An innovative new sewer cleaning Jet-Vac machine with continous water recycling is set to make its public debut at next month’s CV show in Birmingham. Developed by Whale Tankers in partnership with Kaiser AG, the Kaiser-Whale takes a totally new approach to heavy duty jetting machine applications using recycled water.

Whilst the concept of a jetting machine that recycles water as it is working is not a new one, operational factors such as weight, reliability and durability have to date limited their uptake in the UK and Irish market. Never afraid of a challenge, Whale Tankers – one of Europe’s most innovative manufacturers of specialist tankers for waste applications – has teamed up with Kaiser AG, an acknowledged leader in water recycling equipment in Europe.

The successful outcome of this partnership is the Kaiser-Whale – a 26/32 tonne GVW jetting machine capable of recycling the water it uses, designed, built and supported for the specific needs of operators in the British Isles.

Recycling water used for jetting operations means more time spent on site and less time off it taking on fresh water, making more productive use of capital equipment and faster overall job times. It also offers a number of significant operational, environmental and economic benefits.

The Kaiser-Whale features the Kaiser KDU 148 High Pressure Water Pump assembly, providing significant benefits over conventional water recycling machines. Instead of adding additional filtration to a more traditional type of unit, the KDU pump operates at a much slower speed (50 times slower than a typical triplex pump). which greatly reduces the wear on the pump as well as making it significantly quieter in operation. The large pump cylinder capacity delivers high flow and pressure performance – up to 500 l/min at 2,900 psi is possible.

As a fully integrated assembly – incorporating a jetting pump, a pressure accumulator, oil reservoir/cooler and tipping ram housing – weight is significantly reduced, with its attendant payload advantages.

Hydraulically driven and controlled, water pressure and flow is independently adjustable, with a pressure accumulator maintaining a constant water pressure. Hydraulic load sensing means that when jetting stops and pressure is reached, the pump stops until water demand is reinstated, further improving efficiency and reducing fuel consumption.

The KWP High Performance Liquid Ring Pump – available in two sizes to provide a performance range between 1,600m3/hr and 3,100m3/hr at 85% vacuum – provides important weight savings thanks to its compact design and alumination construction. The liquid ring within the pump is Teflon coated, with permanently lubricated bearings reducing abrasion and extending service life of the pump unit.

The use of aluminium in the vacuum pump allows the unit to be positioned at the front of the vehicle, providing optimal weight distribution. In additional, the unit is submerged in the front sealing water, reducing the amount of pipe work on the vehicle and providing both a natural form of cooling and noise insulation.

The Kaiser-Whale uses a single stage filtration system, further reducing weight and reducing maintenance requirements for cleaning of filters. The design of a special wedge-shaped 500 micron stainless steel mesh in a large circular shaped filter drum (approximately 1m²) means that a high volume of water can pass through the filter thanks to the large screen area. The use of such a coarse mesh is only made possible with the KDU pump.

A low pressure flushing system provides continuous cleaning of the filter when jetting and water recycling operation are in progress, with an external centrifugal pump drawing water through the filter at a rate of 800 litres/min. The constant clockwise to anticlockwise rotation of this Rotomax filter reduces the possiblity of blockage, which is further aided by the “trislot” shape of the filter mesh.

The Kaiser-Whale features a hydraulically operated dividing door inside the tank which gives the vehicle even greater operational flexibility. With the divider door in a closed position with the seal inflated, two seperate components are created allowing the machine to be operated as a traditional Jet-Vac combination, especially useful when clean water is a requirement.

When in the open position, a single large compartment is created, giving maximum capacity of debris and sludge. When empty, the raised divider door also provides easy access to the Rotomax filter for cleaning and regular maintenance.

Dependent on the specific operating requirements, the Kaiser Whale can be fitted either with a telescopic loading boom, or with a “spiral disc” cassette type of boom. The spiral cassette option provides the same 300º rotation as the standard boom, with the added ability to reach depths between 6m and 7m without extension, reducing the amount of manual handling required in operation, as well as the need to carry additional extension pipes on the vehicle.

Located at the rear of the vehicle, the hydraulically operated Whale “Mega Reel” provides a highly effective and manageble means of handling the heavy duty hose and is capable of holding up to 180m of 1¼” or 200m of 1″ rubber hose.

Safe and simple operation is key in a major piece of capital equipment and the Kaiser-Whale benefits from the fitment of the Whale Control panel, featuring Programmable Logic Control (PLC) and is located at the rear of the vehicle off the main hose reel frame.

Having all the controls for jetting, vacuum and water recycling on a single panel, clearly and logically set out, facilitates efficient day to day operation of the machine. With Whale’s Programmable Logic Control, all valves are controlled pneumatically from a single point eliminating the need for manual valves. Complex interlocks, timing and sequential operations can be implemented in a small space, greatly simplifying the operation of the vehicle.

Every Whale product comes with an industry-leading support infrastructure and the Kaiser-Whale is no exception. This support is delivered regionally through an extensive network of in-house service engineers, with intimate knowledge and understanding of the Kaiser-Whale product and its applications. Additional back up and support is also provided through Whale’s Ravenshaw factory, centrally located in the Midlands.

One of the first Kaiser-Whale’s – mounted on a Volvo chassis and destined to enter into service with Anglian Water, is set to make its debut on the Whale Tankers stand (stand 3240, hall 3) at the CV show at the NEC Birmingham 24-26th April.

According to Managing Director Mark Warmington, with the Kaiser-Whale, “Operators can make every drop of water count with a specialist yet highly flexible machine designed to meet the weight sensitive requirements of the UK and Irish market. With more time spent on site, better fuel efficiency and significant payload advantages over more traditional water recycling technology, the Kaiser-Whale is a highly effective and profitable solution for specialist sewer cleaning applications”.