Installation and Service Manual - Solar production Equipment Corp
Contents
1. Solar Production Equipment Corp Chemical Injection Pump Installation and Service Manual www solarproductionequipment com mp Models P 075 M1 8 1750 12 ALU 075 1 8 1750 12 55 CLASS 1 DIV 1 EC PUMP USER GUIDE Table of Contents Overview Pump Specifications Installation instructions Location of pump Tubing Connections Suction line Discharge line Electrical Connections Priming the pump Routine Maintenance and repai Monthly maintenance check 1 Piston plunger bearing inspection 2 Pump motor wear check Parts Replacement or Rebuild Re assembly 0000000000005 Table of Figures Figure 1 Typical Installation Diagram Figure 2 Assembly Diagram 1 Figure 3 Assembly Diagram 2 Figure 4 Typical Pump Assembly 2 www solarproductionequipment com SPEC PUMP R GUIDE Overview Chemical injection pump SPEC Chemical Injection Pumps are used to accurately metre and inject chemicals at well sites and production facilities The pump is a directly opposed dual head reciprocating piston design The pump uses an eccentric bearing mounted directly to the end of the prime mover shaft The bearing fits into a close tolerance indentation machined into the middle section of the reciprocating piston assembly The bearing moves in an orbit as the motor spins driving the piston shaft back and forth between the horizontally opposed pump heads As a result of this mo2. c zz le m s o e TEE SPEG SOLAR PRODUCTION ror m EQUIPMENT CORP 0010 NTS SOLAR PRODUCTION EQUIPMENT LII 1725708 O PUMP P amp ID TYPICAL E www solarproductionequipment com Thank you for choosing Solar Production Equipment Corp SPEC Solar Production Equipment Corp 10 12180 44st S E Calgary Alberta T2Z 4A2 Phone 403 730 5951 Fax 403 236 8858 24 hour emergency service 403 990 5558 Account inquiries payables and receivables admin solarproductionequipment com Sales or technical inquiries and field assistance gclark solarproductionequipment com www solarproductionequipment com 2009 SPEC prepared by von Hauff Skalka Consulting
3. be within 10 of recorded measurements unless operating conditions have changed If the motor current draw rises significantly have the motor inspected by qualified personnel Parts Replacement or Rebuild The only wear parts in the pump are the Seals O rings piston assembly and bearing Various replacement kits are available from SPEC This type of maintenance should always be done in a clean environment The drawings on pages 9 10 show an expanded view of the pump assembly www solarproductionequipment com 7 SPEC PUMP USER GUIDE To replace O rings and seals Disconnect all electrical connections before servicing Remove pump head from pump motor Disassemble as per drawings note the orientation of the poppet valves Thoroughly clean all components Blow out poppet valves pump bodies and manifolds in preparation for re assembly SPEC Seal Insertion Tool O rings Discard old o rings Press the new o rings into the depression in the pump body Seals Carefully remove the old seals using the piston assembly to gently pry out the seal see picture labelled 1 below ensuring you do not scratch or mark the seal seats Insert the new seals into the pump body using the SPEC seal insertion tool provided in the kit and press the seal into place Note the spring side of seal is placed toward the pump body Re assembly Once the new O rings and seals have been properly installed insert the popp
4. d its entries are located at the bottom Suction line The intake or suction connection is identified by an S stamped into the metal next to the threaded entries on the suction manifold The entries come from the factory with a stainless steel plug installed at one end Configure the plug to facilitate the desired suction entry and connect the suction line It is strongly recommended that the suction line have an appropriate medium filter installed directly ahead of the pump entry to ensure that particles do not enter into the pump head and plug up the poppet valves Discharge line The discharge connection is identified by a D stamped into the metal next to the plugged 4 threaded entries on the discharge manifold Again configure the plug to facilitate the desired discharge entry and connect the discharge line The discharge line installation should always include a pressure safety valve PSV and recycle loop to insure discharge pressure is limited to a safe level It is also necessary to place an in line check valve in the discharge line as close to the pump head as possible to eliminate leak back and maximize pump efficiency 4 www solarproductionequipment com SPEC PUMP R GUIDE Electrical Connections The pump is a 12 volt direct current machine Polarity of the connections is critical for proper functioning of the pump Do not run the pump with reversed polarity as significant damage will occur The leads are clear
5. et valves ensuring proper orientation see 2 and 3 Align the suction and discharge manifolds with the valves and pump body Use a large C clamp to press together and align the manifolds with the pump bodies see illustration below Install and tighten all eight manifold bolts Tighten to 140 inch Ibs Remove clamp and attach the pump body to the mounting plate and then reattach the completed pump head to the pump motor UN E E WE ge Suction Discharge www solarproductionequipment com SPEC PUMP USER GUIDE MANIFOLD BOLT 8 N DISCHARGE MANIFOLD LOCK WASHER 8 DISCHARGE POPPET VALVES 2 O RING 4 39a PISTON PLUNGER PUMP BODY SUCTION POPPET VALVES 2 SUCTION MANIFOLD S FRONT VIEW SIDE VIEW Figure 2 Assembly Diagram 1 www solarproductionequipment com SPEC PUMP USER GUIDE WAS NIA aqls MAIA dOL L 17108 HHSVA AAS NOLSId I3NIV 13421 1995 3NIV 132 1935 Figure 3 Assembly Diagram 2 www solarproductionequipment com 10 SPEC PUMP USER GUIDE nut NEU c c 11 Figure 4 Typical Pump Assembly 5 PART DESCRIPTION TANK ISOLATION VALVE SIGHT GLASS Psv 440 MICRON FILTER SPEC PUMP CHECK VALVE ruse sTUB TUBING
6. ine in the event of a PSV valve release 3 An inline check valve placed in the discharge line as close as possible to the discharge port of the pump and after the PSV Typical layout for the electrical feed to pump must incorporate A A CSA Class 1 div 1 electrical fitting approved for terminations to connect the motor and conduit feed system The motor is factory sealed and employs a 5 rigid nipple for connection to the fitting B ACSA Class1 div 1 approved flexible conduit or HL approved Teck Cable must be installed to allow for vibration as per the applicable codes www solarproductionequipment com SPEC PUMP USER GUIDE Routine Maintenance and repair SPEC pumps are designed for years of reliable service with minimal maintenance All maintenance that is necessary must be carried out by qualified technicians Monthly maintenance check 1 Piston plunger bearing inspection Remove the four allen screws that hold the pump nameplate Inspect the piston plunger cavity for debris and remove any foreign objects or debris If bearing or piston assembly show wear they should be replaced Apply a small amount of grease to the reservoir pad Reinstall the pump nameplate 2 Pump motor wear check At initial installation use a clamp on amp meter to read normal motor current draw for the individual installation and record this measurement During routine maintenance re check the motor current draw Readings should
7. ly marked for polarity is to be connected to the positive of the controller load terminals The positive lead is also identified with a red band is to be connected to the DC negative bus The motor feeders should be properly fused for protection as per the Canadian Electrical Code Recommended Ferraz Shawmut ATP 12 or 15 Amp Slow Blow Fuse Priming the pump The pump is designed to be self priming and incorporates a flooded section design that requires some fluid head to operate effectively The pump should not require any special attention to achieve priming If you do encounter difficulty you can bleed the plug opposite the discharge entry that you are using and allow the air to escape the manifold until the fluid stream is solid Tighten the plug and the pump should now be primed www solarproductionequipment com 5 SPEC PUMP USER GUIDE Figure 1 Typical Instrumentation and Electrical Configuration Minimum instrumentation tubing and accessory requirements for proper operation of the pump are 1 A suitable medium filter 440 micron filter placed in the feed line between the sight glass and suction port The filter should be as close as possible to the suction port of the pump 2 Apressure safety valve PSV positioned in the discharge line as close as possible to the discharge port of the pump configured so that the discharge line pressure can be safely released back into the suction l
8. procating piston Voltage 12 VDC FLA 14 Maximum static pressure 3000 PSI Maximum operating pressure 2500 PSI Pumping Capacity Maximum 1500 liters day Classification Class 1 div 1 Group D T2D www solarproductionequipment com 3 EC PUMP USER GUIDE Installation instructions Location of pump We recommend that you locate the pump as close to the controller battery enclosure as possible while still observing the area classification as dictated by section 18 of the Canadian Electrical Code and any local code requirements It is important to remember that the pump assembly is certified Class 1 Div 1 group D while the SPEC controller battery enclosure is certified Class 1 Div 2 Since this is a 12 Volt DC powered system it is necessary to keep the distance between the pump motor and the batteries as short as possible maximum 20 to limit the line losses and maximize the pumps output The pump is a gravity fed flooded section design and therefore must be located below the fluid reservoir from which it draws Tubing Connections There are two manifolds on the pump one for suction and one for discharge Each manifold is common to both the opposing pump heads There is one threaded entry at each end of both the suction and the discharge manifolds to allow for installation flexibility in the field The discharge manifold and its entries are always located at the top of the pump body and the suction manifold an
9. tion the pump simultaneously draws fluid into one pump head while pressurizing the other pump head As the bearing moves through 180 degrees it reaches the end of travel causing the piston assembly to reverse direction The pump consists of two directly opposed pump heads positioned between the suction and discharge manifolds Two Poppet valves are located at each end of the pump between the suction and discharge manifolds and the pump heads As the piston plunger moves past the seal and into the bore of the pump head assembly one poppet valve is forced open while the other is forced closed This causes fluid to be driven into the discharge manifold pressure or discharge stroke As the eccentric bearing drive assembly rotates through 180 degrees on the end of the motor shaft the piston assembly changes direction and draws back from the pump head The poppet valve operation reverses direction and the fluid is drawn from the suction manifold into the pump head suction stroke At the same time one of the horizontally opposed pump heads is pressurizing the other pump head is drawing fluid from the reservoir creating the concurrent suction and discharge The pump repeats this operation one discharge stroke and one suction stroke at each of the opposing pump heads for every 360 degree full circle rotation of the motor The motor is rotating at 1750RPM equalling 3500 discharge strokes per minute Pump Specifications Type Dual head reci
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