hydraulic pressure booster (hpb™)
Contents
1. Figure 34 Positioning Casing for Assembly NOTE The groove in the thrust bearing must be facing BEARING upward towards the tool shoulder INSTALLATION GROOVE IN THRUST 5 Place the thrust bearing on the rotor removal tool BEARING MUST BE i FACING UP and lubricate the thrust bearing O ring Figure 35 Figure 35 Installing Thrust Bearing on Rotor Removal Tool 6 Install the thrust bearing into the casing using hand pressure until the thrust bearing seats against the booster casing Figure 36 Figure 36 Installing Thrust Bearing 24 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 FEDCO HPB Series Booster Overhaul cont 7 Install the rotor filter into the impeller end of the rotor Figure 37 NOTE The rotor filter can be easily damaged during removal and installation Always have an additional rotor filter on hand in case of damage Figure 37 Installing Rotor Filter 8 Lubricate the center bearing O rings and install the center bearing halves onto the rotor shaft Secure the center bearing halves with the O rings Figure 38 Figure 38 Assembling Center Bearing and Rotor 9 Rotate the rotor in both directions while holding the center bearing stationary the rotor should rotate smoothly with no drag Figure 39 Figure 39 Inspecting Rotor Assembly Rotation 25 Copyright 2009 Fluid Equipment Development Company Version HPB 12. GENERAL NOTES Overhauled by Telephone Fax E mail Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 35
3. 8 H0O120 RTK 8 H0030 RRK Rotor Removal Tool Kit Rotor removal tool 8 H0O120 TBK 8 H0030 RTK Rotor Kit Dynamically balanced custom rotor 8 H0030 TBK Thrust Bearing Kit Thrust bearing O ring kit HPB 160 HPB 40 aoe 3 are 8 H0160 CBK Center Bearing Kit Center bearing O ring kit can Number 8 HO160 DFK Diffuser Kit Diffuser and O ring kit 8 H0040 CBK Center Beating Kit Center bearing O ring Kit 8 H0160 OHK Overhaul Kit Rotor diffuser center amp thrust 8 H0040 DFK Diffuser Kit Diffuser and O ring kit bearing o ring kit 8 H0040 OHK Overhaul Kit Rotor diffuser center amp thrust 8 H0160 ORK O ring Kit Complete set of o rings bearing o ring kit 8 H0160 RRK Rotor Removal Tool Kit Rotor removal tool 8 H0040 ORK _ O ring Kit Complete set of o rings 8 HO160 RTK Rotor Kit Dynamically balanced custom rotor 8 H0040 RRK Rotor Removal Tool Kit Rotor removal tool 8 H0160 TBK Thrust Bearing Kit Thrust bearing O ring kit 8 H0040 RTK Rotor Kit Dynamically balanced custom rotor 8 H0040 TBK Thrust Bearing Kit Thrust bearing O ring kit Center Bearing Kit Center bearing O ring kit Diffuser Kit Diffuser and O ring kit Overhaul Kit Rotor diffuser center amp thrust bearing o ring kit O ring Kit Complete set of o rings Rotor Removal Tool Kit Rotor removal tool Rotor Kit Dynamically balanced custom rotor Thrust Bearing Kit Thrust bearing O ring kit Copyright 2009 Fluid Equipment
4. Inspect the thrust bearing and wear ring for signs of excessive wear and replace as necessary Rotor Inspect the rotor and turbine impellers for any cracks or signs of fatigue Used compressed air to ensure all rotor thrust passages are clear Figure 39 These passages are responsible for maintaining proper pressure against the thrust bearing and rotor end play If the thrust passages are blocked and cannot be cleaned contact a Fedco representative Figure 30 Rotor Thrust Passages 22 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Booster Overhaul cont Assembly APPLY LUBRICANT 1 Apply system compliant anti seize compound to the valve stem threads and apply lubricant to the valve stem O rings Figure 31 APPLY SYSTEM COMPLIANT ANTI SEIZE COMPOUND Figure 31 Applying Anti Seize and Lubricant 2 Rotate the auxiliary nozzle valve to the right clockwise and install the auxiliary nozzle valve with retaining plate Figure 32 Figure 32 Installing Auxiliary Nozzle Valve 3 Install the two 2 retaining plate screws Figure 33 Figure 33 Installing Retaining Plate Screws Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 23 HPB Series Booster Overhaul cont 4 Position the casing in an upright position with the end cap opening of the casing facing upward Figure 34
5. 1 Last revised 02 2012 FEDCO HPB Series Booster Overhaul cont 10 Install the rotor assembly into the casing with the turbine impeller going in first Figure 40 NOTE Make sure the rotor is completely seated against the thrust bearing Figure 40 Installing Rotor into Casing 8 NOTE Use even pressure on all sides to properly APPLY EQUAL PRESSURE TO BOTH seat the center bearing and prevent damage to the SIDES OF THE CENTER BEARING center bearing O rings 11 Using suitable tools and hand pressure seat the center bearing in the casing Figure 41 Figure 41 Seating Center Bearing 12 Locate the diffuser ring anti rotation pin in the end cap and note the cavity in the diffuser ring Figure 42 Figure 42 Locating Diffuser Ring Anti Rotation Pin 26 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Booster Overhaul cont 13 Lubricate the diffuser ring and end cap O rings and install the diffuser ring into the end cap Figure 43 Figure 43 Assembling Diffuser Ring and End Cap 14 Install the end cap and diffuser ring into the booster casing Figure 44 15 Secure the end cap with the end cap bolts Figure 45 Tighten the end cap bolts in a star pattern according to the size bolt used in the chart below rHPe 10 120x75 6 75 66Lbin mal aaner 6 Nm otot mea ae 4ex114 6 12Nm oton Hesa 143x104 6 24Nm 1
6. Development Company Version HPB 1 1 Last revised 02 2012 29 FEDCO HPB Series Specifications cont Fastener Torque Specifications Item Metric Standard End cap bolts HPB 10 66 Lb in End cap bolts HPB 20 amp 30 9 Lb ft End cap bolts HPB 160 Lubricants and Compounds Lubricant Standard Glycerine or ASTM D1257 fresh water with soap Anti seize compound Compliant with specific system Foundation Specifications Refer to Foundation Specifications earlier in this manual Maintenance By following the schedule of preventive maintenance presented below the HPB will deliver years of trouble free performance One 1 day after commissioning 1 Fill out and submit all warranty documentation to FEDCO Six 6 months after commissioning 1 Inspect for leaks damaged gaskets and condition of all pipe couplings 2 Wipe booster and baseplate with a clean damp cloth Twelve 12 months after commissioning 1 Inspect for leaks damaged gaskets and condition of all pipe couplings 2 Wipe booster and baseplate with a clean damp cloth Annually 1 Inspect for leaks damaged gaskets and condition of all pipe couplings 2 Wipe booster and baseplate with a clean damp cloth Five 5 Years 1 Annual maintenance per above 2 Disassemble booster for detailed inspection refer to Booster Overhaul 30 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB
7. all piping carefully before installing couplings e DO NOT use couplings to force piping to align Make sure all seals seat correctly inside the coupling e f piping or seals are not aligned correctly leaking may occur under pressure GROOVED COUPLING Se mm N A S E C COUPLING SEAL Figure 12 Typical Grooved Coupling 11 FEDCO HPB Series Installation Procedures cont Inlet Piping Keep the inlet pipe free of high points which could trap air and could disrupt booster operating Pressure gages are recommended to allow measurement of booster inlet pressure Outlet Piping All piping connected to the booster should have removable sections such as a spool piece or elbow to allow for booster service Figure 13 FEED OUTLET BRINE INLET FEED INLET BRINE OUTLET MINIMUM LENGTH OF REMOVABLE SECTIONS MUST BE PIPE DIA X 3 Figure 13 Removable Sections for Booster Service 12 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Installation Procedures cont Recommended Instrumentation and Operation For safe booster operation a pressure switch should be installed at the MSS feed pump inlet to prevent pump operation if the feed pressure to the pump is below minimum Figure 14 Pressure gages should be installed at all four points going into and out of the HPB to monitor booster performance Refer to the rear of the HPB startu
8. 8t messi 1213X112 8 24Nm 18Lb t rHPe 00 se t1x194 8 45Nm 33 Lot ET az 8 76Nm 561i mee maan 8 147 N m 109 Lbs 16 Reconnect inlet and outlet piping as necessary and prime booster Refer to Preparation for Booster Start Figure 45 Installing End Cap Bolts Up earlier in this manual Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 27 FEDCO HPB Series Specifications cont Components Exploded Views Booster Components Wem Description Casing Sd Diffuser O ring Center bearing O rings 2 Req d Auxiliary nozzle valve retaining plate Retaining plate screws Rotor filter Auxiliary nozzle valve O rings Diffuser ring Auxiliary nozzle valve Figure 46 Booster Components Ordering Parts To order a component or service kit simply contact a FEDCO representative at ATTN Field Service Department Additional Contact Information FEDCO Tel 734 241 3935 800 Ternes Drive Fax 134 241 5173 Monroe MI 48162 Web site www fedco usa com USA Choose the Service and Support tab 28 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Specifications cont 4 5 years of service A complete disassembly cleaning and inspection of all booster components is recommended An overhaul parts kit can obtained by contacting FEDCO Service Parts Kits HPB 10 Part Number Description Part Nu
9. AUTION If the feed pump and motor are not rated for operation at full membrane pressure a second pressure relief valve must be installed to prevent motor and feed pump overload if the HPB becomes inoperative Figure 10 MEMBRANE ARRAY PERMEATE PRODUCT RELIEF VALVE LOCATION SECOND RELIEF VALVE LOCATION HIGH IF MOTOR AND PUMP ARE NOT PRESSURE HIGH PRESSURE RATED FOR FULL MEMBRANE FEED BRINE STREAM PRESSURE OPERATION e al H i B BRINE OUTLET g J PULSATION DAMPENER LOCATION N HIGH PRESSURE DISPLACEMENT FEED PUMP Figure 10 Positive Displacement Feed Pump Configuration 10 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series Installation Procedures cont Booster Piping Connections Piping Alignment e Accurate alignment and support of all piping con nected to the booster is critical Figure 11 e Any movement occurring at the inlet or discharge booster connections may cause booster misalign ment and stress over time e Do not force any misaligned pipes to connect to the booster discharge or inlet YES Figure 11 Proper Piping Alignment Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 Pipe Couplings FEDCO e Use only grooved type couplings at all booster and pipe connections Figure 12 e Follow all manufacturer installation and torque speci fications e Align
10. HOCK ELECTROCUTION OR DEATH if instructions are not followed properly PUNCTURE Hazards which are NOT IMMEDIATELY ACCESSIBLE and can HAZARD RESULT IN SEVERE PERSONAL INJURY OR DEATH if instruc tions are not followed properly Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 5 FEDCO Installation Procedures cont AX WARNING All booster and safety precautions must be followed to prevent physical injury to the operator It is illegal to oper ate the equipment in an EU member state which requires CE compliance if the manual is not written in that state s language If a translation is needed please contact a FEDCO representative A hydraulic pressure booster is a pressure generating de vice with rotating parts that can be hazardous Any device containing generated pressure can rupture explode or discharge its contents if it is sufficiently over pressurized and may possibly result in personal injury property dam age environmental damage and death All necessary pre cautions must be exercised to insure over pressurization does not occur FEDCO will not accept responsibility for physical injury damage or delays caused by a failure to observe the instructions in this manual AX WARNING Installation operation or maintenance of the booster unit In any manner which is not covered in this manual could cause damage to the equipment serious injury or death This includes any mo
11. HPB Series z FEDCO HYDRAULIC PRESSURE BOOSTER HPB Installation Operation Maintenance amp Service Manual Models HPB 10 e HPB 20 e HPB 30 e HPB 40 HPB 60 e HPB 80 e HPB 120 e HPB 160 WWW fedco usa com Model HPB 80 WT 43 2 kgs S N 3601 Register the product warranty at the time of installation by completing the Warranty Registration Form at the rear of this manual and fax or e mail it to FEDCO Warranty Registration should be sent to ATTN Field Service Department Additional Contact Information FEDCO Tel 734 241 3935 800 Ternes Drive Fax 134 241 5173 Monroe MI 48162 Web site www fedco usa com USA Choose the Service and Support tab l IMPORTANT FOR REASONS OF SAFETY AND MAINTENANCE ONE COPY OF THIS MANUAL MUST REMAIN WITH THE EQUIPMENT AT ALL TIMES Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 1 FEDCO HPB Series Table of Contents Theory and Operation ccccccsececeeeeeeeseenes 3 Basic Troubleshooting cece 15 HPB External Components onsenoenonnennennnn 3 Visual Inspection eee eeeeee ees 15 LR le 4 Troubleshooting Chart aa aannaanaanaan 16 Installation Procedures cccccecceeeceeeeeeeeeees 5 Booster Overhaul sonsesseneenerrereernennn 17 Warnings and Safety Precautions 5 Disassembly ccccecceccseeeeeteeteee cease 18 User Health and Safety 00n00n00nann
12. Series FEDCO Service Policy Return Authorization Number RAN Please contact a FEDCO representative before returning any equipment You must have a Return Authorization Number RAN issued by FEDCO before we can accept any parts All returned parts must be shipped prepaid to FEDCO with the RAN clearly marked on the package We need this number to ensure proper handling of the returned parts and supply of new parts if needed Repair by FEDCO on equipment that is out of warranty will be warranted for three 3 months Ask FEDCO for details of the repair warranty Parts will be replaced in accordance with the FEDCO warranty Use the following address to return parts ATTN Field Service Department Additional Contact Information FEDCO Tel 734 241 3935 800 Ternes Drive Fax 134 241 5173 Monroe MI 48162 Web site www fedco usa com USA Choose the Service and Support tab Procedure How to Return Parts to FEDCO 1 Provide FEDCO with the following information e Serial number of unit e Description of why parts are being returned 2 FEDCO will provide a Return Authorization Number 3 Pack the unit in the original shipping crate or other suitable crate and clearly mark the Return Authorization Number on the outside of the crate 4 Send unit freight prepaid to FEDCO at the above address Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 34 FEDCO HPB Series Service Policy cont Warran
13. annannann 6 Cleaning E 22 In The Work Area 6 Inspechon ne 22 Booster Installation Heourements 6 PRS SE MDIY ee 23 Inspection of Unit Upon Receipt a an AE ee Le E 28 Booster Storage Requirements onnennan 6 Components Exploded Views 28 Pre Installation 2 0 0 0 cceccccceecseeseeeeeeeeeseeseees 6 Ordering Kate segedgegeeggedresgeegegeed een 28 Lifting and Handling eannannannannnannnnnnnnennnnnno T Recommended Spare Parts List 29 Baseplate Installation cccccecceceeeeeeeeees 8 Fastener Specifications cc 30 Foundation Specifications cccseeeeeeeee 8 Lubricants and Compounds 30 Installation Configurations cccceceeeeeeees 9 Foundation Specifications 6 30 Booster Piping Connections 00n000s000n 11 Maintenance AE 30 Recommended Instrumentation Service EEN eebe 31 and Operation ccccccseccceeeceeeeeeeeeee es 13 Return Authorization Number RAN 31 Upstream Filtration cccceecsecseeeeeeeeeeees 14 Eegen 32 Preparation for Booster Start Up 14 Warranty Registration Form 33 Start Up Precautions cccceceeeeeeeeeeeees 14 Start Up Record 34 Start Up Checker 14 Overhaul Record 35 Booster Slat UDP wcsciendedessdunndeueesenestersintiendtiens 14 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last rev
14. dification to the equipment or the use of parts not provided by FEDCO If there is a ques tion regarding the intended use of the equipment please contact a FEDCO representative before proceeding CAUTION This manual clearly identifies accepted methods for safe disassembly These methods must be strictly adhered to AX WARNING Do not use the booster equipment for a different application than originally specified without the approval of a FEDCO representative Ch WARNING NEVER operate the booster equipment e below the minimum flow rate e when dry e without priming e without proper guards and safety devices installed e with the discharge valve closed e with the suction valve closed HPB Series User Health and Safety Safety Equipment should be used in accordance with company regulations The following safety equipment should be used within the work area e Helmet e Safety Glasses with shields or goggles e Safety Shoes e Protective Gloves e Hearing Protection is recommended e Follow safe lifting methods to avoid personal injury In the Work Area e Always keep the work area clean and dry e Avoid all electrical dangers Be aware of risks from electric shock or arc flash hazards e Utilize adequate lifting equipment and methods Booster Installation Requirements A rigid mounting surface is required for the hydraulic booster assembly in order to prolong the life of critical components Mount
15. ease Permeate Flow Open throttle valve and close auxiliary nozzle valve or increase VFD frequency output Feed Pump Type Centrifugal Positive Displacement Open auxiliary nozzle valve Close auxiliary nozzle valve Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Basic Troubleshooting If the booster does not operate properly refer to the fol The amount of pressure boost depends on many factors lowing troubleshooting charts as a guide to determining including the concern and identifying the potential cause If after consulting the troubleshooting charts the cause is still e brine flow undefined contact FEDCO technical support by e mail e brine pressure techsupport fedco usa com telephone or FAX FEDCO e feed flow will give you easy step by step instructions on how to e auxiliary nozzle valve setting proceed Visual Inspection If the feed pressure boost is not as specified record the pressures and contact FEDCO Technical Support Make sure all items are accounted for on the start up check list Inspect all high pressure booster piping Inspect the booster mountings for signs of any movement or vibration Inspect pressure gauges switches and all other instrumentation for proper operation Record any unusual readings Sufficient Output Pressure Booster Leaking Air Vented from System Sufficient Input Pressure D
16. el baseplate Each provides a good mounting surface for the booster Although each baseplate is precisely manufactured it requires a solid foundation such as a concrete pad or rigid steel substruc ture The baseplate should be installed first to avoid distortion which may occur due to uneven floors or substructure Figure 8 If the booster is installed within a container it must be mounted on a rigid steel substructure that will not distort under the weight of the equipment or from torque reaction forces during booster operation HPB 10 through HPB 60 HPB 80 through HPB 160 Figure 7 Baseplate Designs Foundation Specifications A concrete foundation is recommended for all HPB installations Concrete provides good support and good vibration absorption The foundation should have a mass that is 50 more than the total weight of the equipment and its perim eter should extend at least 6 inches 15 cm on each side from the booster Make sure the concrete is completely dry and level before installing any machinery Make sure anchor bolts and shims are properly sized and installed in cases of uneven surfaces Figure 9 PROPER SHIM S ees PLACEMENT le C 2 ANCHOR BOLTS ITD a 024 WK CONCRETE a ek o FaN SCH N FOUNDATION WS A Figure 8 Proper Shimming 8 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Installation Procedures cont Installation Configurat
17. ided in through the brine outlet and gently tap the rotor assembly loose Figure 22 ROTOR REMOVAL TOOL Figure 22 Loosening Rotor Assembly From Case 9 Remove the rotor assembly with the center bearing from the casing Figure 23 Figure 23 Removing Rotor Assembly Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 19 HPB Series FEDCO Booster Overhaul cont 10 Remove the two 2 center bearing O rings and center bearing halves from the rotor Figure 24 Figure 24 Separating Center Bearing From Rotor 11 Remove the rotor filter from the impeller end of the rotor Figure 25 NOTE The rotor filter can be easily damaged during removal and installation Always have an additional rotor filter on hand in case of damage Figure 25 Removing Rotor Filter 12 Insert the rotor removal tool provided into the he th ing ROTOR oA and gently tap the thrust bearing loose REMOVAL l TOOL Figure 26 Loosening Thrust Bearing from booster Casing Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 20 HPB Series FEDCO Booster Overhaul cont 13 Remove the thrust bearing with O ring from the booster casing Figure 27 Figure 27 Removing Thrust Bearing 14 Remove the two 2 retaining plate screws Figure 28 Figure 28 Removing Retaining Plate Screws 15 Rotate the auxiliary no
18. ing surfaces constructed of wood or other non rigid materials are NOT acceptable as they may distort the booster casing resulting in misalignment All anchoring fasteners used should meet or exceed manufacturers specifications All assemblies must be mounted on one of three types of substrates e concrete foundation e optional baseplate e container with a suitable steel substructure Inspection of Unit Upon Receipt e Review the contents of the packing list to make sure all components have been included e Inspect all components for signs of damage which may have occurred during shipping e If damage is present or if the contents are incomplete please contact your shipping company or a FEDCO representative before proceeding Booster Storage Requirements The HPB unit must be protected from sand grit and other foreign matter For long term storage the booster and all other components should remain in their original un opened crate Both the unit and its actuator if equipped are wrapped and sealed in water humidity proof foil with desiccant bags added The unit may be stored at a temperature of 50 C or less and or a humidity level or 75 or less for an indefinite period of time Do not remove the protective covers until ready to install Pre Installation In some instances the HPB is shipped pre attached to its MSS high pressure feed pump Usually the HPB unit will be shipped in its own crate The crate also contains a r
19. ions High Pressure Centrifugal Feed Pumps In some cases a throttle valve is needed to regulate feed pump discharge pressure The throttle valve should be located between the feed pump and the HPB feed inlet Figure 9 The minimum distance between the high pressure cetrifugal feed pump and the throttle valve can be calculated by multiplying the pipe diameter by 3 If the high pressure feed pump speed is controlled by a variable frequency drive VFD a throttle valve is not required MEMBRANE ARRAY PERMEATE PRODUCT HIGH PRESSURE FEED HIGH PRESSURE THROTTLE VALVE BRINE STREAM LOCATION a a a H LI BRINE OUTLET gt MINIMUM DISTANCE BETWEEN HIGH PRESSURE PUMP AND THROTTLE VALVE IS PIPE DIA X 3 UU EE PUMP Figure 9 Centrifugal Feed Pump Configuration Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 Q FEDCO HPB Series Installation Procedures cont Positive Displacement DP High Pressure Feed Pumps With a positive displacement PD feed pump configuration DO NOT use a throttle valve A pulsation dampener is required and should be installed between the outlet of the feed pump and the HPB feed pump inlet Figure 10 The pulsation dampener should be adjusted according to the feed pump discharge pressure with the HPB in operation A pressure relief valve is also necessary and should be installed between the HPB feed outlet and the system membrane inlet C
20. ischarge Restrictions TI _ Loose Mountimngs or eto Signs of Movement SS Inlet Restrictions Inlet Piping Leaks a Figure 16 HPB Basic Visual Inspection Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 15 FEDCO HPB Series BASIC TROUBLESHOOTING Symptom Possible Cause Low or no pressure boost Incorrect feed pump Check feed pump VFD for proper speed speed or direction setting if equipped Check feed pump power supply frequency 50 or 60 Hz Check rotational direction of feed pump motor Low permeate brine Check permeate membrane for brine output pressure restrictions Restriction in inlet or Check feed pump discharge pressure discharge pipes Check position of all auxiliary nozzle valve outlined in the technical proposal Thrust Bearing Inspect the thrust bearing for excessive or unusual wear causing excessive rotor end play Inspect booster for damaged O rings Booster vibration or noise Booster cavitation Check feed pump discharge pressure during operation Check for excessive flow rate Purge air from all piping Rotor Check rotor thrust passages for debris or restrictions 16 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series Booster Overhaul Item Description Casing 18 Diffuser O ring Center bearing O rings 2 Req d 13 Auxiliary nozzle valve re
21. ised 02 2012 HPB Series Theory and Operation HPB External Components The Hydraulic Pressure Booster or HPB is designed to provide brine energy recovery in reverse osmosis RO systems The HPB is energized by the high pres sure brine stream which causes the HPB to generate a large pressure boost in the feed stream independent of the high pressure feed pump Typical HPB Booster External Components 5 Mounting feo SSSC sS Figure 1 HPB Booster External Components Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 FEDCO FEDCO HPB Series Theory and Operation cont HPB Energy Recovery Flow The HPB is typically installed between the high pres The HPB recovers the pressure energy and discharges sure feed pump and the membrane Figure 2 The feed the brine at low pressure for disposal The HPB passes through the pretreatment system and then passes through the feed pump which raises the feed pressure e does not require a brine disposal pump The pressurized feed passes through the HPB which e gravity flow piping as the brine can be discharged provides an additional pressure increase before passing to against a back pressure the membrane The membrane produces a high pressure reduces feed pump energy consumption brine stream which is directed back to the HPB e allows use of a smaller feed pump smaller motor smaller motor sta
22. mber 8 H0010 CBK Center Bearing Kit Center bearing kit reduced 8 HO060 CBK we BEER 8 HO060 OHK Overhaul Kit Rotor diffuser center amp thrust 8 H0010 OHK Overhaul Kit Rotor diffuser center amp thrust bearing o ring kit HPB 80 HPB 20 pon Manet 8 H0080 CBK Center Bearing Kit Center bearing O ring kit 8 HO020 CBK Center Bearing Kit Center bearing kit reduced 8 H0080 DEK Diffuser Kit Diffuser and O ring kit ID O ring kit Overhaul Kit Rotor diffuser center amp thrust bearing o ring kit 8 H0020 DFK Diffuser Kit Diffuser and O ring kit eee 8 HO0020 OHK Overhaul Kit Rotor diffuser center amp thrust 8 HO080 ORK bearing o ring kit 8 H0020 ORK O ring Kit Complete set of o rings GREEN 8 HO020 RRK Rotor Removal Tool Kit Rotor removal tool overs 8 H0020 RTK Rotor Kit Dynamically balanced custom rotor GE 8 H0020 TBK Thrust Bearing Kit Thrust bearing O ring kit HPB 120 O ring Kit Complete set of o rings Rotor Removal Tool Kit Rotor removal tool Rotor Kit Dynamically balanced custom rotor Thrust Bearing Kit Thrust bearing O ring kit Part Number Description HPB 30 8 H0O120 CBK 8 H0O120 DFK 8 H0030 CBK Center Bearing Kit Center bearing O ring kit 8 H0O120 OHK 8 H0030 DFK Diffuser Kit Diffuser and O ring kit 8 H0030 OHK Overhaul Kit Rotor diffuser center amp thrust 8 H0120 ORK bearing o ring kit 8 H0O120 RRK 8 H0030 ORK O ring Kit Complete set of o rings
23. ons at booster start up DW All anchor bolts tightened to specifications All pipe couplings tightened to specifications Inlet pressure switch if applicable installed System pipes are clean and upstream filtration in place system leak checked and all air vented from system PILI LI LI vu ALL safety devices in place 14 HPB Series Booster Start Up NOTE Use the Start Up Record located in the rear of this manual to record initial operating conditions at booster start up 1 Start the low pressure feed pump and vent the air from the system 2 Verify that there are no leaks in the system Centrifugal Feed Pump 3 Turn the HPB auxiliary nozzle valve to the fully closed position and make sure any by pass or clearing valves are closed 4 If used make sure the throttle valve opening is set at appriximately 50 Positive Displacement Pump 3 Turn the HPB auxiliary nozzle valve to the fully open position 4 Set the pulsation dampener for the expected feed pump discharge pressure 5 Activate the high pressure feed pump 6 Observe any unusual system noise or vibration 7 If a vibration meter is available record a baseline vibration reading at this time 8 Observe and record all pressure and flow readings 9 Adjust system valves and controls as needed to obtain Decrease Permeate Flow Close throttle valve and open auxiliary nozzle valve or decrease VFD frequency output Incr
24. otor removal tool for HPB overhaul service Figure 3 6 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Installation Procedures cont FEDCO Made In USA WAV fedoo usa Gm Model HPB 80 lt a eee eee S N 3601 US Paten eI5961 9980114 Intl Patent Pending Figure 3 Rotor Removal Tool er i Figure 4 HPB Unit Nameplate Lifting and Handling GR p CAUTION Observe all lifting precautions Failure to follow all lifting and handling precautions may result in serious injury Unit weight is listed on the unit nameplate Figure 4 Determine the weight of the unit to select an appropriate lifting method Suitable lifting equipment such as lifting straps should always be used to prevent damage to the equipment Always make sure the lifting straps are properly cinched around the unit Figure 6 HPB Lifting a ZJF G Figure 5 Improper MSS HPB Lifting Points Figure 6 Proper MSS HPB Lifting Points Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 7 FEDCO HPB Series Installation Procedures cont Baseplate Installation Two different baseplate designs are used for HPB models 10 through 160 Figure 7 The baseplate design is depen dant on the size of the booster HPB 20 through HPB 60 uses a one piece high density polymer base HPB 80 through HPB 160 uses a two piece stainless ste
25. p tag for equipment specifications Figure 15 PUMP INLET HIGH PRESSURE PUMP bei bei bi THROTTLE VALVE S i MEMBRANE IF EQUIPPED FLOW METER IF EQUIPPED Figure 14 Recommended Instrumentation gt STARTUP CHECKLIST S N 3601 Duty Point AFTER STARTUP Feed Flow Inlet Pres Disc Pres Feed SG calc RPM NPSHR ACTIVATE WARRANTY Version 2 3 HPB 30 SEE OPERATING INSTRUCTIONS ON BACK Startup Tag Front Startup Tag Rear Figure 15 HPB Startup Tag Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 13 FEDCO Upstream Filtration e The booster must be protected from debris in the feed water such as sand gravel or other particulate matter e A20 micron filter must be installed upstream of the feed pump inlet to protect against foreign matter entering the system e Temporary strainers should be installed after initial start up or repairs to protect the pump and booster from possible debris Preparation for Booster Start Up Start Up Precautions AX WARNING NEVER operate the booster equipment when dry make sure all mounting bolts are tightened to specification and couplings are securly fastened Start Up Check List An additional Start Up Check List is available in the rear of this manual Also use the Start Up Record at the rear of this manual to record initial operating conditi
26. riginal manufacturer s warranty FEDCO shall not be liable for damage or wear to equipment caused by abnormal conditions excessive temperatures and vibration or caused by corrosives abrasives or foreign objects The foregoing warranty is exclusive and in lieu of all other warranties whether expressed or implied including any warranty of merchantability or fitness for any particular purpose In no event shall FEDCO be liable for liable for consequential or incidental damages Declaration of Conformity This product fulfills the obligations of the applicable EU directives The declaration of conformity is a standalone document and can be requested if required from FEDCO or any FEDCO representa tive Register the product warranty at the time of installation by completing the War ranty Registration Form on the following page and sending it to FEDCO 32 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Service Policy cont Warranty Registration Form THIS FORM MUST BE COMPLETED AND RETURNED TO FEDCO TO ACTIVATE YOUR WARRANTY COVERAGE FEDCO will send confirmation of start of warranty coverage Please FAX this page to FEDCO to register your warranty Retain the original for your future information FAX to 734 241 5173 USA or E MAIL www fedco usa com and choose the Service and Support tab Initial Installation Model Serial Installation Date Start
27. rter electrical wiring etc MEMBRANE ARRAY PERMEATE PRODUCT HIGH PRESSURE FEED HIGH PRESSURE BRINE STREAM BRINE OUTLET cs HIGH PRESSURE FEED PUMP Figure 2 Hydraulic Pressure Booster Flow 4 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Installation Procedures Warnings and Safety Precautions Safety practices and precautions for the operation and maintenance of all FEDCO products MUST BE FOLLOWED This information supplements oral or written instructions that may be received Safety MUST be practiced as part of the standard operating procedures for this equipment during any installation and operation To ensure that safe operating and maintenance procedures are followed operators should develop and keep up a program of safety checks and current instructions This manual contains certain operating and maintenance rocedures that involve exposure to potentially hazardous situations The levels of hazardous situations are as follows Hazards which are IMMEDIATELY ACCESSIBLE and capable DANGER of causing SEVERE PERSONAL INJURY OR DEATH WARNING Hazards which are NOT IMMEDIATELY ACCESSIBLE but are capable of causing SEVERE PERSONAL INJURY OR DEATH CAUTION Hazards which are NOT IMMEDIATELY ACCESSIBLE and can cause PERSONAL INJURY ELECTRICAL Hazards which are related to Electrical Components and can HAZARD RESULT IN ELECTRICAL RISKS S
28. taining plate Retaining plate screws Rotor filter Auxiliary nozzle valve O rings Diffuser ring Auxiliary nozzle valve Figure 17 Booster Components Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 FEDCO 17 HPB Series Booster Overhaul cont Disassembly 1 Drain the piping and booster 2 Disconnect inlet and outlet piping as necessary 3 Using suitable lifting equipment as necessary place the booster on a suitable workspace 4 Remove the end cap bolts Figure 18 NOTE The number of end cap bolts will vary depending on model Figure 18 Removing End Cap Bolts 5 Locate the notches on both sides of the end cap and use a Suitable tool to gently pry the end cap from the casing Figure 19 NOTE During end cap removal make sure to keep the end cap square to the booster casing Pull the end cap straight out of the booster casing to prevent damaging the diffuser 6 Remove the end cap with O ring and diffuser ring Figure 20 Figure 20 Removing End cap with Diffuser Ring 18 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Booster Overhaul cont 7 Locate the notches on the end cap and using a suitable tool gently pry the diffuser ring with O ring from the end cap Figure 21 Figure 21 Separating Diffuser Ring From End Cap 8 Insert the rotor removal tool prov
29. ty Fluid Equipment Development Company LLC FEDCO warrants its HPB unit to be free from defects in design materials or workmanship for a period of 18 months from shipment or 12 months from the date of installation of the product whichever occurs first when said product is operated in accordance with written instructions and is installed properly If the HPB unit is altered or repaired without prior approval of FEDCO all warranties are void All equipment provided by FEDCO including pump motors must be installed on a rigid steel support structure and base capable of handling full loads during operation Failure to do so will void warranty All equipment must be installed such that there are no pipe stresses on FEDCO equipment Failure to do so will void warranty If the HPB unit is not installed and aligned as per FEDCO Installation and Operation Manual any subsequent damage to the booster pump and or motor will be excluded from the warranty lf any defects or poor performance occur during the warranty period FEDCO s sole obligation shall be limited to alteration repair or replacement at FEDCO s expense F O B factory of any parts or equipment which upon return to FEDCO and upon FEDCO s examination prove to be defective All parts returned for warranty service must be shipped prepaid and include FEDCO s return authorization number Equipment and accessories not manufactured by FEDCO are warranted only to the extent of and by the o
30. up Date VFD frequency Hz if used Voltage and Hz of power supply Feed Flow Discharge Pressure Comments Installed by Telephone Fax E mail Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 33 FEDCO HPB Series Service Policy cont Start Up Record Start Up Check List TT All anchor bolts tightened to specifications _ All pipe couplings tightened to specifications TT Inlet pressure switch if applicable installed _ System pipes are clean and upstream filtration in place _ System leak checked and all air vented from system _ ALL safety devices in place Installation and Start up Information Start up Date Model Serial Installation Date Installed By Operating Conditions Feed Flow Suction Pressure to Unit Discharge Pressure Drain flow rate high inlet pressure option only VFD frequency Hz if used Voltage and Hz of power supply VFD Amps VFD Amps after 48 hours of running time GENERAL NOTES This report has been filled out by Date 34 Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 HPB Series FEDCO Service Policy cont Overhaul Record Overhaul Date Operating Hours Reason for Overhaul Operating Data Prior to Overhaul Feed Flow Suction Pressure to Unit Discharge Pressure Operating Data After Overhaul Feed Flow Suction Pressure to Unit Discharge Pressure
31. zzle valve to the left counterclockwise and remove the auxiliary nozzle valve with retaining plate Figure 29 Figure 29 Removing Auxiliary Nozzle Valve Copyright 2009 Fluid Equipment Development Company Version HPB 1 1 Last revised 02 2012 21 HL Booster Overhaul cont Cleaning AX WARNING NEVER use petroleum or alcohol based solvents when cleaning booster components Solvents can degrade or damage vital seals and O rings over time Use fresh water with mild soap and rinse all components thoroughly with fresh water before assembly Rotor Clean the rotor with soap and fresh water Rinse thoroughly before use Pay particular attention to the bearing surfaces and thrust passage ports Casing Clean the casing with soap and fresh water and rinse thoroughly Pay particular attention to pipe coupling grooves in inlet and discharge connections Internal Components Clean all internal components with mild soap and fresh water Rinse thoroughly before use Internal components should dried with a with a clean damp cloth before assembly HPB Series Inspection Internal Components Inspect all internal components for signs of excessive wear or damage Pay particular attention to bearing sur faces Replace if necessary Fasteners Inspect all fastener threads for signs of wear or distortion and replace if necessary O Rings Inspect all O rings for cuts or damage and replace as necessary Bearings
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