Double Disc Pumps Installation, Operating an Maintenance MANUAL 2 Moel 2DDSX04 MK6 PENN VALLEY PUMP Co. Inc. 998 Easton Roa, Warrington, Pa. 18976 (215) 343-8750 Fax (215) 343-8753 www.pennvalleypump.com Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 1 Revise August 2005
Inex Principle of Operation Page 3 General Page 5 Pump Description Page 5 Pump ientification Page 5 Shipping Preparation Page 5 Receiving the pump Page 5 Pump storage Page 5 Synthetic Rubber Covere Equip. Page 5 Installation Page 6 Pump Location Page 6 Founation & Base Page 6 Piping Page 6 Suction Piping Page 6 Discharge piping Page 7 Drives Page 7 Drive alignment Page 7 V-belt & irect connecte rives Page 7 Pump operation Page 8 Direction of rotation Page 8 Noisy operation Page 8 Water hammer & pipe vibration Page 8 Pulsation Dampeners Page 9 Recommene spare parts Page 10 Start-up proceure Page 11 Trouble shooting Page 12 Preventative maintenance Page 13 Lubrication Scheule Page 13 Preventative maintenance scheule Page 14 Pump isassembly Page 15 Pump assembly Page 15 Special tools Page 16 Exploe view Page 17 Parts list Page 18 Material of construction Page 19 Excessive pressure failure escription Page 21 Pressure switch assembly Page 22 Safety instructions Page 24 Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 2 Revise August 2005
INTRODUCTION The Penn Valley Double Disc Pump utilizes a unique principle of operation whereby the iscs perform the uties of both iaphragm an valve, proviing a ouble acting, non-clogging, pumping action. Through an arrangement of connecting ros an a camshaft, a reciprocating action of the iscs is create, forming a large cavity between iscs. This cavity is fille an exhauste in a continuous flow. The large, valve-like iscs mean that large solis an rags can be hanle without loss of the pumping action. The valve-like iscs have large seating areas that provie for low internal velocities, extening the pump wear life on abrasive sluge s an slurries. The flui chamber is seale with flexible trunnions that eliminate packing, mechanical seals, an requires no flushing water or other forms of lubrication. The large iameter iscs are proven to hanle large solis, rags, plastics, etc. that woul cause other pumps to fail. Here s how it works: Suction Cycle (fig. 1) The suction isc (right) is lifte from its seat creating a vacuum. The cavity between the iscs is fille uring the reciprocating motion of the suction isc. The ischarge isc (left) is seate, creating a seal in the flow path uring the suction cycle. A clack valve prevents return flow. Discharge Cycle (fig. 2) The reciprocating action then causes the suction isc (right) to seat an create a seal in the flow path an a ownwar motion of the ischarge isc (left) forces the ischarge. FEATURES The Double Disc pump uses a flexing membrane (trunnion), which achieves the sealing of the flui chamber with no rotating shafts requiring packing or mechanical seals. All Double Disc pumps can operate ry without flui chamber amage. There are no close tolerances or rotating parts within the flui chamber to wear on abrasive applications or bin up on stringy material. There are no internal check valves to plug allowing the Double Disc pump to pass han towel size rags. The Double Disc pump can operate in either irection of shaft rotation without affecting the pump efficiency. The Double Disc pump requires no routine maintenance. All bearings are seale for life with no regreasing require. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 3 Revise August 2005
Penn Valley, Double Disc Pumps are available in four (4) ifferent sizes. The following is general information pertaining to the ifferent sizes. Moel Typical Capacity Max Discharge Hea Port Size Shipping Weight Range 2DDSX04 Up to 40 GPM 70 feet 2 inch NPT & flange 450 lbs 3DDSX12 Up to 130 GPM 100 feet 3 inch flange 850 lbs 4DDSX24 Up to 190 GPM 100 feet 4 inch flange 950 lbs 6DDSX76 Up to 500 GPM 100 feet 6 inch flange 1350 lbs SOLIDS HANDLING The Double Disc Pump will pass large rags (han towel size) an stringy materials that normally cause severe plugging problems with Rotary Positive Displacement Pumps as well as Reciprocating Pumps equippe with check valves. The following spherical solis will pass through the pump. Moel 2DDSX04 Moel 3DDSX12 Moel 4DDSX24 Moel 6DDSX76 1/2" iameter 3/4 iameter 1" iameter 2" iameter Suction Lifts: All Pumps- Dry Prime: 6 Hg (7 feet) Dry Re-prime: 16 Hg (18 feet) Flooe Prime: 25 Hg (28 feet) Percent Solis: Air Hanling: Municipal Sluge s up to 10% ry weight Inustrial Sluge s up to 70% san/clay in suspension Max S.G. 2.2 to 2.4 2-inch pump 9 cu. ft./min at max pressure of 15 psi. All others 25 cu. ft./min at max pressure of 30 psi. Stall Pressure: 2-inch Max working pressure is 30 psi (70 feet). Stall pressure is 60 psi. (138 feet) All others Max working pressure is 43 psi (100 feet). Stall pressure is 110 psi (254 feet) All pumps are capable of withstaning the full stall pressure they are able to prouce on an intermittent basis only. This equipment shoul never be run against close valves on a continuous basis or amage will occur. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 4 Revise August 2005
GENERAL PUMP DESCRIPTION This manual is offere to assist you in unerstaning the construction an the correct methos of installing, opening an maintaining your new Moel 2 Penn Valley Double Disc Pump. The Penn Valley, Double Disc Pump utilizes a unique principle of operation whereby the iscs perform the uties of both iaphragm an valve, proviing a ouble acting, non-clogging, pumping action. The Double Disc Pump has no close tolerances in the flui chamber to wear on abrasive applications. The flui chamber sealing is achieve by flexible trunnions with no rotating shafts requiring packing or mechanical seals. PUMP IDENTIFICATION Penn Valley pumps are permanently recore by serial number at the factory. When orering repair parts, please supply the serial number of the pump, pump moel number, if known, part ientification number an part esignation. SHIPPING AND PREPARATION Penn Valley thoroughly inspects each pump uring the manufacturing process an assembly. Each pump is subjecte to an operational test prior to shipment to assure trouble free operation in the fiel. RECEIVING THE PUMP Check the pump for amage or shortages immeiately upon receiving the pump. Make all claims with the transportation company promptly. This will prevent a controversy when the claim is mae an will expeite prompt an satisfactory settlement. Care shoul be taken when unloaing an receiving the pump to prevent ropping the unit or rough hanling. The same care shoul be taken as you woul with other pieces of precision-engineere equipment. PUMP STORAGE If the pump is not to be place into service immeiately, ft shoul be store in a clean, ry well ventilate place, free from vibration, moisture, irt, rapi or wie variation in temperature an potential amage. Care shoul be taken to protect the Penn Valley Pumps from foreign objects, excessive heat or irect sun light because of the elastomers containe within the pump. CAUTION: SYNTHETIC RUBBER COVERED EQUIPMENT This special notice is to avise you of certain precautions to be exercise in hanling an storing synthetic rubber covere equipment. All items are carefully inspecte an package before shipment an shoul be in excellent conition when receive. Improper hanling of this equipment will often cause serious amage. Synthetic rubber covere equipment is subject to amage by various causes which may be avoie by following these instructions. Do Not allow synthetic rubber line items to contact liquis that are incompatible. Do Not store in temperatures over 100 egrees Fahrenheit. Do Not store where temperature changes faster than 10 egrees Fahrenheit per hour. Do Not allow synthetic rubber to contact other items when temperature is below 40 egrees Fahrenheit. Do Not store in irect sunlight. Do Not store near electrical equipment. Do Not attach slings or any lifting evice on synthetic rubber surfaces. Do Not use anything sharp that may pierce the synthetic rubber covering. Do Not wel in area of lining as it may estroy the lining or the iaphragm. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 5 Revise August 2005
INSTALLATION CAUTION: It is imperative that the coupling hubs or sheaves be a slip fit on the rive shaft. Shock loas from a mallet can have a estructive effect on the bearings, resulting in immeiate failure. The use of taper lock bushings are recommene. PUMP LOCATION The Penn Valley Pump shoul be locate as close to the source as possible, with the suction piping as short an as irect as practical. It is imperative that the suction pipe hyraulics be carefully consiere when locating the pump. Contributing factors are percent solis, losses through elbows, valves, flow in gallons per minute, length of piping run, etc. FOUNDATION & BASE It is essential to provie a soli founation for the proper operation of the pump. The founation must be rigi enough to prevent vibration an misalignment uring operation. The pump sub-base must be anchore to the floor with appropriate anchor bolts an levele by shimming at the anchor bolt locations. PIPING CAUTION: When connecting piping to the pump, the connection shoul be mae with the pipe in a free supporte state an without the nee to apply vertical or sie pressure to obtain alignment of the piping with the pump flanges. All piping shoul be inepenently supporte near the pump so that pipe strain will not be transmitte to the pump. Sufficient, rigi, piping support an bracing must be supplie to prevent the suction an ischarge piping from moving uring the pump operation. If flexible connections are use on the suction an ischarge ports of the pump, care must be taken to support the piping on the up-stream an own-stream sies of the flexible connection as close to the connection as practical. It is recommene that tie ros be installe aroun the flexible connection to provie rigiity. The suction an ischarge piping shoul be equal to the pump suction an ischarge port size. On high suction lifts or on applications hanling high percent solis, the suction piping shoul be one or two sizes larger to reuce friction losses an allow the pump to fill. SUCTION PIPING CAUTION: Do not operate Penn Valley pumps against a close suction line. Excessive vacuum builup will cause isc an/or trunnion failure. The majority of pump problems are create by improper suction line hyraulics. It is imperative that the proper size suction piping system be use in accorance with the suction conitions. Suction pipe size is etermine by the liqui viscosity, length of run, flow in gallons per minute, taking into consieration the number of elbows an other obstructions in the suction piping. A rule of thumb is that the suction pipe size shoul never be smaller than the suction port on the pump being installe. On a horizontal run, the suction piping shoul have a graual rise, up to the suction port of the pump. This is to prevent air entrapment, causing improper pump operation. It is recommene that a vacuum limit switch be installe as close to the pump suction port as possible. This switch is set to turn the pumping system off when excessive vacuum is experience. A vacuum gauge is supplie with the limit switch, permitting the operator to etermine any unstable pump operation by observing this gauge. Any change in the system operating characteristics will be inicate in the gauge reaings. Install isolation valves in suction an ischarge piping as close to the pump as practical. The valves will allow for the removal of the pump or permit maintenance on the pump without raining the system. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 6 Revise August 2005
DISCHARGE PIPING CAUTION: Do not operate Penn Valley pumps against a close ischarge line. Excessive pressure buil-up will cause isc an/or trunnion failure. Penn Valley Double Disc pumps must not be operate against a close valve in the ischarge piping or amage can occur. This type of operation can elaminate or break the ischarge isc. To avoi this, it is recommene that a pressure limit switch installe as close to the ischarge port as practical. This switch is set to turn the pumping system off when excessive ischarge pressure is experience. A pressure gauge is supplie with the limit switch, permitting the operator to etermine any unstable pump operation by observing this gauge. Any change in the system operating characteristics will be inicate in the gauge reaings. DRIVES Penn Valley Pumps will accommoate almost any rive to meet the customer's requirement. These pumps are relatively slow spee pumps an require a spee reuction from the stanar 1150, 1750 rpm motor spees. The reuction is commonly obtaine through a guar enclose, belt an sheave arrangement to arrive at the esire pump spee. A gear reucer between the motor an pump can also be use. The reucer is then irectly couple to the pump shaft through a flexible coupling. DRIVE ALIGNMENT Pumps an rives that are mounte at the factory are mounte on a common base an are accurately aligne before shipment. This alignment must be re-checke after the pump unit has been installe. Perioic checking is avisable uring the pump service life. The 2-inch pump may be either V-belt riven or irect connecte epening on the customer s requirements. V-BELT DRIVES The V-belts must be aligne an property tensione to obtain the most efficient operation. All V-belt rives are furnishe with an OSHA approve guar. This type of rive is the most commonly use on Penn Valley Pumps, proviing for ease of spee change in the fiel. DIRECT CONNECTED DRIVES Certain flexible coupling esigns are more tolerant of misalignment between pump an rive. Misalignment above the maximum coupling manufactures recommenations will result in premature bearing failure an will cause other problems such as excessive power consumption, etc. For this reason the angular an parallel misalignment must be maintaine as close as possible an within the recommene limits of the coupling manufacturer. The following couplings are recommene base on their greater tolerance for misalignment. Spier type couplings generally have less tolerance for misalignment. Sure-Flex coupling (Stanar on Penn Valley pumps) Parallel:*.015 -.025 Angular: 1 egree Gri type coupling Parallel:*.005 -.012 Angular: 1 egree Paraflex coupling Parallel:*.005 -.015 Angular: 1 egree * Depening on size of the coupling. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 7 Revise August 2005
PUMP OPERATION NOTE: All Penn Valley Pumps can operate ry without flui chamber amage. DIRECTION OF ROTATION Penn Valley Pumps can be operate in either irection of rotation without affecting the pump efficiency. NOISY OPERATION Noisy operation an/or excessive vibration is generally cause by pump starvation. This is commonly referre to as cavitation. The most common causes of cavitation are as follows: 1. Suction line size is too small to hanle the percent solis at the existing flow rate. 2. Suction valve is partially close. 3. Suction line is obstructe an will not permit sufficient flow to pump. 4. Suction line is too long, creating excessive resistance, which restricts the flow to the pump. WATER HAMMER & PIPE VIBRATION Inertia is the tenency of matter to remain in its existing state of motion unless acte upon by outsie forces. More energy is require to change steay state motion than to maintain it. Thus more energy is expene to increase or ecrease flowing velocity in a pipeline than is necessary to maintain the liquis steay state motion. One measure of the energy use to change liqui motion is pressure. If velocity is change quickly by the application of much energy in a short perio of time, the pressure change will be more significant than when the same amount of energy is expene over a longer time perio. Thus, the energy applie to change pressure by 100 PSI in one secon is the same amount of energy as that applie for 10 secons to change pressure by 10 PSI. Any change from steay state conitions creates a temporary variation in pressure or flow calle a hyraulic transient. Hyraulic transients are commonly calle surge, shock or water hammer. They are usually cause by opening, closing or regulating valves; or by pumps starting an stopping. Their magnitue is a function of the: (1) change in flowing velocity; (2) liqui ensity; an (3) soun spee in the liqui an piping system. These hyraulic transients may range in importance from a slight pressure an/or velocity change, to sufficiently high vacuum or pressure to collapse or burst pipes an fittings or amage pumps. Water Hammer an/or pipe movement may occur in the ischarge piping system of the Penn Valley Pump uring each revolution. The iscs, acting as valves opening an closing create this conition. When the movement of the liqui column ceases, the weight of the column of liqui causes a slight reversal of flow, thus causing noise an/or pipe movement. The kinetic energy of this reversal of flow causes a series of rapi reversals or waves causing vibration an noise in the pipe until the energy is expene in friction. Pulsation ampeners are esigne to control rapi velocity changes that may cause potentially angerous pressure excursions. This is accomplishe by using a vessel charge with inert gas (air) an connecte to the pipeline carrying the liqui. This vessel has the capability to convert the kinetic energy of the moving liqui into store potential energy when a liqui over-pressure occurs. When a pump stops, the vessel air expans an 'pumps' neee liqui into the line to prevent the formation of vacuum or column separation. With a pulsation ampener installe in the pipeline, flow from the pump is receive within the pulsation ampener compressing the store gas on top of the liqui. Pump energy thus store is release in a controlle fashion to establish steay state flow. After making certain that the ischarge piping is securely supporte an the pump is securely bolte to a rigi founation, the following solution for reucing this phenomenon is recommene. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 8 Revise August 2005
PULSATION DAMPENER RECOMMENDATIONS Generally, suction sie pulsation ampeners are not require, however certain suction piping conitions may warrant the use of a pulsation ampener on the suction sie. Pulsation ampeners installe in the suction piping can improve the NPSH conitions of the application an reuce the acceleration hea. The following are examples of conitions where suction sie pulsation ampeners woul be require: 1. Static lift requirement. (i.e. flui source below pump suction inlet) 2. Suction line iameter smaller than pump inlet. 3. Suction line longer than 50 ft. Vibration an/or noise occurs on the ischarge sie ue to the valving action of the iscs. Discharge chambers are not require on every installation. The system hyraulics must be reviewe to etermine the requirements of the pumping system. The following are examples of conitions where pulsation ampeners woul be require. 1. Discharge pipe in excess of 150 feet - Discharge Chamber require. 2. Static ischarge hea in excess of 10 feet - Discharge Chambers require. 3. Multiple pumps ischarging into a common line - Discharge Chamber require. The ischarge pulsation ampener must be purge after the piping system is fille with liqui. The pressure in the pulsation ampener then equalizes to the ischarge hea conitions. If this is not one, the ischarge hea will cause the liqui to rise in the chamber, thereby reucing the effectiveness of the pulsation ampener. For pulsation ampener sizing an system requirements, please review your system with your local Penn Valley Pump representative. PURGING PULSATION DAMPENERS The stanar style of ampener use by Penn Valley is an open chamber esigne to allow air to be trappe at the top of the chamber. This style of ampener is self compensating to ajustments in flow an system pressure thereby reucing the overall operation an maintenance requirements. It is imperative that the pulsation ampener be seale from the atmosphere, preventing the air charge from escaping. After a perio of time the air will be absorbe in the liqui being pumpe. At this point in time the pulsation ampener must be purge of the liqui that has replace the air charge. This is accomplishe by introucing compresse air through the supplie an quick release air valve installe to the top of the pulsation ampener. The compresse air forces the liqui out of the pulsation ampener an back into the ischarge line. The amount of air require is a function of the system ischarge hea pressure. There is NO specific gauge reaing to obtain. The system will equalize to the system pressure. Typically all that is require a approximately 5 secons of air introuce to the ampener. To check the air charge simply tap on the sie of the ampener with a metallic object. If the ampener pings like a bell then the air charge is complete. If the soun if more of a muffle thu, introuce more air until ampener is empty. The ischarge chamber must be purge after starting up the system. The air cushion on top of the liqui in the chamber then equalizes to the ischarge hea conitions. If this is not one, the ischarge hea will cause the liqui to rise into the chamber thereby reucing the effectiveness of the pulsation ampener. Note: There are times when the use of a blaer style ampener is require for certain applications. If your application requires a blaer style ampener the maintenance information will provie by the specific ampener manufacturer an containe in the project O&M manual. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 9 Revise August 2005
RECOMMENDED SPARE PARTS The proper selection of spare parts is an excellent way to insure a minimum of own time for repairs. The variation in materials being pumpe, pumping rates, etc. are too numerous to enable us to specify the exact quantity of spare parts require. For normal operation in wastewater treatment plants it is suggeste that one set of the following spare parts be in stock for each pump in service. One (1) Suction Disc One (1) Discharge Disc Two (2) Trunnions One (1) Clack valve One (1) Suction gasket One (1) Discharge gasket For more etail information please contact our factory or your local representative to match the spare parts to your particular application. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 10 Revise August 2005
START-UP PROCEDURE FOR A NEW INSTALLATION 1. Back flush the piping system to be certain the system is free of foreign material left from construction. Isolate the pump prior to back flushing. Do not use the Penn Valley Pump to flush the system. 2. Pressurize the system with a non-hazarous liqui to check that all piping connections are tight an free from leakage. CAUTION: Do not pressurize over 30 psi. 3. Check that all valves in the ischarge piping system are open an the ischarge piping is un-obstructe. 4. Check that all valves in the suction piping system are open an the suction line if open to the source. 5. Check that all guars are in place an secure. 6. Pump rotation can be in either irection without affecting the pump efficiency. 7. Start pump rive. Where possible, start at a low spee or jog the rive. 8. If the system is equippe with a suction vacuum switch an/or a ischarge pressure switch, check to be certain that the switch is set at the proper pressure. The cut off pressure of the limit switches are preset at the Penn Valley factory at 30 psi. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 11 Revise August 2005
Troubleshooting a Penn Valley Pump Installation It is common to assume on a pumping installation that the pump is the problem, being the only mechanical evice in the system. More often than not the problem is create by pipeline hyraulics. This is particularly true on new installations. The following checkpoints are offere to ientify some of the problems that may arise. Symptom Cause Solution A. Will not prime or slow to prime. 1. Air leak in the suction line. 1. Tighten connections. 2. Clack valve not seating properly. 2. Replace clack valve. 3. Discs worn or amage. 3. Replace iscs. 4. Suction strainer clogge. 4. Clean strainer. 5. Suction lift to high. 5. Reuce suction lift. 6. Liqui temp. to high for lift. 6. Reuce temp. or lift. 7. Discs not seating property ue to 7. Clean or replace iscs. solis accumulation. B. Low Pump capacity or ischarge 1. Discharge hea too high. 1. Reuce pump capacity. pressure lower than planne 2. Excessive suction lift. 2. Reuce suction lift. 3. Pump obstructe. 3. Remove obstruction. 4. Pump worn. 4. Disassemble an replace worn parts. 5. Pump spee too low. 5. Increase pump spee. C. Pump requires excessive horse- 1. Liqui viscosity or specific gravity 1. Review liqui an system power. greater than planne. specifications. 2. Total hea higher than planne. 2. Review liqui an system specifications. 3. Close or partially close 3. Check ischarge piping ischarge valve. system for close valve. 4. Piping obstructe by solis buil-up. 4. Clean piping system. D. Excessive vibration. 1. Discharge hea too high. 1. Reuce pump capacity. 2. Liqui viscosity too high. 2. Reuce pump spee. 3. Cavitation cause by obstructe 3. Remove suction line suction piping system. obstruction. 4. Pump amage. 4. Disassemble an repair pump. 5. Pipe line obstructe. 5. Remove obstruction. E. Poor isc wear life. 1. Discharge hea too high. 1. Reuce pump capacity. 2. Liqui attacking isc elastomer. 2. Replace iscs with compatible elastomer. 3. Liqui temperature too high for 3. Replace isc's with isc elastomer. compatible elastomer. F. Poor rive life 1. Misalignment between pump an rive. Obvious but often overlooke E. No flow. 1. Suction pipe not immerse in liqui. 1. Lengthen suction pipe. 2. Drive not operating. 2. Check circuit breaker. 3. Flow being iverte in ischarge 3. Check valves in piping system. ischarge piping system. 4. Obstruction in suction piping system. 4. Open valve or clear obstruction. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 12 Revise August 2005
PREVENTATIVE MAINTENANCE 1. Be sure that all nuts an cap screws are fully tightene. Gaskets have a tenency to compress over a perio of time therefore the cap screws shoul be checke for tightness. 2. Check coupling wear an alignment perioically. Replace coupling element before excessive backlash evelops on irect connecte units. The belt tension shoul be checke an re-ajuste to normal stanars if a V-belt rive is use. 3. Be sure the rive cover is always in place to protect personnel from injury an to keep foreign material from entering the area above the sealing trunnions. 4. After extensive usage the upper surface of the trunnions shoul be visually inspecte for any signs of cracking or flex failure. Replace trunnions immeiately if any eterioration is notice. 5. Check suction an ischarge pressure gauges occasionally. Higher pressure may inicate a piping obstruction an lower pressure may inicate flui chamber wear or amage. LUBRICATION SCHEDULE Long-term experience has show that the best bearing life is achieve when the pump shaft bearings are never re-lube. These bearings are grease packe for life with a specially formulate lubricant that shoul not be replenishe. Traitional equipment maintenance normally inclues a re-greasing scheule that we outline in the past. In many cases we have foun that over greasing significantly reuces the life of the pump shaft bearings. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 13 Revise August 2005
PUMP: PREVENTATIVE MAINTENANCE FOR THE PENN VALLEY DOUBLE DISC PUMP Description Frequency Reason O&M Reference Tighten all nuts an bolts, keep belt an rive guar bolts tight Every 6 months Gaskets compress over time Section 3: Page 10 Check Belts Tension Every 2 months Improper tension can cause belt slippage leaing to a poor pump operation. (Do not use belt ressings as these proucts reuce belt life) Section 6 Inspect trunnion surfaces for any signs of wear an cracking Every 6 months If broken pump will leak Section 3 Page 10 Check all supplie gauges for proper working orer Once a week High pressure/vacuum is a sign of a line obstruction an will lea to isc failure over time. Section 3: Page 10 Lubrication Never The bearings are grease packe for life with a specially formulate lubricant that shoul not be replenishe. Section 3: Page 10 MOTOR: Description Frequency Reason O&M Reference Inspect motor for ust an cleanliness, keep all ventilation openings clear Every 3 months Motor may overheat Section 5: Page 8 Lubrication Every 9,500 Hours Over time bearings lose their lubrication Section 5: Pages 8, 9, 10, 11 Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 14 Revise August 2005
PUMP DISASSEMBLY INSTRUCTIONS 1. Drain pump by removing pipe plug (30) from sump. 2. Remove four (4) screws an lift off rive cover (29). 3. Disconnect suction an ischarge piping. 4. Remove six (6) screws an four (4) through bolts which secures the suction housing (1) an rop suction housing. 5. Clean an securely grasp suction isc (17) an unscrew from rive ro. Two people may be require. Drape a newspaper over the isc to ai grip an wear gloves to protect hans from the cuts or abrasions as the isc releases. 6. Remove four (4) screws an four (4) through bolts to release the intermeiate housing (2) from the ischarge housing (3) to separate. The suction trunnion (12) an clamp ring (13) can now be remove. 7. Clean an remove ischarge isc (18) as in step 5. 8. Remove four (4) short bolts on peestals (4) to release rive assembly. Lift off rive assembly, which releases the ischarge trunnion (12) an clamp (13). PUMP ASSEMBLY INSTRUCTIONS 1. Fit ischarge trunnion (12) an position clamp ring (13) into ischarge casting (3). Conical face of trunnion must point upwars as shown. 2. Position complete rive assembly over the ischarge casing an lower on to the top face while passing the ischarge rive ro (10) an ischarge trunnion holer (15) through the trunnion center. Secure using four (4) short hex hea screws through the ischarge peestal (4). Use short hex hea screw an washer to support trunnion at center of housing. 3. Apply a liberal amount of grease to the ischarge rive ro (10) an insie the conical form of the ischarge isc (18). Screw the isc on to the rive ro. Tighten by han until it bottoms against the shouler. The isc cannot be properly seate an tightene without greasing the rubber cone. This allows the isc to slie against the trunnion uner sie. 4. Fit the suction trunnion (12) into the intermeiate housing (1) groove an position the suction clamp ring (13) above the trunnion. Fit a new gasket on to the cleane upper face of the intermeiate housing. 5. Place the ischarge housing an rive assembly onto the intermeiate housing, ensuring that the suction rive ro (11) an suction trunnion holer (14) slips through the trunnion. Secure with four (4) long cap screws through the rive peestals an ischarge housing into the intermeiate housing, two (2) short screws an four (4) thru bolts. irmly tighten all screws. 6. Fit suction Disc (21) as in step 3. Don't forget the grease. 7. Inspect the flapper valve for cracks or wear. Replace if necessary. Don't forget the three (3) spacers. 8. Position the suction gasket on the suction casing an replace the casing, securing with four (4) through bolts an six (6) hex screws. 9. Double check all screws for tightness. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 15 Revise August 2005
10. The pump is now reay to place back in service. The numbers after the parts are item numbers on the exploe view on page 13. SPECIAL TOOLS Maintenance an repair of Double Disc pumps requires no special tools, stanar repair shop tools will be sufficient. Normal tools will inclue. 7/16", 1/2", 9/16", 3/4", AF Wrenches Gasket scraper 1/4" Punch Soft mallet Press ring bearing puller (if replacing bearing) 17/64" twist rill Other materials neee. Shop rags Loctite, Permatex or equal Never Seize or equal Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 16 Revise August 2005
Moel 2DDSX04 MK6 Double Disc Pump Exploe View Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 17 Revise August 2005
Moel 2DDSX04 MK6 Double Disc Pump Parts List Item Quantity Description Part Number per Unit Number 1 1 Suction Housing PVC248 2 1 Intermeiate Housing PVC249 3 1 Discharge Housing PVC250 4 1 Peestal PVC252 5 1 Suction Aapter PVC251 6 1 Drive Shaft PVB253 7 2 Cam Lobe PVA254 8 2 Con Ro PVB255 9 4 Cam Drive Pin PVA256 10 1 Drive Ro Discharge (short) PVA257 11 1 Drive Ro Suction (long) PVA258 12* 2 Trunnion PVA207 13 2 Trunnion Clamp Ring PVB259 14 1 Upper Trunnion Holer, Suction (long) PVB260 15 1 Upper Trunnion Holer, Discharge (short) PVB261 17* 1 Suction Disc (larger) PVB286 18 1 Discharge Disc (smaller) PVB287 22* 1 Clack Valve PVA218 23 3 Clack Valve Spacer PVA219 25 1 Suction Gasket PVB262 26* 1 Discharge Gasket PVA263 27 2 Bearing Peestal PVA264 28 2 Bearing Con Ro PVA265 29 1 Drive Cover PVB266 * Recommene spare parts When orering trunnions, suction iscs, ischarge iscs or clack valves, specify the elastomer require. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 18 Revise August 2005
Moel 2DDSX04 MK6 Materials of Construction Common Parts Item Quantity Description Construction Number per Unit 1 1 Peestal Aluminum Alloy 6 1 Drive Shaft High Tensile, Stainless Steel 7 2 Cam Lobe 8 2 Con Ro Aluminum Alloy 9 2 Cam Drive Pin Stanar Commercial 10 1 Drive Ro Discharge (short) Stainless Steel 11 1 Drive Ro Discharge (short) Stainless Steel 13 2 Trunnion Clamp Ring Aluminum Alloy 14 1 Upper Trunnion Holer, Suction (long) 15 1 Upper Trunnion Holer, Discharge (short) 23 3 Clack Valve Spacer Stainless Steel 25 1 Suction Gasket 26 1 Discharge Gasket 27 2 Bearing Peestal Stanar Commercial 28 2 Bearing Con Ro 29 1 Drive Cover Aluminum Alloy Construction with Neoprene Elastomers 1 1 Suction Housing Aluminum Alloy 2 1 Intermeiate Housing Aluminum Alloy 3 1 Discharge Housing Aluminum Alloy 4 1 Swan Neck Aluminum Alloy 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Cast Iron Construction with Neoprene Elastomers 1 1 Suction Housing Cast Iron 2 1 Intermeiate Housing Cast Iron 3 1 Discharge Housing Cast Iron 4 1 Swan Neck Cast Iron 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Stainless Steel (316) Construction with Neoprene Elastomers 1 1 Suction Housing 316 Stainless Steel 2 1 Intermeiate Housing 316 Stainless Steel 3 1 Discharge Housing 316 Stainless Steel 4 1 Swan Neck 316 Stainless Steel 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 19 Revise August 2005
Moel 2DDSX04 MK6 Materials of Construction Item Quantity Description Construction Number per Unit Hypalon Line, Cast Iron Construction with Hypalon Elastomers 1 1 Suction Housing Cast Iron, Hypalon Line 2 1 Intermeiate Housing Cast Iron, Hypalon Line 3 1 Discharge Housing Cast Iron, Hypalon Line 4 1 Swan Neck Cast Iron, Hypalon Line 14 2 Trunnion Hypalon 21 1 Integral Disc Suction Hypalon 22 1 Integral Disc Discharge Hypalon 26 1 Clack Valve Hypalon Soft Rubber Line, Cast Iron Construction with Neoprene Disc's, trunnions & Clack valves 1 1 Suction Housing Cast Iron, Soft Rubber Line 2 1 Intermeiate Housing Cast Iron, Soft Rubber Line 3 1 Discharge Housing Cast Iron, Soft Rubber Line 4 1 Swan Neck Cast Iron, Soft Rubber Line 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Ebonite Line, Cast Iron Construction with Neoprene Discs, trunnions & Clack valves 1 1 Suction Housing Cast Iron, Ebonite Line 2 1 Intermeiate Housing Cast Iron, Ebonite Line 3 1 Discharge Housing Cast Iron, Ebonite Line 4 1 Swan Neck Cast Iron, Ebonite Line 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Epoxy Resin Line, Cast Iron Construction with Neoprene Elastomers 1 1 Suction Housing Cast Iron, Epoxy Resin Line 2 1 Intermeiate Housing Cast Iron, Epoxy Resin Line 3 1 Discharge Housing Cast Iron, Epoxy Resin Line 4 1 Swan Neck Cast Iron, Epoxy Resin Line 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Neoprene Line, Cast Iron Construction with Neoprene Disc's, trunnions & Clack valves 1 1 Suction Housing Cast Iron, Neoprene Line 2 1 Intermeiate Housing Cast Iron, Neoprene Line 3 1 Discharge Housing Cast Iron, Neoprene Line 4 1 Swan Neck Cast Iron, Neoprene Line 14 2 Trunnion Neoprene 21 1 Integral Disc Suction Neoprene 22 1 Integral Disc Discharge Neoprene 26 1 Clack Valve Neoprene Other stanar elastomer parts are: Viton suction & ischarge iscs, Viton trunnions an Viton clack valves, EPDM suction & ischarge iscs, EPDM trunnions an EPDM clack valves. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 20 Revise August 2005
PENN VALLEY DOUBLE DISC PUMPS Failure cause by excessive ischarge pressure. Cause: Effect: Double Disc Pump operate against a close ischarge valve or a plugge ischarge line. 1. Discharge isc is force below it's seat. 2. Suction isc is force ownwar off of it's seat. 3. Clack valve is force off of it's seat an into the swan neck. Solution: Install a pressure switch in the ischarge line set to turn pump off at a preetermine pressure. Typically this pressure woul be the maximum recommene operating pressure. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 21 Revise August 2005
Vacuum/Pressure Sensor an Switch Assembly PURPOSE The Penn Valley, Double Disc Pump is a positive isplacement pump. The pump shoul never be operate against close valves or obstructe lines. If this happens the unit will buil high vacuum or high pressure an can lea to pump failure. Failure associate with high pressure is escribe on page 20. A high vacuum conition is not as immeiately catastrophic, however if the pump is operate at extene perio at high vacuum premature elastomer failure is likely. The vacuum/pressure switch assembly is recommene to limit the vacuum/ischarge pressure to the maximum recommene operating pressure of the Double Disc Pump. The following are the maximum recommene vacuum/ischarge pressures: Pump Moel Vacuum Discharge 2" Moel 2DDSX04 28ft (35 Hg) 70 ft. hea (30 psi) 3" Moel 3DDSX12 28ft (35 Hg) 100 ft. hea (43 psi) 4" Moel 4DDSX24 28ft (35 Hg) 100 ft. hea (43 psi) 6" Moel 6DDSX76 28ft (35 Hg) 100 ft. hea (43 psi) The above hea / pressure conversions are base on a specific gravity of one (1). If other than one (1) ivie hea in feet by the specific gravity an the multiply by 2.31. Installation The PVP 420 Vacuum/Pressure switch assembly is esigne to be installe to the 1 NPT port at the top of our stanar pulsation ampener. If no ampener is supplie the unit is then mounte to the 1 NPT connection at the pump suction an ischarge. If a unit other than the PVP 420 is use the unit shoul be installe as close to the pump suction an ischarge ports as possible. Over time solis buil-up can occur in the sensing chamber. In most cases the buil-up can be cleare by opening the isolation valve an utilizing the system pressure to clear the buil-up. If the system pressure is not sufficient to remove the buil-up, then Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 22 Revise August 2005
the potable or non-potable water system can be use to back flush the sensing chamber. This cleane in place feature eliminates the nee to remove the pressure sensor for cleaning such as is the case with iaphragm seals. The system consists of a pressure sensor, pressure gauge an a pressure switch. The pressure sensor reas the line pressure in the pump ischarge line. The pressure switch is activate when the set pressure is exceee an that in turn shuts the pumping system own. The pressure sensor is supplie as stanar with an EPDM sensing tube. The sensing system is fille with a 50% ethylene glycol an water solution an is completely protecte from the process slurry by the sensing tube. The sensing tube is one-piece construction with integral flanges locke into the pressure sensor with bolte en covers. The pressure switch is supplie in a watertight alloy enclosure for corrosion resistance that meets 4 requirements. For severe corrosive atmospheres type 3l6 stainless steel an Monel are available. The actuator seal is constructe of Buna-N with process temperature limits of 0 to 150 eg. F. The pressure switch has a plus or minus 1 percent of the range set point repeatability an a minimum of 400 percent of range proof pressures. This unit performs well on applications where shock an vibration coul be problem on services such as slurries or abrasive process fluis. Calibration Proceure The vacuum switch assemblies are preset to 10 Hg an the pressure switch assemblies are preset at 30 psi. If recalibration is require in the fiel, the following proceure woul be require. 1. Remove the switch cover (environment permitting). 2. Open all system valves an turn the pump on. 3. Check the pressure gauge, the gauge inicator shoul swing slightly (not more than plus or minus 3 psi) to show line pressure. Ajust the neele valve to achieve the esire gauge inicator fluctuation-open (turn counterclockwise) to increase - close (turn clockwise) to ecrease. 4. The following instructions apply to both vacuum an pressure. Carefully throttle the pump using the valve until the esire vacuum or pressure is achieve. Caution: Do not excee 25 Hg suction or 45 psi ischarge. The pressure switch is factory set at 10 Hg on vacuum an 30 psi so the pump shoul shut own when that pressure is exceee. 5. Move the ajusting screw to cut out at the esire pressure. If a lower pressure is being set, the pump will continue to operate until the ajusting nut is turne own (counterclockwise) to the new trip point. It a higher pressure is being set, it will be necessary to ajust the switch (clockwise), then open the valve. Re-start the pumping unit. Then throttle the pump again up to the esire pressure Caution: Do not excee 25 Hg suction or 45 psi ischarge. If the pressure switch oes not trip, ajust the switch again, repeating the throttling proceure until the correct cut out pressure is achieve. 6. Always re-check the cut out pressure two or three times to be certain that the pressure sensing switch is operating properly. The motor shoul be wire such that it stays off after the pressure is relieve an requires a manual re-set to be place back into operation. 7. Re-install the pressure switch cover. The system is reay to be place in operation. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 23 Revise August 2005
SAFETY Safety instructions for Double Disc Pumps 1. Pumping equipment must only be operate by personnel who are fully traine in all safety proceures. 2. To prevent personnel injury, equipment must not be operate unless all guars an covers are in place an secure. 3. No maintenance or ajustments are to be performe until the equipment is stoppe an electrical power has been locke out. 4. Suitable safety equipment must be worn by any personnel performing maintenance on this equipment; incluing safety glasses, safety shoes an har hats. 5. Keep hans, clothing etc. away from moving parts. 6. Never permit people who have been rinking alcohol or using rugs to maintain or repair this equipment. 7. Locate "WARNING" signs in areas where moving parts are present. Limit access to authorize personnel only. 8. Inspect an maintain equipment as per equipment operating instructions. 9. Always use factory replacement parts for equipment maintenance, always follow equipment maintenance manual for assembly an isassembly instructions. Penn Valley Pump, Inc., 2DDSX04 Double Disc Pump Page 24 Revise August 2005