17_images','field_6170d8df9800d'),(72734,2968,'content_blocks_18_header','Summary'),(72735,2968,'_content_blocks_18_header','field_6170d8ba9800b'),(72736,2968,'content_blocks_18_description','In this chapter we looked at the three critical specifications of a high pressure pump: horsepower, pressure and water output. We reviewed how to figure out what size orifice to use based upon these pump specifications and how many cutting heads are being used. We covered the productivity increases and cost savings of using two smaller orifices versus one large orifice. Additionally, abrasive nozzle diameter selection was discussed in terms of the ratio to the orifice being used. Finally, we looked at waterjet feed rate calculators and how Machinability Indices can be used to extrapolate the cutting speed of one material from a different material.'),(72737,2968,'_content_blocks_18_description','field_6170d8cd9800c'),(72738,2968,'content_blocks_18_images',''),(72739,2968,'_content_blocks_18_images','field_6170d8df9800d'),(72741,2969,'_menu_item_type','post_type'),(72742,2969,'_menu_item_menu_item_parent','0'),(72743,2969,'_menu_item_object_id','2848'),(72744,2969,'_menu_item_object','page'),(72745,2969,'_menu_item_target',''),(72746,2969,'_menu_item_classes','a:1:{i:0;s:0:\"\";}'),(72747,2969,'_menu_item_xfn',''),(72748,2969,'_menu_item_url',''),(72750,2794,'_wp_old_date','2021-10-25'),(72752,2828,'_wp_old_date','2021-10-25'),(72753,2827,'_wp_old_date','2021-10-25'),(72754,2847,'_wp_old_date','2021-10-25'),(72755,2970,'inline_featured_image','0'),(72756,2970,'_wpml_word_count','{\"total\":193,\"to_translate\":{\"fr\":193,\"es\":193}}'),(72757,2970,'_edit_lock','1646921117:3'),(72758,2971,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Intensifier-Cut-Away.jpg'),(72759,2971,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:630;s:6:\"height\";i:315;s:4:\"file\";s:67:\"2021/11/Waterjet-University_Waterjet-Pumps-Intensifier-Cut-Away.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"1\";s:8:\"keywords\";a:0:{}}}'),(72760,2972,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Pressuration-Process-2.jpg'),(72761,2972,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:630;s:6:\"height\";i:269;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Waterjet-Pumps-Pressuration-Process-2.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72762,2973,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Pressuration-Process.jpg'),(72763,2973,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:630;s:6:\"height\";i:227;s:4:\"file\";s:67:\"2021/11/Waterjet-University_Waterjet-Pumps-Pressuration-Process.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72764,2970,'_wp_page_template','wardjet-university-1.php'),(72765,2970,'_edit_last','3'),(72766,2970,'_yoast_wpseo_estimated-reading-time-minutes',''),(72767,2970,'hero_gallery',''),(72768,2970,'_hero_gallery','field_60c23d554e4a3'),(72769,2970,'hero_banner','6934'),(72770,2970,'_hero_banner','field_6170dbe179470'),(72771,2970,'page_title','Pumps'),(72772,2970,'_page_title','field_6170d88998008'),(72773,2970,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(72774,2970,'_page_description','field_6170d89398009'),(72775,2970,'content_blocks_0_header','High pressure waterjet cutting'),(72776,2970,'_content_blocks_0_header','field_6170d8ba9800b'),(72777,2970,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(72778,2970,'_content_blocks_0_description','field_6170d8cd9800c'),(72779,2970,'content_blocks_0_images',''),(72780,2970,'_content_blocks_0_images','field_6170d8df9800d'),(72781,2970,'content_blocks_1_header','Types of pumps'),(72782,2970,'_content_blocks_1_header','field_6170d8ba9800b'),(72783,2970,'content_blocks_1_description',''),(72784,2970,'_content_blocks_1_description','field_6170d8cd9800c'),(72785,2970,'content_blocks_1_images',''),(72786,2970,'_content_blocks_1_images','field_6170d8df9800d'),(72787,2970,'content_blocks_2_header','Intensifier'),(72788,2970,'_content_blocks_2_header','field_6170d8ba9800b'),(72789,2970,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(72790,2970,'_content_blocks_2_description','field_6170d8cd9800c'),(72791,2970,'content_blocks_2_images_0_image','2971'),(72792,2970,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(72793,2970,'content_blocks_2_images_0_header',''),(72794,2970,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(72795,2970,'content_blocks_2_images_0_description',''),(72796,2970,'_content_blocks_2_images_0_description','field_6170d90398010'),(72797,2970,'content_blocks_2_images','1'),(72798,2970,'_content_blocks_2_images','field_6170d8df9800d'),(72799,2970,'content_blocks_3_header','The pressurization process'),(72800,2970,'_content_blocks_3_header','field_6170d8ba9800b'),(72801,2970,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(72802,2970,'_content_blocks_3_description','field_6170d8cd9800c'),(72803,2970,'content_blocks_3_images_0_image','2972'),(72804,2970,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(72805,2970,'content_blocks_3_images_0_header',''),(72806,2970,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(72807,2970,'content_blocks_3_images_0_description',''),(72808,2970,'_content_blocks_3_images_0_description','field_6170d90398010'),(72809,2970,'content_blocks_3_images_1_image','2973'),(72810,2970,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(72811,2970,'content_blocks_3_images_1_header',''),(72812,2970,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(72813,2970,'content_blocks_3_images_1_description',''),(72814,2970,'_content_blocks_3_images_1_description','field_6170d90398010'),(72815,2970,'content_blocks_3_images','2'),(72816,2970,'_content_blocks_3_images','field_6170d8df9800d'),(72817,2970,'content_blocks','24'),(72818,2970,'_content_blocks','field_6170d8ac9800a'),(72819,2970,'menu','37'),(72820,2970,'_menu','field_6170d9e059837'),(72821,2970,'display_left_column','1'),(72822,2970,'_display_left_column','field_613563c4d424b'),(72823,2970,'contact_left_heading',''),(72824,2970,'_contact_left_heading','field_60c249d645c99'),(72825,2970,'contact_left_copy',''),(72826,2970,'_contact_left_copy','field_60c24a0845c9c'),(72827,2970,'display_right_column','1'),(72828,2970,'_display_right_column','field_613563f4d424c'),(72829,2970,'contact_right_heading',''),(72830,2970,'_contact_right_heading','field_60c249e945c9a'),(72831,2970,'contact_right_copy',''),(72832,2970,'_contact_right_copy','field_60c249f845c9b'),(72833,2970,'contact_right_cta',''),(72834,2970,'_contact_right_cta','field_60c24a1945c9d'),(72835,2975,'hero_gallery',''),(72836,2975,'_hero_gallery','field_60c23d554e4a3'),(72837,2975,'hero_banner',''),(72838,2975,'_hero_banner','field_6170dbe179470'),(72839,2975,'page_title','Pumps'),(72840,2975,'_page_title','field_6170d88998008'),(72841,2975,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(72842,2975,'_page_description','field_6170d89398009'),(72843,2975,'content_blocks_0_header','High pressure waterjet cutting'),(72844,2975,'_content_blocks_0_header','field_6170d8ba9800b'),(72845,2975,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(72846,2975,'_content_blocks_0_description','field_6170d8cd9800c'),(72847,2975,'content_blocks_0_images',''),(72848,2975,'_content_blocks_0_images','field_6170d8df9800d'),(72849,2975,'content_blocks_1_header','Types of pumps'),(72850,2975,'_content_blocks_1_header','field_6170d8ba9800b'),(72851,2975,'content_blocks_1_description',''),(72852,2975,'_content_blocks_1_description','field_6170d8cd9800c'),(72853,2975,'content_blocks_1_images',''),(72854,2975,'_content_blocks_1_images','field_6170d8df9800d'),(72855,2975,'content_blocks_2_header','Intensifier'),(72856,2975,'_content_blocks_2_header','field_6170d8ba9800b'),(72857,2975,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(72858,2975,'_content_blocks_2_description','field_6170d8cd9800c'),(72859,2975,'content_blocks_2_images_0_image','2971'),(72860,2975,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(72861,2975,'content_blocks_2_images_0_header',''),(72862,2975,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(72863,2975,'content_blocks_2_images_0_description',''),(72864,2975,'_content_blocks_2_images_0_description','field_6170d90398010'),(72865,2975,'content_blocks_2_images','1'),(72866,2975,'_content_blocks_2_images','field_6170d8df9800d'),(72867,2975,'content_blocks_3_header','The pressurization process'),(72868,2975,'_content_blocks_3_header','field_6170d8ba9800b'),(72869,2975,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(72870,2975,'_content_blocks_3_description','field_6170d8cd9800c'),(72871,2975,'content_blocks_3_images_0_image','2972'),(72872,2975,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(72873,2975,'content_blocks_3_images_0_header',''),(72874,2975,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(72875,2975,'content_blocks_3_images_0_description',''),(72876,2975,'_content_blocks_3_images_0_description','field_6170d90398010'),(72877,2975,'content_blocks_3_images_1_image','2973'),(72878,2975,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(72879,2975,'content_blocks_3_images_1_header',''),(72880,2975,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(72881,2975,'content_blocks_3_images_1_description',''),(72882,2975,'_content_blocks_3_images_1_description','field_6170d90398010'),(72883,2975,'content_blocks_3_images','2'),(72884,2975,'_content_blocks_3_images','field_6170d8df9800d'),(72885,2975,'content_blocks','4'),(72886,2975,'_content_blocks','field_6170d8ac9800a'),(72887,2975,'menu','11'),(72888,2975,'_menu','field_6170d9e059837'),(72889,2975,'display_left_column','1'),(72890,2975,'_display_left_column','field_613563c4d424b'),(72891,2975,'contact_left_heading',''),(72892,2975,'_contact_left_heading','field_60c249d645c99'),(72893,2975,'contact_left_copy',''),(72894,2975,'_contact_left_copy','field_60c24a0845c9c'),(72895,2975,'display_right_column','1'),(72896,2975,'_display_right_column','field_613563f4d424c'),(72897,2975,'contact_right_heading',''),(72898,2975,'_contact_right_heading','field_60c249e945c9a'),(72899,2975,'contact_right_copy',''),(72900,2975,'_contact_right_copy','field_60c249f845c9b'),(72901,2975,'contact_right_cta',''),(72902,2975,'_contact_right_cta','field_60c24a1945c9d'),(72904,2970,'_wpml_media_featured','0'),(72905,2970,'_wpml_media_duplicate','0'),(72906,2973,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(72907,2972,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(72908,2971,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(72909,2976,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Process-1.jpg'),(72910,2976,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:586;s:6:\"height\";i:284;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Process-1.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72911,2977,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Process-3.jpg'),(72912,2977,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:390;s:6:\"height\";i:270;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Process-3.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(72913,2977,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(72914,2976,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(72915,2970,'content_blocks_4_header','Direct Drive'),(72916,2970,'_content_blocks_4_header','field_6170d8ba9800b'),(72917,2970,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(72918,2970,'_content_blocks_4_description','field_6170d8cd9800c'),(72919,2970,'content_blocks_4_images_0_image','2976'),(72920,2970,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(72921,2970,'content_blocks_4_images_0_header',''),(72922,2970,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(72923,2970,'content_blocks_4_images_0_description',''),(72924,2970,'_content_blocks_4_images_0_description','field_6170d90398010'),(72925,2970,'content_blocks_4_images_1_image','2977'),(72926,2970,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(72927,2970,'content_blocks_4_images_1_header',''),(72928,2970,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(72929,2970,'content_blocks_4_images_1_description',''),(72930,2970,'_content_blocks_4_images_1_description','field_6170d90398010'),(72931,2970,'content_blocks_4_images','2'),(72932,2970,'_content_blocks_4_images','field_6170d8df9800d'),(72933,2978,'hero_gallery',''),(72934,2978,'_hero_gallery','field_60c23d554e4a3'),(72935,2978,'hero_banner',''),(72936,2978,'_hero_banner','field_6170dbe179470'),(72937,2978,'page_title','Pumps'),(72938,2978,'_page_title','field_6170d88998008'),(72939,2978,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(72940,2978,'_page_description','field_6170d89398009'),(72941,2978,'content_blocks_0_header','High pressure waterjet cutting'),(72942,2978,'_content_blocks_0_header','field_6170d8ba9800b'),(72943,2978,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(72944,2978,'_content_blocks_0_description','field_6170d8cd9800c'),(72945,2978,'content_blocks_0_images',''),(72946,2978,'_content_blocks_0_images','field_6170d8df9800d'),(72947,2978,'content_blocks_1_header','Types of pumps'),(72948,2978,'_content_blocks_1_header','field_6170d8ba9800b'),(72949,2978,'content_blocks_1_description',''),(72950,2978,'_content_blocks_1_description','field_6170d8cd9800c'),(72951,2978,'content_blocks_1_images',''),(72952,2978,'_content_blocks_1_images','field_6170d8df9800d'),(72953,2978,'content_blocks_2_header','Intensifier'),(72954,2978,'_content_blocks_2_header','field_6170d8ba9800b'),(72955,2978,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(72956,2978,'_content_blocks_2_description','field_6170d8cd9800c'),(72957,2978,'content_blocks_2_images_0_image','2971'),(72958,2978,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(72959,2978,'content_blocks_2_images_0_header',''),(72960,2978,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(72961,2978,'content_blocks_2_images_0_description',''),(72962,2978,'_content_blocks_2_images_0_description','field_6170d90398010'),(72963,2978,'content_blocks_2_images','1'),(72964,2978,'_content_blocks_2_images','field_6170d8df9800d'),(72965,2978,'content_blocks_3_header','The pressurization process'),(72966,2978,'_content_blocks_3_header','field_6170d8ba9800b'),(72967,2978,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(72968,2978,'_content_blocks_3_description','field_6170d8cd9800c'),(72969,2978,'content_blocks_3_images_0_image','2972'),(72970,2978,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(72971,2978,'content_blocks_3_images_0_header',''),(72972,2978,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(72973,2978,'content_blocks_3_images_0_description',''),(72974,2978,'_content_blocks_3_images_0_description','field_6170d90398010'),(72975,2978,'content_blocks_3_images_1_image','2973'),(72976,2978,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(72977,2978,'content_blocks_3_images_1_header',''),(72978,2978,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(72979,2978,'content_blocks_3_images_1_description',''),(72980,2978,'_content_blocks_3_images_1_description','field_6170d90398010'),(72981,2978,'content_blocks_3_images','2'),(72982,2978,'_content_blocks_3_images','field_6170d8df9800d'),(72983,2978,'content_blocks','5'),(72984,2978,'_content_blocks','field_6170d8ac9800a'),(72985,2978,'menu','11'),(72986,2978,'_menu','field_6170d9e059837'),(72987,2978,'display_left_column','1'),(72988,2978,'_display_left_column','field_613563c4d424b'),(72989,2978,'contact_left_heading',''),(72990,2978,'_contact_left_heading','field_60c249d645c99'),(72991,2978,'contact_left_copy',''),(72992,2978,'_contact_left_copy','field_60c24a0845c9c'),(72993,2978,'display_right_column','1'),(72994,2978,'_display_right_column','field_613563f4d424c'),(72995,2978,'contact_right_heading',''),(72996,2978,'_contact_right_heading','field_60c249e945c9a'),(72997,2978,'contact_right_copy',''),(72998,2978,'_contact_right_copy','field_60c249f845c9b'),(72999,2978,'contact_right_cta',''),(73000,2978,'_contact_right_cta','field_60c24a1945c9d'),(73001,2978,'content_blocks_4_header','Direct Drive'),(73002,2978,'_content_blocks_4_header','field_6170d8ba9800b'),(73003,2978,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(73004,2978,'_content_blocks_4_description','field_6170d8cd9800c'),(73005,2978,'content_blocks_4_images_0_image','2976'),(73006,2978,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(73007,2978,'content_blocks_4_images_0_header',''),(73008,2978,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(73009,2978,'content_blocks_4_images_0_description',''),(73010,2978,'_content_blocks_4_images_0_description','field_6170d90398010'),(73011,2978,'content_blocks_4_images_1_image','2977'),(73012,2978,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(73013,2978,'content_blocks_4_images_1_header',''),(73014,2978,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(73015,2978,'content_blocks_4_images_1_description',''),(73016,2978,'_content_blocks_4_images_1_description','field_6170d90398010'),(73017,2978,'content_blocks_4_images','2'),(73018,2978,'_content_blocks_4_images','field_6170d8df9800d'),(73020,2979,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Graphic-1.jpg'),(73021,2979,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:258;s:6:\"height\";i:316;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Graphic-1.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"1\";s:8:\"keywords\";a:0:{}}}'),(73022,2980,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Graphic-2.png'),(73023,2980,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:646;s:6:\"height\";i:401;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Waterjet-Pumps-Direct-Drive-Graphic-2.png\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73024,2981,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Electric-motor-and-hydraulic-pump.jpg'),(73025,2981,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:550;s:6:\"height\";i:463;s:4:\"file\";s:80:\"2021/11/Waterjet-University_Waterjet-Pumps-Electric-motor-and-hydraulic-pump.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73026,2982,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Directional-control-valves.jpg'),(73027,2982,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:519;s:6:\"height\";i:389;s:4:\"file\";s:73:\"2021/11/Waterjet-University_Waterjet-Pumps-Directional-control-valves.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73028,2982,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73029,2981,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73030,2980,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73031,2979,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73032,2970,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(73033,2970,'_content_blocks_5_header','field_6170d8ba9800b'),(73034,2970,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(73035,2970,'_content_blocks_5_description','field_6170d8cd9800c'),(73036,2970,'content_blocks_5_images_0_image','2979'),(73037,2970,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(73038,2970,'content_blocks_5_images_0_header',''),(73039,2970,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(73040,2970,'content_blocks_5_images_0_description',''),(73041,2970,'_content_blocks_5_images_0_description','field_6170d90398010'),(73042,2970,'content_blocks_5_images_1_image','2980'),(73043,2970,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(73044,2970,'content_blocks_5_images_1_header',''),(73045,2970,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(73046,2970,'content_blocks_5_images_1_description',''),(73047,2970,'_content_blocks_5_images_1_description','field_6170d90398010'),(73048,2970,'content_blocks_5_images','2'),(73049,2970,'_content_blocks_5_images','field_6170d8df9800d'),(73050,2970,'content_blocks_6_header','Parts of the intensifier pump'),(73051,2970,'_content_blocks_6_header','field_6170d8ba9800b'),(73052,2970,'content_blocks_6_description',''),(73053,2970,'_content_blocks_6_description','field_6170d8cd9800c'),(73054,2970,'content_blocks_6_images',''),(73055,2970,'_content_blocks_6_images','field_6170d8df9800d'),(73056,2970,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(73057,2970,'_content_blocks_7_header','field_6170d8ba9800b'),(73058,2970,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(73059,2970,'_content_blocks_7_description','field_6170d8cd9800c'),(73060,2970,'content_blocks_7_images_0_image','2981'),(73061,2970,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(73062,2970,'content_blocks_7_images_0_header',''),(73063,2970,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(73064,2970,'content_blocks_7_images_0_description',''),(73065,2970,'_content_blocks_7_images_0_description','field_6170d90398010'),(73066,2970,'content_blocks_7_images','1'),(73067,2970,'_content_blocks_7_images','field_6170d8df9800d'),(73068,2970,'content_blocks_8_header','2. Directional control valves'),(73069,2970,'_content_blocks_8_header','field_6170d8ba9800b'),(73070,2970,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(73071,2970,'_content_blocks_8_description','field_6170d8cd9800c'),(73072,2970,'content_blocks_8_images_0_image','2982'),(73073,2970,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(73074,2970,'content_blocks_8_images_0_header',''),(73075,2970,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(73076,2970,'content_blocks_8_images_0_description',''),(73077,2970,'_content_blocks_8_images_0_description','field_6170d90398010'),(73078,2970,'content_blocks_8_images','1'),(73079,2970,'_content_blocks_8_images','field_6170d8df9800d'),(73080,2983,'hero_gallery',''),(73081,2983,'_hero_gallery','field_60c23d554e4a3'),(73082,2983,'hero_banner',''),(73083,2983,'_hero_banner','field_6170dbe179470'),(73084,2983,'page_title','Pumps'),(73085,2983,'_page_title','field_6170d88998008'),(73086,2983,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(73087,2983,'_page_description','field_6170d89398009'),(73088,2983,'content_blocks_0_header','High pressure waterjet cutting'),(73089,2983,'_content_blocks_0_header','field_6170d8ba9800b'),(73090,2983,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(73091,2983,'_content_blocks_0_description','field_6170d8cd9800c'),(73092,2983,'content_blocks_0_images',''),(73093,2983,'_content_blocks_0_images','field_6170d8df9800d'),(73094,2983,'content_blocks_1_header','Types of pumps'),(73095,2983,'_content_blocks_1_header','field_6170d8ba9800b'),(73096,2983,'content_blocks_1_description',''),(73097,2983,'_content_blocks_1_description','field_6170d8cd9800c'),(73098,2983,'content_blocks_1_images',''),(73099,2983,'_content_blocks_1_images','field_6170d8df9800d'),(73100,2983,'content_blocks_2_header','Intensifier'),(73101,2983,'_content_blocks_2_header','field_6170d8ba9800b'),(73102,2983,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(73103,2983,'_content_blocks_2_description','field_6170d8cd9800c'),(73104,2983,'content_blocks_2_images_0_image','2971'),(73105,2983,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(73106,2983,'content_blocks_2_images_0_header',''),(73107,2983,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(73108,2983,'content_blocks_2_images_0_description',''),(73109,2983,'_content_blocks_2_images_0_description','field_6170d90398010'),(73110,2983,'content_blocks_2_images','1'),(73111,2983,'_content_blocks_2_images','field_6170d8df9800d'),(73112,2983,'content_blocks_3_header','The pressurization process'),(73113,2983,'_content_blocks_3_header','field_6170d8ba9800b'),(73114,2983,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(73115,2983,'_content_blocks_3_description','field_6170d8cd9800c'),(73116,2983,'content_blocks_3_images_0_image','2972'),(73117,2983,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(73118,2983,'content_blocks_3_images_0_header',''),(73119,2983,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(73120,2983,'content_blocks_3_images_0_description',''),(73121,2983,'_content_blocks_3_images_0_description','field_6170d90398010'),(73122,2983,'content_blocks_3_images_1_image','2973'),(73123,2983,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(73124,2983,'content_blocks_3_images_1_header',''),(73125,2983,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(73126,2983,'content_blocks_3_images_1_description',''),(73127,2983,'_content_blocks_3_images_1_description','field_6170d90398010'),(73128,2983,'content_blocks_3_images','2'),(73129,2983,'_content_blocks_3_images','field_6170d8df9800d'),(73130,2983,'content_blocks','9'),(73131,2983,'_content_blocks','field_6170d8ac9800a'),(73132,2983,'menu','11'),(73133,2983,'_menu','field_6170d9e059837'),(73134,2983,'display_left_column','1'),(73135,2983,'_display_left_column','field_613563c4d424b'),(73136,2983,'contact_left_heading',''),(73137,2983,'_contact_left_heading','field_60c249d645c99'),(73138,2983,'contact_left_copy',''),(73139,2983,'_contact_left_copy','field_60c24a0845c9c'),(73140,2983,'display_right_column','1'),(73141,2983,'_display_right_column','field_613563f4d424c'),(73142,2983,'contact_right_heading',''),(73143,2983,'_contact_right_heading','field_60c249e945c9a'),(73144,2983,'contact_right_copy',''),(73145,2983,'_contact_right_copy','field_60c249f845c9b'),(73146,2983,'contact_right_cta',''),(73147,2983,'_contact_right_cta','field_60c24a1945c9d'),(73148,2983,'content_blocks_4_header','Direct Drive'),(73149,2983,'_content_blocks_4_header','field_6170d8ba9800b'),(73150,2983,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(73151,2983,'_content_blocks_4_description','field_6170d8cd9800c'),(73152,2983,'content_blocks_4_images_0_image','2976'),(73153,2983,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(73154,2983,'content_blocks_4_images_0_header',''),(73155,2983,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(73156,2983,'content_blocks_4_images_0_description',''),(73157,2983,'_content_blocks_4_images_0_description','field_6170d90398010'),(73158,2983,'content_blocks_4_images_1_image','2977'),(73159,2983,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(73160,2983,'content_blocks_4_images_1_header',''),(73161,2983,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(73162,2983,'content_blocks_4_images_1_description',''),(73163,2983,'_content_blocks_4_images_1_description','field_6170d90398010'),(73164,2983,'content_blocks_4_images','2'),(73165,2983,'_content_blocks_4_images','field_6170d8df9800d'),(73166,2983,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(73167,2983,'_content_blocks_5_header','field_6170d8ba9800b'),(73168,2983,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(73169,2983,'_content_blocks_5_description','field_6170d8cd9800c'),(73170,2983,'content_blocks_5_images_0_image','2979'),(73171,2983,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(73172,2983,'content_blocks_5_images_0_header',''),(73173,2983,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(73174,2983,'content_blocks_5_images_0_description',''),(73175,2983,'_content_blocks_5_images_0_description','field_6170d90398010'),(73176,2983,'content_blocks_5_images_1_image','2980'),(73177,2983,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(73178,2983,'content_blocks_5_images_1_header',''),(73179,2983,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(73180,2983,'content_blocks_5_images_1_description',''),(73181,2983,'_content_blocks_5_images_1_description','field_6170d90398010'),(73182,2983,'content_blocks_5_images','2'),(73183,2983,'_content_blocks_5_images','field_6170d8df9800d'),(73184,2983,'content_blocks_6_header','Parts of the intensifier pump'),(73185,2983,'_content_blocks_6_header','field_6170d8ba9800b'),(73186,2983,'content_blocks_6_description',''),(73187,2983,'_content_blocks_6_description','field_6170d8cd9800c'),(73188,2983,'content_blocks_6_images',''),(73189,2983,'_content_blocks_6_images','field_6170d8df9800d'),(73190,2983,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(73191,2983,'_content_blocks_7_header','field_6170d8ba9800b'),(73192,2983,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(73193,2983,'_content_blocks_7_description','field_6170d8cd9800c'),(73194,2983,'content_blocks_7_images_0_image','2981'),(73195,2983,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(73196,2983,'content_blocks_7_images_0_header',''),(73197,2983,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(73198,2983,'content_blocks_7_images_0_description',''),(73199,2983,'_content_blocks_7_images_0_description','field_6170d90398010'),(73200,2983,'content_blocks_7_images','1'),(73201,2983,'_content_blocks_7_images','field_6170d8df9800d'),(73202,2983,'content_blocks_8_header','2. Directional control valves'),(73203,2983,'_content_blocks_8_header','field_6170d8ba9800b'),(73204,2983,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(73205,2983,'_content_blocks_8_description','field_6170d8cd9800c'),(73206,2983,'content_blocks_8_images_0_image','2982'),(73207,2983,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(73208,2983,'content_blocks_8_images_0_header',''),(73209,2983,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(73210,2983,'content_blocks_8_images_0_description',''),(73211,2983,'_content_blocks_8_images_0_description','field_6170d90398010'),(73212,2983,'content_blocks_8_images','1'),(73213,2983,'_content_blocks_8_images','field_6170d8df9800d'),(73215,2984,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-High-pressure-cylinder.jpg'),(73216,2984,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:612;s:6:\"height\";i:229;s:4:\"file\";s:69:\"2021/11/Waterjet-University_Waterjet-Pumps-High-pressure-cylinder.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73217,2985,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Hydraulic-cylinder.jpg'),(73218,2985,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:301;s:6:\"height\";i:240;s:4:\"file\";s:65:\"2021/11/Waterjet-University_Waterjet-Pumps-Hydraulic-cylinder.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73219,2986,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Piston.jpg'),(73220,2986,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:468;s:6:\"height\";i:318;s:4:\"file\";s:53:\"2021/11/Waterjet-University_Waterjet-Pumps-Piston.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73221,2987,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Plunger.jpg'),(73222,2987,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:564;s:6:\"height\";i:240;s:4:\"file\";s:54:\"2021/11/Waterjet-University_Waterjet-Pumps-Plunger.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73223,2988,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Check-valve-Cross-Section.jpg'),(73224,2988,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:300;s:6:\"height\";i:256;s:4:\"file\";s:72:\"2021/11/Waterjet-University_Waterjet-Pumps-Check-valve-Cross-Section.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73225,2989,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Check-valve-body.jpg'),(73226,2989,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:300;s:6:\"height\";i:246;s:4:\"file\";s:63:\"2021/11/Waterjet-University_Waterjet-Pumps-Check-valve-body.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73227,2989,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73228,2988,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73229,2987,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73230,2986,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73231,2985,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73232,2984,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73233,2970,'content_blocks_9_header','3. Intensifier'),(73234,2970,'_content_blocks_9_header','field_6170d8ba9800b'),(73235,2970,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(73236,2970,'_content_blocks_9_description','field_6170d8cd9800c'),(73237,2970,'content_blocks_9_images_0_image','2984'),(73238,2970,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(73239,2970,'content_blocks_9_images_0_header',''),(73240,2970,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(73241,2970,'content_blocks_9_images_0_description',''),(73242,2970,'_content_blocks_9_images_0_description','field_6170d90398010'),(73243,2970,'content_blocks_9_images','1'),(73244,2970,'_content_blocks_9_images','field_6170d8df9800d'),(73245,2970,'content_blocks_10_header','4. Hydraulic cylinder'),(73246,2970,'_content_blocks_10_header','field_6170d8ba9800b'),(73247,2970,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(73248,2970,'_content_blocks_10_description','field_6170d8cd9800c'),(73249,2970,'content_blocks_10_images_0_image','2985'),(73250,2970,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(73251,2970,'content_blocks_10_images_0_header',''),(73252,2970,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(73253,2970,'content_blocks_10_images_0_description',''),(73254,2970,'_content_blocks_10_images_0_description','field_6170d90398010'),(73255,2970,'content_blocks_10_images','1'),(73256,2970,'_content_blocks_10_images','field_6170d8df9800d'),(73257,2970,'content_blocks_11_header','5. Piston'),(73258,2970,'_content_blocks_11_header','field_6170d8ba9800b'),(73259,2970,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(73260,2970,'_content_blocks_11_description','field_6170d8cd9800c'),(73261,2970,'content_blocks_11_images_0_image','2986'),(73262,2970,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(73263,2970,'content_blocks_11_images_0_header',''),(73264,2970,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(73265,2970,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(73266,2970,'_content_blocks_11_images_0_description','field_6170d90398010'),(73267,2970,'content_blocks_11_images','1'),(73268,2970,'_content_blocks_11_images','field_6170d8df9800d'),(73269,2970,'content_blocks_12_header','6. Plunger'),(73270,2970,'_content_blocks_12_header','field_6170d8ba9800b'),(73271,2970,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(73272,2970,'_content_blocks_12_description','field_6170d8cd9800c'),(73273,2970,'content_blocks_12_images_0_image','2987'),(73274,2970,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(73275,2970,'content_blocks_12_images_0_header',''),(73276,2970,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(73277,2970,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(73278,2970,'_content_blocks_12_images_0_description','field_6170d90398010'),(73279,2970,'content_blocks_12_images','1'),(73280,2970,'_content_blocks_12_images','field_6170d8df9800d'),(73281,2970,'content_blocks_13_header','7. High pressure cylinder'),(73282,2970,'_content_blocks_13_header','field_6170d8ba9800b'),(73283,2970,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(73284,2970,'_content_blocks_13_description','field_6170d8cd9800c'),(73285,2970,'content_blocks_13_images_0_image','2984'),(73286,2970,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(73287,2970,'content_blocks_13_images_0_header',''),(73288,2970,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(73289,2970,'content_blocks_13_images_0_description',''),(73290,2970,'_content_blocks_13_images_0_description','field_6170d90398010'),(73291,2970,'content_blocks_13_images','1'),(73292,2970,'_content_blocks_13_images','field_6170d8df9800d'),(73293,2970,'content_blocks_14_header','8. Check valve'),(73294,2970,'_content_blocks_14_header','field_6170d8ba9800b'),(73295,2970,'content_blocks_14_description','There is one check valve (number 8 in Figures 10 and 8) at the end of each high pressure cylinder at the end opposite from the hydraulic cylinder. The check valve allows fresh water to enter the high pressure cylinder and high pressure water to exit the intensifier. The check valve is designed to only let water flow in one direction. Fresh water comes in though channels machined in the sides and exits through one or more holes in the face of the valve. Various seals, poppets and springs are used to maintain this water flow. Over several hundred hours these components will wear, allowing pressurized water to flow out the water inlet path, or allowing pressurized water to seep back into the high pressure cylinder. The symptoms and diagnosis of these various situations will be discussed later in the \"Maintenance\" chapter.'),(73296,2970,'_content_blocks_14_description','field_6170d8cd9800c'),(73297,2970,'content_blocks_14_images_0_image','2988'),(73298,2970,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(73299,2970,'content_blocks_14_images_0_header',''),(73300,2970,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(73301,2970,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(73302,2970,'_content_blocks_14_images_0_description','field_6170d90398010'),(73303,2970,'content_blocks_14_images_1_image','2989'),(73304,2970,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(73305,2970,'content_blocks_14_images_1_header',''),(73306,2970,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(73307,2970,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(73308,2970,'_content_blocks_14_images_1_description','field_6170d90398010'),(73309,2970,'content_blocks_14_images','3'),(73310,2970,'_content_blocks_14_images','field_6170d8df9800d'),(73311,2990,'hero_gallery',''),(73312,2990,'_hero_gallery','field_60c23d554e4a3'),(73313,2990,'hero_banner',''),(73314,2990,'_hero_banner','field_6170dbe179470'),(73315,2990,'page_title','Pumps'),(73316,2990,'_page_title','field_6170d88998008'),(73317,2990,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(73318,2990,'_page_description','field_6170d89398009'),(73319,2990,'content_blocks_0_header','High pressure waterjet cutting'),(73320,2990,'_content_blocks_0_header','field_6170d8ba9800b'),(73321,2990,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(73322,2990,'_content_blocks_0_description','field_6170d8cd9800c'),(73323,2990,'content_blocks_0_images',''),(73324,2990,'_content_blocks_0_images','field_6170d8df9800d'),(73325,2990,'content_blocks_1_header','Types of pumps'),(73326,2990,'_content_blocks_1_header','field_6170d8ba9800b'),(73327,2990,'content_blocks_1_description',''),(73328,2990,'_content_blocks_1_description','field_6170d8cd9800c'),(73329,2990,'content_blocks_1_images',''),(73330,2990,'_content_blocks_1_images','field_6170d8df9800d'),(73331,2990,'content_blocks_2_header','Intensifier'),(73332,2990,'_content_blocks_2_header','field_6170d8ba9800b'),(73333,2990,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(73334,2990,'_content_blocks_2_description','field_6170d8cd9800c'),(73335,2990,'content_blocks_2_images_0_image','2971'),(73336,2990,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(73337,2990,'content_blocks_2_images_0_header',''),(73338,2990,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(73339,2990,'content_blocks_2_images_0_description',''),(73340,2990,'_content_blocks_2_images_0_description','field_6170d90398010'),(73341,2990,'content_blocks_2_images','1'),(73342,2990,'_content_blocks_2_images','field_6170d8df9800d'),(73343,2990,'content_blocks_3_header','The pressurization process'),(73344,2990,'_content_blocks_3_header','field_6170d8ba9800b'),(73345,2990,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(73346,2990,'_content_blocks_3_description','field_6170d8cd9800c'),(73347,2990,'content_blocks_3_images_0_image','2972'),(73348,2990,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(73349,2990,'content_blocks_3_images_0_header',''),(73350,2990,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(73351,2990,'content_blocks_3_images_0_description',''),(73352,2990,'_content_blocks_3_images_0_description','field_6170d90398010'),(73353,2990,'content_blocks_3_images_1_image','2973'),(73354,2990,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(73355,2990,'content_blocks_3_images_1_header',''),(73356,2990,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(73357,2990,'content_blocks_3_images_1_description',''),(73358,2990,'_content_blocks_3_images_1_description','field_6170d90398010'),(73359,2990,'content_blocks_3_images','2'),(73360,2990,'_content_blocks_3_images','field_6170d8df9800d'),(73361,2990,'content_blocks','15'),(73362,2990,'_content_blocks','field_6170d8ac9800a'),(73363,2990,'menu','11'),(73364,2990,'_menu','field_6170d9e059837'),(73365,2990,'display_left_column','1'),(73366,2990,'_display_left_column','field_613563c4d424b'),(73367,2990,'contact_left_heading',''),(73368,2990,'_contact_left_heading','field_60c249d645c99'),(73369,2990,'contact_left_copy',''),(73370,2990,'_contact_left_copy','field_60c24a0845c9c'),(73371,2990,'display_right_column','1'),(73372,2990,'_display_right_column','field_613563f4d424c'),(73373,2990,'contact_right_heading',''),(73374,2990,'_contact_right_heading','field_60c249e945c9a'),(73375,2990,'contact_right_copy',''),(73376,2990,'_contact_right_copy','field_60c249f845c9b'),(73377,2990,'contact_right_cta',''),(73378,2990,'_contact_right_cta','field_60c24a1945c9d'),(73379,2990,'content_blocks_4_header','Direct Drive'),(73380,2990,'_content_blocks_4_header','field_6170d8ba9800b'),(73381,2990,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(73382,2990,'_content_blocks_4_description','field_6170d8cd9800c'),(73383,2990,'content_blocks_4_images_0_image','2976'),(73384,2990,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(73385,2990,'content_blocks_4_images_0_header',''),(73386,2990,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(73387,2990,'content_blocks_4_images_0_description',''),(73388,2990,'_content_blocks_4_images_0_description','field_6170d90398010'),(73389,2990,'content_blocks_4_images_1_image','2977'),(73390,2990,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(73391,2990,'content_blocks_4_images_1_header',''),(73392,2990,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(73393,2990,'content_blocks_4_images_1_description',''),(73394,2990,'_content_blocks_4_images_1_description','field_6170d90398010'),(73395,2990,'content_blocks_4_images','2'),(73396,2990,'_content_blocks_4_images','field_6170d8df9800d'),(73397,2990,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(73398,2990,'_content_blocks_5_header','field_6170d8ba9800b'),(73399,2990,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(73400,2990,'_content_blocks_5_description','field_6170d8cd9800c'),(73401,2990,'content_blocks_5_images_0_image','2979'),(73402,2990,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(73403,2990,'content_blocks_5_images_0_header',''),(73404,2990,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(73405,2990,'content_blocks_5_images_0_description',''),(73406,2990,'_content_blocks_5_images_0_description','field_6170d90398010'),(73407,2990,'content_blocks_5_images_1_image','2980'),(73408,2990,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(73409,2990,'content_blocks_5_images_1_header',''),(73410,2990,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(73411,2990,'content_blocks_5_images_1_description',''),(73412,2990,'_content_blocks_5_images_1_description','field_6170d90398010'),(73413,2990,'content_blocks_5_images','2'),(73414,2990,'_content_blocks_5_images','field_6170d8df9800d'),(73415,2990,'content_blocks_6_header','Parts of the intensifier pump'),(73416,2990,'_content_blocks_6_header','field_6170d8ba9800b'),(73417,2990,'content_blocks_6_description',''),(73418,2990,'_content_blocks_6_description','field_6170d8cd9800c'),(73419,2990,'content_blocks_6_images',''),(73420,2990,'_content_blocks_6_images','field_6170d8df9800d'),(73421,2990,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(73422,2990,'_content_blocks_7_header','field_6170d8ba9800b'),(73423,2990,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(73424,2990,'_content_blocks_7_description','field_6170d8cd9800c'),(73425,2990,'content_blocks_7_images_0_image','2981'),(73426,2990,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(73427,2990,'content_blocks_7_images_0_header',''),(73428,2990,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(73429,2990,'content_blocks_7_images_0_description',''),(73430,2990,'_content_blocks_7_images_0_description','field_6170d90398010'),(73431,2990,'content_blocks_7_images','1'),(73432,2990,'_content_blocks_7_images','field_6170d8df9800d'),(73433,2990,'content_blocks_8_header','2. Directional control valves'),(73434,2990,'_content_blocks_8_header','field_6170d8ba9800b'),(73435,2990,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(73436,2990,'_content_blocks_8_description','field_6170d8cd9800c'),(73437,2990,'content_blocks_8_images_0_image','2982'),(73438,2990,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(73439,2990,'content_blocks_8_images_0_header',''),(73440,2990,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(73441,2990,'content_blocks_8_images_0_description',''),(73442,2990,'_content_blocks_8_images_0_description','field_6170d90398010'),(73443,2990,'content_blocks_8_images','1'),(73444,2990,'_content_blocks_8_images','field_6170d8df9800d'),(73445,2990,'content_blocks_9_header','3. Intensifier'),(73446,2990,'_content_blocks_9_header','field_6170d8ba9800b'),(73447,2990,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(73448,2990,'_content_blocks_9_description','field_6170d8cd9800c'),(73449,2990,'content_blocks_9_images_0_image','2984'),(73450,2990,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(73451,2990,'content_blocks_9_images_0_header',''),(73452,2990,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(73453,2990,'content_blocks_9_images_0_description',''),(73454,2990,'_content_blocks_9_images_0_description','field_6170d90398010'),(73455,2990,'content_blocks_9_images','1'),(73456,2990,'_content_blocks_9_images','field_6170d8df9800d'),(73457,2990,'content_blocks_10_header','4. Hydraulic cylinder'),(73458,2990,'_content_blocks_10_header','field_6170d8ba9800b'),(73459,2990,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(73460,2990,'_content_blocks_10_description','field_6170d8cd9800c'),(73461,2990,'content_blocks_10_images_0_image','2985'),(73462,2990,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(73463,2990,'content_blocks_10_images_0_header',''),(73464,2990,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(73465,2990,'content_blocks_10_images_0_description',''),(73466,2990,'_content_blocks_10_images_0_description','field_6170d90398010'),(73467,2990,'content_blocks_10_images','1'),(73468,2990,'_content_blocks_10_images','field_6170d8df9800d'),(73469,2990,'content_blocks_11_header','5. Piston'),(73470,2990,'_content_blocks_11_header','field_6170d8ba9800b'),(73471,2990,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(73472,2990,'_content_blocks_11_description','field_6170d8cd9800c'),(73473,2990,'content_blocks_11_images_0_image','2986'),(73474,2990,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(73475,2990,'content_blocks_11_images_0_header',''),(73476,2990,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(73477,2990,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(73478,2990,'_content_blocks_11_images_0_description','field_6170d90398010'),(73479,2990,'content_blocks_11_images','1'),(73480,2990,'_content_blocks_11_images','field_6170d8df9800d'),(73481,2990,'content_blocks_12_header','6. Plunger'),(73482,2990,'_content_blocks_12_header','field_6170d8ba9800b'),(73483,2990,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(73484,2990,'_content_blocks_12_description','field_6170d8cd9800c'),(73485,2990,'content_blocks_12_images_0_image','2987'),(73486,2990,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(73487,2990,'content_blocks_12_images_0_header',''),(73488,2990,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(73489,2990,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(73490,2990,'_content_blocks_12_images_0_description','field_6170d90398010'),(73491,2990,'content_blocks_12_images','1'),(73492,2990,'_content_blocks_12_images','field_6170d8df9800d'),(73493,2990,'content_blocks_13_header','7. High pressure cylinder'),(73494,2990,'_content_blocks_13_header','field_6170d8ba9800b'),(73495,2990,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(73496,2990,'_content_blocks_13_description','field_6170d8cd9800c'),(73497,2990,'content_blocks_13_images_0_image','2984'),(73498,2990,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(73499,2990,'content_blocks_13_images_0_header',''),(73500,2990,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(73501,2990,'content_blocks_13_images_0_description',''),(73502,2990,'_content_blocks_13_images_0_description','field_6170d90398010'),(73503,2990,'content_blocks_13_images','1'),(73504,2990,'_content_blocks_13_images','field_6170d8df9800d'),(73505,2990,'content_blocks_14_header','8. Check valve'),(73506,2990,'_content_blocks_14_header','field_6170d8ba9800b'),(73507,2990,'content_blocks_14_description',''),(73508,2990,'_content_blocks_14_description','field_6170d8cd9800c'),(73509,2990,'content_blocks_14_images_0_image','2988'),(73510,2990,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(73511,2990,'content_blocks_14_images_0_header',''),(73512,2990,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(73513,2990,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(73514,2990,'_content_blocks_14_images_0_description','field_6170d90398010'),(73515,2990,'content_blocks_14_images_1_image','2989'),(73516,2990,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(73517,2990,'content_blocks_14_images_1_header',''),(73518,2990,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(73519,2990,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(73520,2990,'_content_blocks_14_images_1_description','field_6170d90398010'),(73521,2990,'content_blocks_14_images','2'),(73522,2990,'_content_blocks_14_images','field_6170d8df9800d'),(73524,2991,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-upper-portion-of-intensifier-cabinet.jpg'),(73525,2991,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:585;s:6:\"height\";i:398;s:4:\"file\";s:83:\"2021/11/Waterjet-University_Waterjet-Pumps-upper-portion-of-intensifier-cabinet.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73526,2992,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-End-Cap.jpg'),(73527,2992,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:630;s:6:\"height\";i:251;s:4:\"file\";s:54:\"2021/11/Waterjet-University_Waterjet-Pumps-End-Cap.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73528,2992,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73529,2991,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73530,2970,'content_blocks_14_images_2_image','2991'),(73531,2970,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(73532,2970,'content_blocks_14_images_2_header',''),(73533,2970,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(73534,2970,'content_blocks_14_images_2_description','Figure 11 - View of upper portion of intensifier cabinet'),(73535,2970,'_content_blocks_14_images_2_description','field_6170d90398010'),(73536,2970,'content_blocks_15_header','End Cap'),(73537,2970,'_content_blocks_15_header','field_6170d8ba9800b'),(73538,2970,'content_blocks_15_description','The end cap (number 9 in Figures 11 and 2) is either a cylindrical or square item. The cylindrical version screws onto the output end of the high pressure cylinder. The square type is held in place with tie rods and bolts. The end cap has a hole in the center for the check valve and outlet body. It will also have a connection point for the incoming fresh water. The water flows through holes machined through the cap to line up with inlet holes in the check valve.'),(73539,2970,'_content_blocks_15_description','field_6170d8cd9800c'),(73540,2970,'content_blocks_15_images_0_image','2992'),(73541,2970,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(73542,2970,'content_blocks_15_images_0_header',''),(73543,2970,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(73544,2970,'content_blocks_15_images_0_description',''),(73545,2970,'_content_blocks_15_images_0_description','field_6170d90398010'),(73546,2970,'content_blocks_15_images','1'),(73547,2970,'_content_blocks_15_images','field_6170d8df9800d'),(73548,2993,'hero_gallery',''),(73549,2993,'_hero_gallery','field_60c23d554e4a3'),(73550,2993,'hero_banner',''),(73551,2993,'_hero_banner','field_6170dbe179470'),(73552,2993,'page_title','Pumps'),(73553,2993,'_page_title','field_6170d88998008'),(73554,2993,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(73555,2993,'_page_description','field_6170d89398009'),(73556,2993,'content_blocks_0_header','High pressure waterjet cutting'),(73557,2993,'_content_blocks_0_header','field_6170d8ba9800b'),(73558,2993,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(73559,2993,'_content_blocks_0_description','field_6170d8cd9800c'),(73560,2993,'content_blocks_0_images',''),(73561,2993,'_content_blocks_0_images','field_6170d8df9800d'),(73562,2993,'content_blocks_1_header','Types of pumps'),(73563,2993,'_content_blocks_1_header','field_6170d8ba9800b'),(73564,2993,'content_blocks_1_description',''),(73565,2993,'_content_blocks_1_description','field_6170d8cd9800c'),(73566,2993,'content_blocks_1_images',''),(73567,2993,'_content_blocks_1_images','field_6170d8df9800d'),(73568,2993,'content_blocks_2_header','Intensifier'),(73569,2993,'_content_blocks_2_header','field_6170d8ba9800b'),(73570,2993,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(73571,2993,'_content_blocks_2_description','field_6170d8cd9800c'),(73572,2993,'content_blocks_2_images_0_image','2971'),(73573,2993,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(73574,2993,'content_blocks_2_images_0_header',''),(73575,2993,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(73576,2993,'content_blocks_2_images_0_description',''),(73577,2993,'_content_blocks_2_images_0_description','field_6170d90398010'),(73578,2993,'content_blocks_2_images','1'),(73579,2993,'_content_blocks_2_images','field_6170d8df9800d'),(73580,2993,'content_blocks_3_header','The pressurization process'),(73581,2993,'_content_blocks_3_header','field_6170d8ba9800b'),(73582,2993,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(73583,2993,'_content_blocks_3_description','field_6170d8cd9800c'),(73584,2993,'content_blocks_3_images_0_image','2972'),(73585,2993,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(73586,2993,'content_blocks_3_images_0_header',''),(73587,2993,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(73588,2993,'content_blocks_3_images_0_description',''),(73589,2993,'_content_blocks_3_images_0_description','field_6170d90398010'),(73590,2993,'content_blocks_3_images_1_image','2973'),(73591,2993,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(73592,2993,'content_blocks_3_images_1_header',''),(73593,2993,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(73594,2993,'content_blocks_3_images_1_description',''),(73595,2993,'_content_blocks_3_images_1_description','field_6170d90398010'),(73596,2993,'content_blocks_3_images','2'),(73597,2993,'_content_blocks_3_images','field_6170d8df9800d'),(73598,2993,'content_blocks','16'),(73599,2993,'_content_blocks','field_6170d8ac9800a'),(73600,2993,'menu','11'),(73601,2993,'_menu','field_6170d9e059837'),(73602,2993,'display_left_column','1'),(73603,2993,'_display_left_column','field_613563c4d424b'),(73604,2993,'contact_left_heading',''),(73605,2993,'_contact_left_heading','field_60c249d645c99'),(73606,2993,'contact_left_copy',''),(73607,2993,'_contact_left_copy','field_60c24a0845c9c'),(73608,2993,'display_right_column','1'),(73609,2993,'_display_right_column','field_613563f4d424c'),(73610,2993,'contact_right_heading',''),(73611,2993,'_contact_right_heading','field_60c249e945c9a'),(73612,2993,'contact_right_copy',''),(73613,2993,'_contact_right_copy','field_60c249f845c9b'),(73614,2993,'contact_right_cta',''),(73615,2993,'_contact_right_cta','field_60c24a1945c9d'),(73616,2993,'content_blocks_4_header','Direct Drive'),(73617,2993,'_content_blocks_4_header','field_6170d8ba9800b'),(73618,2993,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(73619,2993,'_content_blocks_4_description','field_6170d8cd9800c'),(73620,2993,'content_blocks_4_images_0_image','2976'),(73621,2993,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(73622,2993,'content_blocks_4_images_0_header',''),(73623,2993,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(73624,2993,'content_blocks_4_images_0_description',''),(73625,2993,'_content_blocks_4_images_0_description','field_6170d90398010'),(73626,2993,'content_blocks_4_images_1_image','2977'),(73627,2993,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(73628,2993,'content_blocks_4_images_1_header',''),(73629,2993,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(73630,2993,'content_blocks_4_images_1_description',''),(73631,2993,'_content_blocks_4_images_1_description','field_6170d90398010'),(73632,2993,'content_blocks_4_images','2'),(73633,2993,'_content_blocks_4_images','field_6170d8df9800d'),(73634,2993,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(73635,2993,'_content_blocks_5_header','field_6170d8ba9800b'),(73636,2993,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(73637,2993,'_content_blocks_5_description','field_6170d8cd9800c'),(73638,2993,'content_blocks_5_images_0_image','2979'),(73639,2993,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(73640,2993,'content_blocks_5_images_0_header',''),(73641,2993,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(73642,2993,'content_blocks_5_images_0_description',''),(73643,2993,'_content_blocks_5_images_0_description','field_6170d90398010'),(73644,2993,'content_blocks_5_images_1_image','2980'),(73645,2993,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(73646,2993,'content_blocks_5_images_1_header',''),(73647,2993,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(73648,2993,'content_blocks_5_images_1_description',''),(73649,2993,'_content_blocks_5_images_1_description','field_6170d90398010'),(73650,2993,'content_blocks_5_images','2'),(73651,2993,'_content_blocks_5_images','field_6170d8df9800d'),(73652,2993,'content_blocks_6_header','Parts of the intensifier pump'),(73653,2993,'_content_blocks_6_header','field_6170d8ba9800b'),(73654,2993,'content_blocks_6_description',''),(73655,2993,'_content_blocks_6_description','field_6170d8cd9800c'),(73656,2993,'content_blocks_6_images',''),(73657,2993,'_content_blocks_6_images','field_6170d8df9800d'),(73658,2993,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(73659,2993,'_content_blocks_7_header','field_6170d8ba9800b'),(73660,2993,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(73661,2993,'_content_blocks_7_description','field_6170d8cd9800c'),(73662,2993,'content_blocks_7_images_0_image','2981'),(73663,2993,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(73664,2993,'content_blocks_7_images_0_header',''),(73665,2993,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(73666,2993,'content_blocks_7_images_0_description',''),(73667,2993,'_content_blocks_7_images_0_description','field_6170d90398010'),(73668,2993,'content_blocks_7_images','1'),(73669,2993,'_content_blocks_7_images','field_6170d8df9800d'),(73670,2993,'content_blocks_8_header','2. Directional control valves'),(73671,2993,'_content_blocks_8_header','field_6170d8ba9800b'),(73672,2993,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(73673,2993,'_content_blocks_8_description','field_6170d8cd9800c'),(73674,2993,'content_blocks_8_images_0_image','2982'),(73675,2993,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(73676,2993,'content_blocks_8_images_0_header',''),(73677,2993,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(73678,2993,'content_blocks_8_images_0_description',''),(73679,2993,'_content_blocks_8_images_0_description','field_6170d90398010'),(73680,2993,'content_blocks_8_images','1'),(73681,2993,'_content_blocks_8_images','field_6170d8df9800d'),(73682,2993,'content_blocks_9_header','3. Intensifier'),(73683,2993,'_content_blocks_9_header','field_6170d8ba9800b'),(73684,2993,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(73685,2993,'_content_blocks_9_description','field_6170d8cd9800c'),(73686,2993,'content_blocks_9_images_0_image','2984'),(73687,2993,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(73688,2993,'content_blocks_9_images_0_header',''),(73689,2993,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(73690,2993,'content_blocks_9_images_0_description',''),(73691,2993,'_content_blocks_9_images_0_description','field_6170d90398010'),(73692,2993,'content_blocks_9_images','1'),(73693,2993,'_content_blocks_9_images','field_6170d8df9800d'),(73694,2993,'content_blocks_10_header','4. Hydraulic cylinder'),(73695,2993,'_content_blocks_10_header','field_6170d8ba9800b'),(73696,2993,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(73697,2993,'_content_blocks_10_description','field_6170d8cd9800c'),(73698,2993,'content_blocks_10_images_0_image','2985'),(73699,2993,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(73700,2993,'content_blocks_10_images_0_header',''),(73701,2993,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(73702,2993,'content_blocks_10_images_0_description',''),(73703,2993,'_content_blocks_10_images_0_description','field_6170d90398010'),(73704,2993,'content_blocks_10_images','1'),(73705,2993,'_content_blocks_10_images','field_6170d8df9800d'),(73706,2993,'content_blocks_11_header','5. Piston'),(73707,2993,'_content_blocks_11_header','field_6170d8ba9800b'),(73708,2993,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(73709,2993,'_content_blocks_11_description','field_6170d8cd9800c'),(73710,2993,'content_blocks_11_images_0_image','2986'),(73711,2993,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(73712,2993,'content_blocks_11_images_0_header',''),(73713,2993,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(73714,2993,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(73715,2993,'_content_blocks_11_images_0_description','field_6170d90398010'),(73716,2993,'content_blocks_11_images','1'),(73717,2993,'_content_blocks_11_images','field_6170d8df9800d'),(73718,2993,'content_blocks_12_header','6. Plunger'),(73719,2993,'_content_blocks_12_header','field_6170d8ba9800b'),(73720,2993,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(73721,2993,'_content_blocks_12_description','field_6170d8cd9800c'),(73722,2993,'content_blocks_12_images_0_image','2987'),(73723,2993,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(73724,2993,'content_blocks_12_images_0_header',''),(73725,2993,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(73726,2993,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(73727,2993,'_content_blocks_12_images_0_description','field_6170d90398010'),(73728,2993,'content_blocks_12_images','1'),(73729,2993,'_content_blocks_12_images','field_6170d8df9800d'),(73730,2993,'content_blocks_13_header','7. High pressure cylinder'),(73731,2993,'_content_blocks_13_header','field_6170d8ba9800b'),(73732,2993,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(73733,2993,'_content_blocks_13_description','field_6170d8cd9800c'),(73734,2993,'content_blocks_13_images_0_image','2984'),(73735,2993,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(73736,2993,'content_blocks_13_images_0_header',''),(73737,2993,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(73738,2993,'content_blocks_13_images_0_description',''),(73739,2993,'_content_blocks_13_images_0_description','field_6170d90398010'),(73740,2993,'content_blocks_13_images','1'),(73741,2993,'_content_blocks_13_images','field_6170d8df9800d'),(73742,2993,'content_blocks_14_header','8. Check valve'),(73743,2993,'_content_blocks_14_header','field_6170d8ba9800b'),(73744,2993,'content_blocks_14_description','There is one check valve (number 8 in Figures 10 and 8) at the end of each high pressure cylinder at the end opposite from the hydraulic cylinder. The check valve allows fresh water to enter the high pressure cylinder and high pressure water to exit the intensifier. The check valve is designed to only let water flow in one direction. Fresh water comes in though channels machined in the sides and exits through one or more holes in the face of the valve. Various seals, poppets and springs are used to maintain this water flow. Over several hundred hours these components will wear, allowing pressurized water to flow out the water inlet path, or allowing pressurized water to seep back into the high pressure cylinder. The symptoms and diagnosis of these various situations will be discussed later in the \"Maintenance\" chapter.'),(73745,2993,'_content_blocks_14_description','field_6170d8cd9800c'),(73746,2993,'content_blocks_14_images_0_image','2988'),(73747,2993,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(73748,2993,'content_blocks_14_images_0_header',''),(73749,2993,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(73750,2993,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(73751,2993,'_content_blocks_14_images_0_description','field_6170d90398010'),(73752,2993,'content_blocks_14_images_1_image','2989'),(73753,2993,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(73754,2993,'content_blocks_14_images_1_header',''),(73755,2993,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(73756,2993,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(73757,2993,'_content_blocks_14_images_1_description','field_6170d90398010'),(73758,2993,'content_blocks_14_images','3'),(73759,2993,'_content_blocks_14_images','field_6170d8df9800d'),(73760,2993,'content_blocks_14_images_2_image','2991'),(73761,2993,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(73762,2993,'content_blocks_14_images_2_header',''),(73763,2993,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(73764,2993,'content_blocks_14_images_2_description','Figure 11 - View of upper portion of intensifier cabinet'),(73765,2993,'_content_blocks_14_images_2_description','field_6170d90398010'),(73766,2993,'content_blocks_15_header','End Cap'),(73767,2993,'_content_blocks_15_header','field_6170d8ba9800b'),(73768,2993,'content_blocks_15_description','The end cap (number 9 in Figures 11 and 2) is either a cylindrical or square item. The cylindrical version screws onto the output end of the high pressure cylinder. The square type is held in place with tie rods and bolts. The end cap has a hole in the center for the check valve and outlet body. It will also have a connection point for the incoming fresh water. The water flows through holes machined through the cap to line up with inlet holes in the check valve.'),(73769,2993,'_content_blocks_15_description','field_6170d8cd9800c'),(73770,2993,'content_blocks_15_images_0_image','2992'),(73771,2993,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(73772,2993,'content_blocks_15_images_0_header',''),(73773,2993,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(73774,2993,'content_blocks_15_images_0_description',''),(73775,2993,'_content_blocks_15_images_0_description','field_6170d90398010'),(73776,2993,'content_blocks_15_images','1'),(73777,2993,'_content_blocks_15_images','field_6170d8df9800d'),(73779,2994,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-High-pressure-tubing.jpg'),(73780,2994,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:375;s:6:\"height\";i:254;s:4:\"file\";s:67:\"2021/11/Waterjet-University_Waterjet-Pumps-High-pressure-tubing.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73781,2995,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Pressure-attenuator.jpg'),(73782,2995,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:564;s:6:\"height\";i:150;s:4:\"file\";s:66:\"2021/11/Waterjet-University_Waterjet-Pumps-Pressure-attenuator.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73783,2996,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-Pressure-attenuator-Chart.jpg'),(73784,2996,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:630;s:6:\"height\";i:327;s:4:\"file\";s:72:\"2021/11/Waterjet-University_Waterjet-Pumps-Pressure-attenuator-Chart.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73785,2997,'_wp_attached_file','2021/11/Waterjet-University_Waterjet-Pumps-On-Off-Valve.jpg'),(73786,2997,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:585;s:6:\"height\";i:545;s:4:\"file\";s:59:\"2021/11/Waterjet-University_Waterjet-Pumps-On-Off-Valve.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(73787,2997,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73788,2996,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73789,2995,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73790,2994,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2970;}}'),(73791,2970,'content_blocks_16_header','10. High pressure tubing'),(73792,2970,'_content_blocks_16_header','field_6170d8ba9800b'),(73793,2970,'content_blocks_16_description','High pressure 304 or 316 stainless steel tubing (number 10 in Figure 11) is attached to the outlet of each check valve. Common outer diameters are 0.25\", 0.313\", 0.375\" and 0.563\". Inner diameters range from 0.062\" to 0.312\". There is usually a flexible protective covering around the tube.\r\n\r\nThe high pressure tubing from the left hand high pressure cylinder will join together at some point with the high pressure tubing from the right hand cylinder. The high pressure tubing carries the pressurized water to the pressure attenuator. Additional high pressure tubing will channel the high pressure water to the cutting head.\r\n\r\nThe length, number of bends and other obstructions to flow (e.g. hand valves) in the high pressure tubing path must be taken into consideration when designing a high pressure waterjet system. Pressure will drop with each bend in the tubing. Also, as the distance between the pump and the cutting head increases, internal friction of the water as it drags against the inner walls will generate heat resulting in a loss of water pressure. This topic will be discussed in more detail in the Chapter 5 \"Pressure Drop in Tubing.\"'),(73794,2970,'_content_blocks_16_description','field_6170d8cd9800c'),(73795,2970,'content_blocks_16_images_0_image','2994'),(73796,2970,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(73797,2970,'content_blocks_16_images_0_header',''),(73798,2970,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(73799,2970,'content_blocks_16_images_0_description',''),(73800,2970,'_content_blocks_16_images_0_description','field_6170d90398010'),(73801,2970,'content_blocks_16_images','1'),(73802,2970,'_content_blocks_16_images','field_6170d8df9800d'),(73803,2970,'content_blocks_17_header','11. Pressure attenuator'),(73804,2970,'_content_blocks_17_header','field_6170d8ba9800b'),(73805,2970,'content_blocks_17_description','The pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nThe pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nFigure 14 shows the pressure fluctuations in the high pressure water line prior to the pressure accumulator. This shows a pressure change from high to low of almost 22,000 psi. So, for a 60,000 psi system, the high pressure water would be going from 60,000 psi to 40,000 psi after every stroke of the intensifier.\r\n\r\nIf this pressure fluctuation were not smoothed out by the pressure attenuator, cutting results at the work piece would be undesirable. There would be a significant line in the part with every stroke of the intensifier. Recall that any change in pressure results in a change in speed of the waterjet stream at the cutting head. This change in speed changes the speed at which the abrasive particles are moving and, therefore, the amount of force they will impart on the work piece. Lower pressure leads to less speed of the water which leads to less force of the abrasive which leads to slower cutting, or rougher edge quality.\r\n\r\nFortunately the pressure attenuator smoothes out these pressure spikes so that the water at the cutting head maintains a steady pressure, speed and cutting power.\r\n\r\n&nbsp;'),(73806,2970,'_content_blocks_17_description','field_6170d8cd9800c'),(73807,2970,'content_blocks_17_images_0_image','2995'),(73808,2970,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(73809,2970,'content_blocks_17_images_0_header',''),(73810,2970,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(73811,2970,'content_blocks_17_images_0_description','Figure 13 - Pressure Attenuator'),(73812,2970,'_content_blocks_17_images_0_description','field_6170d90398010'),(73813,2970,'content_blocks_17_images_1_image','2996'),(73814,2970,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(73815,2970,'content_blocks_17_images_1_header',''),(73816,2970,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(73817,2970,'content_blocks_17_images_1_description','Figure 14 - Pressure fluctuation prior to accumulator\r\n\r\nSource: \"Pressure and Flow Rate Fluctuations at High Pressure Intensifier Pumps\", F. Trieb, et.al., 2007 American WJTA Conference and Expo'),(73818,2970,'_content_blocks_17_images_1_description','field_6170d90398010'),(73819,2970,'content_blocks_17_images','2'),(73820,2970,'_content_blocks_17_images','field_6170d8df9800d'),(73821,2970,'content_blocks_18_header','12. Inlet water'),(73822,2970,'_content_blocks_18_header','field_6170d8ba9800b'),(73823,2970,'content_blocks_18_description','Prior to entering the pump cabinet, water may have to be treated to get the water within the waterjet manufacturer’s specifications. Within the pump cabinet, usually in the lower portion, the water will typically go through one or more final filters just prior to entering the intensifier (number 12 in Figures 15 and 2).\r\n\r\nThe inlet water must be able to maintain a specified flow rate and pressure to ensure that the intensifier receives enough water. Incoming water must also meet certain requirements with respect to Total Dissolved Solids (TDS), pH, organic matter, temperature, etc. Poor water quality will result in drastically reduced high pressure component life (i.e. anything the high pressure water comes in contact with). Different pump manufacturers require different inlet water pressures, with some needing as little as 30 psi, and others mandating a water pressure booster pump to maintain 100 psi. Water quality will be discussed in more detail in the chapter 4 \"Water Quality.\"'),(73824,2970,'_content_blocks_18_description','field_6170d8cd9800c'),(73825,2970,'content_blocks_18_images_0_image',''),(73826,2970,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(73827,2970,'content_blocks_18_images_0_header',''),(73828,2970,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(73829,2970,'content_blocks_18_images_0_description','Figure 15 - Inlet water filters'),(73830,2970,'_content_blocks_18_images_0_description','field_6170d90398010'),(73831,2970,'content_blocks_18_images','1'),(73832,2970,'_content_blocks_18_images','field_6170d8df9800d'),(73833,2970,'content_blocks_19_header','13. Controls and PLC'),(73834,2970,'_content_blocks_19_header','field_6170d8ba9800b'),(73835,2970,'content_blocks_19_description','The controls and PLC (not pictured) control the valves in the hydraulic circuit to determine the pressure and flow of the hydraulic oil to and from the intensifier. Various sensor and proximity switches can also be integrated into the controls to monitor the entire pump to verify things like stroke rate, oil temperature and pressure, inlet water pressure and flow rate and more. This capability makes working with and troubleshooting the modern day intensifier much easier.\r\n\r\nThe pneumatic On-Off valve controls the flow of water to the cutting head. The On-Off valve at the cutting is \"normally closed.\" That is, when there is no compressed air supplied to the On-Off valve, a needle fits tightly against a seat to stop any high pressure water from getting to the cutting head. When compressed air is supplied to the On-Off valve (i.e. \"tool on\" command from the control), the needle is forced up from its seating location and the high pressure water can flow through the orifice to the cutting head.\r\n\r\nIn, or near, the high pressure pump cabinet is another On-Off valve that works in tandem with the On-Off valve at the cutting head. The On-Off valve in the pump is typically called the Safety Relief valve. This Safety Relief valve in the pump is \"normally open.\" This valve will stay open when there is no air supplied to it. When the On-Off valve at the cutting head closes (\"tool off\" command by control or no power to the system), the Safety Relief valve in the pump will open, relieving all water pressure from the high pressure tubing. When the \"tool on\" command is issued by the control, the Safety Relief valve closes so that all high pressure water will go to the cutting head. Note, not all manufacturers of new pumps have the Safety Relief valve as standard. We strongly suggest you ask your pump manufacturer if they supply this standard, and when it is activated. Again, some pump manufacturers will only activate the Safety Valve when an E-Stop is pressed; when the pump stops, high pressure lines are still pressurized.\r\n\r\nBoth of these On-Off valves must be in good working order to protect against accidental high pressure water discharge at the cutting head that could severely injure someone working on or near the cutting head or any of the high pressure lines. Periodic replacement of the needle, seat and associated parts is required to maintain these valves.'),(73836,2970,'_content_blocks_19_description','field_6170d8cd9800c'),(73837,2970,'content_blocks_19_images_0_image','2997'),(73838,2970,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(73839,2970,'content_blocks_19_images_0_header',''),(73840,2970,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(73841,2970,'content_blocks_19_images_0_description',''),(73842,2970,'_content_blocks_19_images_0_description','field_6170d90398010'),(73843,2970,'content_blocks_19_images','1'),(73844,2970,'_content_blocks_19_images','field_6170d8df9800d'),(73845,2998,'hero_gallery',''),(73846,2998,'_hero_gallery','field_60c23d554e4a3'),(73847,2998,'hero_banner',''),(73848,2998,'_hero_banner','field_6170dbe179470'),(73849,2998,'page_title','Pumps'),(73850,2998,'_page_title','field_6170d88998008'),(73851,2998,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(73852,2998,'_page_description','field_6170d89398009'),(73853,2998,'content_blocks_0_header','High pressure waterjet cutting'),(73854,2998,'_content_blocks_0_header','field_6170d8ba9800b'),(73855,2998,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(73856,2998,'_content_blocks_0_description','field_6170d8cd9800c'),(73857,2998,'content_blocks_0_images',''),(73858,2998,'_content_blocks_0_images','field_6170d8df9800d'),(73859,2998,'content_blocks_1_header','Types of pumps'),(73860,2998,'_content_blocks_1_header','field_6170d8ba9800b'),(73861,2998,'content_blocks_1_description',''),(73862,2998,'_content_blocks_1_description','field_6170d8cd9800c'),(73863,2998,'content_blocks_1_images',''),(73864,2998,'_content_blocks_1_images','field_6170d8df9800d'),(73865,2998,'content_blocks_2_header','Intensifier'),(73866,2998,'_content_blocks_2_header','field_6170d8ba9800b'),(73867,2998,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(73868,2998,'_content_blocks_2_description','field_6170d8cd9800c'),(73869,2998,'content_blocks_2_images_0_image','2971'),(73870,2998,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(73871,2998,'content_blocks_2_images_0_header',''),(73872,2998,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(73873,2998,'content_blocks_2_images_0_description',''),(73874,2998,'_content_blocks_2_images_0_description','field_6170d90398010'),(73875,2998,'content_blocks_2_images','1'),(73876,2998,'_content_blocks_2_images','field_6170d8df9800d'),(73877,2998,'content_blocks_3_header','The pressurization process'),(73878,2998,'_content_blocks_3_header','field_6170d8ba9800b'),(73879,2998,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(73880,2998,'_content_blocks_3_description','field_6170d8cd9800c'),(73881,2998,'content_blocks_3_images_0_image','2972'),(73882,2998,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(73883,2998,'content_blocks_3_images_0_header',''),(73884,2998,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(73885,2998,'content_blocks_3_images_0_description',''),(73886,2998,'_content_blocks_3_images_0_description','field_6170d90398010'),(73887,2998,'content_blocks_3_images_1_image','2973'),(73888,2998,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(73889,2998,'content_blocks_3_images_1_header',''),(73890,2998,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(73891,2998,'content_blocks_3_images_1_description',''),(73892,2998,'_content_blocks_3_images_1_description','field_6170d90398010'),(73893,2998,'content_blocks_3_images','2'),(73894,2998,'_content_blocks_3_images','field_6170d8df9800d'),(73895,2998,'content_blocks','20'),(73896,2998,'_content_blocks','field_6170d8ac9800a'),(73897,2998,'menu','11'),(73898,2998,'_menu','field_6170d9e059837'),(73899,2998,'display_left_column','1'),(73900,2998,'_display_left_column','field_613563c4d424b'),(73901,2998,'contact_left_heading',''),(73902,2998,'_contact_left_heading','field_60c249d645c99'),(73903,2998,'contact_left_copy',''),(73904,2998,'_contact_left_copy','field_60c24a0845c9c'),(73905,2998,'display_right_column','1'),(73906,2998,'_display_right_column','field_613563f4d424c'),(73907,2998,'contact_right_heading',''),(73908,2998,'_contact_right_heading','field_60c249e945c9a'),(73909,2998,'contact_right_copy',''),(73910,2998,'_contact_right_copy','field_60c249f845c9b'),(73911,2998,'contact_right_cta',''),(73912,2998,'_contact_right_cta','field_60c24a1945c9d'),(73913,2998,'content_blocks_4_header','Direct Drive'),(73914,2998,'_content_blocks_4_header','field_6170d8ba9800b'),(73915,2998,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(73916,2998,'_content_blocks_4_description','field_6170d8cd9800c'),(73917,2998,'content_blocks_4_images_0_image','2976'),(73918,2998,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(73919,2998,'content_blocks_4_images_0_header',''),(73920,2998,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(73921,2998,'content_blocks_4_images_0_description',''),(73922,2998,'_content_blocks_4_images_0_description','field_6170d90398010'),(73923,2998,'content_blocks_4_images_1_image','2977'),(73924,2998,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(73925,2998,'content_blocks_4_images_1_header',''),(73926,2998,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(73927,2998,'content_blocks_4_images_1_description',''),(73928,2998,'_content_blocks_4_images_1_description','field_6170d90398010'),(73929,2998,'content_blocks_4_images','2'),(73930,2998,'_content_blocks_4_images','field_6170d8df9800d'),(73931,2998,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(73932,2998,'_content_blocks_5_header','field_6170d8ba9800b'),(73933,2998,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(73934,2998,'_content_blocks_5_description','field_6170d8cd9800c'),(73935,2998,'content_blocks_5_images_0_image','2979'),(73936,2998,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(73937,2998,'content_blocks_5_images_0_header',''),(73938,2998,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(73939,2998,'content_blocks_5_images_0_description',''),(73940,2998,'_content_blocks_5_images_0_description','field_6170d90398010'),(73941,2998,'content_blocks_5_images_1_image','2980'),(73942,2998,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(73943,2998,'content_blocks_5_images_1_header',''),(73944,2998,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(73945,2998,'content_blocks_5_images_1_description',''),(73946,2998,'_content_blocks_5_images_1_description','field_6170d90398010'),(73947,2998,'content_blocks_5_images','2'),(73948,2998,'_content_blocks_5_images','field_6170d8df9800d'),(73949,2998,'content_blocks_6_header','Parts of the intensifier pump'),(73950,2998,'_content_blocks_6_header','field_6170d8ba9800b'),(73951,2998,'content_blocks_6_description',''),(73952,2998,'_content_blocks_6_description','field_6170d8cd9800c'),(73953,2998,'content_blocks_6_images',''),(73954,2998,'_content_blocks_6_images','field_6170d8df9800d'),(73955,2998,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(73956,2998,'_content_blocks_7_header','field_6170d8ba9800b'),(73957,2998,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(73958,2998,'_content_blocks_7_description','field_6170d8cd9800c'),(73959,2998,'content_blocks_7_images_0_image','2981'),(73960,2998,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(73961,2998,'content_blocks_7_images_0_header',''),(73962,2998,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(73963,2998,'content_blocks_7_images_0_description',''),(73964,2998,'_content_blocks_7_images_0_description','field_6170d90398010'),(73965,2998,'content_blocks_7_images','1'),(73966,2998,'_content_blocks_7_images','field_6170d8df9800d'),(73967,2998,'content_blocks_8_header','2. Directional control valves'),(73968,2998,'_content_blocks_8_header','field_6170d8ba9800b'),(73969,2998,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(73970,2998,'_content_blocks_8_description','field_6170d8cd9800c'),(73971,2998,'content_blocks_8_images_0_image','2982'),(73972,2998,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(73973,2998,'content_blocks_8_images_0_header',''),(73974,2998,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(73975,2998,'content_blocks_8_images_0_description',''),(73976,2998,'_content_blocks_8_images_0_description','field_6170d90398010'),(73977,2998,'content_blocks_8_images','1'),(73978,2998,'_content_blocks_8_images','field_6170d8df9800d'),(73979,2998,'content_blocks_9_header','3. Intensifier'),(73980,2998,'_content_blocks_9_header','field_6170d8ba9800b'),(73981,2998,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(73982,2998,'_content_blocks_9_description','field_6170d8cd9800c'),(73983,2998,'content_blocks_9_images_0_image','2984'),(73984,2998,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(73985,2998,'content_blocks_9_images_0_header',''),(73986,2998,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(73987,2998,'content_blocks_9_images_0_description',''),(73988,2998,'_content_blocks_9_images_0_description','field_6170d90398010'),(73989,2998,'content_blocks_9_images','1'),(73990,2998,'_content_blocks_9_images','field_6170d8df9800d'),(73991,2998,'content_blocks_10_header','4. Hydraulic cylinder'),(73992,2998,'_content_blocks_10_header','field_6170d8ba9800b'),(73993,2998,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(73994,2998,'_content_blocks_10_description','field_6170d8cd9800c'),(73995,2998,'content_blocks_10_images_0_image','2985'),(73996,2998,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(73997,2998,'content_blocks_10_images_0_header',''),(73998,2998,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(73999,2998,'content_blocks_10_images_0_description',''),(74000,2998,'_content_blocks_10_images_0_description','field_6170d90398010'),(74001,2998,'content_blocks_10_images','1'),(74002,2998,'_content_blocks_10_images','field_6170d8df9800d'),(74003,2998,'content_blocks_11_header','5. Piston'),(74004,2998,'_content_blocks_11_header','field_6170d8ba9800b'),(74005,2998,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(74006,2998,'_content_blocks_11_description','field_6170d8cd9800c'),(74007,2998,'content_blocks_11_images_0_image','2986'),(74008,2998,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(74009,2998,'content_blocks_11_images_0_header',''),(74010,2998,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(74011,2998,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(74012,2998,'_content_blocks_11_images_0_description','field_6170d90398010'),(74013,2998,'content_blocks_11_images','1'),(74014,2998,'_content_blocks_11_images','field_6170d8df9800d'),(74015,2998,'content_blocks_12_header','6. Plunger'),(74016,2998,'_content_blocks_12_header','field_6170d8ba9800b'),(74017,2998,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(74018,2998,'_content_blocks_12_description','field_6170d8cd9800c'),(74019,2998,'content_blocks_12_images_0_image','2987'),(74020,2998,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(74021,2998,'content_blocks_12_images_0_header',''),(74022,2998,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(74023,2998,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(74024,2998,'_content_blocks_12_images_0_description','field_6170d90398010'),(74025,2998,'content_blocks_12_images','1'),(74026,2998,'_content_blocks_12_images','field_6170d8df9800d'),(74027,2998,'content_blocks_13_header','7. High pressure cylinder'),(74028,2998,'_content_blocks_13_header','field_6170d8ba9800b'),(74029,2998,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(74030,2998,'_content_blocks_13_description','field_6170d8cd9800c'),(74031,2998,'content_blocks_13_images_0_image','2984'),(74032,2998,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(74033,2998,'content_blocks_13_images_0_header',''),(74034,2998,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(74035,2998,'content_blocks_13_images_0_description',''),(74036,2998,'_content_blocks_13_images_0_description','field_6170d90398010'),(74037,2998,'content_blocks_13_images','1'),(74038,2998,'_content_blocks_13_images','field_6170d8df9800d'),(74039,2998,'content_blocks_14_header','8. Check valve'),(74040,2998,'_content_blocks_14_header','field_6170d8ba9800b'),(74041,2998,'content_blocks_14_description','There is one check valve (number 8 in Figures 10 and 8) at the end of each high pressure cylinder at the end opposite from the hydraulic cylinder. The check valve allows fresh water to enter the high pressure cylinder and high pressure water to exit the intensifier. The check valve is designed to only let water flow in one direction. Fresh water comes in though channels machined in the sides and exits through one or more holes in the face of the valve. Various seals, poppets and springs are used to maintain this water flow. Over several hundred hours these components will wear, allowing pressurized water to flow out the water inlet path, or allowing pressurized water to seep back into the high pressure cylinder. The symptoms and diagnosis of these various situations will be discussed later in the \"Maintenance\" chapter.'),(74042,2998,'_content_blocks_14_description','field_6170d8cd9800c'),(74043,2998,'content_blocks_14_images_0_image','2988'),(74044,2998,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(74045,2998,'content_blocks_14_images_0_header',''),(74046,2998,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(74047,2998,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(74048,2998,'_content_blocks_14_images_0_description','field_6170d90398010'),(74049,2998,'content_blocks_14_images_1_image','2989'),(74050,2998,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(74051,2998,'content_blocks_14_images_1_header',''),(74052,2998,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(74053,2998,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(74054,2998,'_content_blocks_14_images_1_description','field_6170d90398010'),(74055,2998,'content_blocks_14_images','3'),(74056,2998,'_content_blocks_14_images','field_6170d8df9800d'),(74057,2998,'content_blocks_14_images_2_image','2991'),(74058,2998,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(74059,2998,'content_blocks_14_images_2_header',''),(74060,2998,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(74061,2998,'content_blocks_14_images_2_description','Figure 11 - View of upper portion of intensifier cabinet'),(74062,2998,'_content_blocks_14_images_2_description','field_6170d90398010'),(74063,2998,'content_blocks_15_header','End Cap'),(74064,2998,'_content_blocks_15_header','field_6170d8ba9800b'),(74065,2998,'content_blocks_15_description','The end cap (number 9 in Figures 11 and 2) is either a cylindrical or square item. The cylindrical version screws onto the output end of the high pressure cylinder. The square type is held in place with tie rods and bolts. The end cap has a hole in the center for the check valve and outlet body. It will also have a connection point for the incoming fresh water. The water flows through holes machined through the cap to line up with inlet holes in the check valve.'),(74066,2998,'_content_blocks_15_description','field_6170d8cd9800c'),(74067,2998,'content_blocks_15_images_0_image','2992'),(74068,2998,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(74069,2998,'content_blocks_15_images_0_header',''),(74070,2998,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(74071,2998,'content_blocks_15_images_0_description',''),(74072,2998,'_content_blocks_15_images_0_description','field_6170d90398010'),(74073,2998,'content_blocks_15_images','1'),(74074,2998,'_content_blocks_15_images','field_6170d8df9800d'),(74075,2998,'content_blocks_16_header','10. High pressure tubing'),(74076,2998,'_content_blocks_16_header','field_6170d8ba9800b'),(74077,2998,'content_blocks_16_description','High pressure 304 or 316 stainless steel tubing (number 10 in Figure 11) is attached to the outlet of each check valve. Common outer diameters are 0.25\", 0.313\", 0.375\" and 0.563\". Inner diameters range from 0.062\" to 0.312\". There is usually a flexible protective covering around the tube.\r\n\r\nThe high pressure tubing from the left hand high pressure cylinder will join together at some point with the high pressure tubing from the right hand cylinder. The high pressure tubing carries the pressurized water to the pressure attenuator. Additional high pressure tubing will channel the high pressure water to the cutting head.\r\n\r\nThe length, number of bends and other obstructions to flow (e.g. hand valves) in the high pressure tubing path must be taken into consideration when designing a high pressure waterjet system. Pressure will drop with each bend in the tubing. Also, as the distance between the pump and the cutting head increases, internal friction of the water as it drags against the inner walls will generate heat resulting in a loss of water pressure. This topic will be discussed in more detail in the Chapter 5 \"Pressure Drop in Tubing.\"'),(74078,2998,'_content_blocks_16_description','field_6170d8cd9800c'),(74079,2998,'content_blocks_16_images_0_image','2994'),(74080,2998,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(74081,2998,'content_blocks_16_images_0_header',''),(74082,2998,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(74083,2998,'content_blocks_16_images_0_description',''),(74084,2998,'_content_blocks_16_images_0_description','field_6170d90398010'),(74085,2998,'content_blocks_16_images','1'),(74086,2998,'_content_blocks_16_images','field_6170d8df9800d'),(74087,2998,'content_blocks_17_header','11. Pressure attenuator'),(74088,2998,'_content_blocks_17_header','field_6170d8ba9800b'),(74089,2998,'content_blocks_17_description','The pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nThe pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nFigure 14 shows the pressure fluctuations in the high pressure water line prior to the pressure accumulator. This shows a pressure change from high to low of almost 22,000 psi. So, for a 60,000 psi system, the high pressure water would be going from 60,000 psi to 40,000 psi after every stroke of the intensifier.\r\n\r\nIf this pressure fluctuation were not smoothed out by the pressure attenuator, cutting results at the work piece would be undesirable. There would be a significant line in the part with every stroke of the intensifier. Recall that any change in pressure results in a change in speed of the waterjet stream at the cutting head. This change in speed changes the speed at which the abrasive particles are moving and, therefore, the amount of force they will impart on the work piece. Lower pressure leads to less speed of the water which leads to less force of the abrasive which leads to slower cutting, or rougher edge quality.\r\n\r\nFortunately the pressure attenuator smoothes out these pressure spikes so that the water at the cutting head maintains a steady pressure, speed and cutting power.\r\n\r\n&nbsp;'),(74090,2998,'_content_blocks_17_description','field_6170d8cd9800c'),(74091,2998,'content_blocks_17_images_0_image','2995'),(74092,2998,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(74093,2998,'content_blocks_17_images_0_header',''),(74094,2998,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(74095,2998,'content_blocks_17_images_0_description','Figure 13 - Pressure Attenuator'),(74096,2998,'_content_blocks_17_images_0_description','field_6170d90398010'),(74097,2998,'content_blocks_17_images_1_image','2996'),(74098,2998,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(74099,2998,'content_blocks_17_images_1_header',''),(74100,2998,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(74101,2998,'content_blocks_17_images_1_description','Figure 14 - Pressure fluctuation prior to accumulator\r\n\r\nSource: \"Pressure and Flow Rate Fluctuations at High Pressure Intensifier Pumps\", F. Trieb, et.al., 2007 American WJTA Conference and Expo'),(74102,2998,'_content_blocks_17_images_1_description','field_6170d90398010'),(74103,2998,'content_blocks_17_images','2'),(74104,2998,'_content_blocks_17_images','field_6170d8df9800d'),(74105,2998,'content_blocks_18_header','12. Inlet water'),(74106,2998,'_content_blocks_18_header','field_6170d8ba9800b'),(74107,2998,'content_blocks_18_description','Prior to entering the pump cabinet, water may have to be treated to get the water within the waterjet manufacturer’s specifications. Within the pump cabinet, usually in the lower portion, the water will typically go through one or more final filters just prior to entering the intensifier (number 12 in Figures 15 and 2).\r\n\r\nThe inlet water must be able to maintain a specified flow rate and pressure to ensure that the intensifier receives enough water. Incoming water must also meet certain requirements with respect to Total Dissolved Solids (TDS), pH, organic matter, temperature, etc. Poor water quality will result in drastically reduced high pressure component life (i.e. anything the high pressure water comes in contact with). Different pump manufacturers require different inlet water pressures, with some needing as little as 30 psi, and others mandating a water pressure booster pump to maintain 100 psi. Water quality will be discussed in more detail in the chapter 4 \"Water Quality.\"'),(74108,2998,'_content_blocks_18_description','field_6170d8cd9800c'),(74109,2998,'content_blocks_18_images_0_image',''),(74110,2998,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(74111,2998,'content_blocks_18_images_0_header',''),(74112,2998,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(74113,2998,'content_blocks_18_images_0_description','Figure 15 - Inlet water filters'),(74114,2998,'_content_blocks_18_images_0_description','field_6170d90398010'),(74115,2998,'content_blocks_18_images','1'),(74116,2998,'_content_blocks_18_images','field_6170d8df9800d'),(74117,2998,'content_blocks_19_header','13. Controls and PLC'),(74118,2998,'_content_blocks_19_header','field_6170d8ba9800b'),(74119,2998,'content_blocks_19_description','The controls and PLC (not pictured) control the valves in the hydraulic circuit to determine the pressure and flow of the hydraulic oil to and from the intensifier. Various sensor and proximity switches can also be integrated into the controls to monitor the entire pump to verify things like stroke rate, oil temperature and pressure, inlet water pressure and flow rate and more. This capability makes working with and troubleshooting the modern day intensifier much easier.\r\n\r\nThe pneumatic On-Off valve controls the flow of water to the cutting head. The On-Off valve at the cutting is \"normally closed.\" That is, when there is no compressed air supplied to the On-Off valve, a needle fits tightly against a seat to stop any high pressure water from getting to the cutting head. When compressed air is supplied to the On-Off valve (i.e. \"tool on\" command from the control), the needle is forced up from its seating location and the high pressure water can flow through the orifice to the cutting head.\r\n\r\nIn, or near, the high pressure pump cabinet is another On-Off valve that works in tandem with the On-Off valve at the cutting head. The On-Off valve in the pump is typically called the Safety Relief valve. This Safety Relief valve in the pump is \"normally open.\" This valve will stay open when there is no air supplied to it. When the On-Off valve at the cutting head closes (\"tool off\" command by control or no power to the system), the Safety Relief valve in the pump will open, relieving all water pressure from the high pressure tubing. When the \"tool on\" command is issued by the control, the Safety Relief valve closes so that all high pressure water will go to the cutting head. Note, not all manufacturers of new pumps have the Safety Relief valve as standard. We strongly suggest you ask your pump manufacturer if they supply this standard, and when it is activated. Again, some pump manufacturers will only activate the Safety Valve when an E-Stop is pressed; when the pump stops, high pressure lines are still pressurized.\r\n\r\nBoth of these On-Off valves must be in good working order to protect against accidental high pressure water discharge at the cutting head that could severely injure someone working on or near the cutting head or any of the high pressure lines. Periodic replacement of the needle, seat and associated parts is required to maintain these valves.'),(74120,2998,'_content_blocks_19_description','field_6170d8cd9800c'),(74121,2998,'content_blocks_19_images_0_image','2997'),(74122,2998,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(74123,2998,'content_blocks_19_images_0_header',''),(74124,2998,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(74125,2998,'content_blocks_19_images_0_description',''),(74126,2998,'_content_blocks_19_images_0_description','field_6170d90398010'),(74127,2998,'content_blocks_19_images','1'),(74128,2998,'_content_blocks_19_images','field_6170d8df9800d'),(74130,2999,'hero_gallery',''),(74131,2999,'_hero_gallery','field_60c23d554e4a3'),(74132,2999,'hero_banner',''),(74133,2999,'_hero_banner','field_6170dbe179470'),(74134,2999,'page_title','Pumps'),(74135,2999,'_page_title','field_6170d88998008'),(74136,2999,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(74137,2999,'_page_description','field_6170d89398009'),(74138,2999,'content_blocks_0_header','High pressure waterjet cutting'),(74139,2999,'_content_blocks_0_header','field_6170d8ba9800b'),(74140,2999,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(74141,2999,'_content_blocks_0_description','field_6170d8cd9800c'),(74142,2999,'content_blocks_0_images',''),(74143,2999,'_content_blocks_0_images','field_6170d8df9800d'),(74144,2999,'content_blocks_1_header','Types of pumps'),(74145,2999,'_content_blocks_1_header','field_6170d8ba9800b'),(74146,2999,'content_blocks_1_description',''),(74147,2999,'_content_blocks_1_description','field_6170d8cd9800c'),(74148,2999,'content_blocks_1_images',''),(74149,2999,'_content_blocks_1_images','field_6170d8df9800d'),(74150,2999,'content_blocks_2_header','Intensifier'),(74151,2999,'_content_blocks_2_header','field_6170d8ba9800b'),(74152,2999,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(74153,2999,'_content_blocks_2_description','field_6170d8cd9800c'),(74154,2999,'content_blocks_2_images_0_image','2971'),(74155,2999,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(74156,2999,'content_blocks_2_images_0_header',''),(74157,2999,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(74158,2999,'content_blocks_2_images_0_description',''),(74159,2999,'_content_blocks_2_images_0_description','field_6170d90398010'),(74160,2999,'content_blocks_2_images','1'),(74161,2999,'_content_blocks_2_images','field_6170d8df9800d'),(74162,2999,'content_blocks_3_header','The pressurization process'),(74163,2999,'_content_blocks_3_header','field_6170d8ba9800b'),(74164,2999,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(74165,2999,'_content_blocks_3_description','field_6170d8cd9800c'),(74166,2999,'content_blocks_3_images_0_image','2972'),(74167,2999,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(74168,2999,'content_blocks_3_images_0_header',''),(74169,2999,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(74170,2999,'content_blocks_3_images_0_description',''),(74171,2999,'_content_blocks_3_images_0_description','field_6170d90398010'),(74172,2999,'content_blocks_3_images_1_image','2973'),(74173,2999,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(74174,2999,'content_blocks_3_images_1_header',''),(74175,2999,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(74176,2999,'content_blocks_3_images_1_description',''),(74177,2999,'_content_blocks_3_images_1_description','field_6170d90398010'),(74178,2999,'content_blocks_3_images','2'),(74179,2999,'_content_blocks_3_images','field_6170d8df9800d'),(74180,2999,'content_blocks','20'),(74181,2999,'_content_blocks','field_6170d8ac9800a'),(74182,2999,'menu','11'),(74183,2999,'_menu','field_6170d9e059837'),(74184,2999,'display_left_column','1'),(74185,2999,'_display_left_column','field_613563c4d424b'),(74186,2999,'contact_left_heading',''),(74187,2999,'_contact_left_heading','field_60c249d645c99'),(74188,2999,'contact_left_copy',''),(74189,2999,'_contact_left_copy','field_60c24a0845c9c'),(74190,2999,'display_right_column','1'),(74191,2999,'_display_right_column','field_613563f4d424c'),(74192,2999,'contact_right_heading',''),(74193,2999,'_contact_right_heading','field_60c249e945c9a'),(74194,2999,'contact_right_copy',''),(74195,2999,'_contact_right_copy','field_60c249f845c9b'),(74196,2999,'contact_right_cta',''),(74197,2999,'_contact_right_cta','field_60c24a1945c9d'),(74198,2999,'content_blocks_4_header','Direct Drive'),(74199,2999,'_content_blocks_4_header','field_6170d8ba9800b'),(74200,2999,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(74201,2999,'_content_blocks_4_description','field_6170d8cd9800c'),(74202,2999,'content_blocks_4_images_0_image','2976'),(74203,2999,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(74204,2999,'content_blocks_4_images_0_header',''),(74205,2999,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(74206,2999,'content_blocks_4_images_0_description',''),(74207,2999,'_content_blocks_4_images_0_description','field_6170d90398010'),(74208,2999,'content_blocks_4_images_1_image','2977'),(74209,2999,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(74210,2999,'content_blocks_4_images_1_header',''),(74211,2999,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(74212,2999,'content_blocks_4_images_1_description',''),(74213,2999,'_content_blocks_4_images_1_description','field_6170d90398010'),(74214,2999,'content_blocks_4_images','2'),(74215,2999,'_content_blocks_4_images','field_6170d8df9800d'),(74216,2999,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(74217,2999,'_content_blocks_5_header','field_6170d8ba9800b'),(74218,2999,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(74219,2999,'_content_blocks_5_description','field_6170d8cd9800c'),(74220,2999,'content_blocks_5_images_0_image','2979'),(74221,2999,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(74222,2999,'content_blocks_5_images_0_header',''),(74223,2999,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(74224,2999,'content_blocks_5_images_0_description',''),(74225,2999,'_content_blocks_5_images_0_description','field_6170d90398010'),(74226,2999,'content_blocks_5_images_1_image','2980'),(74227,2999,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(74228,2999,'content_blocks_5_images_1_header',''),(74229,2999,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(74230,2999,'content_blocks_5_images_1_description',''),(74231,2999,'_content_blocks_5_images_1_description','field_6170d90398010'),(74232,2999,'content_blocks_5_images','2'),(74233,2999,'_content_blocks_5_images','field_6170d8df9800d'),(74234,2999,'content_blocks_6_header','Parts of the intensifier pump'),(74235,2999,'_content_blocks_6_header','field_6170d8ba9800b'),(74236,2999,'content_blocks_6_description',''),(74237,2999,'_content_blocks_6_description','field_6170d8cd9800c'),(74238,2999,'content_blocks_6_images',''),(74239,2999,'_content_blocks_6_images','field_6170d8df9800d'),(74240,2999,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(74241,2999,'_content_blocks_7_header','field_6170d8ba9800b'),(74242,2999,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(74243,2999,'_content_blocks_7_description','field_6170d8cd9800c'),(74244,2999,'content_blocks_7_images_0_image','2981'),(74245,2999,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(74246,2999,'content_blocks_7_images_0_header',''),(74247,2999,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(74248,2999,'content_blocks_7_images_0_description',''),(74249,2999,'_content_blocks_7_images_0_description','field_6170d90398010'),(74250,2999,'content_blocks_7_images','1'),(74251,2999,'_content_blocks_7_images','field_6170d8df9800d'),(74252,2999,'content_blocks_8_header','2. Directional control valves'),(74253,2999,'_content_blocks_8_header','field_6170d8ba9800b'),(74254,2999,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(74255,2999,'_content_blocks_8_description','field_6170d8cd9800c'),(74256,2999,'content_blocks_8_images_0_image','2982'),(74257,2999,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(74258,2999,'content_blocks_8_images_0_header',''),(74259,2999,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(74260,2999,'content_blocks_8_images_0_description',''),(74261,2999,'_content_blocks_8_images_0_description','field_6170d90398010'),(74262,2999,'content_blocks_8_images','1'),(74263,2999,'_content_blocks_8_images','field_6170d8df9800d'),(74264,2999,'content_blocks_9_header','3. Intensifier'),(74265,2999,'_content_blocks_9_header','field_6170d8ba9800b'),(74266,2999,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(74267,2999,'_content_blocks_9_description','field_6170d8cd9800c'),(74268,2999,'content_blocks_9_images_0_image','2984'),(74269,2999,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(74270,2999,'content_blocks_9_images_0_header',''),(74271,2999,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(74272,2999,'content_blocks_9_images_0_description',''),(74273,2999,'_content_blocks_9_images_0_description','field_6170d90398010'),(74274,2999,'content_blocks_9_images','1'),(74275,2999,'_content_blocks_9_images','field_6170d8df9800d'),(74276,2999,'content_blocks_10_header','4. Hydraulic cylinder'),(74277,2999,'_content_blocks_10_header','field_6170d8ba9800b'),(74278,2999,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(74279,2999,'_content_blocks_10_description','field_6170d8cd9800c'),(74280,2999,'content_blocks_10_images_0_image','2985'),(74281,2999,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(74282,2999,'content_blocks_10_images_0_header',''),(74283,2999,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(74284,2999,'content_blocks_10_images_0_description',''),(74285,2999,'_content_blocks_10_images_0_description','field_6170d90398010'),(74286,2999,'content_blocks_10_images','1'),(74287,2999,'_content_blocks_10_images','field_6170d8df9800d'),(74288,2999,'content_blocks_11_header','5. Piston'),(74289,2999,'_content_blocks_11_header','field_6170d8ba9800b'),(74290,2999,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(74291,2999,'_content_blocks_11_description','field_6170d8cd9800c'),(74292,2999,'content_blocks_11_images_0_image','2986'),(74293,2999,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(74294,2999,'content_blocks_11_images_0_header',''),(74295,2999,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(74296,2999,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(74297,2999,'_content_blocks_11_images_0_description','field_6170d90398010'),(74298,2999,'content_blocks_11_images','1'),(74299,2999,'_content_blocks_11_images','field_6170d8df9800d'),(74300,2999,'content_blocks_12_header','6. Plunger'),(74301,2999,'_content_blocks_12_header','field_6170d8ba9800b'),(74302,2999,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(74303,2999,'_content_blocks_12_description','field_6170d8cd9800c'),(74304,2999,'content_blocks_12_images_0_image','2987'),(74305,2999,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(74306,2999,'content_blocks_12_images_0_header',''),(74307,2999,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(74308,2999,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(74309,2999,'_content_blocks_12_images_0_description','field_6170d90398010'),(74310,2999,'content_blocks_12_images','1'),(74311,2999,'_content_blocks_12_images','field_6170d8df9800d'),(74312,2999,'content_blocks_13_header','7. High pressure cylinder'),(74313,2999,'_content_blocks_13_header','field_6170d8ba9800b'),(74314,2999,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(74315,2999,'_content_blocks_13_description','field_6170d8cd9800c'),(74316,2999,'content_blocks_13_images_0_image','2984'),(74317,2999,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(74318,2999,'content_blocks_13_images_0_header',''),(74319,2999,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(74320,2999,'content_blocks_13_images_0_description',''),(74321,2999,'_content_blocks_13_images_0_description','field_6170d90398010'),(74322,2999,'content_blocks_13_images','1'),(74323,2999,'_content_blocks_13_images','field_6170d8df9800d'),(74324,2999,'content_blocks_14_header','8. Check valve'),(74325,2999,'_content_blocks_14_header','field_6170d8ba9800b'),(74326,2999,'content_blocks_14_description','There is one check valve (number 8 in Figures 10 and 8) at the end of each high pressure cylinder at the end opposite from the hydraulic cylinder. The check valve allows fresh water to enter the high pressure cylinder and high pressure water to exit the intensifier. The check valve is designed to only let water flow in one direction. Fresh water comes in though channels machined in the sides and exits through one or more holes in the face of the valve. Various seals, poppets and springs are used to maintain this water flow. Over several hundred hours these components will wear, allowing pressurized water to flow out the water inlet path, or allowing pressurized water to seep back into the high pressure cylinder. The symptoms and diagnosis of these various situations will be discussed later in the \"Maintenance\" chapter.'),(74327,2999,'_content_blocks_14_description','field_6170d8cd9800c'),(74328,2999,'content_blocks_14_images_0_image','2988'),(74329,2999,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(74330,2999,'content_blocks_14_images_0_header',''),(74331,2999,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(74332,2999,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(74333,2999,'_content_blocks_14_images_0_description','field_6170d90398010'),(74334,2999,'content_blocks_14_images_1_image','2989'),(74335,2999,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(74336,2999,'content_blocks_14_images_1_header',''),(74337,2999,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(74338,2999,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(74339,2999,'_content_blocks_14_images_1_description','field_6170d90398010'),(74340,2999,'content_blocks_14_images','3'),(74341,2999,'_content_blocks_14_images','field_6170d8df9800d'),(74342,2999,'content_blocks_14_images_2_image','2991'),(74343,2999,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(74344,2999,'content_blocks_14_images_2_header',''),(74345,2999,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(74346,2999,'content_blocks_14_images_2_description','Figure 11 - View of upper portion of intensifier cabinet'),(74347,2999,'_content_blocks_14_images_2_description','field_6170d90398010'),(74348,2999,'content_blocks_15_header','End Cap'),(74349,2999,'_content_blocks_15_header','field_6170d8ba9800b'),(74350,2999,'content_blocks_15_description','The end cap (number 9 in Figures 11 and 2) is either a cylindrical or square item. The cylindrical version screws onto the output end of the high pressure cylinder. The square type is held in place with tie rods and bolts. The end cap has a hole in the center for the check valve and outlet body. It will also have a connection point for the incoming fresh water. The water flows through holes machined through the cap to line up with inlet holes in the check valve.'),(74351,2999,'_content_blocks_15_description','field_6170d8cd9800c'),(74352,2999,'content_blocks_15_images_0_image','2992'),(74353,2999,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(74354,2999,'content_blocks_15_images_0_header',''),(74355,2999,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(74356,2999,'content_blocks_15_images_0_description',''),(74357,2999,'_content_blocks_15_images_0_description','field_6170d90398010'),(74358,2999,'content_blocks_15_images','1'),(74359,2999,'_content_blocks_15_images','field_6170d8df9800d'),(74360,2999,'content_blocks_16_header','10. High pressure tubing'),(74361,2999,'_content_blocks_16_header','field_6170d8ba9800b'),(74362,2999,'content_blocks_16_description','High pressure 304 or 316 stainless steel tubing (number 10 in Figure 11) is attached to the outlet of each check valve. Common outer diameters are 0.25\", 0.313\", 0.375\" and 0.563\". Inner diameters range from 0.062\" to 0.312\". There is usually a flexible protective covering around the tube.\r\n\r\nThe high pressure tubing from the left hand high pressure cylinder will join together at some point with the high pressure tubing from the right hand cylinder. The high pressure tubing carries the pressurized water to the pressure attenuator. Additional high pressure tubing will channel the high pressure water to the cutting head.\r\n\r\nThe length, number of bends and other obstructions to flow (e.g. hand valves) in the high pressure tubing path must be taken into consideration when designing a high pressure waterjet system. Pressure will drop with each bend in the tubing. Also, as the distance between the pump and the cutting head increases, internal friction of the water as it drags against the inner walls will generate heat resulting in a loss of water pressure. This topic will be discussed in more detail in the Chapter 5 \"Pressure Drop in Tubing.\"'),(74363,2999,'_content_blocks_16_description','field_6170d8cd9800c'),(74364,2999,'content_blocks_16_images_0_image','2994'),(74365,2999,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(74366,2999,'content_blocks_16_images_0_header',''),(74367,2999,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(74368,2999,'content_blocks_16_images_0_description',''),(74369,2999,'_content_blocks_16_images_0_description','field_6170d90398010'),(74370,2999,'content_blocks_16_images','1'),(74371,2999,'_content_blocks_16_images','field_6170d8df9800d'),(74372,2999,'content_blocks_17_header','11. Pressure attenuator'),(74373,2999,'_content_blocks_17_header','field_6170d8ba9800b'),(74374,2999,'content_blocks_17_description','The pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nThe pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nFigure 14 shows the pressure fluctuations in the high pressure water line prior to the pressure accumulator. This shows a pressure change from high to low of almost 22,000 psi. So, for a 60,000 psi system, the high pressure water would be going from 60,000 psi to 40,000 psi after every stroke of the intensifier.\r\n\r\nIf this pressure fluctuation were not smoothed out by the pressure attenuator, cutting results at the work piece would be undesirable. There would be a significant line in the part with every stroke of the intensifier. Recall that any change in pressure results in a change in speed of the waterjet stream at the cutting head. This change in speed changes the speed at which the abrasive particles are moving and, therefore, the amount of force they will impart on the work piece. Lower pressure leads to less speed of the water which leads to less force of the abrasive which leads to slower cutting, or rougher edge quality.\r\n\r\nFortunately the pressure attenuator smoothes out these pressure spikes so that the water at the cutting head maintains a steady pressure, speed and cutting power.\r\n\r\n&nbsp;'),(74375,2999,'_content_blocks_17_description','field_6170d8cd9800c'),(74376,2999,'content_blocks_17_images_0_image','2995'),(74377,2999,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(74378,2999,'content_blocks_17_images_0_header',''),(74379,2999,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(74380,2999,'content_blocks_17_images_0_description','Figure 13 - Pressure Attenuator'),(74381,2999,'_content_blocks_17_images_0_description','field_6170d90398010'),(74382,2999,'content_blocks_17_images_1_image','2996'),(74383,2999,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(74384,2999,'content_blocks_17_images_1_header',''),(74385,2999,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(74386,2999,'content_blocks_17_images_1_description','Figure 14 - Pressure fluctuation prior to accumulator\r\n\r\nSource: \"Pressure and Flow Rate Fluctuations at High Pressure Intensifier Pumps\", F. Trieb, et.al., 2007 American WJTA Conference and Expo'),(74387,2999,'_content_blocks_17_images_1_description','field_6170d90398010'),(74388,2999,'content_blocks_17_images','2'),(74389,2999,'_content_blocks_17_images','field_6170d8df9800d'),(74390,2999,'content_blocks_18_header','12. Inlet water'),(74391,2999,'_content_blocks_18_header','field_6170d8ba9800b'),(74392,2999,'content_blocks_18_description','Prior to entering the pump cabinet, water may have to be treated to get the water within the waterjet manufacturer’s specifications. Within the pump cabinet, usually in the lower portion, the water will typically go through one or more final filters just prior to entering the intensifier (number 12 in Figures 15 and 2).\r\n\r\nThe inlet water must be able to maintain a specified flow rate and pressure to ensure that the intensifier receives enough water. Incoming water must also meet certain requirements with respect to Total Dissolved Solids (TDS), pH, organic matter, temperature, etc. Poor water quality will result in drastically reduced high pressure component life (i.e. anything the high pressure water comes in contact with). Different pump manufacturers require different inlet water pressures, with some needing as little as 30 psi, and others mandating a water pressure booster pump to maintain 100 psi. Water quality will be discussed in more detail in the chapter 4 \"Water Quality.\"'),(74393,2999,'_content_blocks_18_description','field_6170d8cd9800c'),(74394,2999,'content_blocks_18_images_0_image',''),(74395,2999,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(74396,2999,'content_blocks_18_images_0_header',''),(74397,2999,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(74398,2999,'content_blocks_18_images_0_description','Figure 15 - Inlet water filters'),(74399,2999,'_content_blocks_18_images_0_description','field_6170d90398010'),(74400,2999,'content_blocks_18_images','1'),(74401,2999,'_content_blocks_18_images','field_6170d8df9800d'),(74402,2999,'content_blocks_19_header','13. Controls and PLC'),(74403,2999,'_content_blocks_19_header','field_6170d8ba9800b'),(74404,2999,'content_blocks_19_description','The controls and PLC (not pictured) control the valves in the hydraulic circuit to determine the pressure and flow of the hydraulic oil to and from the intensifier. Various sensor and proximity switches can also be integrated into the controls to monitor the entire pump to verify things like stroke rate, oil temperature and pressure, inlet water pressure and flow rate and more. This capability makes working with and troubleshooting the modern day intensifier much easier.\r\n\r\nThe pneumatic On-Off valve controls the flow of water to the cutting head. The On-Off valve at the cutting is \"normally closed.\" That is, when there is no compressed air supplied to the On-Off valve, a needle fits tightly against a seat to stop any high pressure water from getting to the cutting head. When compressed air is supplied to the On-Off valve (i.e. \"tool on\" command from the control), the needle is forced up from its seating location and the high pressure water can flow through the orifice to the cutting head.\r\n\r\nIn, or near, the high pressure pump cabinet is another On-Off valve that works in tandem with the On-Off valve at the cutting head. The On-Off valve in the pump is typically called the Safety Relief valve. This Safety Relief valve in the pump is \"normally open.\" This valve will stay open when there is no air supplied to it. When the On-Off valve at the cutting head closes (\"tool off\" command by control or no power to the system), the Safety Relief valve in the pump will open, relieving all water pressure from the high pressure tubing. When the \"tool on\" command is issued by the control, the Safety Relief valve closes so that all high pressure water will go to the cutting head. Note, not all manufacturers of new pumps have the Safety Relief valve as standard. We strongly suggest you ask your pump manufacturer if they supply this standard, and when it is activated. Again, some pump manufacturers will only activate the Safety Valve when an E-Stop is pressed; when the pump stops, high pressure lines are still pressurized.\r\n\r\nBoth of these On-Off valves must be in good working order to protect against accidental high pressure water discharge at the cutting head that could severely injure someone working on or near the cutting head or any of the high pressure lines. Periodic replacement of the needle, seat and associated parts is required to maintain these valves.'),(74405,2999,'_content_blocks_19_description','field_6170d8cd9800c'),(74406,2999,'content_blocks_19_images_0_image','2997'),(74407,2999,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(74408,2999,'content_blocks_19_images_0_header',''),(74409,2999,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(74410,2999,'content_blocks_19_images_0_description',''),(74411,2999,'_content_blocks_19_images_0_description','field_6170d90398010'),(74412,2999,'content_blocks_19_images','1'),(74413,2999,'_content_blocks_19_images','field_6170d8df9800d'),(74415,3000,'hero_gallery',''),(74416,3000,'_hero_gallery','field_60c23d554e4a3'),(74417,3000,'hero_banner',''),(74418,3000,'_hero_banner','field_6170dbe179470'),(74419,3000,'page_title','Pumps'),(74420,3000,'_page_title','field_6170d88998008'),(74421,3000,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(74422,3000,'_page_description','field_6170d89398009'),(74423,3000,'content_blocks_0_header','High pressure waterjet cutting'),(74424,3000,'_content_blocks_0_header','field_6170d8ba9800b'),(74425,3000,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(74426,3000,'_content_blocks_0_description','field_6170d8cd9800c'),(74427,3000,'content_blocks_0_images',''),(74428,3000,'_content_blocks_0_images','field_6170d8df9800d'),(74429,3000,'content_blocks_1_header','Types of pumps'),(74430,3000,'_content_blocks_1_header','field_6170d8ba9800b'),(74431,3000,'content_blocks_1_description',''),(74432,3000,'_content_blocks_1_description','field_6170d8cd9800c'),(74433,3000,'content_blocks_1_images',''),(74434,3000,'_content_blocks_1_images','field_6170d8df9800d'),(74435,3000,'content_blocks_2_header','Intensifier'),(74436,3000,'_content_blocks_2_header','field_6170d8ba9800b'),(74437,3000,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(74438,3000,'_content_blocks_2_description','field_6170d8cd9800c'),(74439,3000,'content_blocks_2_images_0_image','2971'),(74440,3000,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(74441,3000,'content_blocks_2_images_0_header',''),(74442,3000,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(74443,3000,'content_blocks_2_images_0_description',''),(74444,3000,'_content_blocks_2_images_0_description','field_6170d90398010'),(74445,3000,'content_blocks_2_images','1'),(74446,3000,'_content_blocks_2_images','field_6170d8df9800d'),(74447,3000,'content_blocks_3_header','The pressurization process'),(74448,3000,'_content_blocks_3_header','field_6170d8ba9800b'),(74449,3000,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(74450,3000,'_content_blocks_3_description','field_6170d8cd9800c'),(74451,3000,'content_blocks_3_images_0_image','2972'),(74452,3000,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(74453,3000,'content_blocks_3_images_0_header',''),(74454,3000,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(74455,3000,'content_blocks_3_images_0_description',''),(74456,3000,'_content_blocks_3_images_0_description','field_6170d90398010'),(74457,3000,'content_blocks_3_images_1_image','2973'),(74458,3000,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(74459,3000,'content_blocks_3_images_1_header',''),(74460,3000,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(74461,3000,'content_blocks_3_images_1_description',''),(74462,3000,'_content_blocks_3_images_1_description','field_6170d90398010'),(74463,3000,'content_blocks_3_images','2'),(74464,3000,'_content_blocks_3_images','field_6170d8df9800d'),(74465,3000,'content_blocks','20'),(74466,3000,'_content_blocks','field_6170d8ac9800a'),(74467,3000,'menu','11'),(74468,3000,'_menu','field_6170d9e059837'),(74469,3000,'display_left_column','1'),(74470,3000,'_display_left_column','field_613563c4d424b'),(74471,3000,'contact_left_heading',''),(74472,3000,'_contact_left_heading','field_60c249d645c99'),(74473,3000,'contact_left_copy',''),(74474,3000,'_contact_left_copy','field_60c24a0845c9c'),(74475,3000,'display_right_column','1'),(74476,3000,'_display_right_column','field_613563f4d424c'),(74477,3000,'contact_right_heading',''),(74478,3000,'_contact_right_heading','field_60c249e945c9a'),(74479,3000,'contact_right_copy',''),(74480,3000,'_contact_right_copy','field_60c249f845c9b'),(74481,3000,'contact_right_cta',''),(74482,3000,'_contact_right_cta','field_60c24a1945c9d'),(74483,3000,'content_blocks_4_header','Direct Drive'),(74484,3000,'_content_blocks_4_header','field_6170d8ba9800b'),(74485,3000,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(74486,3000,'_content_blocks_4_description','field_6170d8cd9800c'),(74487,3000,'content_blocks_4_images_0_image','2976'),(74488,3000,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(74489,3000,'content_blocks_4_images_0_header',''),(74490,3000,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(74491,3000,'content_blocks_4_images_0_description',''),(74492,3000,'_content_blocks_4_images_0_description','field_6170d90398010'),(74493,3000,'content_blocks_4_images_1_image','2977'),(74494,3000,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(74495,3000,'content_blocks_4_images_1_header',''),(74496,3000,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(74497,3000,'content_blocks_4_images_1_description',''),(74498,3000,'_content_blocks_4_images_1_description','field_6170d90398010'),(74499,3000,'content_blocks_4_images','2'),(74500,3000,'_content_blocks_4_images','field_6170d8df9800d'),(74501,3000,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(74502,3000,'_content_blocks_5_header','field_6170d8ba9800b'),(74503,3000,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(74504,3000,'_content_blocks_5_description','field_6170d8cd9800c'),(74505,3000,'content_blocks_5_images_0_image','2979'),(74506,3000,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(74507,3000,'content_blocks_5_images_0_header',''),(74508,3000,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(74509,3000,'content_blocks_5_images_0_description',''),(74510,3000,'_content_blocks_5_images_0_description','field_6170d90398010'),(74511,3000,'content_blocks_5_images_1_image','2980'),(74512,3000,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(74513,3000,'content_blocks_5_images_1_header',''),(74514,3000,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(74515,3000,'content_blocks_5_images_1_description',''),(74516,3000,'_content_blocks_5_images_1_description','field_6170d90398010'),(74517,3000,'content_blocks_5_images','2'),(74518,3000,'_content_blocks_5_images','field_6170d8df9800d'),(74519,3000,'content_blocks_6_header','Parts of the intensifier pump'),(74520,3000,'_content_blocks_6_header','field_6170d8ba9800b'),(74521,3000,'content_blocks_6_description',''),(74522,3000,'_content_blocks_6_description','field_6170d8cd9800c'),(74523,3000,'content_blocks_6_images',''),(74524,3000,'_content_blocks_6_images','field_6170d8df9800d'),(74525,3000,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(74526,3000,'_content_blocks_7_header','field_6170d8ba9800b'),(74527,3000,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(74528,3000,'_content_blocks_7_description','field_6170d8cd9800c'),(74529,3000,'content_blocks_7_images_0_image','2981'),(74530,3000,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(74531,3000,'content_blocks_7_images_0_header',''),(74532,3000,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(74533,3000,'content_blocks_7_images_0_description',''),(74534,3000,'_content_blocks_7_images_0_description','field_6170d90398010'),(74535,3000,'content_blocks_7_images','1'),(74536,3000,'_content_blocks_7_images','field_6170d8df9800d'),(74537,3000,'content_blocks_8_header','2. Directional control valves'),(74538,3000,'_content_blocks_8_header','field_6170d8ba9800b'),(74539,3000,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(74540,3000,'_content_blocks_8_description','field_6170d8cd9800c'),(74541,3000,'content_blocks_8_images_0_image','2982'),(74542,3000,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(74543,3000,'content_blocks_8_images_0_header',''),(74544,3000,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(74545,3000,'content_blocks_8_images_0_description',''),(74546,3000,'_content_blocks_8_images_0_description','field_6170d90398010'),(74547,3000,'content_blocks_8_images','1'),(74548,3000,'_content_blocks_8_images','field_6170d8df9800d'),(74549,3000,'content_blocks_9_header','3. Intensifier'),(74550,3000,'_content_blocks_9_header','field_6170d8ba9800b'),(74551,3000,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(74552,3000,'_content_blocks_9_description','field_6170d8cd9800c'),(74553,3000,'content_blocks_9_images_0_image','2984'),(74554,3000,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(74555,3000,'content_blocks_9_images_0_header',''),(74556,3000,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(74557,3000,'content_blocks_9_images_0_description',''),(74558,3000,'_content_blocks_9_images_0_description','field_6170d90398010'),(74559,3000,'content_blocks_9_images','1'),(74560,3000,'_content_blocks_9_images','field_6170d8df9800d'),(74561,3000,'content_blocks_10_header','4. Hydraulic cylinder'),(74562,3000,'_content_blocks_10_header','field_6170d8ba9800b'),(74563,3000,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(74564,3000,'_content_blocks_10_description','field_6170d8cd9800c'),(74565,3000,'content_blocks_10_images_0_image','2985'),(74566,3000,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(74567,3000,'content_blocks_10_images_0_header',''),(74568,3000,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(74569,3000,'content_blocks_10_images_0_description',''),(74570,3000,'_content_blocks_10_images_0_description','field_6170d90398010'),(74571,3000,'content_blocks_10_images','1'),(74572,3000,'_content_blocks_10_images','field_6170d8df9800d'),(74573,3000,'content_blocks_11_header','5. Piston'),(74574,3000,'_content_blocks_11_header','field_6170d8ba9800b'),(74575,3000,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(74576,3000,'_content_blocks_11_description','field_6170d8cd9800c'),(74577,3000,'content_blocks_11_images_0_image','2986'),(74578,3000,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(74579,3000,'content_blocks_11_images_0_header',''),(74580,3000,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(74581,3000,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(74582,3000,'_content_blocks_11_images_0_description','field_6170d90398010'),(74583,3000,'content_blocks_11_images','1'),(74584,3000,'_content_blocks_11_images','field_6170d8df9800d'),(74585,3000,'content_blocks_12_header','6. Plunger'),(74586,3000,'_content_blocks_12_header','field_6170d8ba9800b'),(74587,3000,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(74588,3000,'_content_blocks_12_description','field_6170d8cd9800c'),(74589,3000,'content_blocks_12_images_0_image','2987'),(74590,3000,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(74591,3000,'content_blocks_12_images_0_header',''),(74592,3000,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(74593,3000,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(74594,3000,'_content_blocks_12_images_0_description','field_6170d90398010'),(74595,3000,'content_blocks_12_images','1'),(74596,3000,'_content_blocks_12_images','field_6170d8df9800d'),(74597,3000,'content_blocks_13_header','7. High pressure cylinder'),(74598,3000,'_content_blocks_13_header','field_6170d8ba9800b'),(74599,3000,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(74600,3000,'_content_blocks_13_description','field_6170d8cd9800c'),(74601,3000,'content_blocks_13_images_0_image','2984'),(74602,3000,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(74603,3000,'content_blocks_13_images_0_header',''),(74604,3000,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(74605,3000,'content_blocks_13_images_0_description',''),(74606,3000,'_content_blocks_13_images_0_description','field_6170d90398010'),(74607,3000,'content_blocks_13_images','1'),(74608,3000,'_content_blocks_13_images','field_6170d8df9800d'),(74609,3000,'content_blocks_14_header','8. Check valve'),(74610,3000,'_content_blocks_14_header','field_6170d8ba9800b'),(74611,3000,'content_blocks_14_description','There is one check valve (number 8 in Figures 10 and 8) at the end of each high pressure cylinder at the end opposite from the hydraulic cylinder. The check valve allows fresh water to enter the high pressure cylinder and high pressure water to exit the intensifier. The check valve is designed to only let water flow in one direction. Fresh water comes in though channels machined in the sides and exits through one or more holes in the face of the valve. Various seals, poppets and springs are used to maintain this water flow. Over several hundred hours these components will wear, allowing pressurized water to flow out the water inlet path, or allowing pressurized water to seep back into the high pressure cylinder. The symptoms and diagnosis of these various situations will be discussed later in the \"Maintenance\" chapter.'),(74612,3000,'_content_blocks_14_description','field_6170d8cd9800c'),(74613,3000,'content_blocks_14_images_0_image','2988'),(74614,3000,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(74615,3000,'content_blocks_14_images_0_header',''),(74616,3000,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(74617,3000,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(74618,3000,'_content_blocks_14_images_0_description','field_6170d90398010'),(74619,3000,'content_blocks_14_images_1_image','2989'),(74620,3000,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(74621,3000,'content_blocks_14_images_1_header',''),(74622,3000,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(74623,3000,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(74624,3000,'_content_blocks_14_images_1_description','field_6170d90398010'),(74625,3000,'content_blocks_14_images','3'),(74626,3000,'_content_blocks_14_images','field_6170d8df9800d'),(74627,3000,'content_blocks_14_images_2_image','2991'),(74628,3000,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(74629,3000,'content_blocks_14_images_2_header',''),(74630,3000,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(74631,3000,'content_blocks_14_images_2_description','Figure 11 - View of upper portion of intensifier cabinet'),(74632,3000,'_content_blocks_14_images_2_description','field_6170d90398010'),(74633,3000,'content_blocks_15_header','End Cap'),(74634,3000,'_content_blocks_15_header','field_6170d8ba9800b'),(74635,3000,'content_blocks_15_description','The end cap (number 9 in Figures 11 and 2) is either a cylindrical or square item. The cylindrical version screws onto the output end of the high pressure cylinder. The square type is held in place with tie rods and bolts. The end cap has a hole in the center for the check valve and outlet body. It will also have a connection point for the incoming fresh water. The water flows through holes machined through the cap to line up with inlet holes in the check valve.'),(74636,3000,'_content_blocks_15_description','field_6170d8cd9800c'),(74637,3000,'content_blocks_15_images_0_image','2992'),(74638,3000,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(74639,3000,'content_blocks_15_images_0_header',''),(74640,3000,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(74641,3000,'content_blocks_15_images_0_description',''),(74642,3000,'_content_blocks_15_images_0_description','field_6170d90398010'),(74643,3000,'content_blocks_15_images','1'),(74644,3000,'_content_blocks_15_images','field_6170d8df9800d'),(74645,3000,'content_blocks_16_header','10. High pressure tubing'),(74646,3000,'_content_blocks_16_header','field_6170d8ba9800b'),(74647,3000,'content_blocks_16_description','High pressure 304 or 316 stainless steel tubing (number 10 in Figure 11) is attached to the outlet of each check valve. Common outer diameters are 0.25\", 0.313\", 0.375\" and 0.563\". Inner diameters range from 0.062\" to 0.312\". There is usually a flexible protective covering around the tube.\r\n\r\nThe high pressure tubing from the left hand high pressure cylinder will join together at some point with the high pressure tubing from the right hand cylinder. The high pressure tubing carries the pressurized water to the pressure attenuator. Additional high pressure tubing will channel the high pressure water to the cutting head.\r\n\r\nThe length, number of bends and other obstructions to flow (e.g. hand valves) in the high pressure tubing path must be taken into consideration when designing a high pressure waterjet system. Pressure will drop with each bend in the tubing. Also, as the distance between the pump and the cutting head increases, internal friction of the water as it drags against the inner walls will generate heat resulting in a loss of water pressure. This topic will be discussed in more detail in the Chapter 5 \"Pressure Drop in Tubing.\"'),(74648,3000,'_content_blocks_16_description','field_6170d8cd9800c'),(74649,3000,'content_blocks_16_images_0_image','2994'),(74650,3000,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(74651,3000,'content_blocks_16_images_0_header',''),(74652,3000,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(74653,3000,'content_blocks_16_images_0_description',''),(74654,3000,'_content_blocks_16_images_0_description','field_6170d90398010'),(74655,3000,'content_blocks_16_images','1'),(74656,3000,'_content_blocks_16_images','field_6170d8df9800d'),(74657,3000,'content_blocks_17_header','11. Pressure attenuator'),(74658,3000,'_content_blocks_17_header','field_6170d8ba9800b'),(74659,3000,'content_blocks_17_description','The pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nThe pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nFigure 14 shows the pressure fluctuations in the high pressure water line prior to the pressure accumulator. This shows a pressure change from high to low of almost 22,000 psi. So, for a 60,000 psi system, the high pressure water would be going from 60,000 psi to 40,000 psi after every stroke of the intensifier.\r\n\r\nIf this pressure fluctuation were not smoothed out by the pressure attenuator, cutting results at the work piece would be undesirable. There would be a significant line in the part with every stroke of the intensifier. Recall that any change in pressure results in a change in speed of the waterjet stream at the cutting head. This change in speed changes the speed at which the abrasive particles are moving and, therefore, the amount of force they will impart on the work piece. Lower pressure leads to less speed of the water which leads to less force of the abrasive which leads to slower cutting, or rougher edge quality.\r\n\r\nFortunately the pressure attenuator smoothes out these pressure spikes so that the water at the cutting head maintains a steady pressure, speed and cutting power.\r\n\r\n&nbsp;'),(74660,3000,'_content_blocks_17_description','field_6170d8cd9800c'),(74661,3000,'content_blocks_17_images_0_image','2995'),(74662,3000,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(74663,3000,'content_blocks_17_images_0_header',''),(74664,3000,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(74665,3000,'content_blocks_17_images_0_description','Figure 13 - Pressure Attenuator'),(74666,3000,'_content_blocks_17_images_0_description','field_6170d90398010'),(74667,3000,'content_blocks_17_images_1_image','2996'),(74668,3000,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(74669,3000,'content_blocks_17_images_1_header',''),(74670,3000,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(74671,3000,'content_blocks_17_images_1_description','Figure 14 - Pressure fluctuation prior to accumulator\r\n\r\nSource: \"Pressure and Flow Rate Fluctuations at High Pressure Intensifier Pumps\", F. Trieb, et.al., 2007 American WJTA Conference and Expo'),(74672,3000,'_content_blocks_17_images_1_description','field_6170d90398010'),(74673,3000,'content_blocks_17_images','2'),(74674,3000,'_content_blocks_17_images','field_6170d8df9800d'),(74675,3000,'content_blocks_18_header','12. Inlet water'),(74676,3000,'_content_blocks_18_header','field_6170d8ba9800b'),(74677,3000,'content_blocks_18_description','Prior to entering the pump cabinet, water may have to be treated to get the water within the waterjet manufacturer’s specifications. Within the pump cabinet, usually in the lower portion, the water will typically go through one or more final filters just prior to entering the intensifier (number 12 in Figures 15 and 2).\r\n\r\nThe inlet water must be able to maintain a specified flow rate and pressure to ensure that the intensifier receives enough water. Incoming water must also meet certain requirements with respect to Total Dissolved Solids (TDS), pH, organic matter, temperature, etc. Poor water quality will result in drastically reduced high pressure component life (i.e. anything the high pressure water comes in contact with). Different pump manufacturers require different inlet water pressures, with some needing as little as 30 psi, and others mandating a water pressure booster pump to maintain 100 psi. Water quality will be discussed in more detail in the chapter 4 \"Water Quality.\"'),(74678,3000,'_content_blocks_18_description','field_6170d8cd9800c'),(74679,3000,'content_blocks_18_images_0_image',''),(74680,3000,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(74681,3000,'content_blocks_18_images_0_header',''),(74682,3000,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(74683,3000,'content_blocks_18_images_0_description','Figure 15 - Inlet water filters'),(74684,3000,'_content_blocks_18_images_0_description','field_6170d90398010'),(74685,3000,'content_blocks_18_images','1'),(74686,3000,'_content_blocks_18_images','field_6170d8df9800d'),(74687,3000,'content_blocks_19_header','13. Controls and PLC'),(74688,3000,'_content_blocks_19_header','field_6170d8ba9800b'),(74689,3000,'content_blocks_19_description','The controls and PLC (not pictured) control the valves in the hydraulic circuit to determine the pressure and flow of the hydraulic oil to and from the intensifier. Various sensor and proximity switches can also be integrated into the controls to monitor the entire pump to verify things like stroke rate, oil temperature and pressure, inlet water pressure and flow rate and more. This capability makes working with and troubleshooting the modern day intensifier much easier.\r\n\r\nThe pneumatic On-Off valve controls the flow of water to the cutting head. The On-Off valve at the cutting is \"normally closed.\" That is, when there is no compressed air supplied to the On-Off valve, a needle fits tightly against a seat to stop any high pressure water from getting to the cutting head. When compressed air is supplied to the On-Off valve (i.e. \"tool on\" command from the control), the needle is forced up from its seating location and the high pressure water can flow through the orifice to the cutting head.\r\n\r\nIn, or near, the high pressure pump cabinet is another On-Off valve that works in tandem with the On-Off valve at the cutting head. The On-Off valve in the pump is typically called the Safety Relief valve. This Safety Relief valve in the pump is \"normally open.\" This valve will stay open when there is no air supplied to it. When the On-Off valve at the cutting head closes (\"tool off\" command by control or no power to the system), the Safety Relief valve in the pump will open, relieving all water pressure from the high pressure tubing. When the \"tool on\" command is issued by the control, the Safety Relief valve closes so that all high pressure water will go to the cutting head. Note, not all manufacturers of new pumps have the Safety Relief valve as standard. We strongly suggest you ask your pump manufacturer if they supply this standard, and when it is activated. Again, some pump manufacturers will only activate the Safety Valve when an E-Stop is pressed; when the pump stops, high pressure lines are still pressurized.\r\n\r\nBoth of these On-Off valves must be in good working order to protect against accidental high pressure water discharge at the cutting head that could severely injure someone working on or near the cutting head or any of the high pressure lines. Periodic replacement of the needle, seat and associated parts is required to maintain these valves.'),(74690,3000,'_content_blocks_19_description','field_6170d8cd9800c'),(74691,3000,'content_blocks_19_images_0_image','2997'),(74692,3000,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(74693,3000,'content_blocks_19_images_0_header',''),(74694,3000,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(74695,3000,'content_blocks_19_images_0_description',''),(74696,3000,'_content_blocks_19_images_0_description','field_6170d90398010'),(74697,3000,'content_blocks_19_images','1'),(74698,3000,'_content_blocks_19_images','field_6170d8df9800d'),(74700,3001,'_wp_attached_file','2021/11/Vector-Smart-Object.jpg'),(74701,3001,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:599;s:6:\"height\";i:455;s:4:\"file\";s:31:\"2021/11/Vector-Smart-Object.jpg\";s:5:\"sizes\";a:0:{}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(74702,3001,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:49;}}'),(74703,3002,'agg_hero_gallery','1'),(74704,3002,'_agg_hero_gallery','field_60c23d554e4a3'),(74705,3002,'agg_contact_left_heading','Get in touch'),(74706,3002,'_agg_contact_left_heading','field_60c249d645c99'),(74707,3002,'agg_contact_left_copy',''),(74708,3002,'_agg_contact_left_copy','field_60c24a0845c9c'),(74709,3002,'agg_contact_form',''),(74710,3002,'_agg_contact_form','field_60c25852dcb44'),(74711,3002,'agg_contact_right_heading','Join our team'),(74712,3002,'_agg_contact_right_heading','field_60c249e945c9a'),(74713,3002,'agg_contact_right_copy','Sed ut perspiciatis unde omnis iste natus error sit voluptatem accusantium doloremque laudantium, totam rem aperiam unde omnis iste natus error sit voluptatem accusantium doloremque laudantium, totam rem aperiam.'),(74714,3002,'_agg_contact_right_copy','field_60c249f845c9b'),(74715,3002,'agg_contact_right_cta','a:3:{s:5:\"title\";s:10:\"LEARN MORE\";s:3:\"url\";s:1:\"#\";s:6:\"target\";s:0:\"\";}'),(74716,3002,'_agg_contact_right_cta','field_60c24a1945c9d'),(74717,3002,'agg_hero_gallery_0_image','51'),(74718,3002,'_agg_hero_gallery_0_image','field_60c239e3764b2'),(74719,3002,'agg_hero_gallery_0_heading','We help you innovate better.'),(74720,3002,'_agg_hero_gallery_0_heading','field_60c23a02764b3'),(74721,3002,'agg_hero_gallery_0_copy','Lorem ipsum dolor sit amet, libris animal constituam ut has, dolor alienum accusam sit cu, omnis rationibus ne usu. Quas errem petentium at mea. Sed facer laoreet iracundia at, mel malorum inimicus erroribus an.'),(74722,3002,'_agg_hero_gallery_0_copy','field_60c23a0e764b4'),(74723,3002,'agg_hero_gallery_0_cta','a:3:{s:5:\"title\";s:10:\"Learn More\";s:3:\"url\";s:1:\"#\";s:6:\"target\";s:0:\"\";}'),(74724,3002,'_agg_hero_gallery_0_cta','field_60c23a22764b5'),(74725,3002,'product_heading','Products We Sell'),(74726,3002,'_product_heading','field_60f06d268b1b1'),(74727,3002,'product_copy','Our products are tailor made to fit your industry and your specific applications.  Thanks to our system of modular components, your WARDjet, can be customized to your individual needs. Your system can be upgraded with new features at any time and is designed to be flexible.'),(74728,3002,'_product_copy','field_60f06d368b1b2'),(74729,3002,'filter_heading','Find Your Product'),(74730,3002,'_filter_heading','field_60f06fda07434'),(74731,3002,'filter_copy','Use our smart sorter filter to find the right product for you'),(74732,3002,'_filter_copy','field_60f06fe407435'),(74733,3002,'industries','3'),(74734,3002,'_industries','field_60f07423f5340'),(74735,3002,'wardjet_reviews','2'),(74736,3002,'_wardjet_reviews','field_60f07605f3b60'),(74737,3002,'companies_heading','Our Companies'),(74738,3002,'_companies_heading','field_60f076a1085af'),(74739,3002,'companies_copy','Explore our work serving government, institutions, industry, and commerce across Canada, the United States, and overseas.'),(74740,3002,'_companies_copy','field_60f076aa085b0'),(74741,3002,'companies','3'),(74742,3002,'_companies','field_60f076bf085b1'),(74743,3002,'partner_heading','Partnerships'),(74744,3002,'_partner_heading','field_60f0772323e4b'),(74745,3002,'partners','a:6:{i:0;s:3:\"591\";i:1;s:3:\"592\";i:2;s:3:\"593\";i:3;s:3:\"865\";i:4;s:3:\"864\";i:5;s:3:\"863\";}'),(74746,3002,'_partners','field_60f0773123e4c'),(74747,3002,'industries_0_heading','Industries We Serve'),(74748,3002,'_industries_0_heading','field_60f0743ff5341'),(74749,3002,'industries_0_copy','We\'ve built and installed thousands of water jet machines across a diverse industry portfolio to suit specific manufacturing and material cutting needs.'),(74750,3002,'_industries_0_copy','field_60f07444f5342'),(74751,3002,'industries_0_cta','a:3:{s:5:\"title\";s:10:\"Learn More\";s:3:\"url\";s:34:\"http://www.wardjet.com/industries/\";s:6:\"target\";s:0:\"\";}'),(74752,3002,'_industries_0_cta','field_60f07449f5343'),(74753,3002,'wardjet_reviews_0_logo','842'),(74754,3002,'_wardjet_reviews_0_logo','field_60f0761ef3b61'),(74755,3002,'wardjet_reviews_0_review','WARDJet customer service is the best in the industry. They stand behind their product and the customer service is by far better than any other company. If we have a problem, we can get it up and running pretty fast.\"'),(74756,3002,'_wardjet_reviews_0_review','field_60f0762bf3b62'),(74757,3002,'wardjet_reviews_0_name','David Surkamp'),(74758,3002,'_wardjet_reviews_0_name','field_60f07634f3b63'),(74759,3002,'wardjet_reviews_0_position','Surco Inc.'),(74760,3002,'_wardjet_reviews_0_position','field_60f07637f3b64'),(74761,3002,'wardjet_reviews_1_logo','844'),(74762,3002,'_wardjet_reviews_1_logo','field_60f0761ef3b61'),(74763,3002,'wardjet_reviews_1_review','“We run these machines 24-hours a day, six days a week. I’m actually having trouble putting into words how well this machine is designed and built. 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