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    © All Rights Reserved
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    24 views29 pages

    Pump 850

    Uploaded by

    paonemech
    BPCL mudpumps

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    ces CARE AND OPERATION MANUAL TRIPLEX MUD PUMP A-850 PT BHARAT PUMPS & COMPRESSORS LTD. A Government of India Enterprise NAINI, ALLAHABAD-211010 PUMP MODEL: A-850PT BPC S/O CUSTOMER ORDER NO. ait] BHARAT PUMPS & COMPRESSORS LTD. India E pc NAINI, “ALLAMABAD—211010 FOREWORD It is suggested that the PARTS LIST which accompanied the shipment ‘of this machinery be reviewed and maintained as a reference for detailed repair and replacement. Parts identification in this publi will be general terminology and wi part number, size, material, ete. tion ot make reference to specific Before performing any service function, be certain thet the unit js separated from its power source or the power source it locked-out to prevent any form of energy from entering the equipment t would include electrical or mechanical energy into or from the Prime mover (s), electrical energy to the lubricating pump, charging Pump, flushing pump, etc, as well as hydraulic energy from the dis charge or suction lines. When other than routine servicing is necessary, it can be most effi ‘ently performed IT the unit is removed to an area of adequate space where an overhead crane or hydraulic lift, hydraulic press, beating pullers, impact tools, etc. are accessible. Exercise safety in all performances, do not ignore any cautions, use only approved methods, matetials and tools. Do not permit eny fune- tion of questionable safety. SAFETY IS YOUR BUSINESS AND YOU ARE INVOLVED. INTRODUCTION This manuel is published 9s 8 guide for the installation, care and operation, disessembly & reassembly of your unit. The recommenda~ tons made here for the performance of normal servicing are bated ‘on many yeats of experience in the manufacturing, maintenance ‘and servicing of this equipment. However, unusual or extreme clrcumstences may atise and these must be referred to the manufac turer. The manufacturer will, upon request and contact, provide trained, experienced personnel to assist you in the maintenance and servicing of this machinery. Improvements in design, engineering, materials, production methods, ttc, may necessitate changes in this product and result in inconsisten- cles between the contents of this publication and the physical equipment. We reserve the right to make these changes without incurring any obligation for equipment previously ot subsequently delivered. SINo. emrausene £ # ae Important Features Breif Description General Section Of Piston Pump Specification Performance Data Technical Information Installation Preparing For Operation Placing In Operation Torquing values for Fasteners Lubrication Maintenance Trouble Symptoms Storage Of Pump Drawings And Technical Details Out Line Drawing Fluid End Assembly Valve Service Power End Assembly Diaphragm Assembly Connecting Rods ‘Crosshead Shaft Assembly Crank Shaft Assembly * Pinion Shaft Assembly Liner And Piston Assembly Liner And Piston Jack Shaft Assembly Liner Flushing System Internal Lubrication System External Lubrication System Oil Level Assembly Recommended Spares List Of Standard And Special Tools Hydraulic Valve Seat Puller Hydraulic Pump Removal Of Liner Centering Sleeve Removal Of Single Acting Piston Removal Of Liner Wear Plate Mud Pressure Gauge Reset Relieve Valve Pulstaion Dampener 53 57 62 7 74 75 81 RSEBB 98 106 IMPORTANT FEATURES HORIZONTAL DESIGN. WELD FABRICATED STEEL POWER FRAME. ADJUSTABLE REPLACEABLE CROSS HEAD GUIDES AND CROSS HEAD SHOES. INDIVIDUAL FORGED STEEL FLUID CYLINDERS. API VALVES AND SEATS. SCREW TYPE, SELF LOCKING VALVE COVERS. VALVE POTS INDIVIDUALLY ACCESSIBLE SUPPER DI-HARD LINERS. METAL TO METAL LINER RETENTION. SLIP SEAL TYPE PISTONS. INTEGRAL FULL CIRCLE LINER FLUSHING SYSTEM. SEPARATE BOLT ON SUCTION & DISCHARGE MANIFOLDS ROLLER BEARINGS THROUGHOUT : CRANKSHAFT, CONNECTING RODS AND CROSSHEADS. PRESSURE CASCADE LUBRICATION. DOUBLE EXTENDED PINION SHAFT. SINGLE HELICAL GEARING. BRIEF DESCRIPTION. Designed for heavy duty service, this pump is @ 9 inch stroke, horizon tal, single acting triplex pump with a maximum rated horsepower of 850 at 160 rpm. Weight is 16,000 Ka. The use of moder high strength steels and latest techniques in fabrication plus long experience in pump design, menutactrue and ‘essembly have resulted In a product unexcelled in the industry. The extrome volume-pressure capablities of this pump are developed in fan all welded steel! power frame. Double row spherical self-aligning roller bearings support both eranlahaft and pinion shaft. Straight roller bearings are employed in the connecting rods at crank and ‘crosshead ends. Crossheads are cast ductile iron, operating in tenew= fable shim adjustable guides. ‘The connecting rads are two-piece design which permits seperate Installation of connecting rods into pump end in-frame assembly fof connecting rods to crankshaft. ‘The dual lubrication system is designed to provide constant trouble free operation. The cascade oiling system will temporarily provide lubrication even in the event of oll pump failure. An independently driven oll pump Is recommended and is required when the pump Is operated under 50 rpm. ‘The three fully Interchangeable and individually replaceable "L" shaped fluid cylinders afford easy maintenance. For time saving fend convenience, the piston rods and threaded two-piece construc tion, which quickly disassemble to facilitate removal of piston without disturbing the liner. Valves and valve seats gre removed and replaced thru individual Valve covers. This pump incorporates all features contributing to low cost, trouble-free maintenance. ‘The basic pump is comprised of a power-end and « fluid-end mounted fon short steel skids. The power-end contains the shaft assemblies, ‘connecting rods, dlaphragms, etc. The fluid-end contains the fluid ‘chambers, suction manifold, discharge manifold, valves, seats, pistons, liners, ete. ‘The lubricetion system with its provisions for filtration and cooling; the liner flushing system with Its circulation unit, the features of {8 piston rod.back-up tool, the mechenical turning device, etc. are all added to the basic unit to compose the standard unit as outlined Jn this publication. ‘The laterality of the unit i, es reflected here, determined by standing fat the power-end end looking toward the fluid-end-reterence is made to the left hend side and the right hand side. The fluid chambers ‘also designeted from this same position-the No. 1 fluid chamber Js on the left hand side, the No. 2 Chamber is in the center and the ‘No. 3 Chamber is on the right hand side. 4DSD-0101 a { \ ta, se J Neg Cg Wt HY tL US wv a = 5 a. b a uo oO z 9 = 9° a a ) < = w zZ a 0 Pump Specifications: Pump size (Max. Piston diaxstroke) Standard Platon sizes ..ee.eeee seco Rated Input Brake Horse Power at 160 rpm . Gear Ration (Built-in). -+6.eseeeeeeeeeeee Maximum Working pressure Discharge sees pal Suction ees ees sete eee eee pal Suction Connection + (Flange ANSK 150 Ibs WNRF) ..eeeseseeeeeeeeeeees Inches «inches Discharge Connection (Flange API-5000 Ibs, RT}, both sides)... +++ ++ + (Flange API-5000 Ibs, R.T-} Center only) sss +++ inches Pinion Shaft Extension + diameter . . + Length .. Keyway (WidthxDepth) . . Crank Case 26+ Oi Capacity Weight (Pump with std. equipment and Skid) - Over all Size + Length (Pump on Skid) oeseeeeeeee ees + Width (over pinion sheft) ...eesseseeeeees 2 Hight. Maxs 12,6, 61/2 7 and 71/2 850 4aeet 203 3a. 50x19 322 10 RFORMANCE DATA: ton a DISPLACEMENT sim | Preenne | Per rev Gates por mine at pap Speed (ron) Inches pal o | 100 10 | 10 160 5 3565 230 138 1 | (BO 25 3a 367 sa 2906 20 167 m 20 vs | 309 oy 6 2076 330 198 264 330 vor | aes 329 oe 2110 3.88 233 310 388 465 343. eat 7 1019 450 270 360 450 so | 630 70 ae 1508 sis | 310 as 316 oo | om 026 BRAKE Input Horse Power 318 25 ot or | ms 850 Input Pinion Shaft rpm 269 358 aa se | ear m Based on 90% mechanical and 100% volumetric efficiency CONVERSION FORMULAE, 1 cubic Metre per day (m?/d) = 6.2898 Barrels per day (bpd) 1 Gallon per minute (gp) = 3.78533 Litres per minute = 231 Culn/min 1 Kilowatt (KW) = 1.38102 Horee Power 1 Kilogram (Welght) (Mess) = 2.2086 Pounds 11 Kg/Cm? = 98.067 Kllopascals (kpa) = 14.2234 pal ‘9pm x pal Broke Horsepower = 1718 x 0.90 (Mech. EI. Bartels Pet Day = gpm x 34.3 Barrels Per Day = Gal. Per Rev. x rpm x 34.5 ‘Inch = 25.8 me (mllimetres) (exactly) ‘1 euln. (cuble Inch) = 0.016 387 (tres) (exactly) ‘Area of Plunger x(Length of Stroke xNumber of Plungers) 231 Gal. Per Rev. = Gal Per Min. = Gal Per Rev. x rpm 1 TECHNICAL INFORMATION ‘The following details are presented to permit identification of the valve service pistons and piston rods under Industry standards, as @ guide to the proper setting or clearance of ratating and reciprocating parts and includes data pertinent to the unit ot its function. ROTATING AND RECIPROCATING PARTS Pinion Shaft Bearings: Type. Spherical : ble se eteeeeeeeeeeeneeeeeeeseessh25 to 150 mm End Play Clearance Spondosnendd Lateral Clearance of Shaft « Crank shaft Bearings: +++ Spherical + Non-adjustable 1.25 to 1.50 mm End Play Clearance... s..4 0+ soga Lateral Clearance of, Shafts... ssseeeeeeeee Se oe cere +++ Spherical Non-adjustable 1:25 to 38 mm End Play Straight Roller Non-adjustabie seeeseee Straight Roller +++ 0.000 to Minus .075 me Non-adjustable Clearance - Crosshead Pin in Crosshead .. Clearance - Bearing or Bushing to Crosshead Pin. « Croashead: Clearance - Crosshead to Crosshead Guide. VALVE SERVICE Size... ++ 10 to -60 mm teeter eee APINOS 7 Accessibility. eecbaonoanen Baoceoenrdscooen Individual Cm ee -Setew Type PISTONS Dorion eee ee ee Arca Func Material *, PISTON RODS Designation Func Materi CYLINDER LINERS Material . : MISCELLANEOUS Tools: Valve Seat Puller ..sssseeeeeeeeeeeseeereeseseseeseeseeeaessenesens eHydtaullon® Tool for Piston Installation & Removal... +++ssssseeeeeeeeeseeseeees Furnished With Pump Tool for Piston Rod Nuts «+++ ++ si eteeeeeeeeeeecseeees Spline Wrench or Socket Tool for Body Fitted Bolts on Power Frame... Wrench for 7Omm Nut Mechanics Tools (Sockets, Box End Wrenches, etc.)- Max. 45mm Nuts testes sees eren sess s Single Acting = Regular or Oil Resistant + APL SAG Single Acting ++ Super DI-HARD ‘Consult manufacturer for recommendation. + *May be purchased separately from pump manufacturer. 12 INSTALLATION The installation of your pump, if carefully planned and 2. The skid or foundation must be of sufficient strength adequately performed, is the first most important step in to prevent flexing of the equipment. Providing for tong, trouble free service from the PUMP 5 THe skid or foundation must be of sufficient size and 125 well as the associated equipment. Review the specifica- i ted oc e design to maintain the equipment free of strain, tons and performance data on the preceding pages and be sure that the flow system is of sufficient design to insure 4 The equipment, must be adequately secured to the safety at elevated pressures and that it provides a safe skid or the foundation. Hight strength bolts ot capscrews pressure relief In the event of flow interruption as well with locking devices are generally employed. ‘as immediate shut-down should line failure occur. Safety 5. Consideration should be given to the location of the guards for all reciprocating and rotating elements should equipment with its proximity to the associated equip be mandatory at the time of installation. Hand rails, supports, tie-down, shields, deck plating, etc., must be considered ment, fluid supply, fuel supply, environmental contami in your progtam. Make it a safe instalation. ea! ‘The following considered basic installation requirementst 6. Avoid environmental contamination by providing for Aon the proper disposition of drainage from the crankcase, ‘gear case, chain case, sludge sump and any other 1. The skid of foundation must be level Angular installation Iubrioaton reservelrs os well as trom the. thahing media resetvoir, the flushing media sump, the pump cradle, the suction line and the discharge line. land operation may be detrimental to the lubrication of the equipment and may impose high stresses causing equipment f PRIME MOVER GEAR OR PUNP (orien) (riven) it With the pump and prime mover on the skid oF foundation, use a straight-edge or chalk line to determine the relative position of these two components. When close elignment is achieved, install the belts or chain and adjust for proper tension then reposition the prime mover to obtain full surface contact between the straight-edge ot chalk line and the sheaves ot sprockets at points (A), (B), (C) and (0). Retain this alignment and readjust the belts ot chain far tension. Secure the compo- rents to their mounting. ALIGNMENT 1. It is most important thet the pump be accurately aligned with the prime mover. Fig on page 12 will guide you in the alignment if V-belt or chain drives are provided. UF flexible couplings are used, follow the alignment recommended by the coupling manufacturer. When alignment is achieved it should be reinforced by shear blocks or dowel pins. PUMP SUCTION Single acting pumps require @ flooded or charged suction for proper performance. A net positive suction pressure, as provided by en adequate centrifugal charging pump, will ai inthe filling ofthe fluid cylinders oper jing pump should have a capacity ‘and reduce the era fon caused by cavitation Generally, the char equal to 11/2 times that of the triplex pump 2. The suction flow should'be streamlined through gradu turns with friction not greater than those caused by 45 deg, long radius elbows. Do not install any bend directly adjacent to the pump intake. 3. The suction line must not be smaller then the pump suction preferable the line should be at least one pipe size larger. The line should be as short 9s possible ‘nd the fluid velocity should not exceed 3 feet/second. In the pumping of solids it may be necessary to exceed this velocity to prevent the product {rom settling out of the cartier fluld. In this service, maintain the lowest possible velocity ond the lowest possible pump speed to provide for maximum pump performance. ‘A suction stabilizer is: tecommended-inst led a8 close fs possible to the pump suction, Install a full-opening gate valve or butterfly valve at the supply tank to permit the suction line to be closed and drained when necessary. Do not we a with any flow restriction. 6. Install a. drain valve at the lowest point in the suction system. 7. Install @ pressure gauge at the pump suet 8. Install low suction pressure alarm system. 4. Wwitall a theemometer well at the pump suction. 13, 10. n. nm Do not introduce meters or any ricting device 10 the suction tine. is not recommended, but if it should be necessary to manifold @ number of pumps to common suction, the suction pipe from the supply tank and the manifold must ha 8 cross-sectional area equal to or greater than the total cross-sectional areas of all the pump suctions connected to the manifold. Support the suction line st the pump and at the supply tank to remove any Imposed stresses or strains. Additio- ‘nal supports, dependent upon the length and configura tion of the suction line, may be necessaty to reduce fatigue and vibration. 0. PUMP DISCHARGE . ‘The cischarge line must not be smaller than the discharge fat the pump. ‘The discharge from the pump should be stteam-lined through gradual turns with friction not greater then those caused by 45 deg, long radius elbows. Do not install any bend directly adjacent to the pump discharge. Install a discharge pulseion dampener as close to the ump 2s possible. Any valves in the discharge line must be full-apeningtype. Install @ pressure reliet valve ahead of any valve in the discharge line. It must be set at © pressure not ‘greater than 25% above the rated working pressure fof the pistons or plungers being used. The discharge from the relief valve should be directed through @ securely positioned tine back to the supply tank (not to the pump suction). Install a by-f without load. This permits servicing of the equipment ‘and circulation of lubrication prior to loading the pump, ss line to petmit the unit to be operated Install @ pressure gauge at the pump discharge. Install a high-low pressure alarm system. This may be supplemented with time delay shut-down, 14 SHEAR BLOCKS ‘AL GENERAL Machinery items are generally mounted on machined pads, "H!" beams or bed-plates and retained with capscrews ot hhold-down bolts. The flexing of loaded machinery will cause these capscrews or hold-down bolts to become loose land ineffective for the retention of alignment of the machine with its associated equipment. When the equipment Is being made ready for operations it should be carefully aligned, secured with the capscrews or hold-down bolts then its position reinforced with dowel pins or shear blacks (this is applicable to items which need not be moved, [tu pumps, rotary tables, etc, however, engines or other prime movers which must be moved for belt ot chain drive ‘adjustments should be equipped with slide rails and in these installations the slide rails should be "doweled" or "blocked". Also, the shear blocks serve @ dual purpose, they ate guides, fot the re-installation of « machinery it been removed from its base for servicing or any other reason. sm once It has Bi. INSTALLATION 4 Weld side "C" again, start at the outside comer ‘and weld continously toward the retained object. [As indicted above, be certain that the equipment is in alignment and that the capscrews or hold- a epee lore atta be etalleg sonoma, (2) down bolts ate properly tightened. each other this placement with this outlined welding procedure will then place the retained Hold the shear block firmly in place and tack-weld ‘object in compression. it at point "ar, 6 Recheck the alignment of the equipment. If It has been distorted, Continue to hold the shear block in place end weld side "6" start at the outside cornet and weld continously to toward the retained object. seme instructions to install new shear blocks. (1) Object To Be Held (2) Shear Blocks Certain preperations a1 PREPARING FOR OPERATION necessary befo the pump can bbe placed in operation. It Is suggested that all check points in the MAINTENANCE section of this publication be observed fend executed prior to releasing the pump for service. The following is a guide for general preparation. A GENERAL 1. inspect the unit for any damage or defects. 2. Check sheaves/sprockets/couplings for proper alignment. 3. Check belts or chain for proper tension. 4 Check fuel, water, suction, discharge and drainage piping. 5. Check safety guards for maximum protection. 6 Check satety devices for malfuntion. FLUD END 1. The fluid end is normally shipped complete with the valves and seats installed The liners and pistons will, if delayed start-up is. indicated, be shipped unassembled. 2 Remove valve covers-inspect the valve service and the interior of the fluid end for defects ot foreign materjals, POWER END 1. Check rotation. The pump is designed for clockwise rotation of the crankshaft when viewed from the tight hand side. Right or left hand side is determined by standing at the power end and looking towerd the fluid end, REVERSE ROTATION MAY BE DETRIMENTAL TO THE UNIT (check with manufacturer if reverse rotation is necessary). 2 Remove inspection doots and covers-check the interior of the pump for ditt, rust, water ‘and foreign objects, particularly if the pump ‘has been in storage. If necessary clean and ‘wash out the power end with non-toxic, inort- explosive solvent. Replace the inspection doors and cavers. b. Check and be sure the drains are closed. 3. Fill the crankcase with correct amount of the Proper lubricant as indicated in the LUBRICATION section of this manual. The filling may be accomplished by removino the breather on top of the crank-case and Introducing the hubricant at this point. '. Replace the breather. 4 Fill the flushing system with the correct quantity ‘of the proper fluid as indicated in the LUBRI- CATION section of this manual. ‘& The filling is accomplished by introducing the fluid to the cradle section of the pump where it will gravitate to the flushing system sump. 16 PLACING IN OPERATION’ If the unit has been prepared for operation es outlined in the foregoing, procede to place the unit in service. The {following is a guide for initial startup. HH the pump is equipped with an externally driven lubricating oil system, energize the system five minutes in advance of start-up. I the pump is equipped with an integral lubricating cll system or has @ combination splash /cascade ciling system, remove the inspection doors and ‘covers from the power end, introduce @ copious quantity of the lubricating media into the bearing reservoirs, crosshead ways, crenk pin bearing troughs, ete. Replace the doors and covers. Check the temperature of the lubricant in the crankcase, This must be within the limits specified Jn the LUBRICANT TABLE which appears subse- ‘quently’ this publication. It the lubricant is below the minimum specified egree it can possibie be increased in temperature by circulating it through the lubrication system. this action does not bring the temperature &p to the minimum level introduce hot water into the heat exchanger or use emersion type heaters. 11 the lubricant is above the maximum specified degree it must be cooled. The heat exchanger with cool (cold) water flowing through it is for this purpose. Circulate the lubricant through the heat exchenger until it is within the operating range. If the pump Is equipped with @ flushing system, ‘energize the flushing system. 00 NOT PLACE THE PUMP IN OPERATION OR MAINTAIN IT IN OPERATION WHEN THE TEMPE RATURE OF THE LUBRICANT 15 ABOVE OR BELOW: THE LIMITS STATED IN THE LUBRICANT TABLE APPEARING IN THIS PUBLICATION. 5 n 10, Rotate the pump one full revolution by hand to be certain all moving parts are tree and can ‘move unrestricted. Open by-pass valve. Open valve at suction tank. Apply power slowly, check direction of rotation fend control at low rpm to prime the pump fluid chambers. Open the valve in the discharge line, increase power, close by-pass valve and observe the following. Check lubricant pump to be certain of flow In the lubrication system. Check flushing system- for proper distribution, Check for fluid leaks at "tattle-tale" holes in ‘uid cylinders. Check for fluid leaks at "atti valves pots. Check for lubricant Jeaks at diaphragm. Check suction pressure. Check discharge pressure. Check lubricant temperature. Check suction stabil level. Check discharge pulsation dampener for charge pressure. tale" holes in fer for proper operational Check for lubricant leaks in extemal piping. Check for fluid leaks in suction and discharge piping. Check all external bolting for proper torquing. Hf operations are below 50 rpm consult manufac- turer for lubrication instructions.* ‘*Not applicable to pumps with separately driven 7 TORQUING VALUES TORQUING VALUES FOR FASTENERS Sizes Required Torquing values The proper torquing of all bolts, studs and capscrews is DIAMETER | Alloy steel studs | Cap Screws & Botte IMPORTANT. Improper torquing will cause breakage by | —J—— TAGs ars fatigue or yield and serious damage of hazards can ensue. va | Me 09 or 5/6 | Me 18 1 A. GENERAL 3/a | M10 33 23 Original equipment consists of fasteners produced [746 | wiz oa a from alloy steel or heat treated alloy steel (low carbon | yo | sata 17 62 steel or materials of tess yield strength are not used | sig | mie 153 faa 3a | M20 2a 220) 1B. INSTALLATION OR ADJUSTMENT vs | M22 440 326 1. Clean and lubricate threads with » good quality fe eraze) eu ae anti-seize compound. ey Ss ae 2 Be cettsin tightening progresses uniformly to prevent misalignment or damage to the components. GED i) oa 3. The values shown are to be observed in the M36 tro wi final tightening of the fasteners. rave y | 138 Kg. m.. | 69 Kam. 12 Kom, ah i 12 Kg. m. 12 Kg mu . 27 Kg, me 876 Kg: me : 69 Kam \276 Kam. 19 fA film of lubricant must be provided with sufficient strength to withstand localized contact pressures at all points of moving, contact to prevent accelerated wear of the moving patts. The basic principle in the selection of lubricants, Is to choose the least viscous that will retain a fllm coverage and withstand the loading of the moving parts. When filling the ctankease, remove the inspection door from the crankcase cover and introduce at least 20% of the lubricant into the crankcase cover oil trough and scraper trough adjacent to the main gear. Oil may be added to the crankcase by removing the alt breather and pouring the oil through that opening. In the initial filing of the crankcase with lubricating oll and when the oil is being changed, it is suggested that the crankcase cover be removed and the interior of the pump be cleaned and inspected. At the seme time, drain ond clean the sludge trap, clean the oil strainer, clean the air breather, and (when changing oil) change the filter cartridge and clean the magnetic filter. f the oil was contaminated with foreign material, ke. sand, dirt, metal cuttings or chips, paint, light hydrocarbons, pumped product, etc fill the crankcase with a non-toxic, non-explosive solvent, install @ new filter cartridge and use ‘an external drive for the lubricating oil pump to circulate the solvent for a minimum of five minutes. It the pump is equipped with an electric motor dtiven oil pump, use this to circulate the solvent, if the cil pump is driven from the jackshaft, remove the v-belt and use an electric or pneumatic drill (or similar Gevice) to activate the oil pump to cicculate the solvent without rotating the shaft assemblies or moving the reciprocating parts. After circulating the solvent, remove the ctankcase cover, drain the solvent, inspect and clean the intetior of the pump, change the filter cattridge, drain and clean the sludge trap, clean the oil strainer ‘and clean the magnetic filter. Replace the crankcase cover and fill the crankcase with 20-W or 30-W ‘mineral oll or non-detergent motor ofl. Used to circulate the fe minutes. Continue Use the electric motor driven oll pump or externally driven pump, the same solvent and circulate the mineral oil or non-detergent motor oil for @ minimum of i skéwly, without any loading, rotate the crankshaft approximately 10 revolutions, of the to circulate this Drain this oll from the pump and follow the same procedures as that outlined for the remov Use the quantity of specified lubricant as per Table given on next page to fillthe crankcase. If the meche- nical drive was disconnected {rom the oll pump be certein that it Is reinstalled and adjusted before retutning the pump to service. Check the oll level at the oil level dip-stick, the oll level should be between the high and low marks on the stick (do not check the level when the pump is in operation). When initially filled, the level may be above the high mati on the stick ; however, after a few minutes of unloaded ‘operations the filling of the sludge trap and other reservoirs, the oil level should be between the high ‘and low marks on the dipstick. 20 LUBRICANT TABLE CRANKCASE LUBRICANT CAPACITY TYPE LUBRICANT SAE Lock oF TEMPERATURE viscosity | cauiva'eNT uTREs LUBRICANT (OPERATING NUMBER CONDITION) SERVOGEAR EXTREME HP 140 322 PRESSURE 32°c to 82°C 140 oR HEAVY DUTY INDUSTRIAL . 'SERVOMESH La SP. 460 LUBRICANT. OWL CHANGE & CLEANING. After 600 to 800 operating hours the oil is to be changed for the first time. Upon stopping the pump oil drainage is to be effected immediately while the oll is still warm. Subsequent oil changes are to be made within 3000 to 5000 operating hours. During the oll change the pump is to be cleaned throughly and flushed with wash oll. While doing this, absolute cleanliness is essential 50 a8 to ensure that-no foreign matter enters the interior of the gear. When assembling, itis necessary to see that ell joints in the oll piping system are tight. FLUSHING LUBRICANT service | CAPACITY TYPE TEMPERATURE | SAE NO. LOL PERIOD uiTeRs EQUIVALENT ‘SERVO- 50% MOTOR SUPER 30 EVERY 6 8 ‘Ol PLUS, ALL 30 OR SERVO- MONTHS 50% DIESEL No. 2 SUPER 40 FUEL 21 GENERAL 1. Use only the quantity and grades of lubricant listed on 2 Maintain the lubricant free of all contamin-sction (fluids and solids). 3. Change lubricant at the end of the setvice periods listed 4. If contaminated, change tubs 5. Maintain continuous lubricant flow under all operating conditions. Maintain the temperature of the lubricant within the ranges listed above. 7. Change the filter cartridge when the lubticant is changed, 8. Change the filter cartridge when the pressure scross filter incteases 1 Kg/Cm.2 9. Clean the magnetic filter every 8~ hours duting first week of dperations. 10, Clean the magnetic filter once each month (after first week of operations). 11, Clean lubricant strainers once each month (Minimum). 12, Drain sludge sump when dreining crankcase lubricant. Er] MAINTENANCE, GENERAL The requirement for @ maintenance program can- not be over emphasized. This equipment represents ‘considerable investment and its function is necessary te your operations. Neglect is costly and will result in premature failures, early retirement of worn equip- ment and the junking of unusable machinery. ‘The installation of a maintenance program with positive execution will reward your operations economicelly byt 2. Reduce quantity of required repair and replacement parts. 3. Provide for longer periods of service-free operat Extend the life of your equipment. PROVISIONS FOR MAINTENANCE It is strongly recommended that all pumping operations bbe supported with stand-by capacity and by 8 spare parts inventory. The percentage of stand-by capacity needed to sustain operations is determined by the operator and the quantity of spare parts in his inventory is usually dictated by use patterns. Spare parts should be maintained in inventory to be immediately available at the point of operations. © SUGGESTED MINIMUM PROGRAMME 1, The following represents @ suggested MINIMUM equirement for maintenance. It is designed for perioc Inspection and adjustment, it does not preclude the necessity of immediate attention to items or elements which become maladjusted fot worn not is it intended to temave the "common= sense" factor which Is so necessary in the operation fof any machanical equipment. 2 As indicated above, this is only @ guide other maintenance may be desirable and required to satisty your satety programme, to comply with established policies, ete. 23 MAINTENANCE This sisting of cbservations mggested tobe considered when performing maintenance on standard pump Each operating company ‘should prepare their own specific forms for this purpose and insist that an established program be followed and recorded. Daly EK OL TEMPERATURE 1 | etx OSG POLATION OREPOER FoR PROAR PRESSE WEEKLY ‘GOK TOUNORTION WAY OR FOLD-DOWN BOLTS [GHEE DSOARGE FUME BOLTRE MONTHLY, 1 | ere tne pron wean (GEO VALS SATS WO SPARE IX MONTHS Gecx Crossiend GORE ‘OHEOK CROSGAEAO PRN CLEARANCE (GEO CRANR BEARNG CLEARANCE ‘GEOC GINS WO /oR GAN MO SPRODRETS TOR WEAR [OHEEK PUMP SAVE, PRODTT Of COUPH "GUE OF (ae Cre Fier Cann) ‘Gaver Ubi MEO The act of observing and recording a not enough —provide the neceasry tm {functioning safely and property. material ana physical effort to keep your equipment 24 TROUBLE SYMPTOMS It is not possible to diagnose, without a very careful exar ‘operation. The more common symptoms ation, the cause of ll difficulties which may arise in any pumping @ listed below. If the remedy outlined here does not alleviate the difficulty, please refer the matter to the manufacturer's techinicel services department. OBSERVATION PROBABLE SOURCE [ADJUSTMENT Teplace Valve Anonbly fen Ps a [foo ataras lLow Discharge Pressure| Improper Filling ‘increase Charging Pump Speed Decrease Pump speed Prime Fluid Chambers Fluid Slippage } + Replace Piston Liner Erroom Gav Rendng-—{ Reva or Rolece Cape Charging Pump Capacity Increase Charging Pump Speed [aaa Ht 1 Retarded Fluid Flow Remove Restrictions from Suction Line Erroneous Gauge Reading FH. Recalibrate or Replace Gauge ‘Air Entering Suction Line Repair Suction Line }[air Enterina Charging Pump Tighten or Replace Shaft Packing or Seal ‘Ait Entering Suction Ste ‘Repair and Re-balance ‘Allow More Settling Time Fluid Knock or Hammer} Air /Gas in Pumped Fluid Reduce Pump Speed Adjust Suction Stabilizer Sonor Se OBSERVATION 25 ROUBLE SYMPTOMS PROBABLE SOURCE [—{ Discharge Pulsation Dampener KH Repair and Recharge or Replace ADJUSTMENT Unsupported Discharge Line Provide Supports of Hangers Discharge Line Vibration] Sone a Law See Preset — ‘Same as Low Discharge Pressure J ‘Same as Low Sucti Prowse | —[ ew tow Scion Prom Some as Fluid Knock or Hamme }—_ Seme as Fluid Knock ot Hammer KH Loose Liner Adapter Nut Tighten Liner Adapter Nut Loose Valve Cover Tighten Valve Cover Valve Not Seating ‘Short Valve Life 1 {Worn or Damaged Gasket | Reolace Gasket Replace Valve Cover Lf Damaged Gaskat Surtace HH [Reslace tiner Wear Pia ‘Abrasives in Fluid Large: Particles in Fluid | Repair Fluid End (Check Desander Desilter Sereen Pumped Product Broken Valve Spring-Replace ‘Pump Not Filling Pulsation Dampener Maltunction c ‘Abrasives in Fluid eS} \_[ wom vaive/ seat Replece c Treat Pumped Fluid ‘Corrosion H Worn Valve Guide-Replace [Repair or Replace Use Different Materials for Valves/Seate Check Desander /Desilter ‘Short iner Lite | Repair Flushing System Use 50% Oil & 50% Diese! Fuel to Flush Use Super Di-Hard Liners Use Regular or Oil Resistant as Required TROUBLE SYMPTOMS OBSERVATION PROBABLE SOURCE Worn or Demaged Extension Rod ADJUSTMENT Replace Extension Rod {feared tron Roo Clean and Polish or Replace Extension Rod llowscar aap He Cantern Ring Toit sate misplaced Worn Wiper Rings H Wiper Rings Improperly Sealing [Replace Wiper Rings Check Installation Directions Clean and Polish Diaphragm Bore ]—[resnce tate Brg | [eck tatlaton recto [Reservoir in Diaphragm Housing Install Orain Hole at Bottom Clean Drain Hole Worn Sealing Lip [mes Sealing Lip 10.D. Not Seated lean and Polish Bore of Oil Seat Housing Foreign Material at Seal Point p[cecen and Poli shat LY Clean and Polish or Replace Shaft Sleeve | [isms Cran |_[sean or Rape Ar Brea Low oil Level {creck and Add oi 1 Necessry Contaminated Lubr Low Oil Pressure High Oil Temperature sant Relief Valve Maladjusted Leakage in Piping System Repair All Leaks See observation "High Oil Temperature Change Olt ‘Check and Reset Oil Pump Worn a Se [Clogged Suction Screen Clean Screen and Change Oil Erroneous Gauge Reading ]—[Frecatiorate or Replace Gauge OBSERVATION 27 TROUBLE SYMPTOMS, PROBABLE SOURCE ADIUSTMENT {iw 01 Temperate Connie 8 } [ime os in’ Temperature Range High Oil Pressure _ Hietet ave manana } [rece and fet High Oil Temperature Olt Filter Clogged }-{cranse Fitter Conteiage Restrictions in Passageways Erroneous Gauge Reading Recalibrate or Replace Gauge Clean Tubes and Shell Regulate Coolant Rate [improper Bearing Aciustment Check and Adjust Clearances Incorrect Pump Rotation ‘Check Installation Directions l ‘Loose Estension Rod irene ee ttonse Bearing Housings /Covers (Check and Tighten ‘Worn Crosshead Pin ‘Worn Crosthead Pin Bushing /Beating Worn Main or intermediate B ring 28 STORAGE OF PUMPS Al machinery units require protection from corrosion erosion, natural attrition which causes deterioration

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