Hose pumps Safety; operation and maintenance manual (VF5 - VF80 Product Range) Version 5: August 2007
Table of Contents Disclaimer of Warranty and Limitations of Liability......................................................................... 6 1. Introduction ............................................................................................................................. 7 2. Safety Issues........................................................................................................................... 8 2.1 Safety Alert Symbol..........................................................
5.2 Extinguishing Media To Avoid .................................................................................... 62 5.3 Unusual Fire and Explosion Hazards ......................................................................... 62 5.4 Special Protective Equipment for Fire fighters ........................................................... 63 6 Accidental Release Measures............................................................................................... 63 6.1 Personal Protection .........
8. Exposure Controls / Personal Protection .............................................................................. 69 8.1 Personal Protection .................................................................................................... 69 8.2 Occupational Exposure Limits.................................................................................... 70 9. Physical and Chemical Properties ........................................................................................ 70 10.
Appendices A B C D E F VERDERLUBE Safety Data Sheet VERDERSIL Safety Data Sheet Lifting Safety Data Sheet Black Food Grade Hose VERDERFLEX Spares List Shimming Charts & Performance Curves 5
Disclaimer of Warranty and Limitations of Liability This pump is warranted against defects in workmanship and material under normal use (rental use excluded) for two years from date of purchase. This is to the extent that VERDER will at its option replace, repair or refund, in full, the purchase price of the instrument of any part thereof manufactured by VERDER, which in our opinion is defective.
1. Introduction The Verder Group of companies have offices located in Austria, Belgium, China, Czech Republic, France, Germany, Hungary, Japan, Norway, Poland, Romania, Slovakia, South Africa, The Netherlands, United States and the UK. A network of worldwide distributors support our products in other countries of which a full list can be seen at www.verderflex.com. Group headquarters are in Holland.
2. Safety Issues 2.1 Safety Alert Symbol The symbol shown above is used to identify topics of primary safety concern and call attention to instructions concerning your personal safety. Watch for this symbol, it involves important safety precautions, and means “ ATTENTION! BECOME ALERT! YOUR PERSONAL SAFETY IS INVOLVED!” Read the message that follows and be alert to the possibility of personal injury or death 2.2 Signal Words Signal words designate a degree or level of hazard seriousness.
2.3 Safety First • • • • • • The information in this manual is essential for the safe operation and servicing of VERDERFLEX pumps.
2.5 Operational Safety • Always isolate the power supply before working on the pump • Never place hands or other parts of the body inside or near any part of the pump when it is in operation or when the power is not totally isolated • When the pump is running, you should not touch the pump and should maintain an adequate safe distance around it Do not climb onto the pump or connecting pipe work • Maintain a clean environment around the pump.
2.
2.7 Assembly, Installation and Commissioning • A qualified electrician should be consulted on operations where there may be risk of electrical hazard • • • • Always isolate the power supply before working on the pump Check compatibility of the hose material with the product being pumped Check compatibility of the lubricant with the product being pumped Do not over grease the front cover O-ring.
3. Theory of the Pump 3.1 Working Principles The pump is simple by design in its construction and operation. The medium to be pumped does not come into contact with any moving parts and is totally contained within a robust, heavy-duty hose, which consists of an inner layer, two - six reinforcement layers and an outer layer. A rotating shoe passes along the length of the hose, compressing it totally closed.
• • • • No moving parts in contact with the product Hygienic Stainless Steel Port Flanges & Integral hose inserts certified to EHEDG standards Meets the EHEDG specifications for CIP (Clean In Place) pumps. This means it can be cleaned without having to dismantle it Food grade hose 3.4 Product Range The VERDERFLEX pumps are sized and named according to the internal bore diameter of the hose.
The housing provides support for the hose whilst under compression from the shoe / rotor assembly. A flange / insert mechanism is used to retain the hose position within the housing. The flange uses a split collet design to clamp and seal the hose in the casing. The rotor runs in a lubricant bath, which is filled either through the inspection cover or via a pipe at the rear of the housing.
Figure 3 Mounting Options The assembled housing is mounted on a support frame in any one of four positions (as indicated in Figure 4).
Figure 4 (3) (4) 3.6 Limitations of the Pump VERDER is strongly committed to the belief that the customer must always be given as much information as possible in order to make the best possible pump selection. For this reason the list below contains details of the few VERDERFLEX limitations: • Hoses are available in Natural Rubber; Nitrile Buna rubber; EPDM rubber & CSM (Hypalon Ò).
3.7 Pump Selection Pumps can be used to deliver higher capacities and are recommended for intermittent use only to enable the dissipation of heat, which is generated by high speed and pressures. The actual capacity of the pump depends upon the speed at which the rotor revolves.
4. Safety, Operation and Maintenance Instructions 4.1 General – tools and facilities Care should be taken at all times to ensure that any tools are used safely for the purpose for which they are designed and in accordance with the manufacturer’s instructions. Ideally the pump should be installed using a drive, with facilities to inch the pump along and which is able to operate in reverse.
4.2.1 Preparation • • • Prepare the workspace in which the pump is to be built, ensuring there is a clean and level work surface with sufficient room for not only the pump, but also to allow you sufficient access to the pump and fit pipe work, etc Carefully open the packaging and check for completeness by ensuring all the parts listed are present (see the exploded view drawings and parts list at the back of this manual); remove all the loose components and set them out on a workbench.
Figure 5a CD- Utilising 1 of 2 available pump case tappings to use a lifting eye bolt Casing assembly being lifted to the vertical position with the eyebolts at the top end to assist front cover removal and prevent damage to the studs • • Lift off front cover by utilizing case lifting eye and placing in threaded lifting hole (Fig.5).
Figure 6 • Lift the side support frames into position, ensuring that the foot section of the frames have the fixing holes on the outside, and bolt to the pump housing. Do not fully tighten at this stage • Present the cross-members to the support frames (VF25 –80 only) and bolt into position, tightening evenly at the same time as the frame/pump housing bolts.
Long Coupled Mounting Frame Assembly On VF10 to VF50 LC pumps, a mounting frame adaptor kit is needed to convert the closecoupled frame into a long coupled frame and yet maintain the current long coupled footprint. The centre floor-mounting hole becomes redundant but can be used for additional fixing.
Mounting the gearbox Close-coupled assembly • Using the appropriate lifting equipment, to ensure the correct lining up of the gear motor unit to the housing flange it is important to ensure that the gear motor unit is in the correct position on the sling, both horizontally and in relation to the fixing holes Figure 8 • Once the gear motor unit and the pump housing flanges are lined up correctly the fixing bolts and washers are pushed into position.
Note: 1 This does not apply to VF10 and VF15 pumps as the rotor’s design incorporates the shoe profile.
Figure 10 • Position the rotor at the front of the pump, with the use of the appropriate lifting equipment, so that the taper lock screws are facing forward, away from the pump.
Figure 11 • Align the first rule/straight edge against the machined front of the pump housing, then take the other rule and hold it perpendicular from the outer edge of the rotor (not the shoe) and the first rule/straight edge (see Figure 11).
Figure 12 • Lift the front cover into position onto the 4 corner studs (shown in Fig 12), with the use of the lifting eye and appropriate lifting tackle, and hand tighten the four corner nuts (removed earlier). Hand tighten the rest of the front cover bolts, remove the lifting equipment and replace the lifting eye with the remaining front cover bolt.
Figure 13 • Fit the two drain plugs (Fig.
4.3 Installation Prepare the workspace in which the pump is to be installed, ensuring there is a clean and level work surface with sufficient room for not only the pump, but also to allow you sufficient access to the pump for maintenance purposes and fit pipe work, etc Lift the pump & gearbox assembly using the appropriate lifting equipment referring to the weights table (chapter 4.1) and eyebolt-lifting guide (page 81)! The power supply and control panel should be installed.
Check compatibility of the hose material with the product being pumped – this should have been verified by your distributor • • If not already shimmed, shim the pump according to the operating pressure required, following the procedure described in Section 4.
4.5 Operation The pump should only ever be used for the purpose for which it is sold.
4.6 Maintenance It is good practice to wash down the external surfaces of the pump prior to carrying out any maintenance operations. This will prevent the interior of the pump being contaminated with dirt or debris 4.6.1 Hose - Removal and Installation This procedure involves removal and reinstallation of the port flange assembly - installation of the port flange assembly automatically clamps the hose to the insert and seals the flange with the pump housing.
Loosen the lubricant drain plug, and slowly let the lubricant drain into a container for re-use or disposal (lubricant should not be re-used if it is contaminated with the product). Replace the drain plug when all lubricant has drained from the pump housing; check the condition of the sealing washer If the hose has ruptured, the lubricant may be contaminated with the product - care must be taken to handle the mixture appropriately.
4.6.3 Hose Installation Never try to install a hose without the front cover in place • Rest one end of the hose in the mouth of the inlet port (the hose should be fed into the pump in the direction of normal operation) and rub lubricant along the outer wall of the hose, feeding it into the pump housing as each length of hose is lubricated. Once the hose reaches the rotor, the drive can be inched forward to feed in the remainder of the hose.
Figure 18 • Position the insert in the port flange and gently ease into the hose; Use a small amount of lubricant if necessary on the insert and inner part of hose. • • • The port flange bolts must be tightened up evenly - it is important the flange is presented evenly to the pump housing, otherwise the sealing ring will not clamp the hose correctly.
Figure 19 Note: With the four bolts tightened up to the correct torque loading there should be a gap between the port flange and the casing of typically 2-6mm, as shown in Figure 20. It must be noted that the relationship between correct torque and finish gap can vary due to component tolerances. The effort to reach the torque should not override this as the torque figure is a maximum figure and not the minimum requirement. The important factor is to achieve sufficient clamping of the hose.
• • • • • • • When the inlet port flange is fitted, it may be necessary to inch the drive to rotate the pump in the forward direction or to slow run the pump to stretch/elongate the hose sufficiently enough to feed the hose through the outlet flange to be able to fit the sealing ring in the correct position, or to slow run the pump to stretch/elongate the hose It is normal for the hose to be initially under tension, as after approx. 7 days the hose will stretch.
Installation: As the new assembly has a machined o-ring groove it is susceptible to damage due to over tightening therefore the instruction below must be followed: • • • Clean the inspection cover with a non-scratching cloth as previous Position the window taking care to ensure the o ring seal is sat in the groove all the way around before tightening. Tighten the bolt by HAND, until the plastic washer becomes trapped by the bolt head.
Front Cover Removal Never remove front cover when the hose is still in position. The hose must be removed following the procedures in the section on ‘Hose Removal’ • If necessary fit the lifting eye to the front cover by removing the top left of centre fastening bolt and screwing the eye in to the threads provided, then fit the appropriate lifting equipment • Remove the front cover bolts and remove the front cover.
Figure 22 - Rotor Shoe Assembly & Component identification 4.6.
• • Loosen the rotor shoe bolt(s), remove the shims and retighten rotor shoe bolt(s); the shims are slotted to enable their removal without completely removing the bolt(s) Reconnect power supply and inch drive forward until the second rotor shoe is positioned over open inspection hole Do not stand within 3 metres / 9 feet of the pump when operating with the inspection cover removed; follow safety procedures for operation of pump with inspection cover off • Loosen the rotor shoe bolt(s), remove the shims
4.6.10 • • Rotor Shoe Installation (VF25 – VF80) Check the rotor shoe contact surfaces for any signs of damage and replace as required. Any wear or roughened surface will seriously affect the performance of the pump. And also reduce the life of the hose The installation of the rotor shoe is the opposite of the removal procedure Before considering replacement of damaged shoes, any sharp edges and damage to non contact areas can be blended out with fine emery / sandpaper 4.6.
4.6.
Starting Torque at 0 bar Nm 5 bar Nm 7.5 bar Nm 10 bar Nm 15 bar Nm VF10 55 55 55 55 55 VF15 75 75 75 75 75 VF25 115 120 120 140 160 VF32 210 210 210 250 300 VF40 320 320 320 400 480 VF50 620 620 810 1100 1300 VF65 1150 1150 1810 2300 2800 VF80 2000 2000 3100 4000 5000 4.8 Lubrication The standard lubricant is VERDERLUBE, a specially formulated food grade lubricant, which is designed to reduce the friction between hose and rotor shoe, thus reducing the wear and tear on the hose and on the shoes.
4.
4.9.
5. Accessories and Options The VFOCS hose burst pressure switch can be mounted either onto the filler/breather tube or direct to the back of the casing depending on the pump size (see Fig.
Vent Kit: The kit is comprised of a ¼” BSP tee piece with a pipe nut / fitting and a copper vent tube. As above after the ½” x ¼” BSP fitting is installed, this allows the tee piece to be fitted in a way which allows the VFOCS switch to be fitted direct to it.
Hose Failure Detection One of the VERDER’s many advantages is the exceptional lifetime of the hoses. Normal wear does take its toll on the hose and in time it will need to be exchanged for a new one. Throughout the hose’s lifetime, it is essential that any possible failure is noticed in sufficient time to prevent leakage into and damage to the pump housing and unit. Loss of flow can also be monitored as a pre-failure indicator.
RPM Sensor VERDER Sensor installation PCD’s Pump Model VF10 VF15 VF25 VF32 VF40 VF50 VF65 VF80 VF100 VF125 Recommended PCD Ø 110 (Front Cover) Ø 195 (Rear Casing) Ø 240 (Rear Casing) Ø 300 (Rear Casing) Ø 415 (Rear Casing) Ø 537 (Rear Casing) Ø 720 (Rear Casing) Ø 850 (Rear Casing) Ø 1000 (Rear Casing) Ø 1230 (Rear Casing) Offsets 14mm 23mm 27mm 33mm 41mm 54mm 48mm 56mm 91mm 114mm Note: Offset is related to the rib positions on the casing, but the front cover inspection window is best utilized for the V
6. Risk Assessment & Preventative measures Pump Build & Operational Safety: 6.
Rotating Coupling Personal Injury N/A Hazardous medium in pump casing after tube burst Personal Injury N/A Pump operational safety precautions Personal Injury N/A Construction materials not resistant to pumped media Adverse chemical reaction, heat build up, personal injury N/A Verderlube Pump lubricant not resistant to pumped media Adverse chemical reactions to glycerine based products with strong acids and oxidising agents, with risk of explosion N/A All flat packed long coupled assemblies t
Frictional heat of moving parts inside the gearbox N/A Unacceptable loss of oil from gearbox Guarding Mechanical contact Dust deposits on gearbox Static Discharge N/A N/A N/A Hose Failure Liquid transfer through pump outlets N/A Rubbing / cleaning of plastic inspection window The moving parts inside the gearbox are submersed in oil / grease which acts as a lubricant, spark quenching agent & coolant A level plug is provided on the gearbox.
Static Discharge Pump operation in an explosive atmosphere Overfilling & discharge of pump media through filler tube H&S in an explosive environment N/A Frictional heat of moving parts inside the casing Risk of sparking N/A Unacceptable loss of lubricant from casing through leaks or suction N/A Front Cover High surface temperature Change in duty by reduction of rpm OverTemp N/A N/A Earth clamp can be fitted or an optional level sensor fitted.
Optional Hose burst pressure sensor Explosion risk from spark N/A Mechanical coupling Mechanical slippage / breakage Excess temperature N/A Closed liquid internal circuit N/A Closed valve condition Excess temperature and pressure N/A Electrical Vac Assist Explosion risk N/A Current Huba 625 sensor must not be used for explosive operation. An alternative Exd / EExd component should be used Carry out routine maintenance to check for security Fit temp. probe to front cover or continuous temp.
6.
2 • • • 3 • • • • • 4 Pre-Storage Actions The hose should be removed from the pump and the lubricant drained out of the pump casing. The pump casing should be washed out and allowed to dry and any external build up of product removed. The gearbox should be drained and re-filled with oil in accordance with the manufacturers recommendations. Storage Conditions Pumps should be stored in a dry environment.
6.5 Other Information: Warranty Registration Your VERDER distributor will have completed a warranty card on your behalf, which is returned to VERDER for registration on VERDER’s warranty scheme.
VERDER and its distributors undertake to conduct all its dealings with you as comprehensively, courteously and promptly as possible. Customer care is one of VERDER’s top priorities Distributor Contact Details: VERDER Contact Details VERDER Ltd Whitehouse Street Leeds LS10 1AD ENGLAND, UK Tel: (+44) 113 222 0279 Fax: (+44) 113 222 0291 Email: verderflex@verder.co.
Appendix A - Verderlube Safety Data Sheet Used lubricant may become contaminated with pumped product, also verify precautions and advice against relevant product information 1 Identification of the Substance/Preparation and of the Company/Undertaking 1.1 Identification of Substance or Preparation PRODUCT NAME Verderlube® CHEMICAL IDENTIFICATION Glycerine based blend CAS NUMBER Preparation USE Food Grade - Pump Lubricant / Coolant 1.
3 Hazardous Identification This product is not classified as hazardous according to EC directive 91/155/EC • • • • 4 May cause irritation to eyes and skin. Irritating to respiratory system in the form of a mist. Contact with hot product may cause burns.
5.2 Extinguishing Media To Avoid • Do not use water jets 5.3 Unusual Fire and Explosion Hazards • Avoid spraying directly into storage containers because of danger of boil over 5.
7.2 Storage • • 8 Store under cover away from moisture and sources of ignition. Do not overheat in storage. The lubricant/coolant is hygroscopic; keep the container tightly closed Exposure Controls / Personal Protection Used lubricant may become contaminated with pumped product, also verify precautions and advice against relevant product information 8.
10 Stability and Reactivity Used lubricant may become contaminated with pumped product, also verify precautions and advice against relevant product information 10.1 Conditions to Avoid • • • • Preparation is stable and unlikely to react in a hazardous manner under normal conditions of use. No special precautions other than good housekeeping of chemicals. Hazardous polymerisation reactions are unlikely to occur. This material is combustible. 10.
12 Ecological Information Used lubricant may become contaminated with pumped product, also verify precautions and advice against relevant product information 12.1 Mobility • Spillage may penetrate the soil; unused preparation is food grade and is inherently harmless. 12.2 Persistence and Degradability • This preparation is inherently biodegradable. 12.3 Bio Accumulative Potential • There is no evidence to suggest that bioaccumulation will occur. 12.
• 16 • • Classification - Classification not required Other Information Employees of the Verder group have not experienced any harmful effect during normal handling and production. Verderlube® and Verderflex® are registered trademarks. *The information contained in this sheet is based on our knowledge of the preparation at its delivery date and that the information contained herein is current as of the date of this data sheet.
Appendix B - Verdersil Safety Data Sheet Verdersil is the lubricant / coolant used with the Verderflex® range of and other peristaltic or hose pumps Used lubricant may become contaminated with pumped product, also verify precautions and advice against relevant product information 1 Identification of the Substance/Preparation and of the Company/Undertaking 1.
3 Hazardous Identification This product is not classified as hazardous according to EC directive 91/155/EC • • • • 4 May cause irritation to eyes and skin. Irritating to respiratory system in the form of a mist. Contact with hot product may cause burns.
5.2 Extinguishing Media To Avoid • None known 5.3 Unusual Fire and Explosion Hazards • None known 5.4 Special Protective Equipment for Fire fighters • A self-contained respirator and protective clothing should be worn. Keep containers cool with water spray until well after the fire is out. Determine the need to evacuate or isolate any area in accordance with local emergency plans.
7 Handling and Storage Used lubricant may become contaminated with pumped product, also verify precautions and advice against relevant product information 7.1 Handling • • • • Contact with hot product causes burns. Avoid contact with eyes. If splashing is likely to occur wear a full visor or chemical goggles to appropriate local national standards. Avoid frequent or prolonged skin contact with fresh or used product. Wash hands thoroughly after use. 7.
9 Physical and Chemical Properties FORM Viscous liquid COLOUR Colourless ODOUR Odourless SOLIDIFICATION POINT < -45°C / <-60°F approx. FLASH POINT 121°C / 250°F approx. (Closed cup) BOILING POINT >200°C / >390°F SOLUBILITY IN WATER 0 g/litre at 20°C VISCOCITY 350 mPas approx. at 20°C / 68°F AUTO IGNITION TEMPERATURE >200°C / >390°F. EXPLOSION LIMITS Not explosive DENSITY (20°C/68°F) 970 kg/m3 approx.
11.2 Significant Data with Possible Relevance to Human Health • Eyes - • • Skin Ingestion - • Inhalation - Unlikely to cause more than transient stinging or redness if accidental eye contact occurs Unlikely to cause harm to the skin Unlikely to cause harm if accidentally swallowed in small doses, although larger quantities should be avoided At ambient temperatures this product will be unlikely to present an inhalation hazard 11.
12.2 Environmental Effects • Toxicity to Water Organisms: Based on analogy to similar materials this product is expected to exhibit low toxicity to aquatic organisms. • Toxicity to Soil Organisms: Experiments show that when sewage sludge containing polydimethylsiloxane is added to soil, it has no effect on soil micro-organisms, earthworms or subsequent crops grown in the soil. 12.3 Bioaccumulative • This product is a liquid and is a high molecular weight polymer.
14 • • Transport Information Not classified as dangerous for transport (RID/ADR-ADNE-IATA-IMDG-MARPOL-ICAO) DOT Road Shipment Information (49 CFR 172.
16.3 Supplemental State Compliance Information for California • - Warning: This product contains the following chemical(s) listed by the State of California under the Safe Drinking Water and Toxic Enforcement Act of 1986 (Proposition 65) as being known to cause cancer, birth defects or other reproductive harm None known. 16.4 Supplemental State Compliance Information for Massachusetts No ingredient regulated by MA Right-to-Know Law present. 16.
Appendix C 77
Operating Protocol for Verderflex Black NBR Food Grade Hose VERDERFLEX Black NBR Food Grade hoses are suitable for conveying oily and fatty foods in peristaltic pumps Cleaning Protocol VERDERFLEX Black NBR food grade hoses should be cleaned with the following protocol – First flush Second flush or or Final flush 2% Nitric Acid (HNO3) solution for up to 3 minutes at up to 50°C 2% Caustic soda (NaOH) solution for up to 20 minutes at up to 100°C 5% Caustic soda (NaOH) solution for up to 5 minutes at up to 100°C 2
Hose Installation All VERDERFLEX Black NBR Food Grade hoses must be installed in accordance with the procedures defined in the VERDERFLEX Safety, Operating and Maintenance manual.
75
