API 675 METERING PUMP

WEBINAR

SAM LIM
Application & Service Manager
(IR-PST)
- 21 years experience
- Focussed on Asia Wide Technical
Support
- Product: Milton Roy & Williams
LIVE CASE STUDY & QA
Key Speakers
BALINDERJIT SINGH
After Sales Regional Manager (SESB)
- 6 years experience
- Focussed on After Sales Support
for users from KL to JB
- Product: Milton Roy & Williams
INTRODUCTION & HOW
TO SELECT A PUMP
FAIZ HAZIQ
Service Engineer (SESB)
- 3 years experience
- Focussed on Servicing &
Commissioning.
- Product: Milton Roy , Williams
HOW TO OPERATE AN API
675 PUMP
NORAZAM NAZIR
Service Manager (SESB)
- 15 years experience
- Focussed on Servicing
Organization & Hands-On services
- Product: Milton Roy , Williams &
Sundyne
HOW TO MAINTAIN &
TROUBLESHOOT PUMPS
 CONTACT PERSONNEL

Name Contact No. Email Address Area In Charge

Terence Tie +6016-9988470 terence.tie@sanggul-emas.com.my Sabah, Sarawak & East Coast

Balinderjit Singh +6017-3789576 balinderjit.singh@sanggul-emas.com.my KL, Port Dickson, Melaka & JB

Usamah Azman +6013-4449016 usamah@sanggul-emas.com.my East Coast

Do contact us if there are any queries on Milton Roy & Williams Products.
We will get back to you as soon as possible.
INTRODUCTION
1. SESB SUPPORT CENTRES
2. API 675 PUMP APPLICATIONS OFFSHORE/ONSHORE
 AUTHORIZED SERVICE CENTRES

KOTA KINABALU
(COMING SOON)

KEMAMAN BINTULU

KUALA
LUMPUR
PASIR
GUDANG

5
KEMAMAN AUTHORIZED SERVICE CENTRE
NEW EAST COAST AUTHORIZED SERVICE CENTRE
BINTULU AUTHORIZED SERVICE CENTRE

8
JOHOR BHARU AUTHORIZE SERVICE CENTRE
API 675 GENERAL APPLICATIONS SUMMARY
UPSTREAM APPLICATIONS
Chemicals

Methanol x x x
The majority of these products are hazardous to the health and not suitable for
Ethanol x x x discharge into the environment.
Glycol x  Metering solutions need to be reliable and leakproof.
LDHI x x x
Flow improvers X X X X

Anti-scale x x x x
The primary objective is to inject the appropriate volume of treatment chemical in
proportion to the volume of process fluid being treated to ensure that flowrate targets
Biocides x x x x
are achieved and that flow is continuous.
Corrosion inhibitors x x x x
 Metering solutions need to be reliable and accurate.
Paraffin inhibitors x x x
Alphaltene inhibitors x x x
Oxygen scavengers x x x x
Wax inhibitors x

 API 675 pumps are the most suitable to answer to these

Condensate x x x
Demulsifiers x
Antifoam x x x x
Water
needs.
x x x
Waste water

Supercritical fluids x
Wax inhibitors x x x
Pour points depressants

Drag reducers x x

Confidential and Propriet ary

H2S scavengers x x x x
DOWNSTREAM APPLICATIONS
Refining Petro Chemistry Energy

Methanol x x x

Ethanol x x x

Glycol x

Flow improvers X (anti-icing)

Corrosion inhibitors x x X x

Alphaltene inhibitors

Wax inhibitors x x

Condensate x

Demulsifiers x x X

Antifoam x x X

Oil x

 API 675 pumps are the most

Organic waste x

Water x X

Waste water x

Supercritical fluids x x x x suitable to answer to these needs.

Wax inhibitors

Pour points depressants x x

Drag reducers x x

Oxygen scavengers / Binders x

Deposit inhibitors x

Metal desactivers x

Sulfiding agents (HDS) x

Confidential and Proprietar y
Lubricity improvers x x
 HYDRAULIC DRIVEN DIAPHGRAM WITH DIAPHGRAM POSITION VALVE

HYDRAULIC DRIVEN DIAPHGRAM WITH CONTOUR PLATE POSITIONING

LIQUID END
PACKED PLUNGER LIQUID END

HYDRAULIC DRIVEN METALLIC DIAPHRAGM WITH CONTOUR PLATE

API 675
VARIABLE STROKE LENGTH ECCENTRIC DRIVE (MANUAL)

VARIABLE STROKE LENGTH POLAR CRANK DRIVE

DRIVE END

HYDRAULIC BYPASS DRIVE (WITH LIQUID END)

VARIABLE STROKE LENGTH ECCENTRIC DRIVE (ECCENTRIC)

 API 675 REQUIREMENTS
• API 675 (6.1.16) states that Rated Capacity shall be at least 110% of the
maximum capacity specified.
• API 675 (6.1.17) states that Steady State flow accuracy shall be within +-
1% of rated flow over a turndown ratio of 10.1 (How to verify?)
• API 675 (6.12.1) The lubrication system shall be of a forced-feed, splash,
or submerged type and shall lubricate the reduction gears, bearings, and
all other required points except the driver (How to ensure it is
continuously monitored?)
• API 675 (6.13.3) Integral pump devices used to vary capacity either
manually or automatically shall be provided with visual indication of
capacity setting, shown as a percentage of the maximum stroke length.
Manual control shall include a locking device to positively retain the
capacity setting. (Why is this important?)
HOW TO SELECT A PUMP

1. INFORMATION REQUIRED FOR SIZING

2. SPECIFICATIONS TO BE MET
3. PUMP RANGE AVAILABLE
As an example….
• Let say process engineer feed’s you the information below:

• 2LPH @ 25 Bar…? Application for Chemical Injection is required.

This information is minimal and not suggestive for End-Users to make a

decision.
Information Used for Sizing
• There are several information that is required for accurate sizing of API 675
Metering Pumps that is essential in providing the best solution for the
required application.
• Each parameter provided has an impact to sizing.
• Key Information Required:
- Maximum & Minimum required Flowrate.
- Maximum Discharge Pressure
- Characteristics of Chemical being Injected
- NPSHa
- Site Utility Data
Points to be concerned with….
• Pump replacement? Single/Double Diaphragm
• New Application?
• Site Conditions? Offshore/Onshore requirement.
• Pneumatic/Electric Driven? Type of Control?
• Motor Specifications? Single Phase/ Three phase?
• Pressure of Air Available?
• Hazardous chemical?
• Operating Philosophy
 SPECIFICATIONS TO BE MET
Concerns Reason Solution
Hazardous Chemical 1. Shouldn’t have Leak of Containment (LOC) due to 1. Get a Double Diaphragm Pump which will have no leak
risk to Operators. concerns.
2. Time taken to rectify LOC 2. Get a Leak Detection with a Pressure Transmitter that
provides signal back to DCS

Chemical Characteristics 1. Viscosity is important as creates additional 1. Clarify with the pump vendor on the information
resistance. obtained on the best solution for your application.
2. In certain extreme cases, temperature is also a
concern to the pump.

Cavitation 1. Cavitation or dry running of pump will cause 1. Ensure the suction line is flooded.
premature failure of diaphragm. Increased cost of 2. Validate the NPSHa is 1m greater than NPSHr based on
maintenance. API675 Guideline.
2. Premature failure = Downtime = Loss of
Production/Off Spec

Material Compatibility 1. Liquid end premature failure due to corrosion. 1. Ensure that the MSDS together with relevant chemical
information is provided for Pump Vendor to confirm the
suitable liquid end for your application.

Adjustment of Flow 1. Is it a manned platform? Control Philosophy? Is 1. Generally, all API 675 Pumps have a few methods of Flow
response time critical to flowrate adjustment? control. Pneumatic Actuator, Electric Actuator as well as
manual control. What does your operation team prefer?
 JOB NO. ITEM NO. 0
JOB NO. ITEM NO.

PURCHASE ORDER NO.

SPECIFICATION NO. CONTROLLED VOLUME PUMP (API 675-3RD) REVISION NO. 0 DATE 15.7.2021
CONTROLLED VOLUME PUMP (API 675-3RD) REVISION NO. 0 DATE 15.7.2021 DATA SHEET PAGE 2 OF 2 BY AMIRA SHAHIRA

DATA SHEET PAGE 1 OF 2 BY AMIRA SHAHIRA SI UNITS (BARG)

SI UNITS (BARG) 1 MATERIALS CONTROLS
2 LIQUID END SS 316L TYPE: SIGNAL:
1 APPLICABLE TO: PROPOSAL PURCHASE AS BUILT
MRA11-D15S7ABBNLNNNNN-MNNNND 3 CONTOUR PLATE SS 316L MANUAL REMOTE PNEUMATIC
2 FOR UNIT
4 HYDRAULIC DIAPHRAGM PTFE AUTOMATIC LOCAL ELECTRONIC
3 SITE NO. OF PUMPS REQUIRED 2 X 100%
5 PROCESS DIAPHRAGM PTFE STROKE CONTROL:
4 SERVICE Calcium Removal Agent (CRA) MODEL MROY A SIZE AND TYPE
6 DBLE DIAPHRAGM SUPPORT SS 316L PNEUMATIC (kPaG):
5 MANUFACTURER MILTON ROY SERIAL NO.
7 LANTERN RING N/A MINIMUM N.A MAXIMUM N.A
6 NOTE: INDICATES INFORMATION TO BE COMPLETED BY PURCHASER BY MANUFACTURER 8 PACKING GLAND N/A ELECTRONIC (mA):
7 GENERAL 9 PACKING N/A MINIMUM N.A MAXIMUM N.A
8 NO. MOTORS DRIVEN 1 OTHER DRIVER TYPE NA
10 VALVE SS 316L OTHER PURCHASE REQUIREMENTS
9 PUMP ITEM NO'S 1 PUMP ITEM NO'S
11 VALVE SEAT SS 316L NAMEPLATE UNITS U.S. CUSTOMARY SI
10 MOTOR ITEM NO'S 1 DRIVER ITEM NO'S GEAR ITEM NO'S
12 VALVE GUIDE N/A VENDOR FURNISHED PROCESS PIPING
11 MOTOR PROVIDED BY MILTON ROY DRIVER PROVIDED BY SESB GEAR PROVIDED BY MRIS
13 VALVE BODY SS 316L
12 MOTOR MOUNTED BY MILTON ROY DRIVER MOUNTED BY SESB GEAR MOUNTED BY MRIS
14 VALVE GASKET FKM VENDOR REVIEW PIPING DRAWINGS
13 MOTOR DATA SHEET NO. DRIVER DATA SHEET NO. GEAR DATA SHEET NO. 15 FRAME CAST IRON VENDOR FURNISHED PULSATION SUPRESSION DEVICES

14 OPERATING CONDITIONS LIQUID 16 SPECIAL MATERIAL TESTS (6.14.2.5) VENDOR FURNISHED RELIEF VALVE

15 CAPACITY @ PT: (litre/hr) TYPE OR NAME OF LIQUID Calcium Removal Agent (CRA) 17 INTERNAL EXTERNAL
18 LOW AMBIENT TEMPERATURE MATERIALS TESTS (6.14.6) RELIEF VALVE SETTING (BARG) IRV = 24
16 MAXIMUM 6.89 MINIMUM 1.7 RATED PUMPING TEMPERATURE (°C):
19 VENDOR FURNISHED BACK-PRESSURE VALVE
17 DISCHARGE PRESSURE (BARG): NORMAL MAX MIN
18 MAXIMUM 17 MINIMUM RATED SPECIFIC GRAVITY MAX MIN 20 QA INSPECTION AND TEST DOUBLE CHECK VALVES REQUIRED
19 SUCTION PRESSURE (BARG): VAPOR PRESSURE (BARA) MAX MIN 21 COMPLIANCE WITH INSPECTORS CHECK LIST OIL-FILLED PRESSURE GAUGES REQUIRED
20 MAXIMUM ATM MINIMUM RATED SPECIFIC HEAT Cp (kJ/kg °C) 22 CERTIFICATION OF MATERIALS 3.1 VENDOR FURNISHED CONTROL PANEL
21 DIFFERENTIAL PRESSURE (BAR): VISCOSITY (cP) MAX MIN 23 FINAL ASSEMBLY CLEARANCES BASEPLATE PREPARED FOR EPOXY GROUT

22 MAXIMUM MINIMUM RATED CORROSIVE/EROSIVE AGENTS 24 SURFACE AND SUBSURFACE EXAMINATIONS PROVIDE TECHNICAL DATA MANUAL

23 NPSH AVAILABLE (m): 3.5 CHLORIDE CONCENTRATION (PPM) 25 RADIOGRAPHY

24 (EXCLUDING ACCELERATION LOSSES) H2S CONCENTRATION (PPM) 26 ULTRASONIC

25 TURNDOWN RATIO 10:1 LIQUID TOXIC FLAMMABLE OTHER 27 MAGNETIC PARTICLE PREPARATION FOR SHIPMENT
28 LIQUID PENETRANT DOMESTIC EXPORT EXPORT BOXING
26 PERFORMANCE SITE AND UTILITY DATA
29 CLEANLINESS PRIOR TO FINAL ASSEMBLY OUTDOOR STORAGE MORE THAN 6 MONTHS
27 NUMBER OF FEEDS 1 RATED CAPACITY (LPH) 8.473 LOCATION INDOOR OUTDOOR
30 HARDNESS OF PARTS, WELDS & HEAT AFFECTED ZONES WEIGHTS (KGS)
28 NPSH REQUIRED (WITHOUT ACCELERATION LOSSES) , (M) 0.46 HEATED UNHEATED UNDER ROOF
31 FURNISH PROCEDURES FOR OPTIONAL TESTS PUMP 46 BASE NA GEAR INCL DRIVER
29 BHP RATED AT RELIEF SETTING (BARG) ELECTRICAL AREA CLASSZONE 2 GAS GROUP IIC TEMP. CLASS T3
32 TESTS REQ'D WIT OBS DRIVERS
30 PLUNGER SPEED (strokes/min) 96 DESIGN MAX 178 WINTERIZATION REQD TROPICALIZATION REQD
31 DIAMETER (mm) 11.1 LENGTH OF STROKE (mm) 19 SITE DATA 33 HYDROSTATIC (8.3.2) MOTOR:

32 PUMP HEAD: 1 RANGE OF AMBIENT TEMPS ° C:MIN/MAX / 34 STEADY STATE ACCURACY MANUFACTURER Nanyang Weite
35 REPEATABILITY TYPE YBX3-71M1-4
33 MAXIMUM PRESSURE (BARG) 29.30 UNUSUAL CONDITIONS
36 LINEARITY FRAME NO. Frame 71 - FF130 - Ø14x30
34 HYDRO TEST PRESSURE (BARG) 43.95 DUST FUMES SALT ATMOSPHERE
37 PERFORMANCES (8.3.4) CONSTANT SPEED YES
35 MAX DISCH PRESS. W/ JOB DRIVER (BARG) 29.3 OTHER
38 MECHANICAL RUN (8.3.5)
36 MAX BHP BASIS GEAR STRENGTH UTILITY CONDITIONS
39 NPIP (8.3.7.1)
37 CONSTRUCTION ELECTRICITY DRIVERS HEATING CONTROL SHUTDOWN 40 COMPLETE UNIT (8.3.7.2)
38 SIZE ANSI FACING POSITION VOLTAGE 415 41 SOUND LEVEL (8.3.7.3)
39 CONNECTIONS RATING HERTZ 50 42 HIGH DISCHARGE PRES (8.3.7.4)
40 SUCTION 1/2" 150# RF BOTTOM-V PHASE 3 43 FACTORY ACCEPTANCE (8.3.8)
41 DISCHARGE 1/2" 150# RF TOP-V COOLING WATER INLET RETURN DESIGN MAX 38 VARIABLE SPEED NO
42 FLUSH TEMP °F MAX LUBRICATION FLUID
39 KW 0.25 RPM 1500
43 PRESS. (PSIG) MIN 40 CRANKCASE INTERMEDIATE VOLTS 415 PHASE 3
44 LIQUID END JACKET REQ'D SOURCE 41 HYDRAULIC FLUID HERTZ 50 SERVICE FACTOR 1
45 TYPE DIAPHRAGM PLUNGER INSTRUMENT AIR MAX MIN 42 ACCESSORIES ENCLOSURE IP55
46 DIAPHRAGM DIA (mm) 73 NO REQ. 1 PRESSURE (PSIG) 43 SPEED REDUCER MANUFACTURER MILTON ROY OTHER (SEE SEPARATE DATA SHEETS) ExdIIBT4

APPLICABLE SPECIFICATIONS: 44 INTEGRAL SEPARATE GAS DRIVEN

47 VALVES/FEED SUCTION DISCHARGE
45 MODEL WORM / WORM GEAR STEAM TURBINE
48 TYPE BALL BALL API 675 POSITIVE DISPLACEMENT PUMPS - CONTROLLED VOLUME
46 RATIO 1/24 OTHER
49 NUMBER 2 2 GOVERNING SPECIFICATION (IF DIFFERENT)
47 BASEPLATE UNDER
50 NACE MR-0103 (6.14.2.13) NACE MR-0175 (6.14.2.13)
48 COUPLING MANUFACTURER MP FILTRI
51 OTHER
49 TYPE FLEXIBLE, DRY TYPE
52 REMARKS
50 REMARKS

53 51

SHT 1 OF 2 API675SI.XLS REV 0 SHT 2 OF 2 API675SI.XLS REV 0

PUMP RANGE AVAILABLE
• Depending on the requirements mentioned in previous slides,
Metering Pumps have a wide range of flowrates and pressures.
• Pump type is divided into two categories, Pneumatic and Electric
Driven Pumps.
 MILTON ROY PUMP RANGE (ELECTRIC DRIVEN)
MODEL SAMPLE PHOTO RATED FLOWRATE MAX PRESSURE LIQUID END MATERIAL AVAILABILITY
(LPH) (BARG)
MROY A

1.10 – 110 24.10 – 137.90 316SS, PVC, PVDF, ALLOY 20

MROY B

14.80 – 330 27.60 – 103.40 316SS, PVC, PVDF, ALLOY 20

MROY XT/XW

0.87 – 29 138.00 – 207.00 316SS

 MILTON ROY PUMP RANGE (ELECTRIC DRIVEN)
MODEL SAMPLE PHOTO RATED FLOWRATE MAX PRESSURE LIQUID END MATERIAL AVAILABILITY
(LPH) (BARG)
MAXROY

20.00 – 1100 10.0 – 28.0 316SS, PVC, PVDF, 904L SS

MILROYAL D

316SS, PVC, PVDF, 904L SS, ALLOY C22,

0.22 – 329 35.00 – 350.00
TITANIUM

PRIMEROYAL K

316SS, DUPLEX SS, PVC, PVDF, 904L SS,

4.20 – 2500 151.00 – 300.00
ALLOY C22, TITANIUM
 MILTON ROY PUMP RANGE (ELECTRIC DRIVEN)
MODEL SAMPLE PHOTO RATED FLOWRATE MAX PRESSURE LIQUID END MATERIAL AVAILABILITY
(LPH) (BARG)
PRIMEROYAL L

316SS,PVC, PVDF, 904L SS, ALLOY C22,

13.6 - 3480 45.00 – 1034.00
TITANIUM

PRIMEROYAL N

316SS, DUPLEX SS, PVC, PVDF, 904L SS, ALLOY

28.20 – 9863 244 - 1379
C22

PRIMEROYAL P

166.00 - 14665 310 17-4PH, 316SS, DUPLEX SS, 904L SS

 MILTON ROY PUMP RANGE (ELECTRIC DRIVEN)
MODEL RATED FLOWRATE MAX PRESSURE LIQUID END MATERIAL
(LPH) (BARG) AVAILABILITY
PRIMEROYAL R

793 – 15659 319 - 1379 17-4PH, 316SS, DUPLEX SS

PRIMEROYAL X

185 - 8238 252 - 1372 17-4PH, 316SS

MEGAROYAL

48000 252/119/63 316L

 MILTON ROY PUMP RANGE (ELECTRIC DRIVEN)

MODEL RATED FLOWRATE MAX PRESSURE

(LPH) (BARG)
POWEROYAL

*Note:
API 674 Compliant Pump
124,000 LPH 700 Barg
Milton Roy’s key hard-duty products
Cost-effective
mROY
Long lifetime, more than 30 years

The best effective solutions according to customer’s

Dosing of highly concentrated products
MILROYAL
Very compact footprint and weight for pressure up to 500
bar (7,252 PSI) Very low flow rate from 0.11 l/h, API 675
PRIMEROY Compact footprint for high flow rate: ground
implantation of 600 cm2 to reach 3,300 l/h (842 GPH)
Critical processes
needs
even the most challenging
Listed on vendors-lists of the main O&G companies
Project management at each step: offer, cost,
delivery, documentation
Respect of the most stringent standards
Integrity: high ethic and EHS standards

Versatility to meet all type of specifications

PRIMEROYAL Reliability and Robustness
High pressure capability up to 1,039 bar (15,000 PSI)
WILLIAMS V SERIES PUMP
ACCURACY
SMALL INJECTION RATE
PLUNGER PUMP
PNEUMATIC DRIVEN
API 675
RELIABLE
 WILLIAMS PUMP RANGE (PNEUMATIC DRIVEN)

MODEL RATED FLOWRATE MAX PRESSURE SEAL MATERIAL AVAILABLE PLUNGER MATERIAL AVAILABLE
(LPH) (BARG)
WILLIAMS V SERIES
CP125V125 0.27 596.4
CP250V225 2.16 496.4
CP250V300 2.16 903.2
CP500V225 8.71 120.7
CP500V300 8.71 224.1
TG, TC, VITON, KALREZ, BUNA CERAMIC, 17-4PH, 316SS
CRP500V400 8.71 434.4
CRP750V400 18.9 178.3
CRP1000V400 34.37 104.8
CRP1000V600 34.22 234.4
CRP1000V800 33.35 434.4
WILLIAMS W SERIES PUMP
HIGH FLOWRATE
ACCURATE
PLUNGER PUMP
PNEUMATIC DRIVEN
API 675
RELIABLE
WILLIAMS PUMP RANGE (PNEUMATIC DRIVEN)
MODEL RATED FLOWRATE MAX PRESSURE SEAL MATERIAL AVAILABLE PLUNGER MATERIAL AVAILABLE
(LPH) (BARG)
WILLIAMS W SERIES
CRP1500W400 86.40 41
CRP1500W600 86.40 134
CRP1500W800 86.40 238 TG, VITON, BUNA, KALREZ CERAMIC, 17-4PH, 316SS
CRP2250W600L 336.00 62
CRP2250W800L 336 124
WILLIAMS

MILTON ROY
WILROY
Accurate
Leak Proof Design
Diaphragm Pump
Pneumatic Driven
API 675
Reliable
 WILROY (Pneumatically & Hydraulically
Actuated Diaphragm Pump)
MODEL RATED FLOWRATE MAX PRESSURE LIQUID END MATERIAL EXTRA MILE
(LPH) (BARG)
WILROY SERIES
WILROY 2M 2.04 207
WILROY 5M 8.51 207 C5 LEAK DETECTION
1. MANUAL GAUGE
WILROY 754 18.9 172 SS316
2. NEMA 4 PRESSURE SWITCH
WILROY 105 31.0 207 3. NEMA 6 PRESSURE SWITCH
WILROY 106 29.5 207
HOW TO OPERATE API 675 PUMP
1. START-UP PROCEDURE
2. FLOWRATE ADJUSTMENT
3. SHUTDOWN PROCEDURE
GENERAL START UP PROCEDURE
(MILTON ROY)
• Part 1 – Before Start Up
• Ensure that installation of Pump has been done correctly.
This includes Tie-In point and Motor Connection to main
power supply.
• Remove the filling plug on both Hydraulic & Gear Chamber.
Fill up the oil to the middle of the Level Indicator. If pump
has been on standby at site, we would suggest to drain out
old oil and refill with new oil with fear of water ingress
during standby period.
• Disconnect the discharge circuit to ensure that the pump is
installed in flooded suction taking into caution of the liquid
pumped.
• Check that the capacity of the Pump is set to 0%
GENERAL START UP
PROCEDURE
(MILTON ROY)
• Part 2- Start Up
• Start-up the pump
• Check visually and listen to any abnormality's noises.
• Make sure that the hand knob is unlocked. (Locking Knob)
• For priming purposes, increase the pump capacity gradually from
0% to 100% and control the liquid output at priming valve. For
pump without priming valve, the priming can be done at the
Double Block and Bleed valve at the PG. Once there is flow out
from priming valve, close the valve accordingly.
GENERAL START UP
PROCEDURE (WILLIAMS)
• PART 1: AIR GAS SUPPLY
• Ensure that the Air supplied to the Williams pump has a filter regulator installed for
accurate dosing.
• Depending on the Supply Pressure & Flowrate, the correct air pressure required is to be
set at the filter regulator prior to the Pump Controller.
• Please consult us on the set pressure for the air supply based on the application at site.

• PART 2: PUMP STROKE LENGTH

• Ensure the suction line is flooded
• The adjuster scale for the pump's stroke length is factory set so that a ZERO reading
equals ZERO stroke length.

• Calibrate the scale as follows:

• Turn the stroke adjuster tee set screw counterclockwise until the stroke adjuster knob is
unlocked.
• Turn the stroke adjuster knob Counterclockwise as far as it can go. The piston/plunger will
be fully bottomed in the pump.
• Loosen the two screws holding the data plate; move the data plate until the middle of the
pin is at ZERO on the scale. Tighten the two screws.
• Turn the stroke adjuster knob until the middle of the pin is at the desired stroke length on
the scale.
• Tighten the tee knob clockwise until the stroke adjuster knob is locked.
GENERAL SHUTDOWN PROCEDURE
MILTON ROY
1. Stop or switch the Pump from the Local Control Panel/ DCS depending on operation philosophy.
2. Adjust the Stroke Capacity of the pump to 0%.
3. Close Suction & Discharge Valve
4. Release the pressure in pump liquid-end if possible, especially for the suction line with high positive pressure.
5. Depending on the purpose of shutdown:
a) Maintenance & Plant Shutdown: Flush the Pump line with Water for long storage or before disconnection of
Pump for maintenance purposes.
b) Standby Pump: As per Operating Philosophy.

WILLIAMS
To shut down the pump assembly, set the pressure regulator(s) to ZERO, and turn the air/gas supply to OFF.

To store the pump assembly or if it will not be used for a long time, do the following:
1. Remove pump from the system.
2. Flush out the pump chamber and check valves with water or solvent; drain and then blow the pump dry with
compressed air.
3. Cap off the suction and discharge check valve ports.
4. You may leave the pump, controller, and relay assembled, but make sure to store them in a dry, protected place.
HOW TO MAINTAIN API 675
METERING PUMP
1. INTRODUCTION
2. ROUTINE CHECK
3. PREVENTIVE MAINTENANCE
4. COMMON SPARES REQUIRED
 CHALLENGES…..
• The concerns that we have seen in the industry is that:
a) Fail first, repair later or known as reactive maintenance.
b) No capital spare for emergency breakdown.
c) Instrumentations for pumps are incomplete.
d) Spare parts inventory for soft seals exceed lifetime. (1-3 Years for Soft Seal, 5 Years for Hard Parts)

• Critical Equipment is classified if it can cause any of the following:

a) Significantly impair the ability to safely meet business objectives – For example, lost of revenue due to
shutdown or off-spec product.
b) Adversely affect quality levels – For example, insufficient chemical dosing in process may cause process upsets
due to excessive corrosion, scaling and etc.

• For your information API 675 (9.3.4.2), The Vendor shall indicate on each of these complete parts lists all those
parts that are recommended as start-up or maintenance spares, and the recommended stocking quantities of
each.
• In a nutshell, there is importance in ensuring equipment's in Chemical Dosing/Injection facility is well maintained.
 THE IDEAL WAY FORWARD
EMP

EFFECTIVE MANAGEMENT PLAN

Intelligent Maintenance Flow Critical Stocking Planning Stock Sharing Initiatives

SUCCESSFUL ON-TIME MAINTENANCE

MOTOR DRIVEN PUMP
ROUTINE CHECK
• Ideally, we would suggest to do a visual check on the pumps every 6 months
mainly to monitor the pump.
• Oil Change is suggested to be done after 2000 hours upon commissioning
and 8000 hours or yearly subsequently.
• Other things to check would be:
a) Check drain plug is correctly tightened.
b) Check for leakage on the shaft motor side or protective cap side.
c) Check on leakage on Micrometer Screw.
• In an event of an unforeseen failure, the spares such as Check Valve
Cartridges, Diaphragm can be utilized from Warehouse for immediate
rectification. Get it while you can!! Prevention is better than cure.
Preventive Maintenance
• Preventive maintenance (PM) is defined as the maintenance of
equipment and assets in order to keep them running and prevent any
costly unplanned downtime from unexpected equipment failure.
• Key note in this section would be ensuring that the spares required is
sufficiently available.
• For any spare parts inquiry, a nameplate photo of the pump would be
required for accurate spare part proposal to be provided.
 ROUTINE MAINTENANCE (COMMON PARTS)

MROY A DOUBLE DIAPHRAGM PRIMEROYAL L MILROYAL D DOUBLE DIAPHGRAM

MOTOR DRIVEN PUMP
• The table below is a summary of the recommended maintenance
work.
DESCRIPTION FREQUENCY
MECHANICAL ASSEMBLY
Wheel and worm assembly 25,000 H
Bearings 25,000 H
Crosshead and it’s seals 8000 H
Flexible shock absorber 8000 H
LIQUID END ASSEMBLY
Plunger and plunger connection 15,000 H
Diaphragm 15,000 H
Check valves 8000 H
Plunger packing ring 8000 H
PNEUMATIC DRIVEN PUMP
“V” Series “W” Series

“WilRoy” Series
 V Series
• Periodic Maintenance
Once a week: Perform the following procedures:
1. Check for process fluid leaking from the plumbing.
2. Check for process fluid leaking from the pump's vent hole, cylinder faceplate, and
body O-ring.
3. Check for air/gas leaks.
4. Check for loose fittings and screws.
At least once a month:
Unscrew the plug from the top of the fitting tee between the relay and the controller;
put a few drops of William’s SF 96- 100 silicone oil in the hole
At least every six months:
Inspect the piston-plunger assembly and seals. Replace the seals and check the plunger
for wear; replace the piston/ plunger assembly if it is scored, rough, or discolored.
At least every twelve months:
Perform the following procedures:
1. Disassemble and inspect the pump inlet and outlet check valves. Replace worn parts.
2. Inspect the piston/plunger assembly, piston return spring (on all pumps except the
P1000V800), and all seals. Replace the piston/plunger assembly and the seals.
 W Series
• Periodic Maintenance
Once a week: Perform the following procedures:
1. Check the oil level in the lubricator bottle to make sure the seals never run dry
2. When you check the oil level, also check for the signs of a chemical in the oiler
bottle or the weep hole above the seal. If any chemical is present, replace the
pump seal, use SF96-100 William’s silicone oil to lubricate the new seals.

At least once a month:

Unscrew the plug from the top of the fitting tee between the relay and the controller;
put a few drops of William’s SF 96- 100 silicone oil in the hole.
At least every six months:
Perform this procedure at least every six months. Inspect the piston-plunger assembly and
seals. Replace the seals and check for wear: if the assembly is cracked, rough or discoloured,
replace it.
At least every twelve months:
Perform the following procedures:
1. Disassemble and inspect the pump inlet and outlet check valves. Replace worn parts.
2. Inspect the piston/plunger assembly, piston return spring and all seals. If the piston
plunger is scratched or if the seals are nicked, replace them.
 Wilroy
• Periodic Maintenance
At least every six months :
• Inspect the oil level in the pump. Add oil, if necessary,
in order to maintain an oil level approximately 3/8”
below the top of the oil fill hole. Do not overfill, or oil
will pump through the breather port.
• Remove the motor cylinder. Clean, inspect and re-
grease the components. Replace worn parts. It is not
necessary to remove the bore cartridge at this time.
At least every twelve months:
Perform the following procedures:
1. Disassemble and inspect the pump inlet and outlet check valves.
Replace worn parts.
2. Disassemble the liquid end and replace the diaphragm. Discard
the oil and replace with new oil
TROUBLESHOOTING
API 675 PUMP
API 675 TROUBLESHOOTING GUIDE
Problem with Motor (Pump motor won’t operate)
1. No power. Supply correct power in accordance with motor nameplate.
2. Blown fuse. Check for short circuit or overload.
3. Open thermal overload device in starter. Reset overload.
4. Broken wire. Locate and repair.
5. Low voltage. Check for too thin wiring.
6. Low liquid level (where low level cutoff is used). Fill tank.
7. Oil is frozen in pump. Thaw out.
8. Bad motor. Replace motor.
API 675 TROUBLESHOOTING GUIDE
Problem with Motor (Motor overheats thermal overload switches)
1. Power supply does not match motor characteristics. Check power supply against motor nameplate data.
2. Overload caused by operating pump above its discharge pressure. Check operating pressure against
pump manufacturer’s data plate max. rating and correct the cause of the pressure abnormality.
 API 675 TROUBLESHOOTING GUIDE
Pump Doesn’t Deliver Rated Capacity
1. Starved suction. Replace suction piping with larger size or increase suction head.
2. Leaky suction piping. Repair or replace defective piping.
3. Excessive suction lift. Rearrange equipment location to reduce suction lift.
4. Liquid too close to boiling point. Lower temperature or increase suction pressure.
5. Air in hydraulic or reagent system. Bleed system.
6. Air or gas trapped in pump liquid end.
7. Worn or dirty valves or seats. Clean or replace cartridges.
8. Viscosity of liquid too high (CPS). Reduce viscosity by heating or other means, or increase size of suction piping, or increase
suction pressure.
9. Insoluble materials; crystallization of liquid; settling of solids. Limit solution strength to proper value. Flush and clean solution
tank periodically. Suction connection should be 2” to 4” from bottom of solution tank.
10. Low discharge pressure. A minimum discharge pressure is required to ensure proper capacity control.
11. Internal relief valve being popped.
12. Capacity adjustment set above 100% capacity mark. Reposition adjustment knob to 100% mark.
API 675 TROUBLESHOOTING GUIDE
Pump Delivers Erratically
1. Leaky suction line. Repair or replace piping.
2. Worn or dirty valves or seats. Clean or replace cartridges.
3. Excessive excursion of ball valves from seats (indicated by ball
chatter). Replace cartridges.
4. Insufficient suction pressure. Increase suction pressure by raising
tank level or pressurizing suction tank.
5. Leaky system relief valve. Repair or replace relief valve.
API 675 TROUBLESHOOTING GUIDE
Noisy Operation of Liquid End/Drive Casing
1. Pump valves must move to open and close, and they will make a clicking noise as they operate. These noises are
sometimes amplified by natural resonances in the piping system. They are usually indications of normal valve
functioning.
2. Liquid compressibility causes reversal load on gears at end of pressure stroke. Not considered detrimental. No action
needed.
3. Pump internal relief valve actuating abnormally caused by:
a. Excessive suction lift conditions. Lower pump or raise level of liquid.
b. Insufficient suction pressure. Correct poor suction condition.
c. Clogged or partially blocked filter or strainer in suction line. Clean strainer.
d. Clogged or fouled suction or discharge check valves. Clean or replace.
e. Blocked discharge line. Remove blockage.
f. Insufficient discharge pressure. Install back pressure valve or device to create back pressure at pump discharge
connection
API 675 TROUBLESHOOTING GUIDE
Improper Oil Level in reservoir increases and overflows.
Pump Delivery is not Adjustable
Pump does not Develop required Pressure.
1. Flexible diaphragm punctured by foreign material. Replace diaphragm.
2. System pressure too low. Install a back pressure valve in the discharge line (preferred
method) or install a back pressure spring (provided) into discharge cartridge.
3. Check to see if system pressure exceeds rated capacity on data plate.
4. O-rings on control spool are nicked. Replace O-rings. (Note: you must use a special tool.
Contact your local agents for support
5. Carefully review causes and remedies for the second and third symptoms listed.
CASE STUDY SESSION
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Q&A