wm HAN A OPERATOR'S SS MANUAL XS HP- 100L, HP- 100M, HP-165L & HP-165M ~q PLUNGER PUMPSFig. HP-100L, HP-100M, HP-165L And HP-165M Plunger Pump Installation Instructions) Introduction introduction Wheatley pumps are manufactured in accerdance with the highest standards demanded by the pevoleum industry. Proper maintenance and care will prolong the period of satisfactory service. and reduce costs ‘These instructions were writen to promote the care, opera tion, and matatenance of your pump. When trouble arses out- side the scape ofthis manual, our Engincering Deparment and all other factory facilites are ready to help you. Feel free 10 To improve our products, we must be informed of the peab- lems and solutions which occur inthe field, Werecquest that you send 10 us shor reparts of your experiences. Include the pump figure and sersal numbers the operating conditions, the prob- lems, and the solution, if any, and forward to. Wheatley, ATTENTION: Engineering Depateent, P.O. Box 3249, Tulsa, Oklahoma 74101. Your help will be greathy appreciated. Service Wheatley has distributors throughout the United States who have servicemen available in cate af emergency ofa major overhaul, Mott of these diseibure's have peas available and can give you the necessary heip in service work. We prefer that all service be handied through an authorized distributor: however, in extreme emergencies, Wheatley can dispatch 2 serviceman. This normally will require 2 24-hour notice General The Wheatley Figure HP-100 and HP-165 pumps, when properly instalied and when given good care and regular maintenance, will operate satisfactorily tor 2 log period of time. The following paragraphs discuss the general principies thar must be considered ta insure rouble-itee operations, Storage All Wheatley gumps are tested, inspected and protected against corrosion tor the period of chipmeat and installation paly lithe puro 15.901 10 be installed at ance, reer to the section enttied "Preparation of Pkunger Pumps Far Exiended Starage.” Location of Pump ocate the pump in a clean, accessibie piace. so it can be inspected at segular intervals during operation, Place pump as lose wthe liau'd supply as possible, sa.as to make suction aipe 2 shomt ane direct. Provide ample head roam far crane, hoist oF tackle, Protection of Pump Against Seepage or Flood Wit is necessary to place the pump in a pit pravision should ‘be made to protectthe pump from water that may come intothe pit from seepage or flood. Provision for Servicing Space whether mounted on the flocr, oF 3 foundation above the {1g0r tevel, or tn a pit, suificient room should be allowed for removal of plungers, rods, crankshats ec., andor inspection of wearing pars as recommended in this manwal Leveling The Unit Metal blocks and shims ar metal wedges having a small taper should be placed close to the foundation bok. Small jacks made of cap screws and nuts are very convenient. In each case, the suppors shavid be directly under the pan carrying the sreatest weight and spaced closely enaugh ta give uniform support with minimum deflection ofthe uni A gap of about 344° to 17 should be allowed berween the baseplate end the foundation or grouting. ‘Adjust the metal supports or wedges until the shalts or rods of the pump are teva ‘On purmps where couplings are used, do nor connect the coupling unti ll pump and driver alignment operations have bbeen completed. Check the coupling faces, suction and dic charge flanges of the pump for horizontal and vertical position by means of a level, Corcect the positions, if necessary, by acusting the supaonss or wadges, a5 required Foundation Pumps can be located on the oor or suppoting surface, provided that the supponing installation area is subiciently strong to supportat least 150% ofthe total unit weight including river. Pump foundations should be reinforced concrete, to seston dard pan ledge er piling, and about 12" above the surrounding Foor level itshould be entrely independantot walls orfootings, building supports ar loce structures. Proper concrete mixture, correct reinforcements, sufficient mass and satisiactory footing are essential to give rigid, permanent support to prevent vibra- tion, The bearing presses allowad an soil vary widely depend- ing on the underlying nature ofthe soi, 1ocal building laws. etc. ‘This data, available in engineering handoooks and manua's, should be carefully investigated.FOUNDATION BOLT Founparion our: ove FOOT A igsramaias Sree Foundation Bolts Locate the foundation bolts zecording to the elevation draw- ing. Set bolts in sieaves 2 3 times the baitdiameter ta allow for varation in purnp pans or baseplates. The sleeves should be held rigidly yet allowing the bolts ta be moved. Do not ill the sleeves with grout until the. ence unit has been accurately sligned, supported and feveled. ‘The frame or baseplate when so designed should be com- pletely filled with grout. Holes are then provided to serve as filing and vent holes. Do not leave leveling piecas, shims or wedges in place if grout shrinks while hardening. If leveling screws are used, backoff ater rout has hardened. Themachine ‘must NOT finally est only on eveling pieces or shims of ques- tionable area, wedges with the line contacto” screws with paint ‘contac, Foundation bolts should not be ‘finally tightened until the grout has fully hardened, usually about 48 hours after pouring. Piping Pipes must fine up naturally. They must NOT be forced into place with flange bolts, as this may force the pump out of alignment. Pipes should be supported independent of pump, s0.a5 pot to produce ary stain Variations in flaw and pressure, changes indirection of iow, ‘cavitation, warn glungers, pump valves, ec, all contribute to piping vibration. Therefore, suction and discharge piging must, be rigidly fixed in all directigns and nat just ight strapped down, Flush, clean and blow aut sl piping belore connecting to pump. Use pipe dope anc tape oniy sparingly, and on the male threads ony Flange and Fittings Flange fitings, unions aed flexible connectors should be located close 10 the purnp in all pie lines, so a5 to facilitate removal of pum Alignment must be rachecked afer suction and discharge piping have been bolted the pump, ro test the eifectof piping strains. When handling hot or extremely cold liquids, discon rect the nozzletlanges after the unithas been inservice tocheck the direction in which tha piping expansion igacting. Correct for ‘erain eect as required w obtain true flange alignment Suction Piping ‘The suction piping should be as direct and fee of bends and as shom as possible and equal or larger than the pump suction. ‘When the piping length exceeds twenty feet, the diameter should be determined by the calculation af triction lasses and the fluctuation in suction pressure due to liquid acceleration. ‘Thepipe should be ‘aie without high spets and havew continual rise upward towaed the pump. 4 ful-opening valve should be located in the suction piping. A positive suction pressure, ifom gravity arbaoster pump, akwaysis desirable. The pump must be able ta be icolated forservicing, Where asuction itis invalved, ‘the purnp manufacturer must be consulted Piping should be pressuretested, An air leak in the suction piping, especially where a lifts involved, will seriously afect the capacity, Where a booster pump is used to celiver liquid 10 the reciprocating pump suctian, the piping from the liquid source te the baaiter and from the booster othe pum suction should never be smaller than the pump suction opening, Foot Valve ‘When operating on a suction fi, the pump suction should include afoot valve which wil! keep the pump primed. The net area of the foot valve shauld equal or exceed the area of te suction pipe. Strainer To protect the pump from foreign matter, a suction strainer ‘nay be installed with 9 et area three or move Gimes the area a suction pi The steaine’ must be cleaned requenty, to maintain a flow area exceeding the suction pipe area. A clogged strainer wil! reaule in pump eavitation and serious damage. Thereiore, the strainer, # used, ewst be readily accessiole for cleaning and inspection. A pressure gage should be installed near tie puro. If the pressure fails beiow the original stat-up pressure, the strainer ‘must be inspected. Wherea Suction lt isinvoived, a compound sage must be used. ‘charge Piping “To Facilitate starting and eliminate air, aby-pass valve should be installed cfose to the pump. Alen, to protect the pump. asiop 3valve and a check valve should be employed. IFan inereaser i used to increase the size of the siping, it should be placed between the check valve and pump. The vibcation in pipe lines must be minimized, with lines as short and as direct as practicable. When a change in direction is. required, jong radius elbows and tees or a 45° bend in the pine itself should be wilized “Dead-ends” must be avoided. Hydraulic systems, using quick closing valves or similar mechanisms, must provide some means for absorbing the shock resulting from the sudden open ing oF closing of valves Adequate provisions should be made for anchoring high pres- sure piping. Relief Valve ‘The insertion ofa discharge relief valve of suitable size fo: the capacity of the pump, set 0 open at a pressure above the ‘operating discharge pressure required of the pump, is manda- tory because of the safety it afords. The relief valve should be placed inthe discharge ine close to the pump and ahead of any other valves Fullopening, pilot-operated, or shear pin relief valves, or burstdiscs, which require little or no over-pressure to develop fully-open flow capacity are often preferable to spring-loaded relief valves. Spring types may require considerable over- pressure to compress spring, beiore becoming fully open, creat- ing muck pump overload. Pressure-elief valves have a “set” pressure, which may be described as the pressure at which the relief valve cracks and begins to open, allowing some flow to pass through. As additional pressure is applied, above this “set” or “crack” pressure, the spring-loaded relief valve will gradually increase its part area — until fully open, When fully open, the relief valve must have sufficient capac ity so it will relieve the full capacity of the pump without excessive over-pressure, Available spring-loaded relief valves differ among manufactures inextent of over-pressure needed to ‘open from the barely eracked to the fully open, fully relieved position, This range is generally 10% to 25% above the set pressure, depending on spring design. By choosing a larger valve, this increase may be reduced. Recommended Set Pressure ‘The pump relief valve has the purpose of protectingthe pump. full rated pump pressure is desired, select a set pressure 10% above the maximum rated pressure forthe specific plunger size being used, or the prescribed system operating pressure, if lower. {fan attempt is made to set a relief valve too close to the average discharge pressure, the valve will crack, leakingslightly due to pump pulsations. Leakage will quickly ruin the relie! valve seat. Hence, the valve must remain closed during normal ‘operation. t must not leak, li plunger size is reduced or increased later on, the relief valve setting must be altered accordingly. Always install a pressure gage ahead of the relief vaive so it reads the true pump pressure while relieving. The exhaust irom the elif valve should always be directed to supply tank —and not to pump suction. The line fcom the relief valve to tank must be of fullsize and, if cof great length, compute the pressure-drop through it, Addthis lime pressure loss to that within the relief vaive itself — when sizing the relief valve, anc estimating relieving pressure. Where possible, pipe the relief valve exhaust to the sewer so that any leakage can be observed. Drive Alignment After Piping Installation After piping has been installed, the pump-prime mover drive alignment should be checked again and, if necessary, corrected Surge Chambers (Desurgers) ‘A good suction and discharge pipe layout for reciprocating pumps of conventional type frequently requires no devices to ‘compensate for normal vibrations in velocity of flow in the piping system, Where the suction or discharge line, or both, are of consider- able length, or if the suction is under a static head or poor design, or where the liquid handled is hot, a desurging device of suitable size for the suction or discharge lines, or both, may ‘sometimes be necessary to insure smooth, quiet operation of the system. The size and pre-charge of the desurger will depend ‘upon the type of pump, the fluid and the layout of the piping systems. Recommendations as to size and type of desurging devices should be obtained from the desurger manufacturer, making sure to send full information as to piping instalation. Without complete knowledge ofthe layoutot the piping, itis not possible for the desurger manufacturer to determine intelli- sgentiy the size and pre-charge of desurger chamber, or whether fr not such chambers may be necessary. Desurging devices, if used, should be considered asa partofthe piping system, rather than a. a pump accessory. In general, suction desurgers are more frequently required than are discharge desurgers ‘Where desurgers are used, provision should be made to keep them charged with nitrogen or similar inert gas in accordance with the equipment manufacturer's cecommendation. An exhausted device sof no value. A water level gauge is desirable to permit a check on the amount of air in a conventional ait chamber. Desurgers, particularly on the suction, should be located as close as possible tothe pump and in such position that they will absorb the impact of the moving liquid column and thus cush- ion the pulsations in the most eficient manner. ‘The suction chamber volume can be atleast 3 10 4 times the single stroke displacement per revolution. It is always better 10 shave 2 chamber larger than required. The extra aie volume will result in longer operating periods betore the air is absorbed in the water and necessitates recharging, Caskets, Pipe Dope and Pipe Tape ‘The gaskets, pipe dope and pipe tape used in the system piping are exposed to the same conditions of high or low tem perature, oF values, etc. as the pump parts. Careful selection .Correct Tensions For V-Beft Drives To establish correct tension in single or multiple v-hele drives requites the use of a small soving scale, applied at the center of the belt span ~ Deilection Measured Here Soa feng Apply spring pressure (othe tightest belt of the sei to produce the fotlowing belt detections. Then read the scale and lighten or foaten 2s needed below ~ roximate Belt Span 2a" | 32°] 40" | aa Farce tor New rr Belts, Pounds 2.25 (03.0 3106 3751013, 1651022 S5to7 1510148 Belt Size Force for Normal Section Tension, Pounds ma 15 102.25 “— 3.25105.0 “e 6.510.9.75 “0 010165 av 4t0S5 By, 9.5 0113 Ey | DEFLECTION DEFLECTION DEFLECTION DEFLECTION PNG DEFLECTION 516 DERECTION 5a a4 8 1546 DEFLECTION ‘nacessary to avoid jomt failure and the air and iquid teak’ that fallow. “yt -Belt Drive Alt drives must be aligned, The driver and driven shafts must be parallel, and the “\"-belis at right angles to these shat. Misalignment will cause undue helt wear, ar tura-over in the grooves. Alignment should be checked by placing @ straight edge evenly across the rims ef both sheaves. W the face of the sheaves are net of equal width, the elign mentcan be checked by rsting tho straight edge across the vim ofthe widest sheave and easing the distance from the straight ecige othe nearest bell groove witha scale, Adjustether sheave onthe shait la equalize these dimensions ‘The driver should be mounted with adequate provision for beit center distance adjustment, Provide ¢ minus adjustment 10 peer bet installation without stetching and plus allowance to provide belt take-up Do not pr, twist, or force the belis over the sheave grooves This will damage the belis and greatly teduce the belt lie Shorten the dite by moving she driver snough to permit fing, the belts in the proper grooves. When the belts ace in piace, increase the centers until prapar belttansion is obezined. Adjust there unt oni a slight bow appears on the slack side. Ali of By 221029, 291035, For new belts inital tension values should revert to normal values after 24 haurs aperation the belts must2e pulling evenly, Belt tension should be reason- able. tis not necessary io have oelts “idle sting" Ugh During the fret few days of operation, the belts will seat themselves in the grooves, Therelore, the dive must be tight- ented to take uptine slack, Keep belts clean and (tee from ail, Clean oily belts with a sloth dampened with soap and water, There should be a free ‘ircuation of ait around the drive. Excessive heat reduces the life ofthe belts. inusedbelts. Do Never install new belts on the same drive not use sheaves with chipped oF worn grooves, For hazardaus locations, an antstatic-bll should be uses. Consult “V-belt manufacturers tables and data for recom. mended “V" elt cross-sections and belt length, When purchasing replacement "V-belts, the same size and type should be ordered as furnished originally. Slipping belts will result in léwer capacity. Check puma speed with rachameter.Itsheuld equal driver speed mutiptied by driver sheave pitch diameter divided by pump sheave pitch clameter. Squeating ar smoking belts are often the clue to the slipping ofbels, but act always.