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Introduction and Safety

216 Series Twin-Screw Pump -

Installation, Operation & Maintenance Manual

Product warranty

Coverage

CIRCOR undertakes to remedy faults in products from CIRCOR under these conditions:

•

The faults are due to defects in design, materials, or workmanship.

•

The faults are reported to a CIRCOR representative within the warranty period.

•

The product is used only under the conditions described in this manual.

•

The monitoring equipment incorporated in the product is correctly connected and in use.

•

All service and repair 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 does not cover faults caused by these situations:

•

Deficient maintenance

•

Improper installation

•

Modifications or changes to the product and installation made without consulting

CIRCOR

•

Incorrectly executed repair work

•

Normal wear and tear

CIRCOR assumes no liability for these situations:

•

Bodily injuries

•

Material damages

•

Economic losses

Warranty claim

CIRCOR products are high-quality products with expected reliable operation and long life.

However, should the need arise for a warranty claim, then contact your CIRCOR

representative.

Содержание HOUTTUIN 216 Series

Страница 1: ...216 Series Twin Screw Pump Original Installation Operation Maintenance Manual...

Страница 2: ......

Страница 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...

Страница 4: ...the final alignment of the pump and driver 53 Dowelling the driver Optional 54 Maintenance 55 Maintenance schedule 55 Bearing maintenance 216 40 pumps only 56 Mechanical seal maintenance 56 Disassemb...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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____________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ...axial balance between the screws Casing The casing is foot mounted with side suction and top discharge nozzle 216 series are equipped with DIN EN 1092 1 PN16 PN25 PN64 ASME B16 5 150lbs 300lbs and 600...

Страница 23: ...average efficiency over the life of the pump Spur gear are used for transmission For the 216 40 the gears are oil lubricated by means of a self contained system and are sealed off from the environment...

Страница 24: ...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 pump For 216...

Страница 25: ...ssure 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 wh...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 50: ...tate and local rules Refer to driver coupling gear manufacturer s installation and operation manuals IOM for specific instructions and recommendations Bearing lubrication 216 40 pumps only Precautions...

Страница 51: ...lubricants Replacement Oil must be the same as or equivalent to the above Grease quality requirements N A Greased for Life is utilized for grease lubricated bearings Lubricate the bearings with oil 21...

Страница 52: ...ilure to do so will result in excess heat generation and seal failure Follow seal manufacturer s guidelines for proper seal installation procedures Seal lubrication is required Seal faces must have li...

Страница 53: ...ign pressure stated on the nameplate 3 If the pump exceeds the maximum design pressure perform these steps a Stop the driver b Determine the source of restriction in the discharge piping and remove it...

Страница 54: ...liary piping make sure that proper flows have been established and that the equipment is operating properly Establish baseline vibration readings in order to determine normal running conditions If the...

Страница 55: ...g any 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...

Страница 56: ...pump 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 accommo...

Страница 57: ...leaks Check that there is no leakage from the mechanical seal Weekly routine inspections Perform these tasks every week Run any idle pumps under power Check operation of suction and discharge valves...

Страница 58: ...irst lubrication Lubrication intervals Oil Add oil before you install and start the pump Change the oil after 50 operating hours for new bearings After the first 50 operating hours change the oil ever...

Страница 59: ...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...

Страница 60: ...ard that will interfere with the removal 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 housi...

Страница 61: ...s both screw shafts 100 until they are free of bearings 105 12 Use jackscrews tapped holes to break the bond between the cover DF 401 and the pump casing 350 13 Remove cover DF 401 intact with bearing...

Страница 62: ...sing 406 to the cover DF 401 7 Use jackscrews tapped holes to break the bond between the gear housing 406 and the cover DF 401 8 Remove gear housing 406 stationary mechanical seal seat 702 and anti ro...

Страница 63: ...or pitting Thoroughly clean gasket surfaces 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...

Страница 64: ...Disassembly Inspection Reassembly 62 216 Series Twin Screw Pump Installation Operation and Maintenance Manual Body liner cover and seal housings areas...

Страница 65: ...ng and cleaning the parts Failure to do so may result in equipment damage NOTICE You must have access to the appropriate accurate fixtures equipment and balance techniques to successfully balance the...

Страница 66: ...ssembly of the unit Use fasteners of the proper size and material only Replace all damaged or corroded fasteners Ensure that all fasteners are properly tightened and that there are no missing fastener...

Страница 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...

Страница 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...

Страница 69: ...bearing housing bores against the values in the bearing fits table Repair or replace housings as necessary Replacement oil seals 216 40 pump only Replacement oil seals 704 721 must be the same as or...

Страница 70: ...the rotors axial so that the shoulders of the thrust bearings are axially aligned to each other 3 Install the dowel pins 375 376 if they were removed 4 If bushings 725 726 were removed from screw sha...

Страница 71: ...e 243 or equivalent Install the stationary portion of mechanical seal 702 into covers 494 20 Install cover D 407 onto pump casing 350 and secure with screws 309 Verify that the screw shafts turn freel...

Страница 72: ...shafts 100 on a flat surface and center them axial to each other align the rotors axial so that the shoulders of the thrust bearings are axially aligned to each other 3 Install the dowel pins 375 376...

Страница 73: ...rews 309 Verify that the screw shafts turn freely without binding or tight spots 17 Remove temporarily installed screws 310 from cover DF 401 18 Install bush 174 and the rotating portion of mechanical...

Страница 74: ...Disassembly Inspection Reassembly 72 216 Series Twin Screw Pump Installation Operation and Maintenance Manual Machinery Inspection Record Sheet...

Страница 75: ...Disassembly Inspection Reassembly 216 Series Twin Screw Pump Installation Operation and Maintenance Manual 73...

Страница 76: ...Disassembly Inspection Reassembly 74 216 Series Twin Screw Pump Installation Operation and Maintenance Manual...

Страница 77: ...tions in the parts list Usage of non genuine parts may void warranty Minor Kit The purpose of this kit is to enable the user to have immediate access to routine maintenance parts for use during pump c...

Страница 78: ...G 1 479 GASKET WASHER GEAR HOUSING DRAIN 1 702 MECHANICAL SEAL 4 703 O RINGS COVER TO SEAL COVER 4 704 LIP SEAL DE 1 721 LIP SEAL INBOARD 4 LOCTITE 243 RETAINING COMPOUND 1 TUBE MINOR KIT SEE ALL ITEM...

Страница 79: ...BODY TO COVER 2 440 GASKET COVER DF TO GEAR BOX HOUSING 1 479 GASKET WASHER GEAR HOUSING DRAIN 1 702 MECHANICAL SEAL 1 LOCTITE 243 RETAINING COMPOUND 1 TUBE MINOR KIT SEE ALL ITEMS ABOVE 1 100 SCREW S...

Страница 80: ...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...

Страница 81: ...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...

Страница 82: ...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...

Страница 83: ...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...

Страница 84: ...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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