GARDNER DENVER®
`
`300THD996 Revision A
`January 2005
`
`HD-2250
`
`WELL SERVICING PUMP
`
`OPERATING AND
`SERVICE MANUAL
`
`ECN 1024137
`
`Vulcan
`Ex. 1038
`Page 1 of 44
`
`

`

`HD 2250
`WELL SERVICING PUMP
`
`MAINTAIN PUMP RELIABILITY AND PERFORMANCE WITH
`GENUINE GARDNER DENVER
`PARTS AND SUPPORT SERVICES
`
`Gardner Denver® genuine pump parts are manufactured to design tolerances and are developed for
`optimum dependability. Design and material innovations are the result of years of experience with
`hundreds of different pump applications. Reliability in materials and quality assurance is incorporated
`in our genuine replacement parts.
`
`Your authorized Gardner Denver Sales Office offers all the backup you ll need. The Fort Worth
`Manufacturing Facility maintains a large inventory of genuine parts.
`
`Gardner Denver supports your needs with these services:
`
`1. Trained parts specialists to assist you in selecting the correct replacement parts.
`
`2. Repair and maintenance kits designed with the necessary parts to simplify servicing your pump.
`
`Authorized service technicians are factory trained and skilled in pump maintenance and repair. They
`are ready to respond and assist you by providing fast, expert maintenance and repair services.
`
`For the location of your local authorized Gardner Denver distributor, refer to the yellow
`pages of your phone directory or contact:
`
`Factory (Tulsa):
`Gardner Denver Well Servicing Pumps
`4747 South 83rd East Avenue
`Tulsa, Oklahoma 74145
`
`Service Center (Odessa):
`Chaparral
`2121 West 44th Street
`Odessa, Tx 79768
`
`Service Center (Ft. Worth):
`Geoquip
`7533 Kathy Lane
`Ft. Worth, Texas 76126
`
`Phone:
`
`(918) 664-1151
`(800) 738-8099
`
`Phone:
`
`(432) 366-5433
`(800) 368-1134
`
`Phone:
`
`(817) 249-6400
`(800) 824-0271
`
`Fax:
`
`(918) 664-6225
`
`Fax:
`
`(432) 363-9940
`
`Fax:
`
`(817) 249-6401
`
`INSTRUCTIONS FOR ORDERING REPAIR PARTS
`
`When ordering parts, specify Pump MODEL and SERIAL NUMBER (see nameplate on unit).
`The Serial Number is also stamped on top of the cylinder end of the frame (cradle area).
`
`All orders for Parts should be placed with the Tulsa or Ft. Worth facility.
`
`Where NOT specified, quantity of parts required per pump or unit is one (1); where more than
`one is required per unit, quantity is indicated in parenthesis. SPECIFY EXACTLY THE NUMBER
`OF PARTS REQUIRED.
`
`Page i
`
`Vulcan
`Ex. 1038
`Page 2 of 44
`
`

`

`FOREWORD
`
`Gardner Denver® pumps are the result of advanced engineering and skilled manufacturing. To
`be assured of receiving maximum service from this pump the owner must exercise care in its
`operation and maintenance. This book is written to give the operator and maintenance personnel
`essential information for day-to-day operation, maintenance and adjustment. Careful adherence
`to these instructions will result in economical operation and minimal downtime.
`
`Danger is used to indicate the presence of a hazard, which will cause severe
`personal injury, death or substantial property damage if the warning is ignored.
`
`DANGER
`
`Warning is used to indicate the presence of a hazard, which can cause severe
`personal injury, death or substantial property damage if the warning is ignored.
`
`WARNING
`
`Caution is used to indicate the presence of a hazard, which will or can cause
`minor personal injury or property damage if the warning is ignored.
`
`CAUTION
`
`NOTICE
`
`Notice is used to notify people of installation, operation or maintenance
`information which is important but not hazard related.
`
`Page ii
`
`Vulcan
`Ex. 1038
`Page 3 of 44
`
`

`

`TABLE OF CONTENTS
`
`Maintain Pump Reliability and Performance with Genuine Gardner Denver Parts and
`Support Services................................................................................................................ i
`
`Instructions For Ordering Repair Parts...................................................................................... i
`
`Foreword.................................................................................................................................... ii
`
`Index .......................................................................................................................................... iv
`
`List of Illustrations ...................................................................................................................... v
`
`Section 1, Danger Notices ......................................................................................................... 1
`
`Section 2, Design, Description and Specifications .................................................................... 9
`
`Section 3, Preparation, Operation and Maintenance................................................................. 14
`
`Section 4, Service Procedures .................................................................................................. 20
`
`Section 5, Trouble-Shooting ...................................................................................................... 27
`
`Section 6, Rebuilding Data, Recommended Running Clearances ........................................... 33
`
`Warranty................................................................................................................................
`
`.35
`
`{ TC }
`
`Page iii
`
`Vulcan
`Ex. 1038
`Page 4 of 44
`
`

`

`INDEX
`
`Charging Pump Requirement .......................14
`
`Covers and Guards, Danger Notice................2
`
`Crankshaft.....................................................11
`
`Crosshead Assembly ....................................11
`
`Daily Routine Maintenance...........................18
`
`DANGER NOTICES, SECTION 1 ..................1
`
`DESIGN DESCRIPTION AND
`SPECIFICATIONS, SECTION 2.............9
`
`Equipment Moving and Lifting.........................2
`
`Flammable, Hot, cold or Corrosive Fluid
`Pumping, Danger Notice.........................5
`
`Power End.................................................... 10
`
`Power End Internal Lube Sytem .................. 12
`
`Power End Lubrication System .................... 15
`
`Power End Service....................................... 23
`
`Preparation after Shipping and Storage....... 14
`
`PREPARATION, OPERATION AND
`MAINTENANCE, SECTION 3.............. 14
`
`Pressurized Pump Systems, Danger Notice.. 3
`
`Pump Design................................................ 10
`
`Pump Mounting Instructions......................... 14
`
`Fluid Cylinder Installation..............................21
`
`Quarterly Routine Maintenance Schedule ... 18
`
`Fluid End .......................................................12
`
`Rebuilding Data............................................ 33
`
`Fluid End Removal........................................20
`
`Fluid End Service..........................................20
`
`REBUILDING DATA, RUNNING
`CLEARANCES AND TORQUES,
`SECTION 6 .......................................... 33
`
`Gear Train.....................................................11
`
`Repair Parts, Ordering Instructions..................i
`
`General Requirements and Safety Rules .....20
`
`Running Clearances Actual....................... 33
`
`General Specifications ..................................13
`
`SERVICE PROCEDURES, SECTION 4 ...... 20
`
`Startup and New Pump Run-In Procedure .. 16
`
`Torque Specifications................................... 34
`
`TROUBLE-SHOOTING, SECTION 5........... 27
`
`Valves and Seats Replacement ................... 22
`
`Valve Seat Pulling, Danger Notice ..................2
`
`Warranty....................................................... 35
`
`Wedge Puller, Danger Notice..........................2
`
`High Pressure Liquid Jetting, Blasting
`and Cleaning, Danger Notice .................6
`
`Hydraulic Puller, Danger Notice......................2
`
`Introduction .....................................................9
`
`Lube Pump Suction Piping Sizing and..........15
`
`Lube System Pump.......................................15
`
`Monthly Routine Maintenance Schedule ......18
`
`Performance Rating, HD-2250 .....................13
`
`Periodic Routing Maintenance Schedule......18
`
`Plunger/Packing Lubrication .........................16
`
`Plunger Packing Lubrication
`Recommendation Chart........................19
`
`Plungers and Packing Replacement.............21
`
`Page iv
`
`Vulcan
`Ex. 1038
`Page 5 of 44
`
`

`

`LIST OF ILLUSTRATIONS
`
`Figure # Description
`
`Page
`
`Figure 2-1 HD-2250 Pump........................................................................................... 9
`
`Figure 2-2
`
`HD-2250 Power End Section A-A ............................................................. 10
`
`Figure 2-3
`
`HD-2250 Power End Section B-B ............................................................. 11
`
`Figure 2-4
`
`Fluid End ................................................................................................... 12
`
`Figure 3-1
`
`Power End Lubricant Recommendations.................................................. 16
`
`Figure 4-1
`
`Fluid End, Stay Rods, and Heavy Hex Nuts ............................................. 21
`
`Figure 4-2
`
`Packing Assembly ..................................................................................... 21
`
`Figure 4-3
`
`Valve Cage Spring Retainer...................................................................... 22
`
`Figure 4-4
`
`Gunsight Spring Retainer .......................................................................... 22
`
`Figure 4-5
`
`Crosshead Assembly ................................................................................ 24
`
` Page v
`
`Vulcan
`Ex. 1038
`Page 6 of 44
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`

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`
`
`SECTION 1
`DANGER NOTICES
`
`DANGER
`
`following
`the
`Read and understand
`DANGER NOTICES before moving or
`operating the pump or any pump package
`unit equipment.
`
`Reciprocating pumps are machines capable
`of producing high fluid pressures and flow
`rates and are designed to be used with
`proper care and caution by
`trained,
`TO
`AVOID
`experienced
`operators.
`PERSONAL
`INJURY, DEATH AND/OR
`EQUIPMENT DAMAGE, READ AND
`THOROUGHLY
`UNDERSTAND
`THE
`FOLLOWING DANGER NOTICES PLUS
`THE ENTIRE OPERATING AND SERVICE
`MANUAL BEFORE ATTEMPTING TO
`MOVE OR OPERATE THE PUMP. Contact
`a Gardner Denver service representative if
`you are unable to comply with any of the
`danger notices or procedures described in
`these documents.
`
`Closely examine the pump performance
`data upon pump delivery
`to become
`thoroughly familiar with the operating limits
`for this pump model. The pump must
`never be operated at speeds, pressures
`or horsepower exceeding the maximum
`values or at speeds below the minimum.
`Failure to observe the operating limits
`could result in personal injury, death,
`and/or equipment damage and will void
`the warranty. Alterations to the pump, or
`application of the pump outside the limits,
`must not be made without Gardner Denver
`written approval, together with a new set of
`performance data, as dangerous operating
`conditions could result.
`
`Keep in mind that full operator attention and
`alertness are required when operating high
`pressure pumping equipment. Operators
`should not begin or continue operations
`when tired, distracted or under the influence
`of alcohol or any type of prescription or
`nonprescription drugs.
`
`The timely replacement of expendable parts
`and any other worn or damaged parts can
`prevent equipment damage and possible
`injury. The original parts used in Gardner
`Denver pumps are designed and tested to
`exacting standards to provide high quality
`performance and durability. Your best
`insurance
`in
`maintaining
`these
`characteristics is to use genuine Gardner
`Denver replacement parts.
`
`A broad range of danger notices are
`covered on these pages, however, they
`cannot substitute for training, experience
`and common sense in the safe operation of
`high pressure pumping equipment.
`
`HAMMER LUG FASTENERS
`
`DANGER
`
`lug
`On pumps equipped with hammer
`unions and/or hammer lug valve covers the
`following precautions must be observed to
`avoid personal
`injury, death and/or
`equipment damage due to contact with the
`hammer, broken parts from the hammer,
`lugs or other objects propelled by hammer
`blows. When
`tightening or
`loosening
`hammer
`lug unions and valve covers,
`operators or maintenance personnel should:
`
`Inspect the hammer and hammer lugs
`to insure they are all in good condition.
`Replace any of these parts which are
`cracked, damaged or badly worn.
`
`Wear safety shoes and safety glasses.
`
`Alert other personnel to move away
`from the area.
`
`Check to insure they have safe footing.
`
`Fully engage the hammer bar, if one is
`used, to prevent it from disengaging
`violently from the cover as a blow is
`struck.
`
` Page 1
`
`Vulcan
`Ex. 1038
`Page 7 of 44
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`

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`
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`
`
`
`
`
`the hammer
`their hands and
`Wipe
`handle and maintain a firm grip on the
`handle to avoid losing control of the
`hammer while swinging and striking.
`
`Carefully swing the hammer to avoid
`striking themselves, another person and
`objects other than the targeted lugs or
`hammer bar.
`
`Avoid swinging
`shoulder height.
`
`the hammer above
`
`VALVE SEAT PULLING
`
`DANGER
`
`The following precautions must be observed
`by operators and maintenance personnel to
`avoid personal
`injury, death and/or
`equipment damage from contact with the
`puller, hammer, wedge or broken parts from
`these components when using either a
`hydraulic or wedge valve seat puller.
`Operators
`or maintenance
`personnel
`should:
`
`Hydraulic Seat Puller
`
`Wear safety shoes and glasses.
`
`Chain or tie the jack down as it will jump
`violently when
`the
`valve
`seat
`disengages from the valve deck.
`
`Check to insure the pressure applied by
`the hydraulic pump does not exceed the
`hydraulic ram maximum pressure rating.
`
`Check to insure they have safe footing.
`
`Fully engage the wedge to prevent it
`from disengaging violently from the
`cover as a blow is struck.
`
`Wipe their hands and the hammer
`handle and maintain a firm grip on the
`handle to avoid losing control of the
`hammer while swinging and striking.
`
`Carefully swing the hammer to avoid
`striking themselves, another person and
`objects other than the targeted wedge.
`
`Avoid swinging the hammer above
`shoulder height.
`
`DANGER
`
`/or
`injury, death and
`Personal
`equipment damage can result from
`contact with moving parts. All
`moving parts must be equipped with
`covers and guards. All covers and
`guards must be securely positioned
`at all times when the unit is in
`operation.
`
`COVER AND GUARDS
`
`Covers and guards are intended to not only
`protect against personal injury or death, but
`to also protect the equipment from foreign
`object damage
`
`Wedge Puller
`
`EQUIPMENT MOVING AND LIFTING
`
`Grind off any mushroomed material from
`the wedge before use.
`
`Inspect the hammer and wedge to
`insure they are in good condition.
`Replace any of those parts which are
`cracked, damaged or badly worn.
`
`Wear safety shoes and goggles.
`
`DANGER
`
`Heavy equipment including pumps, pump
`packages and components should only be
`moved or lifted by trained, experienced
`operators, who are physically and mentally
`prepared
`to devote
`full attention and
`alertness
`to
`the moving and
`lifting
`operations. An operator should be fully
`aware of the use, capability, and condition of
`
`Page 2
`
`Vulcan
`Ex. 1038
`Page 8 of 44
`
`

`

`both the equipment being moved and the
`equipment being used to move it.
`
`as fully assembled should be separated into
`smaller loads.
`
`DANGER
`
`Failure to follow safe and proper
`pump, pump package or component
`lifting or moving procedures can lead
`to personal
`injury, death and
`/or
`equipment damage
`from shifting,
`falling or other unexpected or
`uncontrolled equipment movements.
`
`Make sure the hoist, lift truck, ropes, slings,
`spreader bar or other lifting equipment you
`are using is in good condition and has a
`rated lifting capacity equal to or greater than
`the weight being lifted. Lifting devices must
`be checked frequently for condition and
`continued conformance
`to
`rated
`load
`capacity. They should then be tagged with
`the rated capacity together with the date of
`inspection.
`
`pump
`and
`pumps
`assembled
`Fully
`packages are heavy and should only be
`moved using the specified lifting lugs or
`attachments.
`
`Many individual components have lifting
`eyes or lugs which must not be used to
`lift assemblies, as they are designed to
`bear the weight of the component only.
`
`individual component
`the
`lifting
`Before
`check to insure the lifting attachment is
`firmly secured
`to
`the component with
`undamaged, properly
`torqued
`fasteners,
`sound welds, or other secure attachments.
`Examine the lifting eyes, lugs, slots, holes or
`other projections to insure they are not
`cracked, otherwise damaged or badly worn.
`The repair of existing or addition of new
`welded lifting eyes, lugs or other projections
`should only be performed by experienced,
`qualified welders.
`
`lifted with
`Package units should be
`the
`lifting
`spreaders
`connected
`to
`attachments normally built into the package
`unit support skid. Packages too large to lift
`
`For these smaller loads the lifting devices
`should be fastened to the lifting attachments
`normally built into the individual motor,
`engine, pump or
`transmission
`/
`torque
`converter, or their separate support skids.
`
`When lifting subassembled components, for
`example a suction stabilizer attached to
`suction piping or a discharge pulsation
`damper attached to a strainer cross and
`piping, use special lifting slings designed to
`safely support the combined weight of the
`components.
`
`If a crane or hoist is being used to lift large
`components or assemblies, one or more
`persons should assist the operator from the
`ground with guide lines attached to the
`equipment being moved to properly position
`it and prevent uncontrolled movement.
`
`When you start to lift a pump, package unit,
`subassemblies or
`individual components
`and you observe the equipment is tilting, or
`appears unbalanced, lower the equipment
`and adjust the lifting device to eliminate
`these
`improper
`lifting conditions before
`proceeding to move the equipment.
`
`It is poor practice and dangerous to allow
`the equipment to pass over or close to your
`body or limbs. Be prepared to move quickly
`out of danger if equipment starts to fall, slip
`or move unexpectedly toward you.
`
`PRESSURIZED PUMP SYSTEMS
`
`DANGER
`
`Fluids under high pressure can
`possess sufficient energy to cause
`personal
`injury,
`death
`and/or
`equipment damage either through
`direct contact with escaping fluid
`streams or by contact with loose
`objects the pressurized fluid propels.
`
`Operating a pump against a blocked or
`restricted discharge
`line can produce
`
`Page 3
`
`Vulcan
`Ex. 1038
`Page 9 of 44
`
`

`

`
`
`
`
`
`
`excessive pressures in the entire discharge
`system, which can damage or burst
`discharge system components.
`
`DANGER
`
`Never operate a pump without a
`properly sized pressure relief valve or
`working overpressure shutdown in
`the discharge
`line
`immediately
`adjacent to the pump discharge.
`
`The relief valve should be placed in the
`flowing discharge
`line and not at
`the
`opposite end of the discharge manifold in a
`dead end connection. The dead end may
`become clogged with solid material carried
`in the fluid, which could prevent proper relief
`valve operation.
`
`DANGER
`
`Never place a shut-off valve or any
`other component between the pump
`discharge connection and the
`pressure relief valve.
`
`Make sure the pressure relief valve is
`installed so any pressurized relief discharge
`from
`the valve
`is directed away
`from
`possible contact with people or equipment.
`The relief valve must be set to relieve at a
`pressure equal to or below the maximum
`pressure values shown on the pump data
`plate. However, if a component is used in
`the discharge system with a lower rated
`pressure capability than that listed on the
`pump data plate, the pressure relief valve
`must be set to relieve at a pressure equal to
`or below the rated capability of the lowest
`rated component.
`
`Before starting the pump every time,
`check to insure:
`
`The pressure relief valve is in good
`operating condition and has been set to
`the proper relief pressure.
`
`Any pipe line used to direct pressurized
`relief flow to another location, such as a
`collecting tank, is not blocked.
`
`The discharge system is not blocked
`and all the discharge line valves are
`open.
`
`Check all fluid end discharge system
`components
`including pipes, elbows
`connections, threads, fasteners, hoses,
`etc., at least once every six months to
`confirm their structural adequacy. With
`time, wear, corrosion and fatigue can reduce
`the strength of all components. Magnetic
`iron and steel components should be
`checked with magnetic particle or dye
`penetrant
`crack detection equipment.
`Nonmagnetic materials should be checked
`for cracks with dye penetrants. All metallic
`components should also be visually checked
`during
`these
`inspections
`for signs of
`corrosion. If a component shows evidence
`of cracking or loss of material due to
`corrosion it must be replaced with a new
`part.
`
`Continually monitor suction and discharge
`hose assemblies when
`the pump
`is
`operating for leakage, kinking, abrasion,
`corrosion or any other signs of wear or
`damage.
`
`Worn or damaged hose assemblies
`should be replaced immediately. At least
`every six months examine hose assemblies
`internally for cut or bulged tube, obstructions
`and cleanliness. For segment style fittings,
`be sure that the hose butts up against the
`nipple shoulder, the band and retaining ring
`are properly set and tight and the segments
`are properly spaced. Check for proper gap
`between nut and socket or hex and socket.
`Nuts should swivel freely. Check the layline
`of the hose to be sure that the assembly is
`not twisted. Cap the ends of the hose with
`plastic covers to keep them clean until they
`are tested or reinstalled on the pump unit.
`Following this visual examination, the hose
`assembly should be hydrostatically tested,
`on test stands having adequate guards to
`protect
`the operator, per
`the hose
`manufacturer's proof test procedure.
`
`Page 4
`
`Vulcan
`Ex. 1038
`Page 10 of 44
`
`

`

`Fluid end component inspections should
`be performed more frequently than every
`six months if pressures above 2500 psi
`are used in the discharge system or if
`corrosive, abrasive, flammable or hot
`(over 110º F) fluids are being pumped.
`
`Proper stuffing box packing selection is
`important for safe pump operation. Contact
`a Gardner Denver service representative for
`assistance in selecting the proper packing
`before beginning operation.
`
`Before starting the pump the first time, and
`periodically
`thereafter check
`the pump,
`suction and discharge system
`fastener
`torques versus the values listed on page 12
`to insure proper tightness. Over and under
`torquing can damage
`threaded pipes,
`connections and fasteners, which may lead
`to component damage and/or
`failure.
`Replace all components
`found
`to be
`damaged or defective. On pumps equipped
`with stuffing boxes, the gland must be
`engaged by at least three (3) threads to hold
`the discharge pressure of the pump.
`
`DANGER
`
`Do not attempt to service, repair or
`adjust the plunger packing or other-
`wise work on the pump while the unit
`is operating. Shut off the pump drive
`engine and relieve the fluid pressure
`in the suction and discharge systems
`before any work or investigation is
`performed on the pump or pump
`systems.
`
`Block the crankshaft from turning and make
`certain that all pump drive motor or engine
`start switches or starter controls are clearly
`tagged with warnings not to start the pump
`while repair work is in process.
`
`Whenever the pump is operating, continually
`monitor the entire suction, discharge and
`pump
`lubricating
`systems
`for
`leaks.
`Thoroughly
`investigate
`the cause
`for
`
`leakage and do not operate the pump until
`the cause of the leak has been corrected.
`Replace any parts which are found to be
`damaged or defective. When a gasketed
`joint is disassembled for any reason, discard
`the used gasket and replace it with a new,
`genuine Gardner Denver gasket before
`reassembling the joint.
`
`the high working pressures
`to
`Due
`contained by
`the
`fluid end, discharge
`manifold and discharge piping, welding on
`these components is not recommended. If
`welding on the discharge system cannot be
`avoided, only experienced, qualified welders
`should be used. In addition, the welded part
`should be hydrostatically proof tested in the
`shop with water or hydraulic fluid to one and
`one half times maximum discharge system
`working pressure, with no observable fluid
`leakage, before the part is reinstalled in the
`pump system.
`
`In summary, high pressure fluid streams can
`possess sufficient energy to cause personal
`injury, death and/or equipment damage.
`These results can occur either through
`direct contact with the fluid stream or by
`contact with loose objects the fluid stream
`has propelled,
`if
`the pump system
`is
`improperly used, or
`if
`the
`fluid
`is
`misdirected, or allowed to escape from
`defective
`or
`improperly maintained
`equipment.
`
`FLAMMABLE, HOT, COLD OR
`CORROSIVE FLUID PUMPING
`
`DANGER
`
`Extreme caution must be exercised
`by trained and experienced operators
`when
`flammable, hot, cold or
`corrosive fluids are being pumped to
`avoid personal injury, death an/or
`equipment damage due to explosion,
`fire, extreme cold or chemical attack.
`
`Never operate a pump which is pumping
`hydrocarbons or other flammable, hot, cold,
`
`Page 5
`
`Vulcan
`Ex. 1038
`Page 11 of 44
`
`

`

`or corrosive fluids when any part of the
`pump, suction system or discharge system
`is leaking. Stop the pump immediately if any
`leakage, other than a few drops per minute
`of packing weepage, is observed. Keep all
`flame, sparks, or hot objects away from any
`part of
`the pump, suction system, or
`discharge system. Shield the pump, suction
`system and discharge system to prevent
`any flammable, hot, cold or corrosive fluid
`leakage from dripping or spraying on any
`components, flame, sparks, hot objects or
`people.
`Inspect the plungers, packing,
`gaskets and seals
`for
`fluid
`leakage
`frequently and replace all worn or leaking
`parts.
`
`Selection of the proper gaskets, seals and
`stuffing box packing is even more critical
`when flammable, hot, cold or corrosive fluids
`are being pumped
`than when other,
`inherently less dangerous fluids are used.
`Contact
`a Gardner Denver
`service
`representative for assistance in selecting the
`proper gaskets, seals and packing before
`beginning operation.
`the
`into
`Since some packing weepage
`cradle area is inevitable, a drain located
`below the bottom of the cradle must be
`connected to a drain line which conducts the
`fluid
`leakage
`to a collection container
`located in a protected area. The entire drain
`system and container must be constructed
`of materials resistant to attack from the
`pumped fluid or from explosion or fire of the
`pumped fluid. Heavy duty cradle covers
`must be securely fastened in the proper
`position on the pump at all times when
`the pump is operating. If the pumped
`fluid releases harmful, explosive or
`flammable vapors the covers must be
`vented to conduct the fumes away from
`the pump unit to a non-hazardous area.
`
`Before beginning pumping operations or
`starting the pump power source (whether an
`engine or electric motor) check
`the
`atmosphere all around the pumping site for
`the presence of flammable or explosive
`vapors. Do not begin operation and stop
`ongoing operation if flammable or explosive
`vapors are detected. Hot surfaces, sparks,
`electric current or engine exhaust could
`ignite flammable or explosive vapors. Each
`
`engine used as a power source on pumping
`units where flammable or explosive vapors
`could form should be equipped with an air
`inlet shut-off.
`If flammable or explosive
`vapors are present in the pumping site
`atmosphere, an engine could continue to
`run on these vapors even after the engine
`fuel line is shut-off if an air inlet shut-off is
`not used.
`
`In addition, on pumping units used where
`flammable or explosive vapors could form,
`all electric motors used as power sources
`must be of explosion proof construction and
`all electrical components and wiring must
`meet the current National Electrical Code for
`explosive atmospheres.
`
`These precautions must be taken to avoid
`possible personal
`injury, death and/or
`equipment damage from explosion, fire or
`burns.
`
`HIGH PRESSURE LIQUID JETTING,
`BLASTING AND CLEANING
`
`DANGER
`
`Extreme caution must be exercised if
`any type of wand, gun, nozzle or any
`other pressure and flow directing
`device
`is attached
`to
`the pump
`discharge system for use in jetting,
`blasting, cleaning, etc. This type of
`equipment must be used by trained,
`experienced operators with
`the
`utmost care. High pressure fluid
`streams can either by direct contact
`or by propelling loose objects, cause
`serious personal injury or death to
`operators and/or other persons.
`
`Pressure or flow directing devices often
`receive pressurized flow through flexible
`hoses, which can burst if they are kinked,
`cut, abraded or are otherwise worn,
`damaged or pressured above their rated
`capacity. Protect the hose and connections
`from damage by people, objects and
`vehicles. A broken, cut or otherwise burst
`
`Page 6
`
`Vulcan
`Ex. 1038
`Page 12 of 44
`
`

`

`hose can release pressurized fluid which
`may cause personal injury, death and/or
`equipment damage.
`
`High pressure fluid from hand held or hand
`directed pressure and flow directing devices
`may overpower an operator s ability
`to
`control or direct the device, which could lead
`to personal injury, death and/or equipment
`damage. The operator must brace against
`the backward thrust of a hand held device.
`In addition, a safety harness or safety net
`must be used when working in an area
`where the operator could be injured in a fall.
`Stand to the side of any tubing or container
`being sprayed to avoid back spray and
`never operate a hand held device above
`shoulder level.
`
`Never direct the pressurized fluid stream at
`yourself or any other person, control valves,
`the pump, pump drive, suction or discharge
`systems. The pressurized stream can
`cause serious personal injury or death and
`can also change valve or control settings
`which could dangerously
`increase
`the
`delivery pressure to the pressure and flow
`directing device.
`
`flow
`When operating a pressure and
`directing device, use only equipment which
`automatically shuts off
`flow when an
`operator releases hand or foot pressure on
`the pressurized
`flow
`trigger control
`to
`prevent injury if the operator is overpowered
`or becomes disabled.
`
`Check to insure this automatic shut-off
`equipment
`is operating properly before
`every use and never circumvent
`the
`automatic shut-off for any reason or by any
`means when operating the equipment.
`
`When operating any type of high pressure
`liquid jetting, blasting or cleaning devices,
`the operators must always wear protective
`clothing including, but not limited to, a hard
`hat with full face visor, heavy duty rain coat
`and pants, boots with nonskid sole and
`safety toe, rubber gloves with rough grip
`surface and ear noise protection.
`
`Full operator attention and alertness are
`required when operating this equipment to
`
`injury, death and/or
`avoid personal
`equipment damage. The operators should
`take
`frequent
`rest breaks and cease
`operations when
`they become
`tired or
`distracted.
`
`Before the equipment is started, the work
`area must be
`inspected and properly
`prepared to avoid personal injury, death,
`and/or damage to equipment. Make sure
`the work area is checked for hazardous
`fumes, has adequate ventilation for engine
`exhaust and sufficient drainage for released
`fluid. Check the work area for electrical
`equipment, connections, outlets, fixtures, or
`lines. If any are present they must be made
`water tight and the electrical power to these
`devices must be shut off to avoid electrical
`shocks from fluid contact. The work area
`should be clearly marked and roped off to
`keep unauthorized people and vehicles from
`entering. Remove all loose parts, tools and
`equipment
`from
`the work area before
`beginning operation.
`
`All pressure containing devices including
`wands, nozzles, guns, hoses, connections,
`etc., should be
`regularly checked
`for
`condition. These components should all be
`tagged with their tested pressure capabilities
`together with
`the date
`testing was
`performed. Always be aware of the
`pressure level in the system and never
`connect any equipment to the system
`which has a rated or tested pressure
`capability below the system operating
`pressure. The equipment must be shut
`down and the system pressure released
`before changing or disconnecting wands,
`nozzles, guns, hoses, connections or any
`other pressurized system components.
`
`All pressure containing devices including
`wands, nozzles, guns, connections, etc.,
`plus all automatic shut-off, pressure and
`control equipment should be treated with
`care. Protect them from damage by people,
`objects and vehicles. Never lay them in dirt,
`mud, ice or other loose material which could
`plug the fluid opening or interfere with their
`operation. Never use the wand, nozzle,
`gun, et