Low pressure
•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.
•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.
PROBLEM PROBABLE CAUSE SOLUTION
Pulsation
•Faulty Pulsation Dampener •Foreign material trapped in inlet/discharge valves.
•Check pre-charge. If low, recharge, or install a new dampener.
•Clean inlet/discharge valves or install new valve kit.
Water leak
•Under the manifold •Into
•Worn V-Packings or Lo-Pressure Seals.
•Worn adapter o-rings.
•Humid air condensing into water
•Install new seal kit. Increase frequency of service. •Install new o-rings.
Sea Water Reverse Osmosis Plant
crankcase inside the crankcase.
•Excessive wear to seals and V- Packing.
or 500 hours.
•Install new seal kit. Increase frequency of service.
Knocking noise
•Inlet supply •Bearing •Pulley
•Inadequate inlet liquid supply. •Broken or worn bearing. •Loose pulley on crankshaft
•Check liquid supply. Increase line size, pressurize or install C.A.T.
•Replace bearing.
•Check key and tighten set screw.
Oil leak
•Crankcase oil seals. •Crankshaft oil seals and o-rings. •Drain plug •Bubble gauge •Rear cover •Filler cap
•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. •Tighten bubble gauge or replace gasket. •Tighten rear cover or replace o-ring. •Tighten filler cap. Fill crankcase to specified capacity. Pump runs extremely rough •Inlet conditions •Pump valves •Pump seals
•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. •Clean out foreign material or install new valve kit. •Install new seal kit. Increase frequency of service.
Premature seal failure
•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. •Eroded manifold.
•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.
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
Sea Water Reverse Osmosis Plant
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 Weekly 50 hrs 500 hrs 1500 hrs 3000 hrs Clean Filters x Oil Level/Quality x Oil Leaks x Water Leaks x Belts, Pulley x Plumbing x
Initial Oil Change x
Oil Change X
Seal Change x
Valve Change x
Accessories x
• If other than CAT PUMPS special multi-viscosity ISO68 oil is used, change cycle
should be every 300 hours. ** Each system’s 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.
Sea Water Reverse Osmosis Plant 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 µm) (3) O-ring
Replacing the Filter Elements:
S
StteeppNNoo AAccttiioonn 1 Stop with rinse
2 Close feed water inlet valve and discharge valve.
3 Unscrew the filter housing Clamp by loosen bolts of clamp and remove top cover.
4 Open nuts from long bolts inside to remove blocking sheet, carefully remove sheet and Teflon product blockers and replace filter elements.
5 Reassemble the filter housing, check O-ring and ensure it fits correctly. 6 Open feed water inlet valve and discharge valve.
Sea Water Reverse Osmosis Plant 5
5..1100 RROOMMeemmbbrraanneess ((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
Sea Water Reverse Osmosis Plant
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.
Sea Water Reverse Osmosis Plant 5
5..1100..11 22nnddSSTTAAGGEERROOMMeemmbbrraannee
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
Sea Water Reverse Osmosis Plant
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.
Sea Water Reverse Osmosis Plant
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.
5.11 Pressure Vessels – PPWT P R E S S U R E V E S S E L 1 Description Value Length 1300 Diameter 300
Design Pressure 1000 psi
Minimum Operating Temp -1ºC
Maximum Operating Temp 49ºC
Application Typ. Seawater
Operating pH range 3-11
Cleaning pH range (<30minutes) 2-12
Feed-water TDS Maximum <= 45,000 ppm P R E S S U R E V E S S E L 2 Description Value Length 1300 Diameter 250
Design Pressure 1000 psi
Minimum Operating Temp -1ºC
Maximum Operating Temp 49ºC
Application Typ. Seawater
Operating pH range 3-11
Cleaning pH range (<30minutes) 2-12
Feed-water TDS Maximum <= 45,000 ppm