ATEX Zone 2 Explosion Proof High Pressure Diesel Sea Water Pump with DNV Frame

The Kingway ATEX Zone 2 Explosion Proof High Pressure Diesel Sea Water Plunger Pump is a purpose-engineered hydrostatic pumping system designed for hazardous area applications across offshore and onshore oil and gas environments. Certified under ATEX Directive 2014/34/EU as Group II Category 3G equipment rated for Zone 2 IIB T3 Gc classified locations, this diesel-driven triplex plunger pump delivers up to 70 MPa discharge pressure at a flow rate of 19.3 cubic meters per hour. This combination of high pressure and substantial flow makes the unit suitable for high-pressure water jetting, pipeline hydrostatic testing, platform deck and equipment washing, and well intervention pumpdown operations in areas where electrically-driven alternatives present unacceptable ignition risks.

Unlike electric motor-driven pump units that require certified explosion-proof motors, specialized variable frequency drives housed in pressurized purged enclosures, and complex hazardous area cable glanding, the diesel engine direct-drive configuration eliminates all potential electrical ignition sources from the hazardous zone entirely. The Perkins 1104D-44T four-cylinder turbocharged industrial diesel engine couples directly to the pump crankshaft through a heavy-duty industrial dry-plate clutch, delivering efficient mechanical power transfer without the intermediate energy losses typically associated with hydraulic pump drives or electric generator-to-motor configurations. This mechanical simplicity translates directly to higher operational reliability in remote desert and offshore locations where specialized electrical technicians may not be immediately available for troubleshooting.

The complete pump assembly is mounted within a DNV 2.7-1 certified lifting frame integrated with a sound-attenuated weatherproof canopy enclosure rated IP55. This enclosure provides protection against dust ingress and low-pressure water jets from any direction, ensuring reliable operation during platform deck washdown procedures or in desert environments characterized by fine airborne silica sand. Multi-layer acoustic insulation with fire-retardant foam reduces the free-field operating noise level to below 75 dBA at seven meters, meeting the increasingly stringent occupational noise exposure regulations enforced on offshore installations in the North Sea, Gulf of Mexico, and Middle East regions.

• ATEX Zone 2 Certified Pump Package: Full compliance with Directive 2014/34/EU, the EN 60079 series of explosive atmosphere standards, and EN 1834 for reciprocating internal combustion engines. The entire pump package is certified as a single Group II Category 3G unit (Zone 2 IIB T3 Gc), providing operators with a single consolidated compliance document rather than requiring management of separate certifications for the engine, pump, instrumentation, and ancillary subsystems.
• 70 MPa Ultra-High Pressure Capability: Triplex plunger pump delivering a continuous 70 MPa discharge pressure, sufficient for hydrostatic proof testing of BOP stacks, wellhead assemblies, choke and kill manifolds, and production flowlines rated to 15,000 PSI working pressure in accordance with API 6A and API 16A test requirements. The triplex configuration with three plungers phased at 120-degree intervals ensures exceptionally smooth pressure delivery with minimal discharge pulsation.
• Perkins 1104D-44T Diesel Engine: Four-cylinder turbocharged and aftercooled industrial engine producing 96 kilowatts at 2200 RPM, fully compliant with EU Stage IIIA emission standards. The mechanical direct-injection fuel system requires zero electrical power for operation, enabling true black-start capability in remote sites without any supporting electrical infrastructure.
• DNV 2.7-1 Offshore Lifting Frame: Certified steel lifting frame integrated into the base skid structure enabling safe single-point hoisting by platform pedestal crane or vessel-mounted marine davit. Four certified pad eyes are positioned and sized for a perfectly level lift with full fuel and fluid tanks, eliminating the time-consuming need for trim angle calculations during rigging operations.
• IP55 Weatherproof Sound-Attenuated Enclosure: Fully enclosed canopy constructed with double-skinned galvanized steel panels and fire-retardant acoustic insulation foam. The IP55 rating certifies protection against harmful dust deposits and low-pressure water jets from any direction. Free-field noise emission is maintained at or below 75 dBA at seven meters during full-load operation.
• Self-Priming Seawater Capability: Integrated vacuum-assisted priming system providing three meters of suction lift capability, enabling direct seawater intake from below-deck sea chest connections without requiring a separate electrically-driven booster pump. This is particularly valuable on offshore platforms and jack-up drilling rigs where below-deck seawater supply is the only available water source.
• Dual-Stage Inlet Filtration System: Primary coarse strainer with a two-millimeter aperture followed by a secondary fine duplex filter rated at two hundred microns absolute. This dual-stage filtration protects the ceramic plungers and high-pressure packing seals from abrasive marine particulates and suspended solids, substantially extending seal service life in raw seawater duty.

This high-pressure diesel pump package is engineered for a diverse range of hazardous area operations across the upstream oil and gas value chain. On offshore production platforms, it functions as the primary high-pressure water jetting unit for deck cleaning, process vessel descaling, and heat exchanger tube bundle cleaning during planned maintenance shutdowns and turnaround activities. The 70 MPa pressure capability fully supports hydrostatic pressure testing of BOP control hoses, choke and kill lines, wellhead Christmas tree assemblies, and production flowlines in accordance with API testing standards.

Drilling contractors deploy this pump for well intervention pumpdown operations requiring high-pressure fluid injection, cementing unit flush water supply, and mud pit cleaning where electric-driven pumps present an unacceptable ignition risk in Zone 2 classified areas around the wellbore and shale shaker zone. Pipeline construction and commissioning teams utilize the high-pressure output for hydrostatic testing of newly installed pipeline sections, where the self-contained diesel drive configuration eliminates the logistical complexity and cost of running high-voltage temporary power cables along pipeline rights-of-way through undeveloped desert or forest terrain. Gas storage operators employ the pump in salt cavern leaching operations where sustained high-pressure seawater injection is required for solution mining of underground salt formations to create storage cavity volume. In refinery and petrochemical plant environments, the unit provides mobile high-pressure water supply for chemical cleaning of process columns, reactor vessels, and heat exchanger networks during planned turnaround maintenance campaigns.

Each pump package undergoes a documented factory performance test including a minimum two-hour continuous run at rated discharge pressure and flow, with real-time verification of pressure stability, temperature rise across all bearing and seal locations, multi-point vibration signature analysis, and functional testing of all emergency shutdown and safety interlock circuits. The plunger pump fluid end receives a 1.5 times working pressure hydrostatic body test prior to final assembly, with individual plunger-to-seal fit verification and suction and discharge valve leak testing documented in the permanent quality assurance record. All fluid-wetted components intended for seawater service are manufactured from duplex stainless steel UNS S31803 or nickel aluminum bronze to prevent galvanic corrosion in marine environments. Prior to shipment, the pump fluid end is flushed and filled with a biodegradable preservation fluid, the engine fuel system is treated with long-term storage preservative, and all external machined surfaces receive corrosion-preventive coating. The shipment includes a complete documentation package: ATEX Declaration of Conformity, DNV 2.7-1 lifting frame certificate, EN 10204 Type 3.1 material test certificates for all pressure-containing components, detailed factory acceptance test report, certified pressure gauge calibration certificate, comprehensive operation and maintenance manuals with troubleshooting guides, and a recommended first-two-year spare parts list with ordering reference numbers. Kingway provides a twelve-month or two-thousand-hour standard warranty from the date of first commissioning, with optional commissioning supervision, extended warranty coverage, and certified operator competency training available for projects worldwide.