High-Pressure

System Design Guide

Product Quality, Reliability and Support You Expect

www.catpumps.com
System Design Basics
Achieving Maximum Pumping System Performance
High-pressure pumping systems typically involve positive displacement pumping technology, where flow directly correlates with
the revolution of a pump crankshaft. The total output of the pump is not only determined by RPM but also cylinder bore and
piston/plunger stroke. Since most liquids are not significantly compressible, pressure is created by restriction on the discharge line
downstream of the pump.

Optimum performance of the pump is dependent upon the entire liquid system and can only be obtained with the proper design,
component selection, installation and maintenance of the pump and system accessories.

This guide contains helpful system design information to assist in all phases of design, from component selection and installation
to establishing a maintenance program and preparing for extended storage. There is also a collection of reference materials to
assist with the system design process. This document is to be used as a guide only. Cat Pumps does not assume any liability
or responsibility for the design or operation of a customer’s high-pressure system.

Table of Contents
System Design Basics 2-3 Preventive Maintenance 14
Selecting Your Pump 4-5 Extended Storing 15
Typical Installation 6-7 Reference Documents 16-18
Standard Nozzle Chart 16
Inlet Design 8-11
Hose Friction Loss 17
Liquid Properties 8
Water Line Pressure Loss 17
Reclaim 9
Resistance of Valves and Fittings 18
Inlet Feed 9
Conversion Chart 18
Inlet Plumbing Recommendations 10
Custom Pumping Systems 19
Cavitation 11
Discharge Design 12-13
Regulator vs. Unloader 12
Primary and Secondary Relief 12
Pulsation 13

Industry Leading Customer Service

Cat Pumps knowledgeable and experienced customer service team provides
assistance with order information, as well as technical support in product selection,
installation, maintenance, pump repair and general system troubleshooting.

Support is available M – F, 8:00 a.m. to 5:00 p.m. CST at (763) 780-5440.

Email: [email protected]

2
Selecting a Pump
Be careful not to fall into the price trap and buy an undersized pump with an oversized rating designed for intermittent duty.
Investigate the longevity of the pump and the typical length of intervals between required servicing. Immediate availability of parts
is also important to consider.

It is important to operate your pump within its rated performance. This not only includes flow and pressure but also includes inlet
conditions, temperature, duty cycle and liquid compatibility. Beyond our standard product offering, we have a variety of different
manifold and elastomer materials available to meet the most demanding application needs.

Selecting Accessories
Your pumping system is only as strong as your weakest component so it is critical that each component is carefully selected based
on the same criteria as the pump. Each system requires carefully sized matching accessories to set and maintain system pressure,
monitor system performance and protect system from over-pressurization. Not all systems require the same accessories. Minimally,
we recommend a primary pressure regulating valve, secondary pressure relief valve and a pressure gauge. Other accessories can be
determined by application and installation.

It is also critical to install and maintain a good inlet filter in your high pressure system. Even city water can contain abrasive particles
that shorten pump life as well as other system accessories.

Selecting a Power Source

Positive displacement pumps can utilize a variety of different power sources including electric motors, gas or diesel engines, hydraulic
and pneumatic motors. Be sure you have sized your system power source with adequate horsepower to handle the maximum system
flow and pressure required.

Handy Formulas
GPM x PSI GPM x PSI
Required Electric Brake HP* = Hydraulic Torque (ft. lbs.) Required = 3.6 x
1460 RPM
*Standard 85% Overall Efficiency

Selecting a Drive
Cat Pumps are offered with a variety of different drive options. Most systems are belt driven by a pulley or clutch, but there are also
direct drive options such as direct coupled, gearbox or hollow shaft direct drive.

Handy Formulas
Rated RPM Pump RPM
Desired RPM = Desired GPM x Pump Pulley* x = Motor Pulley*
Rated GPM Motor/Engine RPM
*Pitch Diameter

System Location
Your pumping system should be mounted in areas away from direct spray, standing water or freezing temperatures. Pump should
be mounted on a rigid, horizontal surface for optimum lubrication and to minimize vibration. If the pump is used in extremely dry
or humid conditions, it is recommended that the pump be enclosed. Do not store or operate in excessively high temperature areas
without proper ventilation.

3
Selecting Your Pump
Plunger Pumps (0.13 – 240 gpm, 100 – 10,000 psi)
Plunger pumps utilize spring-loaded closed and
hydraulically opened inlet and discharge valves
to direct flow through the pump manifold. At the
beginning of the stroke, the plunger displaces
the liquid in the manifold chamber, forcing the
discharge valve open. When the plunger reaches
the end of the stroke, the discharge valve closes.
As the plunger rod begins its backward stroke,
the inlet valve opens to allow more liquid into the
manifold chamber, thereby keeping a smooth
forward flow of liquid.

4 9 8 10 7 6 1 3

XP Series Pumps (0.5 – 2 gpm, 100 – 1,000 psi)

In XP series pumps, fluid enters the inlet port
and flows through the drive-end, lubricating the
connecting rods and plunger rods as it passes
to the inlet valves. Both inlet and discharge
valves are spring-loaded closed and hydraulically
opened, similar to plunger pumps, however, they
utilize a flow- through ceramic plunger design.
The continuous forward flow characteristics in
conjunction with the packing design of plunger
pumps result in improved suction capabilities as
well as extended seal life.

11 10 8 7 1 6 3

Features
1 Specially formulated, Cat Pumps exclusive high pressure 4 Chrome-moly crankshaft provides unmatched strength and
seals/cups offer unmatched performance and seal life. surface hardness for long life.

2 100% wet cup/seal design adds to service life by allowing 5 The patented stepped piston rod with hard chrome-plated
pumped fluids to cool and lubricate the elastomers on sleeve provides a durable wear surface and easy wet end
both sides. servicing.

3 Stainless steel valves, seats, and springs provide corrosion- 6 Precision-polished, solid ceramic plungers provide maximum
resistance, positive seating, and long life. resistance to corrosion and abrasion, extending seal life.

4
Piston Pumps (3.0 – 60 gpm, 100 – 1,500 psi)
The design of the piston pump is for the fluid to
move continually in one, smooth forward direction. 10
This design allows greater suction capabilities and
8
reduces the risk of cavitation provided the pump
is properly primed. At the beginning of the stroke,
the mechanically actuated inlet valve (and piston)
will close. As the piston rod moves forward, the
liquid is forced out through the discharge valves.
Simultaneously, the liquid enters the pump inlet
and flows in behind the inlet valve. As the piston
rod begins the backward stroke, the inlet valve
mechanically opens, permitting the liquid to
continue its flow forward through the piston into
3 2 5 1 7 9 4
the discharge chamber.

SF Series Pumps (0.5 – 5 gpm, 100 – 3,500 psi)

In SF series pumps, both the inlet and discharge
valves are spring-loaded closed and hydraulically
opened, similar to plunger pumps, however, they
have a flow- through ceramic plunger design. The 10
continuous forward flow characteristic of piston
pumps is utilized in conjunction with the packing
design of the plunger pumps. These features give
SF pumps both strong suction capabilities and
higher pressure performances.

3 3 1 7 8 4 9

7 The high strength stainless steel plunger rods have a 360° 10 High Strength, light weight die cast aluminum crankcase
supported crosshead providing uncompromising plunger with splash oil design allows operation at speeds as low as
rod alignment. 100 RPM.
8 Matched oversized connecting rods are made of high 11 Patented greaseless design uses water from inlet as
strength material with exceptional bearing quality. lubrication, eliminating the maintenance and mess of
grease or oil.
9 Oversized ball bearings or tapered roller bearings provide
extended bearing life.

5
Typical Installation
Basic Installation
11

17 5 2

16

18
7

Trigger Gun Installation 11

5 6 1

17

16 12
3
13
18

8
7
15

10

IMPORTANT NOTICE: These illustrations show the basic elements for a typical installation of a high pressure piston or plunger pump. Not all components
shown are required for all applications or systems. Each component may present a potential problem that could interfere with the operation of your
system such as: a clogged strainer, faulty gauge, or a malfunctioning regulator/unloader. Proper system installation, monitoring and maintenance of
components are necessary for optimum pump performance. Cat Pumps does not assume any liability or responsibility for the design or operation of a
customer’s high pressure system.

6
Typical Accessories

Item Part Function Installation Notes

1 Unloader Used to accurately set and maintain system pressure as well as Plumbed to the high pressure side of the pump manifold, preferably on a discharge port.
reduce load on the pump and motor when the system is in by-pass. Must be in line with the discharge hose.

2 Regulator Used to accurately set and maintain consistent system pressure. Plumbed to the high pressure side of the pump manifold, preferably on a discharge port.

3 Pop-Off Valve Provide your system with an accurate and reliable secondary Plumbed to the high pressure side of pump manifold before primary regulating device or
pressure relief to protect your pump and system from damage on an open discharge port.
caused by over-pressurization. Set 200-300 psi above system operating pressure.
4 Relief Valve Provides your system with an accurate and reliable secondary Plumbed to the high pressure side of pump manifold before primary regulating device or
pressure relief to protect your pump and system from damage on an open discharge port.
caused by over-pressurization. Set 200-300 psi above system operating pressure.
5 Pressure Gauge Used to accurately monitor pump pressure. Plumbed to high pressure discharge side of pump.
Note: If mounted before and unloader and there is a shut off valve downstream the pressure will
be near zero. If located after the unloader the pressure will be at the set pressure.

6 Pulsation Used to help provide smooth and consistent flow as well as increase Plumbed on the high pressure side of the pump and as close to the pump as possible for
Dampener overall system life. optimum dampening.
Reduces pulsation to 1-3%. If system uses an unloader where bypass flow is diverted back to pump inlet with a check
valve or inlet regulator, the pulsation dampener must be plumbed after the unloader.

7 Inlet Filter Used to catch particles and debris from reaching and causing Plumbed on the inlet side of a pump near the supply tank or before the any other
damage to your pump. inlet accessories.

8 Inlet Pressure Used to accurately set and maintain consistent system pressure at Plumbed on the inlet side of a pump after a filter or by-pass hose but before a flexible
Regulator pump inlet. hose or inlet pressure stabilizer.

9 Inlet Used to stabilize and maintain consistent inlet pressure when Plumbed directly to the inlet port of a pump.
Stabilizer* dealing with high temperatures, booster pump feed, long inlet
lines or pressure spikes caused by regulating valves.

10 Thermal Valve Used to relieve heat build-up in closed loop by-pass systems. Plumbed in the bypass line near the inlet port for optimum performance.

11 Oil Gauge/Drain Kit Used to provide convenient monitoring of crankcase oil as well as Plumbed to the rear cover of the crankcase.
fast and convenient oil changes.

12 Quick Start Valve Relieves discharge line pressure during system start-up when using Plumbed in the high pressure side of the pump.
pressure lock style unloader with gas/diesel engines. When being used with an unloader, valve must be plumbed to discharge after unloader.

13 Throttle Controller Reduces engine wear and fuel consumption by reducing engine Plumbed to the high pressure side of the pump before and unloader or directly to a
RPM while in system bypass. discharge port.
Cannot be used with a regulator.

14 LPS Monitor* Alerts you when the low pressure seals are worn and need Replaces oil pan behind pump manifold. See product data sheet for selection and
replacement with indication light or can be integrated via PLC. installation guide.

15 Bypass Hose Used to route pump flow from unloader back to pump inlet when Plumbed from the bypass port of a regulator or unloader back to the pump inlet or
system is running in bypass. supply tank.
If plumbed back to the inlet of a pump it should be before an inlet regulator. Always use
a thermal valve to protect from heat buildup when system is running in bypass.

16 Shaft Protector Eliminates exposure of rotating pump shaft. Mounted on pump crankcase side cover.

17 Oil Cap Protector Helps minimize water leakage into crankcase. Mounted on crankcase oil fill cap.

18 Rails Used to mount pump assembly to base. Mounted to crankcase feet.

Ensure that base is on an even, level surface.

* Not Pictured

7
 Inlet Design
Liquid Properties
Before selecting a high-pressure pump for any new pumping system, it is important to start with your desired performance and to
evaluate the fluid you desire to pump. Viscosity, temperature and the chemical make-up of the desired fluid can have great impact
your pumps performance.

Viscosity
Viscosity refers to “thickness” or resistance of a fluid. Due to the tight tolerances and motion of flow through a pump, the positive
displacement, reciprocating design operates best with non-viscous fluids. Cat Pumps recommends operating with liquids up to
500 cP or 2500 SSU. It is also important to consider that the viscosity of a fluid can change due to heat, velocity, exposure to
atmosphere or mixing with other liquids. For applications above 500 cP, contact Cat Pumps for more information.

Temperature
Standard pumps are rated to operate with a maximum fluid temperature between 140°F – 180°F depending on the model. However
for some fluids special elastomers are available to allow temperatures to 240°F. As the temperature of water increases, the vapor
pressure (pressure required to remain liquid) also increases. By increasing the inlet pressure to the pump, you can minimize
the increased risk of cavitation. A pressurized inlet above 130°F, reducing pump RPM, installing an inlet stabilizer in inlet line and
increasing inlet line size to the pump are several aspects of the system that should be considered with elevated temperatures to
achieve optimum performance.

Maximum Pump Speed Vs. Water Temperature

HT SEALS & ‘K’ STYLE 100% 100% 100% 100% 100% 100% 100% 80%
RPM

FPM SEALS 100% 100% 100% 100% 100% 80% 60% 0%

NBR & EPDM SEALS 100% 100% 100% 100% 100% 60% 0% 0%

60 psi (4.1 bar)

Inlet Pressure

50 psi (3.4 bar)

40 psi (2.8 bar)

Safe Liquid Region
30 psi (2.1 bar)

20 psi (1.4 bar)

10 psi (0.7 bar)

Piston Pump Plunger Pump Unsafe Liquid Region
0 psi

-10 psi (-0.7 bar)

-14.5 psi (-0.9 bar) Water/Vapor Barrier Vapor Region
40F 60F 80F 100F 120F 140F 160F 180F 200F 210F
(4C) (16C) (27C) (38C) (49C) (6C) (71C) (82C) (93C) (99C)

Inlet Water Temperature

Pressurized Inlet Reduction in RPM

To achieve the recommended inlet pressures with elevated Reducing pump RPM will also offer added protection from
temperatures, it is often necessary to install a booster pump. cavitation when elevated temperatures exist. Reducing pump
The booster pump flow rate should be approximately twice RPM also reduces the acceleration and vaporization of the
the system capacity to assure adequate flow into the pump. water and its damaging effects.

8
Inlet Stabilizer Increased Inlet Size
The inlet stabilizer absorbs energy from a positive head to increase It is always important to have the inlet supply line sized to match
the liquid acceleration which significantly reduces cavitation and or be one size larger than the pump inlet port for optimum
dampens system spikes. If water tank is more than 5-6 feet from the performance, but it is most critical when the pumped liquid is
pump, long feed lines, or high temperature are present, the inlet at elevated temperatures. Undersizing the line will only
stabilizer should be installed to stabilize inlet pressure. compound the problems of high temperature vaporization.
Note: The inlet stabilizer will not function with a negative suction inlet. See individual pump data sheet.

Chemical Compatibility
If you are working with a fluid other than water, you must check the compatibility of the desired fluid with the seal and manifold
material of your pump. Cat Pumps offer a variety of different elastomers and manifold materials to meet a wide variety of application
needs. Cat Pumps work best with fluids with a pH level between 5 and 9. If you are working outside that range, please contact our
technical support team for proper selection.

Reclaim
Reclaim systems typically operate in the 5 – 50 micron range, with the majority running 5 – 25 micron range. The water quality
and type of particulate does have a direct effect on pump life. As particle sizes increase there is a potential decrease in pump life.
Consequently, we do recommend the specifications below for optimum performance and maximum life.

• Particle Size — Not to exceed 50 Micron

• TSS — Not to exceed 50 PPM
• Sediment pits — Cleaned regularly
• Reclaim Filtration System — Must be operated/maintained according to requirements provided by manufacturer of reclaim system

Inlet Feed
Inlet pressure specifications for proper pump priming vary by the pump design. Ideally, all piston and plunger pumps would have
an inlet pressure of 20 to 30 psi, but inlet pressure can range based on models. Refer to individual pump data sheet for proper inlet
pressure conditions. Gravity fed installations are also acceptable but need to be set up to maintain a positive head pressure to avoid
pump cavitation.

Gravity Feed
When a gravity fed tank is used, Cat Pumps recommends the following precautions be taken:

• T he reservoir should be 6-10 times the rated flow • T he tank should be mounted as high as possible above the
of the pump. pump. Ideally the liquid level (even when the tank is nearly
• T he reservoir should be baffled so turbulent flow is not empty) should be at least 6.5 feet (2 meters) higher than
created causing air bubbles which lead to cavitation. the pump. Applications closer to the liquid vapor pressure
• T he supply line should be on the opposite side of the baffles (i.e., hot water) require a higher static head.
and return line. • A
 low-level switch or inlet pressure sensor should be installed
• The tank should be covered to prevent contamination. to stop the pump should the tank levels fall too low.

9
 Typical Reservoir Tank
T (Dia of pipe)
Bypass Line Supply Line X D
(from regulator or unloader)
1.5 x D (Min) Preferred
Location
Min 4"
Level Sensing
Device Filter
Flexible Bypass Line
Hose Minimum (from regulator
Filter to Pump Liquid or unloader)
Level

Min 4"

Optional location if more filtration is needed Minimum Two Baffles

Suction Feed Pressure Feed

Piston pumps have more suction lift because of their flow — When a liquid is close to its vapor pressure or it is not possible
through design, continuous forward flow design, and to provide adequate head pressure, the pump can be pressure
mechanically actuated inlet valves. For this reason, piston fed with a booster pump, typically a centrifugal pump. For most
pumps are the preferred choice for suction lifting applications. pressure fed applications, an inlet feed pressure of 20 psi is
In most cases the inlet will lose prime when the pump is not in adequate. The maximum inlet pressure allowable for
operation. Consider fitting a non-return foot valve at the bottom plunger pumps is 60-70 psi and 40 psi for piston pumps.
of the inlet feed pipe and manually prime the pump before If your application requires inlet pressure above these ratings,
initial start-up. Exceeding suction limits of pumps will “starve” utilize an inlet pressure regulator or contact Cat Pumps for
the pump for liquid and cause cavitation. more information on our specialty pumps designed for inlet
conditions up to 800 psi.
•P
 iston pumps: Do not exceed - 8.5 psi gauge suction.
•P
 lunger pumps: Do not exceed - 5 psi gauge suction on
some models and flooded inlet on other models (consult
data sheet for the pump model selected).

IMPORTANT NOTICE: Be sure to consider all pressure losses that contribute to reduced inlet pressure when designing a system. This can include vertical
distance, line, fitting and other frictional losses.

Inlet Plumbing Recommendations

Recommendation Description
Avoid Hard Plumbing Do not hard plumb the supply to the pump inlet. The pump will vibrate during normal operation and vibrations can be transmitted though
piping, occasionally causing leaks of hard plumbed fittings. A flexible inlet hose is recommended.
Plunger Pump Inlet Ports A plunger pump can be fed from either side of the pump inlet manifold or both. Feeding the pump from both inlet ports is recommended
when the supply conditions are poor, resulting in a higher risk of pump cavitation.
Piston Pump Inlet Port A piston pump is typically fed at the bottom port of the pump manifold. If a top feed is desired, the manifold can be inverted without
causing issues.
Sizing Plumbing Size the inlet plumbing to allow unrestricted flow into the pump as a safeguard against cavitation. The plumbing should be a minimum of
one pipe size larger than the pump inlet fitting size.
Avoid Unnecessary Fittings Use as few fittings and changes of flow direction as possible.
Use Oversized Elbows Use large radius swept elbows or reinforced inlet hose.
Direct Flow Straight into Inlet When possible, install a straight pipe immediately before the pump inlet connection.
Multiple Pumps If more than one pump will be supplied from the same supply tank, provide separate inlet lines from the tank to the pump. If this is not
possible, use a Y fitting or swept tee to branch off a single supply line to multiple pumps. Ensure the main feed line is of an adequate
diameter to feed all pumps simultaneously.

10
Cavitation
Proper design of the pump inlet supply is critical to avoid cavitation and operate
an effective pumping system. Cavitation occurs when a lack of liquid to the inlet
causes vaporization in the low pressure chamber of the pump. When a vapor bubble
is re-pressurized, it quickly collapses supersonically and the shock wave causes surface
erosion. This release of energy is created by collapsing cavities, causing pitting and
erosion of metallic or ceramic components. Cavitation also produces excessive pump
noise. The noise will be less pronounced when the pump is in bypass due to lower
pressure changes. Piston pumps sound like the connecting rods are knocking or a
bearing is bad. Plunger pumps sound similar to piston pumps, but most of the noise
can be heard in the valve area of the head.
Cavitation will also decrease the pumps output due to the combination of liquid and
vapor in the pumps inlet chamber. Cavitation will not only cause pitting in the valves
and manifold, but also reduces the lubrication of the seals, resulting in reduced seal life.

Conditions Solutions
Inadequate inlet line size Increase line size one size larger than the pump inlet port
Water hammering liquid Install inlet stabilizer at pump inlet
Move pump closer to liquid supply
Add pulsation dampener
Rigid inlet plumbing Use flexible wire reinforced hose at inlet and discharge pump port to absorb pulsation and
pressure spike
Excessive elbows in inlet plumbing Keep elbows to a minimum and less than 90°
Excessive liquid temperature Use thermal relief valve in bypass line
Substitute closed loop with dual baffled holding tank
Size tank for frequent or high volume bypass
Pressure feed high temperature liquids
Properly ventilate cabinets and rooms
Air leaks in plumbing Check all connections
Use PTFE thread tape or pipe thread sealant
Agitation in supply tank Size tank according to pump output (minimum 6 times pump performance rating)
Baffle tank to purge air from liquid and separate inlet / discharge
High viscosity liquids Verify viscosity against pump specifications before operation
Elevate liquid temperature enough to reduce viscosity
Lower RPM of pump
Pressure feed pump
Increase inlet line size
Clogged filters Clean filters regularly
Use clear filters to monitor build up
Use adequate mesh size for liquid and pump specifications (80 mesh recommended for fresh water,
50 micron for reclaim applications)

11
 Discharge Design
Regulator vs. Unloader
One common inquiry from system
designers is the difference between
a pressure regulator and a pressure
regulating unloader. When using a

Piston Assembly
pressure regulator, both the pump and

Piston Assembly
Inlet Port Outlet Port Inlet Port Outlet Port
downstream components will always
be at the set system pressure. A pressure Pump
Check Valve
Discharge Pump
Check Valve
Discharge
Flow Flow
regulating unloader performs the same
function as a regulator but also contains
a check valve on the discharge side. 5 – 10%
Minimum
Bypass Port Bypass Port
When a shut-off device downstream is
closed, the check valve seats against the
body of the unloader, trapping the high- Normal Operation Bypass Operation
pressure from the check valve to shut-off When the check valve on the unloader When downstream flow is stopped,
device, relieving pressure between the is open during normal operation, the the check valve seats with the body of
unloader valve and pump head. This not valve operates the same as a pressure the unloader, trapping high pressure
only reduces wear on pump and drive regulator. The valve is used to set and in the discharge line. The high pressure
components, but also protects against maintain consistent pressure from pump trapped in the discharge line holds
rapid heat rise. If the bypass is being head to discharge line while bypassing open the piston assembly, relieving
redirected to the pump inlet, a thermal a minimum of 5-10% of the flow. pressure between the valve and pump
valve is recommended as a safeguard head, directing low pressure water out
against excessive heat. the bypass port.

Primary and Secondary Relief

To protect your system from damage or costly downtime caused by over pressurization, be sure that your system is equipped
with both a primary and secondary safety relief device. A pressure regulator or pressure regulating unloader can be used as
primary relief device, but it is important to always include a secondary pressure relief or pop-off valve. This provides additional
protection for your pump and system components in the event that the discharge or downstream plumbing becomes restricted.

Setting System Pressure and Relief

1. Tighten pressure adjustment nut on the relief valve 2-3 turns.
2. Start the system with the regulator or unloader at the lowest setting.
3. T ighten the pressure adjustment nut on the regulator or unloader in small increments until you get to the desired system
pressure. If the relief valve starts to leak from the bypass port, tighten the pressure adjustment nut on the relief valve
until leak stops.
4. A
 fter system pressure is set with the regulator or unloader, the relief valve needs to be set. Loosen the adjustment nut on
the relief valve until fluid starts to come out the bypass port. Then tighten it until it stops bypassing fluid plus an additional
1-2 turns. Then the relief valve pressure will be set 200-300 psi higher than the regulator or unloader valve.

NOTE: When using an unloader, there will be a small pressure spike when the check valve engages. If there is a leak out of the relief valve during this
operation, tighten the relief valve adjustment an additional half turn.

12
Pulsation
Due to the design of the positive displacement pumps, small pressure spikes
are created during each rotation. These spikes can cause accelerated wear or
damage to the pump or downstream components in certain applications.
The installation of a pulsation dampener is your best safeguard against Nitrogen
Pre-Charge
the effects of pressure pulsation.

A pulsation dampener contains a dry nitrogen charged bladder that is used to

absorb both the high and low fluctuations of pressure produced by a positive Flexible
Bladder
displacement pump. During each triplex pump rotation, the flow demand
changes direction 6 times, which causes a pressure variance of 16-20% from
nominal. A pulsation dampener’s bladder not only absorbs the pressure spikes
during operation, but due to the nitrogen charged bladder, it pushes flow back
into the stream during the low pressure wave, reducing the total fluctuation to
2-3% with a properly sized dampener.
Pulsation Dampener Benefits:
Model 1530 w/o Pulsation Dampener Model 1530 w/ Pulsation Dampener • Produces smooth, consistent flow
1.75
1.75
• P
 rotects downstream system
1.50 1.50 components (i.e., regulator, unloader,
relief valve)
1.25 1.25
• Reduces water hammer
Min. Pressure = 1275 psi Max. Pressure = 1652 psi Min. Pressure = 1421 psi Max. Pressure = 1543 psi
OP. Pressure = 1500 psi Pressure Range = 377 OP. Pressure = 1500 psi Pressure Range = 122 • Improves performance at low rpm
• H
 igh cycle rate application
For best results, the dampeners should be mounted as close to the pump head as improvement
possible, preferably in a vertical position. Dampener should be charged at 60% of • R
 educes operator fatigue in hand-
operating pressure. operated systems

TECH TIP
Pump Rotation Forward Rotation Reverse Rotation
Forward rotation (towards the
manifold) is recommended to
allow optimum lubrication of the
crosshead area. If your installation
does not allow for forward rotation,
reverse rotation is acceptable if
the crankcase oil is above the red
dot in the oil gauge. This indicates
adequate lubrication.

13
 Preventive Maintenance
The best safeguard against unplanned shut-down or system failure is establishing good preventive maintenance practices.
Cat Pumps triplex pump design offers easy on-site maintenance without the use of special tools, making a routine maintenance
achievable without difficulty. Each pump has a data sheet and service manual to simplify the periodic servicing required.

This schedule is intended as a guide only. Each system/application is different and should be evaluated/serviced according to its
own custom maintenance schedule.
Water leaks or loss of system performance can be an indicator of
50 1500 3000 seal wear. Seal wear has many causes, including contaminated
Check Daily Weekly Hrs. Hrs. Hrs.
liquid or high-temperature/run dry operation. If the low-pressure
Filters • or •
seals show wear, the high-pressure seals most likely are in a
Oil Level/Quality • or • 1 similar condition. It is a good practice to replace both low and
high pressure seals and inspect plungers when leaks are present.
Water Leaks • or •

Oil Leaks •

1 Cat Pumps recommends using our custom-blend premium
grade hydraulic oil, formulated to meet Cat Pumps
Plumbing • specifications. For best results, perform an initial oil change
Belts, Pulley • after the first 50 hours of operation, then every 500 hours.

2 Past performance and maintenance history are the best
Accessories •
indicators of future performance. If system performance
Seals 2
degrades or changes, check seals and valves. Service
Valves 3 as required to restore system performance. Depending
upon operating conditions, maintenance intervals for seal
kits range between 1,500 and 8,000 hours.

3 Valves typically require changing every other seal change.

Industrial Duty Products to Meet

your Application Demands
Cat Pumps has developed a reputation in the industry
for the quality, reliability and durability of our products.
Serving thousands of industries and application around
the globe, Cat Pumps offers a wide range of pump and
accessory options to meet your application needs.

Pumps Accessories:
• Flow: 0.13 to 240 gpm (.49 to 908 lpm) • Oil • Guns
• Pressure: 100 to 10,000 psi (6.9 to 689 bar) • Regulators • Thermal Valves
• Unloader Valves • Oil Drain Kits
• Liquid Temperature: -10° to 240°F (-23° to 115°C)
• Relief/Pop Off Valves • Throttle Controllers
• Manifold Materials : Brass, Nickel Aluminum Bronze,
• Pressure Gauges • Quick Start Valves
304 and 316 Stainless Steel, Duplex Stainless Steel
• Pulsation Dampeners • Specialty Controls
• Inlet Filters • And More…

14
Extended Storing
For systems that are used in a seasonal application or as a standby system, proper precautions must be taken to preserve
the life of the pump/pumping system when subjected to extended storage. For optimum system performance, use the
following guidelines.

Prior to storage During Storage

Location Rotate motor shaft at least 10 turns every two months
Selecting an appropriate location is an important aspect of the during storage (more frequently if possible). This will prevent
storage process. Your pump/pumping system should ideally bearing damage.
be stored in a dry location at ambient indoor temperature, Stored motors require using a “Megger” periodically to ensure
preferably with a poly or canvas cover. Avoid areas that are that the integrity of the winding insulation has been maintained.
subject to excessive heat, humidity, freezing, dust or damage Record the Megger readings. Immediately investigate any
from passing equipment. significant drop in insulation resistance. Review all motor
manufacturer requirements for storing.
Climate
If freezing conditions are a possibility, flush your pump with Prior to initial start-up after storage
50/50 solution of anti-freeze/water. Any supply tanks, hoses
or feed lines should be drained. The use of Cat Pumps Pump After extended storing, seals and O-rings may take a set and
Protector is highly recommended. require replacement. Hand-rotate the pump crankshaft to check
for smooth operation. If shaft is extremely tight or will not turn,
If extremely humid conditions exist, coat any surfaces or
replace seals and O-rings before resuming operation. O-rings in
hardware that are subject to corrosion with a light film of
the relief valves may also require replacement. Typical shelf life
protective oil. Note: Do not lubricate motor bearings during
of seals and O-rings is 5 years.
storage. Bearings are packed with grease at the factory. Excessive
grease can damage insulation quality. Change oil at start-up and fill to the red dot on the bubble
gauge prior to resuming operation.
If damp or humid conditions exist, the motor windings must
be protected from moisture. Apply power to the motor’s space If belts were loosened prior to storage, check for proper tension
heater (if available) while the motor is in storage. before starting system.

Pump Protection
Apply light film of protective oil to pump crankshaft.
Fill crankcase to the top of the bubble gauge with oil to
protect the pump bearings.
Loosen the tension on any belts during extended storage.

Online Resources Available 24/7

Catpumps.com offers a variety of helpful • Training Articles
tools to assist in all phases of system design. • Maintenance and Repair Information
In addition to browsing our complete line • Troubleshooting
of pumps and accessories using the online • FAQ’s
product selector, there are also a variety of • Helpful Resource Documents
training resources including: • Service Videos

15
 Reference Documents
Standard Nozzle Selection Chart

Std. Equiv.
Nozzle Orifice NOZZLE FLOW (GPM) AT VARIOUS PRESSURES (PSI)
(Size)* Diam.
Number (inches) 250 500 600 700 800 1000 1200 1500 2000 2500 3000 3500 4000 5000
2.0 .034 .50 .71 .77 .80 .89 1.00 1.10 1.20 1.40 1.60 1.70 1.90 2.00 2.23
2.5 0.039 0.63 0.88 0.97 1.05 1.12 1.25 1.37 1.53 1.77 1.98 2.17 2.34 2.5 2.8
3.0 .043 .75 1.05 1.19 1.25 1.34 1.50 1.60 1.85 2.10 2.35 2.60 2.85 3.00 3.35
3.5 .048 .87 1.23 1.40 1.47 1.56 1.75 1.90 2.17 2.45 2.73 3.05 3.32 3.50 3.90
4.0 .052 1.00 1.40 1.60 1.70 1.80 2.00 2.20 2.50 2.80 3.10 3.50 3.80 4.00 4.50
4.5 .055 1.10 1.50 1.70 1.90 2.00 2.20 2.40 2.80 3.00 3.60 3.90 4.30 4.50 5.03
5.0 .057 1.30 1.80 1.90 2.10 2.20 2.50 2.80 3.10 3.80 4.00 4.40 4.70 5.00 5.60
5.5 .060 1.40 1.90 2.10 2.30 2.50 2.80 3.00 3.40 3.90 4.40 4.80 5.20 5.50 6.20
6.0 .062 1.50 2.10 2.30 2.50 2.70 3.00 3.20 3.70 4.20 4.80 5.20 5.60 6.00 6.70
6.5 .064 1.70 2.30 2.50 2.70 2.90 3.30 3.60 4.00 4.60 5.20 5.70 6.00 6.50 7.30
7.0 .067 1.80 2.50 2.70 2.90 3.10 3.50 3.80 4.30 5.00 5.60 6.10 6.60 7.00 7.80
7.5 .070 1.90 2.70 2.90 3.20 3.40 3.80 4.10 4.60 5.30 6.00 6.50 7.00 7.50 8.40
8.0 .072 2.00 2.80 3.10 3.40 3.60 4.00 4.40 5.00 5.60 6.20 7.00 7.50 8.00 8.90
8.5 .074 2.20 3.00 3.30 3.60 3.80 4.30 4.60 5.30 6.00 6.70 7.40 8.00 8.50 9.50
9.0 .076 2.30 3.20 3.50 3.80 4.00 4.50 5.00 5.50 6.40 7.10 7.80 8.50 9.00 10.10
9.5 .078 2.40 3.40 3.70 4.00 4.30 4.80 5.20 5.80 6.80 7.60 8.30 9.00 9.50 10.60
10.0 .080 2.50 3.50 3.90 4.20 4.50 5.00 5.40 6.10 7.00 8.00 8.70 9.40 10.00 11.20
12.0 .087 3.00 4.20 4.60 5.00 5.40 6.00 6.40 7.30 8.40 9.50 10.40 11.20 12.00 13.40
15.0 .094 3.80 5.30 5.80 6.40 6.80 7.50 8.20 9.20 10.60 12.00 12.90 14.00 15.00 16.80
20.0 .109 5.00 7.10 7.80 8.40 9.00 10.00 10.80 12.20 14.20 16.00 17.40 18.80 20.00 22.40
30.0 .141 7.50 10.60 11.60 12.80 13.60 15.00 16.40 18.40 21.20 24.00 26.00 28.00 30.00 33.50

*A commonly used standard for nozzle size is the “nozzle number” which is equivalent to the nozzle
capacity in GPM at 4000 PSI. Spray angle does not affect nozzle flow.

• If psi and nozzle gpm is known, then nozzle number can be calculated as follows:
Nozzle number = gpm x √ 4000
psi

• If psi and nozzle number is known, then gpm can be calculated as follows:
gpm = nozzle number x √ psi
4000
• If gpm and nozzle number is known, then psi can be calculated as follows:
gpm
psi = ( nozzle number )2 x 4000

16
Hose Friction Loss

PRESSURE DROP PER 100 FT OF HOSE (PSI)

Water* Flow Hose Inside Diameters, Inches
Gal/Min
1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 1"
.5 16 5 2
1 54 20 7 2
2 180 60 25 6 2
3 380 120 50 13 4 2
4 220 90 24 7 3
5 320 130 34 10 4
6 220 52 16 7 1
8 300 80 25 10 2
10 450 120 38 14 3
15 900 250 80 30 7
20 1600 400 121 50 12
25 650 200 76 19
30 250 96 24
40 410 162 42
50 600 235 62
60 370 93
* Note: At a fixed flow rate with a given size hose, the pressure drop across a given hose length will be directly proportional. A 50 ft. hose will exhibit
one-half the pressure drop of a 100 ft. hose. Above values shown are valid at all pressure levels.

Water Line Pressure Loss

PRESSURE DROP IN PSI PER 100 FT

Water
Gallons Steel Pipe – Nominal Diameter Brass Pipe – Nominal Diameter Copper Tubing O.D. Type L
Per Min

1/4 3/8 1/2 3/4 1 1¼ 1½ 1/4 3/8 1/2 3/4 1 1¼ 1½ 1/4 3/8 1/2 5/8 3/4 7/8

1 8.5 1.9 6.0 1.6 120 13 2.9 1.0

2 30 7.0 2.1 20 5.6 1.8 400 45 10 3.4 1.3
3 60 14 4.5 1.1 40 11 3.6 94 20 6.7 2.6
5 150 36 12 2.8 100 28 9.0 2.2 230 50 17 6.1 3.0
8 330 86 28 6.7 1.9 220 62 21 5.2 1.6 500 120 40 15 6.5
10 520 130 43 10 3.0 320 90 30 7.8 2.4 180 56 22 10
15 270 90 21 6.2 1.6 190 62 16 5.0 1.5 120 44 20
25 670 240 56 16 4.2 2.0 470 150 40 12 3.8 1.7 330 110 50
40 66 17 8.0 39 11 5.0 550 200 88
60 37 17 23 11
80 52 29 40 19
100 210 107 48 61 28

17
 Reference Documents
Resistance of Valves and Fittings

EQUIVALENT LENGTH OF STANDARD PIPE IN FEET

Nominal Inside
Pipe Size Diameter Gate Globe Angle 45º 90º 180º Tee Thru Tee Thru
(inches) (inches) Valve Valve Valve Elbow Elbow Close Ret Run Branch

1/2 0.622 0.41 18.5 9.3 0.78 1.67 3.71 0.93 3.33
3/4 0.824 0.54 24.5 12.3 1.03 2.21 4.90 1.23 4.41
1 1.049 0.69 31.2 15.6 1.31 2.81 6.25 1.56 5.62
1¼ 1.380 0.90 41.0 20.5 1.73 3.70 8.22 2.08 7.40
1½ 1.610 1.05 48.0 24.0 2.15 4.31 9.59 2.40 8.63
2 2.067 1.35 61.5 30.8 2.59 5.55 12.30 3.08 11.60
2½ 2.469 1.62 73.5 36.8 3.09 6.61 14.70 3.68 13.20
3 3.038 2.01 91.5 45.8 3.84 8.23 18.20 4.57 16.40
4 4.026 2.64 120.0 60.0 5.03 10.80 23.90 6.00 21.60
Arriving at a total line pressure loss, consideration should then be given to pressure loss created by valves, fittings and elevation of lines.
If a sufficient number of valves and fittings are incorporated in the system to materially affect the total line loss, add to the total line length, the equivalent
length of line of each valve or fitting.

CONVERSION CHART
From English Units (US) to Système International (Metric)
From To Multiply By or Divide By
C.U. in. (in3) CC (cm3) 16.39 0.06102
C.U. in. (in )
3
Liters 0.01639 61.02
Pounds Feet Newton Meters (Nm) 1.356 0.7376
Gallons (US) Liters 3.785 0.2642
Horsepower BTU 2545.0 0.00093
Horsepower Watts 745.7 0.001341
Horsepower kW 0.7457 1.341
PSI (Pounds/in ) 2
Bar 0.06895 14.5
PSI (Pounds/in2) Kilopascal (kPa) 6.895 0.145
Pound Kilogram 0.4536 2.2046
Inch Millimeter (mm) 25.4 0.03937
Gallons per Minute (GPM) Barrels Per Day (BPD–Petroleum) 34.29 0.02916
Gallons per Minute (GPM) Cu. Meters/hr 0.227 4.403

18
Custom Pumping Systems
YOU DEFINE. WE DESIGN AND DELIVER.

Cat Pumps is an industry leader in providing customers with quality custom-engineered pumping systems to meet a wide range of
application needs. By selecting a Cat Pumps pumping system, customers eliminate the hassle and expense of designing, multiple
source buying, fabrication and testing. Our knowledgeable and helpful technical sales team assists with proper component selection
as well as installation, operation and maintenance support.

Select Cat Pumps for your next custom system

to save the time and expenses of these activities:

• Initial Design
• Multiple Source Buying
• Fabrication
• Assembly
• Testing

Typical Configurations
Base
• Standard • Vertically Stacked • Portable • Enclosed • Multiple Pump

Power Source
• Electric • Gas • Diesel • Hydraulic • Pneumatic

Drive Package
• Belt • Direct Drive • Gearbox • Flex Coupling/Bell Housing • Clutch

Accessories
• Regulator • Unloader • Relief / Pop-off Valve • Pressure Gauge • Pulsation Dampener • Inlet Stabilizer
• Inlet Filter / Strainer • Guns • Oil

Call or go online to start your quote today.

19
 ABOUT CAT PUMPS Proven Quality, Customer Focused
Cat Pumps is the world leader in the design, manufacture and marketing of the most
dependable high-pressure positive displacement reciprocating triplex pumps and systems
in the market. Our mission to exceed customer expectations for quality, reliability, availability,
delivery, technical expertise and aftermarket support to assure the best value in all the
industries served.

LOCATIONS Worldwide Headquarters

Cat Pumps Cat Pump (U.K.) Ltd.
1681 94th Lane Northeast 1 Fleet Business Park, Sandy Lane
Minneapolis, MN 55449 Church Crookham
USA FLEET, Hampshire GU52 8BF
England
P: 763-780-5440
F: 763-780-2958 P: +44 1252 622031
[email protected] F: +44 1252 626655
www.catpumps.com [email protected]
[email protected]
Territories Served www.catpumps.co.uk
U.S., Canada
Territories Served
International Division England, Ireland, Scotland,
P: 763-780-5440 N. Ireland, Wales
F: 763-785-4329
[email protected]
www.catpumps.com
Territories Served
Africa, Asia, Australia, Central and
South America, Mexico, Middle East,
New Zealand, Turkey

Cat Pumps International N.V. Cat Pumps Deutschland GmbH

Heiveldekens 6A Buchwiesse 2, D-65510
2550 Kontich Idstein
Belgium Germany
P: 32 3 450 71 50 P: +49 6126 9303 0
F: 32 3 450 71 51 F: +49 6126 9303 33
[email protected] [email protected]
www.catpumps.be www.catpumps.de
Territories Served Territories Served
Western Europe (except U.K., Austria, Commonwealth of Independent States
Germany, and Austria) (CIS), Germany and Eastern Europe

SALES, DISTRIBUTION, Call today for product and application assistance.

SERVICE 763-780-5440 or visit us at www.catpumps.com

CAT PUMPS
1681 - 94TH LANE N.E. MINNEAPOLIS, MN 55449-4324
PHONE (763) 780-5440 — FAX (763) 780-2958
e-mail: [email protected]
www.catpumps.com

For International inquiries go to www.catpumps.com and navigate to the “Contact Us” link.

©2017 Cat Pumps Inc. All rights reserved. All written and visual data contained in this document are based on the latest product information available at the time of publication. Cat Pumps reserves the
right to make changes at any time without notice. All other brand names or marks are used for identification purposes and are trademarks of their respective owners.

PN 993330 Rev C 5/17