INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR THE ROTARY TANKER PUMP Page 0
Page 1
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR RTPTM ROTARY LOBE PUMPS. 1.0 SAFETY INFORMATION. 4 1.1 RISK ASSESSMENT RELATING TO THE USE OF JOHNSON PUMP (UK) LTD. RTP ROTARY LOBE PUMPS 7 AND PUMP UNITS IN POTENTIALLY EXPLOSIVE ATMOSPHERES. 2.0 INTRODUCTION. 8 2.1 2.2 2.3 2.4 2.5 2.5.1 2.6 GENERAL. JOHNSON PUMP (UK) LTD. DISTRIBUTORS. RECEIPT AND STORAGE. CLEANING. PUMP MODEL DESIGNATION. ATEX INFORMATION PLATE PUMP MODEL AND SERIAL NUMBER. 8 8 8 9 9 10 11 3.0 GENERAL. 12 3.1 3.2 3.3 3.3.
.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 PRODUCT SEAL FITTING AND REMOVAL. GENERAL PROCEDURES FOR INSTALLING SEALS. RTP20 O-RING SEAL. RTP30 CLASS 1 HYGIENIC MECHANICAL SEAL. RTP30 CLASS 2 HYGIENIC MECHANICAL SEAL. RTP30 STANDARD RADIAL LIP SEAL. RTP30 O-RING SEAL. 33 33 35 36 37 38 39 5.0 SPECIFICATIONS. 40 5.1 5.2 5.3 5.4 5.5 5.5.1 5.6 5.7 5.8 5.9 CLEARANCE CHART FASTENERS & TORQUE SETTINGS. LUBRICANTS. TOOL LIST. RTP30 FOUNDATION DIMENSIONS – STUB SHAFT DRIVE.
1.0 Safety Information. INCORRECT INSTALLATION, OPERATION, OR MAINTENANCE OF EQUIPMENT MAY CAUSE SEVERE PERSONAL INJURY OR DEATH AND/OR EQUIPMENT DAMAGE THAT MAY INVALIDATE THE WARRANTY. THIS INFORMATION MUST BE READ FULLY BEFORE BEGINNING INSTALLATION, OPERATION, OR MAINTENANCE AND MUST BE KEPT WITH THE PUMP. ONLY SUITABLY TRAINED OR QUALIFIED PERSONS SHOULD UNDERTAKE INSTALLATION AND MAINTENANCE. Danger - Failure to follow the listed precautionary measures may result in serious injury or death.
The mounting of the pump or pump unit should be solid and stable. Pump orientation must be considered in relation to drainage requirements. Once mounted, shaft drive elements must be checked for correct alignment. Rotate pump shaft by at least one full revolution to ensure smoothness of operation. Incorrect alignment will produce excessive loading, create high temperatures and increased noise emissions. Do not use any drive arrangements, which cause side loading of the drive shaft.
DO NOT attempt any maintenance or disassembly of the pump or pump unit without first ensuring that: - The pump is fully isolated from the power source (electric, hydraulic, pneumatic). - The pumping chamber, pneumatic relief valve and any shaft seal support system are depressurised and purged. - Any temperature control devices (jackets, heat-tracing, etc.) are fully isolated, that they are depressurised and purged, and components are allowed to reach a safe handling temperature.
1.1 Risk assessment relating to the use of Johnson Pump (UK) Ltd. RTP rotary lobe pumps and pump units in potentially explosive atmospheres. Note:- For a feature to be suitable for an application, The feature must be fit for its designated purpose and also suitable for the environment where it is to be installed.
2.0 Introduction. 2.1 General. RTPTM rotary lobe pump is manufactured by Johnson Pump (UK) Ltd. a subsidiary of Viking Pump Inc., Cedar Falls, USA, (a unit of the IDEX Corporation) herein after referred to as ‘JPUK’. This manual includes all the necessary information for RTPTM pumps and should be read prior to beginning installation, operation, or maintenance. Should you require any additional information regarding the RTPTM pumps contact JPUK or their local authorised distributor (refer to section 2.2).
2.4 Cleaning. The RTPTM pump series is suitable for both manual cleaning and CIP (Cleaning In Place), refer to section 3.3.2. The product seals are mounted directly behind the rotors and are designed and positioned to minimise product entrapment and maximise the effects of cleaning. This strategic positioning of the product seals, combined with their ease of access provides an arrangement that can be more effectively cleaned by both manual and CIP procedures.
2.5.1 Atex Information Plate Group II. Unit is suitable for environments containing dus or gas Category 2 Temperature Class. 2.5.
2.6 Pump Model and Serial Number. Should you require any information regarding your RTPTM rotary lobe pump contact JPUK or your JPUK distributor, providing the pump model and serial number as stated on the pump nameplate, see Fig 2, which is fixed to the pump gearbox cover. Should this be damaged or missing, the pump serial number is also stamped on opposite corners of the rotorcase, (see Fig 3). Fig 2 Nameplate. R T P R ANG E Fig 3 Serial Number Location.
3.0 General. 3.1 RTPTM Pumping Principle. The pumping action of the rotary lobe pump principle is generated by the contra-rotation of two pumping elements (rotors) within a chamber (rotorcase), Fig 4. The shaft assemblies comprise of, the shaft support bearings and the timing gears. The gears transfer the energy from the drive shaft to the driven shaft, synchronising the rotors such that they rotate without contact with each other.
3.2 RTPTM Operating Parameters. Fig 5 Operating Parameters RTP20 Theoretical Displacement Nominal Connection Size Max Diff. Pressure Maximum Speed Max Temp Max Temp Litre/ rev Imp.gal /100 rev US gal / 100 rev mm inches bar psi rev/min C F 1.00 21.9 26.4 50 or 75 2 or 3 10 145 1000 110 230 RTP30 Theoretical Displacement Nominal Connection Size Max Diff. Pressure Maximum Speed Max Temp Max Temp Litre/ rev Imp.
Be sure ample room is provided around the pump to allow for: • Access to the pump and drive for routine inspection and maintenance, i.e. to remove pump front cover and rotors. • Ventilation of the drive to prevent over heating. The exterior of the pump unit may exceed 68°C (154°F), Appropriate measures must be taken to warn or protect operators. WARNING The pump must not be used to support piping. All piping to and from the pump unit must be independently supported.
Observing the following general guidelines should ensure the best possible suction condition is created. • Suction piping is at least the same diameter as the pump connections. • The length of suction piping is kept to the absolute minimum. • The minimum number of bends, tees and pipework restrictions are used. • Calculations to determine system NPSHa are carried out for the worst condition see below.
Where motor mounted options are to be installed follow the manufactures recommended guidelines. However, when installing a pump complete with base and drive the following guidelines must be observed: • The preferred drive arrangement for any rotary lobe pump is in-line direct coupled. • Flexible couplings must always be incorporated and correctly aligned within the limits recommended by the coupling manufacturer.
3.4 WARNING Start Up Procedure. - Check that all piping and associated equipment are clean and free from debris and that all pipe connections are secure and leak free. - For pumps installed with flushed product seals check that all auxiliary services are in place and connected and provide sufficient flow and pressure for flushing purposes, refer to product seal section 4.3. - Ensure lubrication is provided for both pump and drive. RTPTM pumps are shipped without oil. Refer to section 5.
- Ensure product is available in the tank before starting pump. This is very important for pumps installed with unflushed product seals, as these sealing arrangements must never be allowed to run dry. - Before beginning operation it is considered good practice to momentarily start/stop the pump to check the direction of rotation and ensure that the pump is free of obstructions.
Where heating/cooling devices are employed, the heating/cooling media should be circulated 15-20 minutes prior to pump start-up and should be allowed to continue for a similar period of time after the pump has been shutdown. Where a CIP cycle is employed as part of the process, the heating/cooling media should continue to be circulated during the cleaning cycle. Fig 8 Dimensions for Heating/Cooling.
3.8 Integral Pressure Relief Valve. Integral pressure relief valves are normally used to protect the pump from the effects of increases in system pressure caused, for example, by a restricted or closed discharge line. In response to a pressure increase the valve opens and internally circulates the pumped media within the pump chamber.
101 112 Fig 9 Pre-Set Relief Valve. 110 109 106 126 116 103 ITEM NUMBER DESCRIPTION 101 103 106 109 110 112 116 126 RV FRONT COVER DIAPHRAGM (PTFE FACE TO THE PRODUCT) SPRING HOUSING SPRING SCREW VALVE HEAD O-RING SPACER (IF REQUIRED) DANGER Under no circumstances should any attempt be made to dismantle a pressure relief valve which has not had the spring pressure relieved (where applicable) or is mounted on a pump that is operating. Serious personal injury or pump damage may occur.
4.0 RTPTM Pump Dismantling and Assembly. Before undertaking any work on the pump the Shutdown Procedure should be followed in section 3.5, and site safety practices must be observed. While dismantling or assembling the pump it is essential to ensure that the pump and/or components are secured to provide adequate stability. Large pump components or assemblies should be lifted using suitable devices. Use threaded holes for attaching lifting eyes where appropriate.
4.1 Disassembly. 4.1.1 Front Cover and Rotor Removal see Fig 10. - Follow recommended Shutdown Procedure, referring to section 3.5. - Gradually loosen front cover retaining nuts (36). Care should be taken as residual product and pressure may still be present in the pump head. As the dome nuts are loosened this will vent to atmosphere. - Remove dome nuts (36). - Remove front cover (38), using lever slots where necessary, continue and remove the front cover o-ring (39) from rotorcase (40).
4.1.2 Gearbox Dismantling (After Completing 4.1.1). The following procedures assume that pump has been removed from the baseplate and that the product seals have been removed (see section 4.3). - Remove drain plug (5) and breather (21). Drain lubricant into suitable container and retain if later inspection is required. - Remove retaining screws (74), and remove the endplate (70) from the gearbox (16) utilising the retaining screws (74) in the jacking points provided, see fig 12.
- Remove shaft assemblies from the gearbox (16, see fig 5.6). Shaft assemblies will be complete with gears (14), and bearings (24 and 19) – see fig 13. - Remove lipseals (17) from the gearbox (16). - Disassemble gearbox (16) from rotorcase (40) by removing the retaining screw (7). Utilising the retaining screws (7) in the jacking points on the gearbox; the gearbox (16) and rotorcase (40) can be separated, see fig 12. - Remove bearing cup (24) from the gearbox (16).
4.1.3 Shaft Disassembly. - Remove the rear bearing assembly (19). - Remove the timing gear screws (23). - Remove the timing gear (14) and locating dowel (80). - Remove o-rings (26) from the rear of the shaft (9 or 10). - Remove o-rings (25) from the front of the shafts (9 or 10). - Remove front bearing assembly (24). Fig 13 Bearing & Timing Gear Removal. Note: Right hand helix for drive shaft gear (stamped D), left hand helix for driven shaft gear (stamped L).
4.2 Assembly. 4.2.1 Gearbox & Rotorcase Assembly, see fig 14. WARNING Install front bearing cups (24 not shown). Do not install the front lip seals (17) until the bearing pre-load has been set. The lips may give a false rolling torque reading as well as increasing the risk of damage during assembly. - Install rotorcase (40) to gearbox (16) and secure using cap screws (7). - Install drain plug (5) , where required in required position in gearbox cover (16).
4.2.2 Shaft Assembly – RTP20 - Install front bearing (24) to shaft (9 or 10). - Install o-rings (26 and 25), to shafts (9 or 10) in the appropriate grooves. Lightly lubricate all o-rings with a compatible lubricant. - Install the gear (14) over the o-rings (26) and secure with retaining bolts (23). It is recommended that the screws be aligned at the centre of the slots provided to give an equal amount of adjustment in either direction.
4.2.3 Shaft Assembly – RTP30 - Install front bearing (24) to shaft (9 or 10). - Install o-rings (26 and 25), to shafts (9 or 10) in the appropriate grooves. Lightly lubricate all o-rings with a compatible lubricant. - Install the gear (14) over the o-rings (26) and secure with retaining bolts (23). It is recommended that the screws be aligned at the centre of the slots provided to give an equal amount of adjustment in either direction.
4.2.4 Timing. - Rotate the shafts (9 and 10) so as to position the gaps made by the missing splines, in the vertically uppermost position, see fig 16. Fig 16 Aligning the missing splines. - Assemble the rotors (41), rotor retainers (35) and o-rings (34) onto the shafts (9 and 10). - To achieve the correct timing clearance rotate one shaft, whilst securing the other. The gear (14) will rotate on the lubricated o-rings until the correct mesh clearance is achieved. For mesh clearances refer to section 5.
Fig 17 Aligning the mesh point. - Remove the shaft assemblies from the gearbox (16). - Using the holes provided drill and ream both gear (14) and shaft (9 and 10) to suit Ø6.0 mm dowel (80), as shown in fig 18. It is important to drill and ream the hole so that the dowel is positioned equally between the gears (14) and shafts (9 and 10). Fig 18 Installing and positioning the timing dowel. Drill & Ream to suit Ø6.0 mm dowel. - Install the Ø6.
4.2.5 Setting the rolling torque. WARNING It is important that the product seals and both front and rear lip seals are not installed until the bearing pre-load has been set and the clearances checked. The seals may give a false rolling torque reading as well as increasing the risk of damage during assembly. - Re-install one of the shaft assemblies into the gearbox (16) and replace the endplate assembly, ensure that the retaining screws (74) are tightened to the correct torque, see section 5.2.
4.3 Product Seal Fitting and Removal. 4.3.1 General Procedures for Installing Seals. WARNING - Mechanical seals are precision-engineered assemblies incorporating finely lapped seal faces and seats. They must therefore be handled with care and will not give optimum performance unless installed carefully and according to instructions. - Where mechanical seals are to be reused ensure that seal components are kept in their appropriate sets. Do not mix old and new seal faces on the same seal.
i) Terminology. a) "Quench" To provide a liquid barrier, which is not, induced to flow through the seal area by any external means. b) "Flush" To provide a liquid barrier that is induced to flow through the seal area by an external means. ii) Quench or Flush Media. WARNING The media used for quenching or flushing a seal area must be fully compatible with the pumped media, and the relevant materials of construction of the pump.
4.3.2 RTP20 O-Ring Seal. Fig 22 O-Ring Seal Cartridge. Read the general procedures before proceeding, refer to section 4.3.1. - Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover o-ring (39), see section 4.1. - Remove the o-ring seal cartridge assembly from the rotor (41). - The seals can now be accessed for inspection. - The o-ring seals can now be removed and replaced (if required) from the cartridge.
4.3.3 RTP30 Class 1 Hygienic Mechanical Seal. Fig 19 Class 1 Hygienic Mechanical Seal. Read the general procedures before proceeding, refer to section 4.3.1. - Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover o-ring (39), see section 4.1. The seal can now be accessed for inspection. - Remove the rotary seal face assembly from inside the rotor, taking care not to damage the o-rings.
4.3.4 RTP30 Class 2 Hygienic Mechanical Seal. Fig 20 Class 2 Hygienic Mechanical Seal. Read the general procedures before proceeding, refer to section 4.3.1. - Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover o-ring (39), see section 4.1. - The seal can now be accessed for inspection. - Remove o-ring (25), from the end of the shaft. - Remove the rotary seal face assembly from the shaft.
4.3.5 RTP30 Standard Radial Lip Seal. Fig 21 Standard Radial Lip Seal Cartridge. Read the general procedures before proceeding, refer to section 4.3.1. - Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover o-ring (39), see section 4.1. - Remove the lip seal cartridge assembly from the rotor (41). - The seals can now be accessed for inspection. - The individual lip seals can now be removed and replaced (if required) from the cartridge.
4.3.6 RTP30 O-Ring Seal. Fig 22 O-Ring Seal Cartridge. Read the general procedures before proceeding, refer to section 4.3.1. - Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover o-ring (39), see section 4.1. - Remove the o-ring seal cartridge assembly from the rotor (41). - The seals can now be accessed for inspection. - The o-ring seals can now be removed and replaced (if required) from the cartridge.
5.0 Specifications. 5.1 Clearance Chart D C (Radial) C (Radial) B A A B C D Millimetres 0.30 – 0.50 0.25 – 0.50 0.45 – 0.65 0.25 – 0.40 Inches 0.012 – 0.020 0.010 – 0.020 0.018 – 0.026 0.010 – 0.016 Millimetres 0.30 – 0.70 0.25 – 0.60 0.55– 0.75 0.35 – 0.50 Inches 0.012 – 0.028 0.010 – 0.023 0.022 – 0.030 0.014 – 0.
5.2 Fasteners & Torque Settings. ITEM DESCRIPTION 2 Socket Head Cap Screw 7 Socket Head Cap Screw - Seal Lock Nut (See 1.0) 14 Socket Head Cap Screw 35 Retainer 36 Dome Nut (Acorn) 37 Stud 56 Hammer Drive Screw 74 Socket Head Cap Screw - POSITION Quantity / Pump Foot / Rotorcase Size Torque (NM) Quantity / Pump Gearbox / Size Rotorcase Torque (NM) Quantity / Pump Rotorcase Size Torque (NM) Quantity / Pump Timing Gear / Size Shaft Torque (NM) Quantity / Pump Rotor / Shaft Part No.
5.3 Grease Oil Lubricants. The recommended synthetic gearbox grease for use in the RTPTM is one that is intended for ‘sealed for life’ units. Suitable for operating temperatures between –20°C and 120°C (-4°F to 248°F) and a base viscosity in the region of 150 Cst at 40°C (104°F). The recommended gearbox oil for use in the RTPTM is an “EP (Extreme Pressure) grade gear lube”. The following grades should be used in these temperature ranges: EP150 EP220 EP320 -18 to 0°C 0 to 30°C 30°C and higher.
5.4 Tool List. Listed below are tools required for the maintenance of the RTPTM pump. RTP20 TYPE SIZE OR RANGE HEXAGON (ALLEN) KEY 3 MM HEXAGON (ALLEN) KEY 5 MM HEXAGON (ALLEN) KEY 8 MM COMBINATION SPANNER 19 MM TORQUE WRENCH ADJUSTABLE TO MIN. 135 NM (99.57 FT-LB) DEPTH MICROMETER 0 - 25 MM (0 - 1") FEELER GAUGE SET 0.03 MM TO 0.50 MM (0.0012” TO 0.0197”) – 388M ROLLING TORQUE METER 0 - 5 NM (0 - 3.
5.5 RTP30 Foundation Dimensions – Stub Shaft Drive.
5.5.
Dimensions in millimetres A 50 RTP20 80 80 RTP30 100 B1 117 131 135 B2 139 149 163 178 B3 131 145 B4 131 139 B5 139 144 C D E HB HS HT L M N P Q R S T U V W X Weight (kg) 142 275 22 88 88 196 299 42 174 90 14 117 222 195 11 303 330 54 49 153 158 157 305 29 97 100 217 311 62 161 124 14 152 243 214 13 329 358 60 67 B4 5.16 5.47 B5 5.47 5.67 C D E HB HS HT L M N P Q R S T U V W X Weight (lb) 5.59 10.83 0.87 3.46 3.46 7.
5.
PUMP STALLS ON START UP SEIZURE NOISE / VIBRATION EXCESSIVE SEAL WEAR EXCESSIVE ROTOR WEAR MOTOR OVERHEATS PUMP OVERHEATS UNDER CAPACITY Trouble Shooting. IRREGULAR FLOW NO FLOW 5.7 Causes ACTION INCORRECT DIRECTION OF ROTATION. REVERSE MOTOR. PUMP NOT PRIMED. EXPEL GAS FROM SUCTION LINE / PUMP CHAMBER & PRIME. INSUFFICIENT NPSH AVAILABLE. INCREASE SUCTION LINE & STATIC SUCTION HEAD DIAMETER. SIMPLIFY SUCTION LINE & REDUCE LENGTH. REDUCE PUMP SPEED & PRODUCT TEMPERATURE.
5.8 RTPTM Service History.
5.9 Notes. The information contained in this document is correct at time of print, but may be subject to change without prior notice.
Johnson Pump (UK) Ltd. A unit of IDEX Corporation Highfield Industrial Estate, Edison Road Eastbourne, East Sussex, BN23 6PT, England Phone: Natl (01323) 509211 – Intl +44 1323 509211 Fax: Natl (01323) 507306 – Intl +44 1323 507306 E-Mail: mailto:jinfo@idexcorp.
