METERING PUMP

Operating Instruction

Maintenance Mannual

.P

A' . .

'&* <"$

. : 2 <

ISSUED BY :

ISSUED ON : 1. 1. 96

MR-OM IDESNER 11 1.1.96

a ;,

1 f -. . - 1 l' - - _.--. .-- . a,.*- ' ':

*..

" ' -. Plot No.-2109, Phase Ill, G.I.D.C, VATWA, AHMEDABAD 382,445 . -

,:;:> ?"$< . * 7 * ;;::;. ,

-

INDEX

*f I

I "( i

SECTION CONTENTS PAGE NO

FORWARD 1

WARRANTY 3

A TECHNICAL INFORMATION A1

B OPERATING INSTRUCTIONS B1 ..B6 (GENERAL)

C SCHEDULE OF LUBRICANTS C1 ..C2

D OPERATING INSTRUCTiONS D l ..Dl 1 (POWER END)

E OPERATING INSTRUCTIONS E l ..E3 (PLUNGER PUMP HEADS)

F O?ERAT!NG INSTRUCTICFS F1 ..F9 (DIAPiiRAGM PUMP HEADS)

G OPERATING INSTRUC'I'IONS, G I ..G4 (SANDWICH TYPE DIAPHRAGM & RUPTURE MONITORING)

i

FORWARD

Dear Customer,

Thank you for purchasing WELORE METERING PUMP & for the trust you have kept in SWELORE product. Though you have purchased a product which has passed through stingent quality test, it is equally important at your end that extreme care is taken while you install or maintain the pump.

Before you read proceeding pages we would like to explain "WHAT IS METERING PUMP" by comparing it is function with human organ "HEART".

The above question in our view can be best explained by way of a simple & nearer to every day l~ fe example.

FUNCTIONALLY a dosing pump is like a human organ we call HEART. Human heart is a unique metering pump - a hollow muscular bag-a bit larger than a cricket ball, weighting about ten ounces. It pulsated (Beats) seventy two times a minute. Each minute it handiss about 1.112 gallon of blood - which it dozes under the required pressure to every rook and corner of human body - in exactly measured Quantities ! For as long as person livers 50,70 or 100 years, heart continuous to pump without any rest WHATSOVER. When it falls, the entire human body fails & the person is dead.

What should one do to avoid or possibly eliminate "Premature" heart troubles & heart failure. There is no ready answer to !his except that one should take all possible "Preventive" measure in the form of moderate habits in respect of food, drink, exercise, rest etcetra. And when the trouble signals are thrown-up, one should consult a specialist - and, at times, undergo, major surgery ! Heart trouble & its failure is, by & large, associated to excesses - when one fails to take the "Preventive" measures to take care of one's general health. Often enough, heart trouble is also attributable to the malfunctioning of one more peripherals a dcseased kinely cr bad lungs or liver or pancreas, etcetera - and let's not forget about the clotting of the fluid (blood).

Although heart is a unqiue extremely expensive dozing pump, it's manufacturer gives no guarantee on ~ t s moving parts & He does not even promise any replacement parts or it's lifo expectancy ! Despite these seeming disadvantagss, Let's consider the marvel of this magnigient machine - the HEART which is basicallly a biologi~al growth and yet performs, with such profound accuracy the MECHANICAL FUNCTION of dozing blood in measured quantities to a living system ! And consider the population of this machifie at any point of time. B~ll~ons!!

A WELORE MetkringIDozing pump is an instrument, and it is designed to perform with the precision & reliability of an instrument. Since it is a vital part of the plant's system, it is reasonable to expect that it should be subjected to regular inspection, cleaning, adjustment an replacement of w o w parts. Most "emergency" shut downs would not happen if the pump were given n ~ r m a l "preventive" maintenance care. It may not be true in your case, but our experience reveals that in most of the other cases since the pump usually sits in a dark corner, working away hour after hour, day after day, it is forgotten un!il the inevitable problems of chemical & mechanical wear catch-up & product flow ceases.

0 1

1

- In this MANUAL we have sought to specify general service instruciions. Unfortunately, however we cannot, control installation & operating conditions and hence have sought to give general service recommendations. It is upto the plant's Maintenance Ma~iager to establish a "Preventive" maintenance programme based on mainte~ance records established in the early stages or operation.

Equally, or perhaps more important aspect is to establish routine maitenance schedules on SYSTEM components that support the metering pumps operation. An analysis of complaints that we have received reveal that in an extremely high precentage of complaints, the prob- lems were SYS'rEIbl related - partially closed or corroded shut-off valves, plugged strainers, missing strainer screens improperly charged pulsation dampners, corroded relief valves, defective instrumentation, leaky & or misaligned piping inadequate size of piping or tee or elbow were just a few of the common culprits involved. In certain cases though the system was properly designed & installled. POOR SYSTEM SERVICE lead to poor pump performance.

While once could go on almost adinifinitum on the subject, we hope the above should serve as an adequate guide line to obtain the best performance R life out of a WELORE Meterin~lDozing pump.

MANAGING DIRECTOR

02

WARRANTY

SUBJECT TO THE TERMS & CONDITIONS hereinafter set-forth, SWELORE ENGINEERING PRIVATE LIMITED (hereinafter referred to as the company) warrants the products & Parts sold by it directllr or through it's authorised distributor, in so far those are of its own manufacture, against defects of the materials &/or workmanship, under use and service in accordanze with the Company's written instructions, recommendations & rating for installation, operating, maintenance & service of products, for a period (unless otherwise provided in the Buyer's purchase order and confirmed in writing by the Company) of eighteen (18) months from the date of despatch or for a period of twelve (12) months from the date of its initial use, whichever event occures earlier.

THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT, AS THC, COMPANY MAY ELECT, OF ANY DEFECTIVE PARTS, REGARDING WHICH, UPON DISCOVERY OF THE DEFECTS (S). THE BUYER HAS GIVEN IMMEDIATE WRITTEN NOTICE TO THE COMPANY WITHIN THE ABOVE MENTIONED WARRANTY PERIOD.

Installation & transportation cost are not included, the company shall have the option of requiring the return to it of the defective material, transportation pre-paid for the Company's inspections.

Because of varying conditions of installation and operation, all guarantees of performance are subject to variation.

THE COMPANY DOES NOT WARRANTY THE MERCHANTIBILlTY OF ITS PROUCTS AND DOES NOT MAKE ANY WARRANTY, EXPRESS OR IMPLIED, OTHER THAN THE WARRANTY CONTAINED HEREIN. THE COMPANY HAS NOT AUTHORISED ANYBODY TO MAKE ANY REPRESENTATION OR WARRANTY OTHER THAN THE WARRANTY CONTAINED HERE IN.

CAUTION

BEFORE STARTING THE PurnP, PLEASE CAREFULLY GO THROUGH THIS INSTRUC- TION MANUAL AND, AMONG OTHER PARTS, ESPECIALLY ITS THAT PART WHICH DEALS WITH THE "START UP PROCEDURE", IN CASE OF ANY DOLIBLE, PLEASE DO NOT HESITATE TO CONTACT THE MANUFACTURERS.

NAME A LIQUID YOU WISH TO DOZE "WELORE" WILL OFFER YOU P SUITABLE METERING PUMP

03

CONTENTS

DESPATCH

STORAGE

START UP

MEASURING DELIVERY FLOW

INSTALLATION & PIPING

FAULTS & REPAIRS

TYPICAL INSTALLATION EXAMPLES

PAGE NO

61

B1

61

63

84

84

B6

METERING PUMPS

OPERATING INSTRUCTIONS

GErlERAL INFORMATION

1 .O DESPATCH All pumps are supplied without oils from the factory. When you receive ?ump & accessories at site, check goods in presence of forwarder if required, establish official deciaration of damages & inform insurance Company & take photographs of damaged parts.

2.0 STORAGE If the pump is not installed & operated immediately following delivery ensure that pump & its accessories are stored and covered in proper manner to avoide any damage, rusting etc. Pump should also be filled with Oil & z'I bright parts protected against corrosion.

3.0 START UP Before switching on note folllowing precautions :

3.1 Check the installation & foundation work.

3.2 Is the Oil content & level correct ?

3.3 Are heating or cooling connections in place ?

3.4 All suction & discharge line is free from foreign particles, welding etc. ?

3.5 Check alignment of all couplings

3.6 Is electrical connection are in order ?

3.7 Direction of rotation is as per arrow provided.

3.8 Pipe line sections should be amply dimensioned to avoide cavitations,

which will cause severe damage to pump. Consults us for determining pipeline sections.

3.9 To avoide suction difficulty of p ~ m p , we recommend the liquid to be fed to the pump.

3.10 Liquid handled should be absolutely clean & free from foreign particles. If they cannot be avoided, provide adequatly sized filter in suction line.

3.1 1 Clean filter on regular intervals.

B 1

1 Ensure that discharge shut off valve is open before starting the pump. h9ETERING PUMP BEING RECIPROCATING PUMP, GENERATE PRESSURE WITHIN VERY SHORT TIME. IT MAY CREAT DAMAGE TO PIPING, PUMP & SITE PERSONALS.

3.13 Ensure that suction valve is open before starting the Pump. Also check proper placement of flange gaskets & all suction poarts are open.

3.14 Please note that pump does not generate pressure by itself. It should always be connected to back pressurelsystem pressure to check hhether pump is generating pressure or not.

3.15 It is always necessary to have pressure differential of 0.3 kgJcm2 between discharge & suction pressure. Discharge point should be approximate 3 meter higher than suction taqk level. Failure to meet th~s requirement will result in over delivery & eratic flows.

3.16 After checking all above points throughly, start the pump keeping stroke adjustment knob at "ON & check for any abnormality in power end.

Gradually increase the stroke setting to 25% of full stroke.

Run for 10 minutes.

Increase the stroke setting upto 100%

CAUTION : STROKE ADJUSTING SPINDLE IS PROVIDED WITH MAXIMUM TRAVEL LOCK & ATTEMPT

TO IIVCREASE STROKE BEYCND 100% WILL RESULT IN DAMAGE OF PARTS.

B 2

SUSTlON DISCHARGE MEASURMENT MEASURMENT RISE IN WEIGHT

4.0 MEASUREMENT & CALIBRATION

AT SITE

4.1 DESPACTH

It Is recommanded that all Metering Pumps must be calibrated with actual piping layout & liquid at site.

Flow n.easurement can be done by

- Volumetric

- by weight

- Rate of flow

Fig. 1 Fig. 2 Fig. 3 Fig. 4

Fig-1 : slr~tion side measute~nent with calibidiion pottburette.

Fig-2 : Discharge side volumetric measurement with measurig clyinder.

Fig-3 . Measuring drop in weight in suction vessel.

Fig-4 : Measuring rise in weight in delivery vessel.

4.2 For flow r ~ t e measurement, the pulsating discharge flow must be smoothened with a pulsation dampner.

Best way is to have a by pass line from pump discharge line with pulsation dampner, pressure gauge & throttle valve installed. Start the pump, throttle the discharge valve & generate desired pressure in pressure gauge. Allow some time for flow to be steady & then measure the flow using stop watch.

However flow meter must never be installed between the Pump & pulsation dampner.

B 3

4.3 SWELORE Metering Pump stroke adjustment scale is graduated in mm of stroke. In actual field operation the stroke setting required for desired flow rate can be calculated as follows.

Example : To calculate stroke setting required for 40 Vhr using Me- tering Pump of 0-15mm stroke & actual flow at 15mm stroke is 100 LtIHr

DESIRED STROKE = GESIRED FLOW UH X MAX STROKE MM

FLOW AT MAX!MUM STROKE UH

= 40 X 15 100

= 6MM STROKE SETTING

It is always best to use graph for precise dosing applications.

5.0 INSTALLATION & PIPING Please refer to drawings in proceeding pages for layout & in- stallation of accessories.

6.0 FAULTS & REPAIRS 6.1 PUMP DRIVES Before returning a pump to the manufacturer's factory or to another repair shop, the oil should be drained from the drive.

6.2 PUMP HEADS Before despatch all residual product traces should be re- moved from the pump head by flushing out if necessary.

6 4

suction

5. SUCTION PIPING 5.1 DISCHARGE PlPllVG

Layout for avoiding cavitation

Wrong ~ s s u r e Ovsr- Ps>PO r d valve flow

Avoiding over - delivery

narrow;air wil l be diamebr fk pulsation trapped In darnpnar vertical

i

Layout of suction-side pipework Combination of pressure holding valve and pulsation dampner

Wrong

L - - - Suction from line under pressure I Combiaation of pressure holding valve

and relief valve

General layout of a metering pump 85 B 5

13

oling 1

7. TYPICAL INSTALLAT!ON EXAMPLES

Metering of liquiefied gases

---

Batch metering

1. Sudion vessel 2. Agitator 3. Sudion strainer 4. Metering pump 5. Valve for

flushing

Metering of suspensions

- - - - -

Batch metering with pulsation damping

Suction via a syphone pipe

I Circuit for vacuum extraction .Gas release vessel

B 6

SCHEDULE OF LUBRI'CANTS 1

ALL PUMPS ARE DRAINED PRIOR TO DESPATCH FROM SWELORE FACTORY. 1'HEREFORE . . . I

IT REQUIRED FILLING WITH PROPER GRADE OF OIL (SEE TABLE BELOW). 1

ENSLIRE THAT OIL IS FILLED TO PROPER LEVEL. * 1 ' I

CHAtJGE FREQUENCY : 1) DRAIN ; FLUSH & REFILL AFTER 500 HOURS INITIAL OPERATION

2) SURSEQUENTLY 2000 I-IOURS OF N.ORMAL RUNNING.

1. C.PANK CASE i

OIL GRADES ( INDIAN )

E!;:. QUANTITY PER CRANK CASE

3ETHOD OF FILLING . J

OIL GRADES ( INTERNATIONAL ) - I ,"-

1125

1.00 LITER

'&

MAKE

. HINEUSTAN PETROLEUM

GHARAT PETROLEU~I

INDIAN OIL

~ E V E L OF INDICATION

DRAINING

REMOVE TOP PLUG -- HALF OF OIL EYE AT THE BACK OF CRANK CASE

REMOVE LOWEST PLUG AT THE BACK OF PUMP

1750

2.1 5 LITER

.9: - BSADE OF OIL 1

ENKLO 320

t-iYDROL 320

SERVO 320

MAKE -. . -

B P

ESSO

2250

4.47 LITER

VlSCOClTY cst 40' C

- 320

320

320

SHELL OMALA 220 220

ELF REDULTELF SP 220 220

. - . - GRADE O r 011. - - -- CNFI<GOL (;I< 720 XI'

PEN-O-LED EP 220

1

A

VlSCOClTY cst 40' C

220

220

2) HYDRAULIC DIAPHRAGM HEAD

CHAkGE FREQUENCY : 1) DRAIN ; FLUSH 8 REFILL AFTER 500 HOURS INITIAL OPERATION

2) SUBSEQUENTLY 2000 HOURS OF NORMAL RUNNING.

MODEL

APROX. QUANTITY PER CRANK CASE

METHOD OF FILLING

L N E L OF INDICATION

DRAINING

OIL GRADES ( INDIAN )

I-^- MAKE 1 GRADE OF OIL 1 VlSCOClTY cst 40' C I

1125

0.59 LITER

REMOVE TOP PLUG OF OIL RESERVOIR

HALF OF OIL EYE ON SIDE OF OIL RESERVOIR

807 TOM PLUG AT THE BOTTOM OF OIL RESERVOIR

1750

1 8 LITER

2250

2.97 LITER

HINDUSTAN PETROLEUM 1- BHARAT PETROLEUM

L

3) INTERMEDIATE SPACE ( F3ETWEEN TWO DIAPHRAGM ) (APPLICABLE TO SAN3WICIi TYI'L- 8 DOUULE DIAPI-iRAGM VERSIONS )

3000

5.10 L17ER

ENKLO 32

HYDROL 32

INDIAN OIL

INTERMEDIATE SPICE BETWEEN TWO DIAPHRAGMS CAN BE FILLED WITH ANY COMPITAE'LE LIQUID. * '

5000

10.75 LITER

32

VlSCOClTY cst 40' C 4.8

10.0

- -- 46.0 - -

MAKE

SHELL

SHELL

SHELL

FOLLOWING ARE SAMPLES OF LIOUIDS WHICH CAN BE FILLED. .. -7-

I OIL GRADES ( INTERNI'.,'TIONAL )

SERVO 32

GRADE OF OIL

TELLUS OIL 5

TELLUS OIL C 10

TELLUS OIL C 46

32

NOTE , NORMAL PRACTICE IS TO FILL INTEf:

MEDIATE SPACE VVITH HYDRAULIC OIL

SPECIFIED ABOVE IF MIXING OF THIS OIL

WITH PUMPING LIQUID IS PERMITTED IN

CASE OF DIAPHRAGM IIUPTURE.

SR. NO.

1

2

3

4

5

6

MEDlUMlLlOLllD

67%GLYCERIN + H20 + INH.

80%GLYCERIN + H,O + INH

90°hGLYCERIN + H:O + INH -. - .- -- .

95%GLYCERIN + I-i;.C) 4- INI-l - MINERAL OIL

PARAFFIN OIL

SECTION

OPERATIKG INSTRUCTIONS (POWER END)

CONTENTS

1. DESIGN & FUNCTION

2. ASSEMBLY & DISASSEMBLY INSTRUCTIONS

3. TROUBLE SHOOTING

4. POWER END DRAWINGS

5. ADJUSTMENT OF MULTIPLEX. PUMPS

6. TROUBLE SHOOTING OF MULTIPLEX PUMPS

PAGE NO

D l

D2

D8

j I I .

1.0 DESIGN & FUNCTION

The Swelore Metering Pump is positive returned plunger, variable stroke reciprocating pump. The metered flow

can be varied over wide range with the help of welproven WELCRANK mechanism.

The design

The Welore Metering Pump consists of worm reduction gear train, eccenter, connecting rod, cross head, plunger, cylinder and valves.

ZERO STROKE

Zero stroke

When connected with motor and stroke adjustment knob set at '0' gear assembly and eccenter revolves without

producing reciprocating motion of plunger.

FULL OR PARTIAL STROKE

Full or Partial stroke.

When stroke adjustment knob is set at full or partial stroke, gear assembly & eccenter revolves in inclined pos~t~on corresponding to the stroke setting. Thus reciprocating ,notion is prouced to desired stroke length.

D l

&

CRANK CASE ( POWER END ) SERVICE INSTRUCTIONS

( A ) DISASSEMBLY PROCEDURE

NOTE - BEFORE PROCEEDING ENSURE TO DRAIN OIL FROM POWER END

1 ) REMOVAL OF CROSS HEAD - DRAWING REF. - C.S. MODEL 11 25 , 1750 , 2250 & 3000

NO. 1

-- 2

3

4

5

6

7

NO.

I

2.

3

4

5.

6.

7

2 ) REMOVAL OF STROKE SETTING KNOB -

Preparation Open top cover & set pump at ZERO stroke knob setting

D2

29

MODEL NO. 5000 ACTION

Remove l~qu~d end assembly

Remove bracket (011 reservoir) from power end

Remove plunger from cross head by unscrewing Screw & Hex nut.

Remove cross head gu~de by loosening & removlng 4 pins

unscrew connectlng rod trun~on ( Eccenter side )

CAUTION Trun~on is locked by settlng grub screw Before unscrewing trunion Trunlon setting grub screw

must be loosened Remove cross head along with connect~ng rod from the front hole

Remove connecting roa by loosening trunion settlng grub screw & trunlon

ACTION First loosen the side cover flat pln provided at the Back siae of the Wel Houslng Remove the stroke adjustment screw by loosening the grub screw provided for trunion setting and also the trunion

Remove slide

Loosen the Grub Screw provided at the knob & remove the knob

Remove end cover

Take out End Cover Then remove screw houslng from stroke adjusting screw by llnscrewing Take out stroke adjusting screw & slide trunion

PART NO.

Refer to llquld end drawing In thrs MANUAL

17,18 ( 19,20 Model - 5000 )

23,24 ( 25,26 Model - 5000 )

13,22 ( 15,24 Model - 5000 )

21,24 ( 23,26 Model - 5000 )

PART NO.

60 ( 74 Model - 5000 )

52,58,24 ( 59,72,26 Model - 5000 )

56,58 ( 70,72 Model - 5000 )

51,54 ( 56,61 Model - 5000 )

49 ( 54 Model - 5000 )

53,45,52 ( 60,50,59 Model - 5000 )

52,58 ( 59,72 Model - 5000 )

NO. ACTION PART NO.

1 Remove protection cover 44

( 49 Model - 5000 )

2 Remove adjuster cover from both the ends 38,40

of shaft by removing pins. ( 43,45 Model - 5000 )

Remove side cover ( both side ) by removing 41,42,43 3.

pins ( 46,47,48 Model - 5000 )

4. Remove worm shaft with bearing 33,34

( 38,39 Model - 5000 )

Remove Wel Housing along with worm 27,31,37 5.

wheel & eccenfer ( 29,36,42 Model - 5000 )

NO.

l a .

I b .

I c.

Id .

I e.

3B ) ASSEMBLY PROCEDURE

Power end assembly can be carried out as under :

1 ) WEL HOUSING ADJUSTMENT -

After above adjustment is done worm shaft bearing setting should be done following way.

I Remove Wel Housing & Worm shaft from the Pump Casing once above adjustment is done.

2 ) CONNECTING ROD ASSEMBLY IN CROSS HEAD

Please note that connect~ng rod is supplied as a single piece alongwith Two nos. Trunions, Do not attempt to remove ball ends. Also connecting rod length is very important for each size of pump model & any variation in this length will lead to wrong stroke length R connecting rod breaka~e

D4

22

NO.

I f .

g'

1 h.

ACTION

Install we1 housing in pump casing

Install Two nos. side covers alongwith shims & pins

Center hole of we1 houslng should be concentric with front hole of pump casing. This can be checked with the help of a).

special centering tool or b). By measurement.

Add of Remove shims to bring Wel Housing

in the center of pump casing. Tighten Side Cover pins & check inclination of Housing by applying hand pressure at the top of Wel Housing. Wel Housing should move only with enough pressure.

PART NO.

37 ( 42 Model - 5000 )

41.42,43 ( 46,47,48 Model - 5000 )

37 . ( 42 Model - 5000 )

42 ( 47 Model - 5000 )

43,37 ( 42,48 ILlodel - 5000 )

ACTION

Inset Worm Shaft with bearing in the we1 housing hole of side cover. Install Two nos adjuster cover along with shims. Check rotation of worm shaft & ensure that Worm shaft rotates freely without axial play. Add or remove shim's if required.

PART NO.

33,34 ( 38,39 Model - 5000 )

38,39 ( 43,44 Model - 5000 )

33.34,38,39 ( 38,39,43,44 Model - 5000 )

NO.

1.

2.

3.

4.

Keep aside this assembly

3 ) ASSEMBLY OF CROSS HEAD GUIDE -

4 ) ASSEMBLY OF CROSS HEAD GUIDE -

This assembly is done out side after we1 housing adjustment is done.

05

2 3

ACTION

Install Cross Head Seat in cross head. .-.

lnstall Cross Head key.

lnstall connecting rod one end in Cross Head by screwing trunion. Tight trunion & check free rotation of

connecting rod in full inclined position. There should not be any axial play in ball joint.

Lock the trunion setting grub screw.

PART NO.

15 ( 17 Model - 5000 )

26 ( 28 Model - 5000 )

16 ( 18 Model - 5000 )

NO.

1.

2.

3'

NO.

1.

2.

3.

4.

5.

PART NO.

20 ( 22 Model - 5000 )

14 ( 16 Model - 5000 )

22,21 ( 23,24 Model - 5000 )

24 ( 26 Model - 5000 )

ACTION

lnstall oi; seal with its Ilp facing inside.

lnstall circlips in the groove provided in cross head guide. Install second oil seal w~th its lip facing out side.

ACTION

Hold Wel Housirlg in wice.

Install eccenter with gear key in center

hole of we1 housing.

lnstall Worm Gear along with sh~ms as

shown in the drawing Fit eccenter lock nut & check nut with appropriate spanner. Check free rotation of eccenter & Worm wheel without axial movement. Add or

Remove shims.

PART NO.

37 ( 42 Model - 5000 )

27,32 ( 29,37 Model - 5000 )

31,29 ( 36,33 Model - 5000 )

30 ( 34 Model - 5000 )

27,29,31 ( 29,33,36 Model - 5000 )

r

After carrying out above sub assembly final power and can be assembled as under.

I

D6

24 .

-NO.

1.

2.

.3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

ACTION lnstall Wel Housing assembly in pump casing with TWO no. side covers along with shims. lnstall worm Shaft with bearing & adjuster covers.

lnstall cross head & connecting rod assembly in cross head guide from the back side. Ensure that key fits in key way. lnstall entire assembly as specified in point 110.3 above & in to front hole of pump casing & tighten cross head guide pins.

Connect open end of connecting rod in the eccenter. Tighten trunion & check the free rotation of ball joint without any pixal play. Lock trunion with trunion setting grub screw.

PART NO. 1,41,42

( 1,4647 Model - 5000 )

33,34,38 ( 38,39,43 Model - 5000 )

13,22,17,14 ( 15,24,19.16 Model - 5000 )

18 ( 20 Model - 5000 )

23,24,27 ( 25,26,29 Model - 5000 )

lnstall stroke adjusting screw along with slide trunion.

lnstall slide in Wel Housing.

Tighten slide cover flat with slide cover flat pin.

lnstall screw'housing by screwing in stroke adjusting screw. Insert lock nut on stroke adjusting screw &

position quotation on top 8 screw in lock lever.

lnstall end cover 8 end cover pins

lnstall stroke adjusting screw along with slide trunion & trunion setting grub screw Couple worm shaft to motor 8 start the motor. Ensure to fill oil in power end.

52,58 ( 59,72 Model - 5000 )

56,37 ( 70,42 Model - 5000 )

59,60 ( 73,74 Model - 5000 )

45,52 ( 50,59 Model - 5000 )

47,48,55 ( 52,53,62 Model - 5000 )

53,49 ( 60,54 Model - 5000 )

52,58,24 ( 59,72,26 Model - 5000 )

3 3 ( 38 Model - 5000 )

Now your power end IS ready to use Run power end for about 10 m~nutes Observr for

any abnormal sound

D7

25

PART NO.

52,37,13 ( 59,42,15 Model - 5000 )

52 ( 59 Model - 5000 )

54.51 ( 61,56 Model - 5000 )

2 ( 4 Model - 5000 )

NO.

14.

15.

16.

17.

ACTION' Slowly screw in or screw out stroke

adjusting screw & bring Wel Housing in

vertical position check the movement of

cross head.

Set stroke adjusting screw in such a way that reciprocating movement of cross head is ZERO. Install knob positioning at ZERO stroke -

marking. Tighten grub screw.

Install casing cover.

4

SECTION F OPERATING INSTRUCTIONS (DIAPHRAGM PUMP HEADS)

CONTENTS

1. GENERAL

2. ERRECTION AT SITE

3. OPERATIONS

4. MAINTENANCE & REPAIR

5. FILLING, VENTING, GETTING UP

6. TROUBLE SHOOTING

7. DRAWING

7.1 HEAD CROSS SECTIONAL DRAWING

7.2 PUMP VALVES

7.3 HYDRAULIC COMBINE SAFETY VALVE

7.4 GATE 'VALVE ,

7.5 REPLENISHING VALVE (OIL REFlL VALVE)

7.6 NON RETURN VALVE (RUPTURE)

7.7 FILLING NIPPLE

PAGE NO

F1

F3

F3

F5

F7

F9

OPERATING INSTRUCTION

DIAPHRAGMPUMP HEADS

1 0 GENERAL

1 1 APPLICATION

These operating instructions apply to hydraulically flexed diaphragm heads series 930 metal as well as plastic.

1.2 Performance & appl~cations

See techn~cal data sheet

1 3 Head Design & Operation

Metering Pump Diaphragm Head is Provided with special feature for fit & forget operation at site & off course 100°/~ leak free.

Special feature of diaphragm head consists of following three main component.

(1) PUMPING CHAMBER

(2) HYDRALlLlC CHAMBER

(3) HYDRAULIC OIL itESERVOIR

F 1

Operation of Metering Pump ' ~ i a p h r a ~ m head can be explained as follows :

Reciprocating Plunger (P) attached wi!i'b power end, reciprocates in guide bush & transmits displace-

ment through hydraulic oil to the diaphragm. In turn diaphragm oscilates and produces pumping action on process fluid.

HYDRAULIC COMBINE VALVE (HC)

Hydraulic combine valve has to functions (1) it vents gases produced in hydraulic fuid 8 (2) it protects the pump against high pressure i.e.Safety valve.

CENTRAL GATE VALVE (CG)

This valve is provided for diaphragm actuated replenishing of oil when diaphragm is in Suction stroke.

REPLENISHING VALVE (RPV)

In case of drop in pressure in hydraulic chamber, due to oil leakage, replenishing valve opens and

compensate the hydrualic oil. This action always ensures pumping accuracies for I ~ n g period.

Series 930 diaphragm heads are provided with freely occilating diaphragm (without front support Plates). This has following advantages.

(a) High Suction Pressure can be handled because the diaphragm deflection is clearly defined

by center control gate valve.

(c) Diaphragm has no front support plate & hence it is suitable for handling suspensions &

contammated liquid.

F 2

CAUTION

It Pur~ping chamber (cylinder) is exposed to negative pressure, with the Pump stopped, the diaphragm

rnay bulge in forward in course of tiine. On re-starting the Pump there will b e then be a risk of diaphragm rupture.

With sar:dwich type diaphragms both the diaphragms will rupture simultaniously.

HENCE

(a) Avoid negative pressure

(b) Commission the Pump as per proceeding paragraphs.

2 .O ERECTION AT SITE

Refer installation examples.

3.0 OPERATION

3.1 HYDRAULIC OIL

Please refer to schedule of lubricant section in this manual for grade of iubricants.

Before despatciiing eacti pump, we invariable drain our hydraulic oil from diaphragm head. I

v;'hile filling oil level should be maintained up to center line of level gauge provided at the side of

yeservoir.

F 3

i

Fill the hydraulic oil & check, lhe level.

Also verlfy that pressure condilions in suclion & discharge line agress with those laid down in lechnical

data sheet. Pirmp narne plates.

3.2.1 Suclion Pressure Greater than atrnosplleric pressure.

- Unscrew Relief Valve.

-.Open Suction Valve & Prepressilrise the Pump chamber

- Replace & tighten Relief Valve.

- Run Pump after starting & stopping for 10 to 15 times wilh on off motor switch.

3.2.2 Suction ~ressure less or equal to Atmospheric pressure.

- Unscre~v Relief Valve

- Pre (~ressurise pump chamber ( e x . compressed air in to si~ction pipe) so thal the diaphragm bottoms

on read plate.

- Replace & tighter relief Valve

- Run tile Pump after starting & stopping for 10 lo 15 times with on off motor switch.

3 2.3 SANDWICH TYPE DlAPHRAGlvl HEAD

Please see separate section for this design in this manual.

4 .O TROUBLE SHOOTING

Please refer trouble shcoting chart

. .

5. MAINTENANCE & REPAIR

5.1 SUCTION & DISCHARGE VALVES

SWLORE Pul-rips are provided normally with three types of- Suction and discharge valve (Refer c;oss

sectional drawings)

(1) Ball Valve yith or without spring

(2) Puppet Valve ~vitl i or without spririg

(3) Plale Valve with spririg

For maintenance 8 inspectior1

- Open s~~ct ion & discharge pipe line

- Retnove valve holding flange bolts1 studs

- Remove assembly

- Check for wear on valve & seat

- Seat can be replaced & used again

Installation after riiaintenance

- Replace all valve seat gaskets

- Ensure proper installation of respective valve assembly for suc!ion & discharge.

- ?;~i;:e:; hsitiing screws S ciieck ior ieakage.

5.2 DIAPHRAGtwiS

- Flush out all the pipirig & pump chamber before opening.

- Take of pipe line.

- Remove cylinder bolts. First remove two bolts & replace these by two long stud or bolts; Open

balance bolts & slide cylinder over two long studs.

You can also support diaphragm cylinder from bottom or from lifling hook if available.

- Hydraulic fluid will escape from the hydraulic chamber. Provide tray at the bottom to collect.

- In case of. Sandwich Diaphragm remove intermediate ring by removing allen screw.

- Drain off hydraulic fluid.

F 5

+i

, . *

4 5.2.1. HYDRAULIC COMBINE VALVE (SAFETY VALVE) '

This valve can be removed as a combine assemble.

- UIISC~~W & remove

- Clieck for wear

- Reassemble using assembly drawing in this manual. After installation do not forget to reset for its

pop LIP pressure.

- This can be done outside with hydrualic pump & pressure guage or else.

Ey tlirotlling tlie discharge of some Pump & adjusting Screw at the top of valve.

5.2.2 REPLENISHING VALVE

- Undo screwed plug underneath the hydraulic cliarnber & drain off hydraulic fluid.

- Remove valj~e assemble.

- Check for wear. 1 - Assernble wilh lielp of drawing in this manual.

CAUTION I Before opertirlg spring I-~ut of this vaive take dimension of spring cornpression (Distance between nut & body) & ensure that this dimension is maintained while assembling Ule valve. Failing to ~ o ' s o pump will not fcr~lction properly.

5.2.3 HYDRAULIC CHAMBER

. . - Drain Hydraulic oil I - Provide suitable rnode to cotlect hydraulic oil. I - Unscrew 4 bolts to the reservoir. I - Pull hydraulic cliarnber carefully. I

5.2.4 PLUNGER SEAL 1 Rernove purnp head as described above.

- All purnps above 30mm Plunger sizes are provided with metalic szal rings.

- Pull & rernove ring

- Check & Replace i f necessary.

F 6

48

- 5.2.5 CENTRE GATE VALVE

Remove Pump head

- Take off circlip (refer assembly drawing) 8 press coinplete valve fo~ward & out.

- Keep watch on '0 nngs

1 - Check & replace r f necessary

ASSEMBLY i i

Proceed in reverse order to disrnantiirlg

Observe following poirlts.

(a) All cornponent rnust be t h ~ r ~ ~ g i i i y cleaned & their conditions checked.

(b) Metallic valve seats of ball type valves should be relaped with ball of same lapping paste.

! (c) All stainless steel threads shculd be greased against pick ups.

jd) Piston rings r:l~:st be fitted wit11 gaps at 180" to each other.

6. FILLING, VENTING, GETTING UP.

6.1 FILLING WITH HYDRAULIC OIL

(a) Pour oil in to reservoir

(b) With hydraulic combine (Safety Valve)

Out pour hyaraulic oil into rlole below until1 illere are no only very small air bulles corning up.

6.2 VENTING

The Pump is self venting via the venting valve in hydraulic combine.

HYDRAULIC COMBINE (SAFETY VALVE) -7 1 - Unscrew & relax spring Pressure

- Start tile Purnp with delivery val'je open

- Slowly throttle delivery v a l ~ e L1 bv;ltcll the pressure rise on pressure gauge.

- Slowly increase spring pressure of Safety Valve.

- Set the pressure approxi17iately 20"; liigher than discharge przssure & lock the check nut

6.3.2. Replenishing Valve.

TROUBLE SHOOTING (DIAPHRAGM HEAD)

I REMEDY TROUBLE CAUSE

DOES I..lOT DEI..IVER

PUMP SUCTION 8 [)ISCHARGE

FIT CORRECTLY

-+ 1 i OPEN SUCTION VALVE

1

I i FLUID SOLIDIFIED - / IMPROVE HEATING OF FLUID I

CLOSED 1 DEILIVERY STOP VALVE + CLOSED

OPEN DELIVERY VALVE

INSPECT & REPLACE

HYDRAULIC OIL IS P O 0 3 I

PGESSUfiE RELIEF VALVE or REPLENISHING VALVE

FOLLOW FILLING PROCEDiJRE PROPERLY

I

I

w h y O R REPLACE

AIR IN SANDWICH I CHAMEER

GAS IN FLUID 1 )

EXESSlVE 1 SUCTION PRESSUhE HIGhER REDUCE SUC-rION PRESSURE, ++ TtiEN DELIVERY PRESSURE + ELEVATE PUPvtPINSTALL PRESSUR I r SUSTAIIJIPJG VALVE AT DISCHARG

I

----j

CHECK lhSTALLATlON

LINE CAUSE SL!CTION PRESSURE RECALCULATE PIPE LI-INE & PAOPvlENTORALY TO EXCEED DELIVERY PRESSURE

-3 MODIFY 1 GAS FORMING BECALJSE

I

GAS FORMLILATION BECAUSE OF REPLANISHING VAL1!E IS j CHECK SETTI;\IG SET TOO HIGH H C

FORiilATION 1 CHECK 8 FILL SUITABLE UNSUITABLE HYDRAULIC OIL GRADE OF OIL

I DIAPHRAGM RUPTURES STARTING PROCEDURE NOT -+ READ STARTING PR CEDURE k+I i oLLoY jED , 1 CAREFULLY & FoLL 8 w

4 I CLEAN CHAMBER & LINES DUE TO FOREIGN PARTICLE I THROUGHLY INSTALL FILTER

1 PLANT ITEM N O I I I

(CONSULTANT NAME: 1 PROJECT: 1 (REV. 1 DESCRIPTION I

I I I

DATE I P. O. NO: I DRG. NO : L ~ ~ 7 9 i ~ ~ 1 I

D R N SECTIONAL ARRAKGEMENT OF: C H D SAFETY VALVE A P P D 1 SCALE

13--"""""'-" we----------

-

----------- I), - - - - -, , ,, , - -- ,

CLIENTS NAME: PLANT ITEM NO. :

CONSULTANT NAME: PROJECT: REV. DESC91PTION DATE P. 0 . NO: DRG. NO M180lGV

D R N SECI'IONAL ARRANGEMEF:T OF: C H D GATE VALVE A P P D SCALE

PUMP MODEL PLUNGER DIAMETER LENGTH L IN M.M

1125 5 TO 36 10

1750 5 TO 70 10 P

3000 10 TO 52 10

3000 50 TO 108 17

5000 30 TO 36 10

5000 40 TO 130 17

CLIENT'S NAME. PLANT ITEM NO. : -

CONSULTANT NAME. PROJECT: RE;J. DESCRIPTION DATE P. 0 NO: DRG N O . M181,OFjV D R N SECTIONAL ARRANGEMENT OF:

C H D OIL REFlL VALVE A P P D

SCALE

CLIENT'S INAME: PLANT ITEM NO. : CONSULTANT N&:JIE: PROJECT:

REV. DESCRIPTION DATE P. 0. NO: DRG. NO: M1821DRV D R IV SECTIONAL ARRANGEMENT OF: C H D RUPTURE VALVE A P P D SCALE

- OPERATING INSTRUCTIONS

SANDWICH TYPE DIAPHRAGM, WITH RUPTURE INDICATOR

1. GENERAL

1.1 APPLICATION

These operating instructing instructions apply to sandwich type diaphragms of metalic or plastic dia- C

phragm heads.

1.2 CONSTRUCTION & METHOD OF OPERATION

Two super imposed diaphragms seperate the liquid chamber from hydrulic chamber. The two dia-

phragms are held together by a film, the action being mechanical during the delivery & hydraulic

during suction stroke. During the first few strokes surplus intermediate medium is expelled via the non

return valve.

If & when one the two diaphragm ruptures, metering or hydraulic medium will find its way in to the space between the diaphragms. The subsequent delivery stroke will push this medium to rupture

indicator the non return valve.

please refer the drawing of DETAILS OF DIAPHRAGM LIQUID HEAD SERIES 930

1.2.1 Followig types of rupture detection devices are supplied.

(1) Local indicator pressure gauge.

(2) Rernote alarm 'c' Pressure Switch

1.2.1 . l . PRESSURE BAUGE

A small pressure gauge is mounted on sandwich plate after non return valve. In case of diaphragm

rupture pressure gauge will show pressure & rupture can be detected.

CAUTION

During initial start up & refilling time remove pressure gauge & allow intermediate liquid t'o flow out for

few strokes. After this install presssure gauge.

1 1.2.1.2. PRESSURE SWITCH

Intermediate chamber is connected to a pressure switch after nonreturn valve. In case of diaphragm

rupture pressure switch will activate & give alaram in the control room or stops the pump.

CAUTION

During initial start up & refilling time remove pressure switch connection and allow intermediate liquid

to flow out for few strokes. After this connect the pressure switch.

FILLING VENTING ADJUSTING

Remove indicator or pressure switch & slaken hose

nipple. Connect reservoir for intermediate liquid to the hose nipple by means of a hose. Fill reservoir

with intermediate liquid. Raise reservoir (1 meter) or

Pressurise (0.1-0.2 bar) as shown in fig.

TROUBLE CAUSE 1 REMEDY I

1 - - - j - . . 1 ?

'b

INDICATED SHORTY AFTER PUSHED INTO SENSOR

RETIGHTEN CLAMPING BOLTS

INDICATED WHILST PUMP IS REPLACE DIAPHRAGMS