series) 100 TEXSTEAM Pumps GAS/PNEUMATIC DRIVEN INJECTION PUMP DESCRIPTION ‘The 5100 Series Texsteam Chemical Injectors are single acting, positive displacement plunger-type pumps, powered by gas via a diaphragm with a spring return, Speed control is accomplished by regulating the exhaust gas discharge flow. Reversal is accomplished by a direct spring- actuated Switching mechanism (rotary three-way valve). Volume is controlled by the speed of the pump and by the stroke length, either 1" or 1/3” lengths. The $100 Series is capable of pumping high pressures with {gas pressure as low as 8 psi and handling volume output up to 30 gallons per day, The pump is lightweight, compact and contains a minimum of working parts for easy maintenance. Each fluid pump head is equipped with a stainless stee! plunger, ball checks, ball check springs, top seat, top bushing, bottom bushing, adjustable VEE type packing and a priming valve. The packing yoke is equipped with a drain to monitor for possible packing leaks Beoauseioftharsealed bearings) ‘the unit is oles. Series 5100 LP Wn 45 pounds Microswitch Option Available The 5100 Series performs accurately because (1) the head is designed for high volumetric efficiency, (2) a positive trip machanism assures fine contol of plunger stroke length, and (3) the speed is regulated by controling the exhaust gas discharge tlow which creates 2 rapid fluid discharge with slow suction APPLICATIONS ‘The introduction of de-emulsifiers, solvents, corrosion inhibitors, de-salting agents and flacculant in oil country operation + High pressure bearing lubrication + Water treatment + Blending processes in refining and process plants ‘+ Injection of methanol in gas pipelines + Hydrostati testing + SamplingACCESSORIES, OPTIONS, & VOLUME ‘Sour Gas Trim - Pump models L and LP are furn’shed with sour gas ‘rim as standard, Models H and HP are available for sour gas service | 5199 Series (Standard Packing) Model Number Maximum Volume specification ae"_[ 1500 PSI 5104 4260 ‘TB-40 Regulator - for inlet gas 1 $ eae — Ao pressure greater than 36 PSI and — S upto 1500 PSI Tz TS00PSI 5105 S20GPD (igh Pressure Packing) Model Nunber Maximum Volume Alternate Parts - Teflon, Viton, or |” angr | —go002S am 78 SPD Fluorosilicone packing, hastelloy "Te BOOOFS Atal ee balls a S000PSI 5103 12.0 GPO. Vz —|3500PS 5105 22.06PD |: Bsc pune no ing ae, gu a hn ei: 5, 1. Hime ith Saar sarees stele runedon ty ges wh fl guge a sucton In ba e requ or auae hoara Wnt Se 4. Fume Wi eater and gun ut ean oe Shp Weg a8 Be ‘tne gouge suetor tw, arse gage Shang Wee een) ales shown for lw pressure heads with sancare packing af at zre PSIG dlscharge pressure. ‘Noire arbinh prose se win ad pas ae sown 1300 P51 asaya bus a equpond Model 5105 1/2" Plunger 1" Stroke a unger | Operating Rate Sie | rides aig — eon z Model 5105 1/2” Plunger 1" Stroke Gallons Per Day Model $105 1/2" Plunger 13° Stroke Model $101 1/4” Plunger 1” Stoke Model $193 3/8" Plungor 1/3" Stroke Model 8104 3/16" Plunger 1" stroke Model 6101 1/4” Plunger 1" Stroke Model 8104 3/16" Plunger 1/3" Stoke o 3) 6 Sk Stroke Per Minute (1” Max. Stroke Length) For int reguiator sizing, GAS CONSUMPTION CHART (Standard cubic Feet of Gas Required to Pump One Gallon) double the requirement indicated oda SIC OD 2" Plunger 1” Stroke | st0s| ss | s4 | s7_| ez | mm | 76 | a4 | 95 12" Plunger 1/8" Stroke 153_| 162 [a7t_| 186 [213 [228 | 252 | 2a5 3/8" Plunger” Stoke | 6108 | 120] 126 | 148 | 164 | 177 | 195 | 243 | 278 | 314 | 365 | a74 3/8" Plunger 1/3" Stroke 360_| 378 | 4a | aoz | sar | 555 | 729 | #34 | 942 | 1055 | 1120 4" Plunger” Stroke | stor |_284 | 245 | 248 | 270 | 288 | a08 | 340 | 355 | 369 | 405 | 407 1/4" Plunger 18" Stroke 7sz_| 735 | 7a | 810 | s64 | 924 | 1000] toes | itor] i215 | 143i BAB Plunger T Stowe | S104 | __4e7 | 438 | 462 | 46a | are | 530 | 45 | 55 | 560 | 575 | 589 3/16" Plunger 1/3" Stroke ia7t_[ 1374 [ase | vao7| 1428 [1590 [ 1635 [ t665 | ses0] 1725 [1776 2INSTALLATION on 9 1, Remove pump from carton and inspect for possible damage in transit from factory. The cardboard carton was designed especially for this pump and offers ample protection for normal handing. It the pump has been damaged in transit file claim with the cate. 10 2, Loosen and remove the four thumb screws that hold the cover 3. Oilthe thrust rod 4, Select the stroke length desired, ether ful or short according to your requirements. See the data chat, fll stroke is 1, and short stroke is equal to 13", 5. Check plunger packing oland to make sure packing is 1/4 ‘turn past finger tight n 6, Install the priming valve TA-1497 init position on the pump head 7. Blow or clean tine before hooking up ar or gas tne to inlet, On models 5100 LP and 5100 L te ar or gas line (i it does not exceed 35 psi is piped directly into the inlet TA-908. The inlet is @ 1/4” female connection. Do not hook up the gas supply to the small valve, This isthe gas exhaust, Gas supply should be constant pressure to assure even stroke speed Ifthe gas supply pressure exceeds 35 psi ors erratic, some means of reducing the gas pressure to below 35 psi must be used, Model 5100 HP and 5100 H are equipped with a pressure regulator and pressure gauge for reducing the gas pressure. The regulator supplied with the 5100 HP and 5100 H can be used up 400 psi. ifthe gas supply pressure exceeds 400 psi, the customer should equip the pump with a Texsteam TB-40 regulator which has a maximum inlet pressure of 1500 psi. START UP AND OPERATION 12. Close gas exhaust valve, The gas exhaust is a 1/4 female pipe connection. Hook up the fluid suction piping to the bottom bushing on the pump head, This is a 1/4” female pipe connection. Care should be exercised in that a suitable strainer should be installed in the suction line to trap foreign matter that might injure the plunger, plunger packing or interfere with the check valve operation, ‘On hooking up the fluid discharge line, the top connection on the pump head is the outlet and itis a 1/4” FNPT. The discharge line should be at least 5/16" tubing and a TA-676 line check should be installed at the point of injection in case the fluid discharge line ruptures or is broken. Gareful observation ofthe flow direction during installation wil eliminate the possibility of a ruptured fluid discharge line. ‘Tum the gas on and slowly open the gas exhaust valve The pump will start automatically, Make certain the suction line is filled with fluid by opening the priming valve to check for fluid. After the pump discharges clear fluid without bubbles, close the priming valve for normal pumping operations. At this point make a visual check of the plunger drip and using the TA-316 gland \wrench, slowly tighten the gland nut until leakage just stops. It may be necessary to readjust the packing the next day. A slight leak during break-in is beneficial Sufficient time should be allowed to let the packing ‘seat in’. Packing should only be adjusted after pres ‘sure has been removed from the pump head, Never adjust packing against pressure. After the pump is in operation, replace the cover and thumb screws. Ate the pump has been installed, only a few minor adjustments are necessary for every day operation, Here are a fow check points. 1. Check gas supply pressure 2, Check speed control with the chart wich will ive you the volume the pump is injecting, 3. Check for excess leakage around the packing gland, i is not possible to stop excess leaking, replace the packing. Ifthe plunger is badly scored, replace the plunger, Do not adjust packing against pressure, 4. Open the priming valve to check pump action. 5, Oil thrust rod occasionally,MAINTENANCE Should the pump run but fil to pump chemical, remove TB-736 bottom bushing and TA-1496 top bushing - inspect and clean balls and seats. Inspect for damage and replace if necessary. Should pump still not pump chemical, remove ‘TB-548 cover and check to see if TA-290 Cotter Pin and TA-1828 Stroke Adjusting Pin are in place CCheck to see if chemical is getting to pump, unscrew TA-1497 priming valve stem. When chemical flows from bleed hole, shut TA-1497 priming valve It the pump fails to operate after hooking up gas or air to ‘TA-906 (inlet bushing); make sure the inlet pressure does not exceed 35 psi - excessive pressure could tend to lock the pump; make sure the speed control valve (gas exhaust) is open; and make sure the plunger packing 's not too tight. Use gland wrench TA-315 to adjust packing gland nut TA-6353, if necessary. It pump stops and a constant flow of gas comes from TA-1836 air vent, this means that the TC-2128 diaphragm has ruptured TO REPLACE DIAPHRAGM Remove TC-252 diaphragm cover. Remove lock nut and washer on end of TB-444. Do not allow TB-444 thrust rod to turn when removing lock nut and washer. To prevent the rad from turning, remove TB-S48 cover and hold the rod in position by inserting punch or drift pin into the “large” hole forward of the TA-6564 Stirrup assembly. Replace burst diaphragm and reassemble. TO REPLACE RETURN SPRING Remove TC-252 diaphragm cover - remove lock nut and \washer on end of TB-444 thrust rod. Itis important that you ddo not allow TB-444 thrust rod to return when moving lock nut and washer. To prevent the rod from turning remove TB-548 cover and hold the rod in position by inserting punch or drift pin into the “large” hole forward of the TA-6564 stirrup assembly. Pull TC-2128 diaphragm - TB-438 diaohragm plate - return spring TA-1821 can then be removed. Reassemble in reverse of above. REPLACING TA-4147 VALVE DISC ASSEMBLY It the pump has a heavy continuous leaking of gas — TA-4147 valve disc assembly probably needs replacing Disconnect power supply into TA-906 disc retainer. Remove ‘TA-906 Disc retainer from TA-441 body - caution: care ‘should be taken not to lose TA-77 valve spring and TA-S79 washer located directly under TA-906 disc retainer. Before removing, note the position of the TA-4056 valve disc, so thatthe disc is replaced to the same position as it was removed (see page 8). Lap the TA-4056 disc with a good valve grinding compound before replacing When replacing TA-4056 valve disc be sure to also replace the TA-4062 drive pin that was supplied when you ordered the disc assembly. REMOVING TB-446 VALVE ASSEMBLY FROM PUMP HOUSING Should it be necessary to remove TB-1631 flipper arm assembly from the pump housing, disconnect TB-1193 SS tubing, the power inlet from TA-906 disc retainer and the gas exhaust line. Remove the four PO1-031100-3800 machine screws and four P52-031000-8900 lock washers. ‘The TB-446 valve assembly can then be withdrawn from pump body. ‘The tipper arm bearing is an integral part of the TB-1634 flipper arm assembly and is press fit into the TB-441 body, A punch must be used to remove the flipper arm from the valve body, To do this the procedure under the heading, “Replacing TA~4147 Valve Disc Assembly,” must be performed. When these parts are removed the TB-1631 flipper arm assembly may be punched from the body. Upon reassembling the lower shaft of the TB-1627 flipper ‘arm must fit into the TA-6563 flipper spring adapter. TO REPLACE THE FLIPPER SPRING Follow the procedure as outlined under “Removing TB~446 Valve Assembly from Pump Housing.” Ater removing the valve assembly, remove TB-$48 cover. At this point TA-6564 stirup assembly may be turned upside down on the thrust rod - unscrew TA-1820 flipper spring, To reassemble follow the above procedure in reverse,LP & HP ae SME ste ax, Ca~ tue tee oe ka y——20\, rursnes / \ ae sf eae [Loman | caste ‘lyase =| tera ee mae fine Sain ETL sap Sinen haga — fo =| te ae fest a Ter [pore srg hie a frets fig ee a [esa fa ag ey — fea Sa se [teste [1 Se sever {ean [1 erg —[ se Tre (fener eae esp et eas 1 feat fron + ferme Tisat — [fe ta is — [i Ps fers Tas eit [oe 3 ffesorescae © Tate emt thea earn ia ene — fie set oe at Stet ef eine far rf NOTES. Farndon BNP eae Bas nt pected wt unitieee, — 2 “Lee a WEFT ve yer sisi Mio bschaoe I 600 BE AS is tt 18 othe 6x 59° Bea ‘atte ie (oba) vs PARTS LIST | ste (aun Se Gaon Stacie Sie [ee ge SET GET | Sass Se zo als Tak a0 Sib SST 7st Taser Palme sombi TB Tare Fey CHRaTaT a —[ Pon angina len 3 nen bosom pct neue nea 7] a Sat eee Aseny | OptoTNTHTOU es Sts ease as TOG 3 “tas —[ [ton tne Sioa Papaiee “arse | + Tis Bias Tz Pseansrop6 3000 |2[ Lace s 13 pesr0o6 3803 |— 2 Rae 3S 15__[Porcatioe 300] 2 [rowed ap Seen 6 | PHEUIT12-0209] “Pat Hl Sted — | STZREPL seine Sr =| oe [Toor ss TS=[ scot —[ Bol Gane Fie | Tes Sh ees bog] — [ea sp wart Shuto aera [sae 5 oesert Tsk sige al — [Ha Tes Tink Gauge To cal —[ Ase posal Wb supplant am 25, Tan Cage Fovomrrees ep an Beswen uy a eter ane lve pina Rew 13)PILOT VALVE ASSEMBLY PARTS LIST = Ee 4 +f ows | Cast ron Pin Only ~ aS (TA-4062) el ass [+ [Bee Sel Hrdenee = [coor — [1 [vee Sonne | Sinn Sn 7 ow Gener *NOTE: To assomble, s | reso | 1 | Stamrenion’ | 6,2 Pues mave lever arm to left as Ja ay. shown and align hole in © | rmazso7 200] 7 Suet pilot valve dise with hale Al 7 essa [Waster o 1 8 in pilot valve body SS eee | tetest | 1 | Elser am & fog Te] TW Saas Se [—tesast [1 sping Sinha Sea [tease [1 [oa Sine Se a on rae [Tora sane ie [tester [1 Pe ay ras Te [eto [1 | ut bey [Sa Se a7 [tetas [1 [ae 05) [sais ee Backside View Outside View se} anes te ara Ped + Recmrded Spe Pt Parts Required for Sour Gas Applications Furnished Only When Ordering Purp Brass Line Check 303 SS Line Chock Models H and AP for Sour Gas Applications owe ae FEE ~, S| a frmsue | + | rege ance | 88.conm che a | \ \ - 20_| PESS000- 07, Teer SSD Tank Gauge [eae For 5 Gal. 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TE [ees | ea | uy wh 3 wa_[ Wa Plunger Packing - Max Discharge Pressure commend Soe Pas ett alse fe ea eat [rR eat 3005100 MICROSWITCH VALVE INSTALLATION TA 7093 Microswitch Valve Kit INSTALLATION a 1. If pump is installed inthe field, shutoff gas flow to the pump, 2, Disconnect the gas supply pipe from the TA-0906 disc retainer gas inlet to the pump. Disconnect and remove the TB-1198 pilot valve line assembly as shown below, 3, Remove the four P01-031-3900 machine screws and four P52-031000-3800 lock washers and remove the switching valve assembly, TB 0446, from the pump housing. TB 1193 Removal Switching Valve Assembly RemovalRemove the T8-0548 cover. Remove adjusting pin, TA-1828. Remove TO-0252 diaphragm cover. Pull diaphragm TC-2128 and thrust rod TB-0444 out. Remove stirrup assembly TA-6564 Stops 4 through 8 98, Remove Bumper Plate Assembly, TA-1823, TA-0459,, JA-8323, and TA-1827, Bumper Plate 10. Install microswiteh thrust rod collar assembly TA-7090-1. Ensure that the clamping bolt is on the opposite side ofthe thrust rod from where the ‘micraswiteh will be installed. Place TA 7090-1 lover the area where the stirrup assembly TA 6564 would normally attach to the thrust rod, Do not tighten the clamping bolt at this time. Stops 10 through 12 11. Push the diaphragm TC-2128 back into position and reinstall the TC-0252 diaphragm cover 42. Reinsert TA-1828 adjusting pin. 18. Install TA-7082 microswitch valve onto the TA-7088 mounting plate with the two PO1-025050-0200 HHCS. Ensure the "TXT" tg is facing up. 414, With the microswitch installed inthe mounting pate, ensue the lever arm is switched tothe let position Place the gasket, TA-0058 between the mounting plate and the housing, then attach the mounting plate to the pump housing, TD-053! using the four HHCS, PO'-031050-0200, wth the four lock washers, 52-031000-0200. Ensure the microswitch valve extended shaft fs between the forks on the TA-7080-1 assembly ch Assembly Installed18. Attach the speed contol valve, TA-2489 to the exhaust, Port 3 (lft port) d Control Valve Installation 16, Attach the 1/4 MNPT X 3/8 tubing 90° elbow, TA-7096, to Port 2 (center port) ‘Assemble the tubing using the ferrule, TA-7097, and flareless nut, TA-7098, then attach the tubing assembly, TA-7092, tothe elbow and to the pump head 17. Steps 16 through 19 18. Tighten the clamping bolt on the thrust rod collar assembly. Connect supply gas to Port 1 on the microswitch valve, Stroke the pump several times. You may need to adjust the location of the thrust rod colar to optimize operation of the pump. 19. " 20. Control the speed ofthe pump using the gas supply pressure and the speed control valve to achieve the desired stroke rate Min. gas pressure: 18 psi Max. gas prossure: 3 psi Microswitch Valve Replacement 41. Shutoff gas flow to the pump. 2 Disconnect the gas supply pipe from Port 1 on the microswitch valve 3. Disconnect and remove TA-7092 tubing assembly. 4. Remove two bushings, TA-7096, from Ports 2 and 3.on the microswitch valve 5. Remove the TB-0548 cover Remove the four PO1-081-8900 machine screws and {our P52-031000-3800 lock washers. Remove the Imicroswitch valve assembly from the pump housing 7. Remove the old microswitch trom the mounting plate and replace with the new micraswtch, 8. Reinstall the mounting plate with microswitch valve and gasket using the four machine screws and lock washers. Ensure the microswitch valve extended shaft is between the forks of the TA-7090-1 assembly. 9. Reinstall the TB-0548 cover. Replace the TA-7095 bushings back into ports 2 and 3 as shown 11 12. Reconnect the gas supply line to the microswitch valve. Reconnect the TA-7092 tubing assembly.‘Toxsteam Pumps Dresser, Inc. 16240 Port Northwest Dive Houston, Texas 77041-2645 USA Ph: 892.590.2308 Fax: 713.849.2879 Tall Free Phone: 800.945.9898 Email: btpumps@dressercom Teestam ana resseare cei waa) of Ose wwwdressencom seres 5100, 08