3GP SERIES STEAM BOILER FEED PUMP

USER’S MANUL

Manufactured by: Yongtai Machinery Manufacture Co., Ltd

Ningbo High Pressure Pump Factory
 I. Brief Instruction
3GP series steam boiler feed pump is specially designed for the oil well steam

boiler in oil field, the pump is horizontal type with high-pressure reciprocating

triple-plunge, and is for single use. The pump can be divided into two types: water

pump and anti-erosion pump.

The 3GP series pump consists of gearing part, driving part, hydraulic part and

electric part, and is installed on a metal base plate. As it is symmetrically designed,

the pump has inlet and outlet ports on each side, thus making it easy to be installed.

The pump is installed with relief valve, ball buffer installed, oil level controller,

and it works in forced lubrication with a lubricating pump installed. The pump is

tiny in structure, small in volume, light in weight, and high in working efficiency,

thus making its operation agile, stable and easy to be operated and maintained.

Technical Parameters Of 3GP Series Steam Boiler Feed Pump

Model Inlet Outlet Theoretic Plunger Strokes Motor Lubrication Shape Weight
Pressure Pressure Flow Diameter (1/min) Power (Length (Kg)
(MPa) (MPa) (㎡/h) (mm) (Kw) ×
Width
×
Height)
(mm)
3GP-7/20 0.02-0.05 20 7.7 ￠45 270 55 Splash 2400 × 2150
Lubrication 1050 ×
1000
3GP-9.2/20 0.02-0.05 20 10.12 ￠47 325 75 Splash 2400 × 2150
Lubrication 1050 ×
1000
3GP-11.2/20 0.02-0.05 20 12 ￠55 235 90 Splash 2643 × 3000
Lubrication 1155 ×
1100
3GP-23/20 0.02-0.05 20 23 ￠64 248 160 Splash 3410 × 6000
Lubrication 2000 ×
1550
 See Affixed Table I for pump component details. See Affixed Table II and III

for special tools and spare accessory details. Product codes definition

3 GP 9.2/20 “3” stands for triple-plunge “GP” stands for Steam Boiler Feed Pump

“9.2/20” stands for Boiler-tonnage/Pressure (Mpa)

II. PARAMETERS AND SPECIFICATIONS OF PUMP

Model 3GP-100-11.5/14boiler water-supply pump

Fluid water
Fluid temperature (℃) ≤76℃
Inlet Pressure (MPa) 0.02～1MPa
Outlet Pressure (MPa)
Flow (M3/h) 11.5m³/h
Plunger diameter (mm) 54
Stroke distance (mm)
Strokes (1/min) 316
Model
Motor Power (Kw) 75KW
Voltage (V) 460V
Model
Lubrication Dosage
 Pressure (Mpa) 14
Inlet pipe diameter (mm) φ 114×5
Outlet pipe diameter (mm) φ 60×9
Shape (mm)
III. STRUCTURE & OPERATION PRINCIPLE 1、Driving
part (refer to driving part structure drawing)

1.The pump has a box type structure, and is made of cast iron. A lubrication container

with volumeter is set under crankshaft, please inject lubrication till the volume reaches mid

level of the gauge. We may install a heat exchanger in the crankshaft box to control the oil

temperature, if there is a special requirement from our customer.

2. The crankshaft is made of 42CrMo-alloyed steel, the shifter pole is made of cast steel,
and its pump is operated in a forced lubrication mode, with oil hole in crankshaft and shifter
pole.
3. Forced lubrication is applied as defaulted lubricating technique in model 3GP-9.2/20,
3GP-11.2/20, the lubrication which is used in their arbor collars of shifter poles and
crossheads are carried by oil inlet pump, and transported to all frictional parts through the
oil holes in the filter and shifter pole of the crankshaft. Splash lubrication is applied on the
bearings of the crankshaft’s 2 sides.
4. The arbor collar of shifter pole is made of 08 hyper-tutania, and a bronze sleeve is
installed at the shifter pole’s end.
5. The crosshead and crosshead pin in splash lubricating pumps have a suspending-type
structure. Half-suspending type is applied in the crosshead and
crosshead pin of splash lubricating pumps, that is to say, the crosshead and shifter

pole sleeve are operated in freely fitting. After crosshead pin being installed into

crosshead, the two ends of crosshead pin are well clipped to void sliding out.

6. Two skeleton-frame rubber oil-seal prevent the lubrication in drive part from

being squeezed out when the center pole reciprocating.

7. The magnetic pole in lubrication container functions to draw dirt in the oil.

8. The oil level controller (depends on the requirement from customer) connected

with power panel functions to stop the pump in case that the oil level is below the

lower-limit. Oil filter pole and pressure controller in the forced lubricating pump

function to adjust oil pressure between 0.3Mpa-0.4Mpa. While operating the pump,

please run the lubricating pump first till the oil pressure reaches a required value

and pressure indicator on the power panel lights yellow, OR THE PUMP WILL

NOT OPERATE. If oil pressure falls below the required value (0.3Mpa) during

pump operation, the protection circuit will begin to work, thus shutting down the

pump to void damage.

2、Hydraulic part (refer to hydraulic part drawing)

Hydraulic part can be divided into two types according to its structure: Integrated

rectangular bump, and branching inlet-pipe rectangular pump. Taper valve is

installed in the hydraulic part and function as inlet valve and outlet valve (we can

install valves of other types, according to the requirement from customers),

similarly, the pump body, valve core, and valve base also can be made of different

materials, according to the customers’ requirements. The erosion-proof pump is

made of stainless steel.

3.、Electric part

Electrical part consists of motor and power panel (transducer included).

4、Driving part

Driving part consists of 2 belt wheels, narrow V-type belts and belt shields.

5、Operation principle

The motor drives crankshaft to rotate, which is connected by belt wheels and

narrow V-type belt, then crankshaft reciprocates shifter pole, crosshead, central

pole, and plunger. When the plunger shifts backward, inlet valve opens, and liquid

flows into bump body until the plunger reaches maximum stroke. On the other hand,

when the plunger shifts forward, the liquid in the pump will be squeezed, and the

pressure rises up, thus closing inlet valve and opening outlet valve, and the liquid

will be drained out. As the plunger reaches the other maximum stroke, a round of

operation is over, and the pump begins another circulation.

IV. DISMANTLING & INSTALLING THE COMPONENTS

4. 1 How to dismantle shifter pole, crosshead, crankshaft, etc. (refer to

Illustration 1-1)
 3 7 8 9 10 11 2 6 4 5 1

A B

图1-1

Illustration 1-1

4.1.1 Remove covers① ② ③, sealing gasket and oil seal ④ ⑤, then screw off

central pole ⑥ and bolt ⑦, pull out shifter pole cover ⑧ from A side, push

shifter pole ⑨ and crosshead ⑩ to B side until they can be taken out from B

side.

4.1.2 Remove restraining spring, and take out crosshead pin 11. To the forced

lubricating pump, please use hammer and pole to knock out the crosshead pin (refer

to Illustration 1-2).
 铁锤

固定架

芯棒
十字头销 连杆

十字头

垫铁
内孔大于十字头销径

图1-2
Illustration 1-2

铁锤：hammer, 固定架：support block, 芯棒：columned pole , 十字头销：

crosshead pin, 连杆：shifter pole, 十字头：crosshead, 垫铁(内径大于十字头销

径)：stow-iron(its inner radius should be longer than that of crosshead pin).

4.1.3 Remove belt shield, belt, cone sleeve of the big belt-wheel, then remove

shaft cover from the two ends of crankshaft. Knock the end of shaft, and take out it.

4.1.4 Install the components above in a reversed order, but make sure all of them

have been cleaned and all burrs on the components have been removed. Smear

lubrication at friction parts during installation. To prevent the pump from being

contaminated, please install upper-cover and back-cover immediately after

installation is finished.

4.2 How to dismantle inlet valve and outlet valve.

4.2.1 To dismantle the four-way valve (refer to illustration 1-3), please remove
the flange (1,2) from pump body, use hook to remove backing block, plug (3,4),

and valve core (5). Jog the pump manually to slide the plunger out of central sleeve,

use valve-remover to pull out upper valve base and central sleeve (6,7). Use hook

to remove lower valve sleeve and valve core (8,9), use valve-remover to pull out

lower valve base (10).

Illustration 1-3

调节螺母：adjusting nut
 4.2.2 To dismantle the compounding valve (refer to illustration 1-3a), please

remove the horizontal flange first, then use hook to remove valve sleeve, outlet

valve components and inlet valve components, include inlet valve plate and spring.

Illustration 1-3a

进液阀簧 inlet valve spring 进液阀板 inlet valve plate 排液阀组件 outlet

valve components 阀套 valve sleeve 横法兰 horizontal flange.

4.2.3 To dismantle inlet valve and outlet valve on the flat valve (refer to

illustration 1-3b), please remove nut and flange (1,2), then remove the nuts on

spring gasket of inlet valve and outlet valve, take out spring gasket, spring, fitting

sleeve, valve plate (3, 4, 5, 6, 7) (refer to Illustration 1-3a), put valve remover into

valve base, rotate it clockwise until the feet of remover hitch the bottom of valve

base (refer to Illustration 1-4a), then use spanner to pull out the valve base. If the

valve is jammed by dirt and rust, and is difficult to be removed, please heat up the
valve base, then feed water into it at once to cool it down, thus the valve base can

be pulled out easily. Also, the valve base can be removed by using jack.

4.2.4 Install inlet valve and outlet valve in a reversed order, please clean the

valves before installation, remove burrs on the components, and smear lubrication

on friction parts during installing.

4.2.5 To install inlet and outlet valves on 3GP-23/20.5 pump:

a. Use coal oil or diesel oil to clean anti-rust cere on the taper side of inlet valve,

out valve and valve base.

b. Put inlet and outlet valves into the pump in a top down order, put valve

installation-tool on the valve base, knock upper part of the tool with hammer,

making the taper side of valve base closely contact with taper side of pump.

Illustration 1-3b
 Illustration 1-4a

泵体 pump 排液阀阀座 inlet valve base 进液阀阀座 outlet valve base 扳手

spanner 拆阀工具 valve remover

4.3 How to dismantle plunger and sealing gasket (refer to Illustration 1-3,1-4).

4.3.1 Remove front flange (2), use hook to remove plug (4), loosen the screws on

central pole and plunger, use hook to pull out plunger from B side.

Generally, if to dismantle the plunger is the only purpose, it is no need to remove

inlet valve and outlet valve.

4.3.2 To dismantle sealing gasket and guiding sleeve, please remove the plunger

and adjusting bolt first, use pole knock out sealing gasket and guiding sleeve. The

dismantling should be processed by the following order: front guiding sleeve,

sealing gasket, back guiding sleeve. (refer to Illustration 1-6)

 调节螺母
柱塞

吊钩

图1-4

Illustration 1-4

柱塞 plunger 调节螺母 adjusting nut 吊钩 hook

1 2 4 5

图1-6
B 1. 后导向套 2. 密封圈
3. 阻流隔环 4. 前导向套
拆密封顶杆
拆卸头

Illustration 1-6

1. 后导向套 back guiding sleeve 2. 密封圈 sealing gasket 3.阻流隔环 spacer

ring 4.前导向套 front guiding sleeve

拆御头 pole head 拆密封顶杆 seal remover pole

4.4 How to install plunger and gasket

4.4.1 Before installing, please clean plunger and gasket, and remove the burrs on

them.

4.4.2 Install guiding sleeve and sealing gasket into sealing case, make sure the

stability and fastness meets requirement, tighten the adjusting bolt. Push in plunger

from B side, tighten the screws on central pole and plunger (refer to Illustration1-5,

1-3).

Illustration 1-5
 4.5 Fitting intervals of gearing part

No. Part Interval Value Annotation

1 Axial interval between shaft-base

cover and main shaft

2 Radial interval between crankshaft

and shifter pole’s arbor-collar

3 Axial interval between crankshaft

and shifter pole’s large end

4 Radial interval between shifter pole

and crosshead pin

5 Radial interval between crosshead

and guidance-hole on the crosshead

V. GROUNDING & INSTALLATION

1. Grounding (refer to grounding drawing)

Please design the depth of grounding according to local geology.

2. Installation

1. Before installation, please check relative position of the holes drilled for

installing anchor-screw, level off the grounding and check its leveling.

2. Lay stow-iron beside anchor-screw hole, put the pump on stow-iron, then

insert the anchor-screws, concrete the grounding. After 5 to 7 days’ concreting, take

out stow-iron, use gradienter to check and adjust level, tighten the anchor-screw
when the level meets requirement.

3. To reduce friction and additional pressure, please install the feeding pipe and

draining pipe in line. To check relief-valve’s working condition easily, please DO

NOT bury the draining pipe of relief valve under ground. After installation is

finished, please use high-pressure water or high-pressure gas to clean the pipes

ahead of operation.

4. Connect lubricating pump’s circuit.

5. Connect inlet pipe of the cooler with outlet pipe of feeding pump, the

connection mode of cooler’s inlet and outlet pipes is customized by user.

Grounding Drawing

H1
H
D

D
B1
B

L2 L2
L1
L
 Model L L1 L2 B B1 D H H1

3GP-7/20 2450 2000 1000 1060 660 200 650 450

3GP-9.2/20 2450 2000 1000 1060 660 200 650 450

3GP-11.2/20 2540 2090 1045 1060 660 200 700 500

3GP-23/20 3160 2660 1330 1270 820 250 800 550

6. After the installation is finished, please check the screws’ fastness, as well as

the tightness of all belts. Clean both inner side and outer side of the pump, then put

enough lubrication into oil container. Check motor, and electrical circuit before

operating.

VI. PRECAUTIONS ON OPERATING & STOPPING THE PUMP

1、Operation Steps

1. Check the fastness of all screws and junctions.

2. Check oil quantity and oil volume.

3. Check the tightness of belt and adjust them if necessary.

4. Check motor and circuit-connection.

5. To check operation smoothness of the pump, please jog the pump manually to

rotate large belt wheel for more than two circles.

6. Open the valve on inlet pipe, and the by-pass valve on draining pipe, as well

as draining valve on the pump body. Close draining valve if all substances drained

out from it are oil instead of air.

7. Operate lubricating pump check whether the working pressure is normal.

 8. Power on the pump after operation security has been confirmed (MAKE SURE

THE PUMP IS UNLOADED, WHEN STARTING UP PUMP).

9. When the pump reaches rated speed, close by-pass valve, thus the pump

begins to operate on-loaded.

2、Stop the pump

1. Open by-pass valve, the pump begins to operate unloaded.

2. Shut down the power.

3. Close all valves on inlet pipe and outlet pipe.

3、Precautions

1. DO NOT OPERATE PUMP IF THERE IS NO LIQUEFIED CO2 IN THE

PUMP.

2. DO NOT OPERATE PUMP IF THE VALVES ON FEEDING PIPE AND

DRAINING PIPE ARE CLOSED.

3. The lubrication cooler functions to control the temperature of gearing part.

Open inlet valve when lubrication temperature is above 60℃, adjust or close the

inlet valve if the lubrication temperature is below 60℃.

4. If the pump is newly installed or is lately repaired, please keep the pump

idling for at least 2 hours before it is on-loaded. It is recommended to boost

pressure in every 30 minutes, and 1/4 of rated value per time. Stop and check the

pump if any trouble appearing, do not operate the pump until the pump is repaired.

Boost pressure directly to the rated value if the pressure could not be boosted

linearly, but make sure to keep pump idling for at least 4 hours before it is

on-loaded.
 5. The highest instantaneous pressure must be controlled below 110% of rate

pressure.

6. To avoid any accident, DO NOT REPAIR THE PUMP WHEN THE PUMP IS

RUNNING.

VII. PERFORMANCE CHECK-UP DURING OPERATION

1. Check the mechanical noise of running part, as well as the lubrication volume.

2. Check the temperature of all parts, shaft temperature must not go beyond 75℃,

motor temperature must not go beyond 90℃, lubrication temperature must not go

beyond 70℃,temperature of plunger’s frictional parts must not go beyond 75℃.

3. Check lubricating pump’s operating condition, lubricant pressure should be

above 0.2Mpa.

4. Check whether the output pressure and draining-amount meet requirement.

5. Check feeding valve and draining valve, abnormal noise should not be allowed

to occur.

6. Always check the fastness of adjusting nuts on sealing case. If there is an

amount of liquid leaking from plunger, please stop and check the pump, tighten

adjusting bolts or replace sealing gaskets if necessary.

7. Always check the fastness of all screws and flange nuts.

VIII. MAINTENANCE

1. Lubricant model.

Use 40CC(or CD) diesel lubrication (GB11122-1997) 50W/30, 10w/30 in

summer. Use 30CC (or CD) diesel lubrication (GB 11122-1997) 5W/30, 10w/30 in
winter.

SAE 20W/50 can be used as a universal lubrication in all seasons.

2. To the new pump or fully repaired one, please replace lubrication after 500

hours’ operation.

3. Check and clean oil container and magnetic pole periodically. To the new pump,

periodically clean the filter at feeding port.

4. Periodically check and adjust relief valve, make sure its output pressure is 1.08

to 1.1 times of rated operation pressure. In case that the relief valve leaks, please

take a sanding process on the valve core and valve base by using abradum, then

take a finely sanding on them by using alundum before installation.

5. Periodically check the accuracy of manometer.

6. Periodically check the tightness of belts, replace the whole set of belts instead of

only displacing one belt. Do not use new belt mixed with old one.

7. Replace damaged components with new ones in time.

8. Check and adjust the interval of all parts, as well as the fastness of all screws.

9. If the pump (especially the sewage pump) will not be in use for a long period,

please drain up liquid and clean the pump with water, then dismantle all valves,

smear them with antirust grease, and take anti-erosion maintenances.

10. The pump idled for a long period should be fully checked before re-operating.

11. Maintenance period of the pump is recommended to be 12000 hours.

IX. TROUBLESHOOTING

No. Trouble Causation Resolve the problem

1. Bolts on shifter pole may

1. Tighten the bolts on
be loosened.
shifter pole
Mechanical 2. Friction interval of shift
2. Adjust arbor collar,
noise of pole’s arbor collar is too
1 or replace it with
running parts large.
new one
is abnormal. 3. Other components on
3. Replace the
running parts may be
loosened component
loosened.

1. Fitting interval of the shaft 1. Re-install the shaft,

does not meet requirement re-adjust its fitting

The shaft’s 2. The shaft may has some interval

2 temperature is dirt inside 2. Remove the dirt

too high. 3. The shaft needs lubricating 3. Lubricate the shaft

4. The shaft is worn out 4. Replace the shaft

caused by over-operating. with a new one

 1. Clean the filtering

1. The filtering pole may pole, or replace it

work abnormally. with new one

Lubrication 2. The intervals of all parts in 2. Re-adjust the

3 pressure is lubricating pump do not intervals or replace

unstable. meet requirements. the pump with new

3. Lubricating pipes may be one.

blocked. 3. Clean the pipes or

replace lubrication.

1. The installation of drive

Lubrication part does not meet 1. Re-install drive part

4 temperature is requirements. 2. Improve lubricating

too high. 2. Lubricating does not meet quality.

requirements.

1. Pressure accumulator or
1. Repair or replace it
ball bumper does not
The with a new one
function well
manometer 2. Replace the valve
5 2. Feeding valve or draining
vibrates with new one
valve may leak
seriously. 3. Replace the gasket
3. Sealing gasket on the
with new one
valves may leak
 1. The nut on the flange is 1. Tighten the nut
The flange
6 loosened 2. Replace the gasket
leaks
2. Sealing gasket is damaged with new one

1. Adjusting nut is loosened

2. The sealing gasket and

1. Tighten the nut
Plunger sealing plunger are abraded
2. replace the sealing
7 case leaks 3. There is dirt in the
gasket or plunger
seriously material which the pump
3. Remove the dirt
transported, the material is

not clean

The sound is 1. The flange nut on pump

1. Tighten flange nut
asymmetric body is loosened.
8 2. Replace valve base
when knocking 2. The valve base or the valve
or valve core
valve cavity core is damaged.

1. The pump may have gas in 1. Vent out the gas

it 2. Repair the valve or

Feeding pipe 2. Feeding valve and draining replace it with new

and draining valve leaks one

9
pipe vibrates 3. Sealing gasket on the 3. Replace the sealing

seriously valves is damaged. gasket with new one

4. The pipes may be not fixed 4. Reinforce the pipes.

well. 5. Clean filter, check

 5. Feeding pipe is blocked the pipe

6. Valve spring is damaged or 6. Replace the spring

broken. with new one

1. Check or replace
1. The motor’s power is
Pump power is motor
10 lower than required.
insufficient 2. Adjust the belt’s
2. Belt loosens
tightness

CARGO CONTENTS

No. Name Quantity Remark

1 Pump 1 Driving part and

Hydraulic part

2 Base plate 1 On pump

3 Belt wheels and V shape belt 1 On pump

4 Belt shield 1 On pump

5 Motor 1 On pump

6 Pressure buffer 1 In cargo

7 Manometer 1 In cargo

8 Relief valve 1 On pump

9 Special tools 1 set In cargo

10 Electric panel 1 Depends on the

contract
 SPECIAL TOOLS

No Name Quantity Use

1 Hook 1 Dismantle plunger

2 Hook 1 Dismantle plug

3 Long hook 2 Dismantle valve core

4 Valve base remover 1 set Dismantle inlet and

outlet valve base

5 Adjusting pole 1 Adjust nut

6 Supporting pole 1 Dismantle sealing

gasket

7 Guiding pipe of sealing gasket 1 Install sealing gasket

and sleeve