Circor HOUTTUIN TT Twin-Screw Installation, Operation & Maintenance Manual Download Page 4

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Table of Contents

TT 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 & grease ....................................................................... 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 two-piece bracket pump (standard) .................................................. 59

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

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

Screw shaft replacement guidelines ............................................................................. 64

Bearings inspection ....................................................................................................... 65

Reassembly of the two-piece bracket pump (standard) .................................................. 66

Spare parts .................................................................................................................... 71

Minor Kit ........................................................................................................................ 71

Major Kit ........................................................................................................................ 71

Troubleshooting .................................................................................................................. 72

Operation troubleshooting................................................................................................ 72

Alignment troubleshooting ............................................................................................... 74

Supplemental assembly information ................................................................................... 75

Maximum torque values for fasteners .............................................................................. 75

Recommended torqueing sequence for bolted joints ...................................................... 76

Summary of Contents for HOUTTUIN TT Twin-Screw

Page 1: ...TT Twin Screw Pump Installation Operation Maintenance...

Page 2: ......

Page 3: ...ounting 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 for a...

Page 4: ...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 5...

Page 5: ...equesting 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 injury o...

Page 6: ...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 over...

Page 7: ...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 emissions A...

Page 8: ...ical 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 specifica...

Page 9: ...le 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 pump wi...

Page 10: ...n 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 Operation M...

Page 11: ...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 chemical...

Page 12: ...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: ...f Conformity 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 th...

Page 14: ...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 equipment...

Page 15: ...he 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 sur...

Page 16: ...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 c Add grease as per SKF every 2000 hours minimum if found t...

Page 17: ...k 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 does...

Page 18: ...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 of o...

Page 19: ...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 otherwise in...

Page 20: ...y 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 flanges or...

Page 21: ...commended 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 alternat...

Page 22: ...0 300 350 400 450 and 600 DIN Discharge flanges class PN200 250 300 350 400 and 550 ASME flanges class 150 and 300 are also available The solid cast body has thick cross sections for rigidity Body pas...

Page 23: ...ge efficiency over the life of the pump Spur gear are used for transmission Factory performed timing is easily repeated with TT s method of gear and screw synchronization timing Gears are oil lubricat...

Page 24: ...he 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 pump For TT pumps...

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

Page 26: ...outine 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 proper...

Page 27: ...o 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 h...

Page 28: ...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 comp...

Page 29: ...y 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 important...

Page 30: ...outing 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 installed...

Page 31: ...ignment 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 temperature I...

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

Page 33: ...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 Difference 0...

Page 34: ...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 must h...

Page 35: ...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 one...

Page 36: ...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 ali...

Page 37: ...lignment 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 the...

Page 38: ...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 Rotate t...

Page 39: ...hly 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 dry 5...

Page 40: ...lt 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 pu...

Page 41: ...o 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 guidelines Gu...

Page 42: ...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 of t...

Page 43: ...tric 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 ec...

Page 44: ...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 are a...

Page 45: ...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 up...

Page 46: ...ent 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 value...

Page 47: ...nt 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 WAR...

Page 48: ...t The recommended warm up rate is 2 F to 4 F 1 1 C to 2 2 C per minute During the warm up process confirm the temperature differential between the top and bottom of the pump is less than 17 C 30 F All...

Page 49: ...awing 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 float in the motor rotor If specif...

Page 50: ...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 manufacturer s install...

Page 51: ...cteristics ISO Synthetic Grade VG100 Viscosity kinematic 104 F 40oC 95 105 cSt Viscosity kinematic 212 F 100oC 13 2 cSt Viscosity Index Min 140 Flash point Min 428 F 220 C Acceptable lubricants Replac...

Page 52: ...d seal failure Cooling systems such as those for bearing lubrication and mechanical seal systems must be operating properly to prevent excess heat generation sparks and premature failure Sealing syste...

Page 53: ...pment damage due to dry operation Immediately observe the pressure gauges If discharge pressure is not quickly attained stop the driver immediately reprime and attempt to restart the pump 2 To avoid r...

Page 54: ...em is developing and a check of the bearing should be made When bearing temperature monitoring is utilized the bearing temperature alarm shutdown settings should be set to Alarm at 180 F 82 C Shutdown...

Page 55: ...up can cause rotating parts to score or seize Observe pump for excessive heat build up If normal levels are exceeded shut down and resolve NOTICE Cavitation can cause damage to the internal surfaces...

Page 56: ...ance 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 componen...

Page 57: ...t 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 dif...

Page 58: ...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 inspec...

Page 59: ...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 Change the grease every 2000 operati...

Page 60: ...ipment 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 equipment...

Page 61: ...aft coupling with spanning type puller 5 Remove the oil drain plug 342 from the bottom of the gear housing and side of the casing 350 and drain the oil Dispose of the oil in accordance with applicable...

Page 62: ...ntermediate cover 419 12 Remove bearing cover D 407 from the intermediate cover 419 using jacking tap holes available in cover D 407 Oil seals 704 and bearings 105 will remain in bearing cover D 407 1...

Page 63: ...s and alignment fits to remove rust and debris Repair or replace these parts if you notice any of these conditions Localized wear or grooving that is greater than 0 125 3 2mm deep Pitting that is grea...

Page 64: ...rances 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 doubt refe...

Page 65: ...ling 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 66: ...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 shaft...

Page 67: ...list company is recommended Inspect the bearings to see if they are loose rough or noisy when you rotate them In the case of separable bearings inspect each component individually noting the location...

Page 68: ...embly of the two piece bracket pump standard WARNING Lifting and handling heavy equipment poses a crush hazard Use caution during lifting and handling and wear appropriate Personal Protective Equipmen...

Page 69: ...Cartridge Seal Install the cartridge seal 702 to the intermediate cover with screws 471 Ensure the correct location of each seal direction of rotation up and down markings Not applicable for componen...

Page 70: ...the drive shaft position 101 and fill the bearing covers 409 410 with grease 28 Close all drain ports using a plug 342 382 with fiber washer 343 383 29 Close all pressure monitoring port using plug 3...

Page 71: ...Disassembly Inspection Reassembly TT Twin Screw Pump Installation Operation and Maintenance Manual 69 Machinery Inspection Record Sheet...

Page 72: ...Disassembly Inspection Reassembly 70 TT Twin Screw Pump Installation Operation and Maintenance Manual...

Page 73: ...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 emergency repai...

Page 74: ...eed 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 pipe...

Page 75: ...ant 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 necessa...

Page 76: ...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 Inspect...

Page 77: ...24 x 3 00 798 7062 3 1136 10053 6 1329 11761 65 M27 x 3 00 1176 10407 6 1674 14814 9 1959 17337 15 M30 x 3 50 1597 14133 45 2274 20124 9 2662 23558 7 M33 x 3 50 2161 19124 85 3078 27240 3 3601 31868 8...

Page 78: ...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 fas...

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