progressive cavity (pc) pump operation, maintenance...

PSI PC Pump Operation, Maintenance, & Technical File

Process Solutions International Rev 002 07/24/2014

COMPANY PROPRIETARY AND CONFIDENTIAL

7519 Prairie Oak Dr. Houston TX, 77086 281-893-4774 office 281-893-1027 fax www.psimax2000.com

Progressive Cavity (PC) Pump Operation, Maintenance, & Technical Manual

(MAX2000-60, 70, 80, 90, 100 Pumps) Document Filename: PCM-001

Revision Level

Revision Date Description of Revision

Revision Author

DRAFT 4/2/14 Draft Daniel Vasquez

1 5/28/14 Approved Copy D. Vasquez

2 7/24/14 Added Warranty D. Vasquez



PCM-001 COMPANY PROPRIETARY AND CONFIDENTIAL

Table of Contents

1.0 SAFETY

2.0 WARRANTY

3.0 GENERAL ARRANGEMENT DRAWING

3.1 MAJOR COMPONENT DRAWINGS

4.0 TECHNICAL MANUAL CONTENTS

4.1 GENERAL DESCRIPTION

5.0 LIFTING PROCEDURE

6.0 INSTALLATION PROCEDURE

7.0 STARTUP PROCEDURE

8.0 ROUTINE MAINTENANCE

9.0 SHUT DOWN AND STORAGE

9.1 SHORT TERM SHUTDOWN 9.2 LONG TERM SHUTDOWN

10.0 PARTS LIST

11.0 INSPECTION AND TESTS

12.0 CERTIFICATION(S)

13.0 ADDITIONAL DRAWINGS, DIAGRAMS, ETC.

14.0 CONTACT INFORMATION




1.0 Safety

General safety rules and warnings This manual contains important information concerning installation, operation, and proper maintenance of your MAX2000 Progressive Cavity Pump. To prevent injury to personnel or equipment damage, this manual should be read by those responsible for the installation and operation of the Pump. In addition, the safety precautions below should be followed at all times. 1. Follow your companies LOCK-OUT/TAG-OUT Procedures before performing any

maintenance.

2. Inspect equipment for damages, loose fittings, safety guards (if applicable), and proper installation.

3. Wear proper PPE based on your companies Personal Protective Equipment and Safety procedures.

4. When lifting equipment, ensure proper lift points are used. Use properly rated slings that are capable of handling the equipment.

5. Do not use the equipment for anything but its intended use.

***NO ATTEMPT SHOULD BE MADE TO STOP A ROPE OR HOSE OR ANY OTHER OBJECT ONCE IT HAS BEEN WRAPPED AROUND A MOVING SHAFT!!!

2.0 Warranty

Warranty Terms and Conditions The MAX2000

®, MAKDADDY

®, and Vak

® name are registered trade names of Kelbro, Inc dba

Process Solutions International (PSI). Their use is reserved by Kelbro, Inc. dba Process Solutions International (PSI) and applicable laws. It shall not be used without permission and written authorization from Kelbro, Inc. dba Process Solutions International (PSI).

Terms of Sale Any terms and conditions contained in any purchase order or other form of communication from PSI’s customers, which are additional to or different from these terms and conditions, shall be deemed rejected by PSI unless expressly accepted in writing by PSI. In general, no modification, amendment, waiver or other change of any of these terms and conditions or attachments hereto, or of any of PSI’s right or remedies thereunder, shall be binding on PSI unless expressly accepted in writing by PSI’s authorized officers. No course of dealing, usage of trade or course of performance shall be relevant to explain or supplement any of these terms and conditions. If any document issued by any party hereto is sent by facsimile or another form of electronic document transmission, the parties hereto agree that (a) the copy of any such document printed on the facsimile machine or printer of the recipient thereof is a counterpart original copy thereof and is an “writing”, (b) an electronically stored and reproduced copy of any such document shall be deemed to be legally sufficient evidence of the terms of such document for all purposes. Delivery; Risk of Loss All sales are F.O.B. PSI’s plant or other point of shipment designated by PSI. Shipping dates are estimates only which are not guaranteed and are based upon prompt receipt from Buyer of all necessary shipping and other information. PSI reserves the right to make delivery in installments, all installments to be separately invoice and paid for by Buyer when due per invoice, without regard to subsequent deliveries. Delivery of equipment to a commercial carrier at PSI’s plant or other loading pint shall constitute delivery to Buyer, and any risk of loss and further cost and responsibility




thereafter for claims, delivery, loss or damage, including, if applicable, placement and storage, shall be borne by Buyer. When equipment is delivered by PSI’s truck, unloading at Buyer’s dock shall constitute delivery to Buyer. Claims for shortages or other errors in delivery must be made in writing to PSI within ten (10) days after receipt of shipment and failure to give such notice shall constitute unqualified acceptance and a waiver of all such claims by Buyer. Claims for loss or damage to equipment in transit by common carrier must be made to the carrier and not to PSI. Freight and handling charges by PSI may not reflect actual freight charges prepaid to the carrier by PSI due to incentive discounts earned by PSI based upon PSI’s aggregate volume of freight tendered to a carrier or when a carrier must be used which charges a rate which is different than the rate upon which PSI’s freight and handling charges were based. When shipments are delivered in PSI’s private trucks, Buyer will be charged an amount approximating the prevailing common carrier rate. Excusable Delays; Force Majeure PSI shall not be liable for any ordinary, incidental, or consequential loss or damage as a result of PSI’s delay in or failure of delivery or installation due to (i) any cause beyond PSI’s reasonable control, (ii) an act of God, act of the Buyer, embargo or other government act, authority, regulation or request, fire, theft, accident, strike, slowdown, or other labor disturbance, war, riot, delay in transportation, or (iii) inability to obtain necessary labor, material, components, or facilities. Should any of the aforementioned events of force majeure occur, PSI, at its option, may cancel Buyer’s order with respect to any undelivered equipment or extend the delivery date for a period equal to the time lost because of delay. Notice of such election shall be given promptly to Buyer. In the event PSI elects to so cancel the order, PSI shall be released of and from all liability for failure to deliver the equipment, including, but not limited to, any and all claims on behalf of Buyer for lost profits, or any other claim of any nature which Buyer might have. If shipping or progress of the work is delayed or interrupted by Buyer, directly or indirectly, Buyer shall pay PSI for all additional charges resulting therefrom. Storage If the equipment is not shipped within fourteen (14) days after notification has been made to Buyer that it is ready for shipping, for any reason beyond PSI’s control, including Buyer’s failure to give shipping instructions, PSI may store the equipment at Buyer’s risk and expense in a warehouse or on PSI’s premises, and Buyer shall pay all handling, transportation and storage costs at the prevailing commercial rates promptly following PSI’s submission of invoices for such costs. Warranty Period PSI warrants the products manufactured under the Kelbro register trade name mentioned above to be free from defects in materials and workmanship and to conform to PSI written specifications for a period of 12 months from the date of manufacture. Warranty Remedies If, prior to expiration of the foregoing applicable warranty period, any of such products shall be proved to PSI’s satisfaction to be defective or nonconforming, PSI will repair or replace such defective equipment or components thereof, F.O.B. PSI’s plant or other destination designated by PSI, or will refund or provide Buyer with a credit in the amount of the purchase price paid therefore by Buyer, at PSI’s sole option. Buyer’s exclusive remedy and PSI’s sole obligation under this warranty shall be limited to such repair or replacement, F.O.B. PSI’s plant or other destination designated by PSI, or refund or credit by PSI, and shall be conditioned upon PSI’s receiving written notice of any defect within a reasonable period of time (but in no event more than thirty (30) days) after it was discovered or by reasonable care should have been discovered. In no event shall PSI’s liability for such defective or nonconforming products exceed the purchase price paid by Buyer therefore. Exclusions




This warranty does not (i) cover shipping expenses to and from PSI factory or other destination designated by PSI for repair or replacement of defective equipment or any tax, duty, custom, inspection or testing fee, or any other charge of any nature related thereto, nor does it cover the cost of disassembling or removing defective equipment or reassembling, reinstalling, or testing repaired or replaced equipment or finishing the reinstallation thereof, (ii) apply and shall be void with respect to equipment operated in excess of rated capacity or otherwise not in accordance with installation, maintenance, or operating instructions or requirements, to equipment repaired or altered by others than PSI or PSI’s authorized service agencies, or to equipment which was subjected to abuse, negligence, misuse, misapplication accident, damages by circumstances beyond PSI’s control, to improper installation (if by others than PSI), operation, maintenance or storage, or to other than normal use or service, and (iii) apply to equipment or components not manufactured by or for PSI. With respect to equipment or components not manufactured by PSI, PSI’s warranty obligations shall in all respects conform and be limited to the warranty actually extended to PSI by its suppliers, but in no event shall PSI’s obligation be greater than those provided under PSI’s warranty set forth in this section. The fore going warranties are in lieu of all other express and implied warranties (except title0, including, without limitation, the implied warranties of merchantability and fitness for a particular purpose. No employee, representative, or agent of PSI other than an officer of PSI is authorized to alter or modify any provision of this section or to make any guarantee, warranty, or representation, express or implied, orally or in writing, which is contrary to the foregoing. Any description of the equipment, whether in writing or made orally by PSI or PSI’s agents, specifications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar material used in connection with Buyer’s order are for the sole purpose of identifying the equipment and shall not be construed as an express warranty. Any suggestions by PSI or PSI’s agents regarding use, application or suitability of the equipment shall not be construed as an express warranty unless confirmed to be such in writing by PSI’s authorized officer. Consequential Damage Disclaimer PSI’s liability with respect to equipment proved to its satisfaction to be defective within the warranty period shall be limited to repair, replacement or refund as provided hereof, and in no event shall PSI’s liability exceed the purchase price of the equipment involved. Kelbro shall not be subject to any other obligations or liabilities, whether arising out of breach of contract, warranty, tort (including negligence) or other theories of law, with respect to equipment sold or services rendered by PSI, or any undertakings, act or omissions relating thereto. Without limiting the generality of the foregoing, PSI specifically disclaims any liability for property or personal injury damages, penalties, special or punitive damages, damages for lost profits or revenues, loss of use of equipment or any associated equipment, cost of capital, cost of substitute products, facilities or services, downtime, shutdown, or slowdown costs, or for any other types of economic loss, and for claims of Buyer’s customer for any such damages. PSI shall not be liable for and disclaims all consequential, incidental and contingent damages whatsoever. Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under section 2-719 of the uniform commercial code, PSI shall have no liability to Buyer for consequential damages, such as lost profits, lost revenue, damage to other equipment or liability or injury to a third party. Indemnification by Buyer Buyer shall indemnify, hold harmless, and defend PSI and PSI’s employees and agents from and against any and all damages, liability, claims, losses and expenses (including reasonable attorneys’ fees, court costs, and out-of-pocket expenses) arising out of or resulting in any way from claims by customers of Buyer or third parties against PSI alleging a breach of contract or warranty by PSI to the extent that such damages, liability claims, losses and expenses which may be payable by PSI to Buyer pursuant to the and as limited by PSI’s warranty and damage obligations as contained hereof so as to effectively limit Kelbro’s obligations to customers of Buyer or third parties to those set forth.




Return of Equipment No equipment or part shall be returned to Kelbro without written authorization and shipping instructions first having been obtained from PSI under the company’s Return Policy. Return Policy:

Client/Customer requests an RMA from Sales Department

Sales shall issue an RMA with an assigned number along with the Product Warranty information and a quote for replacement cost.

Client/Customer issues a Purchase Order to PSI (pending evaluation), with the RMA properly filled in.

Product is returned back to PSI at Client/Customers expense with all RMA documents for reference. If the product is warrantied, then the freight cost will be credited back.

An evaluation will be conducted to determine warranty status.

If product is not returned within 30 days of issued RMA, then an invoice will be issued regardless of warranty status.

A copy of the evaluation is available upon request.

3.0 General Arrangement Drawing

Drive and skid shown is a MAX2000 60 pump with

a Shimpo Dr, and 5hp motor on an inline skid with a

center point lift.

(This may not reflect your actual configuration. For

configuration options, see next page.)




3.1 Major Component Drawings

Bare Shaft Pump

Skid

Motor

Gearbox/Drive

Lift Point

Drive and skid shown is a MAX2000 60 pump with a Shimpo Dr, and 5hp motor on an inline skid with a

center point lift.

(This may not reflect your actual configuration. For configuration options, see previous page.)




4.0 Technical Manual Contents

4.1 General Description

The MAX2000® PC Pump has been designed to provide you with reliable service and is ideal for a multitude of applications. Drilling mud, waste water, sludge, slurries and polymerized fluids are just a few of the items that are included in the wide variety of products that are successfully pumped with the MAX2000® PC Pump. Each of these products have unique physical properties that should be noted: high viscosity, abrasive and shear sensitive. Through the use of different elastomers, a MAX2000® PC Pump can be tailored to fit your application. Buna-N (Nitrile) is the standard elastomer provided on a MAX2000® PC Pump. An “Application Data Sheet”, should be submitted for review, for all applications. Most importantly, when there are process changes or when alternative products are to be introduced into the system, the components and size of your MAX2000® PC Pump must be checked for compatibility. An Application Data Sheet has been provided, the last page in this IOM Manual, for this purpose and for all future applications.

Characteristics and Pump Size Options

Pump Sizes Maximum Particle size in inches

MAX 2000-

60 Pump

MAX 2000-

70 Pump

MAX 2000-

80 Pump

MAX 2000-

90 Pump

MAX 2000-

100 Pump

.83 1.0 1.1 1.25 1.39

Particle size can be reduced by a screen or filter on the suction side of the pump. However, the screen or filter must be monitored constantly to prevent blocking product flow. A blockage will cause the pump to run dry and destroy the pumping elements. The MAX2000® PC Pump requires a flooded suction.

Flow Rate In GALLONS/LITERS

MAX 2000-

60 Pump

MAX 2000-

70 Pump

MAX 2000-

80 Pump

MAX 2000-

90 Pump

MAX 2000-

100 Pump

22G/83.3L 37G/140L 54G/204.4L 68G/257.4L 105G/397.5L

The listed flow rates are based on 100 RPM and at a zero discharge differential pressure. A zero discharge differential pressure does not suggest an “open ended” discharge. The product discharge line size, viscosity, specific gravity and elevation change must be evaluated to determine discharge pressure. As the discharge pressure increases, a decrease in flow rate will be seen, unless pump rpm is increased. Pump curves are available, upon request only.

From the above information, it is easy to understand that all information relating to a process should be provided to ensure the accuracy in sizing of a MAX2000® PC Pump




5.0 Lifting Procedure

Extreme care must be taken to prevent damage when moving PC Pumps. Use properly rated slings that are capable of handling the equipment. 1. When lifting equipment, ensure proper lift points are used.

NEVER LIFT A PC PUMP WITH ONLY ONE SUPPORT POINT.

6.0 Installation Procedure

After proper fitting or placement of the equipment, ensure that the power source is isolated and locked out before proceeding. Check for installation of any safety equipment (if applicable) such as, belt guards, coupling guards, horns, beacons, pull cords, etc. Check all assemblies or parts with shipping papers and inspect for damage. Specifically, check for dented or damaged casting housing. Electrical Installation TURN OFF. LOCK OUT AND TAG OUT the electrical power supply to the pump before working on the pump or opening the motor starter or junction box on the side of the motor. A qualified electrician should make electrical connections inside the junction box on the side of the motor. Care should be taken to make sure that voltage and frequency of the power supply match the motor nameplate voltage and frequency. Checking Motor Rotation

BEFORE STARTING OR EVEN “BUMPING’” THE MOTOR, MAKE SURE THAT GEARBOX IS FILLED WITH OIL AND THAT THE “BREATHER” VENT PLUG IS PROPERLY INSTALLED.

The electrical installation is not complete until the motor rotation has been checked. Reversing any two legs on a three-phase power will reverse direction of rotation if necessary.

FAILURE TO PROPERLY INSTALL, OPERATE AND MAINTAIN THE PUMPS AND/OR COMPONENTS CAN CAUSE SEVERE INJURY.

7.0 Startup Procedure

Before proceeding, check all fasteners/bolts to make sure that they are tight and that all parts are secure prior to continuing.

1. When you receive your new pumping unit, please do some preliminary inspections.

2. Check to see that all bolts and nuts are tightened to secure the equipment to the skid and

that all safety equipment is installed correctly.

3. If the gearbox has a sight glass, check the oil level, with the unit sitting level to the ground.

4. Before starting the pump, make sure the packing gland is filled with grease. If grease is needed, remove the grease plug from the gland housing. Opposite of the grease zerk. Water resistant/marine grade synthetic grease is a recommendation. The bolts on the




packing gland should be loose. They need only to be finger tight once the grease has been applied and the grease plug replaced. Please take care when filling with grease. Over greasing can cause a breakage of the packing gland, due to pressure build up. (Most grease guns can generate 10,000 psi)

The packing gland is designed to leak.

5. It is very important to understand that this is acceptable. An attempt to prevent a slight leakage of the packing will cause a premature wearing of the drive shaft and facilitate the wearing of the pump internals.

6. When flanging up the unit on the discharge and suction, make sure that all connections ensure a good seal. The progressive cavity pump will form suction when in operation and will pull air through any avenue that it can find.

7. For three phase motors, check rotation of the motor. On an inline skid design, from the drive end looking toward the discharge end of pump, the pump is designed to turn in a counter clockwise rotation.

8. Prior to energizing the unit, fill the suction housing and the suction line with water or the product that is to be pumped. This will ensure a flooded suction and minimize the wear of the stator at start up.

***If the pump is test run with water and then is not utilized for an extended period of time, the metal rotor and rubber stator can form a very strong seal line, causing the pump to require extra torque to “break” this seal at start up.

9. Once the pump is placed into motion, it is important to monitor the operation of the pump.

Frequently checking the discharge of the pump for pressure and volume will aid in providing longevity.

10. Now that the pump is running, the packing gland should be tightened with a wrench to minimize the leakage of the packing. Overly tightening the bolts on the packing gland can cause the gland to break. A ½ turn of the nut per side, alternating sides, is the acceptable manner in which to tighten the gland.

If you are not using any safety measures or control devises on this pump, the pumping unit has no automatic shut off. All it knows and wants to do is pump and will in most instances continue attempting to pump if a blockage occurs in the feed line or if it is fed a particle size that is too large for it to pass. If you run the risk of feeding the pump a particle too large to pass, we recommend placing a filter screen on the suction line to prevent these particles from entering the pump. The service life of this unit is very dependent on how well you take care of the unit and its exposure to harmful scenarios.

8.0 Routine Maintenance

Use proper lock-out/tag-out precautions when performing maintenance.

Once the unit is placed into full operation, a Preventative Maintenance Program should begin. This program should include regular inspection set up on a periodic basis.

The Preventive Maintenance Program should include a general inspection of:




Periodically check that the exterior of the assembly is clean, especially in the areas where the motors fan in located.

Periodically check to see if there are any leaks, especially in the areas around the oil seals.

Assemblies that are lubricated for life do not have any oil plugs and do not require any special maintenance.

Assemblies not lubricated for life require an oil change at 8,000-10,000 hours of use. The timing of the oil change depends on the type of environment and application of the reducer.

Keep the breather plug clean and free of obstructions.

Check for the correct level of the lubricant through the sight glass (if applicable).

Always use the same type of lubricant that is already in the reducer (or a compatible lubricant) if it becomes necessary to top-off the lubrication. If the type of lubrication is unknown or in doubt, empty the oil from the reducer completely and wash out the unit to remove any residue before refilling with new oil.

When changing the oil, empty the oil from the reducer completely and wash out the unit to remove any residue before refilling with new oil.

9.0 Shut down and Storage

On shut down, make sure that you are following proper lock-out/tag out procedures before taking off any feeds, discharges, or coupling guards.

9.1 Short Term Shutdown

The following recommendations are offered for storage of up to six months:

If indoor storage is not possible, cover the pump with a protective covering and spray any non-painted metals with a rust inhibitor. Do not allow moisture to collect in or around the pump.

Relieve the compression on the packing by loosening the packing gland. If you intend to grease lubricate the packing after installing the pump, inject a liberal amount of grease into the stuffing box through the zerk.

9.2 Long Term Shutdown

If the pump is to be in storage for over six months, follow both the recommendations above for short term storage and the following recommendations: • If applicable, remove the drive belts from belt-driven units and/or disconnect the coupling on direct-connected units.

• Apply a rust inhibitor to the pump. • At least once a month rotate the drive shaft of the pump manually for several revolutions. This will help avoid a set condition between the rotor and stator, thereby making startup easier. This will also help avoid deformation of the stator profile which may cause excessive vibration.




10.0 Parts List




DWG. #

Description 60

Pump QTY

70 Pump QTY

80 Pump QTY

90 Pump QTY

100 Pump QTY

0001 BEARING HOUSING 1 1 1 1 1

0002 DRIVE SHAFT 1 1 1 1 1

0003 BOLT STYLE END CAP 1 1 1 1 1

0004 BEARING SPACER 1 1 1 1 1

0005 BALL BEARING 2 2 2 2 2

0006 SNAP RING 1 1 1 1 1

0007 GREASE SEAL 1 1 1 1 1

0008 NYLOS RINGS 3 3 3 3 3

0009 CASTING SEAL 1 1 1 1 1

0010 SHAFT SEAL 1 1 1 1 1

0011 DRIVE KEY 1 1 1 1 1

0012 ALLEN HEAD BOLT 8 8 8 8 8

0013 HEX HEAD CAP SCREW 4 4 4 4 4

0014 LOCK WASHER 4 4 4 4 4

0015 PIN JOINT O-RING 4 4 4 4 4

0016 PACKING GLAND BOLT 2 2 2 2 2

0017 GREASE(joint, bearing & packing) 5 5 5 5 5

0018 PACKING RING 4 4 4 4 4

0019 FLAT WASHER 2 2 2 2 2

0020 LANTERN RING 1 1 1 1 1

0021 ROTOR 1 1 1 1 1

0022 PIN RETAINER SLEEVE 2 2 2 2 2

0023 PIN 2 2 2 2 2

0024 CON ROD SEAL 2 2 2 2 2

0025 COVER PLATE 2 2 2 2 0

0026 STATOR 1 1 1 1 1

0027 THROUGH BOLT 4 4 4 4 4

0028 HEX HEAD CAP SCREW 12 12 12 12 0

0029 DRAIN PLUG 4 4 4 4 1

0030 LOCK WASHER 12 12 12 12 12

0031 LOCK WASHER 4 4 4 4 4

0032 HEX HEAD NUT 4 4 4 4 4

0033 CLEANOUT PORT GASKET 2 2 2 2 0

0034 STATOR O-RING 2 & 2 2 & 2 2 2 2

0035 PIPE THREAD TAPE 4 4 4 4 1

0036 PACKING GLAND SPLIT 1 1 1 1 1

0037 GLAND HOUSING 1 1 1 1 1

0038 ZERK 1 1 1 1 1

0039 DRAIN PLUG 1 1 1 1 1

0040 PIPE THREAD TAPE 2 2 2 2 1

0041 DISCHARGE FLANGE 1 1 1 1 1

0042 SUCTION HOUSING 1 1 1 1 1

0043 CONNECTING ROD 1 1 1 1 1

0044 PIN JOINT BOOT 2 2 2 2 2

0045 BOOT CLAMP (con-rod side) 2 2 2 2 2

0046 BOOT CLAMP (head side) 2 2 2 2 2

0047 ALLEN HEAD BOLT (clamp) 16 16 16 16 16

0048 STATOR ADAPTER 2 2 0 0 0




11.0 Inspection and Tests

SEE ATTACHED (if applicable)

12.0 Certification(s)


13.0 Additional drawings, diagrams, etc.


14.0 Contact Information

Replacement parts for PSI SUPPLIED equipment can be ordered from Process Solutions International or any of their agents, worldwide. Please include the model number if possible. To order parts or to receive technical support via telephone, contact Process Solutions International using the information listed below.

Process Solutions International A Division of Kelbro, Inc.

7519 Prairie Oak Drive Houston, TX 77086

(281) 893-4774; FAX (281) 893-1027

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