TWO STAGE REVERSE OSMOSIS PLANT OPERATIONAL / MAINTENANCE MANUAL V 0.02 Date: 05-07-2013 Type of Unit:
MODEL: SW-38B
Project: JADE PALMS
Order No:
Serial No:
ORION OFFSHORE MARINE SERVICES PTE LTD 1 SOON LEE STREET #05-48/49 PIONEER CENTRE SINGAPORE 627605 TEL: +65 97451496; FAX : +65 65706907 Email :
[email protected]
Sea Water Reverse Osmosis Plant
001/002/2013
CONTENTS 1.
2.
3.
4.
5.
6.
INTRODUCTION I. Preface II. How to use this Manual III. Safety Remarks IV. Log Sheet V. W arranty VI. Notes VII. Service FUNCTIONAL DESCRIPTION 2.1 Description of Process 2.2 Unit Arrangement 2.3 Controls, Displays & Measurements 2.4 Safety and Behavior Rules OPERATION 3.1 Commissioning 3.2 Starting of Unit 3.3 Initial Startup 3.4 Normal Operation Monitoring 3.5 Preservation FAULT INDICATION & FINDING 4.1 Error Indication and Implication 4.2 Faults without Lamp Indication MAINTENANCE, CLEANING & CALIBRATION 5.1 Schedule for Checks & Maintenance W ork 5.2 Contactors 5.3 Electric Motor 5.4 Centrifugal Pumps 5.5 Plunger Pump 5.6 Multimedia Carbon Filter 5.7 Cartridge Filter 5.8 RO Membrane 5.9 Pressure Vessels – W AVE CYBER SPECIFICATIONS 6.1 Specification 6.2 Tools and Resources 6.3 Annual Consumable Items 6.4 W ater Analysis
Sea Water Reverse Osmosis Plant
INTRODUCTION I.
Preface This Reverse Osmosis System has been designed and fabricated as space saving modular plant in order to provide installation flexibility to the user, where space is restricted. All components and material used have been selected as per user requirements and guaranteeing on a self-controlling 24 hours operation. The said system is simple to operate and require minimum service.
II.
How to Use this Manual This manual should provide to you all the necessary and required information for operating and maintaining of the said system. During the design and fabrication of the said system, great regard has been paid for safety. W hen working on this system or any other system, there is always an element of danger which the owner, operator and technician need to be aware of. Appropriate maintenance minimizes any danger and maximizes availability. Any work of maintenance or repair, must be carried out correctly. Appropriate technical knowledge as well as any applicable regulations for safety and environment must be provided by the owner, operator and/or the maintenance personnel. THIS MANUAL DOES NOT REPLACE ANY PERSONAL TRAINING!
III.
Safety Remarks
The fresh water generator must not be operated within harbor area or in waters
When operating this equipment, certain parts are electrified. Ignorance of
polluted with oil.
operating procedure can cause death, injury or material damage. For any work at or on the plant must only be done by persons trained on the machine and familiarized with the information in this manual. Repair and maintenance must only be done by appropriately qualified technical personnel.
Protection, such as Pulley / Belt and Belt Guards, must be only done for maintenance or repair and must be re-installed immediately after any such
Sea Water Reverse Osmosis Plant
repair or maintenance completion.
All personnel involved in the operation, maintenance, inspection and
installation / reinstallation of the product or part of the product must be fully qualified. Personnel responsibilities, competence and supervision must be clearly defined by the operator.
The product is made with greatest possible care. Modifications in the construction
Make sure that the product operates within its working range. Only then the
Check the rotating parts regularly. Always use biodegradable lubricants for
Always act according to the laws by laws regulations and instructions with respect
Extra safety care may be required depending upon the specific operations on the
or the use of non-original parts may lead to a safety risk.
product performance is guaranteed.
maintenance.
to health, safety and environment.
system.
The OWNER and USER are responsible for complying with all the prevailing laws to maintain a safe working environment. IMPORTANT ITEMS FOR PLANT PROTECTION:
There must not be any visible movement (vibration/pulsation) of the pointer on pressure gauge. If this occur then the causing this fault may be ‘High pressure pump or valves or packing defects’.
The RO Membrane damage possible, if there is any vacuum in the feed water supply line or concentrate discharge line.
Do not allow any back pressure on the permeate outlet, when there is no pressure on the feed supply, otherwise the membrane cushions will be damaged. Do not allow pressure on the permeate side of the modules when
Sea Water Reverse Osmosis Plant
the unit is stopped. The maximum pressure in the permeate line is 3bar. Add an additional booster pump, if a permanent pressure above this value is required.
The feed pressure to the high pressure pump must not fall below 0.5bar. If this happens, the pump will be damaged by cavitations.
The membranes are not resistant against chlorine or any oxidizing agent. De-ionized or distilled water in the unit will reverse the flow direction and destroy the membranes.
Feed-water quality conditions care is essential for membrane performance.
Do not allow to operate the RO Unit in the areas of river esturiances, especially in regions with low draft where the water can be expected to carry a high amount of suspended solids and silicates. This could cause unremovable deposits on the membrane surfaces affecting the desalination process, reducing capacity and finally requiring the membranes to be replaced.
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V. LOG SHEET In order to make any troubleshooting as easy as possible, the following chart is recommended for daily use with the parameters measured on the unit: Date
Hours
Fresh Water T DS
Feed Water T DS
PH
PG 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
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PG 2
PG 3
PG 4
PG 5
PG 6
PG 7
PG 8
FM 1
FM 2
FM 3
FM 4
VI.
WARRANTY ORION OFFSHORE warrants that this system will produce pure water within its designed limitations for a period of Twelve (12) months from the date of dispatch, provided that the system is operated on feed water of the minimum standard in accordance with the submitted reference analysis and that the operator adheres exactly to the installation, operation and maintenance instructions and recommendations. Components of the system supplied by ORION OFFSHORE which are found to be defective through poor workmanship or materials will be repaired or replaced if their performance is proven to be less than normal by industry standards. This warranty will be considered null and void if a unit is operated with malfunctioning components or controls which result in the system being unable to meet its designed performance. ORION OFFSHORE will repair or replace a unit or component found to be defective due to bad workmanship or materials on a free of charge under this warranty and defective unit or component will be returned. This warranty does not cover any system or component which fails due to damage from mishandling, misuse, substandard feed water, improper maintenance or neglect of maintenance, poor or improper installation or incorrect electrical supply. This warranty may also be voided if serial numbers or components are found to be mutilated or missing. This warranty does not cover or apply to consumable items such as filter elements, lubricants, shaft seals of centrifugal pumps, seats/seals of the high pressure pumps or chemicals used in the operation or maintenance of the system. The terms of this warranty become effective on dispatch of the equipment from ORION OFFSHORE premises. There are no warranties expressed or implied which go beyond the foregoing statement.
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VII.
Notes
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VIII.
Service Order Form for Spares
For Vessel
Authorized By:
Unit Type
Approved By:
Delivery Instructions:
Serial No
Date
Delivery Required By:
Order No:
Additional Instructions:
To be charged / Invoiced to:
To ensure that the correct parts are delivered, please complete each block correctly. The section block refers to the header number of the page that contains the description or servicing of the item (if any). ITEM
QTY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
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PART NO
DESCRIPTION
SECTION
2.
FUNCTIONAL DESCRIPTION 2.1
Description of Process This system uses the principle of the 'Reverse Osmosis’. ‘Reverse Osmosis is a process in which water is de-mineralized by using a semi-permeable membrane at high pressure’. If two saline liquids are separated from one another by a semi-permeable membrane, which does only allow molecules over a certain size to pass through, then these liquids will tend to equalize their concentrations. This phenomenon is called Osmosis. Should one of these liquids be salt water and the other pure water, water molecules would diffuse through the membrane towards the salt water and dilute this. A certain pressure would occur in the system when this happens, the pressure is known as ‘Osmotic Pressure’. For water desalination or de-chlorination this process is artificially reversed, Reverse Osmosis. The system is subject to a pressure above Osmotic Pressure, causing a molecule movement into the reverse direction; only the water molecules diffuse from the salt water through the membrane to the pure water side. The ions of the salt water cannot pass through and remain on the salt water side. W ithin the RO membranes, the Reverse Osmosis process takes place whilst the feed water is in motion flowing over the membrane surfaces. About 30% of the water in the feed water passes through the membrane, the remaining 70% retaining the rejected salts. The feed water is gradually increasing in salt concentration as it flows through the RO membrane. The salts filtered out and left behind by the membrane are carried away and dis-charged, in case of sea water desalination they are returned to the sea as brine (concentrate). The pure water ‘permeate’ produced flows to a fresh water storage facility. The amount of pure water that can be produced depends on the following: aThe operating pressure bThe salt content of the feed water cThe feed water temperature For example, the oceans have a salt content of approximately 3½%, whereas the Red Sea has a much higher salt content of approximately 4 ½% and to overcome the increase in salinity the operating pressure is increased. Each standard system is designed for a certain production rate of pure water, assuming a feed water temperature of 25C°. For each 1C° drop in feed water temperature, the permeate production drops by 3%. For example, if designed output at 25C° is 100l/h. Then with a feed temperature of say 15C°, the permeate output is 100-30%=70l/h. A rise in temperature above 25C°, increases the pure water production only slightly. 25C° is the optimum feed temperature.
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Note: Some systems can be supplied to produce the required quantity with a low feed water temperature. 2.2
Unit Arrangement
The system consists mainly of the following components:
SW MEMBRANE
BW MEMBRANE DOSING PUMP
DEIONIZER (NOT SUPPLIED)
PRESSURE GAUGES HIGH PRESSURE PUMP MOTOR
FLOW METER GATE VALVE
HIGH PRESSURE PUMP - I
FEED PUMP -1
(General arrangement of the System) (DE- IONIZER WILL NOT BE INCLUDED IN JADE PALM UNIT)
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Feed Pump (Centrifugal Type) (FP1) filter pump, delivers the feed water at a pressure of up to 4 bar through the cartridge filter and from there to the high pressure pump (HPP). This centrifugal pump has its own integral electric motor.
Multi Cartridge Filter Ten micron pre-filtration housing constructed from Stainless Steel 316 materials, designed to meet ASME code requirements shall be provided for Reverse Osmosis unit. The pre-filtration stage of the system has been designed for a maximum flow of 10 GPM (each) with 7 Nos of (2.5 x 20) inch Slim Line Cartridge Filter inside.
Cartridge Filters (CF) in it sediment particles of 10 µm or more in size are retained within the filter element. These cartridge filter elements have to be replaced when dirty, they cannot be cleaned.
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High
Pressure
Pump1
(HPP1)
is
a
positive
displacement pump (plunger pump). This pump delivers feed to the 1st stage RO Membrane at a pressure of up to 65 bar. The pump is powered through a belt derive from a 3-phase motor. Minimum feed pressure to this pump is 0.5 bar.
RO Membrane RO membranes are imperfect barriers to dissolved salts in feed-water, there is always some salt passage through the membrane. As feed-water pressure is increased, this salt passage is increasingly overcome as water is pushed through the membrane at a faster rate than salt can be transported. However, there is an upper limit to the amount of salt that can be excluded via increasing feedwater pressure.
The concentrate flows from the unit through the manually operated Concentrate Valve (CV) which allows three positions: TDS Sensor (TDS-S) transmits the conductivity of the permeate to the conductivity meter (measure of the remaining salt content). An increase in conductivity implies a higher salt content. The value displayed in the conductivity meter is in µs/cm. As a rough guide, if the reading shown is divided by 2 the figure obtained would be the approximate value of salts as ppm (mg/l).
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Level Switches (LS1 & LS2) Starting and stopping the unit will then be actuated by 2 level switches fitted in the buffer tank and chemical tanks. When the low level switch is activated, the plant will start automatically. When the tank is full the high level switch will be activated and the unit stops and will be in a “stand by” mode waiting to be restarted either by remote (level switch) or manually by pressing the start button.
2.3
Controls, Displays & Measurements
Control Panel (CP) is equipped with a Main Circuit Breaker, Switches, TDS Controller & Display, Amp Meter, Volt Meter, Indicators, Hour Meter etc.
Flow Meters (FM1, FM2, FM3, FM4) are installed in different lines in and from the RO Membrane(s). Inside the plastic body there is a floating indicator. When its top edge aligns to the appropriate mark on the scale, indicates the rate of pure water produced. The scale is marked in liters per minute / gallons per minute on the front of the transparent plastic body.
Conductivity
Controller
(TDS
C)
displays
the
conductivity of the permeate, measured by the conductivity sensor. Conductivity provides a measure for the salt content remaining. The higher the conductivity, the higher the salt content.
Sea Water Reverse Osmosis Plant
Pressure Gauges (PG1, PG2, PG3, PG4, PG5) indicate the pressure loss across the cartridge filter, sand-filter & RO Membranes. Check the operating pressures for each unit as per functional requirements. The pressure gauges are filled with a glycerin type liquid to minimize the pointer vibration.
2.4
Safety and Behavior Rules Intended use This system is for drinking water process and boiler feed use. Briefing When operating this equipment certain parts are electrified. Ignorance of operating procedure can cause death, injury or material damage. Any work at or on the plant must only be done by persons trained on the machine and familiarized with the information in this manual. Repair and maintenance must only be done by appropriately qualified technical personnel. Electrical endangerments During the operation of electrical devices some sections are energized dangerous. Negligence of warning notes can cause death, bodily injury, or damages to property. The cabinets and devices are only to be opened by qualified personnel. Mechanical endangerments The system is designed in the state of the art. In order to ensure safe handling of the system, all preventive measures have to be checked for effectiveness. The operator has to ensure by regular maintenance that the function of the respective protection devices will preserved.
Sea Water Reverse Osmosis Plant
Chemical endangerments The operation of the unit and functions depend upon the field of application and use of different chemicals (e.g cleaner, pH stabilizers and flocculants, disinfectant). Adopt the proper safety for protection.
3.
3.1
OPERATION
Commissioning
Read the safety remarks and before commissioning the plant, please take note of the following: LIMITS OF PERFORMANCE
Maximum flow rates
Feed Water:
40 gpm (Approx)
Permeate:
Designed + 20%
Note: High feed flow will cause an unacceptable pressure loss across the RO membranes and a higher ampere loading on the HP pumps motors
Operating pressure
65 bar
Maximum operating pressure
73 bar
Before first commissioning of the plant, the following checks must be made: ASSEMBLY
CHECKS BEFORE FIRST COMMISSIONING
Control cabinet - Check voltage
- Check frequency
The voltage must be checked across each two phases: from L1 to L2 from L1 to L3 from L2 to L3 The plant must only be operated at the ratings it was designed for.
- Check control voltage
Check different circuits output voltage, pressure switches and level switches.
RO Membranes
Check loading
Flow meter
Check setting and connections of flow meter.
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3.2
Starting of the Unit Lamp signals :
lamp on
lamp off
Lamp signals: Step No.
Action
1
Open all valves to and from the RO unit.
2
Set valves to Normal operation:
Normal operation 3
Check PB 1 for ‘Feed Pump 1’.
4
Check PB 2 for ‘High Pressure Pump 1’.
5
Check the pressures and flow rates
6
Check PB 3 & PB 4 for ‘Feed Pump 2’ and High Pressure Pump2.
7
Check the pressures and flow rates
8
Activate Cleaning Pumps on requirement by selecting PB 5 & PB 6.
9
Activate Dosing Pumps on requirement by selecting Selector Switches.
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Effect
Lamp signal
Adjust all valves as per requirement. Feed Pump 1 is ready for operation.
Pressure Gauges and Flowmeters indications. Pumps are ready for operation.
Pressure Gauges and Flowmeters indications. Pumps are ready for operation
3.3
Initial Startup
OPERATING PROCEDURE Stage – 01 (Sea water to Fresh Water) Refer Flow Diagram
‘BEFORE PLANT STARTUP, GATE VALVES (GV 1 & GV 2) MUST BE IN FULLY OPENED POSITION’
1.
Check feed line, FGR Strainer for any suspended impurity, Ball valve (BV 1) (open position).
2.
Push button PB 1 for Feed Pump 1 ( FP 1), Feed pump will start functioning and Pressure Gauge (PG 2) will indicate pressure 20-55 PSI.
3.
Water flow will start and it will enter into the Cartridge Filter 1 and Cartridge Filter 2 respectively.
4.
Turn ‘ON’ Dosing Pump 1 (DP 1) through Selector Switch 1.
5.
Replace Filter Cartridges, If Pressure Differential of PG 1 and PG 2 decreased by 20 PSI.
6.
Now turn ‘ON’ High Pressure Pump by pushing ‘PB 2’.
7.
For smooth and safe operation, allow High Pressure Pump 1 (HPP 1) to run 5 minutes for stability.
8.
Slowly and gradually turn Gate Valve (GV 1) towards close position. By closing the valve, the system pressure will start increasing and will be displayed on PG 3 and PG 4, respectively.
9.
Stop closing of the said valve when system pressure will reach at 750–850 PSI at PG 3 & PG 4 or flow rate of 9 GPM will be displayed on Flow Meter 2 (FM 2).
10.
When one of the above mentioned parameter will achieved, let the system run for 15 minutes and observe the system stability, if R.O plant does not run smoothly or parameters are fluctuating, repeat step 1 – 10.
Sea Water Reverse Osmosis Plant
Stage – 02 (Fresh water to Boiler Feed Water) Refer Flow Diagram 11.
For starting of stage 02, press push button 3 (PB 3) to operate Feed Pump (FP 2).
12.
When Feed Pump 2 is in operation, fresh water will start passing through the Multimedia Carbon Filter 2 (CF 1) and Feed Pump 2 pressure will be displayed at PG 5.
13.
After CF 2, water will flow through the Cartridge Filter 2 (Cart. F 2).
14.
If Feed Pump 2 pressure exceeds 70 PSI at PG 8, stop Stage 02 and replace Cartridge.
15.
Turn ‘ON’ Dosing Pump 3 by selecting Selector Switch 3 (SS 3).
16.
Start High Pressure Pump 2 (HPP 2) by pushing PB 4.
17.
Slowly and gradually turn Gate Valve 2 (GV 2) towards close position. By closing the valve, the system pressure will start increasing and will be displayed on PG 9 and PG 10, respectively.
18.
Stop closing of the said valve when system pressure will reach at 150-225 PSI at PG 9 & PG 10 or flow rate of 3 GPM will be displayed on Flow Meter 3 (FM 3).
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3.4
Normal Operation Monitoring SEA WATER: Description 0
Value
0
Temp ( C or F) Pre filter pressure (psi or bar) Post filter pressure (psi or bar) Primary pressure (psi or bar) Final Pressure (psi or bar) Permeate Flow (GPM or m3/hr) Qp Concentrate Flow (GPM or m3/hr) Qc Recovery (R1) Qp/(Qp+Qc)
FEED WATER: Description
Value
Temp (0C or 0F) HP Pump Pressure (psi or bar) Final Pressure (psi or bar) Permeate Flow (GPM or m3/hr) Qp1 Concentrate Flow (GPM or m3/hr) Qc1 Recovery (R2) Qp1/(Qp1+Qc1)
3.5
Preservation
To prevent fouling during a stand still for > 07 days the unit must be preserved.
Must circulate preservation solution after every 12-15 days.
Circulate preservation solution at least 30 minutes by turning cleaning pump ‘ON’.
Note:
For the first start after preservation, the unit must be rinsed by raw water for at least 5 minutes under pressure. During this time period permeate produced may not be supplied to fresh or feed water tank.
Sea Water Reverse Osmosis Plant
FAULT INDICATION & FINDING
4.1
Error Indication and Implication Fault conditions are indicated by various lamps (different colors) on the control panel. Lamp signals:
Lamp signal Device Red
EOCR ST
LAMP SIGNALS @ 1
Red
Red
PSD
BTL
ND
LAMP SIGNALS @ 2
Meaning
Possible causes
Electronic Over-current Relay
-
Motors over loaded Wrong Current Setting
STAGE: RED LAMP IS ILLUMINATED PERMANENTLY FOR FAULT
Power Safety Device
- Phase failure - High/low Voltage - Phase sequence - Device calibration - 1Pole circuit breakers
Buffer Tank level
- High feed-water supply - High pressure pump not operational - Level Switch
STAGE: RED LAMP IS ILLUMINATED PERMANENTLY FOR FAULT
Red
BTL
Buffer Tank level
- High feed-water supply - High pressure pump not operational - Level Switch
Red
TDSC
TDS Controller
- High TDS over the set value
Red
PHM
pH Monitor
- High pH over the set value
4.2
Faults without Lamp Indication
Lamp signal Device
Meaning
Possible causes
FAILURES WITHOUT FAULT INDICATION
CP
Control Panel not operative - Power supply, Circuit breakers, Relay
RSS
Rotary Selector Switches
- Wrong auto/manual adjustment
DIP
De-Ionizer Pump
- Thermal Overload/Circuit
CCP
Chemical Cleaning Pump
- Thermal Overload/Circuit
-
Excessive pressure - Valves in HP pump worn or damaged fluctuation during operation
-
- Normal wear HPP valves malfunctioning - Particles between valve plate and valve seat.
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5.
MAINTENANCE, CLEANING & CALIBRATION 5.1
Schedule for Checks & Maintenance Work In order to maximize availability the unit must be maintained regularly. Checks and
maintenance works should be carried out according to the tables below. Detailed instructions, as far as necessary, can be found in the following chapters. The check list at the end of this manual should be filled in daily. This assists to detect failures sooner and easier. 5.1.1
Schedules for Checks & Maintenance Works
REGULAR CHECKS Action
Frequency Daily
- visually inspect all sections for leakages - check if motors or pumps make unusual noises and oil levels - check pressure losses across cartridge filters and RO membranes and fill in log sheet
Monthly
- check calibration of conductivity meters by comparing with readings taken with a manual measurement - check and update stock of spares and consumables, if necessary - visually check all safety devices, such as overfill couplings etc - Check equipments fastening nut bolts, PVC pipe lines upto product tanks and flanges.
Half-yearly
- check contactors for lose screws or wires and base plate nut bolts.
Sea Water Reverse Osmosis Plant
Device
Designation 0n P&I diagram
Electric motors Cartridge filter RO membranes
Required action
(for plunger pump HPP1) Cart. F
replace bearings replace filter elements
As required or after approx. 20,000 operating hours As required
SWM & BWM
replace membranes
(only if necessary)
circuit cleaning
every 500 operating hours or earlier, if required 150 hours after commissioning, then monthly every 3,000 operating hours or as required
check torque Plunger pump
Centrifugal Pumps
5.2
Recommended frequency
HPP1
check plungers, pumping section and crankshaft section check valves and seals, replace as necessary check valves and seals, replace as necessary check belt tension check oil level, top up if necessary replace oil filling
FP1, HHP2, FP2, DIP, CP
Priming Noise RPM, if required
every 3,000 operating hours or as required every 3,000 operating hours or as required weekly weekly 50 hours after first commissioning, then every 750 operating hours or monthly as required Daily As and when required 10000 hrs or if required
Contactors Maintenance requires qualified personnel ‘ACCESS ONLY BY ELECTRICIAN’
Due to thermal load upon the contactors, the screws that tighten the wires could become loose after some time.
Step #
Action
1
Turn off master-switch.
2
Check, if necessary re-tighten, screws L1, L2, L3 and T1, T2, T3 with a suitable screwdriver.
Sea Water Reverse Osmosis Plant
5.3
Electric Motor This motor is ‘Induction Type’, 3-Phase, 20HP, 400Volts and brand ‘Western Electric Australia’ After about 20,000 operating hours or as necessary, the roller-bearings should be checked and, if necessary, replace. The type of bearings fitted do not allow for cleaning or regreasing. TYPICAL PARTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
stator feet rotor end shield drive end flanged end shield drive end end-shield, non-drive end V-ring drive end bearing, outer cap grease thrower roller-bearing DIN 625 bearing, inner cap V-ring non-drive end bearing, outer cap grease thrower roller-bearing DIN 625 bearing, inner cap
16 17/18 19 20 21 22 23 24 25 26 27 28 29 30
external fan external fan sing (sheet steel) terminal board (according to DIN) terminal plate with insulators protective cable bushing for flameproof motor (stud terminal) terminal clamp for ex motors gland cover terminal box terminal box, bottom part terminal box lid entry section (A or B) single-entry sealing chamber (E) double-entry sealing chamber (F) compression gland
Note: These are typical parts of an electric motor and for separate parts, refer to motor manufacturer (OEM) or DESTO.
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5.6 5.6
Centrifugal Pumps Grundfos Pump Models: 1)
FEED PUMP1, Multistage, Vertical, 3KW, CRN8-30
2)
FEED PUMP2, Multistage, Vertical, 2.2KW, CR4-100
3)
HIGH PRESSURE PUMP2, Multistage, Vertical, CR4-40
These pumps are virtually maintenance free because of the materials used in its construction. If the mechanical seals leak it should be replaced as soon as possible. The motors are totally enclosed, fan-cooled, 2-pole Grundfos standard motors with principal dimensions in accordance with the IEC and DIN standards. Electrical tolerances according to IEC 34/EN 60034. These pumps are used to boost the seawater through the sand filter, carbon filter and cartridge filters. When pumps are re-installed and the RO unit is started for the 1st time after removal, the pumps must be purged of air. Use the air release valves to remove air from the pump. Do not over tighten as this could damage the valve seat. It is preferred that it should only be ‘hand tight’. Applications: CR
Hot and chilled water, boiler feed, condensate return, glycols and solar thermal fluids etc.
CRN
De-ionized, de-mineralized and distilled water, Brackish water and other liquids unsuitable for contact with iron or copper alloys etc. (consult manufacturer for specific compatibilities)
Minimum Inlet Pressure: All CR and CRN Pumps
NPSHR+2 feet
Installation Checklist: 1)
Pump location
2)
Foundation
3)
Pipe work
4)
Motor and position of terminal box
5)
Field wiring and protection
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General Data CR4
SECTIONAL DRAWING
MATERIAL
The pump consists of a base and a pump head. The pump body and outer sleeve are fixed between the base and the pump head by means of stay bolts. The base has inline suction and discharge ports. The pump has a free maintenance mechanical shaft seal with dimensions to DIN 24960. The pumps should be checked regularly for air that may be trapped in the upper chamber of the pump. In normal operation this will not be a problem but in rough seas there could be a considerable amount of air entrapped in the feed water.
General Data CRN8
SECTIONAL DRAWING
Sea Water Reverse Osmosis Plant
MATERIAL
The pump consists of a base and a pump head. The pump body and outer sleeve are fixed between the base and the pump head by means of stay bolts. The base, the pump head cover as well as vital pump components are made from stainless steel. The base has inline suction and discharge ports. The pump has a free maintenance mechanical shaft seal with dimensions to DIN 24960. The pumps should be checked regularly for air that may be trapped in the upper chamber of the pump. In normal operation this will not be a problem but in rough seas there could be a considerable amount of air entrapped in the feed water.
For separate parts, refer to pump manufacturer (OEM).
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Operation: Starting of the Pump: a)
Check priming of the pump both for open and closed systems.
b)
Check the direction of rotation: -
Switch off power
-
Make sure that the pump has been filled and vented.
-
Remove the coupling guard and rotate the pump shaft by hand to be certain it runs freely.
-
Verify the electrical connections
-
Click the power on and check the rotation direction, to reverse the direction of rotation off the pump.
-
Interchange the power leads and check rotation on pump start.
-
If rotation is correct, re-install the coupling guard on off position. Reapply the power to start the pump.
c)
Check all piping connections, supports and foundation bolting.
d)
Isolate all the valves for initial startup.
e)
Check and record all the voltages and pressures. Readjust, if required.
f)
Check all controls for proper operation. If pump is controlled by pressure switch, check and adjust the cut-in & cut-out pressures.
Maintenance: Freeze Protection: If the pumps are installed in an area where freezing could occur, the pumps and systems should be drained during freezing temperatures to avoid damage. To drain the pumps, close the isolation valves, remove the priming plugs and drain plugs at the base of the pump. Do not replace the plugs until the pumps are to be used again. Always replace the drain plugs with the original or exact replacement. Do not replace with a standard plugs. Internal recirculation will occur, reducing the output pressure and flow. Motor Inspection: Inspect the motors at regular intervals, approximately every 500 hours of operation or every three months, whichever occurs first. Keep the motors clean and the ventilation openings clear. The following steps should be performed at each inspection: 1.
Check that the motor is clean and interior and exterior of the motor is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc can accumulate and
Sea Water Reverse Osmosis Plant
block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure. 2.
Use an Ohmmeter (Megger) periodically to ensure that the integrity of the winding insulation has been maintained. Record the Ohmmeter readings. Immediately investigate any significant drop in insulation resistance.
3.
Check all electrical connectors to be sure that they are tight.
Motor Lubrication: Electric motors are pre-lubricated at the factory and do not require additional lubrication at start-up. Motors without external grease fittings have sealed bearings that cannot be re-lubricated. Motors with grease fittings should only be lubricated with approved types of grease. Do not over grease the bearings. Over greasing will cause increased bearing heat and can result in bearing/motor failure. Do not mix petroleum grease and silicon grease in bearings. Lubrication Schedule* NEMA/(IEC) Frame Size
Up through 210 (132) Over 210 through 280 (180) Over 280 up through 360 (225) Over 360 (225)
Standard Severe Interval
Severe Service Interval
Extreme Service Interval
Weight of grease to add z./(Grams)
Volume of grease to 3 add Inch /Teaspoon
5500 hrs.
2750 hrs.
550 hrs.
0.30 (8.4)
0.6 (2)
3600 hrs.
1800 hrs.
360 hrs.
0.61 (17.4)*
1.2 (3.9)**
2200 hrs.
1100 hrs.
220 hrs.
0.81 (23.1)*
1.5 (5.2)**
2200 hrs.
1100 hrs.
220 hrs.
2.12 (60.0)*
4.1 (13.4)**
*Optional bearing flange also. **The grease outlet plug MUST be removed before adding new grease.
1.
Clean all grease fittings. If the motor does not have grease fittings, the bearing is sealed and cannot be greased externally.
2.
If the motors are equipped with a grease outlet plug, remove it. This will allow the old grease to be displaced by the new grease.
3.
If the motors are stopped, add the recommended amount of grease. If the motor is to be greased while running, add a slightly greater quantity of grease.
4.
For motors equipped with a grease outlet plug, let the motor run for 20 minutes before replacing the plug.
Regular Checkups: At regular intervals depending on the conditions and time of operation, the following checks should be made: 1.
Pumps meet required performance and is operating smoothly and quietly.
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2.
There are no leaks, particularly at the shaft seal.
3.
The motors are not overheating.
4.
Remove and clean all strainers or filters in the system.
5.
Verify the tripping of the motor overload protections.
6.
Check operation of all controls & unit control cycling twice and adjust, if required.
7.
If the pumps are not operated for unusually long periods, the unit should be maintained accordingly. In addition, if the pumps are not drained, the pump shafts should be manually rotated or run for short periods of time at monthly intervals. If the pumps fail to operate or there is a loss of performance.
Motor Replacement: If the motor is damaged due to bearing / electrical failure or burning, follow the instructions for motor removal / replacement. It must be emphasized that motors used on CR pumps are specifically selected to our rigid specifications. Replacement of motors must be of the same frame, size & be equipped with the same or better bearings of the same service factor. Failure to follow these recommendations may result in premature motor failure. Disassembly 1. Turn off and lock out power supply. The power supply wiring can now be safely disconnected from the motor wires. 2. Remove the coupling guards.
3. Using the proper metric Allen wrench, loosen the four cap screws in the coupling. Completely remove coupling halves. On CR2-CR60s, the shaft pin can be left in the pump shaft, if exists. 4. With the correct size wrench, loosen and remove the four bolts which hold the motor to the pump end. 5. Lift the motor straight up until the shaft has cleared the motor stool.
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Assembly 1. Remove key from the motor shaft, if present and discard.
2. Thoroughly clean the surfaces of the motor and pump end mounting flanges. The motor and shaft must be cleaned of all oil / grease and other contaminants where the coupling attaches. Set the motor on the pump end. 3. Place the terminal box in the desired position by rotating the motor.
Figure
Trouble Shooting: Problem
Possible Cause 1. No power at
Check power at motor. If no voltage at motor, check
motor.
feeder panel for tripped circuits and reset it.
2. Fuses are blown or circuit breakers are tripped.
with ohmmeter. Replace blown fuses or reset circuit breaker. If new fuses blow or circuit breaker trips, the electrical installation, motor and wires must be checked. Check for voltage on line and load side of starter.
overloads are
Replace burned heaters or reset. Inspect starter for
burned or have
other damage. If heater trips again, check the supply
tripped out.
voltage and starter holding coil.
not energize. The pump run
Turn off power and remove fuses. Check for continuity
3. Motor starter
4. Starter does
does not
Possible Solution
5. Defective controls.
Energize control circuit and check for voltage at the holding coil. If no voltage, check control circuit fuses. If voltage, check holding coil for shorts. Replace bad coil. Check all safety, pressure switches for operation. Inspect contacts in control devices. Replace worn or defective parts or controls. Turn off power and disconnect wiring. Measure the
6. Motor is defective.
lead to lead resistances with ohmmeter. Measure lead to ground values with ohmmeter. Record measured values. If an open or grounded winding is found, remove motor and repair or replace.
7. Defective capacitor.
Turn off power and discharge capacitor. Check with ohmmeter. Check the meter needle when connected with capacitor, the needle should move towards 0
(Single-phase motors)
ohms and slowly drift back to infinity. Replace if defective. Turn off power and manually rotate pump shaft. If shaft
8. Pump is
does not rotate easily, check coupling setting as
bound.
necessary. If shaft rotation is still tight, remove pump and inspect. Repair if required.
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Problem
Possible Cause 1. Wrong
Possible Solution Check wiring for proper connections. Correct wiring.
rotation 2. Pump is not primed or is air bound.
Turn pump off, close isolation valve(s), remove priming plug. Check fluid level. Refill the pump, replace plug and start the pump. Long suction lines must be filled before starting the pump.
3. Strainers
Remove strainer, screen or valve and inspect. Clean
check or foot
and replace. Re-prime pump.
Valves clogging. Install compound pressure gauge at the suction side of 4. Suction lift too large. The pump
the pump. Start pump and compare reading to performance data. Reduce suction lift by lowering pump, increase suction line size or removing high friction loss devices.
runs but at reduced
5. Suction
Pump runs backwards when turned off. Air in suction
capacity or
and/or
pipe. Suction pipe, valves and fittings must be airtight.
does not
discharge
Repair any leaks and retighten all loose fittings.
deliver
piping leaks. Install pressure gauge, start pump, gradually close the
water 6. Pump worn.
discharge valve and read pressure at shutoff. Convert measured pressure (in PSI) to head (in feet). Remove pump and inspect, if required.
7. Pump
Disassemble and inspect pump passageways.
impeller or
Remove any foreign materials found.
guide vane is clogged. 8. Incorrect
If the proper drain plug is replaced with a standard
drain plug
plug, water will re-circulate internally. Replace with
Installed.
proper plug.
9. Improper
Check/reset the coupling.
coupling setting.
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Possible Cause
Problem
Possible Solution
1. Pressure
Check pressure setting on switch and operation.
switch is not
Check voltage across closed contacts. Readjust switch
properly
or replace if defective.
adjusted or is defective. 2. Level control
Check setting and operation. Readjust setting/replace
is not properly
if defective.
set
Pump cycles too
3. Insufficient
Pump air into tank or diaphragm chamber. Check
air charging or
diaphragm for leak. Check tank and piping for leaks
leaking tank or
with soap and water solution. Check air to water
piping
volume. Repair as necessary. Check tank size and air volume in tank. Tank volume
much 4. Tank is too small.
should be approximately 10 gallons for each gpm of pump capacity. The normal air volume is 2/3 of the total tank volume at the pump cut-in pressure. Replace tank with one of correct size. Install pressure gauges near pump suction and discharge. Start and run pump under normal
5. Pump is
conditions, record gauge readings. Ensure that total
oversized.
head is sufficient to limit pump delivery within its design flow range. Throttle pump discharge flow if necessary.
1. Low voltage.
Check voltage at starter panel / motor. If voltage varies more than ±10%, contact power company / wire sizing.
2. Motor
Cycle pump and measure amperage. Increase heater
Circuit
overloads are
size or adjust trip setting to a maximum of motor
breakers
set too low.
nameplate (full load) current.
or overload
3. Three-phase
Check current draw on each lead to the motor. Must
relays trip
current is
be within ±5%. If not, check motor and wiring. Rotating
imbalanced.
all leads may eliminate this problem.
4. Motor is
Turn off power and disconnect wiring. Measure the
shorted or
lead-to-lead resistance with an ohmmeter. Measure
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grounded.
lead-to-ground values with an ohmmeter or a megaohm meter record values. If an open or grounded winding is found, remove the motor, repair or replace.
Problem
Possible Cause
Possible Solution
5. Wiring or
Check proper wiring and loose terminals. Tighten
connections are
loose terminals. Replace damaged wire.
faulty. Turn off power and manually rotate pump shaft. If shaft 6. Pump is bound.
does not rotate easily, check coupling setting and adjust as necessary. If shaft rotation is still tight, remove pump and inspect. Disassemble and repair.
7. Defective
Turn off power and discharge capacitor. Check with
capacitor
ohmmeter. When the meter is connected to the
(single-phase
capacitor, the needle should jump towards 0 ohms and
motors).
slowly drift back to infinity. Replace if defective.
8. Motor overloads at higher ambient temperature than motor.
Use a thermometer to check the ambient temperature near the overloads and motor. Record these values. If ambient temperature at motor is lower than at overloads, especially where temperature at overloads is above 104°F (40°C), ambient-compensated heaters should replace standard heaters.
Service: Various steps involved in service (dismantling and Reassembly) are elaborated below on Grundfos CR4 pump type: Torques Shaft Lock Nut (Reassembly step 9) Stay bolt nut (Reassembly step 17) Motor Bolt UNC 3/8” bolts UNC ½” bolts Coupling Allen Screws M6 Screws M8 Screws
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9ft-lbs / 12Nm 30ft-lbs / 40Nm 10ft-lbs / 13Nm 23ft-lbs / 31Nm 10ft-lbs / 13Nm 23ft-lbs / 31Nm
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When should a part be replaced
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Order of Stage Assembly
Note: For separate parts, refer Pump Manufacturer (OEM)
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5.7
Plunger Pump, CAT-3537
3537 Frame Plunger Pump
3537 Frame Plunger Pump with Motor
Model Types:
Material Type
Model
Nickel Aluminum Bronze,Standard
3537,3537C
and Flushed
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FEATURES Superior Design > Triplex plunger design gives smoother liquid flow. > V-Packings are completely lubricated and cooled by the liquid being pumped. > Special flushed inlet manifold lubricates and cools seals for extended life with DI water and high temp liquids. >Lubricated Lo-Pressure Seals provide double protection against external leakage. >Oil bath crankcase assures optimum lubrication. >Close tolerance concentricity of the ceramic plunger maximizes seal life. Quality Materials > Precision design 304 and 316 stainless steel valves and seats are hardened and polished for ultimate seating and extended valve life. > Forged Brass, 316 Stainless Steel, Duplex Stainless or Nickel Aluminum Bronze manifolds for strength and corrosion resistance. > Special concentric, high-density, polished, solid ceramic plungers provide a true wear surface and extended seal life. > Specially formulated, CAT PUMP exclusive, V-Packings offer unmatched performance and seal life. > Die cast aluminum crankcase provides high strength, minimum weight and precision tolerance control. > Chrome-moly crankshaft gives unmatched strength and surface hardness. > Oversized crankshaft bearings with greater loading capacity means longer bearing life. Easy Maintenance > Wet-end is easily serviced without entering crankcase, requiring less time and effort. > Valve assemblies are accessible without disturbing piping, for quick service. > Inlet and discharge valve assemblies interchange for easier maintenance. >Preset packings, no packing gland adjustment is necessary, reducing maintenance costs. WARNING All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume
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any liability or responsibility for the operation of a customer’s high pressure system. SPECIFICATIONS U.S. Measure Metric Measure Flow..........................................................................36 GPM (136 L/M) Pressure Range...........................................100 to 1200 PSI (7 to 85 BAR) Inlet Pressure Range ................................Flooded to 70 PSI (Flooded to 4.9 BAR) RPM .......................................................................800 RPM (800 RPM) Bore ............................................................................1.575" (40 mm) Stroke..........................................................................1.890" (48 mm) Crankcase Capacity..................................................4.2 Qts. (4 L) Maximum Liquid Temperature ....................................160°F (71°C) Above 130°F call CAT PUMPS for inlet conditions and elastomer recommendations. Inlet Ports (2) .....................................................1-1/2" NPTF (1-1/2 NPTF) Flushing Ports (2) (3531C) ...................................1/4" NPTF 1/4" NPTF Discharge Ports (2)..................................................1" NPTF (1" NPTF) Pulley Mounting ...................................................Either Side (Either Side) Shaft Diameter ........................................................... 1.378" (35 mm) Weight.......................................................................139 lbs. (63 kg) Dimensions (3535, 3535C) .................24.09 x 18.11 x 9.72" (612 x 460 x 247 mm) Dimensions (3531-31C, 3537-37C) ....24.33 x 18.11 x 9.72" (618 x 460 x 247 mm) ELECTRIC HORSEPOWER REQUIREMENTS FLOW U.S. GPM 36 30 25
L/M 136 114 95
BAR 55 1 9 .8 1 6 .5 1 3 .7
PRESSURE BAR 70 2 4 .7 2 0 .6 1 7 .2
BAR 85 2 9 .7 2 4 .7 2 0 .6
DRIVE
RPM 800 667 556
Consult CAT PUMPS for Pump and Motor Pulley Sizes
PARTS LIST ITEM 2 5 8 9 10 11 15 20 21 22 23 25 31 32 33 34 37 38 40 48 49 50
PART NO 34021 125753 44542 815279 12398 13296 29326 121467 126749 126574 122045 29325 828710 43211 14177 126743 92241 44428 125753 25625 23170 45936
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MAT’L STL S AL FBR NBR NBR STL TNM STCP R STZP R STZP FCM ABS NBR STCP R NBR S STCP NBR AL
DESCRIPTION Key (M10x8x70) Screw, HHC Sems (M8x25) Cover, Bearing Shim, Split 2-Pc O-Ring, Bearing Cover - 70D Seal, Oil, Crankshaft Bearing, Roller Rod, Connecting Assy (Inclds: 21,22,23) [10/00] Locking Washer (M10) Washer, Flat (M10) Replace as a set Screw, HH (M10x55) Crankshaft, Dual End Protector, Oil Cap w/Foam Gasket Cap, Oil Filler O-Ring, Oil Filler Cap - 70D Bolt, Eye (M12x1.75) (For Lifting Pump Only) Gauge, Oil, Bubble w/Gasket Gasket, Flat, Oil Gauge - 80D Screw, HHC Sems (M8x25) Plug, Drain (1/4"x19BSP O-Ring, Drain Plug – 70D Cover, Rear
QTY 1 8 2 4 2 2 2 3 3 6 6 1 1 1 1 1 1 1 8 1 1 1
51 53 54 56 59 64 ITEM 65 69 70 75 88 90 95 96 97 98 99 100 101 106 107 110 112 117 126 127 128 141 142 155 156 157 158 159 162 163 164 166 167 168
16612 44487 27488 27790 92538 43864 PART NO †45116 126587 100488 44739 43865 45676 43921 †89778 20189 11345 11375 ♦ 701490 44085 44084 814279 44112 44113 44740 ♦ 46955 43925 46392 46392C 11379 14183 ♦ 701491 44585 43926 44609 44741 43928 45113 46352 48860 20137 ♦ 701492 48362 †45369 48362 48860 20137 ♦ 701492 48363 26142 14330 ♦ 701493 44727 43932 44109 44728
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NBR AL S POP S CM MAT’L SSZZ STCP R NBRS FPM S S CC SS PTFE NBR FPM EPDM SS SS PVDF NBR FPM EPDM BB BBCP BBCP NBR FMM EPDM S BB STG* SFG BB SS BB NBR FPM EPDM D SS D NBR FPM EPDM D NBR FPM EPDM S S SS PVDF
O-Ring, Crankcase Cover - 70D Crankcase Assy (Inclds: 34, 54) Pins, Guide Pan, Oil Screw, HHC Sems (M6x16) Pin, Crosshead DESCRIPTION Rod, Plunger Washer, Oil Seal Seal, Oil, Crankcase Slinger, Barrier Washer, Keyhole (M16) Plunger (M40x145) Stud, Plunger Retainer (M10x135) Back-up-Ring, Plunger Retainer O-Ring, Plunger Retainer - 70D O-Ring, Plunger Retainer O-Ring, Plunger Retainer Gasket, Retainer Retainer, Plunger (M10 Retainer, Seal, 2 Pc. Wick, Long Tab Seal, LPS w/SS-Spg Seal, LPS w/SS-Spg Seal, LPS w/SS-Spg Spacer, Lo-Pressure Seal Manifold, Inlet Manifold, Inlet, Flushed (1/4" Flush Ports) O-Ring, Inlet Manifold - 70D O-Ring, Inlet Manifold O-Ring, Inlet Manifold - 70D Screw, HSH (M14x40) Adapter, Female V-Packing V-Packing Adapter, Male Springs, Coil Spacer, w/Coil Springs O-Ring, V-Packing-Spacer - 90D O-Ring, V-Packing-Spacer - 70D O-Ring, V-Packing-Spacer Back-up-Ring, Spacer Spacer, V-Packing Back-up-Ring, V-Packing-Spacer O-Ring, V-Packing-Spacer - 90D O-Ring, V-Packing-Spacer - 70D O-Ring, V-Packing-Spacer Back-up-Ring, Valve Seat O-Ring, Seat - 80D O-Ring, Seat O-Ring, Seat Seat, Stepped Valve Spring Retainer, Spring
1 1 2 1 2 3 QTY 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 1 3 3 3 4 3 6 6 3 6/18 3 3 3 3 3 3 3 3 3 3 6 6 6 6 6 6 6 6
170 171
173 174 185 188
44729 44644 89827 11747 ♦ 701494 48364 46444 76394 89981
ITEM
PART NO
172
SS SS NBR FPM EPDM D FBB BBCP S
Washer, Spring Retainer Coil Spring (70kg), Valve Plug O-Ring, Valve Plug - 90D O-Ring, Valve Plug - 90D O-Ring, Valve Plug – 70D Back-up-Ring, Valve Plug Plug, Valve Manifold, Discharge Screw, HSH (M12x70)
MAT’L
DESCRIPTION Protector, Shaft w/2 Screws, Lock-washers 250 44516 NY and Washers 34018 STZP R Kit, Direct Mount 255 34039 SS Kit, Direct Mount 92674 STZP Mounting, Box Assy (Inclds: 34018) 260 990013 STL Hub, ‘B’ 35mm w/Keyway 275 80540 ZP Screw, HH (M12x100) (Rail Adjusting Screw) 278 30278 STZP Oiler (1 oz.) 279 30967 Glass, Oiler 281 10069 NBR Gasket, Oiler 282 34314 Kit, Oil Drain 283 6124 Gasket, Liquid (3 oz.) 290 814821 BBCP Complete Head 299 31040 NBR* Kit, Seal (Inclds: 33055 FPM 97,106,112,127,155,156,158,159) ♦ 33262 EPDM Kit, Seal (Inclds: 300 97,106,112,127,155,156,158,159) Kit, Seal (Inclds: 97,106,112,127,155,156,158,159) 34235 NBR Kit, Valve (Inclds: 31955 FPM 162,163,164,166,167,168,170,172,173) ♦ 31952 EPDM Kit, Valve (Inclds: 310 162,163,164,166,167,168,170,172,173) Kit, Valve (Inclds: 162,163,164,166,167,168,170,172,173) 819000 F Assy, Crankcase, Cast Iron Conversion 714500 SS C.A.T. (Inlet pressure stabilizer for RO and boosted inlet applications) 714506 SS Adapter (2 per C.A.T.) 6100 Oil, Case (12 Bottles) ISO 68 Multi-viscosity Hydraulic † Production parts are different than repair parts. * Review material codes
Note: For separate parts, refer pump manufacturer
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6 6 6 6 6 6 6 1 8
QTY 1 1 1 1 1 1 1 3 3 3 1 1 1 1 1
2 2 2
1 1 2 1
EXPLODED VIEW – CAT 3535, 3537
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Models 3535, 3535C, 3531, 3531C, 3537, 3537C
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Die cast aluminum crankcase means high strength, light weight, and excellent tolerance control. Oversized crankshaft bearings provide extended bearing life and pump performance. Chrome-moly crankshaft provides unmatched strength and surface hardness for long life. Matched oversized TNM connecting rods noted for superior tensile strength and bearing quality. Special stainless steel plunger rods with high strength crossheads for longevity and corrosion resistance. The stainless steel slinger provides back-up protection for the crankcase seal, keeping pumped liquids out of the crankcase. Special concentric, high-density, polished, solid ceramic plungers provide a true wear surface and extended seal life. Manifolds are a high tensile strength forged brass, 316 stainless steel, duplex stainless or nickel aluminum bronze for long term, continuous duty. 100% wet seal design adds to service life by allowing pumped liquids to cool and lubricate on both sides. Stainless steel valves, seats and springs provide corrosion-resistance, ultimate seating and extended life. Special prepared, CAT PUMP exclusive, V-Packings offer unmatched performance and seal life.
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12. 13.
Crossheads are 360° supported providing uncompromising alignment. Optional special ported Flushed Inlet Manifold permits external flush for lubricating and cooling seals when pumping liquids such as DI water, Hi-Temp or low lubricity.
INSTALLATION AND START-UP INFORMATION Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only with the proper selection, installation of plumbing and operation of the pump and accessories. SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not implied that all maximums can be performed simultaneously. If more than one maximum is considered, check CAT PUMPS supplier for proper performance and pump selection. Refer to individual pump Data Sheets for complete specifications, parts list and exploded view. LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications (4.2 Qts. - 4.0 L). Do not Run Pump without Oil in Crankcase. Change initial fill after 50 hours running period. Thereafter, change oil every 3 months or 500 hour intervals. Oiler adjustment is vertical to start feed, horizontal to stop feed, dial to adjust flow rate. Additional lubrication may be required with increased hours of operation and temperature. PUMP ROTATION: Pump was designed for forward rotation to allow optimum lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil level is increased slightly above center dot to assure adequate lubrication. PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow. DRIVE SELECTION: The motor or engine driving the pump must be of adequate horsepower to maintain full RPM when the pump is under load. Select the electric motor according to required pump discharge flow, maximum pressure at the pump and drive losses of approximately 3-5%. MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit drainage of crankcase oil. An uneven mounting surface will cause extensive damage to the pump base. To minimize piping stress, use appropriate flexible hose to inlet and discharge ports. Use the correct belt; make sure pulleys are aligned. Excessive belt tension may be harmful to the bearings. Hand rotate pump before starting to be certain shaft and bearings are free moving. LOCATION: If the pump is used in extremely dirty or humid conditions, it is recommended pump be enclosed. Do not store or operate in excessively high temperature areas or without proper ventilation. INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual before starting system. Do not starve the pump or run dry. Temperatures above 130°F
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are permissible. Add 1/2 PSI inlet pressure per each degree °F over 130°F. RPM changes may be required. C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in applications with stressful inlet conditions such as high temperatures, booster pump feed, long inlet lines/valves. DISCHARGE CONDITIONS: Open all valves before starting system to avoid deadhead overpressure condition and severe damage to the pump or system. Install a Pulsation Dampening device on the discharge head or in the discharge line as close to the head as possible. Be certain the pulsation dampener is properly pre-charged for the system pressure. A reliable Pressure Gauge should be installed near the discharge outlet of the high pressure manifold. This is extremely important for adjusting pressure regulating devices and also for proper sizing of the nozzle or restricting orifice. The pump is rated for a maximum pressure; the pressure which would be ‘read at the discharge manifold of the pump’, not at the gun/ nozzle. Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape from becoming lodged in the pump or accessories. This condition will cause a malfunction of the pump or system. PRESSURE REGULATION: All systems require both a primary pressure regulating device (i.e., regulator, un-loader) and a secondary pressure safety relief device (i.e., popoff valve, safety valve). The primary pressure device must be installed on the discharge side of the pump. The function of the primary pressure regulating device is to protect the pump from over pressurization, which can be caused by a plugged or closed off discharge line. Over pressurization can severely damage the pump, other system components and can cause bodily harm. The secondary safety relief device must be installed in-line between the primary device and pump or on the opposite side of the manifold head. This will ensure pressure relief of the system if the primary regulating device fails. Failure to install such a safely device will void the warranty on the pump. If a large portion of the pumped liquid is by-passed (not used) when the high pressure system is running, this by-pass liquid should be routed to an adequately sized, baffled supply tank or to drain. If routed to the pump inlet, the by-pass liquid can quickly develop excessive heat and result in damage to the pump. A temperature control device to shut the system down within the pump limits or multiple THERMO VALVES must be installed in the by-pass line to protect the pump. NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure regulating device to compensate. Replace nozzle and reset regulating device to system pressure.
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PUMPED LIQUIDS: Some liquids may require a flush between operations or before storing. STORING: For extended storing or between use in cold climates, drain all pumped liquids from pump and flush with antifreeze solution to prevent freezing and damage to the pump. Do not run pump with frozen liquid. WARNING: All systems require both a primary pressure regulating device (i.e., regulator, un-loader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve). Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility for the operation of a customer’s high pressure system.
Removal of Discharge Valve Plug
Discharge Valve Assembly
CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel engine) and turn off water supply to pump. Relieve all discharge line pressure by triggering gun or opening valve in discharge line. After servicing is completed, turn on water supply to pump, start drive, reset pressure regulating device and secondary valve, read system pressure on the gauge at the pump head. Check for any leaks, vibration or pressure fluctuations and resume operation. SERVICING THE VALVES Disassembly 1.
Remove the six (6) M41 Hex Valve Plugs.
2.
Remove the exposed Coil Spring from the top of the Spring Retainer. Thread an M10 bolt into the top of the Spring Retainer. The assembly will usually remain together. To separate, continue threading the bolt into the back side of the Valve Seat until it separates from the Spring Retainer. In all models if the assembly separates during removal, use a valve seat removal tool and lift the Seats from the chamber.
Reassembly NOTE: For certain applications apply liquid gasket to the o-ring crevices and seal surfaces. 1.
Examine the O-Rings and Back-up-Rings on the Seat and replace if cut or worn. Lubricate the O-Ring before installing.
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2.
Examine the surface of the Valve and Seat for pitting, grooves or wear and replace if necessary.
3.
Assemble Valve Retainer, Spring, Valve and Seat by snapping together securely. Thread the M10 bolt into spring retainer for installation.
4.
Lubricate outer O-Ring and Back-up-Ring surface and walls of valve chamber and press Valve Assembly squarely into chamber. Remove M10 bolt. Place the washer over the top of the Spring Retainer and then the Coil Spring on top of the Washer.
5.
Examine the O-Ring and Back-up-Ring on the Valve Plug and replace if cut or worn. Lubricate new O-Ring and Back-up-Ring before installing onto Valve Plug. Exercise caution to avoid damage from the valve plug threads.
NOTE: 6.
The Back-up-Ring is installed first, then the O-Ring. Slowly thread the Valve Plug into chamber. Exercise caution to avoid extruding or cutting the Back-up-Ring or O-Ring. Then torque to specifications.
NOTE:
It is highly recommended that anti-seize lubricant (PN6119) be applied to the threads of all stainless steel components to prevent galling.
NOTE:
Apply Loctite 242 to the threads of the Valve Plug (brass models) before threading into the valve chamber. All models except 3560. Removal of Discharge Valve Plug
Removal of Discharge Manifold Screws
Removal of Discharge Manifold
Removal of Inlet Screws and Inlet manifold
Removal of Inlet Manifold O-Rings
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Removal of V-Packing Spacer from Inlet Manifold
7.
Lubricate and install new O-Ring onto each Inlet Seat.
8.
Place Inlet Seat on work surface with small diameter side up.
9.
Place the Valve onto Inlet Seat with concave side down.
10.
Place Spring on Valve.
11.
Install Inlet Spring Retainer with deep stepped end over Spring and snap onto Inlet seat.
12.
Lubricate and install O-Ring, then Back-up-Ring onto the Discharge Seats.
13.
Place Discharge Seat on a work surface with small diameter down.
14.
Place Valve onto Discharge Seat with the concave side down.
15.
Place Spring on Valve.
16.
Install Discharge Spring Retainer with deep stepped end over Spring and snap onto Discharge Seat.
17.
Complete the stacked assembly by pressing the Discharge Valve Assembly into the Inlet Valve Assembly.
18.
Place the complete stacked valve assly into each Valve Chamber until completely seated.
19.
Lubricate and install Back-up-Ring, then O-Ring onto each Valve Plug. Press Valve Plug into each Valve Chamber. Exercise caution to avoid damage from the valve plug threads.
20.
Apply anti-seize lubricant (PN6119) to HSH screw threads and thread in hand tight. Torque to specifications.
REMOVING THE DISCHARGE MANIFOLD 1.
Remove the eight (8) HSH screws.
2.
Tap the back side of the Discharge Manifold with a soft mallet and gradually work head from pump.
3.
Remove the O-Rings from lower chambers of the face of the Inlet Manifold.
REMOVING THE INLET MANIFOLD 1.
Using a hex allen wrench, remove the four (4) HSH screws. Rotate the Crankshaft to begin the separation of the Inlet Manifold from the Crankcase.
2.
Tap the rear of the Inlet Manifold with a soft mallet and gradually work from pump.
Sea Water Reverse Osmosis Plant
NOTE:
Support from the underside and exercise caution to keep manifold aligned with Plungers to avoid damage to the Plungers as the manifold is removed.
NOTE:
Two screwdrivers on opposite sides of the manifold may be used to assist separation.
v-Packing and Spacer Arrangement
V-Packing Spacer and Spacer with Coil Springs
Removal of Lo-Pressure Seal from Inlet Manifold
Lo-Pressure Seal and Washer Assembly
SERVICING THE SEALS Disassembly of the V-Packings 1.
Place the crankcase side of the Inlet Manifold down on the work surface.
2.
Remove the V-Packing Spacer. These may stay in either the Inlet or Discharge Manifold ports when the Discharge Manifold is removed. If they are extremely dirty or dry, remove the exposed O-Ring and Back-up-Ring and insert two screwdrivers on opposite sides to pry out of chamber.
3.
Examine both front and rear O-Rings and Back-up-Rings on the V-Packing Spacer for cuts or wear and replace as needed.
4.
Remove V-Packing Cylinder (3520, 3521, 3527), by inserting two screwdrivers on opposite sides of the V-Packing Cylinder and pry out. Examine O-Ring for wear and replace as needed.
5.
Remove Spacer with Coil Springs (except 3560). Examine for broken or fatigued springs or scale build up or pitting and replace as needed.
6.
With a reverse pliers remove Male Adapter, V-Packings and Female Adapter.
7.
Examine Female Adapter for worn I.D. and replace as needed.
Reassembly of the V-Packings 1.
Lubricate outer surface of V-Packing Cylinder and install new O-Ring in groove. Press V-Packing cylinder with O-Ring end down into the manifold chamber until completely seated.
Sea Water Reverse Osmosis Plant
2.
Insert Female Adapter into V-Packing Cylinder/manifold chamber with the Vgroove up.
3.
Fit the new V-Packings together, lubricate outer surface of the packing and insert into V-Packing Cylinder or manifold chamber with the V groove up.
4.
Install Male Adapter into V-Packing Cylinder or manifold chamber with the V groove down (notches up).
5.
Lubricate outer surface of Spacer with Coil Springs and insert into V-Packing Cylinder or manifold chamber with springs facing down.
6.
Lubricate outer surface of V-Packing Spacer, install new O-Rings and Back-upRings in both front and rear groove and press into V-Packing Cylinder or manifold chamber with small diameter down until completely seated.
Disassembly of the Lo-Pressure Seal 1.
With the crankcase side of Inlet manifold up insert the LPS Spacer into the seal chamber.
2.
Install Lo-Pressure Seal into seal chamber with garter spring facing down and press squarely into position.
3.
V-Packing Spacer and Spacer with Coil Springs, Removal of Lo-Pressure Seal from Inlet Manifold, Lo-Pressure Seal and Washer Assembly
Plunger Arrangement
SERVICING THE PLUNGERS Disassembly 1.
To service the plungers it is necessary to remove the Discharge and Inlet Manifolds. Follow the disassembly procedure found under removing the discharge manifold and removing the inlet manifold.
2.
Remove the Seal Retainers from the Ceramic Plungers.
3.
Remove the Inner Collar from the front of the seal retainer.
4.
Remove the used Wick and install new Wick.
5.
Replace Inner Collar on Seal Retainer.
6.
Loosen Plunger Retainer 4 to 5 turns. Push Plunger towards Crankcase until Plunger Retainer pops out.
Sea Water Reverse Osmosis Plant
7.
Unscrew and remove Plunger Retainer, Gasket, O-Ring, Back-up- Ring and Ceramic Plunger, Keyhole Washer and Barrier Slinger from each Plunger Rod.
Reassembly 1.
With these plunger items removed, examine the Crankcase Oil Seal for wear or deterioration and replace as needed.
2.
Replace Keyhole Washer on Plunger Rod.
3.
Carefully examine each Plunger for scoring or cracks and replace if worn.
4.
Examine Gasket, O-Ring and Back-up-Ring on Plunger Retainer and replace if cut or worn. Lubricate O-Ring for ease of installation and to avoid damaging O-Rings.
5.
Apply loctite 242 to the threads of the Plunger Retainer and thread Plunger Retainer onto Plunger Rod. Torque per specifications.
6.
Slip Seal Retainers over Plungers.
7.
Rotate crankshaft by hand so the two outside Plungers are extended equally.
8.
Lubricate the Plungers.
9.
Carefully replace Inlet Manifold onto Plungers and press into Crankcase. Keep manifold aligned to avoid damaging Plungers.
10.
Replace four (4) HSH screws and torque per chart.
11.
Examine inlet port o-rings at bottom of manifold and replace if cut or worn.
12.
Lubricate outer surface of V-Packing Spacer, O-Rings and valve chamber walls and carefully slip Discharge Manifold over V-Packing Spacer.
13.
Hand tighten the two (2) HSH screws first. Then hand tighten the remaining six (6) HSH screws. Torque per chart and in this sequence. 1
3
5 8
7 6 4
2
SERVICING THE CRANKCASE SECTION 1.
While manifolds, plungers and seal retainers are removed examine crankcase oil seals for leaking and wear.
2.
Check for signs of leaking at Bearing Covers, Rear Cover, Drain Plug, and Bubble Oil Gauge.
3.
Check oil level and for evidence of water in oil. Change crankcase oil on a regular schedule.
4.
Rotate Crankshaft by hand to feel for smooth bearing movement.
5.
Examine Crankshaft Oil Seals externally for drying, cracking or leaking.
INLET CONDITION CHECK-LIST
Sea Water Reverse Osmosis Plant
Review Before Start-Up Inadequate inlet conditions can cause serious malfunctions in the best designed pump. Surprisingly, the simplest of things can cause the most severe problems or go unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST BEFORE OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so there can be no ONE best way to set-up a system. All factors must be carefully considered. INLET SUPPLY should exceed the maximum flow being delivered by the pump to assure proper performance. ❏ Open inlet shut-off valve and turn on water supply to avoid starving pump.
DO NOT RUN PUMP DRY. ❏
Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each degree F over 130°F. Elastomer or RPM changes may be required.
❏
Avoid closed loop systems especially with high temperature, ultra-high pressure or large volumes. Conditions vary with regulating/unloader valve.
❏
Low vapor pressure liquids, such as solvents, require a booster pump and C.A.T. to maintain adequate inlet supply.
❏
Higher viscosity liquids require a positive head and a C.A.T. to assure adequate inlet supply.
❏
Higher temperature liquids tend to vaporize and require positive heads and C.A.T. to assure adequate inlet supply.
❏
When using an inlet supply reservoir, size it to provide adequate liquid to accommodate the maximum output of the pump, generally a minimum of 6 to 10 times the GPM (however, a combination of system factors can change this requirement); provide adequate baffling in the tank to eliminate air bubbles and turbulence; install diffusers on all return lines to the tank. INLET LINE SIZE should be adequate to avoid starving the pump.
❏
Line size must be a minimum of one size larger than the pump inlet fitting. Avoid tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of flow restriction and cavitations.
❏
The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION systems to avoid collapsing.
❏
The simpler the inlet plumbing the less the potential for problems. Keep the length to a minimum, the number of elbows and joints to a minimum (ideally no elbows) and the inlet accessories to a minimum.
❏
Use pipe sealant to assure air-tight, positive sealing pipe joints. INLET PRESSURE should fall within the specifications of the pump.
Sea Water Reverse Osmosis Plant
❏
Acceleration loss of liquids may be increased by high RPM, high temperatures, low vapor pressures or high viscosity and may require pressurized inlet and C.A.T. to maintain adequate inlet supply. DO NOT USE C.A.T WITH SUCTION INLET.
❏
Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure and a C.A.T. for certain applications. With adequate inlet plumbing, most pumps will perform with flooded suction. Maximum inlet pressure is 70 PSI (4.9 BAR).
❏
After prolonged storage, pump should be rotated by hand and purged of air to facilitate priming. Disconnect the discharge port and allow liquid to pass through pump and measure flow. INLET ACCESSORIES are designed to protect against over-pressurization, control inlet flow, contamination or temperature and provide ease of servicing.
❏
A shut-off valve is recommended to facilitate maintenance.
❏
Installation of a C.A.T. is essential in applications with stressful conditions such as high emperatures, booster pump feed or long inlet lines. Do not use C.A.T. with negative inlet pressure.
❏
A stand pipe can be used in some applications to help maintain a positive head at the pump inlet line.
❏
Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
❏
A pressure transducer is necessary to accurately read inlet pressure.
❏
All accessories should be sized to avoid restricting the inlet flow.
❏
All accessories should be compatible with the solution being pumped to prevent premature failure.
❏
Optional inlet protection can be achieved by installing a pressure cut off switch between the inlet filter and the pump to shut off pump when there is no positive inlet pressure. BY-PASS TO INLET Care should be exercised when deciding the method of bypass from control valves.
❏
It is recommended the by-pass be directed to a baffled reservoir tank, with at least one baffle between the by-pass line and the inlet line to the pump.
❏
Although not recommended, by-pass liquid may be returned to the inlet line of the pump if the system is properly designed to protect your pump. When a pulsation dampener is used, a PRESSURE REDUCING VALVE must be installed on the inlet line (BETWEEN THE BY-PASS CONNECTION AND THE INLET TO THE PUMP) to avoid excessive pressure to the inlet of the pump. It is also recommended that a THERMO VALVE be used in the by-pass line to monitor the temperature build-up in the by-pass loop to avoid premature seal failure.
Sea Water Reverse Osmosis Plant
❏
A reinforced, flexible, low pressure hose rated up to 300 PSI should be used for routing by-pass back to the pump inlet.
❏
Caution should be exercised not to undersize the by-pass hose diameter and length. Refer to Technical Bulletin 064 for additional information on the size and length of the by-pass line
❏
Check the pressure in the by-pass line to avoid over-pressurizing the inlet.
❏
The by-pass line should be connected to the pump inlet line at a gentle angle of 45° or less and no closer than 10 times the pump inlet port diameter e.g. 1-1/2" port size = 15" distance from pump inlet port.
Avoid Cavitations Damage
One or several of the conditions shown in the chart below may contribute to cavitations in a system resulting in premature wear, system downtime and unnecessary operating costs. CONDITION
SOLUTION
Inadequate inlet size
• Increase line size to the inlet port or one size line size larger
Water hammering, liquid acceleration / deceleration
• Install C.A.T. Tube
Rigid Inlet Plumbing
• Use flexible wire reinforced hose to absorb pulsation and pressure spikes
Excessive Elbows in inlet Plumbing
• Keep elbows to a minimum and less than 90°
• Move pump closer to liquid supply
CONDITION Excessive Liquid Temperature
SOLUTION • Use Thermo Valve in bypass line • Do not exceed pump temperature specifications • Substitute closed loop with baffled holding tank • Adequately size tank for frequent or high volume bypass • Pressure feed high temperature liquids • Properly ventilate cabinets and rooms
Air Leaks in Plumbing
• Check all connections • Use PTFE thread tape or pipe thread sealant
Sea Water Reverse Osmosis Plant
Agitation in Supply Tank
• Size tank according to pump output- tank min. 6-10 times system GPM • Baffle tank to purge air from liquid and separate inlet from discharge
High Viscosity Liquids
• Verify viscosity against pump specifications before operation • Elevate liquid temperature enough to reduce viscosity • Lower RPM of pump • Pressure feed pump • Increase inlet line size
Clogged Filters
• Perform regular maintenance or use clean filters and monitor build up • Use adequate mesh size for liquid and pump specifications
DIAGNOSIS AND MAINTENANCE One of the most important steps in a high pressure system is to establish a regular maintenance program. This will vary slightly with each system and the system accessories. A careful review of the necessary inlet conditions and protection devices required before the system is installed will eliminate many potential problems. CAT PUMPS are very easy to service and require less frequent service. The following guide will assist in determining the cause and remedy to various operating conditions. PROBLEM
Low pressure
PROBLEM Pulsation Water leak •Under the manifold •Into
PROBABLE CAUSE •Worn nozzle. •Belt slippage •Air leak in inlet plumbing •Pressure gauge inoperative or not registering accurately. •Relief valve stuck, partially plugged or improperly adjusted. •Inlet suction strainer (filter) clogged or improperly sized. •Abrasives in pumped liquid. •Leaky discharge hose. •Inadequate liquid supply. •Severe cavitation. •Worn seals. •Worn or dirty inlet/discharge valves. PROBABLE CAUSE •Faulty Pulsation Dampener •Foreign material trapped in inlet/discharge valves. •Worn V-Packings or Lo-Pressure Seals. •Worn adapter o-rings. •Humid air condensing into water
Sea Water Reverse Osmosis Plant
SOLUTION •Replace with properly sized nozzle. •Tighten belt(s) or install new belt(s). •Tighten fittings and hoses using PTFE liquid or tape. •Check with new gauge. Replace worn or damaged gauge. •Clean/adjust relief valve. Replace worn seats/valves and o-rings. •Clean filter. Use adequate size filter. Check more frequently. •Install proper filter. •Replace discharge hose with proper rating for system. •Pressurize inlet and install C.A.T. •Check inlet conditions. •Install new seal kit. Increase frequency of service. •Clean inlet/discharge valves or install new valve kit. SOLUTION •Check pre-charge. If low, recharge, or install a new dampener. •Clean inlet/discharge valves or install new valve kit. •Install new seal kit. Increase frequency of service. •Install new o-rings. •Install oil cap protector. Change oil every 3 months
crankcase
Knocking noise •Inlet supply •Bearing •Pulley Oil leak •Crankcase oil seals. •Crankshaft oil seals and o-rings. •Drain plug •Bubble gauge •Rear cover •Filler cap Pump runs extremely rough •Inlet conditions •Pump valves •Pump seals
Premature seal failure
inside the crankcase. •Excessive wear to seals and VPacking. •Inadequate inlet liquid supply. •Broken or worn bearing. •Loose pulley on crankshaft
or 500 hours. •Install new seal kit. Increase frequency of service. •Check liquid supply. Increase line size, pressurize or install C.A.T. •Replace bearing. •Check key and tighten set screw.
•Worn crankcase oil seals. •Worn crankshaft oil seals or o-rings on bearing cover. •Loose drain plug or worn drain plug o-ring. •Loose bubble gauge or worn bubble gauge gasket. •Loose rear cover or worn rear cover o-ring. •Loose filler cap or excessive oil in crankcase.
•Replace crankcase oil seals. •Remove bearing cover and replace o-rings and/or oil seals. •Tighten drain plug or replace o-ring.
•Restricted inlet or air entering the inlet plumbing •Stuck inlet/discharge valves. •Leaking V-Packings or Lo-Pressure seals.
•Correct inlet size plumbing. Check for air tight seal.
•Scored plungers. •Over pressure to inlet manifold. •Abrasive material in the liquid being pumped. •Excessive pressure and/or temperature of pumped liquid. •Running pump dry. •Starving pump of adequate liquid.
•Replace plungers. •Reduce inlet pressure per specifications. •Install proper filtration at pump inlet and clean regularly. •Check pressure and inlet liquid temperature. •DO NOT RUN PUMP WITHOUT LIQUID. •Increase hose one size larger than inlet port size. Pressurize and install C.A.T. •Replace manifold. Check liquid compatibility.
•Eroded manifold.
•Tighten bubble gauge or replace gasket. •Tighten rear cover or replace o-ring. •Tighten filler cap. Fill crankcase to specified capacity.
•Clean out foreign material or install new valve kit. •Install new seal kit. Increase frequency of service.
Custom Maintenance Schedule The table above shows the recommended preventative maintenance schedule, however it is only to be used as a guide. The life of your pump and wear parts will vary by application depending on duty-cycle, pumped liquid, temperature, inlet conditions, location of installation and system accessories. It is important to monitor your system carefully and at the first sign of low pressure, examine your pumping system. Low pressure may be caused by system components other than the pump such as:
• • • • • •
Clogged filter Leaks from fittings or connections Cracked or kinked hoses Worn o-rings in safety regulators, check valves or relief valves Loose or worn belts Worn nozzles
Sea Water Reverse Osmosis Plant
If no problems are found with other system components, shut down system and inspect pump. Check for debris in valves. Change seals and record hours for your preventative maintenance schedule. Typically valves should be replaced at every other seal replacement. After maintenance is performed continue to monitor all system components. Often it is other elements in the system that will be the cause of poor performance. In order to protect the pump, always inspect the entire system when there is a decrease in system performance. Preventative Maintenance The best safeguards against unplanned shut-down or system failure are good preventative maintenance practices and proper pump diagnosis. Cat Pumps triplex pump design offers easy on-site maintenance without the use of special tools, making a routine maintenance achievable without difficulty. Each pump has a Data Sheet, Service Manual and Diagnosis Chart to simplify the periodic servicing required. Every installation differs from one another, so a unique maintenance schedule may be required. Below you will find more information about adopting a proper maintenance schedule as well as how to diagnose any pump issues. Preventive Maintenance Check List Check
Daily
Clean Filters
x
Oil Level/Quality
x
Oil Leaks
x
Water Leaks
x
Weekly
Belts, Pulley
x
Plumbing
x
Initial Oil Change Oil Change
50 hrs
500 hrs
1500 hrs
x X
Seal Change
x
Valve Change Accessories •
3000 hrs
x x
If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change cycle should be every 300 hours. ** Each system’s maintenance cycle will be exclusive. If system performance decreases, check immediately. If no wear at 1500 hours, check again at 2000 hours and each 500 hours until wear is observed. Valves typically require changing every other seal change. Duty cycle, temperature, quality of pumped liquid and inlet feed conditions all effect the life of pump wear parts and service cycle. ** Remember to service the regulator/un-loader at each seal servicing and check all system accessories and connections before resuming operation.
Sea Water Reverse Osmosis Plant
5.9
Cartridge Filters
The cartridge filter elements must be replaced, when the pressure loss across the cartridge filter has reached 2 bars. The filter elements cannot be cleaned. A check should be carried out daily and after any circuit cleaning the filter elements should be replaced. (1) Filter Housing (2) Filter Element (10 µm) (3) O-ring Replacing the Filter Elements: Step No 1 2 3 4 5 6
Action Stop with rinse Close feed water inlet valve and discharge valve. Unscrew the filter housing Clamp by loosen bolts of clamp and remove top cover. Open nuts from long bolts inside to remove blocking sheet, carefully remove sheet and Teflon product blockers and replace filter elements. Reassemble the filter housing, check O-ring and ensure it fits correctly. Open feed water inlet valve and discharge valve.
The unit is now ready for restarting.
Sea Water Reverse Osmosis Plant
5.10
RO Membranes (TORAY Membranes)
Important Information Proper start-up of reverse osmosis water treatment systems is essential to prepare the membranes for operating service and to prevent membrane damage due to
Sea Water Reverse Osmosis Plant
overfeeding or hydraulic shock. Following the proper start-up sequence also helps to ensure that system operating parameters conform to design specifications so that system water quality and productivity goals can be achieved. Before initiating system start-up procedures, membrane pretreatment, loading of the membrane elements, instrument calibration and other system checks should be completed. Operation Guidelines Avoid any abrupt pressure or cross-flow variations on the spiral elements during start-up, shutdown, cleaning or other sequences to prevent possible membrane damage. During start-up, a gradual change from a standstill to operating state is recommended as follows: •
Feed pressure should be increased gradually over a 30-60 second time frame.
•
Cross-flow velocity at set operating point should be achieved gradually over 15-20 seconds.
•
Permeate obtained from first hour of operation should be discarded.
General Information •
Keep elements moist at all times after initial wetting.
•
If operating limits and guidelines not followed properly, the limited Warranty will be null and void.
•
To prevent biological growth during prolonged system shutdowns, it is recommended that membrane elements be immersed in a preservative solution.
•
The customer is fully responsible for the effects of incompatible chemicals and lubricants on elements.
•
Max. Pressure drop across an entire pressure vessel (housing) is 50 psi (3.4 bar).
•
Avoid permeate-side backpressure at all times.
Notice: The use of this product in and of itself does not necessarily guarantee the removal of cysts and pathogens from water. Effective cyst and pathogen reduction is dependent on the complete system design and on the operation and maintenance of the system.
Sea Water Reverse Osmosis Plant
5.10.1
2nd STAGE RO Membrane
Important Information Proper start-up of reverse osmosis water treatment systems is essential to prepare the membranes for operating service and to prevent membrane damage due to
Sea Water Reverse Osmosis Plant
overfeeding or hydraulic shock. Following the proper start-up sequence also helps to ensure that system operating parameters conform to design specifications so that system water quality and productivity goals can be achieved. Before initiating system start-up procedures, membrane pretreatment, loading of the membrane elements, instrument calibration and other system checks should be completed. Operation Guidelines Avoid any abrupt pressure or cross-flow variations on the spiral elements during start-up, shutdown, cleaning or other sequences to prevent possible membrane damage. During start-up, a gradual change from a standstill to operating state is recommended as follows: •
Feed pressure should be increased gradually over a 30-60 second time frame.
•
Cross-flow velocity at set operating point should be achieved gradually over 15-20 seconds.
•
Permeate obtained from first hour of operation should be discarded.
General Information •
Keep elements moist at all times after initial wetting.
•
If operating limits and guidelines not followed properly, the DOW™ FILMTEC™ Reverse Osmosis and Nanofiltration The Warranty limit will be null and void.
•
To prevent biological growth during prolonged system shutdowns, it is recommended that membrane elements be immersed in a preservative solution.
•
The customer is fully responsible for the effects of incompatible chemicals and lubricants on elements.
•
Max pressure drop across an entire pressure vessel (housing) is 50 psi (3.4 bar).
•
Avoid static permeate-side backpressure at all times.
Regulatory Note These membranes may be subject to drinking water application restrictions in some countries, please check the application status before use and sale. Notice: The use of this product in and of itself does not necessarily guarantee the removal of cysts and pathogens from water. Effective cyst and pathogen reduction is dependent on the complete system design and on the operation and maintenance of the system.
Factors Affecting RO Membrane Performance Recovery: Percentage of membrane system feed-water that emerges from the system product water. Rejection: Percentage of solids concentration removed from system feed-water by the membrane. Passage: Opposite of rejection, passage is the percentage of dissolved constituents (contaminants) in the feed-water allowed to pass through the membrane.
Sea Water Reverse Osmosis Plant
Permeate: The purified product water produced by a membrane system. Flow:
Flow of feed is the rate of feed-water introduced to the membrane element, usually measured in gallons per minute (gpm). Concentrate flow is the rate of flow of non-permeated feed-water that exits the membrane element. This concentrate contains most of the dissolved constituents originally carried into the element from the feed source.
Flux:
The rate of permeate transported per unit of membrane area, measured in gallons per square foot per day (gfd).
Dilute solution: Purified water solution, RO system product water. Concentrated solution: The brackish water solution such as RO system feed-water. Pressure, Temperature, Salt Concentration also effect the membrane performances.
PRESSURE VESSEL 2
PRESSURE VESSEL 1
5.11
Pressure Vessels – PPWT Description Length Diameter Design Pressure Minimum Operating Temp Maximum Operating Temp Application Operating pH range Cleaning pH range (
Never support other components with the vessel and never support other components with the vessel.
>
Do not over tighten the Permeate Port connection.
>
Ensure that the Thrust Ring is installed downstream and double check end closure installation.
>
Never operate the vessel in excess of its ratings, do not operate the vessel permeate port over 125 psi and operate the vessel in only positive pressure applications.
>
Flush the vessel before system shut down and operate the vessel within the recommended pH range.
Loading and Unloading Procedure:
HEAD LOADING PROCEDURE
HEAD REMOVAL PROCEDURE
HEAD REBUILDING
Step1: Inspect the Shell
Step1: Shut Down System
Step1: Remove Adapter
Step2: Head Seal & Shell Lubrication
Step2: Disconnect Piping
Step2: Remove Permeate Port
Step3: Install Head
Step3: Check End Closure
Step3: Inspect Feed Port
Step4: Install Retaining Ring
Step4: Remove Retaining Ring
Step4: Remove Seals
Step5: Reconnect Piping
Step5: Remove Head
Step5: Clean All Components
Step6: Pressurize System
-
Step6: Inspect Components
Step7: Check for Leaks
-
Step7: Lubricate Seals
-
-
Step8: Reassemble Head
Sea Water Reverse Osmosis Plant
Note: For separate parts, refer pressure vessels manufacturer (OEM).
Sea Water Reverse Osmosis Plant
6
SPECIFICATIONS
6.1
SPECIFICATIONS
Raw W ater Quality
:
Sea W ater
Model
:
SW 38B
Quantity of RO Membranes
:
03 (Sea W ater), 01 (Brackish W ater)
Voltage Supplied (3 Phase) (V)
:
440
Frequency (Hz)
:
60
Electric Load (KW)
:
27 (APPROX)
Control
:
Semi – Automatic
:
35
RAW WATER Raw W ater input (GPM)
Raw W ater Pre – Pressure (min/max) (PSI) :
15 – 80
Operation Pressure (PSI)
:
850
Operation Pressure Max (PSI)
:
950
o
Raw W ater Temperature nominal ( C)
:
25
Raw W ater Temperature range (oC)
:
10 - 45
Raw W ater Quality
:
Sea W ater
Total Dissolved Solids (TDS) max (PPM)
:
40,000
pH Value nominal
:
7–8
pH Value Range Cleaning
:
2 – 11
Silt Density Index (SDI)
:
>3
Concentration Free Cl2 (PPM)
:
0.00
Concentration Free Cl2 Short Time (PPM)
:
0.1
:
6
TANK WATER Fresh W ater input (GPM)
Fresh W ater Pre – Pressure (min/max) (PSI):
15 – 80
Operation Pressure (PSI)
:
150
Operation Pressure Max (PSI)
:
225
o
:
25
Fresh W ater Temperature range ( C)
:
10 - 55
Fresh W ater Temperature nominal ( C) o
Sea Water Reverse Osmosis Plant
Fresh W ater Quality
:
Fresh W ater
Total Dissolved Solids (TDS) max (PPM)
:
1,000
pH Value nominal
:
7–8
pH Value Range Cleaning
:
2 – 11
Silt Density Index (SDI)
:
>3
Concentration Free Cl2 (PPM)
:
0.00
Concentration Free Cl2 Short Time (PPM)
:
0.1
Fresh W ater Output (GPD)
:
5000
Conductivity Designed (µS/cm)
:
900
Total Dissolved Solids (TDS) max (PPM)
:
400
pH Value nominal
:
6.0 – 7.2
Recovery Rate Calculated (%)
:
25
Boiler Feed W ater Output (GPD)
:
5000
Conductivity Designed (µS/cm)
:
5
Total Dissolved Solids (TDS) max (PPM)
:
3
pH Value nominal
:
5.7 – 6.7
Recovery Rate Calculated (%)
:
50
Total Transport (KG)
:
1300
Total Operation (KG)
:
1900
:
Sch 80, ½” – 2” diameter
FRESH WATER
BOILER FEED WATER
WEIGHT
PIPE CONNECTIONS PVC Pipe
Sea Water Reverse Osmosis Plant
6.2
Tools and Resources Description
Qty
Filter Materials
2
Cartridge Filter Element (PP 10µm)
2
SPECIAL TOOLS Hand-meter conductivity /temp.
1
Torque spanner 1/2", 150Nm
1
Belt spanner small
1
Socket spanner
1
Open-end spanner 50mm
1
OPERATING MATERIALS Membrane Biocide (if microorganism growth is noted in system)
80 Liter
Chemical 1 (Anti Scalant)
80 Liter
Chemical 2 (Anti Scalant)
80 Liter
Cleaner (Membrane Cleaner)
As Per Requirement
WEARING PARTS V-belt
1
Shaft seals
1
HP-Pump seal kit
1
HP-Pump valve kit
1
O-Ring Cartridge filter housing
1
Sea Water Reverse Osmosis Plant
6.3
Annual Consumable Items General consumable items are described below for their replacement:
SR. NO
ITEMS
QUANTITY
REMARKS
01
Slim Line Multi Cartridge Filter
504
As per requirement
02
Cartridge Filter
03
Anti – Scalant Chemical
04
Membrane Cleaning Chemical
Sea Water Reverse Osmosis Plant
48 Nos
As per requirement
6.4
Water Analysis
SEA WATER Total Dissolved Solids (TDS) PPM
:
40000 Approx
Hardness (CaCO3) PPM
:
5,200 Approx
Oil & Greases PPM
:
2.0 – 0.2
Total Dissolved Solids (TDS) PPM
:
140 – 190 Approx
Hardness (CaCO3) PPM
:
8.4 Approx
Oil & Greases PPM
:
0.00
Total Dissolved Solids (TDS) PPM
:
10 Approx
Hardness (CaCO3) PPM
:
0
Oil & Greases PPM
:
0.00
Product Water 1st Stage
Product Water 2nd Stage
6.5
Sales & Enquries
For sales and enquires contact our sales team.
ORION OFFSHORE MARINE SERVICES PTE LTD 1 SOON LEE STREET #05-48/49 PIONEER CENTRE SINGAPORE 627605 TEL: +65 97451496; FAX : +65 65706907 Email :
[email protected]
Sea Water Reverse Osmosis Plant
NOTES
Sea Water Reverse Osmosis Plant
NOTES
Sea Water Reverse Osmosis Plant
