Circor HOUTTUIN 236 Series Original Installation, Operation And Maintenance Manual Download Page 4

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Table of Contents

236 Series Twin-Screw Pump -

Installation, Operation & Maintenance Manual

Final piping checklist ..................................................................................................... 44

Commissioning, Startup, Operation & Shutdown ............................................................... 45

Preparation for startup ..................................................................................................... 45

Check the rotation ............................................................................................................ 46

Couple the pump and driver ............................................................................................ 47

Bearing lubrication ........................................................................................................... 48

Oil volume requirements ............................................................................................... 49

Lubricating-oil requirements .......................................................................................... 49

Lubricate the bearings with oil ....................................................................................... 49

Lubricate the gear/bearings after a shutdown period .................................................... 50

Shaft sealing with a mechanical seal ............................................................................... 50

How to prime the pump with the suction supply above the pump ................................... 51

Start the pump ................................................................................................................. 51

Pump operation precautions ............................................................................................ 52

Shut down the pump ........................................................................................................ 53

Make the final alignment of the pump and driver ............................................................. 54

Dowelling the driver (Optional) ........................................................................................ 55

Maintenance ....................................................................................................................... 56

Maintenance schedule ..................................................................................................... 56

Bearing maintenance ....................................................................................................... 57

Mechanical-seal maintenance ......................................................................................... 57

Disassembly........................................................................................................................ 58

Disassembly precautions ................................................................................................. 58

Tools required .................................................................................................................. 58

Prepare for disassembly .................................................................................................. 59

Disassembly of the pump (standard component method) ............................................... 59

Preassembly inspections ................................................................................................. 61

Replacement guidelines ................................................................................................ 61

Screw shaft replacement guidelines ............................................................................. 65

Bearings inspection ....................................................................................................... 66

Reassembly of the pump (standard component method) ................................................ 68

Spare parts .................................................................................................................... 72

Minor Kit ........................................................................................................................ 72

Major Kit ........................................................................................................................ 72

Troubleshooting .................................................................................................................. 74

Operation troubleshooting................................................................................................ 74

Alignment troubleshooting ............................................................................................... 76

Supplemental assembly information ................................................................................... 77

Maximum torque values for fasteners .............................................................................. 77

Recommended torqueing sequence for bolted joints ...................................................... 78

Summary of Contents for HOUTTUIN 236 Series

Page 1: ...236 Series Twin Screw Pump Original Installation Operation Maintenance Manual...

Page 2: ......

Page 3: ...or mounting 26 Prepare the foundation for mounting 27 Install the baseplate 27 Install the pump driver and coupling 28 Pump to driver alignment 28 Alignment checks 29 Allowable dial indicator values f...

Page 4: ...s 52 Shut down the pump 53 Make the final alignment of the pump and driver 54 Dowelling the driver Optional 55 Maintenance 56 Maintenance schedule 56 Bearing maintenance 57 Mechanical seal maintenance...

Page 5: ...en requesting technical information or spare parts Safety WARNING The operator must be aware of the pumped fluid and take appropriate safety precautions to prevent physical injury Risk of serious inju...

Page 6: ...erly installed See specific information about safety devices in other sections of this manual CAUTION Risk of injury and or property damage Operating a pump in an inappropriate application can cause o...

Page 7: ...The work area Always keep the station clean to allow early discovery of any emissions due to a malfunction Waste and emissions regulations Observe these safety regulations regarding waste and emissio...

Page 8: ...ectrical connections must be made by certified electricians in compliance with all international national state and local regulations For more information about requirements see sections dealing speci...

Page 9: ...while the system is pressurized Make sure that the pump is isolated from the system and that pressure is relieved before you disassemble the pump remove plugs or disconnect piping Never operate a pum...

Page 10: ...osion protection labeling Explosion protection marking for group II category 2 and 3 Section 3 Installation and commissioning Category 2 and 3 Section 4 Points to note during operation of pump Operati...

Page 11: ...the information on order data sheet Inform personnel regarding special dangers Danger of explosions through removal of dust buildup All users must know about the risks of electric current and the chem...

Page 12: ...ion Atmosphere G Gas h ______________________________Ignition protection reference see 2 4 below T4 T1__________________________Temperature class see 2 3 below for Special Use Conditions X____________...

Page 13: ...formity for T code and Maximum Fluid Temperature indicated Special Use Condition In certain pumps with mechanical seals the maximum permissible medium temperature must not be exceeded Refer to the Dec...

Page 14: ...the requirements in the explosion hazard area group and category 6 Earthing Terminals must be provided for pump units including base plate and motor 3 1 2 Category 2 1 Ensure there is monitoring equip...

Page 15: ...in the maximum permissible temperature on the order data sheet Housing surface Only relevant to category 2 If the pumped liquid is contaminated with solid particles monitor the temperature of the case...

Page 16: ...ses 2 Change at appropriate intervals a Change seal when leakage exceeds 5 drops per hour b Change Spherical roller bearings every 25000 hours if found to be overheating or noisy 4 Additional measures...

Page 17: ...work is done by CIRCOR authorized personnel Genuine CIRCOR parts are used Only Ex approved spare parts and accessories authorized by CIRCOR are used in Ex approved products Limitations The warranty d...

Page 18: ...3 If applicable unfasten the product by removing any screws bolts or straps For your personal safety be careful when you handle nails and straps 4 Contact your sales representative if anything is out...

Page 19: ...toed shoes gloves etc at all times Seek assistance if necessary Safe lifting points are specifically identified in this manual It is critical to lift the equipment only at these points Unless otherwis...

Page 20: ...tably boxed or crated to prevent damage from normal handling All exterior unpainted surfaces subject to corrosion are coated with a rust preventive compound Pump openings are covered with blank flange...

Page 21: ...s recommended that a tag be attached to the housing indicating that it is full of oil Protect pump and driver with a plastic or canvas covering Fill cast iron or carbon steel pumps with oil As an alte...

Page 22: ...ulic axial balance between the screws Casing The casing is foot mounted with side suction and top discharge nozzle 236 series are equipped with DIN EN 1092 1 PN16 PN25 PN64 ASME B16 5 150lbs 300lbs an...

Page 23: ...screws The timing or placement of the gears on the shaft prevents rotational contact of the pumping screws This clearance between the pumping screws relates to extended pump life and higher average e...

Page 24: ...nameplate on the pump casing for most of the information See Parts List for item numbers Nameplate types Nameplate Description Pump Provides information about the hydraulic characteristics of the pum...

Page 25: ...g pressure when considering both maximum and minimum temperature MAX ALLOWABLE WORKING TEMPERATRUE Highest allowable working temperature at maximum allowable working pressure CRITICAL SPEED The speed...

Page 26: ...rm routine maintenance This facilitates ventilation inspection maintenance and service Ensured space enough for rigging lifting equipment etc such as a crane hoist or tackle This makes it easier to pr...

Page 27: ...to secure and prevent bolts from turning are A washer is placed between the bolt head and pipe sleeve with a lug welded to the bolt head Figure 3a An opening in the foundation to allow the lower bolt...

Page 28: ...e a cleaner that will not leave any residue NOTICE You may need to sandblast the surfaces of a baseplate that come into contact with the grout and then coat those surfaces with a primer that is grout...

Page 29: ...egrity of the foundation 1 Remove any water or accumulated debris from the foundation bolt holes or sleeves using an industrial vacuum 2 If the baseplate uses sleeve type bolts recommended it is impor...

Page 30: ...fter grouting 6 Do not use oils or liquid wax 7 Install washers and then thread the nuts onto the foundation bolts and hand tighten WARNING It is to be noted that conventional baseplates have to be in...

Page 31: ...d alignment check Prior to operation when the pump and the driver are at ambient temperature Final alignment hot alignment check After operation when the pump and the driver are at operating temperatu...

Page 32: ...dicated Reading TIR operating temperature 3600 RPM 0 05mm 0 002in 1800 RPM 0 1mm 0 004in 1200 RPM 0 15mm 0 006in 0 to 900 RPM 0 2mm 0 008in Calculate the thermal expansion Thermal expansion of the dri...

Page 33: ...r CL Height Pump 13 CL Height Driver 11 Change at pump shaft due to temperature rise 8 9 x10 6 x 100 80 x 13 0 002 Change at driver shaft due to temperature rise 6 5 x10 6 x 224 80 x 11 0 010 Differen...

Page 34: ...make alignment corrections Check the alignment again after any mechanical adjustments This corrects any misalignments that an adjustment may have caused Attach the dial indicators for alignment You mu...

Page 35: ...rder to raise the feet of the driver at the DE Remove shims in order to lower the feet of the driver at the NDE Positive The coupling halves are closer at the bottom than at the top To correct this do...

Page 36: ...the driver temperature rise and the pump operating temperature Before you start this procedure make sure that the dial indicators are correctly set up A unit is in parallel alignment when the parallel...

Page 37: ...el alignment indicator does not vary by more than the table limits when measured at four points 90 apart at the operating temperature 1 Set the parallel alignment indicator to zero on the left side of...

Page 38: ...o do so can result in being unable to successfully perform hot alignment 1 Set the angular and parallel dial indicators to zero at the top center position 12 o clock of the driver coupling half 2 Rota...

Page 39: ...oroughly wet and saturate the foundation that will come into contact with the grout for at least 24 hours prior to grout placement 4 If epoxy type grout is used then the foundation must be completely...

Page 40: ...sult in body stresses that may result in shortened bearing life Soft foot may be checked as follows 1 Attach the base of a dial indicator to the base plate placing the tip of the indicator one of the...

Page 41: ...pt to throttle the flow from the either the suction side or discharge side of a PD pump This action can result in decreased performance unexpected heat generation and equipment damage Piping guideline...

Page 42: ...of the check valve The isolation valve is required for inspection and maintenance of the pump The check valve will prevent hydraulic shock acting upon the pump and will also prevent reverse rotation...

Page 43: ...entric reducer can be used The suction piping should never have a smaller diameter than the suction inlet of the pump This minimizes the pipework friction losses leading up to the pump Check that the...

Page 44: ...of air and cavitation in the pump inlet Check that the suction piping slopes upwards from the liquid source to the pump inlet This helps to eliminate any air from the pipework Check that all joints a...

Page 45: ...ump and piping system The valve and piping system must be solidly constructed of proper material with ample opening for passage of full discharge capacity because positive displacement pumps can build...

Page 46: ...comment Checked Check that the minimum flow for each component meets or exceeds the GA outline drawing value Check that the supplied pressure does not exceed the GA outline drawing maximum allowable v...

Page 47: ...ipment damage Ensure the pump operates only between minimum and maximum rated flows Operation outside of these limits can cause high vibration mechanical seal and or shaft failure and or loss of prime...

Page 48: ...luded in warm up circuit The recommended warm up rate is 1 1 C to 2 2 C 2 F to 4 F per minute During the warm up process confirm the temperature differential between the top and bottom of the pump is...

Page 49: ...n on the general arrangement drawing or as stamped on the coupling hub For any necessary adjustment move the driver not the pump 2 Motors with sleeve bearings may be manufactured with end movement flo...

Page 50: ...y installation or maintenance tasks Electrical connections must be made by certified electricians in compliance with all international national state and local rules Refer to driver coupling gear manu...

Page 51: ...orm approximately to the followingcharacteristics Maximum pumped fluid temperature 100 C 212 F 160 C 320 F 160 C 320 F Bearing Alarm temperature 82 C 180 F 120 C 248 F 120 C 248 F Bearing Shutdown tem...

Page 52: ...l must have an appropriate seal flush system Failure to do so will result in excess heat generation and seal failure Cooling systems such as those for bearing lubrication and mechanical seal systems m...

Page 53: ...Ensure all flush and cooling systems are operating correctly prior to starting pump NOTICE 1 Risk of equipment damage due to dry operation Immediately observe the pressure gauges If discharge pressure...

Page 54: ...es is the best indication of normal operation A sudden increase in temperature indicates that a bearing problem is developing and a check of the bearing should be made When bearing temperature monitor...

Page 55: ...umped fluid Risk of equipment damage and serious physical injury Heat build up can cause rotating parts to score or seize Observe pump for excessive heat build up If normal levels are exceeded shut do...

Page 56: ...formance equipment damage and even catastrophic failure leading to serious injury Proper alignment is the responsibility of the installer and the user of the unit Check the alignment of all drive comp...

Page 57: ...foot on the drive end of the pump will require taper pins installed to secure the pump to the baseplate If the temperature differential is high the baseplate is supplied with provision to accommodate...

Page 58: ...seal Weekly routine inspections Perform these tasks every week Run any idle pumps under power Check operation of suction and discharge valves Check all automatic controls and regulators Three month in...

Page 59: ...p Change the oil after 50 operating hours for new bearings After the first 50 operating hours change the oil every 4000 operating hours Grease Pump will be shipped with grease Bearings are Greased for...

Page 60: ...ective Equipment PPE such as steel toed shoes gloves etc at all times Precautions must be taken to prevent physical injury The pump may handle hazardous and or toxic fluids Proper personal protective...

Page 61: ...l of the pump assembly 4 Remove shaft coupling with spanning type puller 5 Remove the oil drain plug 443 and sealing washer 479 from the bottom of the gear housing 406 and drain the oil Dispose of the...

Page 62: ...s 110 to loosen both spur gears 108 from the screw shafts 100 13 Remove both spur gears 108 from the screw shafts 100 Remove both keys 132 14 Remove both distance bushings 124 from the gear side of th...

Page 63: ...al from cover DF 401 27 Remove screws 433 then remove covers KK 404 from cover DF 401 28 Press out bearings 105 and oil seals 721 from cover DF 401 29 Remove and retain shims 130 131 from cover DF It...

Page 64: ...is likely to be impaired Screw shaft to body clearances that exceed the values in the Minimum running clearances table by more than 50 NOTICE When clearances between the screw shaft and body become ex...

Page 65: ...nning clearances table by more than 50 Check the screw shaft balance Rebalance the screw shaft if it exceeds ISO 1940 1 grade 16 Note that some pumps are supplied with a higher grade of balance If in...

Page 66: ...aling surfaces for damage and repair or replace as necessary Fasteners WARNING Risk of serious personal injury or property damage Fasteners such as bolts and nuts are critical to the safe and reliable...

Page 67: ...shaft Screw shaft inspection NOTICE Do not use the screw shaft centers for the runout check as they may have been damaged during the removal of the bearings or gears Screw shaft inspection Screw shaf...

Page 68: ...the pump to service Replacement bearings Replacement bearings 103 105 must be the same as or equivalent to those listed in these tables Size Front Bearing Rear Bearing Bearing Housing ID Screw shaft O...

Page 69: ...usings are clean with no burrs or other surface damage Check the bearing housing bores against the values in the bearing fits table Repair or replace housings as necessary Replacement oil seals Replac...

Page 70: ...are axially aligned to each other 3 Install the dowel pins 376 if they were removed 4 If bushings 725 were removed install new bushings onto screw shafts 100 using Loctite 638 or equivalent 5 If the...

Page 71: ...re with screws 471 Install the stationary portion of the mechanical seal 702 and anti rotation pin 480 into the seal cover 470 If a cartridge seal is fitted the cartridge seal install the cartridge se...

Page 72: ...Disassembly Inspection Reassembly 70 236 Series Twin Screw Pump Installation Operation and Maintenance Manual Machinery Inspection Record Sheet...

Page 73: ...Disassembly Inspection Reassembly 236 Series Twin Screw Pump Installation Operation and Maintenance Manual 71...

Page 74: ...repair during the first two years of operation Major Kit The purpose of this kit is to enable the user to have immediate access to routine maintenance parts for use during pump commissioning or for em...

Page 75: ...Operation and Maintenance Manual 73 110 LOCKNUT 2 124 DISTANCE BUSH 2 130 SHIM 2 131 SHIM 2 132 TIMING GEAR KEY 2 133 SHAFT KEY 1 352 LINER 1 375 DOWEL COVER TO GEAR CASING 2 376 DOWEL COVER TO PUMP...

Page 76: ...g speed is too low when a VFD or gearbox is used Verify the VFD settings and correct as required Verify the motor and or gearbox nameplate speeds and change out if necessary The foot valve or suction...

Page 77: ...bricant for suitability and level The pump is noisy or vibrates The pump and driver are not aligned properly Realign the pump and driver The pump is worn or damaged Inspect and replace the pump if nec...

Page 78: ...for the new condition The discharge pressure is too high Bring the discharge pressure to within specification or have the pump and motor rerated for the new condition The pump is worn or damaged Insp...

Page 79: ...In lbs Torque for Type 12 9 Nm Torque for Type 12 9 In lbs M6 x 1 00 11 3 100 16 5 146 19 3 171 M8 x 1 25 27 3 241 40 1 355 46 9 415 M10 x 1 50 54 478 79 699 93 823 M12 x 1 75 93 823 137 1212 160 1416...

Page 80: ...ross star pattern for circular joints 3 Work in a Spiral pattern for non circular joints 4 Use the Rule of 3 for tightening 5 The first pass of tightening should be to approximately 1 3rd of the final...

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