3000 SERIES DIAPHRAGM METERING PUMP

Transcription

1 3000 SERIES DIAPHRAGM METERING PUMP Precise metering begins with precise design

2 MP3000PR 001 to 010 Plunger Pump Updated June 2012 Precise metering begins with precise design Choosing the right metering pump may seem like a straight forward decision...but in industry today there are often pumps that are either under-specified, so the job is not being performed efficiently, inadequate for the duty...or over-specified. You need to be looking for the right pump at the right price by making sure you are specifying the right pump for the job. We supply Australia s only manufactured range of metering pumps to suit the right application to a remarkable range of industries. For more than 45 years there has been one name synonymous with quality, accuracy and reliability in metering pumps...and this is Acromet. Laboratory Accuracy, Industrial Reliability Proudly manufactured in Australia, every piece of Acromet equipment is the product of leading edge technology in design and manufacture. Our commitment to our own in-house R & D, our patented designs, plus our precision manufacturing, has built the Acromet reputation for laboratory accuracy and industrial reliability. From the very first stages of design and specification, right through to the delivery of each finished product, and our after sales service, Acromet quality is never compromised. Heavy duty credentials You will find the Acromet name working in some of the toughest industrial applications. From water treatment...to oil refineries...to mining...to petro-chemical installations wherever an environment demands outstanding performance and equipment durability. Australian Owned Plunger Pump

3 MP3000PR 001 to 010 Plunger Pump Updated June 2012 Plunger Pump

4 MP3000PR 001 to 010 Plunger Pump Updated June 2012 Contents 1. SAFETY General Mechanical Precautions Electrical Precautions INTRODUCTION INSTALLATION Location PIPING General Suction Discharge Piping Arrangement OPERATION Before Starting After Starting CAPACITY ADJUSTMENT MAINTENANCE Pre Maintenance Cleaning Lubrication Suction & Discharge Valves V Packings (Packing Seal Item 5) Capacity Control Zero Adjustment TROUBLESHOOTING SERIES METERING PUMPS Drive End Model 3000PR Series - Section A-A Drive End Model 3000PR Series Section A-A Parts List Drive End Model 3000PR Series Section A-A - Parts List cont Drive End Model 3000PR Series Section B-B Drive End Model 3000PR Series Section B-B - Parts List Solution End Model 3000PR Series Solution End Model 3000PR Series Parts List Valve Assembly Model 3000 PR CALIBRATION OF A METERING PUMP CALIBRATION CYLINDER INSTALLATION GUIDE SERIES 500 VALVE INSTRUCTIONS APPENDIX EQUIPMENT DECONTAMINATION PROCEDURE DOC. No. QAPM-SD EQUIPMENT DECONTAMINATION ADVICE DOC. No. SD Rev:12/2015 Plunger Pump

5 MP3000PR 001 to 010 Plunger Pump Updated June 2012 Plunger Pump

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7 METERING PUMPS 3000PR PLUNGER PUMP SERIES 1. SAFETY 1.1 General Please read and familiarise yourself with all sections of this and other equipment manuals before proceeding with installation. Observe all standard precautions which apply to moving machinery. Observe all standard precautions which apply to electrical equipment, drives and controls. Pay particular attention to special safety 'cautions' and 'notes' in this manual. 1.2 Mechanical Precautions Prior to undertaking any mechanical maintenance repair, installation, etc. SWITCH OFF, and disconnect the power before proceeding. Personnel must wear the appropriate protective safety attire and remove loose clothing, jewellery etc. 1.3 Electrical Precautions Before undertaking work on the electrical controls or drives, disconnect power and place a notice to advise others of the type of work in process. Ensure all necessary grounds are in place and solid. Do not disconnect or disable ground connections CAUTION Follow all electrical regulations where required by electrical engineering trades. 2. INTRODUCTION 2.1 Acromet metering pumps are designed and manufactured for long, low maintenance service life and when properly applied, will give many years of consistent accurate metering and trouble free operation. 2.2 The following instructions should be read and followed to correctly install and operate the pump and ensure optimum pump life and performance. 2.3 The Pump specification sheet is enclosed at the end of this manual. Page 1

8 3. INSTALLATION 3.1 Location It is desirable to locate the pump as close as possible to the supply source (eg tank) in order to minimise suction losses The location should be dry and protected from rain and the possibility of hosing down, with sufficient free space provided around the pump to allow access for adjustment and maintenance The mounting surface should be even and level. The pump base is provided with two (2) holes for mounting bolts. 4. PIPING 4.1 General The pump suction valve is located at the bottom of the pump head and the discharge valve on top. The pump cannot operate without these valves and for correct operation, valves must be vertical Discharge pressure should be more than 20 kpa greater than suction pressure to prevent over feeding or syphoning and to maintain metering accuracy. NOTE When the difference is less than 20 kpa, a back pressure valve and pulsation dampener should be installed in the discharge line. The pulsation dampener should be located between pump and valve, as close to the pump as possible A characteristic of reciprocating pump performance is pulsating flow. Piping should be sized for flow rates at least 3.5 times greater than maximum capacity of pumps. NOTE Small diameter piping will produce unpredictable flow rates and system pressures Piping should be as short and straight as possible and arranged to avoid loops or pockets where gas may accumulate All piping should be separately supported close to the pump to avoid imposing pipe loads on the pump. When handling high or low temperature liquids, measures should be taken to prevent distortion of piping imposing loads on the pump All pipe work should be flushed clean of any solids which may be present in the pipe work (i.e. weldslag, dirt following construction or repair) before final connection to the pump and start-up. Page 2

9 4.2 Suction Piping must be air tight For ease of maintenance an isolating valve should be located near the pump inlet Solids should be prevented from entering low volume pumps or pumps used for high accuracy metering. A strainer of mesh is recommended and should be adequately sized to prevent restriction of flow Suction pipe entrance should be at least 75 mm above the bottom of solution tank to allow settlement of larger solids in the tank. 4.3 Discharge Should it be necessary to install an isolating valve in the discharge line, a relief valve must be installed between the pump and isolating valve The 3000 Metering Pump, being a positive displacement pump, will be damaged if operated against a closed or partially open isolating valve. NOTE CAUTION NOTE The relief valve should be set to operate at the maximum rated pump discharge pressure or maximum rated system operating pressure, whichever is lower. When pumping hazardous liquids the relief valve discharge should be piped back to the supply source. This will avoid spillage should relief valve operate. To ensure correct operation and maximise valve life, a pulsation dampener should be installed between valve and pump A pressure gauge with gauge protector should be installed to check if the pump is not operating at too great a discharge pressure. The gauge should be provided with a petcock valve for isolation from the system when not required When pumping into a high pressure system, a non return valve should be installed as a safety precaution at the injection point. Page 3

10 4.4 Piping Arrangement Please note Plunger Pumps must have a flooded suction to avoid damage by running the unit dry WRONG Should it be necessary to install an isolating valve in the discharge line, a relief valve must be installed in the line between the pump and isolating valve. CORRECT Metering pumps are positive displacement pumps and produce pulsating flow. Consequently there is considerable line pressure loss and suction piping should be sized to ensure adequate NPSHA. If piping extends for a considerable distance a suitable break tank or pulsation dampener should be installed near pump. the pump. Avoid pockets or loops in piping where gas may accumulate. WRONG CORRECT Where the pump discharge line connects with a high pressure line, install a non return valve as a safety precaution. The presence of solids in the pumped liquid can cause incorrect pump valve operation and affect metering accuracy. If solids are present install a strainer with 150 to 200 mesh and large mesh surface in order to keep pressure drop as small as possible and ensure that strainer does not become quickly clogged. CORRECT NOTE The diagrams above are representational and are intended as a guide only. For specific system design or advice please consult a pump systems engineer or contact Acromet. Page 4

11 5. OPERATION 5.1 Before Starting Ensure the pump will be operated within its specification Check gearbox oil level. Prior to leaving factory, each pump is filled to the correct level with the recommended grade of oil (see maintenance section). Any suggestion of oil loss should be investigated Check direction of rotation. Correct direction is clockwise when viewing pump from top of motor Ensure system control or isolating valves in discharge line are open. 5.2 After Starting Pump will normally prime automatically. However, it may be necessary to run the pump at maximum capacity to clear air. If this is unsuccessful, disconnect the discharge pipe work or install a petcock in the discharge line next to the pump to allow air to escape. CAUTION If pumped liquid is hazardous do not disconnect discharge pipe work. Install a petcock in the discharge line next to the pump and pipe petcock discharge to suction vessel or drain to avoid spillage Check that pump is operating correctly against discharge pressure Ensure that any problems are noted and appropriate corrective or preventative action is taken. 6. CAPACITY ADJUSTMENT 6.1 Standard manual capacity adjustment is by means of a micrometer. For multiplex pumps, each pump head is individually controlled by a micrometer located behind the respective pump head. 6.2 Adjustment should be made whilst the pump is running, though under certain conditions adjustment is possible when the pump is stopped. To adjust whilst stopped, rotate the flexible coupling by hand to unload the micrometer. This can be sensed by the ease with which adjustment can be made. When unloaded, adjust to desired setting. NOTE Ensure power supply is disconnected before removing drive-shaft guard. [Type a quote from the document or the summary of an interesting point. You can position the text box anywhere in the document. Use the Text Box Tools tab to change the formatting of the pull quote text box.] Page 5

12 7. MAINTENANCE 7.1 Pre Maintenance Cleaning Flush the pump to remove all chemical residue. Clean the pumps exterior to ensure chemical free surface. Check that appropriate chemical handling and cleaning standards have been met. CAUTION ACROMET (AUST) PTY LTD IS UNABLE TO ACCEPT ANY METERING PUMP RETURNED FOR MAINTENANCE THAT HAS NOT BEEN SUITABLY CLEANED. It is an Acromet Quality Assurance policy that all equipment returned for repair or service be supplied with a completed copy of the 'Equipment Decontamination Advice' form, as shown on page 42 of this manual. 7.2 Lubrication Change oil after the first month of operation and at 6 months intervals thereafter. The following are recommended grades: SHELL : OMALA 320 BP : GR-XP-320 ISO MOBIL : MOBIL GEAR 632 CASTROL : ALPHA SP Correct oil level is the horizontal centre line of the solution head. 7.3 Suction & Discharge Valves During routine maintenance, valves should be dismantled and checked. Replace worn balls and valve seats. When pumping clean liquids of moderate viscosity, valves will give many years of trouble free service. However, valve life can be reduced in applications where discharge pressure is high, liquid viscosity low or solids are present. NOTE Should it be necessary to service the valves, cleanliness is essential and care should be taken to avoid damaging components. Refer to valve drawing at end of manual prior to dismantling When reassembling, ensure that all O-Rings, ball checks and ball stops are in the correct position. Failure to fit ball stops can result in closed head situation and severe pump damage. Page 6

13 7.4 V Packings (Packing Seal Item 5) Pump maintenance should only be carried out by authorised qualified personnel with appropriate metering pump and system maintenance experience. The suction and discharge lines must be isolated and pipework depressurised and drained of chemicals. Procedure for replacing packing seals is as follows: First isolate suction and discharge lines Disconnect suction and discharge pipe work from Pumping Head. CAUTION If liquid is hazardous then all necessary precautions must be taken Slacken off Adjustment Cap (Item 9) Remove Pumping Head securing bolts (Item 20) and gently slide off pumping head Remove Adjustment Cap (Item 9) Follower (Item 8) Glad Spacer (Item 7) Lantern Ring (Item 6) V-Packings (Item 5) and Necking bush (Item 4) Discard damaged or worn V-Packing seals and thoroughly was and clean all parts. Check plunger, gland spacer and necking bush for signs of excessive wear or scoring. If excessive wear or scoring is evident, then parts must be replaced Re-assemble in reverse order using new V-Packing Set. NOTE V-Packings must face towards pressure (Product) Adjust seal pressure via Adjustment Cap (Item 9). Correct adjustment is critical and care must be taken not to over tighten. Adjust as Follows: (i) (ii) Rotate Adjustment Cap (Item (9) just sufficient to stop end float of Packing Seal arrangement. (No pressure on seal). Start up pump. Slowly adjust Cap (Item 9) until leakage stops. NOTE Adjustment should be just sufficient to stop leakage. (iii) Run pump and check for leakage re-adjust as necessary as seals bed in. Page 7

14 7.5 Capacity Control Zero Adjustment Individual capacity control is provided for each pump head by means of a micrometer located directly behind the respective pump head. Should it become necessary to reset the mechanism, the procedure is as follows: With pump running, screw micrometer mechanism in until piston movement is just stopped. This can be sensed when resistance to turning becomes constant. Stop pump. Unfasten both mounting screws and remove micrometer mechanism NOTE On some units, oil level will be above micrometer and spillage will occur on removal. Hence measures should be taken to catch spillage or tilt pump forward to avoid spillage Clamp micrometer anvil in vice and holding the barrel to prevent rotation, loosen the socket set screw located in rear of barrel. This set screw locks the barrel to the anvil Now, holding the mounting flange to prevent it turning, rotate the barrel until it reads zero Again hold barrel to prevent it rotating and retighten set screw Set micrometer at 100% and refit to pump. CAUTION Should oil spillage have occurred, add oil to correct level before starting pump. All major mechanical repairs should be undertaken by Acromet s specialist servicing workshop in Melbourne. In most cases a pump can be repaired and despatched in one day Page 8

15 8. TROUBLESHOOTING Trouble Cause Corrections (A) Pump does not start. Blown electrical. Fuse. Check cause and change to suitable capacity fuse Electrical overload relay trips. Electrical wiring breakdown or defective contact. Low voltage. Difference in supply voltage and rated voltage of motor. Defective motor. Excessive pressure in discharge line. Valve in discharge line closed. Pump discharge valve incorrectly reassembled during maintenance. Ballstop cushion missing. Air in liquid end. (B) No Flow. Valve in discharge line closed. (c) Pump does not work after operating normally. Pump discharge valve incorrectly reassembled during maintenance. Ballstop cushion missing. Overload relay Overload relay Discharge pipe clogged. Valve in discharge line closed. Pump discharge valve incorrectly reassembled during maintenance. Ballstop cushion missing. Change relay capacity to correct value. Change or reconnect. Find cause and correct. Check and replace. Reduce pressure. Open valve Reassemble correctly. Relieve pressure in discharge line. Open valve. Reassemble correctly. Reset the switch after checking the cause and correcting. Reset the switch after checking the cause and correcting. Clear the pipe. Open valve. Reassemble correctly Page 9

16 Trouble Cause Corrections (D) Reduced pump flow rate or unstable rate. Micrometer out of adjustment Re Zero. Valve clogged. Clean. Worn valve seat. Replace seat or valve. Flow meter incorrect. Inspect meter, repair or change. Leakage from relief valve. Inspect, repair or change. Air leaking into suction piping Check for leak source and repair. Change in pump RPM. Correct electric power sources, speed control etc. (E) Reduced pump flow rate. Unstable flow rate. Flow rate does not increase as stroke length is increased. Cavitation noise may be apparent. Insufficient NPSH available: (a) (b) Suction pipe diameter too small. Suction lift too great. Viscosity of liquid too high. Enlarge suction pipe, or install accumulator in the line close to pump or raise level of tank. Raise liquid level. 1. Heat or lower viscosity by other means. 2. Increase suction pipe diameter. 3. Increase suction pressure. Vapour pressure high. 1. Lower liquid temperature at inlet port. 2. Raise liquid level. Suction piping and/or valve clogged Clean Suction strainer clogged or too small Clean or replace with larger unit. Page 10

17 Trouble Cause Correction (F) Excessive pump flow rate. Flow continues after pump has stopped. Pressure difference across pump less than 20 KPa Increase pressure difference (ie install back pressure valve). Discharge line too long or diameter too small Reduce length and/or increase diameter. Install accumulator in discharge line. (G) Liquid leakage from pump adaptor drain. Loose or worn V-Packings Adjust or replace. See Sec. V-Packings. (H) Knocking sound in gearbox. Excessive discharge pressure Check discharge pressure. (I) Liquid end noise. Rhythmic noise of pump valves Clogged discharge or suction valve Normal Clean valve (J) Overheating of motor. Improper voltage Adjust voltage to motor specification. Overload Inadequate ventilation (Refer to Section K). Change motor or relocate (K) Overload. Improper Oil Change Discharge pressure too high Erratic noise of pump valves Lower to permissible pressure 1. Clean valves. 2. Increase pressure difference (ie install back pressure valve). Page 11

18 SERIES METERING PUMPS 9.1 Drive End Model 3000PR Series - Section A-A Page 12

19 9.2 Drive End Model 3000PR Series - Section A-A Parts List ITEM PART NO DESCRIPTION SIMP DUP QTY QTY NOTES Gearbox 1 A Gearbox Multiplex Chamber - Simplex Multiplex Chamber Duplex Screws Multiplex Chamber * Gaskets End Cover Screws End Cover * End Cover Gasket Motor Spool Screws Spool * Motor Spool Gasket Coupling Key, Motor Shaft (supplied with motor) Screws Motor Shaft Key Key Coupling (on assembly) Screw Coupling Worm Shaft 1 1 B * Oil Seal Worm Shaft * Bearing Worm Shaft Main Shaft - Simplex 1 A Main Shaft - Duplex bush main Shaft Worm Wheel 1 1 B Key Worm Wheel Screw Worm Wheel Key Con Rod 1 2 Notes: A B C Not Shown State Stroking Rate (SPM) State Size * Recommended Spare Parts Page 13

20 9.3 Drive End Model 3000PR Series Section A-A - Parts List cont. ITEM PART NO DESCRIPTION SIMP QTY DUP QTY NOTES Bush Con Rod Eccentric C Liner Eccentric Key Eccentric Screws Eccentric key Piston Primary Cross Head Pin Wrist Spring Return 1 2 C Sleeve, Piston Gasket, Piston Sleeve Screw Piston Sleeve Seal Primary Piston Plug, Drain 2 1 A Plug Plate, Name Screw Name Plate Wrist Pin Bush Spring Washer, Motor 4 4 A Thumb Screw, Barrel Lock 1 2 A Screw, Adaptor 4 8 A Notes: A B C Not Shown State Stroking Rate (SPM) State Size * Recommended Spare Parts Page 14

21 9.4 Drive End Model 3000PR Series Section B-B SECTION B-B 9.5 Drive End Model 3000PR Series Section B-B - Parts List ITEM PART NO DESCRIPTION SIMP QTY DUPL QTY Motor 3 Phase Motor 1 Phase Screws Motor PR Barrel, Micrometer PR Body, Micrometer * O-ring, Micrometer Body Screw, Micrometer Body Gasket, Micrometer Body Anvil Screw Lock Anvil Plug Breather 1 NOTES Notes A Not Shown B State Stroking Rate (SPM) C State Size * Recommended Spare Parts Page 15

22 9.6 Solution End Model 3000PR Series Page 16

23 9.7 Solution End Model 3000PR Series Parts List ITEM PART NO DESCRIPTION SIMP QTY DUPL QTY NOTES 1 P-1 Bracket Cast Iron 1 2 A 2 P-2 Plunger Head 316 SS 1 2 A 3 P-3 Plunger 1 2 A & C 4 P-4 * Necking Bush PTFE - Glass Filled 1 2 A 5 P-5 * Packing Seal PTFE Chevron V 1 set 2 sets A 6 P-6 Lantern Ring 316 SS 1 2 A 7 P-7 * Gland Spacer PTFE 1 2 A 8 P-8 Follower 316 SS 1 2 A 9 P-9 Adjustment Cap 316 SS 1 2 A 10 P-10 Valve Retainer 316 SS 2 4 B 11 P-11 Stud 316 SS 2 4 B 12 P-12 Nut 316 SS 4 8 B 13 P-13 Washer 316 SS 4 8 B 20 P-20 Head Retaining Bolt P-21 Bracket Retaining Bolt PL-27 Plunger Adaptor 316 SS 1 2 A 28 PL-28 Retainer 316 SS 1 2 A 29 PL-29 Retainer Screws 2 4 A 32 SA-1 Valve Body 316 SS 2 4 B 33 SA-2 * Valve Seat 316 SS 4 8 B 34 SA-3 * Ball check 316 SS 4 8 B 35 SA-4 * Ball stop PTFE 4 8 B 36 SA-5 * Head Gasket Adamite 2 4 B Notes A B C State Size See Valve Assembly State Material * Recommended Spare Parts Page 17

24 9.8 Valve Assembly Model 3000 PR Page 18

25 10. CALIBRATION OF A METERING PUMP To perform a calibration test on the delivery rate you will require a stop watch and materials necessary to perform a series of simple calculations. To utilise this system efficiently, the following procedure should be followed whilst the pump is operating. 1. Valve V1 must remain open except when the user is testing the deliver rate. 2. To test the delivery rate, open valve V2 and flood the calibration cylinder well above the top graduation mark. 3. Close valve V1. 4. At the moment when the fluid level reaches the top graduation mark, begin timing the test. 5. When the liquid reaches the desired lower graduation, stop your watch and note down the time and calibration discharge quantity. Open valve V1 quickly and close V2 to avoid air being drawn into the system via the calibration cylinder. 6. Should another calibration test be required, then proceed to Item 2. EXAMPLE OF TYPICAL CALIBRATION TEST FIG. 1 Test volume recorded : 1190 millilitres Test time taken : 63 seconds Flow Rate (L/H) = volume recorded (ml) x 3.6 time taken (sec) = 1190 x 3.6 = 68 litre/hour 63 Page 19

26 CALIBRATION CYLINDER INSTALLATION GUIDE LOCATION Install the calibration cylinder as shown in Figure 1. The cylinders must be installed in the suction piping in a vertical position and as close as possible to the suction tank. Remember the location should make allowance for sufficient free space around the calibration cylinder for easy reading of graduations. PIPING It is essential that the size of the pipe to the calibration cylinder be the same size as the suction piping and cylinder inlet connection. Under-sized pipe work will cause suction losses and, hence, affect calibration accuracy. We strongly recommend that the use of full-flow ball valves to give consistent system throughput and rapid open and shut operation an important feature when checking calibrations. Piping should be air-tight and suitably supported at regular intervals. An overflow/venting line should be connected between the top of the calibration cylinder and the supply tank. CAUTION NEVER USE THE CYLINDER ON THE DISCHARGE SIDE OF ANY PUMP. Page 20

27 11. SERIES 500 VALVE INSTRUCTIONS INSTALLATION Pump maintenance should only be carried out by authorised qualified personnel with appropriate metering pump and system maintenance experience. The suction and discharge lines must be isolated and pipework de-pressurised and drained of chemicals. See diagram overleaf of recommended installation layout for pressure relief and back pressure applications. We recommend installation of a pulsation dampener between valve and pump for both applications to provide smoother, more accurate valve operation and maximise valve life. CAUTION Do not over-tighten screwed connection. Should leakage occur during operation, unfasten, flush to remove any residual chemical and re-coat pipe fittings with suitable thread sealant such as PTFE tape before connecting to prevent leakage. ADJUSTMENT Valve operating pressure is controlled by the spring (8) and can be increased or decreased by varying the spring preload. At date of purchase, Acromet will adjust the valve to meet customer's requirements. To alter or set operating pressure at site, it is necessary for a pressure gauge with snubber to be installed in the line between the valve and the pump and with pump operating:- For Back Pressure: Unfasten locknut (5). Unscrew adjustment screw (4) to decrease pressure or screw in to increase pressure. When required pressure is achieved, retighten locknut. For Pressure Relief: Unfasten locknut. Unscrew adjustment screw to decrease pressure or screw in to increase pressure. When full flow through valve at required relief pressure is achieved, retighten locknut. MAINTENANCE The valve and its components should be inspected annually or when incorrect operation is suspected. Disassembly is relatively simple. Unfasten locknut and unscrew adjustment screw to remove spring preload. Unfasten the three main bolts (3). These bolts hold the upper and lower halves together. Separate body halves and remove internals. Carefully inspect and clean all components. Worn or damaged parts should be replaced. Smear the outer surface of the plunger and the bore of the upper body with grease to prevent plunger sticking in bore during operation. Assembly procedure is reverse of disassembly. After reinstalling, adjust valve operating pressure as previously described. Page 21

28 TYPICAL INSTALLATION LAYOUT 7 1. Supply Tank 2. Metering Pump 3. Pressure Relief Valve 4. Pulsation Dampener 5. Back Pressure Valve 6. Pressure Gauge 7. De-pressurising Valve Page 22

29 GENERAL ASSEMBLY 502 SERIES BACK PRESSURE VALVE Page 23

30 GENERAL ASSEMBLY 502 SERIES PRESSURE RELIEF VALVE Page 24

31 APPENDIX Page 25

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33 1 EQUIPMENT DECONTAMINATION PROCEDURE DOC. No. QAPM-SD Page 26

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35 MP3000PR 001 to 010 Plunger Pump Updated June EQUIPMENT DECONTAMINATION ADVICE DOC. No. SD Page 27