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Introduction and Safety

TT Twin-Screw Pump -

Installation, Operation & Maintenance Manual

3.3

Maintenance

(Reduce maintenance intervals for more difficult operating conditions.)

3.3.1

Maintenance to perform

Check at appropriate intervals:

Motor and pump couplings according to manufacturer

’s operating instructions

Deformation of guard around coupling and spacing to rotating parts

Functioning of monitoring devices

Surface temperature of pump and motor

Entire unit for excess vibrations

Pump during operation for altered running noises

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.

c. Add grease as per SKF every >2000 hours minimum if found to be overheating.

4. Additional measures for category 2

1. Periodically remove dust build up before thickness gets to 5 mm.

2. Remove swarf and dirt from on and below the coupling guards.

Monitoring equipment

For additional safety, use condition-monitoring devices. Condition-monitoring devices include

but are not limited to these devices:

•

Pressure gauges / transducers / switches

•

Flow meters / switches

•

Level indicators / transducers / switches

•

Motor power measurement

•

Temperature indicators / transducers / switches

•

Vibration transducers / switches

•

Leak detectors / switches

•

Suction filter(s)

Содержание HOUTTUIN TT Twin-Screw

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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________________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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