ML20071D927
| ML20071D927 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 02/02/1983 |
| From: | NUTECH ENGINEERS, INC. |
| To: | |
| Shared Package | |
| ML20071D886 | List: |
| References | |
| M-374, NUDOCS 8303110369 | |
| Download: ML20071D927 (111) | |
Text
{{#Wiki_filter:- _ - . . l I 9 i CENTRAL FILE MECHANICAL EQUIPMENT QUALIFICATION PROGRAM M-374 Reactor Building Spray System Hydrazine Addition Positive Displacement Pump ("h l l I 2/2/63 See Revision Control Sheet & ##4 M O 1 /22 /83 Issued for use (U.? WK P(/[5 No. DATE REVISIONS BY CR'K APPR JOB NO. CPC-09 -12 . SPEC / DES GUIDE No. REV. nute*ch m Mechanical M-374 1 i 1
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8303110369 8303iO j PDR ADOCK 05000 A
I' REVISION CONTROL SHEET
. TITLE: Reacter Building Spray System REPORT NUMBER: M-374 d Hydrazine Addition Positive Oisplacement P C.p J. w . 9 llm /
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N AME / TITLE INITIALS l / ' ll -l. m e= N <rH M r21 4 M 6Ha*. QtZ hAS V/ r // 'vakE stlTLE INITI ALS A A CWACY CA RERIA P AGEtS) REV EMARKS SY / DATE CHECK BY / CATE CHECK SY / DATE s 4 1 Added Program No. M-374 p) Added MFFCSS, Page 1 to Note (2) 6 1 Added Throat / Follower Bushings and information on EAES 7 1 Corrected REXN0_RD 8 1 Added Throat / Follower Bushings information and revised C/PSS Form to i non-metallic part des-cription 9 1 Revised to include forty (40) year upgrade for BUNA-N replacement in-terval 11-27 1 Revised MEEQRFs to in-clude additional design data and requirement 30-33 1 Revised notes 4,5,7,9,10, i 11, and 12 of Appendix A 34,35 1 sy znn; ;/,9 Added References 14, 15, pffg yg , anc 16 cs :.s.1.: N Caf O
TABLE OF CONTENTS s-I. QUALIFICATION PROGRAM A. Mechanical Equipment File Cover Summary Sheet (MEFCSS) B. Component Data and Environment Sheet (CDES) C. Mechanical Equipment Environmental Qualification Sheets (MEEQS) D. Equipment Applicability Evaluation Sheet (EAES) E. Component /Part Summary Sheet (C/PSS) F. Mechanical Equipment Environmental Qualification Review Form (MEEQRF) G.- Maintenance and Surveillance Recommendations H. Appendix A I. References and Additional Data J. Generic Figures II. REFERENCES I t i
c Mechanical Equipment File Cover Summary Sheet f'~);
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Equipment Type: Positive Displacement Pump MEO Prog No.: M-374 Manuf acturer/Model No. : Hills-McCanna do./McCannatrol P/D I Model No. J1-15087-10 (See Appendix A No. 1) Safety Function: The Containment Spray System is an engineered safety featured system to remove fission products and to reduce pressure and temperature in the containment following a LOCA. Radiciodine in its various forms is the fission product of primary concern in the evaluation of a LOCA. The pump injects hydrazine into the Reactor Building Spray System to remove airborne iodine resulting from a LOCA. Operation: Hydrazine addition to the Reactor Building Chemical Spray Solution is accomplished via injection from the Hydrazine Positive Displacement Pump which takes suction from the Hydrazine Tank and discharges to the Containment Spray System Header. This operation ensures removal of
/s\ iodine from the LOCA Containment atmosphere.
U Oualifi cation Status': The Containment Spray System Hydrazine Addition Pump Packing must be replaced with a material which has greater radiation resistance properties than the presently installed Teflon TFE to maintain a forty (40) year qualified life including a two (2) hour post accident condition (See Appendix "A", No, 11). I l i
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s , i MIDLAND UNITS 1 AND 2 EQUIPMENT QUALIFICATION
SUMMARY
COMPONENT DATA AND ENVIRONMENT SilEET EQUIPMENT 10 NUMnrn IP-041A PARAMETEll Normal I,0CA 6BCTiiiWTJ Pos1 Live Displacement l' ump . 0FETTKIITUTTRITC ou Years..% Z < llours .. . . :: SrnVICE: Airborno Fisslou Proituct Ron: ova ) S AFETY FUNCTION , N/A. Remove. .,Iod in e._,,,.,,. ,.._,,r . . . ,
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"7 SYStru BKn PO NO. M-374 ErQS NO: M-374 C. sluululTY (PrnC nn) 0-100 100 nOOM NO 026 utDG: AX EtrVATION 568 0 'flADI AT10N fnADSin : " ' 6. 6E06 7" ' ~l.7E05 T"~' s ""i'T. ..
OPinATING CYCLES: N/A NONSEISMIC VfDR NO E.SPnAY N/A 'N/A " nESPONSti SPECinUM IIG: Future use F.'SUDMErl0ENCE 1 IN/AE ' N/A> "F'TT LOCA: Yen MSLn: NO S AFE SD. NO '"- "* IIELD OUTStuE 110: NO G.? ACCURACY
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EQUIPMENT ID NUMDEn PAf1AMETEn UlTCalPilON - OPEHABILITY PLHIOD g. p. SERVICE: r,,S AFETY u-: FUNCTION :-. w ,yg, e. n, e m t.) ~; ;y ,
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( MECilANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION SIIEET (1) TYPE OF EQUIPMENT: Positive Displacement llydrazino Pump MANUFACTURER: Ilills-McCanna (See Appendik A, No. 1) PROGRAM NO.: M-374 MODEL NO.: McCannatrol P/D I Model J1-15087-10 EQUIPMENT APPLICABILITY: ACCEPTANCE REF. PAGEfS) Model Qualified, Configuration and Interfaces Match Installation Apdx. A, _ Y No. 13 EXTERNAL NORMAL OPERATING COUDITIONS REQUIRED QUALIFIED ACCEPT. METliOD III REF. PhGE (S )
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OUALIFIED LIFE (2I 40 years 40 years (2) Y AN No. 14 RESPONSE TIME N/A N/A N/A N/A N/A - s ACCURACY N/A N/A N/A N/A N/A N/A TEMPERATURE, MIN. 50"F 50 F Y AN 9 - AN
** O TEMPERATURE, MAX. 104 F ,
104 F Y - TEMPERATURE, AVE. N/A N/A N/A N/A N/A N/A ATM ATM AN
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PRESSURE Y - IlUMIDITY, MAX. 100 100 Y AN *j ^ - TID (RADS) 6.6F,06 6.6E06 Y AN ^E ** ^ - No. 7
- OPERATING CYCLES N/A N/A N/A N/A N/A N/A i
(1) Qualification Method Symbols: TT-Type Test, PT-Partial Type Test, TC-Tes t of Vital Components , OE-Operating Experience, AN-Analys is (2) Qualified without exception Y with exception (See MEFCSS, page 1) O O O
p (~ MECIIANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION SilEET (2) ACCIDENT ENVIRONMENT: LOCA X MSLD X IIELB OUTSIDE RB N/A PROGRAM NO.: M-374 ACCEPT-REQUIRED QUALIFIED ANCE METilOD III REF. PAGE(S) Apdx. A _ OPERATING TIME 2 Ilours 2 Ilours Y AN No. 15 Apdx. A _ RESPONSE TIME 72 sec 1.15 sec Y AN No. 8 ACCURACY N/A N/A N/A N/A N/A N/A o o AP d x. A TEMPERATURE 104 F 104 F Y AN No. 4
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PRESSURE ATM ATM Y AN No. 4 Y Apdx. A TID (2) (RADS) 6/P 6.8E06 / N/A 6.8E06 / N/A AN No. 7.
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SPRAY N/A N/A N/A N/A N/A N/A SUBMERGENCE N/A N/A N/A N/A N/A N/A LONG TERM FAILURE OF SIIORT-TERM USE l EQUIP, WAS ADDRESSED N/A N/A N/A N/A N/A N/A ACCELERATED AGING TIME / TEMPERATURE' N/A / N/A l (1) Qualification Method Symbols: TT-Type Test, PT-Partial Type Test, TC- Test of Vital Components, OE-Operating Experience, AN-Analysis (2) Includes the dose acquired under normal operating conditions over the equipment qualified 11fe. e e
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.; ) i EQUIPMENT APPLICABILITY SVALUATION SilEET EQUIPMENT: Ilydrazine Pump PROGRAM NO.: M-374 ESSENTIAL FOR MFGR./MODEL NO. C/PSS S UBSYSTEM COMPONENT FUNCTION DATA REF. REMARKS t Drive System N/A Y N/A N/A Pump / Motor Rexnord Inc. i Coupling Y 101-DBZ N/A Appendix A, No. 2 , i i Drive Case Y llills-McCanna B 1 Drive Assembly Y llills-McCanna C w Reliance I Motor Y PB-182T N/A Appendix A, No. 3 Stroke Adjust-l ment Assembly Y llills-McCanna N/A Appendix A, No. 5 i Thermocouple N N/A N/A ' e 4
l S A A _ K x x 4 R i i 7 A d0 d7 3 M n1 n1 E e e M R p . p. po po AN AN O . , A A A N FC / / 2 / EO N N 1 N M RD s A i = R s G - y O E l R RS an P ITT A A no UNE / / N Y Ai QEM N N t EM Na R Ad n
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SUMMARY
SHEET B l EQUIPMENT: Ilydrazine Pump COMPONENT: 0-Rings and Gaskets PROGRAM NO.:M-374 l NON-METALLIC ESSENTIAL REPLACE REQUIRE-PART FOR REF. REF. MENT BASIS REF. MENTS REF. DESCRIPTION FUNCTION DOC. MATERIAL DOC. INTERVAL (1) DOC. MET DOC, REMARKS Apdx. A G-Rina Y 3 BUNA-N 5 40 Years AN 15 N/A N/A No. 7 Apdx. A O-Ring Y' 3 DUNA-N 5 40 Years AN 15 N/A N/A gn_ 7 Apdx. A
- O-Rinc Y 3 BUNA-N 6 40 Years AN 15 N/A N/A No. 7 Apdx. A Gasket Y 3 CORK 5 1 Year 1m 16 N/A N/A No. 16 e apax. n Gasket Y 3 CORK 5 1 Year AN 16 N/A N/A No. 16 Gasket N N/A N/A N/A N/A N/A N/A N/A N/A Gasket N N/A N/A N/A i9/A N/A N/A N/A N/A Gasket N N/A N/A N/A N/A N/A N/A N/A N/A Apdx. A Oil Seal Y 3 BUNA-N 6 40 Years AN 15 N/A N/A lo. 7 Mylar Shim N N/A N/A N/A N/A N/A N/A .N/A N/A J
(1) Replacement Interval Basis Abbreviations: OS-Operating Experience, AN-Analysis, MR-Manufacturers Recommendation
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t N O A < E C I G6 a N R 3 i O E l6 v P T i e M A bl r O M oi b C MO b A FC 2 s EO i RD s a L B p A N I O l u m T I a P NRT Y v EOC r e SFN e n S U t i E F n I z a t r l n d i e y _ l O m I g e N n c
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MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM ,/' 'k COMPONENT: Inlet Check Valve Assembly
- 4 PAGE 1 OF 17
(._,,/ MFGR.: Eills-McCanna* PROGRAM NO.: .:_374 DWG./ DOC. NO.: 5221-12, Sheet 1, (Ref. 3), MODEL NO.: N /A Item Nos.: 27, 28, 33, 34 & 35 LOCATION: Aux. Bldc., 568' SAFETY RELATED: YES x NO DISCUSSION: The inlet check valve normally opens when the pump plunger is withdrawn cylinder. to admit hydrazine from the storage tank into the plunger is The inlet check valve normally closes when the plunger fully extended storage tank. to prevent hydrazine from back flowing to the There are nc non-metallic parts whose failure could impact the safety function. The pump inlet check valve assembly is comprised of components supplied by various manufacturers other than Hills-McCanna. The only non-metallic parts of the pump inlet check valve assembly are the O-rings seals (Item Nos. 27 & 28). [) PART DESCRIPTION: 0-Ring (Item No. 27)
-- FUNCTION:
The O-Rinc seals between the inlet check valve and n"~n ra d -r SAFETY RELATED: YES NO X Seal failure crovides an external leak cath with no sienificant inns - in discharge pressure or flow. MFGR.: ' Parker MODEL NO.: N/A MATERIAL: Ethylene Propylene REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) e i 11
MEEQRF (CONT.) PAGE o OF 17 PROGRAM NO.: M-374 PART DESCRIPTION: 0-Rinc (Item No. 28) FUNCTION: The O-Rinc seals between the inlet check valve and flance SAFETY RELATED: YES NO y The saal ie sub j ar+aa n-l y +-n hyd*ncinn +=n> hana p-neen-a n"? #741nva has no effec
- on the safpry # mction.
i MFGR.: Parker MODEL NO.: N /A MATERIAL: Ethvlene Prom lene REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) l PART DESCRIPTION: FUNCTION: G SAFETY RELATED: YES NO MFGR.: MODEL NO.: MATERIAL: REFERENCE (S) : DESIGN REFER- DEMONSTRATED ACCEPT- REFER-1 RATING (S ) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) I l i I 12 l l
MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM [' r I COMPONENT: Outlet Check Valve Assembly PAGE , OF 17
\m / MFGR.: Hills-McCanna* PROGRAM NO.: M-374 DWG./ DOC. NO.: 5221-12, Sheet 1, (Ref. 3) MODEL NO.: N/A Item Nos.: 25, 26, 27 & 28 LOCATION: Aux Bldg.,568' SAFETY RELATED: YES X NO DISCUSSION:
The pump outlet check valve normally opens when the pump plunger fully extends to inject fluid into the discharge header. The outlet check valve must fully close to prevent reverse flow fror the discharge header to the pump cylinder when the plunger is retracted. There are no non-metallic parts whose failure could impact the safety function. - The pump outlet check valve assembly is comprised of components supplied by various manufacturers other than Hills-McCanna. The only non-metallic parts of the pump outlet check valve assembly are the O-Ring seals (Item Nos. 27 & 28). [} PART DESCRIPTION: 0-Rinc (Iten No. 27) FUNCTION: The O-Rinc seals between the outlet check valve and puro casing. SAFETY RELATED: YES NO 7 Seal failure provides an external leak cath with no sionificant reduc-tion in discharge pressure or flow. MFGR.: Parker MODEL NO.: N/A MATERIAL: Ethylene Propylene REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) a I l l 13
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MEEORF (CONT.) PAGE 4 OF 17 PROGRAM NO.: M-374 _ PART DESCRIPTION: 0-Ring (Item No. 28)
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FUNCTION: The O-Ring provides a seal between the check valve and discharge
'w,/ SAFETY RELATED: YES NO x header.
Seal failure provides an external leak cath with no sianificant reduc-tion in fluid flow or discharge pressure. MFGR.: parker MODEL NO.: N/A MATERIAL: Ethylene Proovlene REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) PART DESCRIPTION: -[ FUNCTION:
\
C ' SAFETY RELATED: YES NO MFGR.: MODEL NO.: MATERIAL: REFERENCE (S) : DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) 14
MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM [D COMPONENT: Pump Seals PAGE 5 OF 17 O !?GR.: See Part Descriptions PROGRAM NO.: M-374 DWG./ DOC. NO.: 5221-12, Sheet 1, (Ref. 3) , MODEL NO.: N/A Iten Nos.: 31, 41, 45 & 46 LOCATION: Aux Bldg.,568' SAFETY RELATED: YES y NO DISCUSSION: Pump seals consist of the pump packing, vent plug seal and pump to sump gasket seal. Only pump packing (Item No. 45) failure will result in leakage which would significantly decrease pump output. I (m'
\
PART DESCRIPTION: 0-RING (Ite NO. 31)
'w/ FUNCTION: The 0-Rinc crovides a seal between the vent pluc and cylinder.
I SAFETY RELATED: YES NO y Seal failure does not significantly reduce pump output. MFGR.: Parker MODEL NO.: N/A MATERIAL: Ethylene Propylene REFERENCE (S) : 3 DESIGN REFER- DFJiONSTRATED ACCEPT- REFER-RATING (S ) ENCE (S ) REQUIREMENTS BY ABLE ENCE (S) I l l - i I l I 1 l I l l 15 y -
MEEORF (CONT.) PAGE 6 OF 17 l PROGRAM NO. : X-374 PART DESCRIPTION: Gasket L. E. to Sumo (Item No. 46) FUNCTION:
-- SAFETY RE*ATED: YES NO y Gasket failure does not reduce cumo cacacity or imoact the safety function.
MFGR.: Hills-McCanna MODEL NO.: N/A MATERIAL: Fiberoil REFERENCE (S ) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S ) REQUIREMENTS BY' ABLE ENCE (S ) l l l l I I I l l l PART DESCRIPTION: pump Packing (Item No. 45) The packing prevents leakage from the pump cylinder. G FUNCTION: SAFETY RELATED: YES x NO Packing failure decreases pump flowrate. MFGR.: John Crane MODEL NO.: C-06 MATERIAL: Teflon-Asbestos REFERENCE (S) : 3 and 12 DESIGN RETER- DEMONSTRATED ! ACCEPT- REFER-RATING (S ) ENCE (S) REQUIREMENTS BY ABLE ENCE(S)
- 1. 5E04 Rads 12 6.8E06 Rads N5$"b5!5 Sb SS9 N 12 replaced by I Lodx A Grafnia_ i %b. 11 UL Temo. JL Temp.
180D F l Index ' 1040F Desian Ratinc Y index l I I I I I I
! l
- I ! : i 16
MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM
/~'N COMPONENT:Plunger Coupling Follower Bushings and Throat /
PAGE 7 OF 17 i, , N
/
MFGR.: Hills-McCanna PROGRA". NO.: g_374 DWG./ DOC. NO.: 5221-12, Sheet 1, (Ref. 3), MODEL NO.: N/A Item Nos.: 48 & 49 LOCATION: Aux. Bldg.,568' SAFETY RELATED: YES X NO DISCUSSION: The plunger coupling connects the driving mechanism to the pump plunger. The coupling contains no non-metallic parts. The LOCA induced environmental conditions will therefore not cause coupling failure within the required 2 hour operability period. A Component Part Summary Sheet is not required because there are no non-metallic components. The Throat / Follower Bushings provide the bearing surface for the pump plunger (See Component Part Summary Sheet "A"). l
!p) PART DESCRIPTION: Throat / Follower Bushings (Item Nos. 41 and 159) t v i FUNCTION : Provides vearing surface for the pump plunger.
SAFETY RELATED: YES v NO Failure m y result in scorinc/bindinc of the cumo cluncer. MFGR.: Hills-McCanna MODEL NO.: 373 MATERIAL: Grachitar, Gr. III REFERENCE (S) : 14 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) l 5000F 14 1040F Analysis Y 14 l A, -Aodx A, ( l2F09 Rads lADdx17 Nb. 6.8E06 Rads Analvsis Y Nb. 17 l l
~
l l l i 1 e i i i l i 17
I MECHANICAL. EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM l
/
I\ ') COMPONENT: pumo/ Motor Couplina PAGE a OF 17
/
v MFGR.: Rexnord Inc. PROGRAM NO.: M-374 DWG./ DOC. NO.: Reference 7 MODEL NO.: 101-DBZ LOCATION: Aux. Bldg.,568' SAFETY RELATED: YES y NO DISCUSSION: The Rexnord pump motor coupling mechanically connects the motor with the pump drive assembly. The coupling requires no lubrication and does not contain any non-metallic parts. Degradation of the coupling due to normal and post LOCA environmental service conditions is not applicable. t l /m l ')' PART DESCRIPTION: l \
~'
FUNCTION: SAFETY RELATED: YES NO i MFGR.: MODEL NO.: 1 MATERIAL: REFERENCE (S) : DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) i l l h i l i I i i 18
MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FOEM
/,h COMPONENT: Drive Case Assembly PAGE 9 OF 17 s
x> MFGR.: Hills-McCanna PROGRAM NO.: M-374 DWG./ DOC. NO.: Dwo. 5221-12, Sheet 1, l MODEL NO. : 52-07-2000-2N (Ref.3), Item No.: 74 - LOCATION: Aux. Bldg.f 568' SAFETY RELATED: YES v NO DISCUSSION: The drive case provides the solid frame for conversion of the rotating motion of the motor shaft into a reciprocating motion to drive the pump plunger. In addition, the drive casing contains the lubricant required to minimize friction and wear which could cause mechanical binding resulting in pump failure. Various seals are used to retain the lubricant where casing penetrations are required for pump monitor-ing, operation or maintenance. n l 4' i PART DESCRIPTION: 0-Ring (Item No. 68)
FUNCTION : The O-Ring seals between the retaining plate and crank support.
SAFETY RELATED: YES x NO Sea 1 failure results in loss of lubricant and mechanical binding of the pump. KFGR.: Parker MODEL NO.: N/A MATERIAL: BUNA-N, 70 DURO REFERENCE (S ) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S ) REQUIREMENTS BY ABLE ENCE (S) 2.039enA 15 6.8E06 Rads Test & Analvmin Y 15 t Rads Mu yrs. plus
+un E ns,- nne*
l;ditic." accident'on-c l l l l l I!!I . I I l I I I l l 19
MEEQRF (CONT.) PAGE 10 OF 17 PROGRAM NO.: M-374 PART DESCRIPTION: 0-Ring (Item No. 64) ps FUNCTION: $$ kcEeOjs (2) provide a seal between the retainer plate and (j SAFETY RELATED: YES y NO Seal failure results in a loss of lubricant and mechanical binding of the pump. MFGR.: Parker MODEL NO.: N/A MATERIAL: BUNA-N REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) 2.03S E08 15 6.8E06 Rads rest & Analysis Y 15 _ (40 yrs. plus nads ..,,,%,,, yc. accicent. con-dition.) PART DESCRIPTION: (T FUNCTION:
\__/ SAFETY RELATED: YES NO yJGR.: MODEL NO.:
MATERIAL: REFERENCE (S) : DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE(S) REQUIREMENTS BY ABLE ENCE(S) l l 1 l
~
i 20
MEEQFJ (CONT.) PAGE A OF 17 lPROGRAMNO.: M-374 PART DESCRIPTION: 0-Rinc (Item NO. 82) FUNCTIO::: hjigggng seal between eM retainer guide Mock and he SAFETi RELATED: YES X NO Seal failure permits loss of lubric nt to upoer drive assemblv bearinc and cross-head. FIGR.: Parker MODEL NO.: N /A MATERIAL: BUNA-N, 70 DURO REFERENCE (S ) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS EY t ASLE ENCE (S) 2.038E08 l 15 l6.8E06 Rads l Test & Analysis l Y l 15 Raas i Hu vrs. pAusi I two hour I accicent condition.) I _ l l l iPART DESCRIPTION: Gasket-Sump (Item No. 12) FUNCTION: The gasket seals oil between the drive casing and sump. SAFETY RELATED: YES v NO Seal failure results in loss of lubricant to pump drive assembly. MFGR.: Hills-McCanna - MODEL NO.: N/A MATERIAL: Cork REFERENCE (S ) : 3 DESIGN REFER-DEMOSSTRATED ACCEPT- REFER-RATING (S) ENCE (S ) REQUIREMENTS BY ABLE ENCE (S) 120 F 104 F l Design Rating l Y 2 l l 1.0E06 Rads 3.05EOS Rads IDecrease in Y 16 . l (one s creaxinc normaiearolus 'strencth of 5 two hour accident done)to 7% l i I I I l ! l 21
MEE O?.F (CONT.) PAGE 12 OF 17 PROGRAM NO.: M-374 PART DESCRIPTION: Gasket (Item 12) FUN CTION : The gasket seals oil between cover plate and drive casing. c!SETY RELATED: YES X NO Seal failure results in loss of lubricant to pump drive assembly. MFGR.: Hills-McCanna MODEL NO.: N/A MATERIAL: Cork REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S ) ENCE (S) REQUIREMENTS BY ABLE ENCE(S) 120 F l > 104 F Design Rating Y 2 l 1.0E06 Radd 3.05E05 Rads Decrease in Y 16 tone year creaxing normal plus strencth cf 5 two hour to 7% accident dose)l l PART DESCRIPTION: Gasket, stroke adjust cover. (Item No. 1) FUN CTION : Seals the stroke adjustment and the drive casing. i SAFETY RELATED: YES NO X l Seal failure does not effect drive assembly. MFGR.: Hills-McCanna MODEL NO.: N/A MATERIAL: Svnthetic Rubber REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S ) ENCE (S) REQUIREMENTS BY ABLE ENCE(S) l I i i l i i i 22
MEEOPS (CONT.) PAGE J OF 17 lPROGRAMNO.: M-374 PART DESCRIPTION: Gasket-Drive Case Cover (Item No. 88) FUNCTION: Seals the drive case cover to the drive case. SIEETY RELATED: YES NO v Seal failure does not effect the drive assembly. MFGR.: Hills-McCanna MODEL NO.: N/A MATERIAL: Synthetic Rubber REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S ) REQUIREMENTS , BY ABLE ENCE (S) l I l I l l l l i l PART DESCRIPTION: Gasket-Sump cover (Item No. 23) FUNCTION: Seals the sump cover to the sump. l l SAFETY RELATED: YES NO X l Seal failure does not effect the drive assembly. MFGR.: Hills-McCanna MODEL NO.: N/A MATERIAL: Synthetic Rubber REFERENCE (S) : 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S ) REQUIREMENTS BY ABLE ENCE (S) I I I I I I I , I l I 1 l l l l l l l I
; 0 !
23
MEEORF (CONT.) PAGE 14 OF 17 PROGPAv. NO.- M- 3 7 4 _ PART DESCRIPTION: Oil Seal (Item No. 115) FUNCTION: 3fysebaEEf*"*
# #9* " # #
_ SAFETY RELATED: YES X NO Seal failure results in loss of lubricant to the drive assemblv. MFGR.: Garlock MODEL NO.: 63 x 141 3/4 soft MATERIAL: Nitrile Rubber REFERENCE (S) : 3 g 9 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S ) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) 2.032E0E ! 15 6.EE06 Rads Test & Analysis Y 15 Rads I tiO vrs. plusi
! two hour I l accident conc 11 tion . )
PART DESCRIPTION: Shim (Item No. 119) j [(/ FUNCTION : The shim adjusts bearing shaft tolerences. SAFETY RELATED: YES NO X Failure of the Mylar Shim does not result in failure of the drive assembly. . MFGR.: Hills-McCanna MODEL NO.: N/A MATERIAL: Mylar REFERENCE (S): 3 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) I I I i i 24
l l l MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM i l COMPONENT: Drive Assembly PAGE 15 OF 17 (j MFGR.: Hills-McCanna PROGRAM NO.: M-374 DWG./ DOC. NO.: Dwg 5221-12, Sheet 1, MODEL NO.: N/A (Ref. 3) LOCATION: Aux. Bldg.,568' SAFETY RELATED: YES X NO DISCUSSION: The drive assembly provides the conversion of rotational motion of the pump shaft to reciprocating motion to move the pump plunger. The only non-metallic component in the drive assembly is the lubricant. PART DESCRIPTION: Lubricant %) FUNCTION: The lubricant prevents wear and binding of the drive assembly. SAFETY RELATED: YES X NO Less or breakdow.- of the lubricant causes overheating, binding and pump motor overload. MFGR.: Mobil Oil MODEL NO.: Mobil gear oil 636 MATERIAL: REFERENCE (S) : 2 and 8 DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE(S) 1E08 Rads 8 6.8E06 Rads Design Rating Y 8 U 120 F k$Ng [' 1040F Design Rating Y N*gA' l 25
MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM N
} COMPONENT: Stroke Adjustment Assembly PAGE 16 07 17 MFGR.: Hills .*cCanna PROGRAM NO.: M-274 DWG./ DOC. NO.: 5221-12, Sheet 1, (Ref. 3) MODEL NO.: N/A LOCATION: Aux . Bldg.,568' SAFETY RELATED: YES X NO DISCUSSION:
The manual stroke adjustment assembly provides for fine control of the stroke length traveled by the pump plunger and hence determines the pump output. The stroke assembly does not contain any non-metallic components and therefore degradation induced by normal and post LOCA environmental service conditions does not exist. The manual stroke adjustment is set quarterly, as required, during pump flowrate test-ing (See Maintenance and Surveillance Recommendations, pg. 28). As a result, manual stroke adjustment is not required during accident conditions. - PART DESCRIPTION:
\
FUNCTION: SAFETY RELATED: YES NO MFGR.: MODEL NO.: MATERIAL: REFERENCE (S) : DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) l 26 l
MECHANICAL EQUIPMENT ENVIRONMENTAL QUALIFICATION REVIEW FORM r~s ( ) COMPONENT: Thermocouple PAGE 17 OF 17
\/ MFGR.: N/A l PROGRAM NO. : M-374 DWG./ DOC. NO.: 5221-12, Sheet 1, (Ref. 3) MODEL NO.: N/A LOCATION: Aux. Bldg.,568' SAFETY RELATED: YES NO X DISCUSSION:
The thermocouple provides an indication of hydrazine pump lubricant temperature. Thermocouple failure does not effect the safety function of the pump.
^s '
j ; PART DESCRIPTION: 1 L./ FUNCTION: SAFETY RELATED: YES NO MFGR.: MODEL NO.: MATERIAL: REFERENCE (S) : DESIGN REFER- DEMONSTRATED ACCEPT- REFER-RATING (S) ENCE (S) REQUIREMENTS BY ABLE ENCE (S) 1 l l l . _ _ l l i l _ l 27
~~, Hydrazine Positive Displacement Pump Maintenance and Surveillance Recommendations M374 l
) Frequency Requirement Action Daily Check pump head for hydrazine Initiate corrective leakage. maintenance as approp-riate. Check pump drive case for - i oil II) Quarterly Run hydrazine pumps to verify Initiate corrective pump performance. Check pump maintenance as appro-head and drive case integrity. priate. Check for abnormal pump vib-brations and noise. Check pump flow rate. Adjust manual stroke
- assembly as required.
Annually Disassemble and inspect inlet Replace check valve and outlet pump check valves seats or ball check if for wear. required. Replace check valve seals. Drain drive case lubricating Refill with fresh oil. l oil. Disassemble and inspect drive assembly.
~
28
l Hydrazine Positive Displacement Pump i Maintenance and Surveillance Recommendations N-(Continued) 1 l M374 , 1 Frequency Requirement Action Annually Check upper and lower bearings for wear. Renew drive case oil seals. - Reassemble and test the pump. Note (1): Periodically check during pump operation.
-~
C/ e 29
.m APPENDIX A
- 1. The Hills-McCanna Positive Displacement Pump is now manuf actured by the PPI Division of the Durion Co., Inc.
- 2. The pump /mo tor coupling manufactured by Rexnord Inc., requires no lubrication and contains no non-metallic parts (See Refer-ence 7).
- 3. The pump / motor qualification analysis is covered under the Electrical Equipment Qualification Program, File Number M-374.
- 4. The Reactor Building Spray System Hydrazine Addition pumps are located in water tight rooms in the Auxiliary Building. Each pump is located in a separate room, therefore the pumps are unaffected by all post LOCA environmental service conditions except radiation. Radioactive fluid is transported by the Reactor Building Spray Pumps when the system is in the recircu-latory mode. The Reactor Building Spray Pumps and Hydrazine Pumps are located in the same rooms.
- 5. Tha manual stroke adjustment assembly does not contain any non-metallic parts and is therefore not affected by radiation induced degradation. The manual stroke adjustment is set quarterly, as required, during pump flowrate testing (See Maintenance and Surveillance Recommendations, Page 28). As a result, manual stroke adjustment is not required during accident conditions.
- 6. The Hydrazine Pump is designed to function without auxiliary cooling water to cool the pump or drive assembly. The drive assembly lubricant is selected to provide lubrication with ambient temperature as high as 120 F which is greater than the 0
maximum temperature listed as 104 0F. Non-metallic components
, are internal to the pump and drive assembly and are therefore ; not exposed to an external 100% relative humidity environment.
l 30 I
l
- 7. The Hydrazine Pump is subjected to a to tal radiation field of
\ 6.8E06 Rads (6.6E06 Rads (40 Yr. Normal) plus 1.7E05 Rads (2 hr.
, accident)). BUNA-N (Nitrile Rubber) O-Rings have been tested to ,- 2.038E08 Rads with no appreciable degradation observed. (See J Reference 15).
- 8. The Hydrazine Pumps are positive displacement pumps activated by a run signal from the Reactor Building Spray Pumps. Due to the direct drive coupling of the pump and ' motor and characteristics of the positive displacement pumps rated flow is available in l.15 seconds (Reference 10). A suf ficient Response Time margin of approximately 70 seconds is inherent to system operation as 6
the required time for RB Spray Pump full flow delivery is 72 seconds (See MFQ File M-054) .
- 9. The hydrazine positive displacement pump was designed by Hills-McCanna to operate with ambient service temperatures as high as 1200 F (See page 13 of Reference 8) . Normal room tmeperature is between 500 F and 104 0F. An average room temperature will be provided during actual plant operating conditions. Drive case gear lubricant should be selected based on average service temperature as follows:
Mobile gear oil 634 410F to 900F Mobil gear oil 636 910F to 1200F
- 10. The Hydrazine Pump packing is composed of asbestos impregnated Teflon TFE. The radiation resistance threshold for degradation of teflon is 1.5E04 Rads (See Reference 12, Page 3-13). Degra-dation of the packing will occur in both the normal und accident environments where the annual normal dose is 1.65E05 and the two (2) hour accident dose is 1.7E05 Rads (See Reference 13).
Therefore, replacement of the Teflon TFE ring packing with a material that has a higher tolerance to radiation is recommended. The recommended replacement packing material is Grafoil (See No. 11). i s 31
. 11. Grafoil pump packing, manuf actured by Crane Packing Company can withstand pressure to 2000 psi and temperatures to 1200 0F . The Grafoil packing has no resin binders or organic fillers and is therefore resistant to radiation degradation. Grafoil with- l l
stands exposure to corrosive fluids. The Crane Packing Company recommends Grafoil packing for this application. Grafoil is a radiation resistant up to lE09 Rads.
- 12. A Site Restriction Form designating the type of drive case gear lubricant (o il) and pump packing to be used in the Hydrazine Pump has been completed to insure that the manufacturer's lubri-cation requirements and the radiation resistance requirements
~
are satisfied.
- 13. The Hydrazine Pumps subjected to analysis as described in this program' is identical to the pumps installed at the Midland Plant, Units 1 and 2 as noted in References 3, 4, 5 and 6.
- 14. With appropriate maintenance and su veillance schedules, developed in the Maintenance and Surveillance Recommendation Section, the qualified life of the Hydrazine Pump is determined to be in excess of 40 years including a 2 hour post accident condition.
- 15. The addition of Hydrazine into the containment atmosphere through the RB Spray System has been assumed to be two (2) hours in duration in accordance with Section 1.4.3.2.3.2 of Reference
- 13. In addition, Table 1-15 of Reference 13 assumes maintenance of the Hydrazine solution for two (2) hours for the qualification program spray chemistry.
- 16. The Hydrazine Pump Cork Gaskets should be replaced as necessary as a result of normal annual raintenance activities.
32
m 17. The Throat / Follower Bushing are fabricated from Graphitar, Gr. III (See Reference 14). This is a carbon-graphite compound with a epoxy resin binding agent. Carbon and graphite are~ radiation insensitive at the radiation levels to which the Throat / Follower Bushings .are subjected,. i.e., 6.8E06 Rads. The epoxy resin I binding agent is radiation insensitive up to radiation levels of 2E08 Rads. As a result it can be concluded that the Throat / Follower Bushings are radiation resistant with regards to their application within the Hydrazine Pump. 1 i i f 9 33 w- - - , - - ,,-a m- - - . - . . - + r4 m_- ,--e, , -,--n a - -- --+-+
s REFERENCES AND ADDITIONAL DATA 4 PAGE 1 OF 2 PROGRAM NO.: M-374
- 1. PPI-Durcometer, Bulletin 800G, Positive Displacement Pump Specifications
- 2. FFI-Durccmeter P/DI Pump Instruction and Maintenance Manual-
- 3. Hills-McCanna Co. DWG. 5221-12, Sheet 1, Rev. D, Parts Identifi-cation Section Assembiv-Hvdrazine Puro
- 4. Hills-McCanna Co. DWG. 5221-13, Sheet 2, Rev. D, Parts Identifi-cation Section Assembly-Hydrazine Pump
- 5. Hills-McCanna Co. DWG. 5221-14, Sheet 3, Rev. D, List of Materials N
- 6. Hills-McCanna Co. DWG. 5 2 21-15. Sheet 4, Rev. D, List of Materials
- 7. Telecommunication, Rexnord Inc., Manufacturer of pump / motor coupling
- 8. Telecommunication, Mobil Oil Co., Manufacturer of Mobil Gear Oil 636
- 9. Telecommunication, GARLOCK, INC., Manufacturer of Garlock Oil Seal .
- 10. Telex, Gary L. Wheeler (Reliance) to W. DeJong, J. Payne (Bschtel), Aucust 17, 1982,
Subject:
Hills-McCanna S.O. lYF882844 , 34 l 1 l._ _ _ _ , _ _ . _ _ ._., _
1 l l 1
'~5 REFERENCES AND ADDITIONAL DATA V
PAGE 2 OF 2 PROGRAM NO.: M-374
- 11. Reference 11 deleted
- 12. Radiation Effects on Orcanic Materials in 'uclear Plants, EPRI NP-2129, November 19El
- 13. Midland Plant, Units 1& 2, Environmental Oualification Reoort, Volume 1. Revision 1
- 14. Telecommunication, PPI Division of Durion Co., Inc., Manufacturer of Hydrazine Pumo fm
%)
- 15. Rotork Qualification Test Report 7220-M123C-105-1, Wyle Laboratories Test Report No. 43979, Rev. A, October 24, 1978 (Retained in CPCo Ecuipment Qualification Central File No.
M-123CC) 1 l
- 16. Radiation Chemistry of Menomers, Polymers, and Plastics by J. E. Wilson, Publisher Marcell Dekker, Inc., 1974 l
l l9 35
i I m I l li i l i Generic Figures Generic Figures are not Required to support this Qualification Documentation 1 i F l l \ r l L i I 36 5
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Durcometer P D Purnps provide continuous accurate. mainte-nance-free metering and proportioning of fluids under widely varying service conditions incorporating a host of new features these versatile pumps entroduce new standards in industrial fluid processing
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) Space crank drive provides for one or two feeds mounted on same drive case; multiple feeds can be provided by running drive IECTION " " * "' "
independent for each feed; direct 0 - 100h', digital readout is standard. Pumps may be provided with diaphragm heads, plunger heads, or a combination of diaphragm and plunger,
@ Capacities per feed from 0.87 to 780 gph; discharge pressures up to 5,000 psig; pumping speeds up to 230 strokes per minute.
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Suction check valve Plunger pumps are used in most all proportioning 1. Longitudinally honed plunger surfaces to better pump applications Due to design features. plunger than 8 microinch finish. pumps are capable of handling much higher pressures
- 2. Hardened SS440 or alumina ceramic plunger than diaphragm type. Plunger pumps have stuffing materials available from stock.
boxes with packing rings Stuffing box leakage and 3. True alignment of plunger to plunger driver is wear is a gradual progression. Properly designed the assured by a self-aligning plunger coupling. plunger liquid end has a long life span before repacking
- 4. Low-friction, nongalling throat and follower is necessary. Gradual take-up on the gland will reduce bushings assure smooth stroking cycles.
or eliminate leakage as wear on the packing rings takes 5. Plunger always travels to full forward position, place Plunger pumps can therefore be repacked on a regardless of stroke length setting, eliminating planned maintenance schedule since immediate failure possibility of crystal!ine buildup on plunger does not occur The P 'D Pump plunger liquid ends in- surface, plus providing full purging of body. N { s corporate many features which greatly extend the life '
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_ li f (' Suction eneck valve l u ' I s.- 1 D* O Vacuum valve, externally adjustable -Y , 3 y , Rehef valve, externally adjustable ~ Diaphragm pumps are most widely used in applica- diaphragm can then become mixed with the fluid being l tions where the nature of the material being pumpedis: pumped. For this reason the P/ D Pimp design in-
- 1. Highly toxic corporates a double diaphragm which provaes an inter-
- 2. Highly corrosive mediate chamber separating the hydrauisc diaphragm
- 3. Radioactive fr m the process diaphragm. The chamber provides for
- 4. Of high purity (no contamination tolerated) a compatible liquid between the two diaphragms. giv.
- 5. Of a high odorant content ing 100% protection against contaminating the process
- 6. Highly volatile fluid in the event of diaphragm failure. This chamber also provides for visual inspection or automatic detec-The packless design features of a diaphragm pump tion of a diaphragm failure completely isolate the fluid being pumped from the For services requiring a diaphragm pump. the double f in conventional diaphragm diaphragm feature of the P/ D Pump insures against
[ y atmosphere. However,hpump design, there is always product the possibility contamination, ofofcon-loss product and valuable l ( " taminating the process fluid in the event of a dia- downtime i phragm rupture, since the hydrauhc oil behind the l 5
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CHECK V ALVE WITH J ACKET CHECK VALVE WITHouT J ACKET time, and Cost. l 1
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MAIN DRIVE SECTION MANUAL STROKE ADJUSTMENT: Spin Handle. 0-100% Digital Readout MOTOR: Standard Four Pole Squirrel Cage induction The spin handle stroke adjustment mounted on antifriction Nema Rerate, flange-mounted,230/460 volt,3 phase,60 cycle, beanngs provides smooth stroke adjustrnent while the pump
'E* . is in operation or stopped. The digital counter, geared to the Motor options available include all current characteristics; anY stroke adjustment shaft, reads from 0 to 100 (can be read to frame size and foot mounting: all enclosures including epoxy 1/100) and is read in percent, a universal readout that does not encapsulated chemical duty, U.L. and Buxton explosionproof. need conversion to other units.
Variable speed drives: hydraulic, mechanical and electric with rnanual or automatic adjustment. The stroke adjustment screw and knuckle thread is a fine pitch acme form to prevent creeping of the strolie adjustment when Engine, air motor, turbine, and sprocket or chain dnves are the pump is in operation and provides the exact 50-turn also avtilaWe. adjustment required for the digital 0-100% counter. COUPLING: Accessible vvithout removing motor, Standard motor coupling with resilient spider insert eliminates PNEUMATIC STROKE ADJUSTMENT: Built-in Signal Trimming fretting corrosion between motor and worm shaft. Motor neumabc se a@pt is avadaW 6 aH Mument coupling halves are plated for atmospheric corrosion resist-signals, including standard linear 3-15 and 3-27 air, or special ance. Coupling is accessible without removing the motor for
*i'I' amp or millivoit to pneumatic conversion. The pneumatic manual turnover of the pump. The provision for manual turn-streke adjustment positioner has a provision for trimming the overis valuable as a preliminary start up precaution. Motor can maximum and minimum output of the pump.This is a necessity be reinoted from the pump without disassembly of the cou-for automated processes that otherwise would require an pi;ng. Options available: All coupling types and manufacture a onal rabo controk or auxWay trimming device.
-including resilient center, gear and grid. ,
COUPLING GUARD: Snap-On Type POSITIVE PACKLESS ROD SEAL: The standard coupling guard is a snap-on type that can be The P/ D Pump mechanical dove section is completely submerged removed by hyd. The guard is supported by the ngid cast in, and lubncated by. a heavy worm and gear lubricant required sections of the motor bracket. Special coupling guards can for rated transmission capacity of the worm and gear set This be made to specification. type of lubncant was developed by the industry for its properties f tena i us adhesi n t wetted surfaces and lubocating avality WORM & GEAR SET. involute Helicoid Form wam temwature ranp. cause of mne pahtin t% Standard gear sets are a nationally advertised catalog item. *# * "" * ** **" "" * * ** # 9 Single and double extended worm shafts are standard. The ' '* * ' ' " * * * '"* '*** "* "*P" double extended worm sMft is used for multiple feed pumps *
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or through drive for accessories such as a tachometer or '#**^* " ' **""***** tachometer generator. The worm gear sets use the advanced involute helicoid thread form with minimum selected backlash for maximum power transmission capacity and long life. PLUNGER COUPLING: Self. Aligning The worm mounting beanngs are tapered steep-angle Timken The P/ D Pump plunger couphng allows self abgnment of the roller bearings for maximum thrust and radial resultant loads. plunger This ehminates plunger side thrusts, binds or possible The worm gear mounting beanngs are a combination of a pre, loosening of the dnve rod The couchng can be disconnected by hand mthout the use of special tools. The outer sleeve snaps back loaded double ball bearing for thrust and light radialloads and a roller bearing for the major radialloads. and the retainer separates into exactly machined halves. SPACE CRANK DRIVE: The P/ D Pump Onve is a vanation of a three-dimensional space crank mechanism. The dnve minimizes the pump space envelope PLUNGER LIQUID ENDS PLUNGERS: Superfinished and allows for one or two feed options ethin the same dnve case. The plungers for stuffing box type pumps are hard, wear Crank a,d crosshead shding block size are proportioned for con-resistant, and superfinished by longitudinally honing to a servative pressure velocity values without need of pressure lubn-cation All power transmission components are submerged in. finish that is better than 8 microinch. Alumina ceramic and hard SS 4408 are standard materials.Other materials can be and lubricated by an oil bath furnished on application. The crosshead section of the P / O Pumo dnve is by definition. "a connecting rod of infinne length' and is supported by four sett. STUFFING BOX: Full Entry y augmng beanngs that run on hardened and ground track sur. Regardless of stroke setting,the fullforward positioning ot the l l
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faces The crosshead is completely load balanced and ehminates cwerhung loads that could cause force deflections in this entica' sactica of the pump pump plunger results in full entry of the plunger into the pump body and the same wetted plunger surface at all times. This feature el minates the possibility of crystalline matenal build-o
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x up on the plunger surface at reduced stroke setting and subse- ties, separation or slurry suspension is a consideration, the quent broaching of the packing when increasing the stroke many small holes will have a detrimental effect. Any particle length. . fallout from the process liquid will eventually be compacted by the diaphragm in its forward limit position and inbed into The combination of superfinished plungers, selection of or dent the diaphragm. This is probably the most frequent bushing materials for their corrosion resistant and anti- cause of diaphragm failure in single diaphragm pumps. galling propertiss, full forward entry of the plunger and stand-ard TFE lubricated, reinforced "V" ring packing result in the The standard double diaphragm P/D Pump esolates the dia-longest possible minimum attention, servicefree stuffing box phragm contour bmit surface to the hydrauhc side of the pump. designed. thus ehmenatmg the maior cause of premature diaphragm failure PUMP HEAD: Unit Construction The pump head and check valves are separate components. CORRUCATED ONE-PIECE TFE allowing for maximum flexibility in the sizing of valves, selec- PROCESS DIAPHRAGM: tion of materials and component servicing. The corrugated process diaphragm is a slave of the hydraulic diaphragm. The process and hydraulic diaphragm can, in All pump head cornponents such as plunger, throat and fol. motion, be considered one diaphragm with a liquid center, lower bushings, lantern rings and packing can be easily re- The corrugated shape of the process diaphragm is formed in moved for servicing without special tools. the back position and results in a uniform rolling action throughout its entire movement. DIAPHRAGM LIQUID ENDS VACUUM VA1.VE: Externally Adjustable The diaphragm head vacuum valve is calibrated for external
'm The P D Diaphragm pump is the result of an ententsve study of adjustments to obtain optimum pump performance at varying what is desired by the industry for optimum performance and rei.- suction conditions.
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# REllEF VALVE: Externally Adjustable b Double diaphragm construction with intermediate reference The P'O Diaphragm pump rehef valve is externally adjustable for chamber is standar( There are many advantages to the varying pump or process pressure requirements With conven.
double diaphragm construction that make it far superior to ,,onal diaphragm pumps using a pressure relief valve. the ten. other type designs. dency is to set the rehef valve for the maximum pressure potential of the pump without considermg the advantage of selectwo set-Visual indication of intermediate chamber contamination (optional): A pressure sight glass can be installed in one of tmgs for process system protection _ The P/D Pump rehef valve the connection ports provided in the side of the intermediate has been designed for minimum .1P by providmg generous flow chamber. A liquid of known pH reference color and process areas through the valve and the use of an adjustment sonng with compat:bility can be selected to fill the intermediate cham, the lowest possible spring rate. (This could eliminate a costly ex-ber. Should the process diaphragm fatigue after extensive temal telief valve ) service, the intermediate liquid pH reference color will AIR BLEED VALVE: Pressure Operated change, providing visualindication of failure. The air bleed valve purges the diaphragm head of entrained air. The valve operates as the pressure changes from positive Automatic indication of intermediate chamber contamina. tion (optional): An electric probe can be installed in one of to negative (above to below atmospheric) in value. The valve the connection ports provided in the side of theintermediate always expels a constant volume, resulting in the same slight chamber. A liquid cf known reference conductivity and volumetric loss regardless of discharge pressure fluctuations. proces s compatibility can be selected to fill the intermediate chamber. Should the process diaphragm fatigue after ex. CHECK VALVES tensive service, the intermediate fluid reference conduc-in-Line, Full Flow , tivity will change, causing an electric relay to operate and The P/ D Pump check valves have been sized for minimum veloc. automatically indicate failure. sty. clean.sweepmg flow Positwo uniform flow supported and ac. Superior diaphragm performance: Diaphragm pumps of curately guided ball ehminates valve chatter. resultmg m positive conventional design rely on two contoured limit surfaces to action and long seat hfe. Simple seat msert provides for unhmited keep the diaphragm within its maximum deflection limits. economical selection of seat matenals. Single diaphragm pumps require one of the contoured limit Stsndard NPT connections: Options available include flanged. surfaces to be located on the process side of the diaphragm. socket weld or other end connections on application.
. This is a poor condition for efficient diaphragm pump operation. Single diaphragm pumps must move the process Jacketed components are also aveilable for heat transfer 9f [L liquid back and forth through small holes on every stroke of the pump. For aqueous process liquid, this condition is not requirements.The flow through the jackets is contained with-out gaskets permitting use of all heat transfer media such as dett mental but when pro' cess liquid viscosity, shear proper- Steam, Dowtherm, Freon or ammonia.
3 ump App.ica';iin Characlerls;ics s/ 1 in1PDcB88 IB8ign < in designing a process system requiring a proportioning pump, the following application characteristics should be considered.
- 1. Proportioning Pump Accuracy
- a. The capacity of the pump is adjustable ,, -Fun supe ,,
-Half stroke from zero to 100%. p-
- b. The pump s highest metering accuracy is obtained in the 10% to 100% range. SINGLE FEED PUMP
- c. In the 10% to 100% range, the pump's 8'S'aa'a0 of cycie repeatable accuracy is within-1% or u.o-cycie better.
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- 2. Positive Differential Pressure To assure accurate pumping action, posi- ,
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- 3. High Vapor Pressure TWO-FEED PUMP Materials with high vapor pressure will re-quire N.P.S.H. (net positive suction head) portioning pump results in a pulsating flow consideration. Jacketed l, i quid ends and on each stroke of the pump as shown above.
check valves are available to cool the material if additional N.P.S.H. is required. Because of this pulsating characteristic:
- 4. High Viscosity a. Pipeline size should be equal to or High-viscosity materials may require con- greater than the pump check valve size, sideration of increased pipeline size, check b. Sudden restrictions in suction or dis-s valve design, or temperature control. charge lines should be avoided. (Select Jacketed pump bodies and check valves valves and fittings with full pipeline should be considered for adding tempera- capacity.)
ture control, if high-viscosity conditions 7. Dampening Pulsations exist. The pulsating flow of a proportioning pump
- 5. Suction Lift can be dampened by the installation of an if flooded suction conditions do not exist: accumulator in the discharge line,
- a. Maximum suction lift for plunger pumps 8. Process System Protection should not exceed 15 feet of water, a. All plunger pumps will require the use
- b. Maximum suction lift for diaphragm of a relief valve in the discharge line for pumps should not exceed 10 feet of water, pump and system protection.
- 6. Pulsating Flow b. Diaphragm pumps have a built-in re-The characteristic performance of a pro- lief valve for pump and system protection.
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1" 35 Se Sone ' Jt-080SS-06 3900 i Js-08047 06 S000 t J1 OdO54 'O l S000 ! J' 080f' '0w S000 JboscS81s Jt-04047 te ,- 1/2 1 '2 ' ' 54 ' 82 -
'.1/4'
- t p6 -
70 l 64500 10 4 3500 J2-040SS-06 J2 040aLO6 4500 k J2-040SS-10 4500 J2-Oe067 'O 4500 J2-040SS *4 J2-04067-14 > 70 2960 J104t t6 06 e 5 00 ' J1 C4116-10 1 5000 J1-Ost t 6-41 "' *1/2 173l tes t 14 0 2650 J2-08116-06 3600 J2-0411610 4500 t J2 oen614 GP 250t J t-De ia0-06 3360 ' Jt 04140 90 5000 - J b04 1t2 , 140 . Ipo t 17 6 l 2: 50 42 08140-06 3025 J2-Cet4014 4$00 i J2 0498014 I tt e 2 30; J t -04175-06 2ep0 J t-ce 9 T* O g 4000 i Jt Ge'40-te '?S 14 t /2 . 4 75 1/4 I 22 0 ! tone J2-Ce t ?S-06 J2-Oe'75-10 3PS3 t J2 04t?S 18
+.
4 te C 1500 J1-Oe230-06 2200 Jt 04:30a0 3000 i Jt-04230 te t/2 230 . SJ4'- 23 0 1350 , J2 08230-06 1940 l 2420J2 Oe:3310 2700 4 J2-04:30a4 h- Oc
': 0
'6 C 240c 2340
'20C Jh060SS-06 ! 2s00 < J1-0acSE 50 J1-06C47 06 2430 J106196-06 . 16J 2 - J t-06'6 *C J' 06G8%'O ' 248: . J' 06G4' 'e
- sR
$ J'-060SS 'e p gia 8,4 3/4
, , gg s 87
( 3J3 e 3 rg - 8/6 16 0 ' 2200 l J2 06CS8 06 24 0 32 0 2'00 ' J2 06087-0E 2200 2000 J2-OneSS i0 J2-0608710 3 J2 06cSB 14 2:30 I J2-06047 a e 2:30 . J2-04 9614
+
, JLO6'6 se 114 9 00 g J2-06116-06 5650 ; J2-061'610
, 1 -
'S c ' t 'C Jt-Ce'so-06 ' 1250 Jt 0614 ~ 'c , ::30 l a106140 te - 3 p4 14e 3,3 38 0 1000 . J2-06143-06 112S , J2-0614013 200C ; J2-0614314
,e sc 600 , J t -06 9 'S-08 I 1000 J'-06' 75 to e t rat i Ji 06t 'S te 3,4 17S 8/8 de c 400 i 42-06*7S 06 600 i J2 0617S *0 1600 t J2-06t'Saa v, , 3; C 6 ?O , J1-M230-06 9 90C J106230 iG 1450 l Ji-on 30 $4 Sie 230 3/6 64 0 600 l J:-06230-06 , 8'O i J: 06:30-tt 1300 : J2-06:30-14 i3 i 94 0 1330 l J1 10CS846 1340 + J1 1005810 - 1 Jbt005414 1 58 1/2 28 0 1195 J2-10058-06 1200 J210058-10 J2100SS 14 2' C 1000 l Jt 10067-06 1340 J b1008714 1 87 1rt 42 0 900 J2-10067-06 1200 J21004710 1250 J21008714 gg 2S C ?SO , J1 10116-06 1000Ji{ 10116do J11008110 1390 ' J1 13901091614 1 .114 1/2 54 0 680 J210116 06 900 J2-1011610 1250 J2 10116-14 Q -1 35 0 44 0 633 Jt 10140-06 Soo ! J1-1017b06 BSC 680 J1 105 60-10 J1 10175-10 1250 1000 J1 10140-14 Jt 10175-14 1 1 140 17S f ft t /t 70 0 88 0 S60 450 J210140 06 - T70 J21017bos 610 J210t4Sto J2-1017510 1130 900 J2-10140 14 J2-10175-14 57 - 57 0 l' 27S ! J1-10230 06 $10 J1 10230-10 8 70 J1.1023014 3 23 1/I ' 114 0 340 J210230-06 480 J2 Ic230-10 780 J21023014 W t
- ;- ; 22 0 RSO J1 12054-06 870 J1-1205410 J1 12058-14 1-l/4 58 1/t 44.0 770 l J2-12058 06 780 J2-120Sa-10 J21205&14
, .-~5 34 0 640 J1-17067-06 8 70 J1-12087-10 900 J1-12087-14 .1.l te 32- - 1/2. )j G&O 57S J212087-06 780 J21208710 810 J212087 's j 45 0 480 J1 12116 06 650 J1-12114-10 900 Jt 1211614 11/4 119 tit 90 0 430 J2-12116-06 $90 J21211610 010 J21211644
$5 0 380 J1 1214J46 540 .J1 12140-10 800 J1 12140-14 11/4 140 t /t . i 110 0 350 J2-12140 06 470 J2-tJte010 720 J2-12140-14
,, , 68 0 310 Jt 121?bos g 43S Jt 1217510 845 J t-12t *S 14 1-1/4 175 1/2 1 136 290 J2 125 75-On 390 J2-1217510 S80 J2121'514 90 0 240 J1 12:30-06 , 325 J112230 'S 490 Jt-12230-14 11/4 230 - t/2 J 100.0 0 215 J212230-06 290 J2 12230-10 440 J2-1223014 g
'; () ia 495 J $ t S058-06 _ ** J'-*N'c_ J i- t SCSe a s 14 1 58 3J4 7e 0 445 J2-15058-06 460 . J2 '505810 i 42 15038 14 gt 3'S J t -t S08 7-06 3 - .I $25 Ji-1508' '4 1 -513 ' 82 386 + 114 0 340 . J215087-04 460 42 *S087a0! 4 70 J21508714 -
> - 200 J1 151'6-06 "'- A 6N $25 JtaS*t6a4 1-6/8 118 814 152 0 340 . J2 tS'1610I 4'O , J2aS116 *4 ti 0 230 Jt t3140-cq 320 ,J' AS$4010 480 Jt 95140a4 1-S/g tat as6 ?B2 0 250 l J2aS"6 210 . J21$140-06 06 280 J21S'4010 ; 430 I J2aSt4014 +
'85 250 J ! .1517b10 . 380 ' Jt 1Si?bte .1-S/S fh.
- 1:50 J1 tS175 06 17E - 3J4 230 0 165 i J2 tS175-06 i 225 , J2 tS17510 ! 340 l J2 tS'70's 150C 141 J' 'S230-06 190 4 5
- S230a 0 280 , Ji-tS21314 14/5 t1e Sie 30J O 125 i J2-15230-06 ; 1 70 J2-tS230 'e ' 250 J2 tS23014 58 0 320 ; J1-20058-Os ~ 340 ! Ji-2005810 I Jt-20058-14 5 SS 1' ~It t.0 310 J2-20058-06 31 0 J2 2005810 J2 20056-14 Y P 879 2SO t Jt-20081-06 340 l J1-20087-10 1 350 J12005714 2 57 ; l ', 174 0 22$ J2-2008 7-06 310 J2-2005710 315 J2-20051-14 t's 0 190 t J120116-06 255 l Jf-201'610 350 J1-2011614 3. 116 1 232.0 170 J2-20116 05 230 J2 2011610 315 J2-20116-14 14:0 150 J1-20140-06 2?0 Ji 20'4010 310 J1 20' 40-14 3 148 1' 290.0 13S J2-20140-06' 190 J2 20140.10 290 J2-20140-14 >
,\ 175 0 125 J 1 2017S-06 170 250 J120t 7v14 2' - 178. f= 350.0 110 J2 2017%06 155 J2-2017%10 22S J2-2017S14 *.-
1 230 0 to i J120230-Os 127e J1-20230101 l J12017b10 190 J1-2023014 a- *3e 1- aso.O 85 J2 20230 06 11S J2 202Jo-10 170 J2-20230-14
'j ' -
Note: Blue area indicates availabsty in both p6nger'and diaphragm styles Whtto'e'ree Indeedtee-1Ivily'pitdiMwion~etru56e'qIe58e64es.$%My @$h. b---- -M y; *tndscate pleanger orp:- d.aphragm contagvestion p u8ing P or D after code, number when ordepnegg.gg/.6' p y,gnnwm'y.3'Q.yy;ysyy&.wfN,gQ** ^
g g -.sg4 .wafft '%
r CAPACITIES AND PRESSURES MODEL P/D H PUMP O' ,2 RO.. ; , d Me - T*' ' E'2 8.$ Ll TWO FEED 4 - Ca0acit, ONE FEED t- "% Speed C'he"ch Capacity I\ J ' at va, pres " Pres 2 en Pres 3 eo Pfunger
.. Dia. ,.
Stroke
? Pet. .
Valve at Mai
. Stregi. Pres. _ Pres.
2 to Pres. 3 oc
. GPM ! PSIG Code' PStG Code
- Unchee) M aule ' lact os GPH PSIG Code' PStG Code *
'I i
,- 11 0 4.600 L106058-20 ' l L1-06038 30 t -Str . 14-* ; 22 0 1 3.900 ' L2-06058 20 L2-06058-30 L. '
17 0 '. 4.200 L1-06087-20 3 4.700 i L106087-30 # SIS ^ ~l ST* 'f4 % 34 0 ! 3.700 i L2-06087 20 4.200 L2-06087 33
'M 23 0 3 100 L1-06116-20 l 4.700 l L106116-30 3/4 ? a 114'~ 14 h 46 0 l' 2.800 4.200 L2-06116-30
'- 28 0 2.500 L1-06140 20 t 3 900 8 L%06140-30 3M '-a . 414S } J1/E " 56.0 2.200 l L2-06116-20 i
L2 06140-20 3.500 L2-06140-30
' l
~
35 0 2.000 L106175 20 3100 ' L1-06175-30 3/8 " ~ ' file 1 M *" 70.0 ! 1.800 - L2-06175 20 2.800 L2 06175-30 e h 21 0 2 600 I L1-10058-20 , ' L1 10058-30 1* ?5: - 14 'T" 42 0 2.200 ! L210058 20 L210058IO~ 4 32 0 2.310 i L110087 20 2 600 L1-10087 30 1. - 87 ,14 ' 64 0 2.100 L210087-20 2.350 L210087 30 42 0 1.750 L1 10116-20 2 600 L1 10116-30 1- 118 - 1/2 - 84 0 1.580 L2101 ? 6-20 2 350 L2 tot 16-30 " 51 0 1.300 L1 10140-20 2.200 L110140 30 1* . 148 ' ' t/t .I 102.0 1.250 L210140-20 1.980 L210140-30 g 64 0 1.160 i L110175-20 1.750 L1-10175-30 - 1 % '- . 175L 1/t ~ 128 0 ! 1.000 L2101'5-20 1.540 L2-10175-30
- ' 40.0 1.330 L1 13058-20 L1 13058-30 .14 4 . b
- SS i JMM 80.0 1.150 L2-13058 20 L2-13058-30 5 80.0 1.250 L1-13087-20 1.400 L1 13087-30 [b34- 87 ; { 3/8 ~ 120.0 1.100 L213087-20 1,350 L2-13087-30 .
, .' h' ' 80 0 930 L1 13116-20 1.400 L1 13116-30
.[03/541-318j :[.11Si . 34% 160.0 830 L2-13116-20 L213140-20 1.250 L2-13116-30 L2-13140-30 7
^s. 97.0 770 L1 13140-20 1.130 L1 13140-30 ' ' SM. / 194.0 690 1.0E0 121.0 610 L1-13175-20 830 L1 13175-30 J 1-34
- k.,140 2-179 '3/f?$ 6 242.0 550 L2-13175-20 830 L2-13175-30 mC I 4- 74 0 700 L1-17058-20 L1-17058-30 bi-7th A i &47 A' .14 148.0 630 L2-17056-20 L2-17058-30 i
"'A tr 112.0 670 L1-17087-20 750 L1-17087-30 N 1-7% @lifg SD sN5 224.0 800 L2-17087-20 670 L2-17087-30 p
-m . 149 0 500 L1 17116-20 750 L1-17116-30 pa74f1Mdgl40 h g
298.0 430 L2-17116-20 , 670 L217116-30 g I ' U. O 180 0 410 L1-17140-20 625 L1-17140-30 , 380 0 375 L2-17140-20 550 L2-17140-30
*.y-
~
225 0 330 L1-17175 20 500 L1 17175-30 bjdes 6 175;.7
'~F* ?, J1M1
, # 450.0 300 L2-17175-20 440 L2-17175-30 ,
7~~ 1460 370 L1-25058-20 L1-25058-30 < S-SJE 292.0 330 L2-25058-20 L2-25058-30 i i S 20 0 293 0 350 260 L1-25087-20 L1-25116-20 375 375 L1 25087-30 L1 25116-30
.fS4ft}'"YSCi fM
~ ~t 54 %, tidh . - 1M 440.0 586 0 320 240 L2-25087-20 L2-25116-20 330 330 L2-25087-30 L2-25116-30 Y
+ -
365 0 210 L1-25140-20 300 L1 25140-30 " M/Si '1 14S E 3 t-t F4 f 730.0 182 L2-25140-20 270 L2 25140-30 _
- 440 0 l 175 L1-25175-20 250 L1-25175-30 W4 - M175 r *1 tW 880 0 150 L2-25175-20 225 L2 25175-30 e 250 0 200 L1-34058-20 L1-34058-30 *;14 21 520.0 180 L2-34058-20 L2-34058-30 390 0 190 L1 -34087-20 21 5 L1-34087-30 ev 34f231M} '~> *' 87%' ,1-4tt 780.0 170 L244087-20 100 L24067-30 520.0 140 L1-34116 20 215 L1-34116-30 [ 34tt ' i 416 1 1-8 /t1 1.040.0 125 L2-34115-20 190 L2-34116-30 s 620 0 120 L1-34140-20 175 L1-34140-30 .' M/2 ' " 140 i -17t t . 1.250.0 105 L2-34140-20 155 L2-34140-30
.83 0 95 L1-34175-20 140 L1-34175-30 3-1ff ' 3 175' ' f-1ft ' 1.560.0 85 L2-34175-10 125 L2-34175-30
*\ g -s* O
- 1. Plunger lequid enda are also svadab6e en lacketed construcbon. - . . u - - ,. e a-- .
, s
- fyh w Ja.4, wa -i- p t* o
- 2. 3/8' and 1/2" p6unoer e.ues are o.aaatne int hech-pressure appi. e cat ' e.m >ons Cw to
- C' I4. pggh.
10.000 psio 1 y, ,g.- T
- y -
.*4, e w,p+.3 s-y
. .- ~
ho:e; B.u. area indicates avadabmty in both plunger and diachragm styles. White area indicates only plunger construccan sveitable' ;, atte.[.1bg 4j,p
*ino,cate paunger or dephragm conftguration by useng P or D after code number when ordermo- g gg --7 .
yyp- g
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4 h2 T ..e-C . n,e
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._ y a - .W
&hrbk $k5 . ... ,7
- 5>$ Y
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~
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* %~
For metering highly corrosive materials most economicafly. Request Bulletm No. ao4 for details. N' _
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er
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'l l.f %Y P/ 0 Pumps mav be ordered with PPI actuation and control systems tai-lored to your process automation requirements or pumps 'already an-Automat 8d stalled may be held converted to automated controts Packages range from pneumatic stroke adjustment through electronic control for either open or closed 'oop systems metering pilmp COntr01 ro, e.a ,ie. a ,acsage cons,s,,ng o, ,um,. elect,ec ac,ua,o,s. and , nod. -
ufar sohd-state servo amphtier responds to any common electric process D B-S0urCe s onal ino aeaoeai stro*e cositioaers oa e ca feto resaoad -heaever the controller senses error between process and actuator position feed-responsibility - aa~ Servo controls are easily mounted in control room consoles or can be supphed in NEM A IV or vil enclost es for installation near pumps Send us details of your apphcation for a package designed to meet your specific requirements q w c.m o n .=. 2 EG Q
.=::= kg-gg w ,
l.EaF=r s g I PPI Division The Dunron Co., Inc. 900 Louis Dnve . Phone 215 675-1600 Wanninstcr. PA 18974 Telex 84-5329 Prmted m U $ A.
5 C P PRESSURE PRODUCTS INDUSTRIES A DIVISION OF THE DURIRON COMPANY, INC. WARMINSTER PENNSYLVANIA 18974 INSTALLATION, OPERATION AND MAINTENANCE MANUAL WHEN COMMUNICATING OR ORDERING PARTS FOR THIS EQUIPMENT PLEASE REFER TO SERIAL NUMBER PRODUCT DESCRIPTION DuncoMETER P/D I PUMP 1 l l DO NOT ATTEMPT TO OPERATE THIS UNIT WITHOUT THOROUGHLY READING THESE INSTRUCTIONS l l l O
H
-a h r oMeter P/D 1 PUMP 1NSTRUCTION MAhJAl o
"'N
- INDEX -
4
- i.0 INSTA'LATION 5.0 GENERAL MAINTENANCE
- 1.10 Mounting the Pu=;....................
Pase 2 5.10 Pump Lubrication..................... M 11 1.20 Piping............................... 5.11 Diaphrag: Head................. 11 1.21 Suction Piping....... ......... 2 5.12 Plunger Head................... 12
- 1.22 Discharge Piping............... 2 5.13 Drive.......................... 13 1.30 Electrical Inst 11ation... ......... 3 5.20 Wo rr. Gear As s e=bly . . . . . . . . . . . . . . . . . . . 13 4 1.31 Voltage Variation.............. 3 5.30 Upper Drive Case Assembly. . . . . . . . . . . . 16 1.32 Frequency...................... 3 5.40 Digital Stroke Adjustment Asse=bly... 21
- 1.33 Electrical Viring.............. 3 5.50 Plunger Head Assembly................ 22 5.60 Diaphra g
- Head Ass e=bly. . . . . . . . . . . . . . 23 5
2.0 SPECIFIC SERT' ICES 2.10 Acid Service.... .................... 3 6.0 EEFERENCE ORAW!NOS 2.20 Alkaline Service . . . . . . . . . . . . ... .. 3 2.30 Slarry Service... ...... ........... 4 52-51-1000 Crank-Gear Asse-bly Drawing.. .. 32 e 1
$2-51-1400 Wo r= A s s e=bly Drawing. . . . . . . . . . 3 3 1 5212-01 Secticn Orientation Assembly... 34 3.0 CENERAL START UP $260-03 Plunger Head and Check Valves.. 35
- 5260-01 Diaphrag=. Head and Check Valves 36 i 3.10 Priming the Pu.p., ......... ........ 4 5260-04 Diaphrag= and Hydraulic Head... 37 t
3.20 calibrating the Pu ;.... ......... . 4 5270-04 Digital Stroke Adjustment....... 36 , 3.30 Start Up........... .. ............ 5 5270-03 Two Feed Cross Head............ 39 3.31 Drive... ....... ... .......... 5 5270-02 One Feed Cross Head............ 40 3.32 Plunger Head..... ............. 5 5270-01 Single Extension Drive Case. .. 41 3.33 Diaphrage Head... ............. 5
/
j w i 4.0 PUMP OPERATION 4.10 Descriptionrof Operation... ....... 6 4.11 Drive.......................... 6 4.12 Plunger Pun;......... ......... 6 4.13 Diaphrag: Pu=p. ..... ......... 7 4.20 Possible Operattng Dif f icult ies. . . . . . 8 4.21 Drive..... . . ..... ......... S , 4.22 Plunger Pu=p ........ ........ 9 4.23 Diaphrag: Pu=p....... ........ 10 i 1 e L 1 I I I I 1 _ ~ ~ , _ . _ _ _ . _ _ _ - - __- _ - - , _ _ , _ , __ ..__..,-.__-.?
/C(( 1.0 INSTC_L TION The maximum suction lift permissible is approx-
[ imately 10 -15 feet for plunger pumps and 5 - 10
\ 1.10 M00* TING Tht PCMP feet for diaphrag= pu=ps (based on water at at-
=ospheric pressure end 62F). k' hen pu= ping with The puer ="at be fir =ly and evenly sup- a suction lift, the fittings must be tight, other-ported. A concrete founda ion especially wise the pu=p will draw in air on the suction prepared to receive the puz; is reco= mended. stroke, resulting in loss of output. A strainer it is to be noted that the pump has no should be installed in the pump suction line as mounting base, but instead it is designed as close as possible to the pump. The strainer will an integral unit with the pads of the drive prevent suspended matter fro settling in the case serving as a mounting and support. check valve and causing icproper seating of the ball on the check valve seat. The sucticn connec-Locate the pump as near as possible to the tion in the supply tank should be 3" to 8" above source of supply'(succion tank). Re=e=ber the botto= of the tank. Solid material can then to leave enough space for maintenance per- settle to the botto= of the tank without being sonnel and for che=ical liquid end removal, drawn into the pump. When low vapor pressure when necessary. liquids are to be =etered, sufficient net positive suction head (NPSH) must be provided to prevent 1.20 PIPING vaporization of the liquid in the pump cylinder on the suction stroke of the pu=p. -
All piping to and from the pu=p should be provided with a fir = support in order to 1.22 DISCRARCE PIPING avoid any stress which might be detrimental to the pipe fittings. While the pu=p will Discharge piping fro = the pu=p should be the same suppcrt considerable weight, it is never size as the check valve or one size larger if the recoc= ended that the pipe hang on the pu=p. line is long or uses many fittings. On plunger If crosses and tees, suitably plugged, are pu=ps a relief valve cust be installed in the used in place of tees and ells, the piping discharge line to protect the pu=p and process will be accessible for cleaning. For conven- equipment in case of a blocked discharge line, ience in dismantling the check valves or lig- The relief valve must be installed as close as 3 uid end for inspection, cleaning or repair, possible to the pump with a free line back to the unions er flanges are reco== ended to be in- supply tank. It is reco= mended that additional stalled in beth the suction and discharge valves not be installed in the return line since (""'N lines near the check valves. The pipe, they may be accidentally closed and obstruct the
\ supply tank, and fittings should be free of relief valve.
dirt, scale, or any foreign =aterial before installation. If shut-off valves are to be To reduce the pulsations of a proportioning pump, used in the suction or discharge lines, they an accumulator may be installed in the discharge shoald be of the full flow type. line of the pu=p as close as possible to the dis-charge check valve. This accumulator should have , 1.21 SUCTION PIPING a volu=e of approxi=stely ten times the full plunger stroke displacement. The accumulator will The suction piping should be kept as short even out the pulsating flow of the pump. In most and direct as possible. Preferably, the pipe cases an accu =ulator will not be required, but should be one size larger than the check when the ru=p causes high pressure surges in the valve suction connection. The pipe shculd be discharge line, the installation of an accu =ulator arranged so that there are no_ places where is reco== ended. Accu =ulators may be purchased air can be trapped. If possible, the suction f* 'm the Greer Hydraulics Co=pany (bladder type) piping should be sloped upwards unifo r:ly o; the Robertshaw Co. (bellows type). f rc= the supply tank to the pu=p, keeping the nu=ber of fittings to a =ini=u=. If a high For proper operation of the pump check valves, the suttien lift condition exists, a foot valve discharre pressure cust alvavs exceed the suction shculd be installed in the botto= of the line pressure bv 5 - 10 PSI. te *-event loss of pri=e during shutcown
- periods.
i N i
O = S ALL VALV E. '
- % - d 3
~*9 T O ...
d.[D , g =S T R AINE R. ' R TG g W- -E m A _ h M=ANGL E P RES S. RELIE F VALVE. a E
' f -
l N s y
^
D " b -dG=lNLlHE BACK PUMP l! PRESS. VALV E.
}.O@ : F -_.
..=
h - i [h]: CHECK VALV q . gi, t __ Q = PRESS. GAUG E
, FLOWm FLOW m #
h = AC C U",~JL ATO ' w Y STAN2r.RD Pl'PIMG _ O PTION AL FtP:.'!'- L E G E__,i..D. i _ Fig.1 1.30 ELECTRICAL INSTALLATION 5. CAUTION: The motor starting current can exceed the full load running current by 1.31 VOLTAGE VARIATION 200-300%. All mater protection devices, All squirrel cage induction inotors are de- electrical wiring and starting switches should be selected accordingly. signed to operate successfully at rated-load with a voltage variation of plus or minus it 2.0 SPECIFIC SERVICES percent when rated frequency is supplied.
- They will also operate successfully when the 2.10 ACID SERVICE
$. sum of the voltage and frequency variation b
does not exceed 10 percent, provided the fre- In pumping acids with a plunger pump it quency variation does not exceed 5 percent should be remembered that the pump sump is above or below nominal ratings as stamped cast iron and is not acid resistant. Always on the motor na=e-plate. keep the pump sump clean, and where possi-1.32 FREQUENCY ble, paint with an acid resisting material to
, minimize corrosion on the sump walls.
In addition to operating successfully with a It is also suggested that the components in voltage variation, squirrel cage induction the sump area be coated with a heavy grease motors will operate successfully with a fre- (Flurolube Co.) to retard corrosion. quency variation which does not exceed 5 per- Refer to Table #1 Page #12 for packing cent above or below its rated frequency. lubrication. 1.33 ELECTRICAL k* IRING 2.29 ALKALINE SERVICE
- 1. Refer to the motor wiring diagram while In pumping aqueous solution of salts and alka-making the installation.
lis with a plunger pump, some solids will
- 2. crystallize on t % plunger unless steps have Be sure that the electrical supply matches been taken to prevent this from happening.
the pump motor nameplate characteristics. These abrasive crystals will score a metallic 3. plunger as the plunger moves in cnd out of Use an adequate wire size to prevent the packing, and will considerably reduce the voltage drop. plunger and/or packing life. All plunger
- 4. pumps are provided with a stuffing box lan-Provide motor protection by fusing or by tern ring to wash away any leakage, lubricate use of a thermal overload device or cir- the packing, and prevent crystals from de-cuit breaker. positing on the plunger.
(a\ < 3
_- r: ,a -
- 3. " : ht du. harps line ha8 te ;s relatively
+
- -c cr.d!.s n ae r;.. se ::. - ar.v Icny. 1; is advisable to use an acet :la-
. * . - ui. - :len v1.; n.- tree , t er or ss ce ether surge da=;ening 6 rice
-? .
rui;i a en :S in the dis:hsrce line. *Jithout a surge
, , a u-ic:. rs e.gtar e of darpenin; d2vice, the fluid in the dis-n :t. . c: r .ind * . . a- .httre lins will be s:ationary on the soc-
. s ~. u rec r(#are t h. .una tien stroke of the pums which greatly in-reases the pratibilfry of selids settling
< at . Insta!;ation cf s preper surge da=p-TL. _ : ra . t .- ; -ward snt,g d.v!<< keep, :he fluid in eatien in
. . .s r wi; :h. s a .73 ws :t ; the discharge line at all tieca, thus re-p . v:+ . t 8;-: ::s re ard;.*, .
- str Gs 'eneth, during this tendency.
Secac>s - :a a chsrs c t e ri.4 : t c . :hs naterial 4 If the suction line has to be relatively wil; net builc up en the pluncer at reduced long, i: is advisable to use a centrifugal . 4:reke v.::irer and tner. re forced into th" pump to centinuously circulate the slurry a:elfing Sen w'ile a iner.2 sing the s:rsce in the line free supply tank to pump suc-
;en : ,. r,e.ver, tb. pr=cau:icr:re precedure tien and back :e the supply tank. This ef ebevr niculd 5s used wr6n i: 15 will prevent settling of the slurry in the
.,:. ::e. :a : :ne punt wil'. be 3:s r;< d and suctien 1;ne during the otherwise station-
. - . .. f t : e csr.:1 Fs is - *
. ' : S '. s last ary fluid flew period on the discharge
.. c- --
- u. 5 : ::1- . stroke e: :ne pump.
" ~ 7 - - - -
- 5. 'Jhen using a plcnser pump a relief valve su=: te inst 111ed in the discharge line as
- r. : :s.:s rm .r g -lurris s is close to tSe pump as possible. Since it is i . < # . 2::er : c kst: : hor: chiv sus- ??^>ible that the relief valve will becc=e
". a : ece4 ns. >w::;e m: in the 'aa cd wi:h solids, it is recom= ended ths:
- and . :nei- 3::ien. 7,e firs: yeu take all possible steps to preven:
.:- ::cr.: 8:e: : : . ..n e s : a<s . e!osure er fouling of the discharge line.
. a .r. . en: 13 tr a ::4 pur duet.-r x2: 6. in case < where it will be necessary to
.snt '- r..- :n s;urr" '- *: star: 'an.' s:cp the pump frequently, we
..:ns. ' -4 1- -e r t.in:( + . t- re.cnn=end tna: :he purp be prined with
, :-s-- . - - - sir :s . ! n mm. . a .s e s , cicar fluid en start-up and flushed with m ~w 4 ; '
. :w3 <(, an; clear f:uid before shutdown.
r; , . . . , .0 GrNER.ih START rp i \ . : i r4 : r ec. na:...s .. r-v i raxir r rm:icie si - !v u- 3.10 PKlMINO THE PUMT j r ena :er. .us.. *
. :nc saccess ar j urs esrsn.sm: cr c: r.e facters vach as The pump must be properly primed before it s
~?:.:ns r2:= e: s .' iia. :encentration ef will operate. To price the pump, it is ree-
; .; a r r .n;A ns e t . ;u?: speed. Obra- enmerded that the pump be operated with the
.-- ^ he .C.u r.. e::. *he a eve disetarge lines open to the atmosphere. Op-
-:: - - : e n ;< .. : c. e -ra:e the rung until liquid, free cf air
- ._; :: c c. b ;and;ed
, :hs. par:; . bubbles. flows from :he discharge connec-1 . 's . . c tre cast. Pre cni defin:t- State- !cn. If treuble is experienced in
- n -
2: c.r i m a:e en t';s v:'je:: ;< ::ut pricing the pump, refer to Section 4.20 of
. ::vr ::c r2r: i ;e i,d :he Icvcr tns
- his =anual where possible operating dif-j s r.. m, ::e :tr is :ne res=.hi: :v ficulties arc discussed.
j .e-:rs. pera*!on. 6* hen hazardcas licuids are to be pu= ped, r -s .-- -.it;e te enntre! th- r r::cle erine the pu p by letting it circulate
.rs . s. :us . ths erarvss require xn:*. back te the supply tank until the lines are ne
~
j ru- rv : reriant far:ar that :nn re c e:.- fu'.1 and Sir free.
- rrile: 11 the piping hock-ur. In many cases w' ore 11 ether easures tavu failed, re- 3.20 CAh!BRATINC. THE PUMP
- arrantement of piping nas eli=ina
- ed recurrent treu*!cs. Our recet=encations fer pipin2 are The stroke adjustment handle mounted on top a : 11.ws: of the drive case provides stroke adjust-
. Kee; :l e Su::icn and discharge lines as nent while the pump is in or out of opera-tion. The digital counter reads from
- short es possibic.
0-100 (can be read to 1/100) and is read in percent. Tifty turns of the handle will *
- . s s: --e nu=ber of :.::ings in the lines enance the stroke length from zero to 100
.1
- w. r in it at. ?!::ings provide percent.
- s . . : e.- and :ctners wners valid .at
- .4. and C:uf2 tr2u 10.
a w f
- v. _v._ . mv-, . ~ , - - .v. -
v, _.~+m v., _
._m . . . . _ , , . -,. .- - - - -
3 ,
, , , , case, replace the plug with the air filter-
; l vent attached te the pu=p.
; e c -_4_ _ _ . -- _ _ _'
gc ' Before starting the motor, recove the motor [o 5 g{ ,C~-- i
, j
[ t coupling guard and turn the pump over by hand until the punt has ec: pleted one stroke cycle. a
/
- This is a necessary start up procedure to pre-t vent pessible da age to the pu=p. Replace the
%,4 !
- motor coupling guard and proceed with next step.
E y ! l I I ! I ' R 5 l Vj j j g 3.32 PLUNCER HEAD 30 1. N l l CAUTION: Before starting take sure that all 0 0- . l l fl obstructions are removed from the discharge line. { [, - l
! ; !l A new pump can be damaged in seconds if the relief valve is not operating.
t
+/i { i ,I , .
. I
! 2.
O Some medel pumps are equipped with a bridge c 20 30 ac 50 to 70 SO 9C tCC type packing gland that requires even take-of Fun: Stroke up en two adjusting nuts. xost plunger _ (; , ! E ps .". ? 'ON "; p A p H puers are suppled with carben graphite fol-pi g. 2 Icwer bushings for secoth non-scratching or galling by plunger action. The carbon graphite eaterial is fragile, and the gland bridge nuts cust be taken up evenly. If The rum should be calibrated under actual eperating the gland bridge is cocked, the carben conditions. Determine the capac- gra;hite bushing will fracture due to the ities which correspend to the various digital uneven load. settings on the stroke adjustment. Plet a graph of capacity versus percent stroke 3. CAUTION The pump stuf fing box take.up length. This graph (ref. Fig. 82) will show gland =ust not be tightened prior to start , what digital setting should be used to ob- up. It is recomended that the pump be tain any desired capatity within the rated started with the taka.up gland backed off range of the pump. Keep'this graph with the slightly and then taken up gradually as the
- pump for future reference. packing seats in. All new packings will generate friction heat because of uneven For occasional checking o'f the pump capacity, seating surfaces. As the packing seats in,'
the following nethod may be used. The supply the f riction heat will drop noticeably. tank may be eq'uipped with an auxiliary meas- It may sometimes be necessary to fill the uring tank which is normally kept at the sump.with water or some other suitable same level of fluid as is in the supply tank. c ling media to help dissipate the stuff-When it is necessary to =easure the with- ing box friction heat. drawal of the pump suction, it is only nec- 4 When it is desirable to flush through the essary to switch the pu:p suction, by suit. lantern ring there should be sufficient able valving, to the fluid in the measuring flow to keep the lantern ring clean. The tank. Isolate the fluid in the supply tank and then note the quantity of fluid with- discharge water should be fairly clean. drawn per unit time. Be certain to switch Flow rates will vary depending upon fluid the pump suction back to the supply tank be- solubility. A recommended rate is approx-imately 5; of the pump capacity but not fore the fluid is exhausted in the auxiliarv less than 1/2 gallon per hour or more than tea m inc tank, as air might inadvertently ~ 10 gallens per heur. enter the p mp.
- 5 When it is desirable to lubricate the 3.30 START UP stuffing box through the lantern ring hole a Rockwell stick lubricant may be used.
3* U MM The recommended stick lubricants are listed in Table #1 on page #12. Before start up, refer to the drive case lu-brication plate locatad on the drive case NOTE: Refer to the Section " Specific cover. The correct lubricating oil proper- Services" for additional installation ties are specified in Section #5.10 for your recommendations. prevalent environmental conditions. Fill the g drive case as specified with the correct tab-ulated lubricant. Vnen filling the drive The diaphragm head must be serviced by filling case, refer to the lubricatien plate for fill- with the proper hydraulic oil prior to s. tart l ing instructions. After filling the drive up. The diaphragm pump is always shipped with [ l 4 5 l l __, , _ _ , yq ^
. ' q e . e ., n . . , n . . .. . . .m.m , y.mp.
the intermediate chamber filled with the T't %'~=r M,c, " ~<. M.0 S M OM8 V N-'1W. aseve% . E4
- r. cour ec rest amoun: of a low viscosity technical f' '%mcC - . . ~ - - sesac S a c* mmr )
[.,n} gra:it mineral oil unless otherwise specified. The it.ter:ediate chamber fluid may be rer:vec k
$9aa.d .7 Grif'. IY ' ' [ ~ ~. "O"'
p ' ", Y NN[d,#- , g.
%.., 9.. v ' O ..s e tl . t r. = - O.' <v.A v and reple:ed by some other nen-corrosive
..uic. i,an is cc patible with the procrss
--j
- nM fluid. If this is done it =ust be in strict F..." l.
9 %--4,.-Ir d '. accerdance with the service instructions given in the =anual. N K~%% bcY. C '* -lT"*,,b@#. Mti .
'.7",' *YM.
,[>N..
' .* EM YCs : . - -- - H. v ).f. e! D cal' TION: t'nder no circumstances should the h l.". .%,rm (h.3 .. .. i .
inter =ediate chamber be opened while the I . . a - s -- v
- 3. C - e---- . . . ~ b i '.c..
t . pu: p is under pressure. rs! M N' .s . " Y'%.7$cnik. ,
.r
- .Wh-J.* &
N Q'8*D " '-W'-$ y ~Y. WCY m.gM.Q;.
- 1. Tilling the hydraulic reservoir and hydrau-
[J -
- e. .
l.E-d h' *; 'E lic diaphrage charber. (Refer to Section 5.^^ - Orawing So. 5260-0a.) .o ., ., . .m ._, %
",m~ ."* #e Ev Pw
- a. .s eneve cap screws *11 and sump cover NygyJ,Q.r,hg.r . ' ...e,q
~' . AFUUlkTftO.R.g* ,o, or pearM-%:.Mw.wrf<;g rl.". exp e....g the e um a. 1nte. ier. WE* 5 *M -
, ' "**CW M .s Roxx 4. -
W.j- .f.
. . ,r4' ' . .'h - m,"m s e. J 3 $
.e. Rc=ove cap #7 and insert a 1/2" drive e:ension, f e:nle end, int.s the esvity tW b.
ch.
- g le. A'- i M- C. A
/
' M wcxcr sa.
f
.M.
o
, Qe.csmart MCQ.
rd re=ove the air bleed valve. $ . S ' ._r #-$ DWip L._
- c. Til! :ne surp with a gecd quality hy-9k-c _
k'A -
'h M y s ,... ,*.c a
.Sv.f'M
~ YsIMM crauli: oil with a viscosity ef apprex-instely 150 SS'J M 7007) unti tbc
- 37. 3fr' g auges.),
rcur.d bcdy hub is covered. (i.efer :o -b '.$h .M adhj)'7 g:d. 1.ym.gi 3. ', ^ e . sn:n- l. c . - . < n -s .11. )
.---s r .y.M'g e 6*-.,,,- m u :,. -h-,_ v.r- s-
- e. @Qgy MM
.. Til; the hydrauli;- diaphrag charber [. .] "(~,',Ms.%_ . T2 g{ g
- . agh the air :.ee va.ve per: until $[@g'.YGC:: Aa.~.E C.ia.(..lsu_Ttog S7stoptj ?.;.f'J
. f.. wm- -- - -.
i., : ::; . the air bleed valve and cap 'O FI N ' 3-
. .n e the sur; cover, cap screw < and 74 d r h.e -. i e m i s the pu :p upne envelope
. -:s;; the filter-ereather at*acnec te ,., g g . s, g ,, , ,. ,. .we f e,e ,,pt i..n = within l (N ~
- 72"F-
~;:s taphrsge head is now ready fer stat:-
tr. n e fr:v- ;<e ae
<r,ni nd cre.sshea?
M a; ort ic: ed for con-j (%/ ) "r. al: din; b'. m se rvat h pra-ure w ;c . tv values withou: l l
. - n e ed . ' - e.:-u n iub h.stion. A'I power
!. 0 p'~v'c OPER; TION trans.is,i n c'-N w rt, are sub=srged in, and lub ':,: -
ar 11 ^sath. .
. . .T A, . . C r.+ u .> na
.- s
.. . u - . -s. l w.-
m . r . .: '- - . t:e P/D I drive m :3, 5 ec a , m.e :1 y red ef infiri: le-::'" anc. ..u;merted by four Refer :c fig.- a3. self-? pH e h. ' f or t:. : run or. hardened The ~/s
- drive is a variation of a and e .a-l :r 4 3rfres. Th. cresshead is three-di ensional space crank eechanis=. co.p Nec'- lead ce? n tIicinates over-
' w w- : and wer: gear revc 1ve :Fe space 5:nr 'ic- t%: .ild c aus. f.sr:e deflecticns c ra:. in a conica! pa:! with its origin at in it. eritica; us. ion of ths punp.
the r ! .m: reint of :he nanger brc.:ie: "'h c
- c. rev .utien vf t u s* ace cran't
,ted rv :ht sliding bic: :< :t: swingir e
* :: sns-pct- ef :re hanger brack. . :h- -: . . . e g: :acking area Fig. W.)
j
- % r; .r ' := w a dynamic seal W !~RCKE between 5. .rn.-3 rresure end of the pump and h a m pawre. He vslumetric efficiency t~nen :ne stroke adjusteen: block position i coin.; des with the pivo point of the hanger cf the pc i. dependcrt upon the effectiveness I bra:ket, nc =ction is transr:itted to tne Of ChiS dFC3Ci' 5'31-crosshead, and the pump is a: zero stroke.
To caleve agreximately even wear distribu-tion and leng serv ue life c: the packing, e u..
. c . o. .n.Kg we have Ni' t in % fellowing:
. ne n :5..e stro.ne adjusteent n, lock position is
.d.'..at:cd to the b :to: cf ethe s._
4 nanger
..e,a. bracket
,o the The p! w er fitii. .5 better than 6 cierc
, . , . . . .ar.4 .a
. .. ~ 4.cn .s
. .ra .. .. .
- u5 ad and the p.u 7 is at full stroke. I" O h # h * ' N tudinal i lay,
, s s l
'V /
6
- 2. The plungar is supportsd by two bushings, on tha displacsmint sida. The passags holas ene fervard and ons to ths rsar of tha are small, minimizing the elastic daflection packing. =aintaining the geometry of the of the diaphragm into the holes should the stuf fing box (see Tig. #4). The bushings diaphragm bottom into either contoured surface
,r-.
are made of materials such as carbon with pressure behind it. The head requires
/ graphite that will not scratch or other. two valves, one that relieves at an over
( vise damage the plunger surface. pressure condition, and one that relieves at a vacuum condition. When suction lift or
- 3. The packing is selected for its bearing starved suction conditions exist, the diaphragm (PV) quality, low coefficient of friction, will work forward until it bottoms into the pressure rating, chemical resistance and Iront limit surface. The relief valve will ex-temperature rating. TFE lubricated Pel any remaining portion of the hydraulic asbestos V ring or square section packings piston discharge cycle to the reservoir. When' are the best choice for most se rvices. a high suction pressure (head) condition exists, the diaphragm will work rearward until 4 Regardless of stroke setting, the full for. it bottoms into the rear limit surface. The ward positioning of the pump plunger re. vacuum valve will intake any remaining portion sults in full entry of the plunger into the of the hydraul'ic piston suction cycle from the pump body and the same wetted plunger sur- reservoir. The pump is also equipped with an face at all times. This eltminates the air bleed valve that is used for continuous possibility of crystalline material build. entrained air elimination from the hydraulic u; on the plunger surface at reduced stroke oil-setting and subsequent breaching of the packing when increasing the stroke length.
..M rw.L;v cc r_LNOE9 .
IEDRACLIC
~
r -:: m3 DIAPHRAGal M.:. .
-c.: :
--- INTERAIEDIATE
- 4. .
s CHA31B ER
. 5:._r-f: s
~
. .- ...s .:
~ "
N ,
~" PROCESS b ' DIAPHRAGAI
' .m
(.-
' @'g~hg AIR BLEED VALVE
~
! .4 4i LIAIIT f--
J -T
" ~ SURFACES fpl .
M ' ' n__- c m PISTON
. = . . .
,7
. _ , . gg~ g 5
L'u 4 ,;' ' . . , -
. y
- C.- .
*~T' "d.
s-
..^ .
- . ' '- t
- y g ".g , fl . 'u.0*
v
.' -}
_ . .-m_ ? o.- m -- ._
,. - p. l
," r-m j." _....y s >
g .. ,
** MMH:ACMPNP ... . . .$. .
e- g ;, c <ty' . The hydraulleally operated diaphragm head is ..... ;.7) "
- shown in Tig. a5. The diaphragm is flexed back bh h in-e, .*.'.b' c.9 f ;.'
and forth by the hydraulic displacement of the . reciprocating piston or plunger, resulting in G i '. . r-a pumping displacement of the diaphragm. T} "- Cj
- s The hydraulically operated diaphragm is kept 'i . M . .
within its deflection limits by two contoured .. . ')i limit surfaces. The' contoured limit surfaces ,N 8'M IIC' #.3 contain many small diameter holes that permit I h DIAPHRAGAI LIQUID END passage of hydraulic fluid from the piston chamber to the diaphrace chamber, and so forth
/%
( N.' 7
.,s w- -
4 {
+
f 1 I I. ! is i 1 1 i i m e l t 4 I 4 . l 1 i ! 1 l t I \ I t l! I l. I l d I f
, , . , ' ...g
' . , , , . , . . .1,*
. . . . . . . . [
a....' -
.L . s*L\- !
p b _ ' _ ' .* [ i . l i . . _ _ . _ _ _ . _ . - .. .. _.._..__.. _. ( e. . . . _ . . _ . ... ._.____ , e j F t.- : : .
- - i. : .-.- .._~.. . Z ~ ; un n - '_..
.. .:6
'rs !** ~~ s *','st -s '.1'Jui* .2' kC"'. *'.'**-
.s * . '.~
. s. ' .. r * ; ' a F ; .- . .
r -- fr :
- cin*er t' 'ricattar i n > : ruc t ier.
8 s
. ; ,. i * - - : =. g. c ,, s ,.
.- r- *.7t .. . i
~
* . ~- !. '. * * *'t.* rs: .." . - ."J. *;r C.'sTlO3d COndi- o
. . _ . . _ _.. 2 c 0 0 . 'n I.33 I
.. ~. _.: _-! .,._._s___ - ._. ... _
s'-'
. _r . 's' _T.
. .. 6
.. . '. ar . .
8'.. 'l- b : T er !' e' r t f btOtiCn I.3)
. . . ... ._...._.._C.*.*...*
. ... 1. * r a .. .
i .
.44 '.*1 _' _* . _ . r. !.d r s: S c t l.? t O r s t 3 r t h T 6
.3j
- _ ' .. : .l_' - . * . _ _ ._ _ . . _ . _ - . _ . . . . _ . . _ . _ . .. .. . . . _ ' . . . . t h r'.1 is ; ass 1.- __i t.s r'.' gecr a : t --
- s in
..net__ _. r i_c ..
.- - e_ a r. ',c . :. :_e.. .:..s .r .. : ..- - - - . .-
*:ter runs na ns _an r :t. . . . cal r..'t.:r s ers 74 rc I
can h ca.:s .:n Ju. to tr.s r: s . f *.'. rs rn in; . -c'. en: . - in ; 4- , . . , I u. ,. - :v. rea t Iv m.e I ar*..;4: . m'* t.s s : i and . ti . i
- m. : he. : Jc -ins .rn::ne . ri.r :cre Dri s+ .- -: '
s . :3 . s . . ..a. .- s %? tc : s .uSraca icr. riate on the r.: u . _d r . s . _. ...s-- - ic- rera:ars r -t i - - th: so . : ' < -. . . - . -;
- 5. 05st i. ..e -era :* -uci um lint obstructier:
E V 1; L .4*
- a r. ! N r . .t
. tr . -es * . . . . I U"t r s' .1 u~.7 291rir. :
q...
. ... .s....-..
, . . . . .. . , . . . . . ...... . 3,__
s* r. . .[ ' Y s',S, . 'Y. ' 3[ ?.% b h r 5 :
- Er.
- ir '". 4 0 ' C 9 * ~ *.* r. ! 'i . Et . . 1 *t
- sC ; < r *i t. ' .'n Ct.2rf- **r is Ti .". i fa. .
;t.. '=.*.
*Cr i$ C r'.* ir. C 00 ..'Ve t :ic . *s r '* .4 '. .* - ' " -
i r'nEh ' "2 0. e ** S I Pt i s -hr.r e s * ._. _.rs i r . _. - i O l i f p ll I
- , - - - , _ ..,-- -- -.c_ _ . - - - - . .._ ---
. 22 til'NCER Pt*!C ifrMS 0M ick El REMI!W T ut; stalb }
- a. Over pressure due to blocked discharge ke:?ve obstruction j line e I
- b. Excessive discharge
/<-C[)'. Place a pressure gauge in the line (200-300* above Pu p rating) rid re- 's\ / , cord the readinc. If it is over pres-sure, shut down the Pu=p and correct j the problem. See Section 1.22 Discharge Pipine
- c. Excessive packing friction 3. See Section 3.32
- b. Loosen the stuffing box gland
- c. Lubricate as' recommended in Check valves Section 5.10 rattle
- a. All pcsitive displace =ent reciprocating Noreal as stated.
plunger Pumps will have soee check valve noise. However, the " click-click" noise frequency of the suction or dis-charee balls should not exceed the stroke frecuency of the Pump.
- b. Insufficient back pressure en the Punp.
See Nete 4.22-1 (Pace e10) [See Section 1.22 f (Increase back pressure) i jIn t e rmit t en t fInsufficient back pressure on the Purp. lSee Section 1.22 valve rattlinc (See Notes 4.22 5 4.22-3 (Pare 810). Pump will not I (Increase back pressure) la. Pump is cet prt=ed jSee Section 3.10 l deliver i See Note 4.22-4 (page #110). I
- b. Pump has lost prime due to a high suc- I See Section 1.21 l tien lift and/or leakv suction fittincs l
! ic. Suction er discharge valve ball is hang- Clean check valve and inspect suction l ing up strainer for damaged screen or i
different tesh
.. Obst ructi n in the suction line Remove obstruction i
- a. Closed valve
,Pu=; doesn't b. Clocced strainer ja. Suction or discharge valve ball is Clean check valve and inspect suction , ~~\ ideliver ratec '
han:tnc u; strainer for da= aged screen or dif ferent' l l j : capacity i mesh \ ' ,/ + lb. Obst ruction in the suction line Remove obstruction ic .. Exce s sive suction lift i See Section 1.21 jd. Leaky suction line drawing air in on Inspect and repair suction line suction lift applications le. Air er tas pockets in the suction line iSee Section 1.21 lf. Licuid is vaoorizine in the suction line
- g. Check valve components are worn or Replace cc=ponents and review 1 corroded l materials of construction th. Packine in the stuf fing box is worn Adjust or replace packing i
- 1. Relief valve is leaking Inspect valve; replace worn components I
and review materials of construction
- j. Relief valve is blowing Place a pressure gauge in the line (200
-300% above Pump rating) and record the reading. If it is over pressure, shut
- down the Pu=p and correct the proble .
ISee Section 1.22 Discharge Piping
- 9. Viscesity of liquid too high ! Porsult factorv
- 1. Clogged strainer Clean strainer
[s S v
'% /
9
7.- s
.22- t.22-3 o
The cvnamic fluici s.:ecitration c!. arac- During normal cycling in a process sys-teristic of a pcsit ave di.<?lacensnt recip- tre, the cperating pressare in a reacter re.ating plunger Pu .p rer.!re. nu:(leient er prsseure vessel cay have "high" and
!cd. pressuru on the died.crp side et t i.s "1 w" l ir.i t e . Ibc Pump =ay operate well icer to prevent velocit hsJJ surgus On at the I.Cr al procCss pressure Du! eVi-tne suction cycle frem carrying over and dence check valve rattle while thm pres-threugh the Pump head on t!.e di eharge sure in Duilding up during the system start cycle. This characteristic is evidenced up. If this condition is understood it is by ratt!ing check valve., erratis not usually objectionable during the short pressure gauge action and an apparent ex- periods while the process pressure is cessive volumetrie delivery of the Pump. building up.
.22-2 4.22 '
Turing rersa: eveling in . process sys- After shut dom perieds the Pump may t s t, t% su; ply tank to t . o. Furp m.w lose pries fer the following reasons:
*uv . a "hig'" ar ": ,"
- vit. The Pu.c
, w rate wel' it 'syvis half and % 1. v The cruses5 fluid nay gas and cause vaper t a ideN s did .h rattis at higher leck in the Tu ; er suction lines. This len . *hir may h .;aused 5v t hs cendi- will occur in systems where we are pu= ping tie < t s t e :i in Nots . 22-1 dus t. the materials with a low vapor pressute, low k .s
- su-tion hsa! e :s P.: m when t'.is supp1v pressure and high ambient tempor-
*:. u fu:1
. ature. ::e t positive suction head O'PSM) problems still also occa- in this typa of systee.
.. _..T,." :".V
, , . E vi. . .
7.ry;;,_ g- -.,e ,, y f % (% S - c .s__._ .-- a. Over pre w.r. d as te blocked discharge Remove obstruction
- wt J,1 ;vs r '. i .e l t. Pung is nat p r i=e d. Ses Ltc 4.22-i. jSee Svetion 3.10 t
; Pase 10 . I !
l
, c. Puns has last prims due to a hign suc- See Section 1.21
_ tion life and 'or leakv suetion fittings . 2 % :id3 Or diChJrre bal'. 18 hanginc up ' Clean c==rk valve and inspect strainer I ! for da . aged screen or large cesh 4
- v. N tructist a th suction 1:ne Setove obstruction
- - a. Closed valve
- b. Clogged strainer Fcr docer't n. Same as Puse d e not deliver"
< diliver rated a. Excessivs auctica litt. See /dfust vacuum valve. j 'MD
- te 1.23-; irage ' 11)
. Locatepumpclcserl to tne supply tank. Remove line re-l strictiens
- en 1
im *
.r line dra. 'n::. air in Inspect and repair suction line
. . . -r t ! -r -
1-? ! i c it .:m i : !- er c.= .sse!< ia : ,e -e.!!cn line See Section 1.21 = t ect valv+ ca .;uner.t a art worn er Replac= compenents .nd review caterials l orroJed ef censtruction
- f. :.f cuid i= vascrizing in ths suctien
! lins ! c. P roc e s.a. re!! valve is irasing Inspe:t valve; replace worn components
.and review materials of construction
.. Dischrac. Hvdraulic Relief Valve is
?lowine.
~
3 4e 'inte ". 23-1._.f.r a re 11) I i 5 'f l L. - t f
, = . . _ , , , __
- _ - . . , _ . . _ ,- . _ . , 1 ~_,____m- , __ , . , . . _ - . -, _._ .-
J. 2 3 DIAPHRACM PUMS - (Cont'd) 4 m l SYMPT 0M CAUSE iiu.c.u ( Pump dcasn't deliver rated
- 1. Viscosity of the liquid too high See Note 4.23-1 (page 11) capacity j. Clegged strainer Clean strainer
- k. Hvdraulic relief valve is leaking Check valves a. All positi c displacement reciprocating Normal as stated rattle plunger pumps will have some check valve noise. However, the " click-click" i noise frequency of the suction or dis-charge ballt thould not exceed the stroke frequenev of the pump
- b. Insuf fi,cient back pressure on the pump S(e Section 1.22 See Note 4.22-2 & 4.22-3 (page 10) -
(ineresse back pressure) Intermittent Insufficient back pressure on the pump See Section 1.22 valve rattling See Note t. 22-2 & 4.22-3 (page 10) (Increase back pressure)
.23-1 NOTEC _
5.0 CENERAL MAINTENANCE The Diaphrage pu=p requires two valves, 5.10 PUMP IIBRICATION
- a. described in Section 4.13. for proper pump operation. The vacuum valve is 5.11 DIAPHRACM HEAD LUBRICATION l
ner ally factory set for approximately a ten foot suction lift including the inter- Experience has shew that the 10W SAE viscority nal hydraulic losses and dynamic fluid "MS" automotive crankcase oils, as described by ve*o:ity line losses expected in a vertical the API service classification and the ASTM line when pumping water at 700F. The engine sequence tests, are excellent for the fa: tory vacuum valve setting is approx- diaphragm head hydraulic oil and lubricant.
, igately one half of one atmosphere. thould However. consideration must be given to the air
*] the application of the pump require pumping humidity since the reciprocating action of the at a greater vacuum setting caused by an hydraulic piston will cause the hydraulic sump s increased viscosity, longer than expected horizontal suction line length, etc., it to breathe in and out on each stroke of the may be necessary to adjust the vacuum pump. With the combined effect of possible changing ambient temperatures and the breathing valve for a greater vacuum. This may be action described, water may precipitate and be acccmplished by turning the valve's exposed emulsified in the oil. The detergent additives screw driver slot plunger clockwise; one in the 10V SAE automotive oils will tend to turn will increase the vacuum potential hold water in a tight emulsion and prevent
, one psi, until the pump performs as separation of water, even on long time standing.
tequired. The total turns available are It should be noted that very few water problems approximately five, when the valve will be have been experienced to date in the use of at the maximum setting of approximately these crankcare oils in the hydraulic dia-two psia. The practical adjustment phrag= head. Normal cor}densation has not been limit, clockwise beyond the factory setting, a problem. If normal maintenance precautions is approxiaately two turns. Beyond this are observed by changing the oil once every six adjustment the hydraulic oil in the dia- months, the pump will operate well without phragm head will become spongy due to the problems. Severe environmental condicions with alternate release and reabsorption of dis- extremes of low temperature, humidity, or solved air and the vapor lock of the oxidizing agents present in the atmosphere chamber. (See Section 5.67 for Valve should be referred to our Engineering Dept. Operation and Servicing .) for selection of the proper hydraulic lubricant. [ 11 ' \
.v .
4*
,.c , - - - , - - - - ,w-w-ww-< i -. m --w- a g q -- - w
?.11 7!.'?:0!R Krr L';?RICATIO': ] On a plunger pu=p a stick lubricater can be installed in the lantern ring hole. The hole, on the
( eppesite side of the lantern rin;, sheuld be plugged with an acid resistant pipe plug. Various L typ s of sti n lubricants are available frer U nwell Manufacturing Cenpany (see Table F1) to wit every particular application. After instal 14tica of th lubricator, the handle shculd be given a periodic turn (ence or twice a day) te acd lubricant to the stuffing bex. TABLE #1 plt'NCER PWP PACKING Lt'BRICATION iThis list is cade up for your information and convenience only. TLe lubricant stick numbers are Rockwell Mfg. Co. sealant nu bers. PPI does not normally furnish these lubricant sticks. We recor=and you centact your local Rockwell Mfg. Co. for availability or write to Rockwell Mfg. Co., Pittsburg, PA. Lub. Te=p. stick Crades Ranee o F. ndner available Free Te Oc!ct Frtncipal Services Unsuitable for 1C Stid 20 125 White Acids (including nitrating), alechels, Organte solvents alkalies, aqueeus solutiens, glycerine, I dyes (alcohol scluble), water. Food and l l pharmaceutical applications as deter-l t nined suitable by the user i 6
- t. 21 Stick 10 350 i creae . Acids, alkalies,alcohcis, amines, as- ' hydrocarbon and
=
lphalt, aqueous soluttens', fats, glycer- aromatic selvents ine, glyco's, soap, water, steam. Teod and pharmaceutical applications as de-l ter:'ined suitable by the user l 555 Stick 10 5X ' Brown General purpose sealant for hydrocarbon Aromatic solvents, [\ l ' i liquids and gases including gaseline,
! kerosen , fuel and lubricating oils, streng checicals, het air
( ' l
* "f crude distillates, sweet or sour natural and canufactured gas with water or cr-l
{ ganic condensates, LPC systems, dilute l , acids and alkalies, glycols, textile l
, ; plants, aqueous soluttens, water ;
' I 6 51. Stick 50 500 Erown Solvent tresting of lubricating oils, hot l ,
l hydrocarbon vapors and gases, general Liquidlighthydrol carbons, aromatic 1 . hot oil service, asphalt solvents, strong l
! ! acids and chemicals l 755 ! Stick i, 30 300 l Pink { Benzene, butane, solvent napthas, tol- Strong acids, ni-i ~ uene, gasoline containing benzene or trating acids, al-j l large amount of aromatic hydrocarbons, cohols, water, ,
I carbon bisulfide, carben tetrachloride, aqueous solutions ; l animal and vegetable eils i 021 Stick 30 650 *4hite , Acids, alkalies, alechols, amines, as- Liquid light hydro-
' carbons, aromatic phalt, aqueous solutions, fats, i !
i glycerine, glycols, soap, water, solvents, ni-i '
; l steam. Teod and pharmaceutical trating acids applications as determined suitable i by the user Suitable for hot hydrocarbon gases 4 j and vapers, high temperature crack'ing
! l and refor=ing to 10000 T. in con-l t junction with hard faced valves.
' Rece=:endations will be supplied on i
}/ recuest V .
12
- 5. . . P"JE trBRICAT!ON r
*he F/D I Pu=p Lubrication lO m
Plate she.m to the richt is located _ 0 en ter et the pump cever and pfp I specifies the correct eil to be in-PUMP LUERIC ATION INSTRUCTIONS /g s stallec in the Drive Case for varyint UNIT H AS SEEN ShlPPED @iY, FILL BEFORE OPERATING W SE % G N (V'! at:1ent conditions. fMSM. 'l CAPAC6TY , f-
/er:T OF OIL AwA v,itcs erwistr
,ry.a l! en so ? s s u ence;rym+ r. l P/D I Pump 1.75 Cal. r" , n.,gg . p i
9, O ! u.oc* b 7 125750 Listed below are several oil com-panies whose lubricants meet the
< gg f g 1,
p gg fri e specifications of our P/D Pumps as O ustos ou oit s= ova ss cuanoco avtav rsoo outlined on the Pump Lubrication f- DOW'ss#8*f sc 6s r. a., tas C8 '"m'mmum ee=n=ts tg wanat.,agcuatetto. 7 woua e mo.s os orts tio= ce tvany vras. Plates. o ' OIL FILL i io J TABLE ('2
~
DRIVE CASE LUBRICATION l Service Pour Point Vender I Brand Description Temp CF. Temp OT.
- 1. Culf 011 Co. Culf Senate 145D 410 - 900 +100 Gulf Senate 155 910 - 1200 +50
- 2. Humble Cil & Refining Pen-0-Led EP 5 41 - 90 +100 Pen-0-Led E? 5 910 - 1200 +150
- 3. Mobile 011 Corp. Mobile Cylinder Oil 660W 410 - 900 +400 i
Mobilegear 634 410 - 900 +200 f4 j Mobilegear 636 910 - 1200 +200 9 Shell Oil Co. Shell Macoma Code 65010 41 - 900 +100 Shell Macoma Ccde 65013 910 - 1200 +100 N t5. Standard 011 Div. Amogear Compound v5 410 - 900 +200 A=erican Oil Co. Amegear Co= pound #6 91 - 120 +300 ( 86. Standard Oil of California Chevron Cear Ceepound el40 410 - 900 +100
. . Chevron Cear Compound #160 910 - 1200 +100
- 7. Standard Oil of Kentucky (same as Standard Oil of Calif.)
- 8. Union Oil Co. of California Union PB Cear Lube #160 41* - 90 0 +100 Union PB Cear Lube *140 910 - 1200 +100 This oil is to be used in all P/D Pumps for operation at room temperatures from 410 to 90"F. For temperatures from 00 to 400P., dilute this oil with very light oil of the same basic crude. The use of kerosene is not recommended.
5.20DurcoMeter P/D I PUMP WORM 5.23 REQUIRED ASSEMBLY EQUIPMENT AND CEAR DRIVE ASSEMBLY INSTRUCTIONS TOOLS 5.21 REFERENCE DRAWINGS 1. An arbor press with approximately 8" throat depth and a capacity of 2-3 5212-01 Section Orientation Assembly cons. 5270-01 Single Extension Drive Case 2. One sleeve 15/16" I.D. x 1-1/8" 0.D. 52-51-1100 Worm Assembly x 2" long with square and smooth 52-51-1000 Crank Assembly ends.
- 3. One sleeve 7/8" 1.D. x l-1/8" 0.D.
5.22 REQUISITES AND PROCEDURES x 4 " long with square and smooth FOR ASSEMBLY ends.
- 4. One 1/2" female drive to 3/8" male A clean surface area approximately 2' drive adapter.
wide x 4' long is required. Cleanliness 5. One bar 7/16" dia. x 6" long with in assembly is essential, since any con- square and smooth ends, tamination of the assembly bearings will 6. One sleeve 3/4" I.D. x 1-1/16" 0.D. result in early failure of the pump drive. x 5" ,long with square and , smooth ends.
- 7. Snap ring tools, purchased from.
A Waldes Truare. v 13
N ens av(n (heas. held er c:her) with ta p-
. Place bearing and seal retainer f49. small vraturc cen:rcl te 500 7.
0 end dia down, en the arbor press. Place
- 9. sne G dia:e:c drill, seal 42 by hand (noting lip surface down)
- 10. & 0-1" dici darth rauge, depth =icros- in the center sesi hole of the retainer.
S
) e'er er accurate vernier caliper. flace a bar against the seal, noting the
- 11. One 7 3 " hex. socket with 3/E" drive. assembly is square, and press until flush
;ns 9 h " hex. sx iet with 1/2" drive. with ths retai cr. Place the assembly on i
\ %. the assembly bench in a clean area prior
_L cnc 3 '1:." hex. Key 1-1/2" long. T. ens l!i." hex. socket with 3/S" drive. to assembly in:o the pump. l
- 13. One 1/2" drive flexible head breaker S. After cooling, place the gear and crank bar 8-1/2" leng. assembly on the bench and drill through
- 16. One 1/8" hex. sccket key. the four holes. (Use drill 3.23-9.)
- 17. One icng nose plier 6" long. NOTE: The drilling should be accomplished i
- 18. One 1/2" hex. socket with l!:" drive, by:
l
- 19. One sleeve 3" dia. 0.D. x 1-3/8" dia, a. A? plying cutting oil to the hole and I.O. x 1" Icng with square and smooth ends. drill.
- 20. One drift pin with a 3/16" dia, point and b. Starting the drill, noting squareness apprcximately 6" length. te the hole.
- 21. 'One 17 cunce ball reen ha er. c. Turning the drill in, noting a free 2.. One pair of asbestos gicves. easy :utting action without binding -
- 23. dra 0-l' micrometer. or rcquiring excessive force.
. Cno terque. wren:h. !!:*~ drive, d. Turning the drill ou:. using the sa=e dire::ict of rotation as when turning C- W lb-in.
- 25. One L ,i suitabic for a 11 '16" diameter in.
shaf . c. Flus 1Gng the holes with solvent and
- 21. 2ns brass bar 1-:/2" 3.D.
- 8" long with blewing off with ec= pressed air.
Huns and s :oth ends. 9. Place the crank and gear shaft up on the arbor press and press the retainer screws ' 5. - W7f AZ OEAR 5"5-ASSE"$'.Y in the drilled holes until bottomed (use
'R+.:er :o Drawin;:s a5:12-01 !. 5270-01) the arber press and tool 5.23-5). Re=ove the asse-bly frc the arber press and
- 1. Ta brenz gear drive G = hall be screw dew:. locinuts #16 until torqued pla:e- in an oven (Ref. 5.23-6) a: i.000 firmly against the crank. (Use socket hr perica of OC to 30 rinutes. 5.23-11 and tm que wrench 5.23-24.)
- 2. I.h the cr. ink V 1) crank pin up and 10 Place the crank and gear shaft up on the rr.rcrly suppertec, and press on sleeve arbor press. Place a sleeve against the r:2. Ese sleeve 5.23-3.) " inner race" surf ace, noting that the 3 Ruravc bearing e55 fro: its wrapper and assembly is square and press until the insert into haaring se:ainer a35 (sleeve bearing bottces against the crank shaft.
may be required). 11. Place the crank and gear sub-assembly in
. Insert snap ring 8'31 angle side up into a vise, shaf L up, with the vise jaws en-rc::.iner $35 and seat the ring against gaging the flat cast surfaces on the side the bearing by tapping around the inside of the crank. Place-spacer against bear-f :i.e ring. This ring cust be seated so ing and press outer bearing and retainer that all clearance betweer. the bearing on shaft until it can't go any further.
j i and, snap ring is taken out. Spacer will be slightly loose. Keep spacer
- 5. Place the crank ^21 shaf: up on a bench. #33 in line with both bearings on shaf t so F,es:ve brenze gear #2 fro: :ne even, it doesn't bind, using ashcstos gloves and pla:e on the 12. Place the crank and gear on flat plate.
crann with tne four holes in :he closest shaft up in the arbor press holding fixture. p:sside align =en:. Allow the gear te Place bearing and retainer sub-assembly as c . : . a r.,. " shrink i C :n:c :he crank described in Sttps 65.21.-3 and f5.24-4 on wi: M : distur' the crank shaft. Place a sleeve agains: L F.. ice wo rr m' it arhor press. place the bearing " inner race" surface, noting ht.. ring e W ", has on the end of tha: the assembly is square and press until the we' - > i. .aee a sleeve against the bearing betto=s against the crank shaft. = :he int g m. . 3 e, noting that the 13. Place the crank and gear assenbly on the assembly is sq m e snd press until the bench, shaft up. Set the retainer clate bearing botto:s against the war: shaft 637 in place and insert cap screw F38 sheulder. Reverse the worn and first (torque 100 lb-in.) using tools #5.23-4 bearing ass ==bly in the arber press and and 5.23-24. espeat the foregoing steps. Place the i asse:bly en the assembly bench in a clean 5.25 '.'Op? AND GEAR ASSEMBLY INTO THE DRIVE CASE
.rea prier to assembly into the pump. (Refer to Dwg. e5270-01) i
- 1. Insert the crank, rear and beat ng sub-t
\ assembly inte the housing center bere. Be t
\
4 v l-4
- , w ---r ----e-,- g>wrw- - . - - - - - - - - - - - , , - - - - rv-
__ . -_ _ -m , _ _ _ _ __ areful not to cock the sub-asse=bly when s:ar:ing, or the bearing retainer v35 will into the bearing retainer tapped holes #1 bind in the here, and a2 (Ref. step #5.26-2) and as shown
- 2. Insert the sure and bearing cone sub- on drawing 652-51-1400 Record the measure-j '
- assembly (Ref. 5.24-6) into the housing ments with paper and pencil accordingly.
ver= bere. Pass the forward bearing cone 7. Subtract the measurements obtained in cently around the gear and into the ster "5.26-2 fre chose obtained in step oppesite housing bere. v3.26-6 (Nete: Dirension al should be subtracted f rem dimension el, and dimension
- 3. Insert bearing cups a50 into the housing #2 from dimension *2.) The remainder should were bere and cap gently from both ends until the cups have seated with the bear- be the same for dimensions #1 and #2.
j ine cones =ounted on the worm. Note that 8. Add .005" to the dimension obtained in the vorm shaf t is centered in the housing step #5.26-7 and select shims #8 that equal i- bore. the total. i
- 4. Place ene gasket-shim F52 (.005 thick) 9. Remove the four fasteners #4 and bearing ente the retainer seal sub-asse:bly retainer 410 (use tools #5.23-13, #5.23-14, i
(Ref. s:ep ~5. 2 -7). #5.23-4 and *5.23-15J.
- 5. Wipe the vorm shaf t diameter lightly 10. Place the shims obtained in step 85.26-8 onto the bearing retainer.
wi:h a coating of =2 cup grease. Insert 11. Repeat ster *3.25-6. bearing retainer, seal and gasket sub-asse-bly Gef. step F5.25-4) over the worm < haft noting tha: the seal lip en- 5.27 SHIM 11NC THE CRANK GEAR-BEARING ASSEMBLY cager crenly. Slide the re:siner assem- (Refer to Drawing a52-51-1000 and =52 70-01) , tly ente the vore shaf t seal diameter, 1. By hand push against the bearing retainer at the sa=e time entering the housing piste (dwg. n5270 part u37), un t i". the shi= and retainer botto: moving the crank-gear-bearing assembly agains: the housing. j t. Fasten with four cap screws #46 and until the gear bears.against the vorm. waiars "47 Tarque to '251t-in. Hold the assembly firmly in this position usin :aels "5.23-13. "$.23-1*, *5.23-4 and ins.ert the dial depth gauge (toci and #5.23-2 . v5.23-I L) against the bearing r2tainer as shown en Drawing n52-51-1030 and record 5.26 SH*r* TFE 201M-5EARINS ASSEMILY the dimension as letter "B" with pencil and paper.
^
(Refer :: Drawing "52-51-1-00) 2. By hand, reach into the drive case and j push agains: :he c rank, moving the crank-The shir=ing of the wer -bsaring assembly bearing asse-bly until the gear bears
. vi'.1 be a simple task if the procedures i *.
of this process specification are followed: against the vorm. Hold the assembly firmly
- in this position and insert the dial depth
- 1. Paper and pencil will be required for gauge (tool r5.23-10) against the bearing addition and subtraction, retainer as shown on Drawing 52-51-1000
- 2. Usinc O-1" micrometer (tool v5.23-23), and record the dimension as letter "C" with pencil and paper.
easure the thickness of the bearing re-
- 3. Insert retaining ring (dwg. 3270-01 tainer flange (part alO, drawing part 836) into the bearing bore using tool
~52-5;-1400). The measurements should be #5.23-7 i
4 taken at the two drilled and tapped 3/5-16 holes. yark the bearing retainer 4. Wipe the "0" ring groove in the retainer j holes :ne and two and record the measure- s ents .ith paper and pencil accordingly. plate (part *41) lightly with a #2 cup grease. Insert Tf' ring a14 into the ] 3. Insert bsaring retainer *10 into the groove. i n; s ine .:rn here. botto ing it against 5. Place the retainer plate ".1 and "0" ring
! t r.v
- earing cup.
against the housing counter bore. Insert Insert feur cap screws e4 into the housing seal washers a4G and chp screws #39 into and :tch:en eveniv "x"ing the cap screws the retainer plate and fasten to the bear- { un:1; tr.e torque level has reached 50 1D- ing retainer 835, using tools e5.23-12 in., using tools a5.23-14, =5.21-4 and , 5.23-2.. Back off on the four cap screws, and #5.23-11 (turque 180 lb-in.) . [' loosening evenly in an "x" pattern until 5.28 COMPLETION OF THE WORM CEAR DRIVE ASSEMBLY the screws are 1/2" turn snug against the
, bearing retainer.
- 1. Turn the worm shaf t using tool #5.23-2 5 and
- 5. Fasten de: for 11/16" shaf t on the wore observe for free rotation of the vorm and snaft and' rotate the were. The worm crank gear assembly. They should not be snould :: tate without undue terque i tight, bind, or evidence looseness in excess j
' ~'
occa.n c: were-gear fi: er excessive o' *008" backlash"*
- i f
r ses t .r. ter;ue en the t(arine retainer 2. Place sliding block c19 on the crani w.... < . . ..
. journal.
- nn rt cial espen gauge (toc 1 vi .23-10) 6.
7 . , s-15 b d e , -
-e . . ~ , .,---r -, , ,n,.- e -,. - , . - , ,- - ~ , - - . y p -
i l l 1 Tlace wa.hcr 5. 34 RANGER BRACKET - CROSSHEAD too'. : ~.23-7. insert sna; ring *1 SUB-ASSE*$LY INTO THE DRIVE CASE
'CQ e. Cover the top of the drive case until the
/ ner.: internal assembly procedure begins. Refer to Drawings 5270-03, 5270-02,
)
(V / 5270-01, 5:12-01 and Figures 6 thru 9.
%.10 Duret@ter ? E
- W
'JTTET. JRTVE CASE A55DTLY 1. Placc the bearings (Dwg. 5270-01-part
#27) in the Hanger bracket and using 5.31 REFERENCE DRAVINCS: tools a5.33-1 and *5.33-24, seat the bearings in the hanger bracket bearing 5:12-01 Section Grientation Assembly bores.
3270-01 Single Extension Pri/e Case 2. Loosely assemble the hanger bracket sub-5270-02 One Feed Crosshead assembly and crosshead sub-assembly as 5270-04 Digital Stroke Adjustment shown in Figure 6. Figures 6, 7, 8 & 9 - Upper Drive Case 3. Uncover the vorm gear drive assembly Assembly previously assembled per Section 5.20. Figures 10, 11 & 12 '.'pper Drive Case 4. Turn the vorm sh'af t using tool #5.33-12 Assembly until the crank journal is in the posi-tion shown in Figure PS. The crank 5.32 RIO'J: SITES AND FRO?E JEES sliding block shall then be turned by 73K ASSEMELT hand until it is in the illustrated pesition. , a civan surface area approxieately 2' 5. Note the fellowing hanger bracket-wide x 4' long is recuired. Cleanliness crosshead position shown in Figure #6 ir Assembly is essential, since any cen- before assembly into the drive case. tamination of the Assembly bearings will a. The crossheads shall have the result in early failure of the Pump machined botton slot surface down. drive. 5.12 '4EorIEIL ASSD2*.Y E T!TvzNT AND TOOLS
- 6. The loesely assembled hanger bracket-
- 1. one Bar 2" dia. x 3" long with crosshead assembly shall be picked up square and smocth ends by hand and installed in the drive case
- 2. Three Crosshsad Alignment Toc!s as shown in Fig. 8. The hanger bracket
[ \ 3/ " x 3/;" sq. x 18" long Ear shall be gently maneuvered until the ( ,) 3. One 15/16" Open End Wrench sliding block engages the hanger brac-4 One Feeler cause ket slot as shown in Fig. 8.
- 5. One Drifl' Pin with a 3/16" dia, point 7. Insert the extension shaft through the and approximately 6" length drive case, and screw into the cross-
- 6. One 17 ounce Sall Peen Ha=mer head antil the extension shaft is en-
- 7. One Torque Wrench, 1/2" drive, gaged as far as possible by hand.
0-620 lb-in. (Figure A8)
. 8. One Iorque Wrench, !!:" drive, 8. Insert the hanger bracket pins (Dvs.
0-200 lb-ft. 5270-01-part #26) into the drive case.
- 9. One 9/16" Hex. socket with 1/2" drive Push against one pin, maneuvering the
- 10. One 7/16" Hex. socket with 1/2" drive hanger bracket slightly until the pin
- 11. One Ratchet Wrench with 1/2" drive begins to engage the Fearing bore. Using
- 12. One Dog suitable f or an 11/16" diae- tool 85.33-24, cap the pin into the eter ahaft. bearing. Repeat this procedure with the
- 3. One 3/a" Slade Screw Driver B" - 10" second pin.
long C. One feed installation of the guide
- 14. One 5/32" Hex. socket key 1-1/2" long blocks (Dwg. =5270-02 part all) inte the
- 15. One 3/16" Hex. socket key 1-1/2" long drive case.
- 16. One 1/4" Hex. socket key 1-1/2" long ONE FEED PUMP 17 One 5/16" Hex. secket key 1-1/2" long NOTE: Positions referred to are
- 15. One 5/32" Hex. socket with 3/8" drive shown in Figure 9.
- 19. One 3/16" Hex. socket with 3/.8" drive
- 20. One 1/4" Hex. socket with 3/8" drive a. Using the extension shaft, lift the
- 21. One 5/16" Hex. socket with 3/8" drive forward end until the crosshead will
- 22. One 1/2" female drive to 3/8" male accept the first crosshead tool.
drive adapter b. By hand, lift the rear uttil the cross-
- 23. Snap Ring Tool, Waldes Truarc - head will accept the second crosshead Internal Plier tool.
~
24 One plastic head mallet c. Insert guide block Dwg. 5270 r 25. One 6 ounce Eall Peen Hammer part 11 into the drive case at position [ \ 't. One 2" dia. bar 9" long with square a2. ( / '7. and smooth ends (brass) One 0-1" Micrometer it
e , 9 "9 f
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9 , l Es
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- d. Pash the guide block, withdrawing h. Insert guide block #7 into the drive tool at the same time, until the case at pcsition #4
\m block has engaged the drive case 1. Push the guide block through, with-hole in position *5.
drawing tool at the same timo until the
- e. Remove tool in position F3 and insert guide block has engaged the drive case tne second guide block into the drive hele in position s1.
case at pcsition e3. j. Apply 42 cup grease to the "O" ring
- f. Push the guide block through until groove in the end retainer #9 and in-the block has engaged che drive case -
sert "0" ring # 8. hole in position #6. .
- g. Apply-#2 cup grease to the k. Insert the end retainers #9 into hole "0" ring positions 44 and 81 with "O" ring groove in the end retainer #13 and #8 into hole position #1. Note that insert "0" ring #12.
the protruding flat tangs of the end
- h. Insert the end retainer #13 into hole retainers engage the top and bottom of positien #3 and end retainer #13 witn the square guide block.
"0" ring *12 into hole position #6. 1. Insert two cap screws $10 across the Note that the protruding flat tangs corners of each end retainer and using of the end retainers engage the top tool #5.33-15 draw dcwn on the cap and bottom of the square guide block, screws evenly until they are snug 1/2 i
- i. !nsert the end retainers al3 into turn tight.
hele positions #2 and =5. Note that m. Remove tool =5.33-2 in position #3 and the pretruding flat tangs of the end insert the third guide block #7 into retainers engage the top and bottom the drive case at position *3. of the squart guide block. n. Fush the guide block *7 through until
- i. Insert two cap screws *15 across the it has engaged the drive case hole in corners of each end retainer (steps position u6.
h - 1) and draw dcwn on the cap screws o. Apply *2, cup grease to the "0" ring even k until they are snug 1/2 turn groove in the end retainer r9 and tight, inse rt "0" ring v8.
- p. Insert the end retainer F9 into hole positten c3 and end retainer "9 with
- 10. Twc Feed Installation of the Guide "0" r in a r ' into hole position a6.
Blecks. (Ng. r5270 part *7) into Note that the protruding flat tangs of the drive case. the end retainer engage the top and kj NOTE: Positiens referred to are bottom of the square guide block. shown in Figure 49. q. Insert two cap screws 410 across the corners of each retainer 89 and draw a, tJing the extension shaft. lift the down en the cap screws evenly until fervard end of the crosshead until they are snug 1/2 turn tight. it will accept the first crosshead tool,
- b. By hand, lift the rear of the second
, crosshead until it will accept the 11. Move the crosshead or crossheads back second crosshead tool, and forth by hand, noting that there
- c. By hand, lift the rear and front of are no binds that impair free move-l the first and second crossheads until ment. Should any binds be noticed,
! the crosshead will accept the third loosen cap screws #10. using tocl cresshead tool. 5.33-15 and tap the end retainers #9 i
- d. Insert guide block *7 into the drive with tool 5.33-21.. When the cross-casi at pcsition =2. *ieads cove freely, retighten the cap
- e. Push the guide block a7 through. screws cl0.
withdrawing tool at the same time i until the guide block has engaged the drive case hole in position a5 12. Insert the remaining cap screws 810
- f. Insert the end retainers 89 inco the and torque all fasteners evenly to
! drive case holes in positions #2 and 75 lb-in.
i a5. Note that the protruding flat tangs of the end retainers engage the top and bottom of the square 5.35 ADJUSTMENT SCREW AND KNUCKLE NUT ASSEMBLY (! quide block. INTO THE DRIVE CASE i g.~ Insert two cap screws PIO across the
, corners of each end retainer 29, and 1. Turn the w rm shaft using tool 5.33-12 .)
( s using toels, draw down on the cap screws evenly until they are snug until the hanger brackt e is in the pesitten shcwn in Figure e!OA.
!!: turn tight. 2. Slide the crc.sshead into the position sha m in Ficure ^A and B.
- 3. Align the hancer bracket-crosshtad 19 1
- - - . . , . - - - - . , _- -- _ , _ . , . _ , . ~_~ _ ,. ..
until the rectangular cavity is in the 10. Refer to Drawing 85:70-01. Select the
] positten shown in Figure e10F.
- 4. Align the sliding blocks on the drive number of shims 857 (.014" thick) to fill the gaps determined in step 8S.
knuckle nuts as eb m in Fig. vilA. The cumulatin shin thickness shall Insert the adjustment knuckle-sliding exceed the ceasured cap by the closest block assectly through the hanger possible margin. bracket and into the rectangular 11. Re=ove cap screws =25 and #26 one at cavity in the cresshead as shown in a time, and install the shims selected Fig. FIM and llE. Gently push down in step 86. Reinstall the pins per pro-on the sliding block asserably until it cedure 85.34-9. Insert cap screws #25 has passed through the hanger bracket and torque to 110 lb-in. for a free and has engaged the crosshead com- fit befcre proceeding. Check that the 4 pletely. This procedure requires adjustment screw asseebly (95.35-7) absolute alignment of the sliding remains free and does not bind. blocks to the crosshead. The clear-ances are very close and patience cay be required to obtain the absolute 12. If this is a Two Feed Pump, repeat pro-alignment ef the sliding blacks, per- cedures #5.35-1 and r5.35-2 and follow mitting entry of the assembly inte stepa F5.35-3 and e5.35 ' through i the crosshead. r5.35-7 for the second feed.
- 5. Insert the cdjustment screw sub- -
assembly (assembled per 3.40) through 5. 36 Sump and Bellows Boot Assemble to the 5 the hanger bracket and engace the ad- Driv
- Case justment knuckle by threading in with a counter clockwise retation (left Eefer to Drawings v5270-02, a5270-03 hand thread). Turn the screw assenbly and Figure =12.
in appreximately lE turns and then push the adjusteent screw down inte 1. Apply a thin coating of a2 cup grease the hanger bracket until the tcp ball en the surp trart a5, Dwg. 5 70-02) to bearing battoms in the hanger bracket drive case gasu t surfacc. Flace the bearing cavity. id8k" 00 th' sump gasket surface and 1
- 6. Insert snap ring a:6 (Ref. Dwg. 5270 press firmly, noting that the gasket 0-) into the snap ring cavity and will remain in pcsitien due to the ad-seat the ring against the bearinF by hesive properties ci the t'2 cup grease.
tapping around the inside of the ring . 2. By hant- hold tne surp a5 in position
.. , on the drive case and insert cap screws ed into the two top sump counting holes
- 7. Insert the universal shaft-pin suh- in the drive case. The One Feed sump assembly (assembled per 5.45) into mounting position is shown on Drawing the adjustment screw coupling guide A5270-02 and the Two Feed mounting as shown on Drawing 5270-04, tsing positions are shown on Dwg. *5370-03.
the handle stroke adjustment shaft 3. Insert two cap screws FS into the two sub-assembly (assembled per 5.40) as lower sump holes and start by handt a tool, engage the universal shaft- using tool #5.33-11, run the screws in, [ pin sub-asse .bly as shown on Drasing and using tool F5.33-8 torque to 35 l I 5:70-04 and turn clockwise until the Ib-ft. adjustment knuckle bottoms in the 4 If this is a Two Feed pump, repeat hanger bracket. Disengage the handle- steps 1, 2 and 3 for the second feed. stroke adjustment shaft sab-asse=bly 5. Turn the were shaf t using tool 5.33-12 and place on the assembly bench until until the crosshead is in the position required in tne further assembly of shown in Figure d12B. the Pump. 6. Place the bellows boot "9 on the exten-
- 8. Refer to Drawing e5270-01. Insert sion shaft $17 as shown in Figure al2A.
j three cap screw's #25 into tne hanger 7. Insert the bellows boot-extension bracket pins 825,and draw down evenly shaft into the drive case and screw the
! until they are snug 1/2 turn tight on extension shaft by hand into the cross-j bcch sides of the drive case. '.*h i l , head, as show in Figurc #12B. I' sin g drawing dow. and tightening thc cap an open end wrench, engage the extension i '
screws, obscrvc that the adjustesnt shaft through the sump bore and turn screw asse=bly t=5.35-7) remain, with the aid of a crc ss bar until the j f ree and do=> not binc. bellows boot-extension shaft is fully
- 9. Using f ecler pua v5.33-4, detsrnine threaded into the crosshead.
i s tne ,ap bete en the hanger bra ne: 6. .uply a thin coating of *2 cup grease on the circular groove of the bellows j nn and the h.ing c . cct sid.3. boot retainer plate i.16 and engage.the j v/ bellows hoot, compressing it to the I I 1
m rw 'n shewn in view E5. Helding 7 One plastic head mallet. f : ns riste "15 in pesition, insert ! One sleeve 2" 1.D. x 2-1/2" 0.D. x 8" ( ) s c rews rli into the sump and tighten icn; with <quare seceth ends. (_,/ wit- tecl "5.33-1.. 9. One bar 5/3" diameter x 3" long with
'. this is a Two Feed pum;, repeat square and smooth ends, steps 3, 6, 7 and S for the second 10. One sleeve 7/16" 1.D. x 5/8" 0.D. x feed. 2-1/4" long with square and smooth ends.
- 5. 3 7 C0"LETION OF THE L'PPER DRIVE CASE-ASS DSLY 5. 4 t. DIGITAL STROKE ADJUSTFENT ASSEMBLY
- 1. Turn the worm shaf t, using tool 5.33- Refer to Drawing 5270-04.
12, and observe that the upper drive cceponents move freely and do not bind. 1. Turn worm shaf t using tool until drive
- 2. Cover the top of the drive case until knucMe ( % at 1001 stroke.
the next asser.bly procedure begins. . Se sun ccmnter (23A for m & 238 for 2FD) reads 100% in counting block.
,, 3 c rsg7;n g y er ng p.e CASE COVEp 3. Insert flexible shaft (ul0) into shaft coupline ($13) inside of adjustment Refer te "rawing r3270-21, ;270-04 * * * "III*
1 P!aee tne cover gasiet iil2 on tep of The adjustment screw sub-assembly is new ready the drive case, being sure the holes in fr installatien in the drive case. Refer to tne gasket line up with the holes in 5.35-5 for installation instructions. t... drive case.
- 2. 'nsert the flexible snaft into the c'urlinc cuide a< sh e on Drawing
?!70-0 . Flace tr.e drive case cover "Il on the drive case as shown en
rawin c "52 70-01.
2 theck to be sure tne holes line up be- 5.46 DIGITAL M ROKE AD ESTMENT HANDLE SUB-ASSEMBLY tween tne drive case "13. drive case Refer te Drawing W -04 CN c a s'- e t rl2, and drive case cover ull. 1. Place the strakc adjustment shaft #9 in f ) ~5e drive case cover is- secured bv means its holding fixture on the arbor press (- ' _ of four cap screws ^10. with the shaft end up.
.. . 2. Place the bearinc #25 on the shaf t and press until the bearing bottoms against the shaft shculder.
- 3. Flace gear e6 (teeth up), sleeve e5 and 5.47 DurcoMeter P/D I Ft::np Dicital Stroke bearing "19 on the shaft and press AD icsi"EN AssEM3Ly until the gear bottoms against the i
lower bearing. , l 5.-l 2r r:rNCE DRm INCS 4 Flace lock washer *16 on the shaft with the bottom tang engaging the slot in the 32 i-i ?teltil Stroke Adjustment shaft. 3l..-- Sect ion Orientatien Assembly 5. Turn bearing nut #16 on to the shaft using tool n5.43-4 until it bottoms 5- < r- > P .0CEDC:'s rai, ASSEygty against the washer-bearing-sleeve gear assembly. Torque the lock nut tightly lean surf ace area ap :r2ximately 2' wide against tne assem W . Ged gear %. x -* <w is required. Cleanliness in observing that the gear is locked aa serM - is essential since any contamin- y ace aM C not rotate. ation o. the stroke adjustment bearings will Jsing t is c5.43-3 and #5.43-6, deflect result in early failure. one f the locn washer tangs into the closest matching lock washer tang slot. S. 4 3 NWWE') ASSEMELY EOUIPMENT AND TOOLS 6. Insert the shaft-bearing-gear assembly into the mounting block #22.
- 1. An arbor preas. with approximatelv 8a 1. Insert set screw #20 into gear #24, t5rnat depth and a capacity of 2-3 tons, noting that the set screw does not pro-h 0. W. hex socket ke, trude into the gear bore.
- 2. On. dri pin with a !!*" dians ter point f. Place the gear n2' en the counter shaft
( an arp ri xi :ately 5" ;enct
- >23A er B. (Single feed puep is 23A;.
,/]j . 'ni m nner vrench, two feed pump uses 23A and 23B)
(' )
'nr rme ene; Walet s -ruarc external 9. ? lace the counter-gear sub-assembly in t- -
th a nting block slet, encaging the s' ' %
- w . i! ! p e ., 3- y7 k.s : cear t u th bv -avinc the counter 21
' forward until the flange bottoms L Unwrap and examine the packing sut. There against the cross slot. (It may also are two types of packing that may be used.
't j be necessary to move the bevel gear 5.51 CHEVRON PACKING
\g forward on the counter shaft).
- 10. Remove the counter gear assembly in this position and tighten set screw *20 Place a male adapter ring, flat side dew.,
using tool #5.43-2 and repeat step #9, in the body bore and push by hand until the
- 11. Place the indicator plate #21 over the ring bottoms against the bushing. Place a mounting block #22, engaging the rec- pressure ring, with the Chevron pointing tangular protrusion window of the toward you, into the bore and push by hand counter with the rectangular slot in the until the ring bottoms against the male adapter ring. If the rings are cut, alter-indicator plate. Push against the slot.
ted diameter of the stroke adjustmeng nacely stagger the cuts as they are placed in the bore. Continue installing the rings shaft P9 and rotate by hand. Observe until there is room lef t for one more ring the bevel. gear tooth engagement by before it will overlap the lantern ring looking at the bottom of the assembly hole. Place a female adapter ring flat side through the mounting block slot while rotating the shaft. Observe the turn. up in the bore and push by hand until it bottoms on the pressure ring. Place the lan-ing of the counter numerals while ro-tern ring al3 in the bore and push until it t ating the shaf t.
- 12. Place handle 4 in the holding fixture bottoms against the packing. Place a calc _
on the arbor press. Start spin knob adapter ring, flat side down, in the body l a2 in the handle by hand, noting that bore and push by hand until the ring bottoms it is square to the handle. Inse rt against the lantern ring. Install the pin #3 through spin knob into handle. pressure rings, as before, until there is rocm luft for one more ring before it will i Press against the pin until it bottoms against the handle. protrude out of the bore. Install a female
- 13. Place the handle-knob assembly on the adapter ring. flat side up, in the bore and stroke adjustment sub-assembly shaft, push by hand until it bottoms against the Push the handle by hand onto the shaf t pressure ring. There should be a slight until the roll pin hele in the handle pertion of the bore exposed for the follo1.er is lined up with the one in the shaft. bushing engagement. Place the follower Rold the asser.bly in this position bushing *13 in the bore. Place the plunger
[N ) g while starting roll pin al7 into the handle and using tool #5.43-6, tap the in the bushing and, while pushing, turn the plunger in a rotational motion back and forth y/ as the plunger engages the packing until it pin until.it engages the shaft. Usin g tools #543.3 and *5.43-6, drive the. has fully entered the stuffing box. roll pin into the handle until it is 5.52 SOCARE SECTION PACKING 1/8" below the handle surface. 5.50 PLUNGER HEAD ASSEMBLY Place a ring in the bor'e and push by hand un-til the ring bottoms against the bushing. If The instructions that follow are for the the rings are cut, alternately stagger the plunger head shown on drawing #5260-03 and are cuts as they are placed in the bore. Continue typical for other plunger head constructions, installing the rings until there is room lef t for one more ring before it will overlap the lantern ring hole. Place the lantern ring The materials of construction used in the 419 in the bore and push until it bottons pump plunger head must be suitable for the acainst the packing. Install the packing intended service. The material reco mendations rings, as before, until there is a slight are given in ~PPI *s pump materials of construction Bulletin M25. pcrtion of the bore exposed for the follower bushing engagement. Place the follower bush-The plunger bushings #13, if they are carbon ing F13 in the bore. Place the plunger in graphite, are fragile and should be handled the bushing and, while pushing, turn the with care. The pump plunger, if it is metal, plunger in a rotational motion back and forth 1s super finished and should be handled with as the plunger engages the packing until it l has fully entered the stuffing box. care.
- 1. Slip each bushing #13 on the plunger 5.53 MOUhTING THE PLUN'GER HEAD ASSEMBLY TO THE and observe for a snug, free rotational PUMP fit. .
- 2. The pu=p body bore should be clean and 1. Screw in studs #16 until they are fully inspected for burrs or the presence engaged.
, 'i (! of scale.
- 3. Place a bushing #13 in the pump body
- 2. Using 82 cup grease, wipe the body gasket with a light coating and place it over the i
I bore and push by hand until the bushing studs firmly against the body. I i \g bottoms in the bore. 20
4 i 3. Lift the plunger head assembly and, en- 8. One 12" Adjustable Wrench. gaging the studs in the sump holes, push 9. One 10" Adjustable Wrench
- 10. Snap Ring Tool, Waldes Truarc -
~/ the plunger head assembly until it Internal Plier t bottoms against the sump.
b} 4 Insert studs a19 into the pump body.
- 5. Tighten securely s20 hex nuts on d19
- 11. Socket Wrench Set 3/S" thru 1" sockets studs. 12. Channel Lock Pliers
- 6. Turn the pump stroke adjustment by hand until the digital counter reads 100%. 5.63 ASSEMBLY OF DI APHRAGM BODY TO THE SUMP
- 7. Turn the pu=p motor coupling over by AND DRIVE CASE r
hand until the extension shaft, drawing
#5270-02 Part #17 is fully retracted.
Reference:
Drawing #5260-04, 5212-01
- 8. Place the gland #15 in the sump and and 5270-02 slide it over the studs d16.
- 1. Carefully inspect the Hydraulic
- 9. Screw the hex nuts v17 onto the studs until they loosely engage the gland. Plunger 86 for burrs or any residue
- 10. Turn the pump stroke adjustment by hand that may be present, until the digital counter reads O';. 2.' Holding the plunger by the button end,
- 11. If the extension shaft and plunger insert it into the bore of the dia-buttons are not flush, place a screw phragm body to insure that the plunger driver or dry bar behind the plunger is a free sliding fit in the bore.
button and, using the gland as a ful- 3. Remove the plunger from the bore, and crum, pr> the plunger towards the ex- place on working surface with button tension, shaft until the buttons meet, end up. Using two small pieces of
- 12. Place the split coupling, drawing crocus clcth or fine emery paper (to a5270-03 part r2, over the extension avoid injury to fingers) spread one of shaft and plunger buttons, chamfered the piston rings #5 just enough to side towards the extensien shaft, and slide it over the piston past the ca; the retaining rings #3 over the uppermost groove,and let it engage the coupling firmly in place. second groove from the button end.
- 13. Refer to Section 3.32 for start up and Assemble another piston ring into the break in procedures. uppermost groove as just described.
Turn the plunger over with the button 5.60 DIAPH R HEAD ASSEMSty end down and assemble the remaining two piston rings bf the method des-Y Reference Drawings: cribed above.
-- . 4. Apply a thin coat of lubricating oil 5212-01 Section Orientation Assembly to both the bore of the diaphragm body 5260-04 Diaphragm and Hydraulic Head 829 and the surface of the plunger #6 5260-01 Diaphragm Head and Check Valves to assist in the assembly of the 5270-02 One Feed Cross Head plunger into the diaphragm body.
5270-01 Two Feed Cross Head 3. Place the diaphragm body e29 face down on the work surface so that the open j 5.61 REOUISITES AND PROCEDURES FOR end of the bore is up. The body ASSEv3LY should be carefully and thoroughly cleaned. Inspect for burrs, sharp j A clean surface area approximately 2' wide corners or any residue that might be x t' long is required. Cleanline'ss in present in the body. asser:bly is essential, since any contam- 6. Holding plunger 86 vertically, with button end up, carefully insert the inn ion of moving parts in the Diaphragm
- iquid End Assembly can c ause' early f ail- plunger into the bore of the diaphragm a ure er inefficient eperation of the liquid body, letting it slide into the bore cnd. until it stops with the first pisten ring resting against the hub of the 5.62 RE0'JIRED ASSEMBLY EOUIPMENT AND TOOLS diaphragm body. .Using crocus cloth, fine emery paper or two pieces of wood to avoid injury to the fingers, com-
- 1. Drift Pin - 1/4" Diameter Point, approx-
! imately 6" long press the piston ring while manipula-
- 2. Hammer - Ball Peen, 14 ting the plunger until the piston ring enters the bore of the diaphragm body.
- 3. Screwdriver - 1/4" Blade, 8"-10" long 4 Pliers - Needle Nose - 6" long Slide the plunger gently into the bore
- 3. One 3/16" Hex Socket Key 1-1/2" long until it stcps with the next piston
- 6. One Torque Wrench with 1/2" Drive ring resting against the hub of the 0 - 150 lb-f t. diaphragm body. Repeat this procedure s) % One Tcrque Wrench with 3/4" Drive for each successive piston ring until T the plunger is entered completely into
) 0 - 450 lb-ft.
i (Q 23 4 y . , . _ . , _
t h.- 5nre of the diarbract tods. tegether by thc groeve in tbe split caupi nc. The external groove in
/,_syN 29 rrevisusly discussed in Sectien 5.36, the split couplinc should be at the end
(\ '
) : n. surp and bcIlow.s 500t are ecurted facinc the drive case. Helding the ceupling
~- - ta the drive case. halve 3 terether with ene hand slide tne re-
.: tnr diaphragm bcdy and nydraulic taining ring
- 7 :nto tae internal greovc in pluncer assembly still face down on the the sleeve. The connection is now cc=plete.
work surface, insert the 0-ring u14 into the recess as shown on drawing F5260-0 5.64 ASSEM3LY OT CENTER DIAPHRAGM PLATE TO THE . A generous applicatien of 82 cup grease DI APHRAGM BODY to the 0-ring before assembling will assist in keeping the 0-ring in place
Reference:
Drawing #5260-0 during the next step in assembling the diaphrage body to the susp. 1. Carefully exa=ine the center diaphrag: S. Refer te drawinc d5270-02. Turn the plate F3. See that all the holes.and digital stroke adjustrent and/cr the ports are clean and free of any chips or were shaft (*28 Dug. r3270-01) until foreign particles. the extension shaft #7 is withdrawn 2. Examine the hydraulic diaphragm 84. It inte the drive case. cust be clean with no particles of dirt or 2 'Jith the diaphrsc: bodv still resting foreign natter present, facc dovr. en the veri surface, note 3. Nete that there are eight bolt heles thru that there is a lo:ating pin "30 pro- the plate, and four smaller holes on the trudinc fro: the surface of the body. sn=e circular center line as the large Also nete the location of the port for holes. The four smaller holes are counter-the air bleed valve vo. At this point bored on ene side of the plate. This side have the rinc not a-1 available within will be referred te as the outer surface essy reach. With the air biced valve of the center diaparage plate 83. rart in the uppe rnest position, insert 4. With the center diaphragn plate resting on the elunger end of the diaphrag body edcc en the work surface, insert two of thru the hele in the su=p. watching the cap screws *28 thru two of the four carefully that the 0-ring "14 retains counterbered holes with the heads of the in place. The lecatine pin #30 should screws en the same side of plate as the line up and enter one of the bolt holes counterbores. Holding the center dia- [h in tne face of the surp. Hold the dia- phrag plate on edge with one hand, place phragr badv against thc face of the surp the hydraulic diaphragm 84 over the two ( s_ - ) and screw the ring nut u41 onto the cap screws with the diaphrag= bearing thrcaded particc cf the"diaphrage body against the inner face of the center dia-until it bears against the inner phrage plate. Using both hands, place
'eschined face ef the sump. Using a this assembly against the exposed face of drift pin and a hanner, er a spanner the diaphra to bofy with one of the ports wrench, turn the ring nut n;l by means in the edge of the center diaphragn plate cf the holes provided until the dia- in the uppernost position. Line up the phragm bady is solidly mounted against two can screws with two corresponding the sump ef fecting a tight seal of the tapped holes in the diaphragm body and 0-ring r14 against the outer face of screw then in bv hand until the center dia-the sumo. phrage plate is held securely in position
- 10. Using a screwdriver er lcng nose with the diaphrag: located between the two pliers, reach into the bore of the surfaces.
diarhrar= bodv and grass or encare the 5. Insert the remaining two cap screws *2S Pa:- n of the hydraulic niungcr r+. thru the appropriate holes and tighten all Pull the plunger out se that the button four cap screws securely, using a 3'16" is exposed outside of the body. Care Allen Wrench. Care should be taken to see must be exercised se that the bere sur- that the diaphrag and center plate are faces will not be marred. positioned to slide into the recess of the
- 11. Turn the digital stroke control and/or diaphragm body before tightening the four the wor = shaft by hand until the ex- cao screws.
tension shaft #17 (Dwg. a5270-02) is . moved outward from the drive case. 5.65 ASSEMBLING REACENT HEAD TO CENTER DIAPHRAGM 5e sure that the snap ring #7 is at PLATE AND DIAPHRACM BODY the end nearest the drive case. Ccntinue n.eving the extension shift
Reference:
Drawing 85260-01 & c5260-04
;utward until the button c: t!w sud 13 again t the butten en the hy- 1. Inspect the diaphrag head *10 carefully to draulic plunper. Take the two see that it is free of burrs, loose par-
, sj ticles or any residue that might be pres-
[ j ralves of the split ceupling c; ent. Alse be sure that the diaphrag: u9 is l ( /Dwc. 5170-03) and engart the twc l
'7 / b.t tt n> s. t .a t tr.ey .i.. be hwie clean and f ree of dirt.
e l
Durec::ctor P/D I PUMP DIAPHRAGM HEAD TIGHTENING SPECIFICATIONS O TORQUE SPECIFICATIONS Diaphragm Bolt Tightening Head Sire Size Torque - Ft. - Lbs. 1" 9/16 - 12 UNC 150 1-1/4" 9/16 - 12 UNC 150 2" 1/2 - 13 UNC 106
, 7 o e . .
A 3
. 4 5 V
8 2 FIGURE 13 25
l i
- 2. Hsin ne the diaphrac. head r!n en cdre body 845, exhausting back into the reservoir with rne hand, place *the diapuragn into (sump) thru hole 8 previoed in the diaphrac:
the recess in the diaphrage head with the body.
\ cencavs face of the diaphrac positioned teward the diaphra p head. Hydraulic 011 is prevented frc: leaking to the outside by ms.in. of an 0-ring #47 contained in Note that the corrugated surface of the the upper portion of the body 848 at the relief
< diaphrage is in the position shewn on valve.
. Drawing =5260-01. Twist the diaphragm in the head until the The relief valve is opened by an over-pressure bolt holes are in alignment with the bolt condition as described in Section 4.13. holes in the diaphragm head. Also the holes corresponding to the s= aller inter- $ mediate plate retainer screws sheuld be Assembly Instructions: coincident with their position. Insert tse ef the cap screws 611 thru the holes 1. Carefully inspect the pressure relief valve parts i in t he diaphragt head and ths diaphragn. to see that they are clean and free of any dirt New assettle the diaphrap heal te the er Icese particiss. All eerner must be f ree of anter ?!an linine ur tnv :wo cap screws burrs.
-ith ccrrerponding hcles in thc center 2. Heldinc ths WJy *45 in cne hand, insert the plan. R:ch clcsely te s<e : Sat tFe elenent * -3 into the bcre of the body with the _
recess in the diaphrag: head slidea ever chaefer end of the element resting against the late. and tha: the ports in orifice end of the body. the thc center p/ head arc in the vertical dig nrag 3. Centinuing te hold the above assecbly in one hand, p sitien. Thread the two c u screws in place the spring 84, into the bore of the element a.- far as pessible by hand. Insert the #43. Place the spring follower 845 into the bore rcnaininc six cae se'rews and screw ther of the body with the center recess area up, in :s :ar as pessible. Usinc a socket 4. The set screw 150 is now threaded into the body e c :cr u wrence, tighten tb eigh; being sure the dog point cf the set screw engages 5c. - . .leving the procedure shos 1 in the center recess area of the spring follower. i :5. c Rrnraer head tightening procedure, 5. Assemble the 0-ring 842 inte the groove area of Tac k 2 Tighten beits gradually, the body vaS near the orifice area of the body. , % al:=rdi:ine frett cne to another fellewinc 6. Assemble the 0-ring ^47 onto the body F48 near the m ence indica:ed until the rerer- the set screw *50. I menced torque value is reached for earh 7. Screw the lacknut 49 cnto the set screw f50 I bc!t see Figure n13. .
- 8. After adjusting the relief valve to open 100 above the oeprating pressure of the pump, screw 3.66 PRISSME RELIEF VALVE ASSEMELY AND the locknut tightly against the body using one INSTAliA 2 wrench to kecp the set screw from turning and another to tighten the locknut. .
Twference: Drawing c526C-0; 9. Install the gasket 46 onto the body and thread , 1" & 1-1 ;" Heads on the cap 851.
- 10. The relief valve is normally installed in the The pressaie relief valve concists of set icwer right hand part provided in the diaphrag i
screw =50 which bears against the spring body. Right and left hand are determined from fellower ne5 and can be locked in position a position facing the outboard and of the by means ei the locknut 849. When tne set diaphrage Itquid end. screw "30 is turned clockwise, it caases 11. Insert the relief valve into the lower right the s; ring folicwer $45 te cave inward, hand part as shew. en Dwg. 5260-04 and screw it compressine the spring 844, increasing firmly in place, tne :c :s against the elemen: 843 which 12. To adjust the pressurc lower, loosen locknut e49 seats against the edge of an erifice and turn the set screw $50 counter-clockwise.
=achined in the end cf the body 48 Observe tne gauge pressure and continue to in: easing the force required to move the adjust the set screw until the desired setting element fec: the seat opening the valve. is obtained.
k* hen the set screw #50 is turned counter- 13. After adjusting the relief valve to the desired clockwise, it allows the spring #44 to setting, screw the locknut tightly against the move outward decreasing the force against body using one wrench to keep the set screw from the element #43 reducing the feree turning and another to tighten the lockout. required to cove the elecent from the seat, cpening the valve. 2" Head The inner:cs: Lnd of the relief valve is
/" sealec int. ne diaphrage bccy n29 hy Referunce: Drawinn #5200-0t.
(N. seant :: at 2-rinc se2 so tnat when the valvc is ::ened t5e hydraulic cil passes
.hr. Ins crifa;= past' the 4e: ent n;3 For operation of the pressure relief valve, 5"" S'" 13' **I2*
an : : : :- the hcies previced in the h
- 5. Fill the diaphras:t head with oil, usin;t Assembly Instructions:
y the same grade oil re=oved, until the hy- ' 4 draulic chamber is full to the top of the 1. Carefully inspect the vacuu: valve parts to see air bleed valve port. that they are clean and free of any dirt or any
- 6. Keplace the air bleed valve and plug u7 loese particles. All corner cust be free of Figure el5. burrs.
- 7. Start the pump and observe the gauge pres- 2. Press the ball seat insert #59 into the bore sure needle swing. of the adjustment screv #54 being sure the E. Shut off the strainer, tank supply, or iso- chamfer side is up.
lation valve in the suction line. The pu=p 3. Install the 0-ring #58 in the recess groove will now behave as described in Section 4.13, of the 0.D. of the adjust =ent screw. Insert "when suction lift or starved suction 0-ring 857 into the recessed area of the ball conditions exist". seat of the adjustment screw.
- 9. Observe the gauge pressure needle swing and 4 Place the check valve ball #52 on the ball lightly depress tne vacuum valve adjust- seat 0-ring #57. Press the ball firmly by ment follower *27 until the =sximum pressure hand against the 0-ring and with a ground has been obtained. The relief valve pres- tester check to be sure the ball is not surc, as set by the factory, should'be 101 making contact with the metallic portion of above the e;erating pressure sta: ped on the the adjustment screw or the ball seat insert.
na:c plate. The snubbed gauge reading 5. Install the spring v56 into the bore of the should net exceed thjs setting. body s:53 being sure it contacts the shoulder IC. To adjust the pressure lower, loosen jas . portion of the body orifice. nut "33 and, turning the adjustment screw 6. Place the ball #52 in the bore of the body "39 counter-clockwise, lightly depress the so that it rests on the spring. vacuu: valve adjust =ent follower and observe 7. Thread the adjustment screw sub-assembly th+ gauge pressure until the desired setting described in Ice = 3 ir.co body being sure is reached. equal ccepression is made on the ball and spring. Thread the adjustment screw all the The methods outlined are not exact and are way into the body and then turn five full intended as a rough estimated relief valve turns counter clockwise. ad,ustment. If closer settings are re- 8. Insert 0-ring F62 in groove area of body near r cuired, a hand-operated hydraulic pump can the tep and install 0-ring #54 in the recess g h cennected te the bottom diaphragm head area of the bcdy near the adjustment screw I pipt thread connection and, while the area. d pu=p is stopped, the hydraulic chamber can be pumped up until the relief valve 2" Head setting is observed on the pressure gauge., For operation of the valve, see Section 4.13 5.67 VACUDI VALVE ASSET _Y AND INSTALLATION vamm va me nism condsts of tre adjustment follower (27) having a
Reference:
Drawing 3260-04 milled slot in one end that engages the 1.- 1-1 4" Eeads adjustment nut (24) wnich in turn is threaded onto the stem portion of the peppet (15). The poppet seals, by means The vacuut valve cechanism consists of an of an 0-Ring (IV; against a machined seat adjust:cnt screw (#51.) with ball seat in- on the body (IS) of the valve. A pin (21) sert (<r59) pressed into the bore of the press fitted thru the poppet stem rides adjust:ent screw, and an 0-ring inserted in opposing slets in the body (18) and int' the adjust:ent screw. A check valve prevents rotation of the poppet when the ball (#32) seals against the 0-ring. A adjustment follower (27) is being turned. spring (=56) is retained at one end by the The ccepression spring (22) is retained shoulder in the body and at the other end at one end by a shoulder in the body and by the check valve ball. at the etber end by a washer (23) which bears against the adjustment nut (24). The above assembly is retained by means of the adjustment screw which threads into the body. The above assembly is held into the body A clockwise rotation of the adjustment screw (18) by meanc of a washer (19) and a re-8154 ccves the ball #5 into compression against taining ring (20). A clockwise rotation the spring 856, increasing the force necessary of the adjustment follower (27) moves the te cpen the valve. Ccnversely a counter- adjustrent nut (24) inward on the poppet cicckwise rotation of the adjustment screw stem, compressing the spring (22), in-
, allcws the spring to extend, decreasing the creasing the force necessary to open the fercs necessary toopen the valve valve. Conversely, a counter-clockwise rototien cf the adjustment follower moves
([f the ad'ustrcnt nut outward on the poppet ste:, allowinc the spring te extend, de-creasine the ferce necessary to open the valve. ,, I
M :iwinc :. held the areve asstrably in one Tb pressure relief valve censists of an NnL Nae = th Im r Ndy 2 m the adjus: tent screw n36 which bears acainst element and sprug, entering the externally the sprinc fellower 'G7 and can bc locked I threaded ccd of the upper body into the in-in p?tition be re.tns cf the iam nut r38. t ernally thNaded portien of :he lower bcdy.
- When the adiu'strent s c rew is' t urned c lock- ' s -crew :5 twe sectiens together by hand vist, it c[uses the s,rin:, follower tc m3ve as t yhtly as possible. !l sing a wrench or inward, compressing :ne spring *33, increas-ing the force against the element #40 which vice, hold the hexagen-shaped portion of the seats against the edge of an orifice valve and with a channel lock pliers (5.62-12) machined in the end of the lower body #32, or a Snall pipe wrench grip the cylindrical p rtion of the upper body and screw the two increasing the force required to move the sectiens tightly together.
element from the seat opening the valve.
- 6. Slide the 0-Ring #34 over the cylindrical end When the adjustment screw v39 is turned f the asse= bled relief valve, carefully counter-clockwise, it allows the spring #33 ver the external threads on tne lower body te move outward decreasing the force against and into the groove provided against the face the element reducing the force required to of the hexagen portion of the lower body.
reve the element free the seat, openine the y g y ,, Masking tape cay be wrapped around the threads to insure against damaging the 0-Ring in The inner =0st end af the relief valve is asse=b1v, sealed in:o the dianhraer body c20 by twans ' Assemble the 0-Ring r31 into the groove pro-ef an J-7.ing c31, se : hat when the valve t' viced in the end of the upper body. - opened the hydraulic eil casses thru the 8. Screw the ja nut ^39 onto the adjustment orif ae past the e'.e ent 840 and out thru m ew 139 until it is nearest the head enu the holes provided in the lower bcdy 832, of the screw. Screw this assembly into the exhausting back inte the reservoir (sump) threaded hole in the upper body until the
- hru N-les previded in the diaphrag i body. reunded or threaded end of the screw con: acts Hydraulic cil is prevented f ree leaking to the sprinc fellower "37.
the outside by means cf an 0-Ring ':34 cen- C. Af ter adjusting the relief valve te open tained in : groeve in the upper 'odyo d35 of at 105 above the Operating pressure of the the relief valve. Another 0-Ring "36, con- pump, screv the ja nut tightly against tained in the spring follower *37, prevents the' lower bedy using ene wrench to keep the leakage ef the hydraulie oil past the adjust- adjustment screw frem turning and another [h ent screw :0 the cutside. to tich:en the ja. nut. This will prevent the relief valve free losing its setting. ( ) j _he A relief valve is opened by an over-pressure 10. The relief valve is nor= ally installed in condition as descri5ed in Section 13. the lower right hand port p'ovided r in the diaphragm body. Right and left hand are determined from a oesitien facing the out-board end of the diaphrag: liquid end.
- 11. Insert the relief valve into the lower right hand port as shown on Drawing p5260-04 and screw it firmly in place using Assembly Instructions: an appropriate wrench.
- 1. Carefully inspect the pressure relief valve Setting the Pressure Relief Valve - Refer to parts to see that they are clean and free of Drawine ' 5260-04, any dir er loose particles. All cerners nust be free of burrs. The pressure relief valve is normally set at
- 2. Assemble tne 0-Ring @ inte the groove in the factary to relieve at a pressore 10 per the spring follower "3' Af ter the n-Ring is cent hirner than the intended operating pres-installec. apply a light coat of lubricating sure of the pum:.
oil or c2 cup grease tn the 0-Ring. Holding the upper body t'35 in one hand, insert the Sheuld it beecte necessary to change the set-l spring follower into the bore of the upper ting of tne pressure relief valve because of a I body with the hole end outward. Push the change in pumping conditions, the following spring follower down into the upper body. procedure should be followed:
- 3. Still holding the upper body *35 in one hand.
insert the spring P33 into the uppe- body, 1. Turn off the power to the pump. making sure that it enters the recess pro- 2. Remove the plug 87 and air bleed valve vided in the spring follower *37. body #1 shewn in Figure d15.
- 4. Holding the above assembly vertical, place the 3. Remove the outboard pipe plug in the side element 640 over the sprinv. beine sure that of diaphragn body "29. .
the saatinc end ef the element is smooth and 4. Install a shut off valve and a snubbed
' (s ;f clean, ,
presnure gauce with a maximum range well above the pump operating pressure stamped on the pue; nace plate. into the side of (7 j . the diashrac. body. H
l i As indicate ' on the graph, Figure #14,the Assembly Instructions:
/
A \ vacuu valve is shipped frem the factory with the setting at 5 turns counter- 1. Carefully inspect the vacuu= valve parts (v ) clockwise frc= the =axi=u: inward adjust-cent. The valve is designed so that one to see that they are clean and free of any dirt or loose particles. All cor-cc=plete turn of the ad;ustment screw in ners must be free of burrs. either direction will cause a change of 2. Assemble 0-Ring #16 into the groove in approximately 1 P.S.I. A. required to open the conical or seat end of the poppet the valve. f15.
- 3. Insert the poppet #15 stem first into If, during the operation of the pu=p, it appears that the vacuum valve is not the body #18 from the end with the conically machined seat. Twist the allowing oil to flow fro = the reservoir g g g (su=p) to the hydraulic head, evidenced by g g a fall off in pu= ping capacity, slowly g
turn the adjusteent screw out (counter- , clockwise) and listen for increased pump- gg ing action in the check valves. the slot in the side of the body and into the hole in the poppet stem. Using a If the adjust n screw is turned out too ha=ner and drift pin, cap the pin #21 far, the vacuu= va'.;e will allow too much thru the poppet ste= until it is equally cil to flew fro: the reservoir to the hy- engaging both of the slots in the body. draulic head, caasing the diaphragm to Check to be certain that the poppet botto= against the forward li=it surface moves freely in the body. creating a pressure condition f. hat will blow 5. Stand the above assembly on the poppet the relief valve. If this condition occurs, end and drop the sprinF #22 into place. slowly turn the adjustment screw inward un- 6. Insert the washer #23 into the body, til the relief valve ceases to open. Evi- making sure that it passes over the dence of the relief valve blowing can be de- poppet stem and down against the spring. tected by a noticeable agitation in the hy- 7. Assemble the 0-Ring #26 into the groove draulic oil contained in the reservoir in the adjustmen follower #27. Insert (sump). the adjustment nut #24 into the body and A s.
~~ . m~......y~., using the adjustment follower e27, en-
/
~ ~ ~
\ , gage two flats on the adjustment nut with
( l '\ the slot in the adjustment follower, and
; .\ screw the nut onto the poppet stem until
.[ T" ~
it stops. Ie \ 8. Drop the washer #19 over the protruding j[' j
~k-
.N
'~
slotted end of the adjustment follower and into the recess in the body #18 of the N valve. f$ m
.s.-e ' 9. Using a snap ring internal plier, insert i a-the snap ring #20 over the protruding stem of the adjustment follower and in-
$,.,, , , e to the recess in the body, sliding it down U H
- O' W , until it engages the internal groove in pru - tem th bWy.
- 10. The vacuum valve is normally installed in The vacuun valve is ner: ally set at the the lower left hand port provided in the factory as shown in Figure 14. The set- diaphragm body, right and left hand being ting is based on a possible lift condition determined from a position facing the out-t of approximately 10 feet, including the board end of the diaphragm liquid end.
l internal hydraulic losses and dyna =ic 11. Insert the vacuum valve into the lower left t fluid velocity line losses expected in a hand port and screw it firmly in place, j vertical line when pu= ping witer at 700 F. using an appropriate wrench. If the adjustment screw is turned in too 5.6f AIR BLEED VALVE ASSEMBLY AND INSTALLATION far a malfuttetion can occur, and a loss in
Reference:
Figure #15 and Drawing #5260-04 pump volumetric efficiency will be evidenced. r (See Section 4.23 Possible Operating Dif- 1. Carefully inspect the air bleed valve parts ! ficulties - Diaphragm Pu=ps). to see that they are clean and free of any
- l,' ( dirt or loose particles. All corners must
- N be free of burrs.
f \ x /
?
29
1 l
- 2. Inser: U-C nr $5 into the 5cdv at: insert 3. place .enta:r.er nenea:5 the sump, and
! e- L :o: N :nto the seat C. Melding the drair the sump by removing the pipe plug ' [n' hady in ene hand with the threJded end ell. Pr wine '5270-OL Re:Nve tbc plug l '
up..drm' the ball r0 into tN epenin:;. "- .G: g r. - ! ? . fre tha diaphrace body. heinc sure that 1: dr.ps inte : % !. ole as the n .'in t% weket vench aA des-shown in ::g re 15. 'rN b. . M-i d av. . rcrave the air bh ed va!ve. D etove the plug from the _ :- bo:te: M th. diaphrag: hody to com-
"' 'Jf ~
1 plate:y Jrain the cil from the diaphragm
. . _ 7 body.
4
% $ t, , _2 . Refer to Drawing #5260-04. Remove pine
; K . { [ Mh, , '
- -i/ plug al from the center plate. Flace L
- f W/t i a cont:iner bsnesth the center diaphragm
-- :t h'. i j'*--- plate r3. Receve the pipe plug from the 1 3 - ',- butto- of the center plate to drain the
' w' 7 . ' J. oil frem the intermediate chamber.
V' e.
"*m f 5. Re:er :. Dr.wir.g "5.M-01. Remeve the W pine ire- t'e suctio t and discharge c eck valvs. beneve the :np screws all 5
v--. ' rem : w lisuid . nd. Lt.ing sure to hold the d:aphr ge h ad 610 to prevent it _ f rem t alling when t he last cap screw is
- 3. Screw sea: #2 with 0-Ring enc first inte the removid. Set the diaphragm head and body wing a screwdriver or the edge of a check niec as 3emb!v aside. At this coin un:il it is tight. The slotted face of peint. the prnro s diaphragm *9 can be the seat will be very neariy flush with the remove 3.
end ef :n.e body. 6. Refer t.' Drawing r5260-04. Re=ove the I. . InstC 1 C-Ring u6 into the groove in thc feur ce ser.w. e29 from the diaphragm bocy . Care should be exerrised shen hydraulic head toinc sure to hold on to passin: th 0-Ring over the threads in the the c.cter dia;hrace plate so that it body. A ;:ece of masking tape can be does not fall when the four cap screws wrapped around :ne threads so as to prevent are re vved. ..** this point the hy-the 0-2:ng from being cut or otherwise draulic dia:heran v4 can be removed. N danaged. - g, place tr.e dama.:ed diaphrag: with a j 5. Insert :ne M r bleed valve into the port new one, and re-assemSle the diaphragm y/ in the u;per side of the diaphragm body liquid end as outlined in 5.6!. and 5.65 629. "nng the connector.end of .* 5/8" above. socket anc a socket wrench with a 1/2" 8. Recont.ect the suction and discharge square connecter, screw the air b'eed valve : heck valves into the piping system. sssensl* tightly into the port- 9. Refill the hydraulic reservoir and the
- 6. As se .b h t he 0-Fing t8. Figure 15. into the hydreu;ic cha-ber as described in croeve in the plug **. using care when see:fon 3.33-1.
passirg the 0-Ring over the threaded portion 10. Peplace the plug in the bottom of the of the plug. Masiing tape wrapped around center diaphragm plate 83, Drawing the :hreads will prevent danage ts the O- *i26C-04. Ring. !!. Withdraw the hydraulic plunger d6 to the r.ar liett of its stroke (toward 5.69 REPLACD'E'r OF DI APHRACv, AND FI'- LING THE the drive case). This can be done by I.NTLDiCDIA'_ C W:bCR turning the manual streke centrol and/or the ecupline vnnecting the motor to the neference: ~;rswings F5212-01 and c52H-04 wn.n snaft.
- 12. This chamber should be filled by the
- 1. To rem 0ve ei:her of the two diaphrag.E fer custocer with ncn-corrosive solution
! replacenent, first be suru the pump is cc=patible with the precess fluid. turned off. Se sure that there is no However, unless otherwise specified by pressure in any part of the diaphragm the customer. this chamber is shipoed liquid end. I'nder no circumstances from the factery filled with mineral oil should any of the plugs be removed from or co=rnercial grade ethylene glycol base the diaphragn liquid end when the pump anti-freeze. is operating.
- 2. Remove the sur p cover #12 by taking out Fluid Capacity-Intermediate Chamber the fcur cas screws P11. Take care that ***M-Sin P C U,d riuid ec s the gasket =13 is not damaged when re- ! .. _
/., } cavinc :.e ecver. ; ..
a ,i 3 1 in 57 I i \,V. , 127
.s 30
- 13. Slewly neve the hydraulic plunger foreard Thread the ball stop fl3 inte the body F12
., ( awa.r fre- the drive case) by turning the until the ball stop bottems the bo.d.v p(,
manaal strekc adjustment or the coupling threads. { } canne,;tinc the meter and the verm shaft.
\~/ Uteh the hele thru which the intermediate lor 1-5/8" and 2" Head chanh r was filled fer the liquid to rise. Referen:e: Drawing 5260-03
'Inen the liquid has risen to the level just at the start of the threads in the port, re- The check valve seat 87 and ball #6 are the plaec the pipe plug bl.
heart of the valve and should be in good con-Note: The above filling procedure should be done carefully, as any air that might not be expelled from the intermediate The seat #7 and ball stop #5 are press fitted into their respective caps #1. To remove the chamber can seriously affect the per-formance of the pump, ar.d full pumping seat, or ball stop. the cap should be placed capacity cannot be obtained. in an arbor press with the threaded end up. Place a bar of suitable diameter with square 1 4rlare the gasiet *13 and the sump cover ends threugh the internal threaded diameter
>!: ard tighten the feur cap screws ell.
b pu r is acain ready for operation. until it bears squarely against the ball reat/ stop. Presa the ball seat / step fro: its cap. 5. '; U L i F /,9FEMELY Reclare the ball seat /stop with a new com-ponent in the same position as re=cved and _ T h : terial, of construction used in the press until it is seated firmly in the cap. chect valve rust be suitable for the in- The press fit of the seat in the cap acts as a metal:ic interference pressure seal, and it is tended service. Material recc=cendatiens important for the proper operation of r W pump are given in Bulletin 725, Materials of ConstractiJn. that the ce=ponents be clean, free frem cor-resion and/cr other defects in the interference
; . end
- 1-1/4" head area.
Referen:e: Drawing 5260-01 Inspertion of the ball should reveal good spherical gueetry, within .0005", and the T: e check valve seat FIS and ball #1: ball surface should be smooth and free from
- . r . the heart of the valve and should pits er etching caused by corrosion. Dis-
/
/4 \ N in gecd ccndition er the p2:p will c 1 ratien will not harm the check valve net eperate properly action and should not be considered cause
( ) ' for rejection. The ball may be seated in The sea #15.is press fitted into the the seat by placing the ball on its, seat bedv 12. To remove the seat. thread in the arbor press. Bring the ram down on th[ ball stop #13 cut of body #12. Place top of the ball and firmly bear down on the a bar cf suitable diarcter with square 5311-ends through the internal threads / diameter until it bears squarelv against the ball Rap the top of the arbor press ram with a seat. Press the ball s' eat out of the brass hammer, causing the ball to form its bedv.' Replace the ball seat with a new se at. (If ceramic balls are required, it is cc penent in the sa=e position as re. eesential that a dum=y steel ball be used
-)ved and press until it is firmly seated for this operation). The ball may now be in the body. The press fit of th'e seat lapped in its seat until it is obvious that
;n the bedy acts as a =etallic inter- the ball is bearing evenly on the full seat furun.c prussure seal and it is i=per: ant rerimeter evidenced by continuity of area er the peper eperation cf the purp that on the teating surface.
ths corp:nents be clean, free free cer-resien anc/cr other defects in the inter. Eefore asse=bly of the valve, the cap screws (, ference area. c3 should be examined fer cerrosion. If any corrosion is evidenced, they should be re-Inspection of the ball should reveal good placed. spherical geometry, within .0035", and the ball surface 'hculd s be smooth and free *'
- hen assembling the cap-ball stop and cap-frc: pits or etching caused by corrosion. seat sub-assemblies to the body #2, it Discoloration will not harm the check should be observed that the cap-seat sub-valve actica and should not be considered assembly is inserted in the bottom side of cause for rejection. The ball may be the check valve coincident with the bottom seated ir. the seat by placing the' ball on of the cast arrow on the side of the body.
l its seat in the arbor press. Bring the ran dawn en top cf the ball and fir:lv ' The remaining assembly procedures are M r down en the ball. obvious when referring to Drawing 85260-03. I i ! %) J
.3:E-2 _
, f $
i e
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,jj,f,h, t/ dy
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n A \. 1:
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i' _ M'44 [Max __ N_ k'9 :h I'M @Xh' INb-
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i M;i li: (ioj -,
'i: IM 1 l L:> ,
., , ' e
- l. p I
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l l '/ i - Ek ! s { l y cAstm) ll A m - - .,t7 u - - :, ,-- ,
.c.y i
6 !; ' 1 x l p..- :l: L__; .
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\ 3 1y
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- h(7 !
9 : I
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Q:ff, I
# f trcTioN A A v'EW B B l
y coi At cruct
~~
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NUTECH COMMUNICATION RECORD
< Persons involved: Tom Larsen Date/ Time: 11/1/82 11:50 Recorded By: D.S. Rosenberg Company: Rexnord,Inc.
G Teleconi." "o. 414-784-1090 Copy To: 1 O Meeting / Location Route To: File: CPC-09-T08 Page 1 of 1
SUBJECT:
Thomas Pump Motor Coupling Model 101-DBZ The Hydrazine Pump / Motor Couplinc is manufactured by Rexnord Inc., Mechanical Power Division, Couplino Operation, in Warren, Pa.
- 1. The Model 101-DBZ couplino has no non-metallic parts.
- 2. The coupling requires no lubrication.
a .. . l l I O l QEP-005.1-0C
NUTECH COMMUNICATION RECORD i
/Q\
Persons involved: Levy Pearson Date/ Time: 11/1/82 Concany: Mobil Oil Corporation Recorded By: D.S. Rosenbero O Telecon/Ph.No. 703-849-3000 Copy To: O Meeting / Location Route To: File: CPC-09-T09 Page 1 of 1
SUBJECT:
Mobil Gear Oil 636 Mobil Gear Oil 636 has been subiected to camma radiation. Significant degradation of the oil does not occur until a total dose of lE08 RADS is accumulated. Replacement of the oil is recommended before this exposure level occurs. J . I l l QEP-005.1-00 [
NUTECH COMMUNICATION RECORD n Persons Involved: David Walters Date/ Time: 11/1/82 3:30 V Compar.y: Garlock, Inc. Recorded By: D.S. Rosenbero O Telecon/Ph.No. 315-597-4811 Copy To: O Meeting / Location Route To: File: cpc-09-T10 Page _ J '1
SUBJECT:
Gar]ock Oil Seal For Hydraz!n' _ve Assembly The Garlock Oil Seal is j_d- .le rubber which is held in place by stain 7 .etainers. i O' .. . 4 9
\
v QEP-005.1-00
J RX TLX: #
'BECHTEL ARB
- I REL ELEC EUCD lATTEdTION: MR. PILL DEJONG CC: JEFF PAYNG l
RE: HILLS MCCANNA S.O. 1YF882844 RASED
'.ld-FT 2. ON LOAD MOTOR INERTIA ACCEL TIME AT0F 70 0.0044 to FT. LB AND ROTOR INERTIA 0F 0.100 'tTR PERFORNANCE CURVES AT 70 VOLTS.. VOLTS SHOULD BE 1.15 SEC BASED ON ,
CEGARDS lARY f. . UNEELER RG0/JLH hUCLEAR PRODUCT SPECIALIST RG0/JLM
\
fLEC EUCD \ ) (kCHTEL ARB .- - ine 171633 Disconnect - Connect 81 Secs Listed 16:34 EST 08/17/82S' l l. l l l k- - - l
- mm_a mmso m ,as-,,amm. u--.mm,.a.a-,,a_m-w_ mm--mm, n,a,.. m m_a 4 a.a- ,-n.,,a1a:__2 -ama_,_m+___a,_;_m ak aa a u___._, _ ,,_ _ , _ _ _ ,,._- _a,__u slam _, _a_, .a,_;,a _sw, i
I i I I l@ I i 1 I i l J s I 1 l Reference 11 I (Deleted) . I I l9 l 1 1 4 i I I i I i i i I e 9 i
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Reference 12 i Radiation Effects on Organic Materials in Nuclear Plants, EPRI NP-2129, Noverber 1981
)
i I I l [ f l O
A l i i i i i l l' l I
- l l 1
i Reference 13
~
i Midland Plant, Units 1 & 2, Environmental Qualification Report, VoDune 1, Revision 1 2 I l. e I ( i 1 ( { I i i l I t 1 4 l
NUTECH COMMUNICATION RECORD
/N Persons involved: Steve Maurer Date/ Time: 2/1/83 12:15 P.M.
( Com:.a r.y : ppI Div. of Durion Co., Inc. Recorded By: C. W. Allen O Telecon/Ph.No. (215) 675-1600 Cocy To: O Meeting / Location Route To: File: CPC-09-T Page 1 of 1
SUBJECT:
Positive Displacement Pump, Model No. J1-15087-10P 1 Dwg. No.: 5221-12, Sheet 1, Revision D (Enclosed in Reference
- 3) - Item No. 41, Part Description - Throat Bushinc. The Gr. III is a commercial name for a Carbon-Graphite (Epoxv Resin Imorec-nated) compound. This compound is apolicable for service temo-eratures up to 500 F. 0 A test conducted by Hills-McCanna has demonstrated the chemical resistance of this material by bathing the Graphitar, Gr. III in a concentrated sulfuric acid bath at room temperature for a period of eleven (11) days with no accre-ciable degradaticn observed. __
/
( ) 2 Dwg. No.: 5221-12, Sheet 1, Revision D (Enclosed in Reference
- 3) - Item No. 51, Part Description - Slidino Block. The Slidina Block is fabricated from Superoilite. Supercilite is a brass-bronze alloy. As a result it.can be concluded that the manual' stroke adjustment contains no non-metallic components. _
u((N .. '/' NS5 ' d'h5?$_% f',ID"" 1.i" :52,7 J C- '. c
' hi$ Yh N.h??5bh,...:.- *h
*h?hYf:A: ~ V?t:- '
- --f, . -
,g l
/
l l l U I QEF .rGS.1-00
i Reference 15 Rotork Qualification Test Report 7220-M123C-105-1, Wyle Laboratories Test Report No. 43979, Rev. A, October 24, 1978 (Retained in CPCo Equipment Qualification Central File No. M-123CC) I f 1
.- . _ _ .- . - . -. - . - - - - - . -- .- . . . . _ . _. . - . . _ - . = - --
I i i l i Reference 16 i Radiation Chemistry of Monomers, Polymers, and Plastics
, by J. E. Wilson, Publisher Marcell Dekker, Inc., 1974 I
i e I
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