Milton Roy PRIMEROYAL Bedienungsanleitung

INSTRUCTION MANUAL

FOR INSTALLATION

OPERATING, AND

MAINTENANCE.

Dosing Pump PRIMEROYAL ®

Packed Plunger

This manual should be made available to the person responsible for installation, operating and

maintenance.

DATE : 5/18/2018 N : 56960 REV : 0

CONTENTS

Page

Section1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Principle of Operation . . . . . . .. . . . . .. . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . .. . . . . .. . . .. . . . . .. . . . .. . . . .. . . 3

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Section2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unpacking. . .. . . . . .. . . . .. . . . . .. . . . .. . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . .. . . . . . .. . . .. . . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . .. . . . . .. . . . . .. . . 5

Mounting. .. . . . .. . . .. . . . .. . . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . .. . . .. . . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . .. . . . .. . . .. . . . . . .. . . .. . . . . .. . . 7

Piping. . .. . .. . . . . .. . . . .. . . . . .. . . . .. . . .. . . .. . . . . .. . . . .. . . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . .. . . . . . .. . .. . . . .. . . . 7

Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Section3 Operation . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . . .. . .. . . . . .. . . . .. . . . . .. . . . .. . . .. . . . . .. . . . . .. . . . .. . . .. 9

Initial Start-Up.. . . .. . . . .. . . . . .. . . . . .. . .. . . . . .. . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . .. . . .. . . . . .. . . . .. . . . . 9

Initial Adjustments . .. . . . .. . . . . . .. . . . .. . . .. . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . . .. . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . . .. . . . .. . . . . . 9

Preventive Maintenance. . . . .. . . . .. . . . . .. . .. . . . . .. . . . .. . . . . .. . .. . . . . .. . . . . .. . . . .. . . . . . . . .. . . .. . . . .. . . . . .. . . . . .. . .. . . . . .. . . . 10

Section 4 Troubleshooting Guide . .. . . . . .. . . . .. . . . .. . . . .. . . .. . . . . .. . . . .. . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . .. . . . .. . . . . .. . . . .. . . .. . . 11

Section 5 Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Packing Replacement. . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 13

Check Valve Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Check Valve Reassembly . . . . .. . . . . . . . . .. . . . . . . ... .. ... .. .... .. ... .... . ... .. .. .. ... . ... .. .. .. ... . ..... .. .. .... .. .. .. .……….. 15

LIST OF ILLUSTRATIONS Page

PrimeRoyal Metering Pump. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 1. Packed Plunger Liquid End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 2. Recommended Valve Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 3. Check Valve Assembly . . . . . . . …………………………………………………………………………………………… . ….... . .. . . . .. . . . .. . . . . .. . 15

Figure 4. Packed Plunger Liquid End Assembly. . . . .. . .. . . . .. . . . . .. . . . .. . …………………………………………………………………. . . . 16

Section 1

PRINCIPLE OF OPERATION

The drive unit moves the pump plunger to draw liquid into the liquid end on the suction stroke and

to expel the liquid on the subsequent discharge stroke. In packed plunger liquid ends, the plunger

contacts the process liquid, therefore a packing lubricant may be necessary depending on the fluid

being pumped. Accurate flowcontrol is achievable only if the discharge line pressure (discharge

head) is greater than the suction line pressure (suction head). For aid in determining acceptable

piping performance, please refer to Milton Roy’s NPSH calculator, available on line at

www.miltonroy.com.

Figure 1. Packed Plunger Pump.

As the plunger reciprocates in the liquid end, the pumped liquid is alternately drawn into and

discharged from the liquid end. Each suction (rearward) stroke of the pump plunger creates a

negative pressure in the displacement chamber. The pressure of the liquid in the suction line un-

seats the suction ball-checks and liquid flows into the displacement chamber. On the discharge

stroke, the plunger moves forward and pressurizes the liquid which unseats the discharge ball-

checks to flow out the discharge port. On each suction stroke, the discharge ball-checks are

seated, and on each discharge stroke, the suction ball-checks are seated (pressure in pump head

is greater than suction line pressure). This mode of operation prevents back flow and ensures

liquid movement from the suction port, through the liquid end, and out the discharge port.

SAFETY PRECAUTIONS

When installing, operating, and maintaining the PrimeRoyal keep safety considerations foremost.

Use proper tools, protective clothing and eye protection when working onthe equipment and

installthe equipment with a viewtoward ensuring safe operation. Followthe instructions in this

manual and take additional safety measures appropriate to the liquid being pumped. Be extremely

careful in the presence of hazardous substances (e.g., corrosives, toxins, solvents, acids,

caustics, flammables, etc.).

SECTION 2

INSTALLATION

UNPACKING

Pumps are shipped f.o.b. factory and title passes to customer when carrier signs for

receipt of pump. The customer, therefore, must file any damage claims with the carrier.

Carefully examine the shipping crate upon receipt from carrier to be sure there is no obvious

damage to contents. Open the crate carefully, as accessory items fastened to the inside of the

crate may be lost or damaged. Examine all material inside crate and check against packing list

to be sure that all items are accounted for and undamaged.

General Rules

Never connect a rigid pipe to plastic liquid ends; rather, use flexible connections to both

suction and discharge.

Use piping materials that will resist corrosion by the liquid being pumped. Use care in

selecting materials to avoid galvanic corrosion at pump liquid end connections.

Use piping heavy enough to withstand maximum pressures.

Size piping to accommodate peak instantaneous flow. Because of the reciprocating motion of

the pump plunger, pump deliveryfollows an approximate sine curve with a peak instantaneous

flow pi (3.14) times the average flow. Therefore, piping must be designed for a flow 3.14 times the

pump capacity; this means that a pump rated for 88 gallons per hour requires piping sufficient for

88 gph (333.1 L/hr) 3.14 (or 276) gph (1044.7 L/hr). Please refer to Milton Roy’s NPSH calculator,

on line at www.miltonroy.com

To minimize viscous flow losses, pipe viscous liquids with line up to four sizes larger

than the pump port.

Remove burrs, sharp edges and debris from inside piping. Flush and blow out all pipe lines

before making final connections to pump.

Provide for pipe expansion when hot liquids are to be pumped. Support piping so that pipe

weight is not placed on the pump. Never spring piping to make connections.

Figure2

Piping should be sloped to prevent vapor pockets, because vapor in the liquid end will

cause inaccurate pump delivery.

When pumping suspended solids (such as slurries), install plugged crosses at all 90 degree

line turns to permit line cleaning without dismantling piping.

Suction Piping

It is preferable to have the suction of the pump flooded by locating the liquid end below the

lowest level of the liquid in the supply tank. Installing a hold-up tower or supply vessel on the

suction line close to the pump can help ensure a flooded suction line. (Consult the Milton Roy

Company, Flow Control Division for assistance in such applications.)

Avoid negative suction pressure conditions (suction lift), as such conditions adversely affect

metering accuracy. If such conditions are unavoidable, contact Milton Roy Flow Control

Division for recommendations.

When pumping a liquid near its boiling point, provide enough suction head to prevent the

liquid from “flashing” into vapor when it enters the pump liquid end on the suction stroke.

If possible, use metal or plastic tubing for the suction line because tubing has a smooth

inner surface and can be formed into long, sweeping bends to minimize frictional flow losses.

A strainer should be used in the suction line to prevent foreign particles from entering the

liquid end. This and any other measures which prevent debris from entering and fouling the

ball-checks will give increased maintenance-free service.

Keep suction piping as short and straight as possible.

When suction piping is long, and particularly at stroke speeds above 70 strokes per minute (spm),

piping size should be larger than the liquid end suctionfitting to prevent pump starvation.

If long suction lines are unavoidable, install a float box or auxiliary feed tank (stand pipe) near the

suction side of the pump. The float box may be calibrated and used to check pump capacity by

measuring the time required for pumping a specific quantity of liquid from the box. In many cases,

installing an accumulator or pulsation dampener at the pump suction connection will promote

flooded suction even when the suction line is long. Consult Milton Roy Flow Control Division for

details. 6

Suction piping must be absolutely airtight to ensure accurate pumping. After installation,

test suction piping for leaks with air and soap solution.

Discharge Piping

Install pipe large enough to prevent excessive pressure losses on the discharge stroke

of the pump. Maximum pressure at the discharge fitting on the liquid end must be kept at

or below the maximum pressure rating shown on the pump data plate.

The pump will not deliver a controlled flow unless the discharge line pressure is greater than the

suction line pressure. Piping should be arranged to provide at least 5 psi (35 kPa) positive

pressure differential between the discharge side and the suction side. There are a number of ways

to create an artificial discharge pressure, such as by installing a vented riser or a back pressure

valve. (Please consult Milton Roy FlowControl Division for recommendations to increase back

pressure in slurry applications.)

When pumping water-treating chemicals directly into boiler drums, use one liquid end

assembly for each boiler drum. Discharging into a manifold having the slightest pressure

difference between its several discharge connections can diminish metering accuracy as the

outlet with the lowest pressure will receive more liquid than the other outlets.

Vented Risers

A vented riser is simply a vertical extension of the discharge pipe into an open tee. The other

side of the tee goes to the process. Practically maintenance-free, this device prevents siphoning

and provides an artificial discharge head; however, a clogged or closed line may cause the riser to

overflow. Therefore, substitute a pulsation dampener and back pressure valve for a vented riser

when pumping hazardous liquids

Check Valves

A check valve should be installed at the point where the discharge line enters a boiler or

other high-pressure vessel. This will prevent back flow through the discharge piping and will

isolate the pump discharge from system pressures (a safety consideration).

Shut-Off Valves

Provide shut-off valves in both suction and discharge lines next to the pump. Locate

discharge line shut-off valve downstream from the inlet connection of the safety valve

Back Pressure Valves

A Milton Roy back pressure valve should be installed in the discharge line near the pump to

ensure sufficient discharge head pressure for proper pump metering action. Normally, the valve

should be located near the pump; however, back pressure valves for large pumps with long and

extremely small discharge lines may have to be installed near the point of discharge into the

process (to minimize siphoning tendencies). Contact Milton Roy Company for sizing

recommendations.

Accumulators (Surge Chambers)

An accumulator, surge chamber, surge suppressor, or pulsation dampener should be used with

the back pressure valve inthe discharge line to absorb theflow peaks between the pump andthe

back pressure valve (see figure 2).Without the pulsation dampener the valve mechanism will snap

open and closed with the surge from each pump stroke. The pulsation dampener will allow the back

pressure valve to oscillate about a partly-closed position, thus minimizing wear onthe valve. Dis-

charge line pulsation dampeners offer thefurther advantage of limiting the flow and pressure varia-

tionscharacteristic of this kind of pump. Installing a properly sized pulsation dampener will improve

pump performance and may reduce system costs dramatically by permitting the substitution of

smaller piping. Pleasecontact Milton Roy Company for further information on pulsation dampeners.

Safety Valves

Motor-driven positive displacement pumps can develop tremendous discharge pressures

long before thermal overload devices interrupt the motor electrical circuit. To prevent a blocked

discharge line from causing damage to the pump, piping, or process equipment, install a Milton

Roy Safety Valve in the pump discharge line. This valve is designed and sized to handle system

flow rates and pressures safely while resisting corrosion by the process liquid.

Install the safety valve in the discharge line between the pump andthe nearest shut-off valve.

(This will prevent pump damage from accidental valve closure.) Pipe the safety valve outlet back to

the suction tank or to drain, but in either case ensure that the pipe end is continuously visible so

safety valve leakage may be detected. See figure 2 for construction and installation.

Piping Concentrated (95-100%) Sulfuric Acid

Packed plunger pumps are not recommended for this service. Diaphragm style liquid end

are more suited for this application.

SECTION 3

OPERATION

INITIAL START-UP

Followthe start up directions in the "Drive" manual (56968) and those listed below.

INITIAL ADJUSTMENTS

NON-ADJUSTABLE TYPE PACKING

"Non-adjustable" Plunger Packing (specified in the pump model number; see Section 1, Model

Code) is preset by internal spring pressure and is complete once the Gland Cap (1660 in fig. 4) is

fully tightened. No adjustments possible

Capacity Calibration

After the first 12 hours of operation, the pump may be tested and calibrated to find the exact

pump capacity under specific operating conditions.

Usually, calibrating the pump at only 100, 50, and 10 percent capacity settings is enough to

indicate pump performance throughout the adjustment range.

The pump can be calibrated byone of two methods carried out in a given time:

1. Measure the decrease in liquid level pumped from a calibrated vessel.

2. Collect and measure pumped liquid at the pump discharge port. (It may be necessary to

create a discharge head (back pressure valve) at the liquid take-off point; otherwise pump

will not operate properly. See Section 2 for ways to do this.)

The first method is recommended for hazardous liquids because it eliminates operator contact

with the liquid.

Filling Pumping System

It is especially important that pump suction and discharge lines be free of entrained air. To

ensure this condition, operate the pump under no discharge pressure and fill the entire pumping

system with liquid before starting pressure tests.

If the pump is idle for long periods, temperature changes in the process liquid may produce

air in the system. To discharge the air, install a valve in the discharge line which will allow the

process liquid to be pumped to exhaust when starting the pump.

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