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HIGH PRESSURE UNIT SAFETY REQUIREMENTS

  • Always use a pressure gauge, when operating pump. The pressure must not exceed from specified rated pressure of pump or pump could be damaged causing leakage, resulting in injury to personnel in vicinity.
  • A security valve should be installed in any delivery line and should be sized to discharge or by-pass the entire pump flow rate.
  • Do not adapt relief valve to maintain more pressure than their specifications state. This could result in relief valve or pump casing bursting due to excess pressure. personnel in general area could be physically harmed.
  • Do not put a valve between the pump and relief valve. If the pump will be started with this valve closed, this could put excessive pressure on the pump, which could cause the pump case to burst and might injure personnel or other equipment in vicinity.
  • Electric components and wirings should be provided with an adequate degree of protection, able to protect them against spray coming from any direction. They should also be suitable for working in wet environment.
  • High pressure hose and any other accessory under pressure, should be sized in accordance with the maximum unit working pressure and must always work within the safety margins indicated by the hose / accessory manufacturer.
  • High pressure hose ends should be fastened to a steady body in order to prevent them from dangerous sweeping around, should they burst or come off their end fittings.
  • Proper safety guards should be provided to adequately cover transmission joints, pulley, belts, auxiliary drivers etc.
  • Do not modify pump to function beyond its specifications.

GENERAL INFORMATION ABOUT THE PUMP USE

High pressure triplex plunger pump has been designed to pump, at room temperature, fresh and filtered water. The standard versions have been designed for fresh water and suitable for pumping other liquids, that have nearly the same viscosity as water and are compatible with the pump construction materials (for questionable liquids, contact our technical department)

 

Pump performance

The performance data indicated in the catalogue (or the rating plate) refers to the maximum performance of the pump. The use of the pump below the rated performances, does not allow the drop in power absorbed to be balanced by altering the pressure or volume of the pump above its maximum value.

 

PUMP INSTALLATION

Positioning

  • The pump must be mounted to a rigid and flat base using the four threaded feet in the main body.
  • The maximum pump inclination during operation does not exceed 5° in order to guarantee the correct splash lubrication.
  • The alignment of the pump with the driver must be proper.
  • On no account must the pump be installed in such a way so that its liquid end rests on the base, where the pump as mounted. The liquid end must be left free and should not be subjected to any force.

  The diagram shows the correct direction of rotation, looking at the pump from the liquid end side:
  • Clockwise with shaft projecting on the left side
  • Counter-clockwise with shaft projecting on the right side

     

     

     

Fluid supply

  • High pressure plunger pumps are not self-priming and, for this reason, must always be installed with a positive suction head.
  • THEY MUST NEVER BE OPERATED WITH A SUCTION LIFT otherwise cavitation will occur.
  • In case of continuous duty, a very long suction line or when hot water is involved, the installation of a centrifugal feed pump is strictly recommended.
  • The feed pump must supply at least twice the plunger pump volume and pressure of 1 kg/cm2 / 15 PSI to 3 kg/cm2 / 45 PSI at the pump suction port (in case of hot water 2 kg/cm2 / 30 PSI at least). The feed pump must be operated independently and supply its full rated performance even if the plunger pump is run below its rated performance. The plunger pump must be start up only when the correct inlet pressure is provided.

Suction line

The pump life is considerably influenced by the effectiveness of the suction line, which MUST HAVE THE FOLLOWING CHARACTERISTICS :
  • The internal diameter of the suction line must be at least 30 mm, possibly larger depending on the drop in pressure due to the length and shape of the line.
  • It must be as straight as possible, minimizing changes in size & direction and positioned in such a way, to allow air pockets and bubbles to escape.
  • It must be perfectly airtight.
  • It must be completely free from 90°elbows, diameter reductions, counter slopes, “T” connections and must not be with other pipelines.

It must be positioned in such a way to prevent the pipe emptying after the pump stops.

 

Please refer our line diagram for the same

 

 

Suction line recommendation :

  • Do not use high pressure flexible hoses for the suction line.
  • Do not use high pressure – hydraulic fittings like 90°elbows, high pressure adaptors, high pressure 3 or 4 way nipples and so on.
  • Do not install along the suction line, any kind of detergent injector.
  • Do not install standing valves, check valves or other kind of one-way valves.
  • In case of a feed tank, make sure that the dimensions of the tank and the minimum water level do not give rise to turbulence at the tank outlet port, which, in turn, might create cavitation at the pump.
  • Do not connect the by-pass line from the relief valve and the unloader valve directly to the pump suction line.
  • In case of feed tank, connect the by-pass line from the relief valve and the unloader valve directly to it and make sure that both the by-pass and tank feeding flows could not give rise to turbulence at the tank outlet port, which, in turn, might create cavitation at the pump. Proper baffle plates should be provided inside the tank.
  • Before connecting the suction line to the pump inlet port make sure that the pipe is perfectly clean inside.

Filtration

All pumps require a suitable filter. The filter should be installed as close as possible to the pump, should allow easy inspection and have the following characteristics:
  • The filter capacity must be at least three times the rated pump volume.
  • Filter port diameters must not be smaller than the pump inlet ports.
  • Filtration degree in between 50 and 80 mesh (360-200 microns).

Important note :

In order to properly safeguard the pump, it is very important to plan cleaning of the filter with a frequency depending on the water
quality, filtration degree and number of hours of each application.



Delivery line
To ensure the delivery line is correct, comply with the following instructions:

  • The first length of delivery hose must be flexible in order to isolate the pump vibrations from the rest of the system.
  • Use only high pressure hoses and fittings able to guarantee the largest possible safety margins in any working condition.
  • A suitable relief valve must be installed on the delivery line.
  • Use always glycerin filled pressure gauges, as they are the most suitable for pulsation loads.
  • When designing the delivery line, take into proper account the unavoidable drop in pressure, due to its length and size.
  • If necessary, the effects of the pump pulsations can be reduced by installing a proper pulsation dampener on the pressure line.
  • In high pressure cleaning systems, to save power and to reduce the load on the pump, use of the Unloader valve & Trigger Operated Gun is recommended.

Start-up and running procedures

Before Start-up Checks

Before starting up the pump, make sure that the following conditions have been complied with:
  • Suction line must be connected the pump : the pump must never run dry.
  • Suction line must be perfectly airtight.
  • Any ON-OFF valve in between pump and water source must be open and make sure the water flows into the pump freely.
  • Make sure all suction/delivery line connections are fully tightened.
  • Joint alignment, belt tightening and PTO shaft inclination tolerances must be within the values indicated by the transmission manufacturer.
  • In case the pump has not run for a long period, check the suction and delivery valves for scaling.
  • First fill oil till the center of oil level glass.

List of recommended oils and oil pump capacity.

BrandType
ESSO/MOBILVACULINE-133 (ISO VG 220)
HPCLENKLO 220
IOCLSYSTEM 220
BPCLHYDROL 220
CASTROLALFA-ZN-220
VEEDOLAVDON-220
IBPGPMO-220

 

 

 

 

 

 

 

 

 

 

 

 



NOTE:- Other brand oil equivalent of above grades, can be used.

 

Starting up

  • Pump and motor/engine must start offload: set the regulating valve to zero or set the pressure line in dump mode by means of proper dumping devices.
  • When starting up the pump for the first time or after every wiring re-connection, check for proper direction of rotation.
  • During operation, check that the rotating speed does not exceed the rated value.
  • Before putting the pump under pressure, let it run for some time, until the oil flows freely.
  • Before stopping the pump, release the pressure form the system by operating the dump device or by releasing the regulating valve and reduce RPM to a minimum (diesel applications).


Note: In case of feeding by a centrifugal pump, make sure that the plunger pump starts only when the correct inlet pressure is provided.

 

Water Leakage

  

During operation, a small amount of water (a few drops a minute) is released from the pump fluid end, this leakage is designed to provide lubrication for the pressure packing. The leakage is drained out of the pump through a hole in the cover. This hole must be always left open.

 


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