NGS-IPG-0015 (2)
NGS-IPG-0015 (2)
Series 5100
Gas/Pneumatic Driven Injection Pump
™
CONTENTS
Description 1
Applications 1
Accessories, Options, and Volume 2
Gas Consumption Chart 2
Installation 3
Important 3
Parts List 6
Injector Heads 8
5100 Microswitch Valve Installation 9
Installation 9
Microswitch Valve Replacement 12
Series 5100
Description Applications
The Texsteam 5100 Series Chemical Injectors from Texsteam • The introduction of de-emulsifiers, solvents, corrosion
Pumps are single acting, positive displacement plunger- inhibitors, de-salting agents and flocculants in oil country
type pumps, powered by gas via a diaphragm with a spring operation
return. Speed control is accomplished by regulating the • High pressure bearing lubrication
exhaust gas discharge flow. Reversal is accomplished by
• Water treatment
a direct spring- actuated switching mechanism (rotary
three-way valve). Volume is controlled by the speed of the • Blending processes in refining and process plants
pump and by the stroke length, either 1” or 1/3” (25.4mm or • Injection of methanol in gas pipelines
8.5mm) lengths. • Hydrostatic testing
The 5100 Series is capable of pumping high pressures with • Sampling
gas pressure as low as 8 psig (0.6 bar ) and handling volume
output up to 30 GPD (113.6 LPD).
The pump is lightweight, compact and contains a minimum
of working parts for easy maintenance. Each fluid pump
head is equipped with a stainless steel plunger, ball
checks, ball check springs, top seat, top bushing, bottom
bushing, adjustable VEE type packing and a priming valve.
The packing yoke is equipped with a drain to monitor for
possible packing leaks. Because of the sealed bearings, the
unit is oil-less.
The 5100 Series performs accurately because: (1) the head
is designed for high volumetric efficiency; (2) a positive trip
mechanism assures fine control of plunger stroke length;
and (3) the speed is regulated by controlling the exhaust gas
discharge flow which creates a rapid fluid discharge with
slow suction.
Series 5100 LP
Wt. 38 pounds (17.2 Kg)
If a model with a base plate has been ordered, pump will be 11. Turn the gas on and slowly open the gas exhaust valve.
secured to the base plate with a 5/16” (7.9mm) x 1 - 1 1/4 “ The pump will start automatically. Make certain the suction
(31.75 mm) bolt, 5/16” (7.9mm) washer, 5/16” (7.9mm) lock line is filled with fluid by opening the priming valve to check
washer, and 5/16” (7.9mm) nut through each of the two slots for fluid. After the pump discharges clear fluid without
in the feet of the base. Additional measures should be taken bubbles, close the priming valve for normal pumping
by the end user to further secure the assembly in place in operations. At this point make a visual check of the plunger
accordance with all local safety codes and regulations. drip and using the TA-315 gland wrench, slowly tighten
the gland nut until leakage just stops. It may be necessary
3. Loosen and remove the four thumb screws that
to readjust the packing the next day. A slight leak during
hold the cover.
break-in is beneficial. Sufficient time should be allowed to
4. Select the stroke length desired, either full or short let the packing “seat in”. Packing should only be adjusted
according to your requirements. See the data chart, full stroke after pressure has been removed from the pump head. Never
is 1“ (25.4mm) and short stroke is equal to 1/3” (8.5mm). adjust packing against pressure.
5. Check plunger packing gland to make sure packing is 1/4 12. After the pump is in operation, replace the cover and
turn past finger tight. thumb screws.
6. Install the priming valve TA-1497 in its position on the Start Up and Operation
pump head.
After the pump has been installed, only a few minor
7. Blow or clean line before hooking up air or gas line to inlet. adjustments are necessary for every day operation. Here are a
On Models 5100 LP and 5100 L the air or gas line [if it does not few check points.
exceed 35 psig (2.4 bar) ] is piped directly into the inlet TA-906.
1. Check gas supply pressure.
The inlet is a 1/4” (8mm) female connection. Do not hook up the
gas supply to the small valve. This is the gas exhaust. Gas supply 2. Check speed control with the chart which will give you the
should be constant pressure to assure even stroke speed. volume the pump is injecting.
If the gas supply pressure exceeds 35 psig (2.4 bar) or is erratic, some 3. Check for excess leakage around the packing gland. If is
means of reducing the gas pressure to below 35 psig (2.4 bar) must not possible to stop excess leaking, replace the packing. If the
be used. Models 5100 HP and 5100 H are equipped with a pressure plunger is badly scored, replace the plunger. Do not adjust
regulator and pressure gauge for reducing the gas pressure. The packing against pressure.
regulator supplied with the 5100 HP and 5100 H can be used up 4. Open the priming valve to check pump action.
™
Maintenance
Lubricate the thrust rod with only Mobilith™ SCH 007 grease removed (see page 8). Lap the TA-4056 disc with a good valve
per recommended maintenance schedule. grinding compound before replacing.
Should the pump run but fail to pump chemical, remove When replacing TA-4056 valve disc be sure to also replace the
TB-736 bottom bushing and TA-1496 top bushing - inspect TA-4062 drive pin that was supplied when you ordered the
and clean balls and seats. Inspect for damage and replace if disc assembly.
necessary. Should pump still not pump chemical, remove TB- Removing TB-446 Valve Assembly from Pump Housing
548 cover and check to see if TA-290 cotter Pin and TA-1828
stroke adjusting pin are in place. Should it be necessary to remove TB-1631 flipper arm assembly
from the pump housing, disconnect TB-1193 SS tubing, the
Check to see if chemical is getting to pump, unscrew TA-1497
power inlet from TA-906 disc retainer and the gas exhaust line.
priming valve stem. When chemical flows from bleed hole,
Remove the four P01-031100-3900 machine screws and four
shut TA-1497 priming valve.
P52-031000-3900 lock washers. The TB-446 valve assembly can
If the pump fails to operate after hooking up gas or air to TA-906 then be withdrawn from pump body.
(inlet bushing); make sure the inlet pressure does not exceed
The flipper arm bearing is an integral part of the TB-1631 flipper
35 psig (2.4 bar) - excessive pressure could tend to lock the
arm assembly and is press fit into the TB-441 body. A punch must
pump; make sure the speed control valve (gas exhaust) is open;
be used to remove the flipper arm from the valve body. To do this
and make sure the plunger packing is not too tight. Use gland
the procedure under the heading, “Replacing TA-4147 Valve Disc
wrench TA-315 to adjust packing gland nut TA-6353, if necessary.
Assembly.” must be performed. When these parts are removed
If pump stops and a constant flow of gas comes from TA-1835 the TB-1631 flipper arm assembly may be punched from the body.
air vent, this means that the TC-2128 diaphragm has ruptured.
Upon reassembling the lower shaft of the TB-1627 flipper arm
To Replace Diaphragm must fit into the TA-6563 flipper spring adapter.
Remove TC-252 diaphragm cover. Remove lock nut and washer To Replace The Flipper Spring
on end of TB-444. Do not allow TB-444 thrust rod to turn when
Follow the procedure as outlined under “Removing TB-446
removing lock nut and washer. To prevent the rod from turning,
Valve Assembly from Pump Housing.”
remove TB-548 cover and hold the rod in position by inserting
punch or drift pin into the “large” hole forward of the TA-6564 After removing the valve assembly, remove TB-548 cover. At
Stirrup assembly. Replace burst diaphragm and reassemble. this point TA-6564 stirrup assembly may be turned upside
down on the thrust rod - unscrew TA-1820 flipper spring. To
To Replace Return Spring
reassemble follow the above procedure in reverse.
Remove TC-252 diaphragm cover - remove lock nut and washer Technical Specifications
on end of TB-444 thrust rod. It is important that you do not
allow TB-444 thrust rod to return when moving lock nut and Approved models of this unit comply with the requirements
washer. To prevent the rod from turning remove TB-548 cover for 94/9/EC-ATEX directive II 2G c II T3
and hold the rod in position by inserting punch or drift pin into Approved Models:
the “large” hole forward of the TA-6564 stirrup assembly. 5101 5103 5104 5105
Pull TC-2128 diaphragm – TB-438 diaphragm plate - return spring
Does NOT include models with
TA-1821 can then be removed. Reassemble in reverse of above.
Replacing Ta-4147 Valve Disc Assembly 1. Ceramic plunger
2. Microswitch
If the pump has a heavy continuous leaking of gas – TA-4147
Standards Used:
valve disc assembly probably needs replacing.
EN ISO 12100:2010 EN 13463-1:2009 EN 13463-5:2011
Disconnect power supply into TA-906 disc retainer. Remove
TA-906 disc retainer from TA-441 body - caution: care should
Pump Weight (without accessories): 38 lbs (17.2Kg)
be taken not to lose TA-77 valve spring and TA-579 washer
located directly under TA-906 disc retainer. TB 0040 Regulator Weight: 3lbs (1.4Kg)
Before removing, note the position of the TA-4056 valve disc, Noise Level @ 35 psig (2.4 bar): less than 70dB(A)
so that the disc is replaced to the same position as it was Ambient operation temperature: -4°F to +140°F (-20°C to +60°C)
Series 5100
LP and HP
8 1/4” 8”
1/4” 20 Furnished
21 on H&HP
models only
22
1/4”
1/4”
9 1/2”
3 9 2 6 8 29 10 28 14 11 15 36 1/4” 34 43 44
Gland (8mm)
4 Wrench FNPT
33 27 13 32
5 19 24
1
18 26
4 7/8”
12
43
1/4”
Drain (8mm)
4 13/16” FNPT 31
2 13/16”
37
38
3 1/16” 2”
16 17 30
Parts List
No. No.
Item Part No. Name Material Item Part No. Name Material
Reqd. Reqd.
1 TC-0252 1 Diaphragm Cover Cast Iron 24 P52-037000-3900 1 Light Lockwasher SS
2 TD-0531 1 Housing Cast Iron 25 TA-0075 1 Street El. C.S. Galv.
32 TC-2128 1 Molded Diaphragm Buna-N, Nylon 26 P26-037000-0200 1 Hex. Nut Semifinish Stl. Zinc Pl.
4 P54-062000-0200 1 Washer Stl. Zinc Pl. 27 TA-1827 1 Bumper Plate Screw Steel
5 TA-3320 1 Locknut Stl. Zinc Pl. 281
TA-1828 1 Adjusting Pin Steel
62 TA-1821 1 Return Spring C.S. Zinc Pl. 291 TA-1546 1 Gasket Buna-N
7 TB-1193 1 Pilot Valve Line Assy. 303 S.S. Tubing 30 TA-1835 1 Air Vent Brass
8 P86-025075-0200 4 Wing Screws Stl. Zinc Pl. 312 TA-1820 1 Flipper Spring Steel
9 TB-0438 1 Diaphragm Plate Steel 32 2
P55-037000-0200 3 Washer C.S. Zinc Pl.
10 TB-0548 1 Cover Cast Iron 33 TA-6564 1 Stirrup Assembly Cast Iron & Steel
11 TB-0444 1 Thrust Rod Steel Head Assemblies
34 1 Injector Head
12 TB-0446 1 Pilot Valve See Page 7 (See page 8 for part list)
362 TA-0315 1 Gland Wrench Steel
13 TA-1823 1 Bumper Plate Steel
372
TA-6563 1 Spring Adapter (Bottom) Steel
14 TB-0447 1 Rod Adapter Steel
382 TA-0058 1 Gasket-Pilot Valve Fiber
15 TA-0290 1 Pin Steel
39 TA-2489 1 Gas Exhaust Valve Ni. Plated Brass
16 P01-037125-3900 8 Hex Hd. Cap Screw SS
40 TA-1829 1 Hex. Hd. Screw Steel
17 P25-037000-3900 8 Hex Nut SS
41 P51-037000-0200 1 Internal Tooth Lockwasher Carbon Stl. Zinc Pl.
18 P01-031100-3900 4 Hex Hd. Mach. Screw SS
42 TB-0471 1 Trip Stirrup Cast Iron
19 P52-031000-3900 4 Lockwasher SS
Pressure Gauge 432 TA-6563 1 Spring Adapter (Top) Steel
201 TA-1854 1 Range 0–35 psig Brass Element 442 TA-2355 1 Rollpin Steel
(0–2.4 bar)
45 TA-4015 1 Male Con. & Comp. Nut C.S. Zinc Pl.
211 TA-1718 1 Regulator Aluminum/Brass
46 TA-4016 1 Elbow Con. & Comp. Nut C.S. Zinc Pl.
221 TA-3324 1 Nipple Stl. Zinc Pl.
Notes: Furnished on H & HP models only
1 2
Recommended spare part 3
Parts not mounted - packaged with unit
™
2
1/4” (8mm) FNPT
1/4” (8mm)
Discharge
FNPT Gas
Inlet 35 psig
(2.4 bar) Max.
16” (5 gal./18.9 L)
24” (10 gal./37.9 L)
1/4”
9 1/2”
6”
3 11 12 9, 10 5 6 4
Bolt Hole c:
8-3/4” x 15-5/8” (5 gal.) /18.9 L)
12-1/4” x 22-1/8” (10 gal.) /37.9 L)
8 1/4” 8”
Parts List
No.
Item Part No. Name Material
Reqd.
7 Diaphragm Vent
2 TA-0664 1 5 gal./18.9L Tank 430 Stainless Steel Assembly
2 TA-1539 1 10 gal./37.9L Tank 304 Stainless Steel 8 (TA-1835)
3 TA-3118 1 Connector Polypropylene 17
1 Elbow Connector & Polypropylene
4 TA-3116 Compression 18
1 Optional Sight Feed
Nut Assy. 3
5 TA-0950 1 Base, 5 gal./18.9L Steel Assembly14(TB-38) 2
Furnished in lieu of 19
TB-0758 1 Base, 10 gal./37.9L Steel
5/16”x22” Item 25 when specified 20
6 TA-3123 1 Suction Line mounted on tank
Polypropylene *5
21
7 1
Parts List
No.
Item Part No. Name Material
Reqd.
1 TB-0441 1 Body Cast Iron Pin Only
Valve Disc and (TA-4062)
17-4 Ph SS Steel 8 4 2
2 TA-4147 TA-4062 1 Drive- Pin Assy.
Hardened
Pin Only
42 TA-0077 1 Valve Spring Stainless Steel
Elbow Connector
5 TA-4016 1 & Compression C.S. Zinc Plated Note: To assemble, move lever arm
Nut Assy. to left as shown and align hole in
Hex Socket Cap pilot valve disc with hole in pilot
6 P03-025037-0200 1 Steel valve body.
Screw
7 P53-025000-0200 1 Washer C.S.
8 TA-0906 1 Disc Retainer C.S. Zinc Plated
17-4 SS Flipper 10 1 9
Flipper Arm &
9 TB-1766 1 Arm with C.S.
Bearing Assy.
Bearing 2
7 6
102 TA-0579 1 Washer Stainless Steel
11 TA-0677 1 Outlet Body Brass
122 TA-0391 1 Spring Stainless Steel
132 TA-0054 1 Ball Stainless Steel
TA-2580 1 O-Ring Viton 5 19
142
TA-0479 1 O-Ring Buna-N
15 TA-0678 1 Inlet Body Brass
16 TA-1296 1 Outlet Body Stainless Steel
17 TA-1297 1 Inlet Body Stainless Steel
182 TA-1574 1 Gasket Stainless Steel
Backside View Outside View
19 TA-2489 1 Valve Brass, Ni Plated
2 Recommended Spare Part
6
A 7
2 12 18
8 11 3
5 1
TB-1472
9
10 5
13 3/16” (4.8mm) Head
15 14
3 4 1 Section A-A
A 14 1/4” (8mm) FNPT 13 18 12 2
Suction
Plunger Size/Model # 3/16” (4.8mm) 5104 1/4” (6.4mm) 5101 3/8” (9.5mm) 5103 1/2” (12.7mm) 5105
All All All
Item Material Ductile w/ Ductile w/ Ductile w/
Material Specification All Stainless Steel** Stainless Stainless Stainless
No. Construction SS Trim SS Trim SS Trim
Steel** Steel** Steel**
Head Assembly No. TB-1472 TB-0166 TB-0755 TB-0203 TB-0756 TB-0496 TB-0732
1 Body TC-2040 TC-0275 TC-0291 TC-0276 TC-0425 TC-0272 TB-0349
2* Plunger 17-4 PH TA-5643 TA-1312 TA-1312 TA-1745 TA-1745 TA-1876 TA-1876
3 Plunger Packing Gland 303-SST TA-5642 TA-1463 TA-1463 TA-0957 TA-0957 TA-1219 TA-1219
Buna-N TA-3969 TA-1461 TA-1461 TA-1456 TA-1456 TA-0959 TA-0959
Buna-N Hard TA-3948 TA-2295 TA-2295 TA-1875 TA-1875 TA-1874 TA-1874
Plunger Packing Viton TA-3967 TA-4102 TA-4102 TA-4101 TA-4101 TA-4103 TA-4103
4* (see table below for maximum
discharge pressures) Viton Hard TA-6253 TA-6555 TA-6555 TA-6556 TA-6556 TA-6557 TA-6557
Teflon TA-3966 TA-1642 TA-1642 TA-1234 TA-1234 TA-1012 TA-1012
Fluorosilicone TA-6574 TA-6257 TA-6257 TA-6258 TA-6258 TA-6259 TA-6259
Buna-N TA-0479 TA-0479 TA-0479 TA-0479 TA-0479 TA-0479 TA-0479
Viton TA-2580 TA-2580 TA-2580 TA-2580 TA-2580 TA-2580 TA-2580
O-Ring, Suction & Discharge Teflon TA-6159 TA-6159 TA-6159 TA-6159 TA-6159 TA-6159 TA-6159
5* (included in items 8 & 14) Fluorosilicone TA-4113 TA-4113 TA-4113 TA-4113 TA-4113 TA-4113 TA-4113
Kalrez TA-5037 TA-5037 TA-5037 TA-5037 TA-5037 TA-5037 TA-5037
Aflas TA-5073 TA-5073 TA-5073 TA-5073 TA-5073 TA-5073 TA-5073
6 Top Bushing 302-SST TA-1496 TA-1496 TA-1496 TA-1496 TA-1496 TA-1496 TA-1496
316-SST TA-0077 TA-0077 TA-0077 TA-0077 TA-0077 TA-0077 TA-0077
7* Ball Check Spring
316-SST TA-0054 TA-0054 TA-0054 TA-0054 TA-0054 TA-0054 TA-0054
8* Large Top Ball 3/8” (9.5mm) Hastelloy TA-0064 TA-0064 TA-0064 TA-0064 TA-0064 TA-0064 TA-0064
Top Seat-Assembly Buna-N “O” Ring 303-SST TB-0737 TB-0737 TB-0737 TB-0737 TB-0737 TB-0737 TB-0737
9*
Top Seat-Assembly (Metal-to-Metal) 303-SST N/A TA-0806 TA-0806 TA-0806 TA-0806 TA-0806 TA-0806
10* Small Top Ball 1/4” (6.4mm) 316-SST N/A TA-0126 TA-0126 TA-0126 TA-0126 TA-0126 TA-0126
11 Priming Valve 303-SST TA-5462 TA-1497 TA-1497 TA-1497 TA-1497 TA-1497 TA-1497
Nut, Plunger Packing Gland 303-SST TA-6353 TA-6353 TA-6353 TA-6353 TA-6353 TA-6353 TA-6353
12 Suction Ball 3/8” (9.5mm) 316-SST TA-0054 TA-0054 TA-0054 TA-0054 TA-0054 TA-0054 TA-0054
Hastelloy TA-0064 TA-0064 TA-0064 TA-0064 TA-0064 TA-0064 TA-0064
Suction Ball 1/2” (12.7mm) (Use
13 with TA-0771) Metal-to Metal 316-SST N/A TB-0053 TB-0053 TB-0053 TB-0053 TB-0053 TB-0053
Bottom Seat only
Bottom Seat (w/Buna-N “O-Ring) 303-SST TB-1216 TB-0736 TB-0736 TB-0736 TB-0736 TB-0736 TB-0736
Bottom Seat Bushing Metal-
14* to Metal (Use w/TA-0053 1/2” 303-SST N/A TA-0771 TA-0771 TA-0771 TA-0771 TA-0771 TA-0771
(12.7mm) Ball Only)
15 Gasket 304-SST TA-4394 N/A N/A N/A N/A N/A N/A
18 Locknut Brass TA-0225 TA-0225 TA-0225 TA-0225 TA-0225 TA-0225 TA-0225
Recommended spare parts
1 2
Ductile not available
Plunger Packing - Max Discharge Pressure (Metric) Plunger Packing - Max Discharge Pressure (U.S. Customary)
Material Pressure (BAR) Material Pressure (PSIG)
4.8mm 6.4mm 9.5mm 12.7mm 3/16” 1/4” 3/8” 1/2”
Buna-N 206.8 206.8 206.8 206.8 Buna-N 3000 3000 3000 3000
Buna Hard 413.7 413.7 413.7 241.3 Buna Hard 6000 6000 6000 3500
Viton Hard™ 413.7 413.7 413.7 241.3 Viton Hard™ 6000 6000 6000 3500
Viton™ 206.8 206.8 206.8 206.8 Viton™ 3000 3000 3000 3000
Teflon™ 206.8 206.8 206.8 206.8 Teflon™ 3000 3000 3000 3000
Series 5100
5100 Microswitch Valve Installation
C Microswitch
E. TA 7088 Aluminum
Mounting Plate
D E Thrust Collar
F. TA 7090-1
Assembly
G. TA 7095 Bushing C.S. Zinc Pl.
G H. TA 4016 Elbow C.S. Zinc Pl.
I. TA 7092 Tubing S.S.
TA 7093 Microswitch Valve Kit J. TA 7097 Ferrule C.S. Zinc Pl.
K. TA 7098 Flareless Nut C.S. Zinc Pl.
TB 1193 Removal
Installation
Steps 4 through 9 Steps 4 through 8
4. Remove the TB-0548 cover.
5. Remove adjusting pin, TA-1828.
6. Remove TC-0252 diaphragm cover.
7. Pull diaphragm TC-2128 and thrust rod TB-0444 out.
8. Remove stirrup assembly TA-6564.
Steps 10 through 12
Steps 10 through 12
10. Install microswitch thrust rod collar assembly TA-7090-1.
Ensure that the clamping bolt is on the opposite side of the
thrust rod from where the microswitch will be installed. Place TA
7090-1 over the area where the stirrup assembly TA 6564 would
normally attach to the thrust rod. Do not tighten the clamping
bolt at this time.
11. Push the diaphragm TC-2128 back into position and reinstall
the TC-0252 diaphragm cover.
12. Reinsert TA-1828 adjusting pin.
Steps 13 through 14
13. Install TA-2222 microswitch valve onto the TA-7088
mounting plate with the two P01-025050-0200 HHCS. Ensure the
“TXT” tag is facing up.
14. With the microswitch installed in the mounting plate, ensure Port 1
Port 3
the lever arm is switched to the left position. Place the gasket,
TA-0058 between the mounting plate and the housing, then
attach the mounting plate to the pump housing, TD-0531 using Port 2
the four HHCS, P01-031050-0200, with the four lock washers,
Steps 13 through 14
P52-031000-0200. Ensure the microswitch valve extended shaft
is between the forks on the TA-7090-1 assembly. Microswitch Assembly Installed
Series 5100
Installation
Steps 16 through 19
16. Attach the 1/4” (8mm) MNPT X 3/8” (9.5mm) tubing 90°
elbow, TA-7096, to Port 2 (center port).
17. Assemble the tubing using the ferrule, TA-7097, and
flareless nut, TA-7098, then attach the tubing assembly,
TA-7092, to the elbow and to the pump head.
18. Tighten the clamping bolt on the thrust rod collar
assembly.
19. Connect supply gas to Port 1 on the microswitch valve. Steps 16 through 19
Stroke the pump several times. You may need to adjust the
location of the thrust rod collar to optimize operation of the
pump.
20. Control the speed of the pump using the gas supply
pressure and the speed control valve to achieve the desired
stroke rate.
Min. gas pressure: 18 psig (1.2 bar)
Max. gas pressure: 35 psig (2.4 bar)
™
Texsteam Pumps
16240 Port Northwest Drive
Houston, TX 77041
T: 832-590-2306
Toll Free: 1-800-945-9898
F: 713-849-2879
© 2021 Natural Gas Solutions North America, LLC – All rights reserved. Dresser
Utility Solutions reserves the right to make changes in specifications and features
shown herein, or discontinue the product described at any time without notice
or obligation. Contact your Dresser Utility Solutions representative for the most
current information. The Dresser Logo and all Trademarks containing the term www.dresserutility.com
“Dresser” are the property of Dresser, LLC, a subsidiary of Baker Hughes. Texsteam 5100 Series IOM NGS.IPG.0015a
08.21