Reverse Osmosis Plant Manual

TWO STAGE REVERSE OSMOSIS
PLANT
OPERATIONAL / MAINTENANCE MANUAL V 0.02
Date: 05-07-2013
Type of Unit:
MODEL: SW-38B
Project: JADE PALMS
Order No:
Serial No:
ORION OFFSHORE MARINE SERVICES PTE LTD

1 SOON LEE STREET
#05-48/49 PIONEER CENTRE
SINGAPORE 627605
TEL: +65 97451496; FAX : +65 65706907
Email : sales@orionoffshore.biz
Sea Water Reverse Osmosis Plant
001/002/2013
CONTENTS
1.
2.
3.
4.
5.
6.
INTRODUCTION
I.
Preface
II.
How to use this Manual
III.
Safety Remarks
IV.
Log Sheet
V.
W arranty
VI.
Notes
VII.
Service
FUNCTIONAL DESCRIPTION
2.1
Description of Process
2.2
Unit Arrangement
2.3
Controls, Displays & Measurements
2.4
Safety and Behavior Rules
OPERATION
3.1
Commissioning
3.2
Starting of Unit
3.3
Initial Startup
3.4
Normal Operation Monitoring
3.5
Preservation
FAULT INDICATION & FINDING
4.1
Error Indication and Implication
4.2
Faults without Lamp Indication
MAINTENANCE, CLEANING & CALIBRATION
5.1
Schedule for Checks & Maintenance W ork
5.2
Contactors
5.3
Electric Motor
5.4
Centrifugal Pumps
5.5
Plunger Pump
5.6
Multimedia Carbon Filter
5.7
Cartridge Filter
5.8
RO Membrane
5.9
Pressure Vessels W AVE CYBER
SPECIFICATIONS
6.1
Specification
6.2
Tools and Resources
6.3
Annual Consumable Items
6.4
W ater Analysis
INTRODUCTION
I.
Preface
This Reverse Osmosis System has been designed and fabricated as space
saving modular plant in order to provide installation flexibility to the user, where space is
restricted.
All components and material used have been selected as per user requirements
and guaranteeing on a self-controlling 24 hours operation. The said system is simple to
operate and require minimum service.
II.
How to Use this Manual

This manual should provide to you all the necessary and required information for
operating and maintaining of the said system. During the design and fabrication of the
said system, great regard has been paid for safety. W hen working on this system or any
other system, there is always an element of danger which the owner, operator and
technician need to be aware of. Appropriate maintenance minimizes any danger and
maximizes availability.
Any work of maintenance or repair, must be carried out correctly. Appropriate
technical knowledge as well as any applicable regulations for safety and environment
must be provided by the owner, operator and/or the maintenance personnel.
THIS MANUAL DOES NOT REPLACE ANY PERSONAL TRAINING!
III.
Safety Remarks
The fresh water generator must not be operated within harbor area or in waters
When operating this equipment, certain parts are electrified. Ignorance of
polluted with oil.
operating procedure can cause death, injury or material damage. For any work
at or on the plant must only be done by persons trained on the machine and
familiarized with the information in this manual. Repair and maintenance
must only be done by appropriately qualified technical personnel.
Protection, such as Pulley / Belt and Belt Guards, must be only done for
maintenance or repair and must be re-installed immediately after any such
repair or maintenance completion.
All personnel involved in the operation, maintenance, inspection and
installation / reinstallation of the product or part of the product must be fully

qualified. Personnel responsibilities, competence and supervision must be clearly
defined by the operator.
The product is made with greatest possible care. Modifications in the construction
Make sure that the product operates within its working range. Only then the
Check the rotating parts regularly. Always use biodegradable lubricants for
Always act according to the laws by laws regulations and instructions with respect
Extra safety care may be required depending upon the specific operations on the
or the use of non-original parts may lead to a safety risk.
product performance is guaranteed.
maintenance.
to health, safety and environment.
system.
The OWNER and USER are responsible for complying with all the prevailing laws to maintain
a safe working environment.
IMPORTANT ITEMS FOR PLANT PROTECTION:
There must not be any visible movement (vibration/pulsation) of the pointer

on pressure gauge. If this occur then the causing this fault may be High
pressure pump or valves or packing defects.
The RO Membrane damage possible, if there is any vacuum in the feed water
supply line or concentrate discharge line.
Do not allow any back pressure on the permeate outlet, when there is no
pressure on the feed supply, otherwise the membrane cushions will be
damaged. Do not allow pressure on the permeate side of the modules when
the unit is stopped. The maximum pressure in the permeate line is 3bar. Add an
additional booster pump, if a permanent pressure above this value is required.
The feed pressure to the high pressure pump must not fall below 0.5bar. If
this happens, the pump will be damaged by cavitations.
The membranes are not resistant against chlorine or any oxidizing agent.
De-ionized or distilled water in the unit will reverse the flow direction and
destroy the membranes.
Feed-water quality conditions care is essential for membrane performance.
Do not allow to operate the RO Unit in the areas of river esturiances,

especially in regions with low draft where the water can be expected to carry
a high amount of suspended solids and silicates. This could cause unremovable deposits on the membrane surfaces affecting the desalination process,
reducing capacity and finally requiring the membranes to be replaced.
V.
LOG SHEET
In order to make any troubleshooting as easy as possible, the following chart is recommended
for daily use with the parameters measured on the unit:
Date
Hours
Fresh
Water
T DS
Feed
Water
T DS
PH
PG
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
PG
2
PG
3
PG
4
PG
5
PG
6
PG
7
PG
8
FM
1
FM
2
FM
3
FM
4
VI.
WARRANTY
ORION OFFSHORE warrants that this system will produce pure water within its
designed limitations for a period of Twelve (12) months from the date of dispatch,
provided that the system is operated on feed water of the minimum standard in
accordance with the submitted reference analysis and that the operator adheres exactly
to the installation, operation and maintenance instructions and recommendations.
Components of the system supplied by ORION OFFSHORE which are found to be
defective through poor workmanship or materials will be repaired or replaced if their
performance is proven to be less than normal by industry standards.
This warranty will be considered null and void if a unit is operated with
malfunctioning components or controls which result in the system being unable to meet
its designed performance.
ORION OFFSHORE will repair or replace a unit or component found to be
defective due to bad workmanship or materials on a free of charge under this warranty
and defective unit or component will be returned. This warranty does not cover any
system or component which fails due to damage from mishandling, misuse, substandard
feed water, improper maintenance or neglect of maintenance, poor or improper
installation or incorrect electrical supply. This warranty may also be voided if serial
numbers or components are found to be mutilated or missing.
This warranty does not cover or apply to consumable items such as filter
elements, lubricants, shaft seals of centrifugal pumps, seats/seals of the high pressure
pumps or chemicals used in the operation or maintenance of the system.
The terms of this warranty become effective on dispatch of the equipment from
ORION OFFSHORE premises. There are no warranties expressed or implied which go
beyond the foregoing statement.
VII.
Notes
VIII.
Service
Order Form for Spares
For Vessel
Authorized By:
Unit Type
Approved By:
Delivery Instructions:
Serial No
Date
Delivery Required By:
Order No:
Additional Instructions:
To be charged / Invoiced to:
To ensure that the correct parts are delivered, please complete each block
correctly. The section block refers to the header number of the page that contains the
description or servicing of the item (if any).
ITEM
QTY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
PART NO
DESCRIPTION
SECTION
2.
FUNCTIONAL DESCRIPTION
2.1
Description of Process
This system uses the principle of the 'Reverse Osmosis. Reverse
Osmosis is a process in which water is de-mineralized by using a semi-permeable
membrane at high pressure. If two saline liquids are separated from one another
by a semi-permeable membrane, which does only allow molecules over a certain
size to pass through, then these liquids will tend to equalize their concentrations.
This phenomenon is called Osmosis. Should one of these liquids be salt water
and the other pure water, water molecules would diffuse through the membrane
towards the salt water and dilute this. A certain pressure would occur in the
system when this happens, the pressure is known as Osmotic Pressure.
For water desalination or de-chlorination this process is artificially
reversed, Reverse Osmosis. The system is subject to a pressure above Osmotic
Pressure, causing a molecule movement into the reverse direction; only the water
molecules diffuse from the salt water through the membrane to the pure water
side. The ions of the salt water cannot pass through and remain on the salt water
side. W ithin the RO membranes, the Reverse Osmosis process takes place whilst
the feed water is in motion flowing over the membrane surfaces. About 30% of the
water in the feed water passes through the membrane, the remaining 70%
retaining the rejected salts. The feed water is gradually increasing in salt
concentration as it flows through the RO membrane. The salts filtered out and left
behind by the membrane are carried away and dis-charged, in case of sea water
desalination they are returned to the sea as brine (concentrate). The pure water
permeate produced flows to a fresh water storage facility. The amount of pure
water that can be produced depends on the following:
aThe operating pressure
bThe salt content of the feed water
cThe feed water temperature
For example, the oceans have a salt content of approximately 3%,
whereas the Red Sea has a much higher salt content of approximately 4 % and
to overcome the increase in salinity the operating pressure is increased.
Each standard system is designed for a certain production rate of pure
water, assuming a feed water temperature of 25C. For each 1C drop in feed
water temperature, the permeate production drops by 3%. For example, if
designed output at 25C is 100l/h. Then with a feed temperature of say 15C, the
permeate output is 100-30%=70l/h. A rise in temperature above 25C, increases
the pure water production only slightly. 25C is the optimum feed temperature.
Note: Some systems can be supplied to produce the required quantity with a low
feed water temperature.
2.2
Unit Arrangement
The system consists mainly of the following components:
SW MEMBRANE
BW MEMBRANE DOSING PUMP
DEIONIZER
(NOT
SUPPLIED)
PRESSURE
GAUGES
HIGH
PRESSURE
PUMP
MOTOR
FLOW
METER
GATE
VALVE
HIGH
PRESSURE
PUMP - I
FEED PUMP
-1
(General arrangement of the System)

(DE- IONIZER WILL NOT BE INCLUDED IN JADE PALM UNIT)
Feed Pump (Centrifugal Type) (FP1) filter pump,

delivers the feed water at a pressure of up to 4 bar through
the cartridge filter and from there to the high pressure pump
(HPP). This centrifugal pump has its own integral electric
motor.
Multi Cartridge Filter

Ten micron pre-filtration housing constructed from
Stainless Steel 316 materials, designed to meet ASME code
requirements shall be provided for Reverse Osmosis unit.
The pre-filtration stage of the system has been designed for a
maximum flow of 10 GPM (each) with 7 Nos of (2.5 x 20) inch
Slim Line Cartridge Filter inside.
Cartridge Filters (CF) in it sediment particles of 10

m or more in size are retained within the filter element.
These cartridge filter elements have to be replaced when
dirty, they cannot be cleaned.
High
Pressure
Pump1
(HPP1)
is
positive
displacement pump (plunger pump). This pump delivers feed

to the 1st stage RO Membrane at a pressure of up to 65 bar.
The pump is powered through a belt derive from a 3-phase
motor. Minimum feed pressure to this pump is 0.5 bar.
RO Membrane RO membranes are imperfect barriers

to dissolved salts in feed-water, there is always some salt
passage through the membrane. As feed-water pressure is
increased, this salt passage is increasingly overcome as
water is pushed through the membrane at a faster rate than
salt can be transported. However, there is an upper limit to
the amount of salt that can be excluded via increasing feedwater pressure.
The concentrate flows from the unit through the manually operated Concentrate
Valve (CV) which allows three positions:
TDS Sensor (TDS-S) transmits the conductivity of the
permeate to the conductivity meter (measure of the remaining
salt content). An increase in conductivity implies a higher salt
content. The value displayed in the conductivity meter is in
s/cm. As a rough guide, if the reading shown is divided by 2
the figure obtained would be the approximate value of salts
as ppm (mg/l).
Level Switches (LS1 & LS2) Starting and stopping the

unit will then be actuated by 2 level switches fitted in the
buffer tank and chemical tanks. When the low level switch is
activated, the plant will start automatically. When the tank is
full the high level switch will be activated and the unit stops
and will be in a stand by mode waiting to be restarted either
by remote (level switch) or manually by pressing the start
button.
2.3
Controls, Displays & Measurements
Control Panel (CP) is equipped with a Main Circuit

Breaker, Switches, TDS Controller & Display, Amp Meter, Volt
Meter, Indicators, Hour Meter etc.
Flow Meters (FM1, FM2, FM3, FM4) are installed in

different lines in and from the RO Membrane(s).
Inside the plastic body there is a floating indicator.
When its top edge aligns to the appropriate mark on the scale,
indicates the rate of pure water produced. The scale is
marked in liters per minute / gallons per minute on the front of
the transparent plastic body.
Conductivity
Controller
(TDS
C)
displays
the
conductivity of the permeate, measured by the conductivity

sensor. Conductivity provides a measure for the salt content
remaining. The higher the conductivity, the higher the salt
content.
Pressure Gauges (PG1, PG2, PG3, PG4, PG5) indicate the

pressure loss across the cartridge filter, sand-filter & RO
Membranes. Check the operating pressures for each unit as
per functional requirements. The pressure gauges are filled
with a glycerin type liquid to minimize the pointer vibration.
2.4
Safety and Behavior Rules

Intended use
This system is for drinking water process and boiler feed use.
Briefing
When operating this equipment certain parts are electrified. Ignorance of
operating procedure can cause death, injury or material damage. Any work at or
on the plant must only be done by persons trained on the machine and
familiarized with the information in this manual. Repair and maintenance
must only be done by appropriately qualified technical personnel.
Electrical endangerments
During the operation of electrical devices some sections are energized
dangerous. Negligence of warning notes can cause death, bodily injury, or
damages to property. The cabinets and devices are only to be opened by qualified
personnel.
Mechanical endangerments
The system is designed in the state of the art. In order to ensure safe
handling of the system, all preventive measures have to be checked for
effectiveness. The operator has to ensure by regular maintenance that the
function of the respective protection devices will preserved.
Chemical endangerments
The operation of the unit and functions depend upon the field of application
and use of different chemicals (e.g cleaner, pH stabilizers and flocculants,
disinfectant). Adopt the proper safety for protection.
3.
3.1
OPERATION
Commissioning
Read the safety remarks and before commissioning the plant, please take note of
the following:
LIMITS OF PERFORMANCE
Maximum flow rates
Feed Water:
40 gpm (Approx)
Permeate:
Designed + 20%
Note: High feed flow will cause an unacceptable

pressure loss across the RO membranes and a
higher ampere loading on the HP pumps motors
Operating pressure
65 bar
Maximum operating pressure
73 bar
Before first commissioning of the plant, the following checks must be made:
ASSEMBLY
CHECKS BEFORE FIRST

COMMISSIONING
Control cabinet
- Check voltage
- Check frequency
The voltage must be checked across each

two phases:
from L1 to L2
from L1 to L3
from L2 to L3
The plant must only be operated at the
ratings it was designed for.
- Check control voltage
Check different circuits output voltage,

pressure switches and level switches.
RO Membranes
Check loading
Flow meter
Check setting and connections of flow meter.
3.2
Starting of the Unit

Lamp signals :
lamp on
lamp off
Lamp signals:
Step
No.
Action
Open all valves to and from the RO unit.
Set valves to Normal operation:
Normal operation
3
Check PB 1 for Feed Pump 1.
Check PB 2 for High Pressure Pump 1.
Check the pressures and flow rates
Check PB 3 & PB 4 for Feed Pump 2

and High Pressure Pump2.
Check the pressures and flow rates
Activate Cleaning Pumps on requirement

by selecting PB 5 & PB 6.
Activate Dosing Pumps on requirement

by selecting Selector Switches.
Effect
Lamp signal
Adjust all valves as per requirement.

Feed Pump 1 is ready for
operation.
Pressure Gauges and Flowmeters indications.

Pumps are ready for operation.

Pressure Gauges and Flowmeters indications.

Pumps are ready for operation

3.3
Initial Startup
OPERATING PROCEDURE
Stage 01 (Sea water to Fresh Water)
Refer Flow Diagram
BEFORE PLANT STARTUP, GATE VALVES (GV 1 & GV 2) MUST BE IN

FULLY OPENED POSITION
1.
Check feed line, FGR Strainer for any suspended impurity, Ball valve (BV 1)
(open position).
2.
Push button PB 1 for Feed Pump 1 ( FP 1), Feed pump will start functioning
and Pressure Gauge (PG 2) will indicate pressure 20-55 PSI.
3.
Water flow will start and it will enter into the Cartridge Filter 1 and Cartridge
Filter 2 respectively.
4.
Turn ON Dosing Pump 1 (DP 1) through Selector Switch 1.
5.
Replace Filter Cartridges, If Pressure Differential of PG 1 and PG 2

decreased by 20 PSI.
6.
Now turn ON High Pressure Pump by pushing PB 2.
7.
For smooth and safe operation, allow High Pressure Pump 1 (HPP 1) to run
5 minutes for stability.
8.
Slowly and gradually turn Gate Valve (GV 1) towards close position. By
closing the valve, the system pressure will start increasing and will be
displayed on PG 3 and PG 4, respectively.
9.
Stop closing of the said valve when system pressure will reach at 750850
PSI at PG 3 & PG 4 or flow rate of 9 GPM will be displayed on Flow Meter 2
(FM 2).
10.
When one of the above mentioned parameter will achieved, let the system
run for 15 minutes and observe the system stability, if R.O plant does not run
smoothly or parameters are fluctuating, repeat step 1 10.
Stage 02 (Fresh water to Boiler Feed Water)

Refer Flow Diagram
11.
For starting of stage 02, press push button 3 (PB 3) to operate Feed Pump
(FP 2).
12.
When Feed Pump 2 is in operation, fresh water will start passing through the
Multimedia Carbon Filter 2 (CF 1) and Feed Pump 2 pressure will be
displayed at PG 5.
13.
After CF 2, water will flow through the Cartridge Filter 2 (Cart. F 2).
14.
If Feed Pump 2 pressure exceeds 70 PSI at PG 8, stop Stage 02 and

replace Cartridge.
15.
Turn ON Dosing Pump 3 by selecting Selector Switch 3 (SS 3).
16.
Start High Pressure Pump 2 (HPP 2) by pushing PB 4.
17.
Slowly and gradually turn Gate Valve 2 (GV 2) towards close position. By
closing the valve, the system pressure will start increasing and will be
displayed on PG 9 and PG 10, respectively.
18.
Stop closing of the said valve when system pressure will reach at 150-225
PSI at PG 9 & PG 10 or flow rate of 3 GPM will be displayed on Flow Meter
3 (FM 3).
3.4
Normal Operation Monitoring

SEA WATER:
Description
0
Value
Temp ( C or F)
Pre filter pressure (psi or bar)
Post filter pressure (psi or bar)
Primary pressure (psi or bar)
Final Pressure (psi or bar)
Permeate Flow (GPM or m3/hr) Qp
Concentrate Flow (GPM or m3/hr) Qc
Recovery (R1) Qp/(Qp+Qc)
FEED WATER:
Description
Value
Temp (0C or 0F)

HP Pump Pressure (psi or bar)
Final Pressure (psi or bar)
Permeate Flow (GPM or m3/hr) Qp1
Concentrate Flow (GPM or m3/hr) Qc1
Recovery (R2) Qp1/(Qp1+Qc1)
3.5
Preservation
To prevent fouling during a stand still for > 07 days the unit must be preserved.
Must circulate preservation solution after every 12-15 days.
Circulate preservation solution at least 30 minutes by turning cleaning pump

ON.
Note:
For the first start after preservation, the unit must be rinsed by raw water for at
least 5 minutes under pressure. During this time period permeate produced
may not be supplied to fresh or feed water tank.
FAULT INDICATION & FINDING
4.1
Error Indication and Implication

Fault conditions are indicated by various lamps (different colors) on the control panel.
Lamp signals:
Lamp signal Device

Red
EOCR
ST
LAMP SIGNALS @ 1
Red
Red
PSD
BTL
ND
LAMP SIGNALS @ 2
Meaning
Possible causes
Electronic Over-current Relay
Motors over loaded

Wrong Current Setting
STAGE: RED LAMP IS ILLUMINATED PERMANENTLY FOR FAULT
Power Safety Device
- Phase failure
- High/low Voltage
- Phase sequence
- Device calibration
- 1Pole circuit breakers
Buffer Tank level
- High feed-water supply

- High pressure pump not
operational
- Level Switch
STAGE: RED LAMP IS ILLUMINATED PERMANENTLY FOR FAULT
Red
BTL
Buffer Tank level
- High feed-water supply

- High pressure pump not
operational
- Level Switch
Red
TDSC
TDS Controller
- High TDS over the set value
Red
PHM
pH Monitor
- High pH over the set value
4.2
Faults without Lamp Indication
Lamp signal Device
Meaning
Possible causes
FAILURES WITHOUT FAULT INDICATION
CP
Control Panel not operative - Power supply, Circuit breakers, Relay
RSS
Rotary Selector Switches
- Wrong auto/manual adjustment
DIP
De-Ionizer Pump
- Thermal Overload/Circuit
CCP
Chemical Cleaning Pump
- Thermal Overload/Circuit
Excessive pressure
- Valves in HP pump worn or damaged
fluctuation during operation
- Normal wear
HPP valves malfunctioning - Particles between valve plate and
valve seat.
5.
MAINTENANCE, CLEANING & CALIBRATION

5.1
Schedule for Checks & Maintenance Work

In order to maximize availability the unit must be maintained regularly. Checks and
maintenance works should be carried out according to the tables below. Detailed instructions, as
far as necessary, can be found in the following chapters. The check list at the end of this manual
should be filled in daily. This assists to detect failures sooner and easier.
5.1.1
Schedules for Checks & Maintenance Works
REGULAR CHECKS
Action
Frequency
Daily
- visually inspect all sections for leakages

- check if motors or pumps make unusual noises and oil levels
- check pressure losses across cartridge filters and RO membranes and fill
in log sheet
Monthly
- check calibration of conductivity meters by comparing with readings taken

with a manual measurement
- check and update stock of spares and consumables, if necessary
- visually check all safety devices, such as overfill couplings etc
- Check equipments fastening nut bolts, PVC pipe lines upto product tanks
and flanges.
Half-yearly
- check contactors for lose screws or wires and base plate nut bolts.
Device
Designation 0n
P&I diagram
Electric
motors
Cartridge
filter
RO
membranes
Required action
(for plunger
pump HPP1)
Cart. F
replace bearings
replace filter elements
As required or after approx.

20,000 operating hours
As required
SWM & BWM
replace membranes
(only if necessary)
circuit cleaning
every 500 operating hours or

earlier, if required
150 hours after
commissioning, then monthly
every 3,000 operating hours or
as required
check torque
Plunger
pump
Centrifugal
Pumps
5.2
Recommended frequency
HPP1
check plungers, pumping

section and crankshaft
section
check valves and seals,
replace as necessary
check valves and seals,
replace as necessary
check belt tension
check oil level, top up if
necessary
replace oil filling
FP1, HHP2,
FP2, DIP, CP
Priming
Noise
RPM, if required

as required
as required
weekly
weekly
50 hours after first
commissioning, then every
750 operating hours or
monthly as required
Daily
As and when required
10000 hrs or if required
Contactors
Maintenance requires qualified personnel ACCESS ONLY BY ELECTRICIAN
Due to thermal load upon the contactors, the screws

that tighten the wires could become loose after some time.
Step #
Action
Turn off master-switch.
Check, if necessary re-tighten, screws L1, L2, L3 and T1, T2, T3 with a suitable
screwdriver.
5.3
Electric Motor
This motor is Induction Type, 3-Phase, 20HP,
400Volts and brand Western Electric Australia
After about 20,000 operating hours or as necessary, the
roller-bearings should be checked and, if necessary, replace.
The type of bearings fitted do not allow for cleaning or regreasing.
TYPICAL PARTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
stator feet
rotor
end shield drive end
flanged end shield drive end
end-shield, non-drive end
V-ring drive end
bearing, outer cap
grease thrower
roller-bearing DIN 625
bearing, inner cap
V-ring non-drive end
bearing, outer cap
grease thrower
roller-bearing DIN 625
bearing, inner cap
16
17/18
19
20
21
22
23
24
25
26
27
28
29
30
external fan
external fan sing (sheet steel)
terminal board (according to DIN)
terminal plate with insulators
protective cable bushing for flameproof
motor (stud terminal)
terminal clamp for ex motors
gland cover
terminal box
terminal box, bottom part
terminal box lid
entry section (A or B)
single-entry sealing chamber (E)
double-entry sealing chamber (F)
compression gland
Note: These are typical parts of an electric motor and for separate parts, refer to motor
manufacturer (OEM) or DESTO.
5.6
5.6
Centrifugal Pumps
Grundfos Pump Models:
1)
FEED PUMP1, Multistage, Vertical, 3KW, CRN8-30
2)
FEED PUMP2, Multistage, Vertical, 2.2KW, CR4-100
3)
HIGH PRESSURE PUMP2, Multistage, Vertical, CR4-40
These pumps are virtually maintenance free because of the materials used in its
construction. If the mechanical seals leak it should be replaced as soon as possible. The
motors are totally enclosed, fan-cooled, 2-pole Grundfos standard motors with principal
dimensions in accordance with the IEC and DIN standards. Electrical tolerances
according to IEC 34/EN 60034. These pumps are used to boost the seawater through the
sand filter, carbon filter and cartridge filters.
When pumps are re-installed and the RO unit is started for the 1st time after
removal, the pumps must be purged of air. Use the air release valves to remove air from
the pump. Do not over tighten as this could damage the valve seat. It is preferred that it
should only be hand tight.
Applications:
CR
Hot and chilled water, boiler feed, condensate return, glycols and
solar thermal fluids etc.
CRN
De-ionized, de-mineralized and distilled water, Brackish water and

other liquids unsuitable for contact with iron or copper alloys etc.
(consult manufacturer for specific compatibilities)
Minimum Inlet Pressure:

All CR and CRN Pumps
NPSHR+2 feet
Installation Checklist:
1)
Pump location
2)
Foundation
3)
Pipe work
4)
Motor and position of terminal box
5)
Field wiring and protection
General Data CR4
SECTIONAL DRAWING
MATERIAL
The pump consists of a base and a pump head. The pump body and
outer sleeve are fixed between the base and the pump head by means of stay bolts.
The base has inline suction and discharge ports. The pump has a free maintenance
mechanical shaft seal with dimensions to DIN 24960. The pumps should be checked
regularly for air that may be trapped in the upper chamber of the pump. In normal
operation this will not be a problem but in rough seas there could be a considerable
amount of air entrapped in the feed water.
General Data CRN8
SECTIONAL DRAWING
MATERIAL
The pump consists of a base and a pump head. The pump body and outer
sleeve are fixed between the base and the pump head by means of stay bolts. The
base, the pump head cover as well as vital pump components are made from
stainless steel. The base has inline suction and discharge ports. The pump has a free
maintenance mechanical shaft seal with dimensions to DIN 24960. The pumps should
be checked regularly for air that may be trapped in the upper chamber of the pump. In
normal operation this will not be a problem but in rough seas there could be a
considerable amount of air entrapped in the feed water.
For separate parts, refer to pump manufacturer (OEM).
Operation:
Starting of the Pump:
a)
Check priming of the pump both for open and closed systems.
b)
Check the direction of rotation:

-
Switch off power
Make sure that the pump has been filled and vented.
Remove the coupling guard and rotate the pump shaft by

hand to be certain it runs freely.
Verify the electrical connections
Click the power on and check the rotation direction, to

reverse the direction of rotation off the pump.
Interchange the power leads and check rotation on

pump start.
If rotation is correct, re-install the coupling guard on off

position. Reapply the power to start the pump.
c)
Check all piping connections, supports and foundation bolting.
d)
Isolate all the valves for initial startup.
e)
Check and record all the voltages and pressures. Readjust, if

required.
f)
Check all controls for proper operation. If pump is controlled by

pressure switch, check and adjust the cut-in & cut-out pressures.
Maintenance:
Freeze Protection:
If the pumps are installed in an area where freezing could occur, the pumps and
systems should be drained during freezing temperatures to avoid damage. To drain the
pumps, close the isolation valves, remove the priming plugs and drain plugs at the base
of the pump. Do not replace the plugs until the pumps are to be used again. Always
replace the drain plugs with the original or exact replacement. Do not replace with a
standard plugs. Internal recirculation will occur, reducing the output pressure and flow.
Motor Inspection:
Inspect the motors at regular intervals, approximately every 500 hours of
operation or every three months, whichever occurs first. Keep the motors clean and the
ventilation openings clear. The following steps should be performed at each inspection:
1.
Check that the motor is clean and interior and exterior of the motor is free of dirt,
oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc can accumulate and
block motor ventilation. If the motor is not properly ventilated, overheating can
occur and cause early motor failure.
2.
Use an Ohmmeter (Megger) periodically to ensure that the integrity of the winding
insulation has been maintained. Record the Ohmmeter readings. Immediately
investigate any significant drop in insulation resistance.
3.
Check all electrical connectors to be sure that they are tight.
Motor Lubrication:
Electric motors are pre-lubricated at the factory and do not require additional
lubrication at start-up. Motors without external grease fittings have sealed bearings that
cannot be re-lubricated. Motors with grease fittings should only be lubricated with
approved types of grease. Do not over grease the bearings. Over greasing will cause
increased bearing heat and can result in bearing/motor failure. Do not mix petroleum
grease and silicon grease in bearings.
Lubrication Schedule*
NEMA/(IEC)
Frame Size
Up through
210 (132)
Over 210
through
280 (180)
Over 280
up through
360 (225)
Over 360
(225)
Standard
Severe
Interval
Severe
Service
Interval
Extreme
Service
Interval
Weight of grease
to add z./(Grams)
Volume of grease to
3
add Inch /Teaspoon
5500 hrs.
2750
hrs.
550 hrs.
0.30 (8.4)
0.6 (2)
3600 hrs.
1800
hrs.
360 hrs.
0.61 (17.4)*
1.2 (3.9)**
2200 hrs.
1100
hrs.
220 hrs.
0.81 (23.1)*
1.5 (5.2)**
2200 hrs.
1100
hrs.
220 hrs.
2.12 (60.0)*
4.1 (13.4)**
*Optional bearing flange also. **The grease outlet plug MUST be removed before adding new grease.
1.
Clean all grease fittings. If the motor does not have grease fittings, the bearing is
sealed and cannot be greased externally.
2.
If the motors are equipped with a grease outlet plug, remove it. This will allow the
old grease to be displaced by the new grease.
3.
If the motors are stopped, add the recommended amount of grease. If the motor is
to be greased while running, add a slightly greater quantity of grease.
4.
For motors equipped with a grease outlet plug, let the motor run for 20 minutes
before replacing the plug.
Regular Checkups:
At regular intervals depending on the conditions and time of operation, the
following checks should be made:
1.
Pumps meet required performance and is operating smoothly and quietly.
2.
There are no leaks, particularly at the shaft seal.
3.
The motors are not overheating.
4.
Remove and clean all strainers or filters in the system.
5.
Verify the tripping of the motor overload protections.
6.
Check operation of all controls & unit control cycling twice and adjust, if required.
7.
If the pumps are not operated for unusually long periods, the unit should be
maintained accordingly. In addition, if the pumps are not drained, the pump shafts
should be manually rotated or run for short periods of time at monthly intervals. If
the pumps fail to operate or there is a loss of performance.
Motor Replacement:
If the motor is damaged due to bearing / electrical failure or burning, follow the
instructions for motor removal / replacement. It must be emphasized that motors used on
CR pumps are specifically selected to our rigid specifications. Replacement of motors
must be of the same frame, size & be equipped with the same or better bearings of the
same service factor. Failure to follow these recommendations may result in premature
motor failure.
Disassembly
1. Turn off and lock out
power supply. The power
supply wiring can now be
safely disconnected from
the motor wires.
2. Remove the coupling
guards.
3. Using the proper metric

Allen wrench, loosen the
four cap screws in the
coupling. Completely
remove coupling halves.
On CR2-CR60s, the shaft
pin can be left in the pump
shaft, if exists.
4. With the correct size
wrench, loosen and
remove the four bolts
which hold the motor to the
pump end.
5. Lift the motor straight up
until the shaft has cleared
the motor stool.
Assembly
1. Remove key from the motor
shaft, if present and discard.
2. Thoroughly clean the

surfaces of the motor and
pump end mounting flanges.
The motor and shaft must be
cleaned of all oil / grease and
other contaminants where the
coupling attaches. Set the
motor on the pump end.
3. Place the terminal box in the
desired position by rotating the
motor.
Figure
Trouble Shooting:
Problem
Possible
Cause
1. No power at
Check power at motor. If no voltage at motor, check
motor.
feeder panel for tripped circuits and reset it.
2. Fuses are
blown or circuit
breakers are
tripped.
with ohmmeter. Replace blown fuses or reset circuit

breaker. If new fuses blow or circuit breaker trips, the
electrical installation, motor and wires must be
checked.
Check for voltage on line and load side of starter.
overloads are
Replace burned heaters or reset. Inspect starter for
burned or have
other damage. If heater trips again, check the supply
tripped out.
voltage and starter holding coil.
not energize.
The pump
run
Turn off power and remove fuses. Check for continuity
3. Motor starter
4. Starter does
does not
Possible Solution
5. Defective
controls.
Energize control circuit and check for voltage at the

holding coil. If no voltage, check control circuit fuses. If
voltage, check holding coil for shorts. Replace bad coil.
Check all safety, pressure switches for operation.
Inspect contacts in control devices. Replace worn or
defective parts or controls.
Turn off power and disconnect wiring. Measure the
6. Motor is
defective.
lead to lead resistances with ohmmeter. Measure lead

to ground values with ohmmeter. Record measured
values. If an open or grounded winding is found,
remove motor and repair or replace.
7. Defective
capacitor.
Turn off power and discharge capacitor. Check with

ohmmeter. Check the meter needle when connected
with capacitor, the needle should move towards 0
(Single-phase
motors)
ohms and slowly drift back to infinity. Replace if

defective.
Turn off power and manually rotate pump shaft. If shaft
8. Pump is
does not rotate easily, check coupling setting as
bound.
necessary. If shaft rotation is still tight, remove pump

and inspect. Repair if required.
Problem
Possible
Cause
1. Wrong
Possible Solution
Check wiring for proper connections. Correct wiring.
rotation
2. Pump is
not primed or
is air bound.
Turn pump off, close isolation valve(s), remove priming

plug. Check fluid level. Refill the pump, replace plug
and start the pump. Long suction lines must be filled
before starting the pump.
3. Strainers
Remove strainer, screen or valve and inspect. Clean
check or foot
and replace. Re-prime pump.
Valves
clogging.
Install compound pressure gauge at the suction side of
4. Suction lift
too large.
The pump
the pump. Start pump and compare reading to

performance data. Reduce suction lift by lowering
pump, increase suction line size or removing high
friction loss devices.
runs but at
reduced
5. Suction
Pump runs backwards when turned off. Air in suction
capacity or
and/or
pipe. Suction pipe, valves and fittings must be airtight.
does not
discharge
Repair any leaks and retighten all loose fittings.
deliver
piping leaks.
Install pressure gauge, start pump, gradually close the
water
6. Pump worn.
discharge valve and read pressure at shutoff. Convert

measured pressure (in PSI) to head (in feet). Remove
pump and inspect, if required.
7. Pump
Disassemble and inspect pump passageways.
impeller or
Remove any foreign materials found.
guide vane is
clogged.
8. Incorrect
If the proper drain plug is replaced with a standard
drain plug
plug, water will re-circulate internally. Replace with
Installed.
proper plug.
9. Improper
Check/reset the coupling.
coupling
setting.
Possible
Cause
Problem
Possible Solution
1. Pressure
Check pressure setting on switch and operation.
switch is not
Check voltage across closed contacts. Readjust switch
properly
or replace if defective.
adjusted or
is defective.
2. Level control
Check setting and operation. Readjust setting/replace
is not properly
if defective.
set
Pump
cycles
too
3. Insufficient
Pump air into tank or diaphragm chamber. Check
air charging or
diaphragm for leak. Check tank and piping for leaks
leaking tank or
with soap and water solution. Check air to water
piping
volume. Repair as necessary.

Check tank size and air volume in tank. Tank volume
much
4. Tank is too
small.
should be approximately 10 gallons for each gpm of

pump capacity. The normal air volume is 2/3 of the
total tank volume at the pump cut-in pressure. Replace
tank with one of correct size.
Install pressure gauges near pump suction and
discharge. Start and run pump under normal
5. Pump is
conditions, record gauge readings. Ensure that total
oversized.
head is sufficient to limit pump delivery within its

design flow range. Throttle pump discharge flow if
necessary.
1. Low voltage.
Check voltage at starter panel / motor. If voltage varies

more than 10%, contact power company / wire sizing.
2. Motor
Cycle pump and measure amperage. Increase heater
Circuit
overloads are
size or adjust trip setting to a maximum of motor
breakers
set too low.
nameplate (full load) current.
or overload
3. Three-phase
Check current draw on each lead to the motor. Must
relays trip
current is
be within 5%. If not, check motor and wiring. Rotating
imbalanced.
all leads may eliminate this problem.
4. Motor is
Turn off power and disconnect wiring. Measure the
shorted or
lead-to-lead resistance with an ohmmeter. Measure
grounded.
lead-to-ground values with an ohmmeter or a megaohm meter record values. If an open or grounded
winding is found, remove the motor, repair or replace.
Problem
Possible
Cause
Possible Solution
5. Wiring or
Check proper wiring and loose terminals. Tighten
connections are
loose terminals. Replace damaged wire.
faulty.
Turn off power and manually rotate pump shaft. If shaft
6. Pump is
bound.
does not rotate easily, check coupling setting and

adjust as necessary. If
shaft rotation is still tight, remove pump and inspect.
Disassemble and repair.
7. Defective
Turn off power and discharge capacitor. Check with
capacitor
ohmmeter. When the meter is connected to the
(single-phase
capacitor, the needle should jump towards 0 ohms and
motors).
slowly drift back to infinity. Replace if defective.
8. Motor
overloads at
higher ambient
temperature
than motor.
Use a thermometer to check the ambient temperature

near the overloads and motor. Record these values. If
ambient temperature at motor is lower than at
overloads, especially where temperature at overloads
is above 104F (40C), ambient-compensated heaters
should replace standard heaters.
Service:
Various steps involved in service (dismantling and Reassembly) are
elaborated below on Grundfos CR4 pump type:
Torques
Shaft Lock Nut (Reassembly step 9)
Stay bolt nut (Reassembly step 17)
Motor Bolt
UNC 3/8 bolts
UNC bolts
Coupling Allen Screws
M6 Screws
M8 Screws
9ft-lbs / 12Nm
30ft-lbs / 40Nm
10ft-lbs / 13Nm
23ft-lbs / 31Nm
10ft-lbs / 13Nm
23ft-lbs / 31Nm
When should a part be replaced
Order of Stage Assembly
Note: For separate parts, refer Pump Manufacturer (OEM)
5.7
Plunger Pump, CAT-3537
3537 Frame
Plunger
Pump
3537 Frame
Plunger
Pump with
Motor
Model Types:
Material Type
Model
Nickel Aluminum Bronze,Standard
3537,3537C
and Flushed
FEATURES
Superior Design
> Triplex plunger design gives smoother liquid flow.
> V-Packings are completely lubricated and cooled by the liquid being pumped.
> Special flushed inlet manifold lubricates and cools seals for extended life with DI
water and high temp liquids.
>Lubricated Lo-Pressure Seals provide double protection against external
leakage.
>Oil bath crankcase assures optimum lubrication.
>Close tolerance concentricity of the ceramic plunger maximizes seal life.
Quality Materials
> Precision design 304 and 316 stainless steel valves and seats are hardened
and polished for ultimate seating and extended valve life.
> Forged Brass, 316 Stainless Steel, Duplex Stainless or Nickel Aluminum Bronze
manifolds for strength and corrosion resistance.
> Special concentric, high-density, polished, solid ceramic plungers provide a true
wear surface and extended seal life.
> Specially formulated, CAT PUMP exclusive, V-Packings offer unmatched
performance and seal life.
> Die cast aluminum crankcase provides high strength, minimum weight and
precision tolerance control.
> Chrome-moly crankshaft gives unmatched strength and surface hardness.
> Oversized crankshaft bearings with greater loading capacity means longer
bearing life.
Easy Maintenance
> Wet-end is easily serviced without entering crankcase, requiring less time and
effort.
> Valve assemblies are accessible without disturbing piping, for quick service.
> Inlet and discharge valve assemblies interchange for easier maintenance.
>Preset packings, no packing gland adjustment is necessary, reducing
maintenance costs.
WARNING
All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety
valve). Failure to install such relief devices could result in personal injury or
damage to the pump or to system components. CAT PUMPS does not assume
any liability or responsibility for the operation of a customers high pressure

system.
SPECIFICATIONS U.S. Measure Metric Measure
Flow..........................................................................36 GPM (136 L/M)
Pressure Range...........................................100 to 1200 PSI (7 to 85 BAR)
Inlet Pressure Range ................................Flooded to 70 PSI (Flooded to 4.9 BAR)
RPM .......................................................................800 RPM (800 RPM)
Bore ............................................................................1.575" (40 mm)
Stroke..........................................................................1.890" (48 mm)
Crankcase Capacity..................................................4.2 Qts. (4 L)
Maximum Liquid Temperature ....................................160F (71C)
Above 130F call CAT PUMPS for inlet conditions and elastomer
recommendations.
Inlet Ports (2) .....................................................1-1/2" NPTF (1-1/2 NPTF)
Flushing Ports (2) (3531C) ...................................1/4" NPTF 1/4" NPTF
Discharge Ports (2)..................................................1" NPTF (1" NPTF)
Pulley Mounting ...................................................Either Side (Either Side)
Shaft Diameter ........................................................... 1.378" (35 mm)
Weight.......................................................................139 lbs. (63 kg)
Dimensions (3535, 3535C) .................24.09 x 18.11 x 9.72" (612 x 460 x 247 mm)
Dimensions (3531-31C, 3537-37C) ....24.33 x 18.11 x 9.72" (618 x 460 x 247 mm)
ELECTRIC HORSEPOWER REQUIREMENTS
FLOW
U.S. GPM
36
30
25
L/M
136
114
95
BAR 55
1 9 .8
1 6 .5
1 3 .7
PRESSURE
BAR 70
2 4 .7
2 0 .6
1 7 .2
BAR 85
2 9 .7
2 4 .7
2 0 .6
DRIVE
RPM
800
667
556
Consult CAT PUMPS

for Pump and
Motor Pulley Sizes
PARTS LIST
ITEM
2
5
8
9
10
11
15
20
21
22
23
25
31
32
33
34
37
38
40
48
49
50
PART NO
34021
125753
44542
815279
12398
13296
29326
121467
126749
126574
122045
29325
828710
43211
14177
126743
92241
44428
125753
25625
23170
45936
MATL
STL
S
AL
FBR
NBR
NBR
STL
TNM
STCP R
STZP R
STZP
FCM
ABS
NBR
STCP R
NBR
S
STCP
NBR
AL
DESCRIPTION
Key (M10x8x70)
Screw, HHC Sems (M8x25)
Cover, Bearing
Shim, Split 2-Pc
O-Ring, Bearing Cover - 70D
Seal, Oil, Crankshaft
Bearing, Roller
Rod, Connecting Assy (Inclds: 21,22,23) [10/00]
Locking Washer (M10)
Washer, Flat (M10)
Replace as a set
Screw, HH (M10x55)
Crankshaft, Dual End
Protector, Oil Cap w/Foam Gasket
Cap, Oil Filler
O-Ring, Oil Filler Cap - 70D
Bolt, Eye (M12x1.75) (For Lifting Pump Only)
Gauge, Oil, Bubble w/Gasket
Gasket, Flat, Oil Gauge - 80D
Plug, Drain (1/4"x19BSP
O-Ring, Drain Plug 70D
Cover, Rear
QTY
1
8
2
4
2
2
2
3
3
6
6
1
1
1
1
1
1
1
8
1
1
1
51
53
54
56
59
64
ITEM
65
69
70
75
88
90
95
96
97
98
99
100
101
106
107
110
112
117
126
127
128
141
142
155
156
157
158
159
162
163
164
166
167
168
16612
44487
27488
27790
92538
43864
PART NO
45116
126587
100488
44739
43865
45676
43921
89778
20189
11345
11375
701490
44085
44084
814279
44112
44113
44740
46955
43925
46392
46392C
11379
14183
701491
44585
43926
44609
44741
43928
45113
46352
48860
20137
701492
48362
45369
48362
48860
20137
701492
48363
26142
14330
701493
44727
43932
44109
44728
NBR
AL
S
POP
S
CM
MATL
SSZZ
STCP R
NBRS
FPM
S
S
CC
SS
PTFE
NBR
FPM
EPDM
SS
SS
PVDF
NBR
FPM
EPDM
BB
BBCP
BBCP
NBR
FMM
EPDM
S
BB
STG*
SFG
BB
SS
BB
NBR
FPM
EPDM
D
SS
D
NBR
FPM
EPDM
D
NBR
FPM
EPDM
S
S
SS
PVDF
O-Ring, Crankcase Cover - 70D

Crankcase Assy (Inclds: 34, 54)
Pins, Guide
Pan, Oil
Pin, Crosshead
DESCRIPTION
Rod, Plunger
Washer, Oil Seal
Seal, Oil, Crankcase
Slinger, Barrier
Washer, Keyhole (M16)
Plunger (M40x145)
Stud, Plunger Retainer (M10x135)
Back-up-Ring, Plunger Retainer
O-Ring, Plunger Retainer - 70D
O-Ring, Plunger Retainer
O-Ring, Plunger Retainer
Gasket, Retainer
Retainer, Plunger (M10
Retainer, Seal, 2 Pc.
Wick, Long Tab
Seal, LPS w/SS-Spg
Seal, LPS w/SS-Spg
Seal, LPS w/SS-Spg
Spacer, Lo-Pressure Seal
Manifold, Inlet
Manifold, Inlet, Flushed (1/4" Flush Ports)
O-Ring, Inlet Manifold - 70D
O-Ring, Inlet Manifold
O-Ring, Inlet Manifold - 70D
Screw, HSH (M14x40)
Adapter, Female
V-Packing
V-Packing
Adapter, Male
Springs, Coil
Spacer, w/Coil Springs
O-Ring, V-Packing-Spacer - 90D
O-Ring, V-Packing-Spacer
Back-up-Ring, Spacer
Spacer, V-Packing
Back-up-Ring, V-Packing-Spacer
O-Ring, V-Packing-Spacer
Back-up-Ring, Valve Seat
O-Ring, Seat - 80D
O-Ring, Seat
O-Ring, Seat
Seat, Stepped
Valve
Spring
Retainer, Spring
1
1
2
1
2
3
QTY
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
1
3
3
3
4
3
6
6
3
6/18
3
3
3
3
3
3
3
3
3
3
6
6
6
6
6
6
6
6
170
171
173
174
185
188
44729
44644
89827
11747
701494
48364
46444
76394
89981
ITEM
PART NO
172
SS
SS
NBR
FPM
EPDM
D
FBB
BBCP
S
Washer, Spring Retainer

Coil Spring (70kg), Valve Plug
O-Ring, Valve Plug - 90D
O-Ring, Valve Plug - 90D
O-Ring, Valve Plug 70D
Back-up-Ring, Valve Plug
Plug, Valve
Manifold, Discharge
Screw, HSH (M12x70)
MATL
DESCRIPTION
Protector, Shaft w/2 Screws, Lock-washers
250
44516
NY
and Washers
34018
STZP R
Kit, Direct Mount
255
34039
SS
Kit, Direct Mount
92674
STZP
Mounting, Box Assy (Inclds: 34018)
260
990013
STL
Hub, B 35mm w/Keyway
275
80540
ZP
Screw, HH (M12x100) (Rail Adjusting Screw)
278
30278
STZP
Oiler (1 oz.)
279
30967
Glass, Oiler
281
10069
NBR
Gasket, Oiler
282
34314
Kit, Oil Drain
283
6124
Gasket, Liquid (3 oz.)
290
814821
BBCP
Complete Head
299
31040
NBR*
Kit, Seal (Inclds:
33055
FPM
97,106,112,127,155,156,158,159)
33262
EPDM
Kit, Seal (Inclds:
300
97,106,112,127,155,156,158,159)
Kit,
Seal
(Inclds:
97,106,112,127,155,156,158,159)
34235
NBR
Kit, Valve (Inclds:
31955
FPM
162,163,164,166,167,168,170,172,173)
31952
EPDM
Kit, Valve (Inclds:
310
162,163,164,166,167,168,170,172,173)
Kit,
Valve
(Inclds:
162,163,164,166,167,168,170,172,173)
819000
F
Assy, Crankcase, Cast Iron Conversion
714500
SS
C.A.T. (Inlet pressure stabilizer for RO and
boosted inlet applications)
714506
SS
Adapter (2 per C.A.T.)
6100
Oil, Case (12 Bottles) ISO 68 Multi-viscosity
Hydraulic
Production parts are different than repair parts. * Review material codes
Note: For separate parts, refer pump manufacturer
6
6
6
6
6
6
6
1
8
QTY
1
1
1
1
1
1
1
3
3
3
1
1
1
1
1
2
2
2
1
1
2
1
EXPLODED VIEW CAT 3535, 3537
Models 3535, 3535C, 3531, 3531C, 3537, 3537C
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Die cast aluminum crankcase means high strength, light weight, and excellent
tolerance control.
Oversized crankshaft bearings provide extended bearing life and pump performance.
Chrome-moly crankshaft provides unmatched strength and surface hardness for long
life.
Matched oversized TNM connecting rods noted for superior tensile strength and
bearing quality.
Special stainless steel plunger rods with high strength crossheads for longevity and
corrosion resistance.
The stainless steel slinger provides back-up protection for the crankcase seal,
keeping pumped liquids out of the crankcase.
Special concentric, high-density, polished, solid ceramic plungers provide a true wear
surface and extended seal life.
Manifolds are a high tensile strength forged brass, 316 stainless steel, duplex
stainless or nickel aluminum bronze for long term, continuous duty.
100% wet seal design adds to service life by allowing pumped liquids to cool and
lubricate on both sides.
Stainless steel valves, seats and springs provide corrosion-resistance, ultimate
seating and extended life.
Special prepared, CAT PUMP exclusive, V-Packings offer unmatched performance
and seal life.
12.
13.
Crossheads are 360 supported providing uncompromising alignment.

Optional special ported Flushed Inlet Manifold permits external flush for lubricating
and cooling seals when pumping liquids such as DI water, Hi-Temp or low lubricity.
INSTALLATION AND START-UP INFORMATION

Optimum performance of the pump is dependent upon the entire liquid system and will be
obtained only with the proper selection, installation of plumbing and operation of the
pump and accessories.
SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not implied
that all maximums can be performed simultaneously. If more than one maximum is
considered, check CAT PUMPS supplier for proper performance and pump selection.
Refer to individual pump Data Sheets for complete specifications, parts list and exploded
view.
LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications (4.2
Qts. - 4.0 L). Do not Run Pump without Oil in Crankcase. Change initial fill after 50 hours
running period. Thereafter, change oil every 3 months or 500 hour intervals. Oiler
adjustment is vertical to start feed, horizontal to stop feed, dial to adjust flow rate.
Additional lubrication may be required with increased hours of operation and temperature.
PUMP ROTATION: Pump was designed for forward rotation to allow optimum lubrication
of the crosshead area. Reverse rotation is acceptable if the crankcase oil level is
increased slightly above center dot to assure adequate lubrication.
PULLEY SELECTION: Select size of motor pulley required to deliver the desired flow.
DRIVE SELECTION: The motor or engine driving the pump must be of adequate
horsepower to maintain full RPM when the pump is under load. Select the electric motor
according to required pump discharge flow, maximum pressure at the pump and drive
losses of approximately 3-5%.
MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit
drainage of crankcase oil. An uneven mounting surface will cause extensive damage to
the pump base. To minimize piping stress, use appropriate flexible hose to inlet and
discharge ports. Use the correct belt; make sure pulleys are aligned. Excessive belt
tension may be harmful to the bearings. Hand rotate pump before starting to be certain
shaft and bearings are free moving.
LOCATION: If the pump is used in extremely dirty or humid conditions, it is
recommended pump be enclosed. Do not store or operate in excessively high
temperature areas or without proper ventilation.
INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual
before starting system. Do not starve the pump or run dry. Temperatures above 130F
are permissible. Add 1/2 PSI inlet pressure per each degree F over 130F. RPM changes
may be required.
C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in
applications with stressful inlet conditions such as high temperatures, booster pump feed,
long inlet lines/valves.
DISCHARGE CONDITIONS: Open all valves before starting system to avoid deadhead
overpressure condition and severe damage to the pump or system. Install a Pulsation
Dampening device on the discharge head or in the discharge line as close to the head as
possible. Be certain the pulsation dampener is properly pre-charged for the system
pressure. A reliable Pressure Gauge should be installed near the discharge outlet of the
high pressure manifold. This is extremely important for adjusting pressure regulating
devices and also for proper sizing of the nozzle or restricting orifice. The pump is rated for
a maximum pressure; the pressure which would be read at the discharge manifold of the
pump, not at the gun/ nozzle.
Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or
plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape from
becoming lodged in the pump or accessories. This condition will cause a malfunction of
the pump or system.
PRESSURE REGULATION: All systems require both a primary pressure regulating
device (i.e., regulator, un-loader) and a secondary pressure safety relief device (i.e., popoff valve, safety valve). The primary pressure device must be installed on the discharge
side of the pump. The function of the primary pressure regulating device is to protect the
pump from over pressurization, which can be caused by a plugged or closed off
discharge line. Over pressurization can severely damage the pump, other system
components and can cause bodily harm. The secondary safety relief device must be
installed in-line between the primary device and pump or on the opposite side of the
manifold head. This will ensure pressure relief of the system if the primary regulating
device fails. Failure to install such a safely device will void the warranty on the pump. If a
large portion of the pumped liquid is by-passed (not used) when the high pressure system
is running, this by-pass liquid should be routed to an adequately sized, baffled supply
tank or to drain. If routed to the pump inlet, the by-pass liquid can quickly develop
excessive heat and result in damage to the pump. A temperature control device to
shut the system down within the pump limits or multiple THERMO VALVES must be
installed in the by-pass line to protect the pump.
NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure regulating
device to compensate. Replace nozzle and reset regulating device to system pressure.
PUMPED LIQUIDS: Some liquids may require a flush between operations or before
storing.
STORING: For extended storing or between use in cold climates, drain all pumped liquids
from pump and flush with antifreeze solution to prevent freezing and damage to the
pump. Do not run pump with frozen liquid.
WARNING: All systems require both a primary pressure regulating device (i.e., regulator,
un-loader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve).
Failure to install such relief devices could result in personal injury or damage to the pump
or to system components. CAT PUMPS does not assume any liability or responsibility for
the operation of a customers high pressure system.
Removal of Discharge Valve Plug
Discharge Valve Assembly
CAUTION: Before commencing with service, shut off drive (electric motor, gas or diesel
engine) and turn off water supply to pump. Relieve all discharge line pressure by
triggering gun or opening valve in discharge line. After servicing is completed, turn on
water supply to pump, start drive, reset pressure regulating device and secondary valve,
read system pressure on the gauge at the pump head. Check for any leaks, vibration or
pressure fluctuations and resume operation.
SERVICING THE VALVES
Disassembly
1.
Remove the six (6) M41 Hex Valve Plugs.
2.
Remove the exposed Coil Spring from the top of the Spring Retainer. Thread an
M10 bolt into the top of the Spring Retainer. The assembly will usually remain
together. To separate, continue threading the bolt into the back side of the Valve
Seat until it separates from the Spring Retainer. In all models if the assembly
separates during removal, use a valve seat removal tool and lift the Seats from
the chamber.
Reassembly
NOTE: For certain applications apply liquid gasket to the o-ring crevices and seal
surfaces.
1.
Examine the O-Rings and Back-up-Rings on the Seat and replace if cut or worn.
Lubricate the O-Ring before installing.
2.
Examine the surface of the Valve and Seat for pitting, grooves or wear and
replace if necessary.
3.
Assemble Valve Retainer, Spring, Valve and Seat by snapping together securely.
Thread the M10 bolt into spring retainer for installation.
4.
Lubricate outer O-Ring and Back-up-Ring surface and walls of valve chamber and
press Valve Assembly squarely into chamber. Remove M10 bolt. Place the
washer over the top of the Spring Retainer and then the Coil Spring on top of the
Washer.
5.
Examine the O-Ring and Back-up-Ring on the Valve Plug and replace if cut or
worn. Lubricate new O-Ring and Back-up-Ring before installing onto Valve Plug.
Exercise caution to avoid damage from the valve plug threads.
NOTE:
6.
The Back-up-Ring is installed first, then the O-Ring.

Slowly thread the Valve Plug into chamber. Exercise caution to avoid extruding or
cutting the Back-up-Ring or O-Ring. Then torque to specifications.
NOTE:
It is highly recommended that anti-seize lubricant (PN6119) be applied to

the threads of all stainless steel components to prevent galling.
NOTE:
Apply Loctite 242 to the threads of the Valve Plug (brass models) before
threading into the valve chamber. All models except 3560.
Removal of Discharge Valve Plug
Removal of Discharge Manifold Screws
Removal of Discharge Manifold
Removal of Inlet Screws and Inlet manifold
Removal of Inlet Manifold O-Rings
Removal of V-Packing Spacer from Inlet Manifold
7.
Lubricate and install new O-Ring onto each Inlet Seat.
8.
Place Inlet Seat on work surface with small diameter side up.
9.
Place the Valve onto Inlet Seat with concave side down.
10.
Place Spring on Valve.
11.
Install Inlet Spring Retainer with deep stepped end over Spring and snap onto
Inlet seat.
12.
Lubricate and install O-Ring, then Back-up-Ring onto the Discharge Seats.
13.
Place Discharge Seat on a work surface with small diameter down.
14.
Place Valve onto Discharge Seat with the concave side down.
15.
Place Spring on Valve.
16.
Install Discharge Spring Retainer with deep stepped end over Spring and snap
onto Discharge Seat.
17.
Complete the stacked assembly by pressing the Discharge Valve Assembly into
the Inlet Valve Assembly.
18.
Place the complete stacked valve assly into each Valve Chamber until completely
seated.
19.
Lubricate and install Back-up-Ring, then O-Ring onto each Valve Plug. Press
Valve Plug into each Valve Chamber. Exercise caution to avoid damage from the
valve plug threads.
20.
Apply anti-seize lubricant (PN6119) to HSH screw threads and thread in hand
tight. Torque to specifications.
REMOVING THE DISCHARGE MANIFOLD

1.
Remove the eight (8) HSH screws.
2.
Tap the back side of the Discharge Manifold with a soft mallet and gradually work
head from pump.
3.
Remove the O-Rings from lower chambers of the face of the Inlet Manifold.
REMOVING THE INLET MANIFOLD

1.
Using a hex allen wrench, remove the four (4) HSH screws. Rotate the Crankshaft
to begin the separation of the Inlet Manifold from the Crankcase.
2.
Tap the rear of the Inlet Manifold with a soft mallet and gradually work from pump.
NOTE:
Support from the underside and exercise caution to keep manifold aligned
with Plungers to avoid damage to the Plungers as the manifold is removed.
NOTE:
Two screwdrivers on opposite sides of the manifold may be used to assist

separation.
v-Packing and Spacer Arrangement
V-Packing Spacer and Spacer with Coil Springs
Removal of Lo-Pressure Seal from Inlet Manifold
Lo-Pressure Seal and Washer Assembly
SERVICING THE SEALS

Disassembly of the V-Packings
1.
Place the crankcase side of the Inlet Manifold down on the work surface.
2.
Remove the V-Packing Spacer. These may stay in either the Inlet or Discharge
Manifold ports when the Discharge Manifold is removed. If they are extremely dirty
or dry, remove the exposed O-Ring and Back-up-Ring and insert two screwdrivers
on opposite sides to pry out of chamber.
3.
Examine both front and rear O-Rings and Back-up-Rings on the V-Packing
Spacer for cuts or wear and replace as needed.
4.
Remove V-Packing Cylinder (3520, 3521, 3527), by inserting two screwdrivers on

opposite sides of the V-Packing Cylinder and pry out. Examine O-Ring for wear
and replace as needed.
5.
Remove Spacer with Coil Springs (except 3560). Examine for broken or fatigued
springs or scale build up or pitting and replace as needed.
6.
With a reverse pliers remove Male Adapter, V-Packings and Female Adapter.
7.
Examine Female Adapter for worn I.D. and replace as needed.
Reassembly of the V-Packings

1.
Lubricate outer surface of V-Packing Cylinder and install new O-Ring in groove.
Press V-Packing cylinder with O-Ring end down into the manifold chamber until
completely seated.
2.
Insert Female Adapter into V-Packing Cylinder/manifold chamber with the

Vgroove up.
3.
Fit the new V-Packings together, lubricate outer surface of the packing and insert
into V-Packing Cylinder or manifold chamber with the V groove up.
4.
Install Male Adapter into V-Packing Cylinder or manifold chamber with the V
groove down (notches up).
5.
Lubricate outer surface of Spacer with Coil Springs and insert into V-Packing
Cylinder or manifold chamber with springs facing down.
6.
Lubricate outer surface of V-Packing Spacer, install new O-Rings and Back-upRings in both front and rear groove and press into V-Packing Cylinder or manifold
chamber with small diameter down until completely seated.
Disassembly of the Lo-Pressure Seal

1.
With the crankcase side of Inlet manifold up insert the LPS Spacer into the seal
chamber.
2.
Install Lo-Pressure Seal into seal chamber with garter spring facing down and
press squarely into position.
3.
V-Packing Spacer and Spacer with Coil Springs, Removal of Lo-Pressure Seal
from Inlet Manifold, Lo-Pressure Seal and Washer Assembly
Plunger Arrangement
SERVICING THE PLUNGERS

Disassembly
1.
To service the plungers it is necessary to remove the Discharge and Inlet

Manifolds. Follow the disassembly procedure found under removing the
discharge manifold and removing the inlet manifold.
2.
Remove the Seal Retainers from the Ceramic Plungers.
3.
Remove the Inner Collar from the front of the seal retainer.
4.
Remove the used Wick and install new Wick.
5.
Replace Inner Collar on Seal Retainer.
6.
Loosen Plunger Retainer 4 to 5 turns. Push Plunger towards Crankcase until

Plunger Retainer pops out.
7.
Unscrew and remove Plunger Retainer, Gasket, O-Ring, Back-up- Ring and
Ceramic Plunger, Keyhole Washer and Barrier Slinger from each Plunger Rod.
Reassembly
1.
With these plunger items removed, examine the Crankcase Oil Seal for wear or
deterioration and replace as needed.
2.
Replace Keyhole Washer on Plunger Rod.
3.
Carefully examine each Plunger for scoring or cracks and replace if worn.
4.
Examine Gasket, O-Ring and Back-up-Ring on Plunger Retainer and replace if cut
or worn. Lubricate O-Ring for ease of installation and to avoid damaging O-Rings.
5.
Apply loctite 242 to the threads of the Plunger Retainer and thread Plunger
Retainer onto Plunger Rod. Torque per specifications.
6.
Slip Seal Retainers over Plungers.
7.
Rotate crankshaft by hand so the two outside Plungers are extended equally.
8.
Lubricate the Plungers.
9.
Carefully replace Inlet Manifold onto Plungers and press into Crankcase. Keep
manifold aligned to avoid damaging Plungers.
10.
Replace four (4) HSH screws and torque per chart.
11.
Examine inlet port o-rings at bottom of manifold and replace if cut or worn.
12.
Lubricate outer surface of V-Packing Spacer, O-Rings and valve chamber walls
and carefully slip Discharge Manifold over V-Packing Spacer.
13.
Hand tighten the two (2) HSH screws first. Then hand tighten the remaining six (6)
HSH screws. Torque per chart and in this sequence.
1
5
8
7
6
4
SERVICING THE CRANKCASE SECTION

1.
While manifolds, plungers and seal retainers are removed examine crankcase oil
seals for leaking and wear.
2.
Check for signs of leaking at Bearing Covers, Rear Cover, Drain Plug, and Bubble
Oil Gauge.
3.
Check oil level and for evidence of water in oil. Change crankcase oil on a regular
schedule.
4.
Rotate Crankshaft by hand to feel for smooth bearing movement.
5.
Examine Crankshaft Oil Seals externally for drying, cracking or leaking.
INLET CONDITION CHECK-LIST
Review Before Start-Up

Inadequate inlet conditions can cause serious malfunctions in the best designed
pump. Surprisingly, the simplest of things can cause the most severe problems or go
unnoticed to the unfamiliar or untrained eye. REVIEW THIS CHECK-LIST BEFORE
OPERATION OF ANY SYSTEM. Remember, no two systems are alike, so there can be
no ONE best way to set-up a system. All factors must be carefully considered.
INLET SUPPLY should exceed the maximum flow being delivered by the pump to
assure proper performance.
Open inlet shut-off valve and turn on water supply to avoid starving pump.
DO NOT RUN PUMP DRY.
Temperatures above 130F are permissible. Add 1/2 PSI inlet pressure per each
degree F over 130F. Elastomer or RPM changes may be required.
Avoid closed loop systems especially with high temperature, ultra-high pressure or
large volumes. Conditions vary with regulating/unloader valve.
Low vapor pressure liquids, such as solvents, require a booster pump and C.A.T. to
maintain adequate inlet supply.
Higher viscosity liquids require a positive head and a C.A.T. to assure adequate inlet
supply.
Higher temperature liquids tend to vaporize and require positive heads and C.A.T. to
assure adequate inlet supply.
When using an inlet supply reservoir, size it to provide adequate liquid to

accommodate the maximum output of the pump, generally a minimum of 6 to 10
times the GPM (however, a combination of system factors can change this
requirement); provide adequate baffling in the tank to eliminate air bubbles and
turbulence; install diffusers on all return lines to the tank.
INLET LINE SIZE should be adequate to avoid starving the pump.
Line size must be a minimum of one size larger than the pump inlet fitting. Avoid
tees, 90 degree elbows or valves in the inlet line of the pump to reduce the risk of
flow restriction and cavitations.
The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and reinforced on SUCTION
systems to avoid collapsing.
The simpler the inlet plumbing the less the potential for problems. Keep the length to
a minimum, the number of elbows and joints to a minimum (ideally no elbows) and
the inlet accessories to a minimum.
Use pipe sealant to assure air-tight, positive sealing pipe joints.

INLET PRESSURE should fall within the specifications of the pump.
Acceleration loss of liquids may be increased by high RPM, high temperatures, low
vapor pressures or high viscosity and may require pressurized inlet and C.A.T. to
maintain adequate inlet supply. DO NOT USE C.A.T WITH SUCTION INLET.
Optimum pump performance is obtained with +20 PSI (1.4 BAR) inlet pressure and
a C.A.T. for certain applications. With adequate inlet plumbing, most pumps will
perform with flooded suction. Maximum inlet pressure is 70 PSI (4.9 BAR).
After prolonged storage, pump should be rotated by hand and purged of air to
facilitate priming. Disconnect the discharge port and allow liquid to pass through
pump and measure flow.
INLET ACCESSORIES are designed to protect against over-pressurization, control
inlet flow, contamination or temperature and provide ease of servicing.
A shut-off valve is recommended to facilitate maintenance.
Installation of a C.A.T. is essential in applications with stressful conditions such as

high emperatures, booster pump feed or long inlet lines. Do not use C.A.T. with
negative inlet pressure.
A stand pipe can be used in some applications to help maintain a positive head at
the pump inlet line.
Inspect and clean inlet filters on a regular schedule to avoid flow restriction.
A pressure transducer is necessary to accurately read inlet pressure.
All accessories should be sized to avoid restricting the inlet flow.
All accessories should be compatible with the solution being pumped to prevent
premature failure.
Optional inlet protection can be achieved by installing a pressure cut off switch
between the inlet filter and the pump to shut off pump when there is no positive inlet
pressure.
BY-PASS TO INLET Care should be exercised when deciding the method of bypass from control valves.
It is recommended the by-pass be directed to a baffled reservoir tank, with at least

one baffle between the by-pass line and the inlet line to the pump.
Although not recommended, by-pass liquid may be returned to the inlet line of the
pump if the system is properly designed to protect your pump. When a pulsation
dampener is used, a PRESSURE REDUCING VALVE must be installed on the inlet
line (BETWEEN THE BY-PASS CONNECTION AND THE INLET TO THE PUMP)
to avoid excessive pressure to the inlet of the pump. It is also recommended that a
THERMO VALVE be used in the by-pass line to monitor the temperature build-up in
the by-pass loop to avoid premature seal failure.
A reinforced, flexible, low pressure hose rated up to 300 PSI should be used for
routing by-pass back to the pump inlet.
Caution should be exercised not to undersize the by-pass hose diameter and length.
Refer to Technical Bulletin 064 for additional information on the size and length of
the by-pass line
Check the pressure in the by-pass line to avoid over-pressurizing the inlet.
The by-pass line should be connected to the pump inlet line at a gentle angle of 45
or less and no closer than 10 times the pump inlet port diameter e.g. 1-1/2" port size
= 15" distance from pump inlet port.
Avoid Cavitations Damage
One or several of the conditions shown in the chart below may contribute to
cavitations in a system resulting in premature wear, system downtime and
unnecessary operating costs.
CONDITION
SOLUTION
Inadequate inlet size
Increase line size to the inlet port or one size line size larger
Water hammering,
liquid acceleration /
deceleration
Install C.A.T. Tube
Rigid Inlet Plumbing
Use flexible wire reinforced hose to absorb pulsation and

pressure spikes
Excessive Elbows in
inlet Plumbing
Keep elbows to a minimum and less than 90
Move pump closer to liquid supply
CONDITION
Excessive Liquid
Temperature
SOLUTION
Use Thermo Valve in bypass line
Do not exceed pump temperature specifications
Substitute closed loop with baffled holding tank
Adequately size tank for frequent or high volume bypass
Pressure feed high temperature liquids
Properly ventilate cabinets and rooms
Air Leaks in
Plumbing
Check all connections

Use PTFE thread tape or pipe thread sealant
Agitation in Supply
Tank
Size tank according to pump output- tank min. 6-10 times

system GPM
Baffle tank to purge air from liquid and separate inlet from
discharge
High Viscosity
Liquids
Verify viscosity against pump specifications before operation

Elevate liquid temperature enough to reduce viscosity
Lower RPM of pump
Pressure feed pump
Increase inlet line size
Clogged Filters
Perform regular maintenance or use clean filters and monitor

build up
Use adequate mesh size for liquid and pump specifications
DIAGNOSIS AND MAINTENANCE

One of the most important steps in a high pressure system is to establish a
regular maintenance program. This will vary slightly with each system and the system
accessories. A careful review of the necessary inlet conditions and protection devices
required before the system is installed will eliminate many potential problems. CAT
PUMPS are very easy to service and require less frequent service. The following guide
will assist in determining the cause and remedy to various operating conditions.
PROBLEM
Low
pressure
PROBLEM
Pulsation
Water leak
Under the
manifold
Into
PROBABLE CAUSE
Worn nozzle.
Belt slippage
Air leak in inlet plumbing
Pressure gauge inoperative or not
registering accurately.
Relief valve stuck, partially plugged
or improperly adjusted.
Inlet suction strainer (filter) clogged
or improperly sized.
Abrasives in pumped liquid.
Leaky discharge hose.
Inadequate liquid supply.
Severe cavitation.
Worn seals.
Worn or dirty inlet/discharge valves.
PROBABLE CAUSE
Faulty Pulsation Dampener
Foreign material trapped in
inlet/discharge valves.
Worn V-Packings or Lo-Pressure
Seals.
Worn adapter o-rings.
Humid air condensing into water
SOLUTION
Replace with properly sized nozzle.
Tighten belt(s) or install new belt(s).
Tighten fittings and hoses using PTFE liquid or
tape.
Check with new gauge. Replace worn or damaged
gauge.
Clean/adjust relief valve. Replace worn
seats/valves and o-rings.
Clean filter. Use adequate size filter. Check more
frequently.
Install proper filter.
Replace discharge hose with proper rating for
system.
Pressurize inlet and install C.A.T.
Check inlet conditions.
Install new seal kit. Increase frequency of service.
Clean inlet/discharge valves or install new valve kit.
SOLUTION
Check pre-charge. If low, recharge, or install a new
dampener.
Clean inlet/discharge valves or install new valve kit.
Install new o-rings.
Install oil cap protector. Change oil every 3 months
crankcase
Knocking
noise
Inlet supply
Bearing
Pulley
Oil leak
Crankcase
oil seals.
Crankshaft
oil seals and
o-rings.
Drain plug
Bubble
gauge
Rear cover
Filler cap
Pump runs
extremely
rough
Inlet
conditions
Pump valves
Pump seals
Premature
seal failure
inside the crankcase.

Excessive wear to seals and VPacking.
Inadequate inlet liquid supply.
Broken or worn bearing.
Loose pulley on crankshaft
or 500 hours.
Check liquid supply. Increase line size, pressurize
or install C.A.T.
Replace bearing.
Check key and tighten set screw.
Worn crankcase oil seals.

Worn crankshaft oil seals or o-rings
on bearing cover.
Loose drain plug or worn drain plug
o-ring.
Loose bubble gauge or worn bubble
gauge gasket.
Loose rear cover or worn rear cover
o-ring.
Loose filler cap or excessive oil in
crankcase.
Replace crankcase oil seals.

Remove bearing cover and replace o-rings and/or
oil seals.
Tighten drain plug or replace o-ring.
Restricted inlet or air entering the

inlet plumbing
Stuck inlet/discharge valves.
Leaking V-Packings or Lo-Pressure
seals.
Correct inlet size plumbing. Check for air tight seal.
Scored plungers.
Over pressure to inlet manifold.
Abrasive material in the liquid being
pumped.
Excessive pressure and/or
temperature of pumped liquid.
Running pump dry.
Starving pump of adequate liquid.
Replace plungers.
Reduce inlet pressure per specifications.
Install proper filtration at pump inlet and clean
regularly.
Check pressure and inlet liquid temperature.
DO NOT RUN PUMP WITHOUT LIQUID.
Increase hose one size larger than inlet port size.
Pressurize and
install C.A.T.
Replace manifold. Check liquid compatibility.
Eroded manifold.
Tighten bubble gauge or replace gasket.

Tighten rear cover or replace o-ring.
Tighten filler cap. Fill crankcase to specified
capacity.
Clean out foreign material or install new valve kit.

Custom Maintenance Schedule

The table above shows the recommended preventative maintenance schedule,
however it is only to be used as a guide. The life of your pump and wear parts will vary by
application depending on duty-cycle, pumped liquid, temperature, inlet conditions,
location of installation and system accessories. It is important to monitor your system
carefully and at the first sign of low pressure, examine your pumping system. Low
pressure may be caused by system components other than the pump such as:
Clogged filter
Leaks from fittings or connections
Cracked or kinked hoses
Worn o-rings in safety regulators, check valves or relief valves
Loose or worn belts
Worn nozzles
If no problems are found with other system components, shut down system and
inspect pump. Check for debris in valves. Change seals and record hours for your
preventative maintenance schedule. Typically valves should be replaced at every other
seal replacement. After maintenance is performed continue to monitor all system
components. Often it is other elements in the system that will be the cause of poor
performance. In order to protect the pump, always inspect the entire system when there is
a decrease in system performance.
Preventative Maintenance
The best safeguards against unplanned shut-down or system failure are good
preventative maintenance practices and proper pump diagnosis. Cat Pumps triplex pump
design offers easy on-site maintenance without the use of special tools, making a routine
maintenance achievable without difficulty. Each pump has a Data Sheet, Service Manual
and Diagnosis Chart to simplify the periodic servicing required. Every installation differs
from one another, so a unique maintenance schedule may be required. Below you will
find more information about adopting a proper maintenance schedule as well as how to
diagnose any pump issues.
Preventive Maintenance Check List
Check
Daily
Clean Filters
Oil Level/Quality
Oil Leaks
Water Leaks
Weekly
Belts, Pulley
Plumbing
Initial Oil Change

Oil Change
50 hrs
500 hrs
1500 hrs
x
X
Seal Change
Valve Change
Accessories
3000 hrs
x
x
If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change cycle
should be every 300 hours. ** Each systems maintenance cycle will be exclusive. If
system performance decreases, check immediately. If no wear at 1500 hours, check
again at 2000 hours and each 500 hours until wear is observed. Valves typically
require changing every other seal change. Duty cycle, temperature, quality of pumped
liquid and inlet feed conditions all effect the life of pump wear parts and service cycle.
** Remember to service the regulator/un-loader at each seal servicing and check all
system accessories and connections before resuming operation.
5.9
Cartridge Filters
The cartridge filter elements must be replaced,

when the pressure loss across the cartridge filter
has reached 2 bars. The filter elements cannot
be cleaned.
A check should be carried out daily and after any
circuit cleaning the filter elements should be
replaced.
(1) Filter Housing
(2) Filter Element (10 m)
(3) O-ring
Replacing the Filter Elements:
Step No
1
2
3
4
5
6
Action
Stop with rinse
Close feed water inlet valve and discharge valve.
Unscrew the filter housing Clamp by loosen bolts of clamp and remove top
cover.
Open nuts from long bolts inside to remove blocking sheet, carefully remove
sheet and Teflon product blockers and replace filter elements.
Reassemble the filter housing, check O-ring and ensure it fits correctly.
Open feed water inlet valve and discharge valve.
The unit is now ready for restarting.
5.10
RO Membranes (TORAY Membranes)
Important Information
Proper start-up of reverse osmosis water treatment systems is essential to
prepare the membranes for operating service and to prevent membrane damage due to
overfeeding or hydraulic shock. Following the proper start-up sequence also helps to
ensure that system operating parameters conform to design specifications so that system
water quality and productivity goals can be achieved.
Before initiating system start-up procedures, membrane pretreatment, loading of
the membrane elements, instrument calibration and other system checks should be
completed.
Operation Guidelines
Avoid any abrupt pressure or cross-flow variations on the spiral elements during
start-up, shutdown, cleaning or other sequences to prevent possible membrane damage.
During start-up, a gradual change from a standstill to operating state is recommended as
follows:
Feed pressure should be increased gradually over a 30-60 second time frame.
Cross-flow velocity at set operating point should be achieved gradually over 15-20
seconds.
Permeate obtained from first hour of operation should be discarded.
General Information
Keep elements moist at all times after initial wetting.
If operating limits and guidelines not followed properly, the limited Warranty will be null
and void.
To prevent biological growth during prolonged system shutdowns, it is

recommended that membrane elements be immersed in a preservative solution.
The customer is fully responsible for the effects of incompatible chemicals and
lubricants on elements.
Max. Pressure drop across an entire pressure vessel (housing) is 50 psi (3.4 bar).
Avoid permeate-side backpressure at all times.
Notice: The use of this product in and of itself does not necessarily guarantee the removal of cysts
and pathogens from water. Effective cyst and pathogen reduction is dependent on the
complete system design and on the operation and maintenance of the system.
5.10.1
2nd STAGE RO Membrane
Important Information
Proper start-up of reverse osmosis water treatment systems is essential to
prepare the membranes for operating service and to prevent membrane damage due to
overfeeding or hydraulic shock. Following the proper start-up sequence also helps to
ensure that system operating parameters conform to design specifications so that system
water quality and productivity goals can be achieved.
Before initiating system start-up procedures, membrane pretreatment, loading of
the membrane elements, instrument calibration and other system checks should be
completed.
Operation Guidelines
Avoid any abrupt pressure or cross-flow variations on the spiral elements during
start-up, shutdown, cleaning or other sequences to prevent possible membrane damage.
During start-up, a gradual change from a standstill to operating state is recommended as
follows:
Feed pressure should be increased gradually over a 30-60 second time frame.
Cross-flow velocity at set operating point should be achieved gradually over 15-20
seconds.
Permeate obtained from first hour of operation should be discarded.
General Information
Keep elements moist at all times after initial wetting.
If operating limits and guidelines not followed properly, the DOW FILMTEC
Reverse Osmosis and Nanofiltration The Warranty limit will be null and void.
To prevent biological growth during prolonged system shutdowns, it is

recommended that membrane elements be immersed in a preservative solution.
The customer is fully responsible for the effects of incompatible chemicals and
lubricants on elements.
Max pressure drop across an entire pressure vessel (housing) is 50 psi (3.4 bar).
Avoid static permeate-side backpressure at all times.
Regulatory Note
These membranes may be subject to drinking water application restrictions in
some countries, please check the application status before use and sale.
Notice: The use of this product in and of itself does not necessarily guarantee the removal of cysts
and pathogens from water. Effective cyst and pathogen reduction is dependent on the
complete system design and on the operation and maintenance of the system.
Factors Affecting RO Membrane Performance

Recovery: Percentage of membrane system feed-water that emerges from the system
product water.
Rejection: Percentage of solids concentration removed from system feed-water by the
membrane.
Passage: Opposite of rejection, passage is the percentage of dissolved constituents
(contaminants) in the feed-water allowed to pass through the membrane.
Permeate: The purified product water produced by a membrane system.

Flow:
Flow of feed is the rate of feed-water introduced to the membrane element,

usually measured in gallons per minute (gpm). Concentrate flow is the rate
of flow of non-permeated feed-water that exits the membrane element. This
concentrate contains most of the dissolved constituents originally carried into
the element from the feed source.
Flux:
The rate of permeate transported per unit of membrane area, measured in

gallons per square foot per day (gfd).
Dilute solution: Purified water solution, RO system product water.

Concentrated solution: The brackish water solution such as RO system feed-water.
Pressure, Temperature, Salt Concentration also effect the membrane performances.
PRESSURE VESSEL 2
PRESSURE VESSEL 1
5.11
Pressure Vessels PPWT

Description
Length
Diameter
Design Pressure
Minimum Operating Temp
Maximum Operating Temp
Application
Operating pH range
Cleaning pH range (<30minutes)
Feed-water TDS Maximum
Description
Length
Diameter
Design Pressure
Minimum Operating Temp
Maximum Operating Temp
Application
Operating pH range
Cleaning pH range (<30minutes)
Feed-water TDS Maximum
Value
1300
300
1000 psi
-1C
49C
Typ. Seawater
3-11
2-12
<= 45,000 ppm
Value
1300
250
1000 psi
-1C
49C
Typ. Seawater
3-11
2-12
<= 45,000 ppm
INTENDED USE:
The PPWT Pressure Vessels are designed for continuous use as housing
for membrane filtration elements to purify typical seawater waters at any positive pressure
up to 1000PSI. These vessel can accommodate any make of eight-inch nominal diameter
spiral-wound element as well as many hollow fiber elements. The element interface
hardware for the specified element is supplied with the vessel. These vessels must be
installed, operated and maintained using good industrial practice and following the
precautions listed in order to help assure safe operation and a long service life. Misuse,
improper installation or operation may result in severe bodily harm or property damage
and will void the vessel warranty. Any undue restraint at the support points or piping
connections can cause non-repairable leaks to develop in the shell. This vessel must not
be subjected to excessive stress caused by bending moments acting at the side ports in
the fiberglass shell. The end closures of the vessel must be kept dry and free of corrosion
at all times. Failure to do so may result in deterioration that can lead to catastrophic
failure of the vessel heads.
PRECAUTIONS:
>
Mount shell using furnished hardware and flexible type groove-end pipe
couplings.
>
Maximize the connection flexibility and provide overpressure protection.
>
Inspect end closures regularly and relieve system pressure before working.
>
Never support other components with the vessel and never support other
components with the vessel.
>
Do not over tighten the Permeate Port connection.
>
Ensure that the Thrust Ring is installed downstream and double check end
closure installation.
>
Never operate the vessel in excess of its ratings, do not operate the vessel
permeate port over 125 psi and operate the vessel in only positive pressure
applications.
>
Flush the vessel before system shut down and operate the vessel within the
recommended pH range.
Loading and Unloading Procedure:
HEAD LOADING PROCEDURE
HEAD REMOVAL PROCEDURE
HEAD REBUILDING
Step1: Inspect the Shell
Step1: Shut Down System
Step1: Remove Adapter
Step2: Head Seal & Shell

Lubrication
Step2: Disconnect Piping
Step2: Remove Permeate Port
Step3: Install Head
Step3: Check End Closure
Step3: Inspect Feed Port
Step4: Install Retaining Ring
Step4: Remove Retaining Ring
Step4: Remove Seals
Step5: Reconnect Piping
Step5: Remove Head
Step5: Clean All Components
Step6: Pressurize System
Step6: Inspect Components
Step7: Check for Leaks
Step7: Lubricate Seals
Step8: Reassemble Head
Note: For separate parts, refer pressure vessels manufacturer (OEM).
SPECIFICATIONS
6.1
SPECIFICATIONS
Raw W ater Quality
Sea W ater
Model
SW 38B
Quantity of RO Membranes
03 (Sea W ater), 01 (Brackish W ater)
Voltage Supplied (3 Phase) (V)
440
Frequency (Hz)
60
Electric Load (KW)
27 (APPROX)
Control
Semi Automatic
35
RAW WATER
Raw W ater input (GPM)
Raw W ater Pre Pressure (min/max) (PSI) :
15 80
Operation Pressure (PSI)
850
Operation Pressure Max (PSI)
950
Raw W ater Temperature nominal ( C)
25
Raw W ater Temperature range (oC)
10 - 45
Raw W ater Quality
Sea W ater
Total Dissolved Solids (TDS) max (PPM)
40,000
pH Value nominal
78
pH Value Range Cleaning
2 11
Silt Density Index (SDI)
>3
Concentration Free Cl2 (PPM)
0.00
Concentration Free Cl2 Short Time (PPM)
0.1
TANK WATER
Fresh W ater input (GPM)
Fresh W ater Pre Pressure (min/max) (PSI):
15 80
Operation Pressure (PSI)
150
Operation Pressure Max (PSI)
225
25
Fresh W ater Temperature range ( C)
10 - 55
Fresh W ater Temperature nominal ( C)

o
Fresh W ater Quality
Fresh W ater
1,000
pH Value nominal
78
pH Value Range Cleaning
2 11
Silt Density Index (SDI)
>3
Concentration Free Cl2 (PPM)
0.00
Concentration Free Cl2 Short Time (PPM)
0.1
Fresh W ater Output (GPD)
5000
Conductivity Designed (S/cm)
900
400
pH Value nominal
6.0 7.2
Recovery Rate Calculated (%)
25
Boiler Feed W ater Output (GPD)
5000
Conductivity Designed (S/cm)
pH Value nominal
5.7 6.7
Recovery Rate Calculated (%)
50
Total Transport (KG)
1300
Total Operation (KG)
1900
Sch 80, 2 diameter
FRESH WATER
BOILER FEED WATER
WEIGHT
PIPE CONNECTIONS
PVC Pipe
6.2
Tools and Resources

Description
Qty
Filter Materials
Cartridge Filter Element (PP 10m)
SPECIAL TOOLS
Hand-meter conductivity /temp.
Torque spanner 1/2", 150Nm
Belt spanner small
Socket spanner
Open-end spanner 50mm
OPERATING MATERIALS
Membrane Biocide (if microorganism growth is noted in system)
80 Liter
Chemical 1 (Anti Scalant)
80 Liter
Chemical 2 (Anti Scalant)
80 Liter
Cleaner (Membrane Cleaner)
As Per Requirement
WEARING PARTS
V-belt
Shaft seals
HP-Pump seal kit
HP-Pump valve kit
O-Ring Cartridge filter housing
6.3
Annual Consumable Items

General consumable items are described below for their replacement:
SR.
NO
ITEMS
QUANTITY
REMARKS
01
Slim Line Multi Cartridge Filter
504
As per requirement
02
Cartridge Filter
03
Anti Scalant Chemical
04
Membrane Cleaning Chemical
48 Nos
As per requirement
6.4
Water Analysis
SEA WATER
Total Dissolved Solids (TDS) PPM
40000 Approx
Hardness (CaCO3) PPM
5,200 Approx
Oil & Greases PPM
2.0 0.2
140 190 Approx
8.4 Approx
Oil & Greases PPM
0.00
10 Approx
Oil & Greases PPM
0.00
Product Water 1st Stage
Product Water 2nd Stage
6.5
Sales & Enquries
For sales and enquires contact our sales team.
ORION OFFSHORE MARINE SERVICES PTE LTD

1 SOON LEE STREET
#05-48/49 PIONEER CENTRE
SINGAPORE 627605
TEL: +65 97451496; FAX : +65 65706907
Email : sales@orionoffshore.biz
NOTES
NOTES

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TWO STAGE REVERSE OSMOSIS

Project: JADE PALMS

ORION OFFSHORE MARINE SERVICES PTE LTD

Sea Water Reverse Osmosis Plant

Sea Water Reverse Osmosis Plant

How to Use this Manual

When operating this equipment, certain parts are electrified. Ignorance of

polluted with oil.

Sea Water Reverse Osmosis Plant

repair or maintenance completion.

All personnel involved in the operation, maintenance, inspection and

installation / reinstallation of the product or part of the product must be fully

or the use of non-original parts may lead to a safety risk.

product performance is guaranteed.

to health, safety and environment.

There must not be any visible movement (vibration/pulsation) of the pointer

Sea Water Reverse Osmosis Plant

Feed-water quality conditions care is essential for membrane performance.

Do not allow to operate the RO Unit in the areas of river esturiances,

Sea Water Reverse Osmosis Plant

Sea Water Reverse Osmosis Plant

Sea Water Reverse Osmosis Plant

Sea Water Reverse Osmosis Plant

Delivery Required By:

To be charged / Invoiced to:

Sea Water Reverse Osmosis Plant

Sea Water Reverse Osmosis Plant

The system consists mainly of the following components:

BW MEMBRANE DOSING PUMP

(General arrangement of the System)

Sea Water Reverse Osmosis Plant

Feed Pump (Centrifugal Type) (FP1) filter pump,

Multi Cartridge Filter

Cartridge Filters (CF) in it sediment particles of 10

Sea Water Reverse Osmosis Plant

displacement pump (plunger pump). This pump delivers feed

RO Membrane RO membranes are imperfect barriers

Sea Water Reverse Osmosis Plant

Level Switches (LS1 & LS2) Starting and stopping the

Controls, Displays & Measurements

Control Panel (CP) is equipped with a Main Circuit

Flow Meters (FM1, FM2, FM3, FM4) are installed in

conductivity of the permeate, measured by the conductivity

Sea Water Reverse Osmosis Plant

Pressure Gauges (PG1, PG2, PG3, PG4, PG5) indicate the

Safety and Behavior Rules

Sea Water Reverse Osmosis Plant

Maximum flow rates

Note: High feed flow will cause an unacceptable

Maximum operating pressure

CHECKS BEFORE FIRST

The voltage must be checked across each

- Check control voltage

Check different circuits output voltage,

Check setting and connections of flow meter.

Sea Water Reverse Osmosis Plant

Starting of the Unit

Open all valves to and from the RO unit.

Set valves to Normal operation:

Check PB 1 for Feed Pump 1.

Check PB 2 for High Pressure Pump 1.

Check the pressures and flow rates

Check PB 3 & PB 4 for Feed Pump 2

Check the pressures and flow rates