Installation, Operation and Maintenance Manual

RDPL
API 674 3rd Edition Reciprocating Plunger Pump
Revision 2, 9th January 2019

These instructions should be read prior to installing, operating and maintaining the RDPL pump.

Ruhrpumpen UK Ltd
Unit 22, Commerce Way, Lancing, West Sussex. BN15 8TA
T: +44 (0) 1273 956410. E: salesuk@ruhrpumpen.com W: www.ruhrpumpen.com
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Contents
1 General Information 3
1.1 Use of User Manual 3
1.2 Additional Documentation 3
1.3 Declaration of Conformity 3
1.4 Environment and Waste 3
1.5 Disclaimer 3
1.6 Duty Conditions 3
2 Warranty 4
3 Safety 4
3.1 Safety Actions 4
3.2 Pictograms 4
3.3 Limitations in Use 5
3.4 Responsibility 5
3.5 Personnel Qualification and Training 5
3.6 Flow Rates 5
3.7 Products used in Potentially Explosive Atmospheres 5
3.8 Scope of Compliance 6
3.9 Avoiding Excessive Surface Temperatures 6
3.10 Preventing the Build-up of Explosive Mixtures 7
4 Pump Overview 9
4.1 Physical Description 9
4.2 High Suction Pressure Operation 10
4.3 General Notes 11
5 Shipping & Commissioning 12
5.1 Shipping and Handling 12
5.2 Installation and Alignment 12
5.3 Pulsation Dampers 13
5.4 Relief Valves 14
6 Start Up and Shut Down Procedures 14
6.1 Preparing to Start 14
6.2 Start Up 14
6.3 Shut Down 15
7 Maintenance 17
7.1 Introduction 17
7.2 Maintenance Schedule 18
7.3 Fluid Head 18
7.4 Fluid Head Removal 21
7.5 Power End 23
7.6 Power End Overhaul 26
7.7 Recommended Lubricants for RDPL models (to Specification API CE/SF) 30
7.8 Stuffing Box 32
7.9 Fault Finding 35
8 Appendix 39
8.1 Glossary 39
8.2 Appendix B - Order Form for Spare Parts 40
8.3 Appendix C – Commissioning and start-up checklist 42

2
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1 GENERAL INFORMATION

In this user manual the term ‘manufacturer’ refers to:

Ruhrpumpen UK Ltd, Unit 22, Commerce Way, Lancing, West Sussex. BN15 8TA. United Kingdom

1.1 Use of User Manual

This manual is meant to be a reference document for the qualified user to install, commission and maintain described
pump.

1.2 Additional Documentation

Manuals of other components, such as motor, coupling, etc. are not part of this manual. If additional documentation
is added, the instructions in this documentation should be followed.

1.3 Declaration of Conformity

It is a legal requirement that machinery and equipment put into service within certain regions of the world shall
conform with the applicable CE Marking Directives covering Machinery and, where applicable, Low Voltage
Equipment, Electromagnetic Compatibility (EMC), Pressure Equipment Directive (PED) and Equipment for Potentially
Explosive Atmospheres (ATEX).

Where applicable the directives, and any additional approvals, cover important safety aspects relating to machinery
and equipment and the satisfactory provision of technical documents and safety instructions. Where applicable this
document incorporates information relevant to these directives. To establish approvals and if the product itself is CE
marked check the serial number plate and the certification. All products of the manufacturer comply with the
applicable health - EN safety regulations, Annex 1 as described in the European Machine Directive 2006/42/EC. See
Appendix A for suppliers EC Declaration of Conformity.

1.4 Environment and Waste

Save the environment and ask your local government for reuse of packing materials, replaced parts
and other waste products, such as oils or grease.

1.5 Disclaimer
Information in this manual is believed to be reliable and correct, however in spite of all the efforts of Ruhrpumpen UK
Ltd to provide sound and all necessary information, the content of this manual may appear insufficient and is not
guaranteed by Ruhrpumpen UK Ltd as to its completeness or accuracy.

1.6 Duty Conditions

This product has been selected to meet the specifications of the purchase order. The acknowledgement of these
conditions has been sent separately to the Purchaser. A copy should be kept with these instructions.

The product must not be operated beyond the parameters specified for the application. If there is any doubt as to the
suitability of the product for the application intended, contact Ruhrpumpen UK Ltd for advice, quoting the serial
number (see section 4.3 for details).
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2 WARRANTY
Warranty is valid according to the contractual agreements.

3 SAFETY
3.1 Safety Actions
Summary of conditions to help prevent injury to personnel, damage to environment and product leakage.
• Do not use pumps as support for piping. Always refer to contractual GAD for the allowable forces and moments
on Suction and Discharge Nozzles.
• Only check direction of motor rotation with coupling element pins removed. Starting in reverse direction of
rotation will damage the pump. Refer to rotation arrows on top of the Pump Crankcase.
• Ensure correct lubrication.
• Start the pump with the outlet valve fully opened.
• Never run the pump dry.
• Isolation valves to be fully open when pump is running.
• Never do any maintenance work when the unit is connected to power.
• Do not run the pump outside of duty conditions.
• When the pump is handling hazardous liquids, care must be taken to avoid personnel exposure to the liquid
by appropriate setting of the pump, limiting personnel access and operator training. If the liquid is flammable
and/or explosive strict safety procedures must be applied.
• Drain pump and isolate pipework before dismantling the pump.
• Guards must not be removed when pump is operating.
• Hot or freezing components or auxiliary heating supplies can present danger to operators, they must be
shielded to avoid accidental contact if complete protection is not possible access must be limited to
maintenance staff only.

3.2 Pictograms
Following Pictograms are used in this manual:

 INFORMATION
Remarks, suggestions and advice.

WARNING
Instructions or procedures which, if not carried out with care, can lead to damage to the product
and/or personal injury.

DANGER
Instructions or procedures which, if not carried out with care, can lead to serious damage to the
product and/or severe personal injury.

ELECTRICAL DANGER
Instructions or procedures which, if not carried out with care, can lead to serious damage to the
product and/or severe personal injury.
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When the pump is handling hazardous liquids care must be taken to avoid exposure to the liquid by
appropriate siting of the pump, limiting personnel access and by operator training. If the liquid is
flammable and/or explosive strict safety procedures must be applied.

This symbol indicates potential risks of a flammable nature

This symbol indicates potential risks connected with extremely high temperatures.

This symbol indicates potential risks connected with extremely low temperatures.

3.3 Limitations in Use

The products of the manufacturer are strictly designed to perform as described in this user manual. Other usage than
described is not allowed.

The manufacturer is not responsible for any damage or personal injury as a result of misusage of the pump unit.

3.4 Responsibility
The user should carefully take notice of full contents of this user manual before installation, commissioning, operating
or maintaining the pump unit.

3.5 Personnel Qualification and Training

All personnel involved in the operation, installation, inspection and maintenance must be competent to carry out the
work involved. If the personnel in question do not possess the necessary knowledge and skill, then appropriate
instruction and training must be provided. If required the operator may commission the manufacturer to provide
applicable training. Always co-ordinate repair activities with operations and health and safety personnel, and follow
all plant safety requirements and applicable safety and health laws and regulations.

3.6 Flow Rates

DO NOT RUN THE PUMP AT ABNORMALLY HIGH OR LOW FLOW RATES.

Operating at a flow rate higher than the working point or at a flow rate with no back pressure may overload the motor
and cause cavitation. Low flow rates may cause a reduction in pump/bearing life, pump overheating, instability and
cavitation/vibration.

3.7 Products used in Potentially Explosive Atmospheres

Measures are required to:
• Avoid excess temperature
• Prevent build-up of explosive mixtures
• Prevent the generation of sparks
• Prevent leakages
• Maintain the pump to avoid hazard

The following instructions for pumps and pump units when installed in potentially explosive atmospheres must be
followed to help ensure explosion protection.
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Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC.

3.8 Scope of Compliance

Use equipment only in the zone for which it is appropriate. Always check the driver, drive coupling assembly, seals
and pump equipment are suitably rated and/or certified for the classification of the specific atmosphere in which they
are to be installed.

Use equipment only in the zone for which it is appropriate. Always check that the driver, drive coupling
assembly, seals and pump equipment are suitably rated and/or certified for the classification of the
specific atmosphere in which they are to be installed.

Where Ruhrpumpen UK Ltd has supplied only the bare shaft pump, the Ex rating applies only to the pump. The party
responsible for assembling the pump set shall select the coupling, driver and any additional equipment, with the
necessary CE Certificate/ Declaration of Conformity establishing it is suitable for the area in which it is to be installed.

The output from a variable frequency drive (VFD) can cause additional motor heating for pump sets with a VFD, the
motor ATEX Certification must state that it covers the situation where electrical supply is from the VFD. This particular
requirement still applies even if the VFD is in a safe area.

An example of ATEX equipment marking is shown below. The actual classification of the pump will be engraved on the
nameplate.

3.9 Avoiding Excessive Surface Temperatures

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ENSURE THE EQUIPMENT TEMPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE

Pumps have a temperature class as stated in the ATEX Ex rating on the nameplate. These are based on a maximum
ambient of 40 °C (104 °F); refer to Ruhrpumpen UK Ltd for higher ambient temperatures.

Temperature Maximum surface Temperature limit of liquid handled (* depending on material and
class to EN 13463-1 Temperature permitted construction variant - check which is lower)

T6 85 °C (185 °F) Consult Ruhrpumpen UK

T5 100 °C (212 °F) Consult Ruhrpumpen UK
T4 135 °C (275 °F) 110 °C (230 °F) *
T3 200 °C (392 °F) 175 °C (347 °F) *
T2 300 °C (572 °F) 250 °C (518 °F) *
T1 450 °C (842 °F) 350 °C (662 °F) *
* The responsibility for compliance with the specified maximum liquid temperature is with the plant operator.

The surface temperature on the pump is influenced by the temperature of the liquid handled. The maximum
permissible liquid temperature depends on the temperature class and must not exceed the values in the table that
follows. The temperature increase at the seals and bearings and due to the minimum permitted flow rate is taken into
account in the temperatures stated above.

Temperature classification “Tx” is used when the liquid temperature varies and when the pump is required to be used
in differently classified potentially explosive atmospheres. In this case the user is responsible for ensuring that the
pump surface temperature does not exceed that permitted in its actual installed location.

Where there is any risk of the pump being run against a closed valve generating liquid and external surface high
temperatures it is recommended the user fits an external surface temperature protection device.

Avoid mechanical, hydraulic or electrical overload by using motor overload trips or a Power Monitor and carry out
routine vibration monitoring. In dirty or dusty environments, regular checks must be made and dirt removed from
areas around close clearances, bearing housings and motors.

It is recommended a Level control fitted in the rod box area to prevent liquid level dropping below minimum.

3.10 Preventing the Build-up of Explosive Mixtures

ENSURE THE PUMP IS PROPERLY FILLED AND VENTED AND DOES NOT RUN DRY

To prevent pockets of explosive gas ensure the pump and associated piping is totally filled with liquid at all times
during the pump operation. In addition it is essential to make sure seal chambers, auxiliary shaft seal systems and any
heating and cooling systems are properly filled.

If the operation of the system cannot avoid this condition the fitting of an appropriate Dry Run protection device is
recommended (e.g. liquid detection or a Power Monitor). To avoid potential hazards from escaping emissions to
atmosphere the surrounding area must be well ventilated.

Preventing Sparks

To prevent a random current inducing a spark the baseplate earth contact must be used.

Avoid electrostatic charge: do not rub any non-metallic surfaces with a dry cloth, ensure it is damp.
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Preventing Leakage

To prevent corrosion the pump must only be used to handle liquids described in the Pump Data Sheet.

When the pump is stationary avoid entrapment of liquid in the pump and associated piping. Do not close the suction
and discharge valves if there is a heat input to the liquid. This could cause dangerous excessive pressures in the system.

Bursting of liquid containing parts due to freezing must be avoided by draining or protecting the pump and ancillary
systems.

CORRECT MAINTENANCE IS REQUIRED TO AVOID HAZARDS WHICH GIVE A RISK OF

EXPLOSION

(See section 7 for maintenance description), contact Ruhrpumpen UK Ltd technical department for further advice if
necessary (See section 4.3 for contact details).

It is Plant Operator’s responsibility for compliance with maintenance instructions given on this IOM.

To avoid explosion hazards during maintenance, tools, cleaning and painting materials used must not
give rise to sparking or adversely affect the ambient conditions. Where there is a risk from such tools or
materials, maintenance must be conducted in a safe area. It is recommended that a maintenance plan
and schedule is adopted (see section 7, Maintenance) It should include, but not be limited to the following:
a) Check for leaks from gaskets and seals. The correct functioning of the shaft seal must be checked regularly
b) Check bearing lubricant level, and if the hours run indicate, a lubricant change is required.
c) Check that the duty condition is in the safe operating range for the pump. As set out in the Pump Data Sheet.
d) Check vibration, noise level and surface temperature at the bearings to confirm satisfactory operation.
e) Check dirt and dust are removed from areas around close clearances, bearing housings and motors.
f) Check coupling alignment and re-align if necessary. Refer to coupling IOM of coupling drawing provided with
project documentation for the alignment limits.
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4 PUMP OVERVIEW
4.1 Physical Description

The RDPL pump type is defined as a horizontal, single acting, reciprocating plunger pump. The RDPL pump type is
manufactured as a Triplex (3) plunger configuration. The basic operation of the pump can be defined in 2
steps.

Figure 1.- Suction Stroke

Figure 2.- Discharge stroke

Pump Flow: During the suction stroke fluid is drawn in, through the suction valve, to the pumping chamber by a
decrease in pressure with respect to the suction line pressure. This pressure drop is due to the movement
of the plunger creating an increase in the chamber acting volume (Figure 1). Then during the discharge
stroke the plunger travels forwards (Figure 2). The liquid is forced out through the discharge valve. During
the suction stroke the discharge valve is closed by the back pressure in the discharge line. During the discharge
stroke the suction valve is closed by the pressure in the pumping chamber ensuring there is no flow back into
the suction line. This action creates a net flow through the pump. The flowrate is a function of plunger area,
stroke length, pump speed, volumetric efficiency, and number of plungers.
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Pump Pressure is created downstream equipment from the discharge line. Pressure Regulators, un-loader valves or a
well head create the backpressure. Pressure is created by the system not by the pump. The pump creates
flow.

4.2 High Suction Pressure Operation

High suction pressure condition is defined when the suction pressure generates a load on plunger equivalent
to40% of the max rod load of the pump. In high suction pressure systems attention must be given to the
pump design as there tends to be increased wear to the connecting rod bearings, particularly on the small
end. During high suction pressure conditions there is no load relief on the suction stroke that normally allows
lubricating oil to enter between the bearing surfaces.

During high suction pressure conditions the pump build may be modified to reduce the bearing wear rate. The first
modification is the replacement of the bearings with high strength bronze alloy items. .The second is the inclusion
of a pressure lubrication system (Figure 3), which takes oil from the crankcase sump and injects it under pressure
into a hole running through the crankshaft. This forces oil onto the big end bearings. A hole between the connecting
rod bushings similarly forces oil onto the small end bearings. See Figure 3 a typical layout for a crankcase pressure
lubrication system.

Figure 3.- Forced lubrication system

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4.3 General Notes

This IOM is a guide only. Ruhrpumpen UK Ltd recommends the use of our specially trained personnel for
commissioning, maintaining and repairing any pump or package it supplies.

For all reciprocating plunger pumps correct installation is paramount. It is important to have the correct NPSHa to
match the pump flow rate. Furthermore, it is not enough to flood and pressurise the suction line if there is a
restriction to the flow. For example, due to a badly installed filter, inadequately size pipeline or too many
pipe bends.

If assistance is required please contact Ruhrpumpen UK Ltd, where our technical staff will be pleased to offer advice.
Contact the UK team on:

Ruhrpumpen UK Ltd,
Unit 22, Commerce Way,
Lancing, West Sussex,
BN15 8TA
Tel: +44 (0) 1273 782240
E-mail: salesuk@ruhrpumpen.com
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5 SHIPPING & COMMISSIONING

5.1 Shipping and Handling
For packing and shipping see project specific procedure delivered on the equipment documentation package.

P470004-38 Packaging and Delivery

5.2 Installation and Alignment

If you are unclear on how to install the equipment please call the Technical department at Ruhrpumpen UK
Ltd where the technical staff will be pleased to offer advice (see section 4.3 for details).

5.2.1 It is important to remember that pump reliability is dependent on good installation of pipe-work
systems, in particular the inlet/suction line.

5.2.2 To lift a bare shaft pump, lifting eye bolts must be fitted to the crankcase (Figure 4). These are not
provided as standard.

DO NOT lift in any way via drive shafts, flanges or couplings.

Figure 4.- Bare shaft pump with Lifting Points fitted

5.2.3 To lift the pump package use the baseplate lifting points.

DO NOT lift in any way via drive shafts, flanges or couplings.

NEVER lift the whole package by the lifting lugs on the pump
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5.2.4 The correct lifting procedure and equipment must be used at all times.

5.2.5 When installing a bare shaft pump in accordance with API674 7.4, all mounting pads must be level within 150
microns (0.0025in/ft), and be of suitable construction as not to deform whilst executing torque down of the
fasteners.

5.2.6 The pump driveshaft must be concentric to the output shaft of a gearbox drive and parallel with a drive belt
system.

5.2.7 Check relevant coupling IOM for correct settings and tolerances. Coupling drawing or IOM is provided within
the document package of the equipment

5.2.8 Once all items on the skid are aligned, all securing bolts should be tightened up to the relevant torques and
the alignment re-checked.

5.2.9 When installing a pump package, the chosen location must be secure, level and capable of supporting the
entire skid.

5.2.10 The correct lifting procedure and equipment must be used at all times to ensure safe and accurate placing of
the skid.

5.2.11 Ruhrpumpen UK Ltd pump skids can be welded or bolted in position, it is essential that the baseplate remains
level and is not twisted or buckled.

5.2.12 Once the baseplate is secure the aliment of the couplings must be re-checked and adjusted where necessary.

5.3 Pulsation Dampers

CAUTION: Most pulsation dampers can only work in the VERTICAL plane. Read
relevant IOM's.

5.3.1 Ruhrpumpen UK Ltd recommends fitting suction and discharge dampeners to the fluid head. If this cannot be
achieved a maximum distance from the fluid head of 1 meter is recommended.

5.3.2 All dampeners should be pre-charged with nitrogen at a set pressure of 70-80% line pressure.
Most shipping regulations do not permit any vessel containing pressure. All pulsation dampeners
must be presumed empty and checked.

5.3.3 If empty, charge with nitrogen using the correct dampener charging kit and the correct procedure.

NOTE: the manufacturer’s instruction on fitting orientation. Most dampeners supplied by Ruhrpumpen UK
should be installed perpendicular to the pipework and should be orientated vertically with the flange at the
bottom of the dampener. Refer to the project P&ID for dampener and PSV recommendations. For any
further advice please contact Ruhrpumpen UK Ltd (see section 4.3 for details.)
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5.4 Relief Valves

CAUTION: Failure to install a relief valve or correctly specify relief valves

installed may cause personal injury or damage to the pump or system.

5.4.1 Time must be taken to guarantee the correct relief valve is selected to match the pressure, this is normally
pre-set 10% above system working pressure, flow and media type of the system.

5.4.2 Relief valves can be attached to the pump fluid head or pipe work but must be fixed to the DISCHARGE side.

5.4.3 NO OTHER EQUIPMENT, VALVES ETC, SHOULD BE INSTALLED BETWEEN THE PUMP AND THE RELIEF VALVE.

THE DISCHARGE OF THE RELIEF VALVE SHOULD BE UNRESTRICTED AND AT ATMOSPHERIC PRESSURE.

6 START UP AND SHUT DOWN PROCEDURES

6.1 Preparing to Start

6.1.1 Ensure that all isolation valves in the suction and discharge pipe work systems are open.

6.1.2 Suction filters are not normally recommended but if fitted they must be the correct size with a coarse mesh.
Suction filters should be checked regularly, they are a key source of potential performance issues. The
differential pressure drop across a filter can force the NPSH available from a system below that required by
the pump.

6.1.3 Belt drives should be checked for tension and drive couplings checked for alignment. Slack belts will slip and
burn resulting in reduced pump output, over tensioned belts will reduce bearing and belt life. Coupling
misalignment will lead to premature bearing and or coupling failure.

6.1.4 It is recommended that un-loader valves (where fitted) should be in the ‘off load’ condition. Generally all
pumps should be started in the ‘off load’ condition.

6.1.5 Check that the crankcase is filled to the centre mark on the site glass on the back cover with the correct type
of lubricating oil, See section 7.7 for lubricant type details.

Note: Overfilling with oil is equally as detrimental as under-filling, as oil will froth and cause
overheating.

6.1.6 If the pump is supplied with a power end pressure lubrication system ensure that the suction line of the
lubrication pump is primed. Capped tee fittings are provided at the top and bottom of this suction line to
aid with priming. Ensure that as much air is blead out as possible.

6.2 Start Up

6.2.1 Where possible, it is ideal to rotate the pump by hand via the belt pulleys or drive coupling for two
revolutions.

6.2.2 Open the suction and discharge line isolation valves.

Note: Leaking from pump packings should not be considered a problem at this stage. Many packing
arrangements are designed to pass a minimal leak rate. This has the effect of lubricating the packing/plunger
contact surface. Some pumps are fitted with a high integrity sealing arrangement within the packing/stuffing
box. This system does not stop the packings from leaking but diverts it to a drain-line to be piped to waste.
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6.2.3 If the pump is fitted with a bleed valve or valves, open and vent the air and make sure all is purged.

6.2.4 Give the pump an initial 2-3 second start to check for the correct direction of rotation. This is very important.
Refer to the directional arrows situated on top of the pump crankcase (Figure 5).

Figure 5.- Direction of rotation

6.2.5 The pump can now be started with initial monitoring of flow rate and pressure. Check pump for air
entrapment, if this is apparent, purge the fluid end.

6.2.6 If possible it is good practice to run new pumps with either no discharge or very little discharge pressure i.e.
‘off load’ for 30 minutes to bed in the packing’s, power end assembly and remove trapped air from with the
pipe work. The pump can be brought to duty point and a check on motor full load current should be made at
this stage.

6.2.7 If the pump is fitted with power end pressure lubrication then the lubrication pump should be turned on
before or at the same as the main pump start-up. Once the lubrication pump has started, check for air
entrapment and purge if necessary. Check the discharge pressure of the lubrication pump to ensure the
system is working correctly. If no pressure gauge is provided there will be additional ports where a gauge can
be added. The pressure shall be over 2 barg but not exceeding 5 barg.

6.2.8 Pumps fitted with packing lubrication are pre-set at the factory. However, one to two drips every minute is
sufficient (viewed from the sight glass on top of the packing Lubricator pump). Do not over lubricate the
packing’s as this may cause carburisation and ultimately packing failure.

6.3 Shut Down

6.3.1 Where possible reduce the back pressure on the pump so it is in the “off load” condition. Pump un-loader
valves (where fitted) should be in the off load position.

6.3.2 Shut down the pump and power end pressure lubrication system (if fitted).

6.3.3 Isolate inlet and discharge lines as required.

6.3.4 Release any residual line pressure.

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CAUTION: Do not attempt to work on any electrical equipment until any residual
current that is present has dissipated. Residual current is particularly an issue for
VFD units and high voltage motors. Contact the manufacturer of the electrical
equipment for advice.
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7 MAINTENANCE
7.1 Introduction

CAUTION: Before commencing with any maintenance work, shut off and isolate
all drive systems and media going to the pump. Relieve all discharge pressure
and isolate.

7.1.1 All pump models are designed to different build specifications to suit various duties and pumped media. For
this reason when ordering spare parts, the pump serial number must be quoted. This can be found on the
pump nameplate, which is normally situated to the rear of the pump on the back cover.

7.1.2 All RDPL pump packages can be split into three main sections (Figure 6). The maintenance of each section
shall be discussed in turn in the following sections.

Figure 6.- Main Sections of the Pump

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7.2 Maintenance Schedule

ITEM SCHEDULE
Stuffing box, Gland nut, packing 4 to 12 months of continuous operation, or increased leakage rate (visual
seals inspection) whichever comes first.
Crank Case, oil Change the oil after the first 24 hr. of continuous operation. Oil to be changed every
4,000 operating hours or 6 months whichever comes first.

Fluid head, valves & Valve seats 9 to 24 months of continuous operation, or when flow measured shows a decay
on its values. Whichever comes first.

7.3 Fluid Head

Figure 7.- Fluid Head

7.3.1 The inlet and discharge valves can be serviced with the fluid head still attached to the pump although care
must be used as the plungers will be exposed.

Note: The Valve Cartridges may require a special tool to remove and install them.

7.3.2 Access to the valves is achieved by removal of the plugs located on the top of the fluid head and the removal
of the front covers located on the front of the fluid head (Figure 7).
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Figure 8.- Fluid Head components.

7.3.3 The Top plugs can be removed by un-screwing the relevant fasteners as shown in (Figure 8).

7.3.4 The Front covers can be removed in a similar fashion as shown in (Figure 8) & (Figure 9).

Figure 9.- Front Cover removal

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Figure 10.- Discharge Cartridge Figure 11.- Suction Cartridge

7.3.5 The suction and discharge valve assembly consists of cartridges shown in (Figure 10) & (Figure 11). The spring
cage is bolted to the valve seat and contains spring and valve as a single unit (cartridge).

7.3.6 Once the front covers and top plugs have been removed the valve cartridge can be accessed. The cartridges
are different for suction and discharge (Figure 12). Undo the spring cage will release the spring and the valve.

Figure 12.- RDPL 50 & 70 Valve cartridges removal

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7.3.7 For the RDPL 50 and 70, to remove the suction valve cartridge, first the front covers need to be removed by
unthreading the relevant bolts. The plunger movement will be used as to push the package from the rod box
area. A special tool is to be required. Disengage the plunger/distance piece and separate these two
components by turning the crankshaft. Once they get separated enough to place the special tool in place,
rotate the crankshaft to start pushing the suction valve cartridge and stuffing box out of the fluid head.

7.3.8 For the RDPL 50 and 70, to remove the discharge valve cartridge, first remove the top plug bolts and use the
jack screws provided to pull everything at once. For old designs of this head and valve cartridges, a special
tool is required.

7.3.9 Inspect all parts for any damage or wear. If upon inspection there is significant damage then the part must
be replaced with a spare part. Please contact Ruhrpumpen UK Ltd for supply of addition spare parts if
required. Replace all O-rings.

7.3.10 During re-assembly great care must be taken to ensure that all seating areas are spotlessly clean; failure to
achieve this will result in poor pump performance and long-term damage to the fluid head.

7.3.11 Cartridges shall be lubricated when inserting them back into the head.

7.3.12 Once the valve cartridges are back on its place in fluid head, front cover and top plugs can be installed back
to the head.

7.4 Fluid Head Removal

7.4.1 The head shall be removed if a major repair or clean-up is to be done to it.

7.4.2 Remove any pipe line connections.

7.4.3 Disconnect all plungers from its corresponding distance pieces.

7.4.4 Support the fluid head and remove the head nuts. Slide the fluid head away from the power frame.

7.4.5 Refitting is the reverse of the above instructions. Use of heavy waterproof grease on studs and faces will
assist in later removal if required. Tighten the head bolts in accordance with the pump torque settings.

Fluid head bolts and studs (12.9 Grade stud/bolt Steel)

Pump Size Lubricated Torque (Nm)
RDPL 50 M12x1.75 100
RDPL 70 * *
RDPL 100 * *
RDPL 150 M30x3.5 1,750
RDPL 200 M36x4 3,050

Note: Fluid head Assemblies shall be supported by using a Sling or Lifting Eyes at all times.
Note: Fluid head SHALL use 12.9 class studs/bolts.
Note: Always apply lubricant when applying torque to the studs/Bolts.
* Contact Ruhrpumpen UK Ltd for further details
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Top plug/front cover bolts Torque (A4-70 Grade stud/bolt

steel)
Pump Size Wet Torque (Nm)
RDPL 50 M10X1.5** 44
RDPL 70 * *
RDPL 100 * *
RDPL 150 M20x2.5 235
RDPL 200 M24x3 405
Note: Top plug/flanges bolts SHOULD be A4-70 grade steel bolts/stud.
Note: Always apply lubricant when applying torque to the studs/Bolts.
* Contact Ruhrpumpen UK Ltd for further details
** This Size use 12.9 grade bolt
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7.5 Power End

Figure 13.- Power End.

7.5.1 The Main power end parts can be seen in (Figure 13).

7.5.2 Maintenance of the power end will be limited to oil changes and checking for leaks on the distance piece seal
housing.

7.5.3 To replace distance piece rod seals, first remove the drain plug (Figure 14) to empty the crankcase of oil.

Figure 14.- Drain Plug

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7.5.4 If a magnetic drain plug is fitted this can be used to inspect the condition of the power end. If the plug has
attracted a large quantity of metal particles then this is an indication that there is a problem somewhere in
the power end and it is likely that a part is damaged. In this event the power end should be disassembled to
identify the problem.

7.5.5 Loosen the plungers by removing the plunger coupling and push forward to create a gap between the distance
piece and plunger (Figure 15).

Figure 15.- Disconnect Plungers

7.5.6 Using a circlip pliers, remove the circlip that holds the rod seal housing in place. Use jacking ports provided
to help with removal and slide them along distance pieces until free (Figure 16).

Figure 16.- Rod Seal Housing Removal

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7.5.7 When the seal housing is removed the rod seal must be replaced. Always replace it (look its relevant reference
on cross sectional drawing) and note the orientation of the seals.

7.5.8 If the distance piece is scored it must be replaced. Loosen and remove from pump as shown in (Figure 17).

Figure 17.- Distance Piece Removal.

7.5.9 Repair or replace items where necessary making sure all parts are clean and grit free before reassembly.

7.5.10 Re-install distance piece in reverse order.

7.5.11 Lubricate the seal housing outside diameter and seal before reassembly.

7.5.12 Reassemble the seal housing. Secure with the circlip back on its place.

7.5.13 If the pump is fitted with a power end lubrication system please refer to the lubrication pump’s installation
and operation manual for maintenance instructions.

7.5.14 The power lubrication system is fitted with filter to ensure clean oil is supplied to the bearing surfaces. The
bottom of the filter can be unscrewed for inspection and/or replacement. The filter should be checked every
month to see if it is full. If it is full the whole bottom attachment shall be thrown away and replaced, please
refer to Ruhrpumpen UK Ltd for replacement parts.
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7.6 Power End Overhaul

7.6.1 In the unlikely event that a complete overhaul is required these procedures must be followed.

CAUTION: IF A COMPLETE OVERHAUL IS REQUIRED THE PUMP MUST FIRST BE

REMOVED FROM ANY SKID AND DRIVE TRAIN. REFERENCE TO ALL RELEVANT
COUPLING IOM'S AND LIFTING PROCEDURES MUST BE MADE.

CAUTION: The power end must be stripped, assessed and re-assembled by a

competent person. Any damaged caused by this process may put the entire pump out
of commission COMPLETELY.

7.6.2 Remove drain plug and drain crankcase completely.

7.6.3 Remove fluid head and distance pieces as described in section 7.4 and 7.5.

7.6.4 Stuffing box on RDPL 50 & 70 are not meant to be removed at this step.

7.6.5 Undo bolts located on the back cover and remove from crankcase as shown (Figure 18).

Figure 18.- Back Cover Removal.

7.6.6 Note the positions of the bolts, washers and connecting rod end caps for re-assembly.
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7.6.7 Remove bolts from the connecting rods as shown in (Figure 19). Remove Connecting rod caps and review its
position to make sure to re-install in the same order.

Figure 19.- Connecting Rod Removal.

7.6.8 Push all three connecting rods fully towards the crank case bores (This action will allow for crankshaft to be
pulled out).

7.6.9 Turn the crankcase on its side as shown in (Figure 23)

7.6.10 If the pump is not fitted with a bearing lock nut then proceed as follows. Detach the end cap bolts from drive
end and withdraw the end cap and associated parts. Ensure that the crankshaft is supported well during this
process to prevent movement. The bearings are kept attached to the crankshaft. Note the positions of these
items for re-assembly.

Figure 20.- Bearing Cap Removal

7.6.11 If the pump is fitted with a bearing lock nut then then proceed as follows. Un-screw the locking nut (Figure
21). Then unscrew the Bearing carrier to remove it along with the bearing outer race and expose the rest of
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bearing and shaft (Figure 22). Detach the end cap bolts from power frame and withdraw the end cap and
associated parts. At this point the crankshaft is able to be pulled out vertically.

Figure 21.- Lock Nut removal.

Figure 22.- Bearing Housing removal.

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Figure 23.- Crank shaft Removal

7.6.12 The crankshaft can then be removed by lifting it out of the crankcase vertically. The use of a lifting lug
threaded to the tip of the crankshaft shall be mandatory (Figure 23).

7.6.13 If required the Connecting Rod / Cross-Head / Distance piece assemblies may be withdrawn.

7.6.14 To separate the connecting rod from the cross head the wrist pin must be removed. The wrist pin is secured
by a bolt as shown in (Figure 24). Remove this bolt and then using a suitable sized punch and hammer push
the wrist pin through. On re-assembly align the pinholes in the connecting rod and crosshead, replace the pin
and then secure the pin with the bolt.
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Figure 24.- Connecting rod/Cross Head Disassembly.

7.6.15 Clean all parts and check all parts for wear. Repair or replace were necessary. Contact Ruhrpumpen UK for
spare parts if necessary.

7.6.16 Re-assemble, in reverse order, taking care to replace in the same positions as removed. Take care to maintain
the crankshaft bearing shimming issued in the same position as removed. Tighten the connecting rod bolts
to a value of 20 NM and secure them using wire locking procedure and locktite on threads to ensure they will
never become loose during operation.

Note: Cap/conn rod bolts SHOULD be 12.9 class.

Note: Always apply lubricant (locktite 222) when applying torque to the bolts.

7.7 Recommended Lubricants for RDPL models (to Specification API CE/SF)

Applications with normal running temperatures:

• Shell Rimula X 15W/40
• Esso HGX Plus 15W/40
• BP Vanellus 15W/40 C3 Multi-grade
• Elf Tecnic Super 15W/40

Or any other 15W/40 lubricant meeting the requirements of Specification API CE/SF

Applications with running temperatures between 100 and 120 °C:

• BP Vanellus M20/50.

Applications with running temperatures greater than 120°C - Contact Ruhrpumpen UK Ltd Engineering Department.

Refer to lubrication schedule for more information.

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Lubricant quantities are listed on the table below:

Oil Volume [Litres]

RDPL-50 11
RDPL-70 -
RDPL-100 -
RDPL-150 108
RDPL-200 240
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7.8 Stuffing Box

7.8.1 Ruhrpumpen UK Ltd use two basic configurations of Stuffing box sealing stack. The two main types of rings
used are braided type packing (Figure 25) and chevron type packing (Figure 26).

Figure 25.- Stuffing box with braided packing.

Figure 26.- Stuffing Box with chevron Packing.

Please see the unique drawings and parts list in the IOM pack for the Stuffing box supplied with your order.
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7.8.2 The RDPL stuffing box design is made in such a way to avoid re-adjustments (Figure 27). RDPL 50 & 70 have
internal stuffing box without the need to adjustments. RDPL 100, 150 & 200 have external stuffing box and
no need to adjustments are required.

Figure 27.- RDPL 50 & 70 Stuffing box

7.8.3 If the sealing stack (packings or chevrons) are required to be replaced the following procedures must be
followed.

7.8.4 Shut down and isolate the pump as per section 6.3.

7.8.5 The packing can be accessed whilst the fluid is still attached.

7.8.6 Remove the front covers as per section 7.3.

7.8.7 Disconnect the plungers from the distance piece. Rotate the crankshaft by hand to make sure the plungers
are pushed forward and keep rotating the crankshaft to make a gap between distance piece and plunger.

7.8.8 Place the pushing tool and start rotating the crankshaft to push the stuffing box/plunger assembly out of the
pump (Figure 28).

Figure 28.- Removal of stuffing box (RDPL 50 & 70)

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Figure 29.- Packing Removal

7.8.9 Once the stuffing box is outside the pump, on a work bench and aided with a bench screw to support the
stuffing box cartridge proceed to remove any remaining packing (Figure 29). First push out the plunger, then
unscrew the two parts of the stuffing box to get access to the packing/chevrons sealing stack. Once the two
body components of the stuffing box are apart, easily can remove the sealing stack.

7.8.10 Inspect the plungers, if damaged or scored the plungers must be replaced.

7.8.11 Re-build stuffing box in the reverse order.

NOTE: Take care not to damage the Plungers during the assembly/disassembly process.

7.8.12 Re-assemble pump and run packing's in as per initial start-up procedure.
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7.9 Fault Finding

SYMPTOM:
Incorrect pressure or flow from pump

POSSIBLE CAUSE REMEDY

No liquid in reservoir or tank. Ensure lines are connected and valves are open.

Inlet line valve closed crankshaft is not turning. Ensure lines are connected and fill tank check for power
to drive and drive connections.

Inlet strainer is totally clogged with debris. Clean or replace strainer.

Pump speed is too low. Check belt tightness or power to motor.
Pump speed it too fast. Correct drive speed.
Relief valve improperly adjusted or worn. Check relief valve and adjust setting.
Pump not filling. Prime pump. Increase suction pressure. Allow pump to
operate at low pressure through a bypass valve.

Excessive leakage from pump seals. Insufficient system Adjust or replace packing or damaged parts. Check
back pressure. Worn valves. Pump valve stuck open. system. Inspect valves and repair or replace.

Gas entrapment or air leaking into pump. Purge gas/air. Check pipe and pump seals.
Capacity of booster pump is less than displacement of Use larger booster pump.
power pump.

SYMPTOM:
Pump runs rough, knocks or is experiencing high levels of vibration

POSSIBLE CAUSE REMEDY

Pump not filling. Prime all chambers, Increase suction pressure.
Pump cavitation. Increase suction size or NPSH.
Insufficient NPSHa. Provide more NPSHa.
Excessive acceleration head in suction line. Install suction stabilizer.
Pulsation dampener inadequately charged. Charge to correct pressure (typically 80% of line
pressure – check the dampener IOM).
By-pass or relief is piped back to suction. Pipe back to reservoir (tank).
Inlet line too long or too small in diameter. Increase suction pipe size.
Air leaks in suction line or fittings. Correct installation to stop leaks.
Vortex in tank near inlet pipe opening. Increase submergence or baffle to stop vortex.
Air entering booster pump. Correct installation of booster pump.
Broken or weak valve spring. Replace valve spring.
Valve damaged. Repair/replace valve.
Loose plunger, piston, or rod. Tighten loose components.
Low oil level in power end. Fill to proper level.
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Excessive main bearing clearance. Adjust end-play.

Worn wrist pin. Replace worn components.
Pump running backward. Correct rotation.
Loose bushes (v-belt drive). Tighten loose components.
Worn packing allows air ingress. Replace packing.
Excessive pressure variation in discharge. Install discharge pulsation dampener.
Piping inadequately supported. Install supports at proper locations.
Excessive short-radius elbow or tee junctions. Correct installation to minimize turns and short-radius
fittings.
Water in Power End crankcase. Drain. Refill with clean oil.

SYMPTOM:
Rapid suction pressure fluctuation

POSSIBLE CAUSE REMEDY

Pump cavitation. Increase suction size or NPSH.
Air is entering suction line. Correct installation to stop leaks.

SYMPTOM:
Pump requires excessive power

POSSIBLE CAUSE REMEDY

Discharge pressure too high. Reduce system back-pressure or relief valve.

Speed too high. Reduce speed.

Packing too tight. Loosen gland nut.
Misaligned coupling. Correct alignment.
Belts too tight. Correctly adjust belt tension.
Power end bearings too tight. Increase end-play.
Low motor voltage. Supply correct voltage.

SYMPTOM:
Power end overheats (above 85°C)

POSSIBLE CAUSE REMEDY

Discharge and/or suction pressure too high. Reduce pressure or reduce plunger size.
Oil level too high or too low. Adjust to correct oil level.
Contaminated power end oil. Refill with clean oil and eliminate contamination.
Incorrect oil viscosity or grade. Fill with correct oil.
Misaligned coupling. Correct alignment.
Belts too tight. Correctly adjust belt tension.
Pump running backward. Correct rotation.
Pump located too close to heat source. Remove heat source or install crank case cooler.
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Worn or damaged power end bearings. Replace damaged bearings.

Tight main bearings. Correct clearance.
Pump speed too low. Increase speed.

SYMPTOM:
Crankshaft jerks or starts and stops rotation

POSSIBLE CAUSE REMEDY

Drive belts loose and slipping (if equipped). Correctly adjust belt tension.
System relief valve pressure set too high. Reduce relief valve pressure setting.
Discharge line blocked or partially blocked. Clear obstructions from piping system.

SYMPTOM:
Fluid leaking from pump

POSSIBLE CAUSE REMEDY

Packing leaking. Replace packing.
Fluid cylinder bolts not properly tightened. Properly tighten and torque bolts.
Fluid head O-rings damaged. Replace damaged O-rings.

SYMPTOM:
Reduced valve life

POSSIBLE CAUSE REMEDY

Highly abrasive particles in fluid. Install strainer or filter.
Cavitation damage. Correct problem and replace damaged valves.
Air leaking into suction line or packing. Correct problem and replace damaged valves.
Suction inlet insufficiently submerged. Increase submergence or baffle to stop vortex.
Relief valve or bypass piped to suction. Pipe back to reservoir tank.
Valve damaged by improper installation. Replace damaged components.

SYMPTOM:
Reduced packing life

POSSIBLE CAUSE REMEDY

Highly abrasive particles in fluid. Install strainer or filter.
Incorrect packing for fluid type. Change to correct packing.
Inadequate packing lubrication. Increase lubrication rate and replace packing.
Pump was run dry for extended time. Correct problem and replace packing.
Gland nut too tight. Properly adjust gland nut.
Gland nut too loose. Properly adjust gland nut.
Too much packing in box. Correct installation problem.
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SYMPTOM:
Broken crankshaft or connecting rod

POSSIBLE CAUSE REMEDY

Discharge pressure too high. Reduce system back pressure or relief valve.
Suction pressure too high. Reduce suction pressure or plunger diameter.
Fluid freezing in fluid end. Change procedure to drain fluid when cold.
Hydraulic shock due to cavitation. Correct piping system problems.

SYMPTOM:
Excessive wear of Power End parts
POSSIBLE CAUSE REMEDY
Poor lubrication. Replace oil as recommended instructions. Keep oil
clean and at correct temperature. Be sure oil is reaching
all bearings.
Liquid in Power End. Drain Power End. Check stuffing box and filler breather
for damage or wear.

These notes are a guide only. Contact Ruhrpumpen UK Ltd for confirmation or advice (see section 4.3 for details).
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8 APPENDIX
8.1 Glossary

Auxiliary Equipment
Other items either attached or packed with the pump, i.e gear box or pulsation dampers.

NPSH (Net Positive Suction Head)

The required NPSH by a pump (NPSHR) is the minimum pressure the suction line has to supply without causing the
media to boil/cavitate within the pump. The available NPSH (NPSHA) should be grater then the NPSHR of the pump.
Many factors can influence the NPSH of a suction line and ideally a pump should be within 1.5 meters of a tank holding
6-10 times the capacity of the pump suction. All sharp bends and pipe reductions should be avoided as much as
possible. Contact Ruhrpumpen UK Ltd for advice (see section 4.3 for details).

Cavitation
The formation of vapor bubbles in a flowing liquid in a region where the pressure of the liquid falls below its vapor
pressure. The bubbles or cavities will collapse when they pass into the higher regions of pressure, causing noise,
vibration, and damage to many of the components. Cavitation will be formed on the suction stroke only. The main
cause is the NPSHA is lower than the NPSHR. Cavitation can generate large forces capable of causing serious damage
to pumps and must be avoided at all cost. Other signs will be loss of capacity, pressure and efficiency.

Acceleration Head
Head loss in a system due to resisting flow fluctuation from the pump. This depends on the mass of the liquid that has
to follow the variations in velocity from the pump (the flow fluctuations).
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8.2 Appendix B - Order Form for Spare Parts

FAX / E-MAIL :

ADDRESS :

Your order will only be dealt if this order form has been correctly completed and signed

Order date:

Your Order Number:

Pump type:

Execution:

Quantity Pos. Nr. Part Article per pump

Delivery address: Invoicing address:

Ordered by: Signature: Telephone:

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NOTES:
Please note, the following can invalidate warranty:

- Use of non-genuine Ruhrpumpen UK Ltd parts for maintenance and repairs.

- Servicing or repairs conducted by non Ruhrpumpen UK Ltd personnel during warranty period.

The information contained in these documents is subject to change without notice.

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8.3 Appendix C – Commissioning and start-up checklist

Field service description / Field activities (FA) for project / offer:

RP Project number:
Customer:
List of units (Tag number):
Commissioning Check-list

Items of fieldwork (TO DO):

N/A? Customer RP

Visual inspection for damages and completeness

1
according to Packing list.

2 Lifting tool supplied.

3 Coupling alignment.

4 Control installation (hardware, elect.).

5 Ensure pulsation dampeners have the correct pre- charge.

Ensure PSV is correctly installed and is working properly with

6
no restrictions.

7 All isolation valves on suction and discharge pipe open.

8 Check filters cleanliness (if provided).

9 Belt drives tension checked (if provided).

10 Unloader valves on “off load” condition (if provided).

Crank case filled with the correct oil to the centre of the sight
11
glass provided.

Gear box is filled with the correct oil to the right level (refer
12
to gearbox data sheet or IOM provided)

13 Check lubrication system is primed (if provided).

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Rotate the pump a couple of revolutions by hand before

14
coupling it.

15 Suction Line primed.

16 Purge the fluid head with the bleed valves provided.

Install coupling and start motor for a couple of seconds to

17 make sure rotation. (Motor rotation direction and speed
check).

18 Free test motor (RP Supervised)

19 Pump operating to correct flow and pressure

Final Mechanical system check (vibrations, temperature,

20
running at least 4 hr)