Flow ESL INTENSIFIER Manuel utilisateur

ESL INTENSIFIER

M-310 | REV. G | JANUARY 2009

Due to continuing product improvement, the information contained in this document is subject to change without

notice. Flow International Corporation shall not be held liable for technical or editorial omissions made herein, nor

for any incidental or consequential damage resulting from the use of this material.

This document contains information protected by copyright. No part of this document shall be reproduced in any

manner without prior written consent from Flow International Corporation.

2 | M-310 © Flow International Corporation

ESL Intensifier

Contents

Introduction

Introduction 4

Safety 4

Related documents

Your equipment was shipped with several manuals. Some are shipped with every system; others are specific de-

pending on the model of intensifier pump purchased. Other manuals than those listed may have been shipped

with your system if the ESL intensifier was installed as a retrofit kit.

Every system comes with the following manual:

•M-127, Small High-Pressure Components

One of these pump and/or system manuals was shipped with the equipment:

•M-287, 7X Intensifier Pump

•M-294, 25X Intensifier Pump

•M-331, 20XW Intensifier Pump

•M-368, IFB DWJ 50iS

•M-371, IFB 50iS

•M-378, IFB DWJ 100iD

•M-380, IFB 100iD

•M-373, WMC2 50iS

•M-375, WMC2 100iD

•M-377, 30XQ Pump

•M-384, IFB StoneCrafter

•M-387, 30SA Intensifier Pump

4 | M-310 © Flow International Corporation

ESL Intensifier

ESL intensifier description

The ESL intensifier is available in 60,000 psi (4138 bar)

and 40,000 psi (2759 bar) output water pressure

ratings.

Specifications

Diameter .........................................7 in. (178 mm)

Length ............................................32 in. (809 mm)

Weight ..............................................105 lb (48 kg)

Type of shift..................................................electric

Output pressures.......................60K/20:1, 40K/20:1

Hydraulic oil

kinematic viscosity.............310 SSU @ 100°F (38°C)

Hydraulic oil

Oil must be ISO viscosity grade 46. The following oils

are recommended, but other manufacturer's equiva-

lents can be used.

•Mobil DTE Medium or DTE 25

•Shell Turbo T 46

•Chevron Turbine Oil GST 46

•Texaco Regal R&O 46

Operating principles

The intensifier pump consists of a hydraulic system, a

high-pressure water delivery system, and a control sys-

tem. Details of the control, hydraulic oil,and high-

pressure water systems can be found in the following

manuals:

•Intensifier pump manual or the intensifier pump

chapter of an IFB or WMC system manual

•MS-2275, Ultrahigh-Pressure Pump Operating

Principles

ESL Intensifier

Periodic maintenance

Daily inspections and periodic maintenance will help

you get the maximum life, safety, and efficiency from

your FLOW equipment. Periodic maintenance is regu-

larly scheduled preventive maintenance and includes

replacing worn parts that have reached the end of their

service life. It will help minimize unscheduled down

time, maximize equipment use, and eliminate unsafe

operating conditions.

Flow recommends that you use a maintenance and ser-

vice log to record all service work. Maintenance Log

MS-2258 is provided on the CD.

Note: Review all maintenance precautions and safety

instructions listed in the intensifier pump manual.

Maintenance tips

•Stock enough spare parts to minimize downtime

and help avoid rush part orders.

•Practice good housekeeping.

•Assign a complete set of service tools to the

workstation.

Maintenance precautions

•Protect all machined and lapped mating surfaces

from damage.

•Carefully work out any damage to seal surfaces, or

seal damage and leaks will be a recurring problem.

•Carefully clean and blow out all parts being reas-

sembled. Do not use paper towels.

•Do not use any substitutes for the sealants and lu-

bricants recommended by Flow.

Torque specifications

Refer to the following table when specific torque re-

quirements are not listed in a service procedure.

Mounting bolts and machine screws shall not be

torqued beyond the manufacturer’s recommended

limits.

High-pressure

gland nuts

U.S.

(ft-lb)

(N-m)

14in. 15-25 20-34

38in. 35-45 47-60

916 in. 60-75 80-100

Note: Before assembly, lubricate threads of all

high-pressure tubing connections with Blue Lubricant.

6 | M-310 © Flow International Corporation

ESL Intensifier

Troubleshooting

Intensifier weep hole identification

Water leaking from weep holes can provide clues to

the condition of components, depending on the tem-

perature and force of the water.

Included with this manual is an intensifier troubleshoot-

ing illustration that identifies the weep holes described

below.

Check valve outlet body

Leakage can be caused by the following:

•Loose high-pressure connection

•Cracked or scored check valve outlet body

•Scored high-pressure tubing

Repair any problems immediately.

Main check valve body

Leakage can be caused by a loose connection and/or a

cracked or scored main body, insert, or outlet body.

Repair any problems immediately.

End cap

High-pressure water seal seepage is the most common

cause for end cap weep hole leakage. It can be caused

by a loose end cap, failure of the high-pressure seal be-

tween the cylinder and check valve main body, failure

of check valve body o-rings, or a cracked or scored

high-pressure water cylinder or check valve main body.

Cold water leaking from this weep hole can be caused

by a damaged o-ring on the check valve body or a

damaged high-pressure seal, whether or not the inten-

sifier is running.

Check leakage quantity. If seepage is very gradually in-

creasing, has not suddenly appeared, is no more than

lukewarm, and is less than two teaspoons

(0.8 oz/23 ml) per stroke, it is safe to continue to oper-

ate the pump. See Intensifier Service Notes.

End bell

The weep hole is drilled into the void separating the

hydraulic oil cylinder and the high-pressure water cylin-

der. Hydraulic oil leakage can be caused by:

•Failure of the end bell hydraulic oil seal and/or

•Cracked or scored end bell or plunger

Leakage is usually due to end bell oil seal damage.

Normal oil seal leakage can be up to one drip per hour.

Water leakage from the end bell weep hole is usually

caused by failure of the high-pressure water seal lo-

cated in the end of the cylinder, but can also result

from a cracked or scored high-pressure water cylinder

or plunger.

Check leakage quantity. If seepage very gradually

increases, has not suddenly appeared, is no more than

lukewarm, and is less than two teaspoons

(0.8 oz/23 ml) per stroke, it is safe to continue to

operate the pump. See Intensifier Service Notes.

ESL Intensifier

Troubleshooting guide

The troubleshooting guide will help you identify the

probable cause of a system malfunction and the most

effective corrective action.

Using the troubleshooting guide

The probable causes of each malfunction are listed in

order from the most likely to the least likely to occur.

The corrective action is a condensed summary of the

service required to remedy the problem. When you

encounter a system malfunction:

1. Carefully and precisely define the problem.

2. On the troubleshooting table, locate the symptom

that most closely resembles your assessment of the

problem.

3. Identify the most likely probable cause.

4. Follow the corrective action procedure.

If the symptoms in the chart do not correspond to your

malfunction, or if the problem is not resolved or elimi-

nated by the recommended corrective action, contact

Flow Technical Service.

8 | M-310 © Flow International Corporation

ESL Intensifier

Troubleshooting guide

1. Intensifier strokes unevenly

Leaky check valve (inlet or outlet) on

one side only

Replace or rework the check valves as necessary. For best results, lap or re-

place all check valves at the same time.

Foreign particles trapped between

check valve and seat

1. Remove the end cap(s). Eliminate the sources of contamination to prevent

problem from recurring.

2. Examine the check valves and remove any foreign material. Relap if neces-

sary.

3. Clean all parts and reassemble.

Worn/bent shift cable or associated

parts (mechanical shift only)

1. Remove the shift cable guide.

2. Install the spare shift cable guide and recheck. Replace any worn parts.

High-pressure water plunger has

separated from the oil piston

Associated with a drop in output water pressure and flow. Avoid prolonged

operation under this condition—it will cause severe damage to the intensifier.

Disassemble the hydraulic oil cylinder and piston and replace parts if defec-

tive.

Wrong shift/actuator pins installed Replace with bronze shift/actuator pins (002226-1 mechanical shift; B-1702-1

electric shift).

Debris in shift circuit Check spool movement on both the pilot and shift valves. Inspect spools for

defects. Hand lap with 600 grit paper. If unable to remove defects, replace

valve.

2. Intensifier knocks severely

Low inlet water pressure to the in-

tensifier

1. Make sure the inlet water pressure output is above the required minimum

for your intensifier pump.

2. Replace filters in filtration system; make sure they are replaced in the same

order they were removed.

Intensifier inlet passages clogged by

debris or corrosion

1. Inspect the filtered water inlet lines.

2. Remove the end cap. Inspect and remove any foreign material clogging the

inlet passages.

3. Inspect the check valve.

Sticky outlet check valve poppet 1. Remove the end cap.

2. Relap the check valve poppet and the insert; reinstall.

3. Oil leakage from end bell weep hole

Worn end bell oil seal Replace the end bell oil seals. Replace all oil seals at the same time.

4. Oil leaking from manifold/end bell interface

Defective/worn o-ring seals, or loose

manifold mounting screws or port

plugs on valve

Retorque the manifold mounting screws, following the torque values provided

in this section. If leak will not stop, replace the o-ring interface seals between

the manifold and the end bells. Lap manifold if the o-ring surface is nicked.

ESL Intensifier

Misaligned end bells 1. Remove intensifier from pump and place on assembly fixture.

2. Loosen tie rods and retorque. Confirm that end bells are aligned correctly.

5. Oil leaking from manifold/shift valve interface

Defective or worn o-ring seals; loose

shift valve mounting screws

Retorque the shift valve mounting screws, using torque values in this manual. If

leak doesn't stop, replace interface o-ring seals between manifold and shift

valve.

6. Oil leaking from shift valve/pilot valve interface

Defective/worn o-rings, loose pilot

valve mounting screws, or incorrect

torque

Retorque pilot valve mounting screws, following the torque values in this man-

ual. If leak won’t stop, replace interface o-ring seals between pilot valve and

shift valve.

7. Water leaking from end bell weep hole

Worn high-pressure water seal Replace all high-pressure water seals and seal backup rings. Be careful not to

scratch the water cylinder during seal extraction and insertion.

Fractured high-pressure water cylin-

der at the end bell side

Replace water cylinder and seals. Be careful not to scratch the high-pressure

water cylinder during seal insertion.

Worn high-pressure water plunger 1. Inspect plunger diameter. The diametrical clearance between plunger and

new backup ring must be less than 0.002 inch (0.05 mm). Replace if

scratched, pitted or below tolerance.

2. Replace water seals and seal backup ring.

8. Water leaking from end cap weep hole

Worn HP water seal Replace high-pressure water seal.

Damaged low-pressure water seal

o-rings on the check valve body

Replace water seal o-rings. Do not pinch the o-ring seals when installing check

valve housing.

Fractured high-pressure water cylin-

der

Replace cylinder and high-pressure seals. After replacement, increase pressure

gradually.

Fractured check valve body Inspect for fractures. Replace check valve body if required. Replace all water

seals.

End cap incorrectly assembled to

high-pressure cylinder

Remove end cap and reassemble. Replace HP water seal (if damaged).

9. Short high-pressure water seal life

Excessive clearance between seal

backup ring and HP water plunger

1. Remove HP water cylinder. Replace all HP water seals (backup ring, seal,

hoop, and o-ring).

2. Examine HP plunger. Replace if diameter is less than specified or if surface

roughness is greater than 4 micro-inch RMS.

Caution: High-pressure seal rings must be replaced whenever high-pres-

sure seals are replaced.

Scratched HP water plunger Deep pits or scratches in excess of 10 micro-inches will cause premature

high-pressure water seal failure. Replace as necessary.

ESL Intensifier

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