How to Install a Wates Pressure Vessel for Booster Pump Systems

1. Introduction

• Importance of pressure vessels in booster pump systems
• How Wates pressure vessels help stabilize pressure, reduce pump cycling, and extend pump lifespan
• Correct installation is critical for performance, warranty validity, and long-term reliability

2. Tools and Materials Required

• Adjustable wrench / pipe wrench set
• PTFE or thread sealing tape
• Ball valve (isolation valve)
• Pressure gauge (0–10 bar or as required)
• Tee fitting or manifold connection for discharge line
• Union fittings for easy removal
• Air pump or small compressor (for pre-charge adjustment)
• Pipe support clamps or brackets
• Optional: anti-vibration rubber base pads

3. Pre-Installation Checks

1. Verify vessel size based on drawdown requirement and pump duty
2. Confirm vessel orientation type (vertical or horizontal)
3. Check for factory pre-charge pressure (marked on label)
4. Inspect tank body, coating, and fittings for damage
5. Ensure installation location meets conditions:
   • No direct sunlight or outdoor exposure unless sheltered
   • Accessible for future maintenance and pressure adjustment
   • Not installed on unstable or vibrating surfaces

4. Step-by-Step Installation Procedure
Step 1: Position the Vessel

• Place vertical vessel on level surface with adequate clearance
• Horizontal tank must be installed on saddle bracket or mounting frame
• Leave access to air valve and bottom connection

Step 2: Install an Isolation Valve

• Fit a ball valve between vessel and pump discharge line
• Allows vessel removal without draining the full booster system
• Mandatory for maintenance-friendly installations

Step 3: Connect Vessel to the Pump Discharge Line

• Use a tee fitting or manifold port after the pump outlet
• Ensure vessel inlet is mounted on pressure side, never on suction side
• Use PTFE tape and torque evenly to prevent thread leaks

Step 4: Install a Pressure Gauge and Drain Point

• Gauge allows pressure monitoring and troubleshooting
• Drain point helps in vessel replacement and servicing
• Recommended: gauge + isolation valve + drain assembly on same branch

Step 5: Set and Verify Pre-Charge Pressure

• Measure air pressure using a tire-type gauge at the Schrader valve
• Adjust air charge before filling with water
• Pre-charge must be 0.2 – 0.5 bar below pump cut-in pressure
  Example: Pump starts at 2.5 bar → Vessel pre-charge 2.0–2.3 bar

Step 6: Commission System

• Turn on pump and allow it to reach cut-out pressure
• Check for leaks at vessel connection and manifold joints
• Confirm that water enters vessel and pressure stabilizes
• Open tap to test drawdown and pump restart sequence

5. Suggested Booster Pump Piping Layout (Text Description)
Pump → Check Valve → Discharge Manifold → Tee → Isolation Valve → Vessel
Additional ports: pressure gauge, pressure switch, PRV, drain valve
(Can be turned into a diagram if needed)

6. Post-Installation Checklist

• Vessel firmly mounted and accessible
• Pre-charge pressure written on tank or log sheet
• Isolation valve and drain valve installed
• Pressure gauge installed and readable
• No visible leaks on pump discharge line
• Pump cycling frequency within acceptable range (10–20 starts/hr)

7. Common Installation Mistakes to Avoid

• Connecting vessel on pump suction side
• Skipping pre-charge adjustment
• Installing vessel without isolation valve
• Mounting vessel in a closed room with no ventilation
• Over-tightening threaded fittings and damaging vessel connection
• Leaving tank unsupported or touching nearby vibrating equipment

8. Maintenance After Installation

• Check vessel pre-charge every 6–12 months
• Replace bladder if tank becomes waterlogged
• Inspect exterior coating for corrosion (especially in high-humidity UAE pump rooms)
• Monitor pump start frequency – rapid cycling indicates wrong sizing or loss of air charge

9. UAE/GCC Installation Notes

• Always install in shaded or indoor pump rooms due to high ambient temperatures
• Use stainless-steel fittings in coastal areas (Dubai Marina, Yas Island, Ajman Corniche)
• PED/CE/WRAS certification required for potable water booster systems
• Consider additional insulation if room temperature exceeds 45°C

A properly installed Wates pressure vessel improves pump performance, increases equipment life, and ensures stable pressure delivery. Correct connection, pre-charge adjustment, and periodic maintenance are the keys to long-term trouble-free operation. For more info contact Wates Pressure Vessel Supplier in UAE or call us at +971 4 2522966.

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