OPERATING AND MAINTENANCE

MANUAL

CLIENTE
CUSTOMER /
IMPIANTO
PLANT /
LOCALITA'
SITE /
PROGETTO
PROJECT /
SERVIZIO
SERVICE /
SIGLA
ITEM /
TIPO POMPA
PUMP TYPE TITANO 3140
ORDINE
PURCH. ORDER /
DATA
DATE /
COMMESSA
WORKS ORDER /

date signature date signature

REV. DESCRIPTION PREPARED APPROVED

Operating and Maintenance Manual

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TITANO 3140
 INDEX

1 GENERAL PRESCRIPTION

2 MACHINE DESCRIPTION

3 DATA SHEET

4 DRAWINGS

5 INSTALLATION
5.1 Positioning of baseplate
5.2 Positioning of the main component of the unit
5.3 Assembly of the auxiliary circuits
5.4 Hydraulic system connection
5.5 Electric system connection

6 PREPARATION TO START-UP & START-UP

6.1 Before start-up
6.2 Preparation to start-up
6.3 Start-up procedure

7 MAINTENANCE AND REVISION

7.1 Hydraulic side disassembly
7.2 Crankshaft mechanism disassembly
7.3 Checking
7.4 Crankshaft mechanism reassembly
7.5 Hydraulic side reassembly
7.6 Stuffing box packing installation
7.7 Maintenance schedule
7.8 Lubrication

8 TROUBLE SHOOTING

9 MANUAL OF COMPONENTS

10 SETTING OUT OF SERVICE AND DEMOLITION

Operating and Maintenance Manual

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1 GENERAL PRESCRIPTIONS
 Carefully read the use and maintenance instructions before transporting,
handling, installing and starting the machine.
 The unit has to be installed in a safe area, assuring the necessary way out and
protection from risks that could be caused while carrying out other operations.
 Keep this manual for future reference.
 For any doubt or use not foreseen in this manual, before installation contact our
after-sale service.
 For any communication, always give the machine type, serial no. and job no.
 Use only original spare parts.

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2 MACHINE DESCRIPTION

Operating and Maintenance Manual

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3 DATA SHEET

Title Document No.

1 Pump data sheet
2 Completed motor data sheet
3 Main pump performance curve
4 Electric motor predicted performance curve
5 Pump & motor speed torque curve
6 Gear reducer data sheet
7 Lubricant list

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4 DRAWINGS

Title Document No.

1 Dimensional dwg
2 Pump cross sectional dwg
3 P & ID
4 Suction pulsation dampener dwg
5 Discharge pulsation dampener dwg
6 Dimensional outline dwg (motor)
7 Sectional dwg (motor)
8 Electrical wiring diagram
9 Gear reducer outline dwg
10 Sectional dwg (gear reducer)
11 Coupling alignment diagram

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5 INSTALLATION
5.1 POSITIONING OF BASEPLATE
The whole unit is housed on a steel baseplate included in the supply.
The baseplate is made up of different plates upon which the various parts of the unit
are placed. These plates are machined with the greatest accuracy and their surfaces
are perfectly parallel to one another when lodged on a flat horizontal surface.
The maximum tolerance allowed horizontally in both directions is 0.1% while the
maximum tolerance allowed in respect to the plates parallel to each other is 0.5%.
In order to obtain the above results proceed as follows:
raise the baseplate and insert the anchor bolts with the U-shaped part down;
lower the baseplate into position on the concrete foundation making sure that the
anchor bolts enter their respective holes;
insert a levelling instrument and check the horizontal position;
for an initial leveling off insert shims near the anchor bolts: the use of slant shims will
facilitate the operation;
fill up the anchor bolt with quick drying cement and wait for the cement to set;
tighten the anchor bolts and check the horizontal position of all plates; should the
required accuracy not be obtained, insert more shims;
seal all the spaces between the baseplate and foundation and then cement the
interior of the baseplate, taking care to fill up the spaces between the sections;
leave the cement to dry before assembling the machines on the baseplate (at least
72 hours).

5.2 POSITIONING OF THE MAIN COMPONENT OF THE UNIT

The whole unit is pre-assembled in our workshop and the position of each machine
has been given by suitable plates welded to the baseplate.
As indicated in the overall dimensions drawings, place the main components
(Pump, gear reducer and motor) on the baseplate and make their feet to adhere at
the plates welded to the baseplate.
Check the alignment of the coupling in the following way:
PUMP - GEAR REDUCER, GEAR REDUCER - MOTOR.

To carry out the control of the alignment, proceed as follows:

check the distance between the inside parts of the two half-couplings at four points
at the farthest end of the two right angles;
the maximum difference allowed between the shortest and longest distance is 0.05
mm;
check with a ruler that the outside cylindrical surfaces of the two half joints are on the
same level; maximum tolerance is  0.05 mm;
Should the above tolerances not be met, insert shims between the machines and the
plates of the baseplate.

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5.3 ASSEMBLY OF THE AUXILIARY CIRCUITS
The assembly of these circuits (lube crank mechanism, injection & flushing system,
heating steam system and gear lube system) has already been done at Peroni shop,
therefore it will be enough to reassembly the items that have been disassembled (if
any) due to transport reasons. This operation must be carried out (preferably under
the supervision of Peroni engineer) referring to Peroni “P & ID Diagram” and
“Outlines Drawing”.

5.4 HYDRAULIC SYSTEM CONNECTIONS

Cleaning of the piping internal part and of the containers connected to it must
absolutely be carried out before and during the assembly phase.
It is advisable to install a cone filter on the suction piping during the running period
until perfect cleaning of the plant is obtained. This filter can be installed between the
connection flanges of the pump.

5.5 ELECTRIC SYSTEM CONNECTION

In order to avoid all electric hazards it is suggested:
• that the control panel, the electric system and connections are exclusively carried
out by skilled personnel in accordance with the rules in force;
• to comply with the motor and electrical equipments’ manufacturer instructions;
• to check the motor rotation direction so as to avoid lack of lubrication to crankshaft
bearings;
• check the correct positioning of both motor and baseplate earthing.

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6 PREPARATION TO START-UP & START-UP
6.1 BEFORE START-UP
Before running the unit, make sure that the system has been properly completed
from both mechanical and electrical point of view, and in particular check:

 If the unit has undergone a preservation treatment (short, medium or long), it is

necessary to verify the type of preservation carried out (this is indicated on the
relevant card together with the pump) and then proceeds with restoring the unit in
the following way:
a) Short preservation.
Fill in the pumps with the operating oils, according to quantity and type shown
on the nameplates.
Run the pumps for at least 50 revolutions, acting manually on the fast
coupling.
Start the group and run it unloaded for at least two hours.
Drain the oil from the machines.
N.B. The oil can be used on other units, after having checked its suitability.
There’s no need to remove any traces of preservation oil, since it can be
mixed with the operating oil.
b) Medium preservation.
- Carry out the operations shown at point “a)”.
- Open the cover and remove the hydroscopic salts.
- Check if the stuffing box packings have been removed; if so, you have to
disassemble the plungers, insert the packings and re-assemble them.
c) Long preservation.
Open the cover and remove the hydroscopic salts.
In this case, the hydraulic end is shipped without gaskets, that are without
stuffing box packings and O-rings, which are inside a separate container
together with the pump.
Therefore, besides the operations at point b), you have to reset the pump by
installing the gaskets.
 Programmed maintenance of all components has been carried out.
 On all components the level and the correct lubricant type has been restored (see
components operating manual).
 All components have been fastened to the baseplate and the hydraulic end bolts
and nuts are properly tightened.
 All foreseen protections have been mounted and switched on, and that their
calibration has been correctly carried out.
 All safety systems (if supplied) are efficiently working.
 Suction and discharge pipes are correctly mounted.
 The motor rotation direction is correct.
 After start-up the absorbed power is the one foreseen or slightly different.

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6.2 PREPARATION FOR START-UP
Before to put the unit into operation the assembly should be thoroughly checked as
follows:

a) check that all machines are firmly secured to the baseplate;

b) carry out the following tests on auxiliary electric motors:
• insulation resistance between the phases;
• insulation resistance to the ground;
• if possible, idling at reduced voltage for a general mechanical check
(rotation direction and so on).
Obviously, before idling, it is suitable that the values measured during test 1 and 2
result at least of 20 M, otherwise you need to dry the windings. Drying can be
performed by feeding two phases with direct current having strength equal to 20-30%
of the rated current for about one hour.

c) check that all couplings are properly connected;

d) check that all safety guards are installed;
e) check all machines oil level and type;
f) check that all safety measures have been taken and their set correctly carried
out;
g) check that auxiliary services piping have been correctly assembled.

At this point disconnect (if already connected) the suction and discharge flanges of
the main pump to be sure that the pump itself is not under pressure, start the crank
lube oil system; start the main motor at the minimum RPM and for the time strictly
necessary for to check the following:
h) make sure the motor runs in the correct direction and that the absorbed
current is adequate;
j) disconnect the Injection pumps tubing from the stuffing boxes and make sure
the liquid flows during the main pump suction stroke; if not, a new adjustment
of the coupling between Main and Injection pump is necessary;
k) make sure that the Flushing liquid flows is correctly; close the Sample Point
valves and open the Regulation valves downstream the sight flow indicators;
l) check that all the aux. circuits are working at the right pressures and there are
no leakages.
Stop the main motor and reconnect the suction and discharge flanges.
Arrange for water feeding to the Main pump (under atmospheric or very low
pressure), start the motor again, check that no leakages in the hydraulic end occur.
Stop the main and aux. motors - Now the unit is ready for the Start up.

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6.3 START-UP PROCEDURE

Check the oil levels of main pump, of gear reducer and make sure the correct type of
lubricants is being used;
Start the main pump crankshaft mechanism lubrication pump (if it’s included), control
the direction is that shown on the gear pump;
For water testing plug with a blind flange the connecting piping between suction and
oil tank;
Check that the valves on suction and delivery pipes are open;
Start the main motor;
Check that the values on the local instruments and control panels are those of
normal running;
Check that there are no losses in the auxiliary circuits, in the process connections
and in the hydraulic part of main pump;
Adjust the pressure gauges cut-off devices to reduce oscillations.

Sequence for start-up. shall be as follows:

a) main pump oil heater start (if it’s included),

Before starting the pump it is necessary to heat the lube oil through the heater
mounted inside the frame of the pump. The heater shall be started through the
power control center if the oil temperature inside the frame is below than 15 °C (59
°F) and shall be stopped when the temperature reaches 30 °C (86 °F).

b) main electric motor start

If the sequences above described have been properly carried out the main electric
motor can be started. If there are no anomalies during operation the electric motor
will run until it is manually stopped. The operating sequence must allow the lube oil
electric motors (if it’s included), be stopped a few seconds after stopping of the main
motor.

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7 MAINTENANCE AND REVISION

For personnel safety purpose and wholeness of the machine it is necessary that:

 the maintenance is carried out by skilled personnel.

Before intervening on the machine and in particular on the pump it is necessary that:

 the flushing machine has been made;

 the voltage has been turned off and the machine is isolated;
 all the machine devices in pressure are at atmospheric pressure;
 the machine is at ambient temperature.

Peroni Pompe S.p.A. refuses all responsibility for damages resulting from alterations
of the machine in respect to its configuration of supply, and by the utilisation of spare
parts non supplied by Peroni Pompe.

For service on Pump unit ("hydraulic end" and "crankshaft mechanism") hereinafter
described, make reference to dwg. 314H S5 000 000 SEZ and to the mentioned pos.
numbers.

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7.1 HYDRAULIC SIDE DISASSEMBLY

DISASSEMBLY OF VALVE AND VALVE SEATS

 Unscrew the front (130-136) and rear screws of the valve body (139).
 Remove the valve body (139) and place it with its front side on the worktable.
 Unscrew the screws (127) on discharge valve flange (137).
 Remove the discharge valve flange and the discharge spacer (111).
 Extract the discharge valve column.
 Do the same to disassemble the suction valve column.

DISASSEMBLY OF HYDRAULIC CYLINDER

 Unscrew the splash guard disk (2), the plunger ring nut (3), the main packing ring
nut (102) and the secondary packing ring nut (101);
 Extract the extensions (106);
 Extract the hydraulic cylinder (131), with which will be removed the plunger (135),
the lantern (132), and rear ring;
 Remove the plunger (135);
 Remove the lantern (132) and the main stuffing box packing;

IMPORTANT NOTE

Should it become necessary to disassemble the manifold, the following operations

must be carried out:

 Disconnect suction and discharge flanges.

 Support the body with hemp ropes.
Unscrew the screw (or tie rod nuts 134) which secure the manifold to the frame.

Operating and Maintenance Manual

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Operating and Maintenance Manual
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 Valve spacer
(111)

OR

Valve plug
(113)

Valve guide
(114)

Valve spring
(115)

Valve
(118)

Valve
seat (116)
OR

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7.2 CRANKSHAFT MECHANISM DISASSEMBLY

 Remove the screws (15-45) that fix upper and lateral covers (16-34-43);
 Remove upper and lateral covers (16-34-43) paying attention not to damage the
gasket in between;
 Remove the lubrication shoot (9);
 Unscrew the connecting rod fixing screws (12) and remove the caps of
connecting rods (11) with relevant half-bushings (33);
 Push the crosshead (22) onwards;
 Keep the three connecting rods (11) on the frame (1);
 Remove the screws (38) that fix the exit shaft cover (25) and screw in the relevant
holes two screws which allow extraction; this cover will also carry together the cap
with relevant MIM gasket (28);
 Unscrew the bearing lock ring nut and push-back together the safety washer;
 Extract the blind cover (39) acting as described for exit shaft cover (25);
 Extract the shaft (26), will also carry the roller bearing;
 Remove splash guard disk (2) and unscrew the plunger ring nut (3);
 Extract from the frame the connecting rods (11) which will carry together the pin
(24), the connecting rod small end bushing (23) and the crosshead (22);
 Using the proper clamps remove the two seeger rings (if any);
 Extract the pin (24), hence disengaging the connecting rod (11) from the
crosshead (22);
 To extract the connecting rod small end bushing (23) uses the press.

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Operating and Maintenance Manual
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7.3 CHECKING

CHECKING ON CRANKSHAFT MECHANISM

 Clean and degrease all disassembled parts and carefully wash the frame inside.
 Inspect the frame inside to verify there are no scorings or scratches in the
crosshead working area.
 The same inspection has to be carried out on all disassembled parts.
 Check with a thickness gauge the clearance between bushing-crosshead and the
pin; if clearance is higher than 0.05 mm, disassemble the pin from the crosshead
and the connecting rod using a press.
 Possible scorings shall be removed by slightly scraping with an emery cloth.

DIMENSIONS TO BE TAKEN TO CHECK THE CRANKSHAFT MECHANISM

 Take dimension A from frame.

 Take dimension A1 from crosshead; take dimension C once bushing is mounted.

 Take dimension C1 from pin.

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Take dimension B1 from shaft.

 Take dimension B from crank bushing; checking is to be done after assembly of

bushing on connecting rod and tightening of bolts D to nominal torque stated in
the table (tightening to be done in two times 50% -100%).

CLEARANCES DEFINITION

 Clearance between crosshead and frame A-A1.

 Clearance between crank and crank bushing B-B1.
 Clearance between crosshead and pin C-C1.
 Clearances must come within the minimum values here below listed.

PUMP TYPE 3140

Min Max
Clearance A-A1 [mm] 0,140 0,330
Clearance B-B1 [mm] 0,130 0,310
Clearance C-C1 [mm] 0,055 0,140
Driving torque connecting rod bolts 588 Nm
Check that surface plate between connecting rod and cap are in contact, otherwise
re-check the surfaces and tighten according to prescribed torque.

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CHECKING TO BE CARRIED OUT ON HYDRAULIC PARTS

 Clean and degrease all disassembled parts.

 Carefully inspect the pump body checking the surface plates of OR.
 The same inspection must be done on all disassembled pieces.
 Verify that all plungers and bronze rings of stuffing box packing do not have any
scorings and/or scratches.
 Light scorings must be removed by scraping PTFE + CARB. and polishing with an
emery cloth of the plungers.
 Check OR status and if in doubt replace them.

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DIMENSIONS TO BE TAKEN FOR HYDRAULIC END CHECKING

D1 - E1
 Take dimensions D1 and E1
from spacer.

D2 - E2

 Take dimensions D2 (E2)

from tap.

 Take dimensions H (H1)

and G (G1) from guide.
H - H1

G - G1
F - F1

 Take dimensions F (F1) - B

(B1) from valve.
B - B1

 Take dimensions C (C1) and

from seat. C - C1

N.B.: Dimensions outside brackets refer to discharge column, while those into brackets are
to be taken on suction column.

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 Take dimensions D-E from valve body.

 Take dimensions P-P1 from support rings and plunger.

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CLEARANCES DETERMINATION
Clearance between spacer and suction valve body E-E1
Clearance between spacer and discharge valve body D-D1
Clearance between cap and suction tap E-E2
Clearance between cap and discharge tap D-D2
Clearance between suction valve and guide G1-F1
Clearance between discharge valve and guide G-F
Clearance between plunger and support rings P1-P

VALVES ELEVATION

Suction valve elevation Aa = H1-( B1 + C1 )

Discharge valve elevation Ap = H-( B + C )

CHECKING AND RESETTING OF CLEARANCES

Clearance Min. Max Resetting

E-E1 0.012 0.104 replace suction spacer
D-D1 0.012 0.104 replace discharge spacer
E-E2 0.012 0.104 replace suction cap
D-D2 0.012 0.104 replace discharge cap
G1-F1 0.130 0.270 replace both
G-F 0.120 0.255
P1-P 0.110 0.344 replace support rings
*measures in [mm]

CHECKING AND RESETTING OF ELEVATIONS

Elevation Min Max Resetting

Aa 8 9 Turn suction valve seat as shown in picture 1
Ap 6.5 7.5 Turn discharge valve seat as shown in picture 1
*measures in [mm]

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7.4 CRANKSHAFT MECHANISM REASSEMBLY
Crankshaft mechanism reassembly is carried out with reverse sequence to the
disassembling one, paying attention to the following:

 In order to assemble the pin (24) on the crosshead (22) and on the connecting rod
(11), it is necessary to heat the connecting rod eye up to 90/100° C; make sure
that after assembly the pin (24) doesn’t project out of the crosshead (22);
 During crank bushing (33) assembly on connecting rod (11), check that between
contact surfaces THERE IS NO OIL;
 Fixing screws of connecting rod (10) to the connecting rod cap (11) will have to be
tightened to nominal torque stated in the previous table in two times;
 Keying of shaft (26) bearings (31) frame (1) is done using a jack and having care
to centre-position the particulars;
 Screws that fix power inlet side cover must be properly tightened but not to the
extent to cause seeger deformation;
 Fixing screws of covers shall be clamped with threads braking loctite; once
assembly is over, oil everything and turn the pump manually, and check any
possible hardening.

7.5 HYDRAULIC SIDE REASSEMBLY

Hydraulic side reassembly is carried out with reverse sequence to the disassembling
one, paying attention to the following:
 Assembly of valves columns must be done as shown on the drawing and without
reversing the operations.
 Assembly of packing must be done as shown on the drawing, having care to
position the bladder cut 180° from previous ring and 90° from previous unit.
 Grease the OR before assembling them;
 Restore oil levels consulting the enclosed table of suggested oils.
Adjustment of seal packings tightening is very important not only during machine
running-in but also when packing are replaced.
During starting phase with new packing, adjust the stuffing box ring nuts , letting the
main packing drip.
It is important not to leave any space between a bladder ring and the other.
Any possible axial clearances of the packing would cause damages to the hydraulic
cylinder and to the plunger.

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7.6 STUFFING BOX PACKINGS INSTALLATION

7.6.1) Introduction
In the following chapters it is described the procedure that must be followed in order
to prepare the stuffing box packings, with description and indication of what must be
done for the braid rings and the supporting rings, their assembly on the plunger and
its installation on the pump. Moreover it is described how to commission a new
stuffing box packing and indication are given for a proper maintenance and care.
The average life of the stuffing box packings is strictly depending upon the care and
experience used for its preparation, the care taken during its assembly, the
commissioning and its further tightening and regulation.
It is important to note that the best maintenance can be done and can be planned
only on the basis of the daily experience of the technical personnel assigned to
reciprocating pumps on the plant. Only after some time the technicians can develop
the best feeling and experience that will lead to a long life of such wearing parts.

IT IS IMPORTANT TO INSTALL ONLY ORIGINAL MATERIAL PROVIDED BY

PERONI.

7.6.2) Preparation of packings

The supplied pump is provided with two packings on each plunger: front seal packing
and rear seal packing. The front seal packing consists of soft braid rings, terminal
rings and spacer rings. The rear seal packing consists of soft braid rings, terminal
rings, spacer rings and lantern:
The drawings below, show sequence and position of above mentioned rings.

Picture #1
Front seal packing sequence

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BRAID RINGS

The soft braid rings, for their characteristics, have a grade of elasticity and, so each
ring must be pre-stressed before being mounted. Procedure for preparation of the
soft braid rings is described below:

Braid rings pressing

To carry out this operation you need to use the special pressing tool
Follow procedure from point 1 to 6 only on one ring before cutting all the required
rings
a) Carefully establish the cut length of the braid using the following formula:

3.14   plunger..diametermm  stuffing..box..chamber..diametermm 

Braid ..length..mm  3
2

do not define braid length by winding it on the plunger, as in this way the length
results too long and during compression phase the inside diameter may be altered.
b) Roll up 2 or 3 times with adesive tape the braid where it will have to be cut.
c) Make a 45° cut using a very sharp blade.

DO NOT USE AN HACKSAW.

d) Roll the braid in order to form a ring as shown in Picture #3.

e) Take the special pressing tool (ref. to dwg. NOR 166-A)
Insert the bushing (pos. 2) in the support (pos. 1).
Insert the spacer ring (pos. 3) in the bushing (pos. 2).
Insert the braid ring previously cut inside the bushing (pos.2) having care to make it
adhere on the bottom and on the sides of bushing.
Insert the plug (pos. 5) in the special pressing tool.
By means of an hydraulic jack, apply a pressure on the plug (pos. 5). The value of
the force to be applied is 14.3 tons.

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Such value can be obtained using the following formula:
P  S 1,2
P1 .[tons ]  2 br
1000

where:

P1 = pressing load [tons]

P2 = max. discharge pressure [kg/cm2]
Ssb = Braid ring surface [cm2]
1.2 = constant
1000 = conversion factor [kg/ton]
Ssb can be evaluated as follows:

S sb .[ cm 2 ] 
stuffing .box .chamber .diameter 2
 plunger .diameter 2
 3,14
4

Once the force has reached the required value, wait 45 seconds before discharging
the pressure.
Introduce the extractor (pos. 6 as shown on dwg. NOR 166-B shown at page 8) and
remove the pressed braid ring, having care not to deform it.
Insert the ring on the plunger and check that a correct overlap of braid ring ends
occurs as shown below. A incorrect overlap could lead to the damage of supporting
rings.
In case a incorrect overlap is checked:
Throw away the soft braid ring in case of negative overlap (Picture #5) and proceed
again from point 1.
Reduce length of soft braid ring correcting the edge, in case of positive overlap
(Picture #6).

Picture 5 # Picture 6 # Picture 7 #

Negative overlap of edges Positive overlap of edges Correct overlap

Repeat procedure from point 1. up to preparation of all the required soft braid rings.
Usually Peroni provides pre-stressed braid rings but, due to elasticity of material,
such stress could reduce along time (for example when material is kept in stock for a

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 long time before it is mounted). So it is important to repeat procedure above
described for every ring, every time a new stuffing box packing is installed.
In case of supply of loose soft braid, procedure must be followed entirely from point
1. to point 7.

1) Support. 1) Support.
2) Bushing. 2) Bushing.
3) Spacer ring. 3) Spacer ring.
4) Braid ring. 4) Braid ring.
5) Braid mold 5) Braid mold.
6) Extractor.

7.6.3) Installation of packings

This procedure must be followed once the stuffing box packings have been prepared
and checked.
Assembly of Rear Sealing System
Place lantern ring in vertical position, after having mounted on the outside diameter
the relevant O-Rings as per main sectional drawing.
Insert one by one the terminal and spacer rings and the soft braid rings, following the
sequence shown in Picture #2.
The soft braid rings must be inserted so that each cut is at 90° clockwise with respect
to the cut of the previous ring.

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 Note

Particular care must be taken in order not to leave

any gap where there is the cut, as this would not
allow the supporting ring to lie perfectly along the
entire surface of the soft braid ring. This could
compromise and even break the supporting ring
during the tightening of the stuffing box.

Insert the rear threaded ring by hands without

tightening and/or adjustment in order to avoid the
releasing of the rings.

Assembly of Main Sealing System

 Place the hydraulic cylinder in vertical position.

 Insert the terminal ring.
 Insert one by one the spacer rings and the soft braid rings, following the
sequence shown in Picture #1.
 The soft braid rings must be inserted so that each cut is at 90° clockwise with
respect to the cut of the previous ring. Refer to Picture # 7.
 Insert the lantern ring, previously prepared with the complete rear sealing system,
into the hydraulic cylinder, previously prepared with the complete main sealing
system.
 Insert the rear threaded ring by hands without tightening and/or adjustment in
order to avoid the releasing of both sealings.

7.6.4) Installation of plunger

Once the hydraulic cylinder has been prepared as above described, it is possible to
proceed with the installation of the plunger:
Lubricate well with oil the internal bottom part of the hydraulic cylinder, paying
attention not to come in touch with any of the two sealings, main or secondary.
Insert the plunger into the hydraulic cylinder, taking maximum care not to damage
the stuffing box packings. The plunger should slide in freely, for almost its entire
length. Only near the end, a pressure should be applied in order to complete the
plunger insertion. The value of such pressure can be indicated as a nominal figure of
100 kg.
The force applied by the technician that is performing the operation should normally
be enough. In case a strong resistance would be requested, few small hits (avoiding
hammer blows) could be applied but it is preferable to remove the plunger, to remove
the lantern ring with the sealing system and re-check the installation of main sealing
system.

Operating and Maintenance Manual

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TITANO 3140
Insert the hydraulic cylinder, complete with plunger, main and rear sealing system, in
the frame of the pump.
7.6.5) Commissioning of new stuffing box packings

 Once the pump have been completely reassembled and before starting the
pump, proceed to tighten the stuffing box packings as follows:
 Tighten main stuffing box packing through main threaded ring by hands, as much
as possible.
 tighten main stuffing box packing through main threaded ring using the front
packing ring nut wrench until resistance is offered.
 now the rings have been packed properly.
 un-tighten main stuffing box packing through main threaded ring using the front
packing ring nut wrench.
 tighten main stuffing box packing through main threaded ring by hands. main
threaded ring must be only in touch with the stuffing box packing.
 now the rings can extend again due to the thermal expansion and the elasticity of
the material.
 repeat the same operation for the rear stuffing box packing.
 pump can now be put in operation, after having followed normal operating
procedure regarding all the auxiliary circuit.
 once the pump has been put in operation, the first thing to be verified is the
checking of eventual leakages from the rear sealing system. the admissible
leakage from this packing is an indicative quantity of few drops per minute. in
case a major leakage is occurring, the rear sealing system must be slightly
tightened of 1/4 of turn. after a period of approximately 30 minutes such checking
must be repeated. In case a major dripping is still occurring, repeat the operation
again (1/4 turn tightening and re-checking after 30 minutes) until the leakage
reaches the rated figures of few drops per minutes.

Operating and Maintenance Manual

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7.7 MAINTENANCE SCHEDULE

POS. P PM P PR P PM P PGR
HRS 2000 4000 6000 8000 10000 12000 14000 16000

POS. DESCRIPTION WOR HRS. NO. PERS. QUALIFICAT.

P Levels checking and filters 0.5 1 Assembler

cleaning.

M Lathe working of valves 2 1 Assembler

seats.

R Valves, seats and relevant 2 1 Assembler

gaskets change;
oil change. 2 1 Assistant

G General revision:
- clearances and surfaces 8 1 Assembler
checking of crankshaft
mechanism; 8 1 Assistant
- clearances and surfaces of
hydraulic side.

- Replace stuffing box packing 4 1 Assembler

when there is no tightening
and check plungers. 4 1 Assistant

Clean the suction filters very often during first running phases.

Adjust the main and secondary packing every time they leak allowing anyway a slight
leakage.
Add oil every time is needed. Replace the oil completely after first 1000 hours of
running and change it every 8000 hours, but not later than 12 calendar months.

Operating and Maintenance Manual

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TITANO 3140
7.8 LUBRICATION

Crankshaft mechanism is placed in a closed vacuum-proof protection guard.

Lubrication is splash type by means of oil flapping blades.
The oil reaches:

 The bearings.
 The bushings of connecting rod big end.
 The crosshead.
 The bushings of connecting rod small end.
 The pin.

The oil quantity to be supplied is shown on relevant level gauge placed on the frame.
First filling quantities are the following:

PUMP TYPE 1st FILLING QUANTITY [l]

3110 8
3120 14
3130 35
3140 54

Operating and Maintenance Manual

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8 TROUBLE SHOOTING

DEFECT CAUSE REMEDY

High temperature of unit  Oil low level.  Restore level.
reducer-pump-motor.  Dirty oil.  Change it.
VALVES
 It can be heard a more  A valve seat is  Replace the valve as
or less strong whistle damaged, hence a part soon as possible.
that repeats in phase of the flow goes through
with the pump. it.

 It can be heard an  Valves guide surfaces  Complete revision or the

emphasized not a are worn. valves and replacement
rhythmic noise. of those worn.

 Strong blows can be  One of the valves closes  Total revision of valves
heard which sporadically late and causes a defect and of valves body
overlap the usual valves in the running. seats.
noise.

 Flowmeter and pressure  One of the valves  Oscillation can be

gauge oscillate in phase doesn’t close well or tolerated for a few hours
with the pump. opens late or was if they are not more than
blocked opened. 5 p.m.; if they are more,
stop the unit and inspect
the valves.

 The pump runs  One of the discharge  Immediately stop the

irregularly (jerkily) and at valves didn’t open unit and replace the
the same time the speed completely and is valve.
indicator oscillates blocked.
considerably.

Operating and Maintenance Manual

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TITANO 3140
9 OPERATION AND MAINTENANCE MANUAL OF
THE COMPONENT

Component Manufacturer
Electric motors

Gear reducer

Couplings

Pulsation dampeners

Injection pump

Pressure gauges

Level switch

Vibration switch

Globe valve

Operating and Maintenance Manual

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TITANO 3140
10 SETTING OUT OF SERVICE AND DEMOLITION

When proceeding with setting out of service and demolition of pumping unit (Ref.
General arrangement n° 3140 ZZ 088 000 NGR it is suggested to carry out materials
separated disposal.
It is important that inside the pump and all the other components there are no
residual lubricants and/or solvents, which in case will have to be eliminated
according to specific rules in force.

Operating and Maintenance Manual

Item
TITANO 3140