Manual de Bombas Fuller Tipo M [PDF]

Zitiervorschau

Instruction

Document No.: 116-99-1-0001

Version: 1.0

Page 1 of 35

Instruction Manual Fuller-Kinyon Type M Pump - 3 Piece Screw 150, 200, 250 And 300mm Grease Lubricated Pressurized Bearing / Seal Assembly

Caution Read this instruction manual before performing any installation, operation or maintenance procedure. All equipment must be operated and maintained in accordance with all applicable governmental safety and health laws and regulations, generally recognized industrial standards, and the user’s plant standards.

Version 1.0

Signed by Lou Dibuo

Release Date 7/1/2004

F.L.Smidth, Inc. 2040 Avenue C Bethlehem, PA 18017-2188 Telephone: 610-264-6011 Fax: +1-610-264-6701 www.flsmidth.com

Parts and Service Call 1-800-795-6825

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TABLE OF CONTENTS INTRODUCTION Receiving and Storage .........................................................................................................3 INSTALLATION Foundation ...........................................................................................................................4 Erection and Alignment .......................................................................................................4 Purge Air Piping ..................................................................................................................5 PRINCIPLE OF OPERATION........................................................................................................5 GENERAL OPERATION ...............................................................................................................7 LUBRICATION Bearings ...............................................................................................................................9 Seals ...................................................................................................................................11 Flapper Valve Shaft ...........................................................................................................12 MAINTENANCE Pump Screw .......................................................................................................................19 Pump Screw Removal........................................................................................................20 Barrel Bushing Removal....................................................................................................21 Barrel Bushing Replacement .............................................................................................22 Pump Screw Installation ....................................................................................................22 Installation from Discharge End ........................................................................................23 Installation from Drive End ...............................................................................................24 Bearings .............................................................................................................................24 Bearing Replacement .........................................................................................................24 Bearing Replacement Drive End of Pump.........................................................................26 Bearing Mounting Drive End of Pump..............................................................................27 Seal Replacement...............................................................................................................29 Wear Sleeve Replacement .................................................................................................30 Flapper Valve Assembly....................................................................................................30 Pump Screw Construction..................................................................................................31 Fuller-Kinyon Pump Screw Inspection Criteria ................................................................31 Troubleshooting Fuller-Kinyon Pumping System .............................................................31 Typical Piping Arrangement..............................................................................................34 Compressor Arrangement ..................................................................................................35

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INTRODUCTION The F.L.Smidth Inc. (FLS) equipment for this installation has been specified and recommended on the basis of information given to FLS by your company. This installation should operate satisfactorily. If any questions arise concerning the safe operation or performance of the equipment supplied, please communicate with the nearest FLS branch or the Service Department at the Main Office in Bethlehem.

Do not make any change to the installation or equipment without consulting FLS first. These operating instructions and parts books apply to your particular installation. Extra copies have been supplied and everyone concerned with the operation and maintenance of this equipment should read them. For easy reference, operating and maintenance instructions are listed under the following headings: Principle of Operation, Lubrication, and Maintenance. When ordering replacement parts for this equipment, please supply pump machine number, PDB (Product number), twelve-digit part number, and correct name of part. These can be obtained from the List of Parts which is a part of this instruction book. RECEIVING AND STORAGE Before and after uncrating, look for damage that may have occurred in transit. Check for shortage by comparing each item received with those listed on the shipping manifest. If damage or shortage is noted, advise the carrier within fifteen days of receipt and request an inspection report. Make the proper claim with the carrier and order replacement part(s) from FLS. If the unit is not installed immediately, place it in a clean, dry, storage area protected from inclement weather. If an extended storage period is necessary, consult FLS Service Department for precautions.

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INSTALLATION FOUNDATION Concrete foundations, extending to firm bearing and having moderate steel rod reinforcing are recommended. However, installations on balconies or steel supports are also satisfactory providing that sufficient stiffness is designed into the supports to maintain Fuller-Kinyon pump and drive alignment. Simple slab type foundations are normally used to raise the Fuller-Kinyon pump to a reasonable height above the floor for convenient servicing and inspection. The basic design should be for static loadings only. The Anchor Bolt Setting Plan drawing indicates the necessary dimensions for the construction of these foundations and gives anchor bolt and pipe sleeve locations. ERECTION AND ALIGNMENT The unit should be placed on its foundation and leveled carefully with wedges located as close to foundation bolts as possible. The drive, with the coupling half assembled, should be placed on the foundation and aligned with the unit. All anchor bolt nuts must be sufficiently tight to hold the unit firmly on wedges or on a plate. Check for proper shaft gap (refer to the general arrangement drawing) and proceed with coupling alignment. After alignment is complete, proceed as follows: Use a cement grout and grout in thoroughly around and well under the base and fill all anchor bolt sleeve openings. After grout is set, tighten all anchor bolts firmly. Be sure to recheck coupling alignment and realign, if necessary. The drive should be checked for rotation, making sure that it agrees with the Fuller-Kinyon pump rotation arrow. The screw should rotate counter-clockwise when viewed from the drive end. The motor and the pump should not be connected for this check. For V-belt driven units, locate sheaves as dimensioned on the general arrangement drawing. Check the alignment of the sheaves before final grouting. Install the driver and its base with allowance for lateral motion to install V-belts and provide proper tension during operation. In adjusting tension of V-belts, follow instructions of the V-belt manufacturer.

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PURGE AIR PIPING Seal purge air must be supplied to both ends of the pump. Refer to figure 4 for piping arrangement. The air purge piping shown in figure 4 utilizes plant air at both ends of the pump. The pump parts list specifies the piping arrangement furnished for your installation. Refer to contract instruction manual.

CAUTION The purge connection union, located at the drive end of the pump is equipped with an orifice plate. The union at the discharge end of a pump utilizing plant air purge also contains an orifice. Check to insure that the orifice plates are in place when assembling piping. Adjust pressure regulators as specified in figure 4.

PRINCIPLE OF OPERATION Material to be conveyed enters the hopper (A, figure 1), the screw (B) advances the material through the barrel (C) to the discharge body (D). In the discharge body, the material is compressed to form a material seal. The material seal prevents a reverse flow of conveying air from the mixing chamber (E). The screw has a reverse pitch flight (F) which repels material thus aiding the advancing screw flights in forcing the material into the mixing chamber. After the material is discharged into the mixing chamber (E), compressor air, entering the mixing chamber through the nozzles (G), fluidizes it sufficiently to permit pumping through the transport line connected to the end of the mixing chamber. The free-floating flapper valve (H), located in the discharge area of the pump, is a mechanical seal which assist in preventing the reverse flow of air from the mixing chamber through the pump barrel. The external flapper valve lever (T) serves as a visual indication that the free-floating flapper valve is operating satisfactorily. This external lever should never be connected by any means to the internal valve. A counterweight (U) is attached to the flapper valve handle to aid in maintaining a material seal. This counterweight position is adjustable along the flapper valve handle to increase or decrease flapper valve pressure. Each pump is supplied with one spacer ring (V) located behind the flapper valve assembly. The proper combination of counterweight (U) plus spacer ring (V) should provide an adequate material seal for proper operation. In some cases, the spacer (V) can be removed to achieve the desired balance between material seal and motor load.

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The pump screw is coupled to a drive motor by either a shaft coupling or a V-belt drive. The screw pitch and speed are determined by FLS for each application. The Fuller-Kinyon pump will operate most efficiently at the maximum capacity for which it was sized. However, it is permissible to operate the type M pump at reduced load conditions.

Figure 1

A B C D E F G H J K

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Hopper Screw Barrel Discharge Body Mixing Chamber Reverse Pitch Flight Nozzles Flapper Valve Manifold Pressure Gauge Line Pressure Gauge

L M N P Q R S T U V

Hopper Cover Plate Barrel Bushing Retainer Screw Barrel Bushing Retainer Screw Set Screws Short Barrel Bushing Barrel Bushing Barrel Bushing External Flapper Valve Lever Counterweight Spacer Ring

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GENERAL OPERATION Carefully observe the following thirteen points prior to initial start-up and during subsequent operation of the Fuller-Kinyon system. 1.

Assuming an individual compressor1 is part of the Fuller-Kinyon system, check the intake duct for loose dirt or other foreign material; then check alignment, orientation, and lubrication of the compressor. (Refer to Compressor Instructions for details).

2.

If the air supply is from an individual compressor to an individual pump, no valve should be in the air line between the compressor and the Fuller-Kinyon pump.

3.

The Fuller-Kinyon pump is a precision piece of machinery which requires a rigid foundation. For maximum maintenance-free operation, the pump base must be flat, true, and anchored solidly in the foundation. If the above is not adhered to, distortion of the Fuller-Kinyon pump will occur, thereby putting undue strain on the pump components.

4.

There are two drive options for the Fuller-Kinyon pump, either V-belt or direct coupling drive. If a coupling drive is used, disconnect the coupling and verify the proper alignment between the motor and the pump coupling halves. Coupling misalignment may cause premature bearing failures and pump vibration. In those instances where a V-belt drive is used, verify the alignment between the pump and motor sheaves.

5.

Inspect the Fuller-Kinyon pump hopper, mixing chamber, and air manifold for foreign material.

6.

Carefully observe the operating instructions furnished before starting the compressor.

7.

On both ends of the Fuller-Kinyon pump, housed in the bearing housing supports (A, figure 4), there are seal arrangements which require a steady flow of air for proper operation. There is an onoff solenoid (H, figure 4) provided for the plant air to the seals. Air to the FK-Pump seals must be turned on prior to the pump motor starting (i.e., first turned on and last turned off). The FullerKinyon pump must never be run without purge air to the seal arrangement. There is a pressure switch (G, figure 4) supplied to indicate loss of plant air pressure. Loss of plant air to the seals must initiate immediate pump shut down.

8.

Start the Fuller-Kinyon pump motor only after air from its individual compressor1 is operating and plant air to the pump seals is entering the pump. Check the Fuller-Kinyon pump screw rotation; it should be counterclockwise when viewed from the motor end.

9.

Start the Fuller-Kinyon pump without feed. Note the pressure on the manifold gauge and line gauge. The manifold pressure gauge (J, figure 1) should be 2-3 psi (0.14-0.21 kg/cm2) higher than line pressure. Without feed, the line pressure should be nearly zero. 1. "Individual compressor" refers to a compressor whose sole purpose is to supply air to the FullerKinyon pump. Normally it is a rotary machine with no after cooler or receiver in the system.

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10.

Open the feed valve or start the feed conveying equipment. As the load through the Fuller-Kinyon pump increases, the pressure on both the manifold gauge (J) and line gauge (K) will rise. The pressure on gauge (J) will always be higher than on gauge (K) throughout the full operating range. If, with normal full feed, the pressure on the gauge (K) fluctuates continuously from high to low reading, the amperage of the pump motor varies through the same cycle, and the flapper valve lever (T) continually moves up and down, blowback through the Fuller-Kinyon pump material seal is indicated. Adjust the counterweight (U) to a position farther out on the flapper valve lever (T). If there is indication of continuous overload on the motor, remove the spacer plate (V) and readjust the counterweight (U) until steady operation is maintained. If the blowback condition persists for a long period of time, consult FLS Inc.

11.

When shutting down the Fuller-Kinyon pump, first stop the material flow and after the pump is completely empty, stop the driving motor.

12.

When the Fuller-Kinyon pump screw has come to a complete stop, the air should be allowed to blow through the transport line until gauge (K) stabilizes at nearly zero. Then the pump air purge can be turned off.

13.

When the material feed rate to the Fuller-Kinyon pump is not controlled (under silos, bins, tanks, railroad cars, etc.), a solenoid air valve complete with an instantaneous trip relay is part of the Fuller-Kinyon pump equipment. (See figure 4). In operation, when the material flow to the Fuller-Kinyon pump becomes excessive, and the pump motor overloads, the trip relay then operates the solenoid air valve (C, figure 4) and air is admitted into the Fuller-Kinyon pump hopper. This reduces the Fuller-Kinyon pump motor overload condition and when the motor load becomes normal again, the solenoid valve closes. The instantaneous trip relay is set at 95% of the motor full-load current and the reset point is 82% of the trip relay setting. The pipe union (D) contains an orifice which meters air through the line (E) to keep it clear. Care must be taken during disassembly and reassembly to insure that the orifice remains in place.

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LUBRICATION BEARINGS For lubrication us a highly stable EP grease, preferably Bentone base, suitable for antifriction bearing lubrication at temperatures from 0˚F to +300˚F (-18˚C to 149˚C). It must meet the following specifications: Worked Penetration ASTM D-217

NLGI No. 2 Grade

Dropping Point ASTM D-566

Minimum 410˚F (210˚C)

Grease Shear Stability ASTM D-217A 10,000 Strokes

Maximum 10% Change

Roll Stability ASTM D-1831 2 Hours

Maximum 25% Change

Grease Oxidation ASTM D-942

Maximum 20 psi Drop (1.4 kg/cm2)

Wheel Bearing Test ASTM D-1263 6 Hours @ 234˚F (113˚C)

Maximum 5% Loss

Timken EP Test ASTM D-2509

Minimum 40 lb (18 kg)

Four Ball EP Test ASTM D-2596

LWI - Minimum 30.0

Four Ball Wear Test ASTM D-2266

Weld Point - Minimum 200 kg Maximum 0.60 mm Scar Diam

Base Oil Viscosity @ 40˚C @ 100˚C

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500 mm2 / sec 32 mm2 / sec

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Compliance with the above specifications in no way lessens the responsibility of the lubricant supplier to furnish products that perform satisfactorily in the application for which they are recommended. Original equipment bearings and replacement bearings are pre-lubricated with grease conforming to the above specifications. Re-lubrication with one of the following greases is recommended: Shell Oil Company

- Darina EP2, Aero Shell No. 5

Before changing to lubricants of another manufacture, the supplier of the new product must show, to the satisfaction of the user, evidence of compatibility with the product being replaced. It must satisfy the specifications listed above and perform equally as well as the one replaced. Failure to do this may result in permanent damage to the antifriction bearings. Bearings Supplied from FLS are packed with Aero Shell No.5. This grease is not compatible with most soap thickened (lithium complex) greases and should not be mixed. We recommend that pumps operating continuously twenty-four hours a day be re-lubricated either monthly or every 700 hours of operation. This time interval is the suggested starting interval for a maintenance program. Check the grease for oiliness and dirt and adjust the greasing frequency accordingly. It is important to maintain the proper amount of grease within the bearing housings. An excessive quantity of grease will result in high temperatures and subsequent damage to the bearing. The best performance and reliability may be achieved by periodically removing the bearings, flushing them clean with a suitable solvent, and repacking them with the proper, fresh lubricant. The old grease in the bearing housing and retainer should be removed before reassembly.

NOTE Grease bearing while the pump is running.

When lubricating the drive end bearing, inject a generous amount of grease (do not fill the cavity) through fittings (A) on figures 3a, 3b, and 3c. Allow the pump to run until bearings attain operating temperature. Remove the plugs (B) and allow the excessive grease to flow out. After the grease stops flowing replace the plugs.

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WARNING Use extreme caution when removing plugs from a hot pump. Very hot grease may splatter and burn any exposed skin.

Because the discharge end bearing housing is pressurized, a different lubrication method is required. With a hand gun, use approximately four to six strokes [0.33 Oz (0.01 Kg)] in each bearing fitting (A, fig. 2a,b,c) for the 150, 200, and 250 mm size pumps, and approximately eight to twelve strokes [0.67 Oz (0.02 Kg)] for the 300 mm pump. This should be done with the pump running. Note: The operating temperature of the bearing housing before and after lubrication. A sustained drop in temperature could indicate that insufficient lubricant was present before the addition of grease. A noticeable rise in temperature after several minutes could indicate excess grease in the cavity. In that case, shut off the system and pump, remove the discharge bearing cover (D), remove the excess grease, and inspect the condition of the grease and the balls of the bearing. Also, if over-lubrication appears to be the problem, adjust the lubrication amount or interval accordingly. WARNING Do not attempt to remove any fittings or disassemble the discharge end housings in any way while they are pressurized!

When installing bearings that are not pre-lubricated, pack each bearing thoroughly with grease between balls and races. Pre-lubricated bearings do not require any additional grease between balls and races. SEALS The lip seal arrangement located in the bearing housing supports at both ends of the pump (figures 2a, 2b, 2c, and 3a, 3b, 3c) requires the same type lubricant as the bearings. Grease the seals with the pump operating. We recommend that pumps operating continuously twenty-four hours a day be re-lubricated daily. Insert the grease through fitting (c) with a hand gun, using approximately one to two strokes [0.11 Oz (0.003 Kg)]. Any excess seal grease will purge out through the outer most lip seal. On the drive end this grease will fall through the opening in the housing, but it will collect inside the housing on the discharge end. It is good practice to remove this excess grease whenever the discharge end bearing housing is removed, for whatever reason. The utmost care should be taken to prevent contamination of lubricant in storage and when transferring lubricant to the pressure gun. Wipe off all pressure fittings before apply the gun. FK-M-3PC-150-300

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FLAPPER VALVE SHAFT The grease fitting provided for lubrication of the flapper valve lever shaft should be given lubrication daily [0.11 Oz (0.003 Kg)]. The use of a centralized lubrication system on Fuller-Kinyon pump is not recommended. Excessive heat may result due to possible over lubrication.

Figure 2a (150 MM and 200 MM type M Pumps)

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Figure 2b (250 MM type M Pump)

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Figure 2c (300 MM type M Pump)

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Figure 3a (150 MM and 200 MM type M Pumps)

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Figure 3b (250 MM type M Pump)

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Figure 3c (300 MM type M Pump)

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Figure 4 (Purge Air piping – Plant Air Supply to Both Ends)

FK Pump Size 150

200

250

300

FK Pump Conveying Air Supply Pressure Range, PSIG 5 - 15 16 - 24 25 - 39 40 - 45 5 - 15 16 - 24 25 - 39 40 - 45 5 - 15 16 - 24 25 - 39 40 - 45 5 - 15 16 - 24 25 - 39 40 - 45

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A B C D E F G H

Bearing Housing Supports Pressure Regulator Solenoid Air Valve Overload Trip Protection Pipe Union Line Pipe Union with Orifice Pressure Switch On-Off Solenoid Valve

Air Purge Regulator Pressure Setting Pressure Critical Flow Orifice Discharge End, Switch Setting Total Air Purge Diameter - F INCHES MM PSIG PSIG Flow SCFM 35 40 23 55 60 27 0.140" 3.6 75 80 32 85 90 35 35 40 24 55 60 33 0.152" 3.8 75 80 38 85 90 42 35 40 31 55 60 38 0.167" 4.2 75 80 46 85 90 51 35 40 36 55 60 43 0.176" 4.5 75 80 52 85 90 58

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MAINTENANCE CAUTION Before removing any covers or doing any maintenance, make sure all sources of compressed air are turned off to the pump and the system pressure has reached 0 (zero) psi.

NOTE The type “M” Fuller-Kinyon pump is a metric designed unit and requires metric tools.

Before dismantling the pump for repairs of any nature, carefully study the general assembly drawing supplied with the pump. Normal maintenance on the Fuller-Kinyon pump varies with the work being done by the individual unit. PUMP SCREW The pump screw is constructed in 3-pieces; drive shaft, discharge shaft, and screw flight shaft. The drive and discharge shafts are mounted in their supporting bearings and attached to the screw flight shaft by a flanged connection. The screw flight shaft is dynamically balanced in two places to reduce vibration and ultimately increase life. The screw flight shaft is hard surfaced to provide maximum life. It is easily replaced by unbolting the flange connections at the supporting shafts. The frequency of replacement depends on load, operating pressure, and the physical nature of the material being handled. In normal operation the pump will operate smoothly. Noise or vibrations are not normal. These conditions are an indication of wear, and that reconditioning is required.

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Figure 5 (Pump Screw) PUMP SCREW REMOVAL The pump screw can be removed from either end of the pump. It is recommended that removal be from the discharge end of the pump. When replacing the screw from the discharge end, it’s not necessary to disconnect the drive. The following steps describe screw removal from the discharge end. See figures 1,2 and 3. 1.

Remove both hopper cover plates (L, figure 1), and clean out the hopper.

2.

Unbolt the screw flight shaft from the drive shaft flange (figures 3a, 3b, and 3c). NOTE: The bolts and nuts for the shaft flanges are high strength.

3.

Remove the discharge end pressurization piping and accompanying filters and dryer (figure 4). Be careful not to lose the orifice contained in the union (figure 4) adjacent to the pressure regulator (B).

4.

Unbolt the bearing support (J, figures 2a, 2b, and 2c) from the discharge housing and pull the bearing support housing and screw flight from the pump to allow access to the screw flight and discharge shaft mounting nuts. Unbolt this connection and separate the screw flight shaft from the support housing assembly.

5.

Pull the screw from the pump.

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Due to space limitations, it may be necessary to replace the screw from the drive end of a V-belt drive pump. For screw removal from the drive end, use the following procedure. See figures 1, 2, and 3. 1.

Remove the drive guard, V-belts, and pump sheave.

2.

Remove both hopper cover plates (L, figure 1) and clean out the hopper.

3.

Unbolt the screw flight shaft from the drive shaft flange (figures 3a, 3b and 3c). NOTE: The bolts and nuts for the shaft flanges are high strength.

4.

Disconnect the seal air purge piping and unbolt the drive end bearing support housing (I, figures 3a, 3b and 3c) from the pump hopper and remove the drive bearing and support housings from the pump.

5.

Unbolt the bearing support (J, figures 2a, 2b, and 2c) from the discharge housing and pull the bearing support housing and screw flight from the pump to allow access to the screw flight and discharge shaft mounting nuts. Unbolt the connection and separate the screw flight shaft from the support housing assembly.

6.

Push the screw back into the pump, and remove from the drive end.

While it is not always necessary to change the barrel bushings each time the screw is changed, a check should be made of the inside diameter of the bushing. If it is grooved to any extend, the bushing should be replaced. BARREL BUSHING REMOVAL 1.

Remove the housing (I and J, figures 2a, 2b, and 2c) and the screw.

2.

Remove the barrel bushing retainer screws (M and N) and the four set screws (P, figure 1).

3.

Pull out the short barrel bushing (Q) from the discharge end of the pump. Apply high pressure air through the set screw hole and rap the bushing sharply with a hammer until all material is blown from between the barrel and bushing, allowing the bushing to slide out freely.

4.

Barrel bushings (R and S, figure 1) are also removed from the discharge end of the pump. Apply high pressure air through the set screw holes and rap the bushings as explained in step 3. Use a Screw jack or hydraulic jack, as shown in figure 7, and jack the bushings out through the discharge end of the pump.

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BARREL BUSHING REPLACEMENT 1.

Clean barrel bushings and barrel bores thoroughly before installing bushings.

2.

Insert the soft barrel bushing (R, figure 1) into the discharge end of the pump. Insert the as-cast face end of the bushing toward the hopper end of the barrel. Push the bushing through the barrel until the bushing extends approximately 25 mm into the hopper. Align the ribs on the OD of the bushing to straddle the anti-rotation set screws (P, figure 1).

3.

Insert the hard barrel bushing (S, figure 1) with the slotted end of the bushing toward the discharge end of the pump. Push the bushing in until it contacts the soft bushing. Position the slot in the end of the bushing on top. Assemble the retainer bolt (N, figure 1) tightly in place. From the hopper, push both barrel bushings forward until the retaining bolt is fully engaged in the barrel bushing slot.

4.

Assemble the retaining bolt (M, figure 1) tightly in place. Insert the short bushing (Q) into the housing with the slot engaging the retainer bolt (M).

5.

Tighten the four set screws (P, figure 1).

Figure 7 Screw Jack

Figure 8 Barrel Bushing

PUMP SCREW INSTALLATION The pump screw may be installed from either end of the pump. Install the screw from the same end of pump from which it was removed. Before installing the screw, clean all foreign material from the pump and check to insure that the barrel bushings are in good condition.

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INSTALLATION FROM DISCHARGE END 1. With the drive end bearing and seal housings assembled, install the screw flight assembly from the discharge end of the pump. DO NOT insert fully to allow assembly of the discharge housing assembly to the screw flight shaft.

CAUTION Insure that the screw is installed with the reverse flight toward the discharge end.

2. Assemble the discharge bearing housing assembly to the screw flight shaft with the (3) hex nuts and hardened washers (R, figures 2a,2b and 2c). Torque the nuts to the proper torque value (refer to the torque value in the table). Insert fully into the pump and bolt the seal housing to the pump. Apply Permatex #1372 to the joint between the seal housing and the pump. 3. Working through the hopper openings, attach the screw flight shaft to the drive shaft with the (3) hex head bolts and hardened washers (R, figures 3a and 3b). Torque the bolts to the proper value refer the torque value in the pump screw flange bolt torque table. NOTE All screw flight hardware is high strength and must be reinstalled with high strength hardware. Bolt failure can occur if proper hardware is not used.

Pump Screw Flange Bolt Torque Pump Size

Bolt Size

Torque N-m

Torque Ft-Lb

150 M

M 12

117

86

200 M

M 16

279

206

250 M

M 20

558

412

300 M

M 24

954

704

4.

Assemble the hopper cover plates and all air purge piping.

5.

Lubricate the lip seals as described in the lubrication instructions.

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INSTALLATION FROM DRIVE END 1.

Install the screw flight assembly into the pump. See caution note above for proper installation.

2.

Assemble the discharge bearing housing assembly to the screw flight shaft with the (3) hex nuts and hardened washers (R, figures 2a, 2b, and 2c). Torque to proper torque value (see Table). Insert fully into the pump and bolt the seal housing to the pump. Apply Permatex #1372 to the joint between the seal housing and the pump.

3.

Assemble the drive end bearing housing assembly to the pump.

4.

Working through the hopper openings, attach the screw flight shaft to the drive shaft with the (3) hex HD bolts and hardened washers (R, figures 3a and 3b). Torque bolts to the proper value (see table).

5.

Assemble the hopper cover plates and all air purge piping.

6.

Lubricate the lip seals as described in the lubrication instructions.

7.

Reassemble the drive.

BEARINGS The type "M" Fuller-Kinyon pump uses angular contact ball bearings. The bearing located at the discharge end of the pump screw is fixed (axially and radially) and absorbs both radial and thrust loads. The bearing located at the drive end is not fixed (axially) in the housing and absorbs radial load only. The 150 mm and 200 mm size pumps utilize a double row angular contact bearing. The 250 mm and 300 mm size pumps utilize a duplex pair of universally flush ground angular contact bearings mounted back-to-back. BEARING REPLACEMENT There are several methods that could be used to replace the pump bearings. The following procedures are the recommended methods. To replace the bearing at the discharge end of pump refer to figure 2a (150 mm and 200 mm size pumps), figure 2b (250 mm pump), and figure 2c (300 mm pump). 1.

Remove the bearing cover (D).

2.

Disengage the lockwasher tab (T) from the bearing retaining nut (U). Then remove the nut (U), lockwasher (T), and thrust washer (S).

3.

Disconnect the seal air purge pressurization piping.

4.

Replace the cover (D) with (2) bolts to prevent the bearing (V) from falling out when removing the bearing (J) and seal housing (I) as a sub-assembly.

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5.

Unbolt the seal housing (J) from the pump and remove the bearing (J) and seal housing (I) as a sub-assembly. NOTE: Do the remainder of the disassemble in a clean work area to prevent dirt from contaminating the bearing and seals

6.

Remove the bearing cover (D).

7.

Slide the bearing (V) and screw bushing (G) out of the bearing housing.

8.

Support the bearing (V) on the inner race and press the screw bushing (G) out of the bearing.

9.

Before replacing the bearing, clean all parts thoroughly and pack the bearing with proper lubricant. Check the seal (H) and the seal wear sleeve (L) for wear or damage and replace them, if necessary. The seal (H) is assembled as shown in Figures 2a, 2b, and 2c.

10.

Assemble the bearing (V) on the screw bushing (G). The 250 mm and 300 mm size pumps use a duplex pair of angular contact bearings mounted back-to-back. Bearings have either the word “THRUST” or “SUPPORT” stamped on one face of the outer ring of the bearing. Assemble the bearings with the thrust faces together. The bearings on 300 mm pump have, in addition to the stamping, four lubrication slots in the thrust face of the outer ring. For 150 mm pump and 200 mm size pumps, assemble the bearing on the screw bushing with the filling notch side of the bearing on the screw bushing with the filling notch side of the bearing in towards the shoulder on the screw bushing as shown in figure 2a.

11.

Slide the bearing (V) and screw bushing (G) assembly into the bearing housing (I). CAUTION Do not push the screw bushing through the seal. This could damage the seal. Make a sleeve out of shim stock and assemble it through the seal and over the screw bushing, see figure 9. Push the bearing assembly into position and remove the shim stock.

12.

Assemble the bearing cover (D) with two bolts to hold the bearing (V) and screw bushing (G) assembly in place.

13.

Attach the bearing (I) and seal housing (I) sub-assembly to the pump.

14.

Remove the bearing cover (D) and assemble the thrust washer (S), lock washer (T), and nut (U). Using a spanner wrench tighten the nut snug and then with a hammer drive the nut until firmly tightened. Bend a lock washer tab into a nut slot.

15.

Assemble the bearing cover (D) and seal pressurization piping.

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BEARING REPLACEMENT DRIVE END OF PUMP To replace the bearings on the drive end of the pump refer to figure 3a (150 mm and 200 mm size pumps), figure 3b (250 mm pump), and figure 3c (300 mm pump). A.

Direct Drive Applications 1.

Remove the hopper cover plates (L figure 1) and clean out all material.

2.

Remove the drive guard and disconnect the drive coupling.

3.

Disconnect the drive end pressurization piping from the pump.

4.

Unbolt the drive shaft(D)from the screw using the three bolts (R).

5.

Unbolt the seal housing (I) from the pump and remove the seal housing (I), bearing housing(E), and drive shaft (D) from the pump as an assembly. CAUTION: Support the housing and shaft assembly when unbolting it from the pump. NOTE:

Do the remainder of the disassemble in a clean work area to prevent dirt from contaiminating the bearing and seals.

6.

Remove the coupling hub from the drive shaft.

7.

Unlock the screw bushing lockwasher (U) and remove the screw bushing locknut (T). NOTE:

A fixture will have to be used to prevent the shaft from turning in the housing when loosening the screw bushing locknut.

8.

Remove the drive shaft (D) from the bearing (E) and seal housing (I)assembly.

9.

Remove the bearing cover (J) from the bearing housing (E).

10.

Remove the bearing (F) and screw bushing (S) as an assembly from the bearing housing (E).

11.

Loosen and remove the bearing locknut (L) and washer (M) and slide the bearing (F) off the screw bushing.

12.

Before replacing the bearing, clean all parts thoroughly. Check the housing seal (O) and cover seal (N) and replace, if necessary.

13.

Pack the bearing with grease and re-assemble the bearing (F) and screw bushing (S). The 250 mm and 300 mm size pumps use a duplex pair of angular contact bearings mounted back-to-back. Bearings have either the word "THRUST" or "SUPPORT" stamped on one face of the outer ring of the bearing. Assemble the bearings with the thrust faces together. The bearings on 300 mm pump have, in addition to the stamping, four lubrication slots in

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the thrust face of the outer ring. For the 150 mm and 200 mm size pumps, assemble the bearing on the screw bushing with the filling notch side of the bearing out towards the bearing locknut. 14.

Lock the bearing (F) to the screw bushing (S) using the lock washer (M) and locknut (L). It is important that the locknut is securely tightened to firmly clamp the inner race of the bearing (F) to the screw bushing (S). To facilitate tightening of the locknut, wrench slots are provided on the screw bushing. Use a spanner wrench to hold the screw bushing and to turn the locknut until snug. Then with a hammer drive the nut until the locknut is tightened firmly. Bend a tab of the lock washer into the nut retaining it in position. NOTE:

15.

Slide the bearing (F) and screw bushing (S) assembly into the bearing housing (E). NOTE:

B.

The firm clamping of the bearings to the screw bushing prevents rotation of the bearing on the bushing and establishes proper bearing preload for the duplex bearings furnished with the 250 mm and 300 mm pumps. Failure to obtain sufficient clamping of the bearings may cause premature bearing and seal failures.

See the caution for installing the screw bushing on the discharge end of the pump.

16.

Install the bearing cover (J) onto the bearing housing (E).

17.

Install the drive shaft (D) into the housing assembly.

18.

Lock the screw bushing (S) to the shaft (D) with the locknut (T) and lock washer (U). Use the same procedure as locking the bearing to the screw bushing.

19.

Reinstall the housing and shaft assembly to the pump housing and bolt the drive shaft (D) to the screw using the three assembly bolts (R). (See the Bolt Torque Table for the proper bolt torque)

20.

Reassemble the drive coupling, guards, hopper cover plate and seal piping.

V-Belt Drive Applications 1.

Remove the drive guard, V-Belts, and Pump Sheave.

2.

Unlock the screw bushing lock washer (U) and remove the screw bushing locknut (J).

3.

Unbolt the drive bearing housing assembly (E) and remove it from the pump.

4.

Unbolt and remove the bearing cover (J).

5.

Slide the bearing (F) and screw bushing (S) out of the housing.

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6.

Disengage the bearing lock washer (M) tab from the nut (L) and loosen the nut and remove the bearing (F).

7.

Before replacing the bearing, clean all parts thoroughly. Check the housing and cover seals and replace, if necessary.

8.

Pack the bearing with grease and re-assemble the bearing and screw bushing (refer to the procedure in the above section A 13 & A 14).

9.

Slide the bearing (F) and screw bushing (S) into the bearing housing (E). See figure 9 for installation through seals.

10.

Install the bearing cover (J) on the housing.

11.

Assemble the bearing housing (E) to the pump.

12.

Lock the screw bushing to the shaft with the locknut (T) and lock washer (U). Use the same procedure as locking the bearing to the screw bushing.

13.

Re-assemble the remainder of the pump in reverse order.

Figure 9 Bushing & Seal Assembly

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SEAL REPLACEMENT At each end of the pump screw, there is a material seal arrangement housed in the bearing housing support. This seal arrangement is identical at both ends; refer to figures 2a, 2b, 2c, 3a, 3b and 3c. This seal arrangement consists of three lip seals (P) and a grease ring spacer (Q). A seal failure on the drive end would be apparent by dusting to atmosphere. On the discharge end of the pump, if seal failure should occur, no visible dusting will appear because of the pressure tight enclosure. Therefore, it is suggested that the following be performed to check seal condition: 1.

With the pump and discharge end purge air off, remove the pipe plug on the side of the bearing housing support (J, figures 2a, 2b, and 2c). Allow the purge air to flow so that air blows through the opening, which is now unplugged. This may require operation of the conveying compressors for a brief time for pumps not utilizing plant air purge to the seals. Any evidence of process material in this cavity indicates the potential for worn seals. If material is found, or if any doubt remains, proceed to step 2. In any case, shut off the purge air and replace the pipe plug.

2.

Again with the pump and purge air off, remove the nipple and cap (R) found under the bearing housing support (J). Remove as much grease as possible and inspect it for material contamination. This may be more easily accomplished with the pump warm. If no contamination is found, the seals are still satisfactory. If contaminated, the housings should be removed as previously described in the screw removal instructions, and the seals replaced as described below. Thorough inspections of the bearing and bearing lip seal is in order at this time. If any material is found in the bearing or its lubricant, or if the lip seal (H) is worn, the bearing should be thoroughly flushed and either replaced with a new bearing or repacked and reinstalled. In any case, remove all old lubricant in the bearing housing. Replace the lip seal, if worn.

3.

A sudden rise in bearing operating temperature may also be indicative of seal failure, which allows bearing contamination. A hot bearing may also be caused by under-lubrication or over-lubrication (see Section Lubrication “Bearings”), but if seal failure is suspected, proceed with steps 1 and 2 as a check.

WARNING Do not attempt to remove any fittings or disassemble the discharge end housings in any way while they are pressurized!

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Use the following procedure to replace seals: 1. Remove the bearing housing support as previously described. 2. Using a hammer and punch, drive the seals out of the housing. 3. Clean all parts and assemble new seals as shown in figures 2a, 2b, 2c, 3a, 3b and 3c. Pack the grease ring (Q) and the seal cavity during assembly with the same grease used for bearing and seal lubrication. This helps to insure adequate seal protection upon start-up. Thereafter, follow the instructions for greasing found in the Lubrication Section. WEAR SLEEVE REPLACEMENT There are two hard, chrome-plated, replaceable wear sleeves on the type "M" pump. These sleeves are located on the drive and discharge shafts adjacent to the balance wheels where they provide a hard, smooth journal for the pump lip seals. The sleeves are a shrink fit on the shafts. Remove the screw and shafts from the pump. The following procedure is suggested for replacing worn or damaged sleeves. SLEEVE REMOVAL Expand the sleeve by heating with a torch. Heat the sleeve rapidly, then drive off the sleeve with a hammer and cold cutter. If heat is applied too slowly, the shaft will get too hot and prevent removal of the sleeve. SLEEVE ASSEMBLY Allow the shafts to cool before installing new sleeves. Heat new sleeves in oil to approximately 300˚F (150˚C). Slide the sleeve over the shaft and position it against the shaft shoulders. The drive end wear sleeve is shorter than the discharge end sleeve. The sleeves have a chamfer on the outside diameter at both ends. The end with the smaller outside diameter chamfer also has a chamfer on the inside diameter. The end with the inside diameter chamfer is assembled towards the shaft flange. To obtain reasonable seal life, the outside diameter of the wear sleeve must be concentric with the bearing journals within 0.10 mm (.004") total indicator reading. FLAPPER VALVE ASSEMBLY The flapper valve assembly is a mechanical seal which prevents a flow of air from the mixing chamber backward through the pump. The seating surfaces of the flapper valve assembly are hard surfaced for maximum life. If these surfaces are air cut or chipped off, the flapper valve assembly should be replaced.

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PUMP SCREW CONSTRUCTION The pump screw consists of a solid steel shaft and flights made from rolled mild steel welded in position (see figure 5). The flights on the discharge end of the screw have peripheral hard surfacing. In additional to the peripheral surfacing, the screw shaft and flight faces nearest the pump discharge also have a hard surfacing layer. The hard surfacing is always applied with gas welding. Any hairline cracks which occur in this surfacing layer are not detrimental provided the hard surfacing has an excellent bond with the base metal. After the screw shaft has received flights, balance wheels, and hard surfacing, it is placed in a lathe and straightened. The flights are then ground to the finished diameter. All screws are dynamically balanced in two planes to improve bearing life and insure vibration-free pump operation. Determining the amount and location of the balancing weight is performed by a balancing machine which indicates the amount of the correction weight cavity is to be used, and the amount of weight determines how much lead shot is to be placed in this cavity. FULLER-KINYON PUMP SCREW INSPECTION CRITERIA In many instances it will be possible for a Fuller-Kinyon pump screw to be repaired or reconditioned. The following standards will allow you to inspect your pump screw. If these criteria are carefully followed you can, in most cases, determine the screw' s suitability for repair. 1.

Flights - If the flight base metal is worn under the hardfacing, either on the flight periphery or face, the flight is replaced. The thickness of the hardfacing on the periphery is approximately 7.5 mm and about 4 mm on the flight face (as shown on figure 5). Flights are replaced in one turn (360˚) segments, and no more than three flights can be replaced on the screw economically. If more flights must be replaced, the screw should be scrapped.

2.

Hardfacing Application - Screws are hard surfaced with Colmonoy by means of gas welding. If hard surfacing is applied with electric welding, it will not be smooth enough on the flight faces for efficient conveying nor will it bond properly.

TROUBLESHOOTING FULLER-KINYON PUMPING SYSTEM An understanding of the Fuller-Kinyon operation is a necessary foundation for operating a Fuller-Kinyon pump system. Start-up and shutdown procedures are recommended in this operation and maintenance manual and these must be adhered to carefully. The Fuller-Kinyon system was designed for a definite material specification and the material handled must match that specification for density, sieve analysis, moisture, composition, temperature, and line length. The following troubleshooting guide should be reviewed prior to pump start-up. Potential system problems may be eliminated.

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A.

THE PUMP DOES NOT HANDLE THE SYSTEM CAPACITY 1.

Check material density and sieve analysis for proper material specifications, since the pump is a volumetric device and changes in either property can cause capacity problems. Coarser material feed than designed for can cause: (a) higher pump motor amps and (b) the necessity for a reduction in capacity and line pressure in order to sustain adequate conveying velocity.

2.

Insure that the pump hopper extension is vented and under a slight negative pressure.

3.

a.

While operating, check for a good material seal at the pump discharge. A certain amount of material compaction is necessary in order to provide a good seal. Too little material can greatly reduce pumping capacity by allowing blowback. Blowback occurs when an improper seal permits conveying air to flow back through the pump. In addition to reduced capacity, back-up in the hopper extension and low motor amps are major symptoms. Too great a seal can cause excessive power consumption and accelerate wear of some components.

b.

The seal may be increased by restricting the material flow out of the discharge hole. First, move the standard weight an additional distance away from the pivot on the blowout handle. If the operation improves, but is still not satisfactory after reaching the outermost hole, extra weight may be added if no motor load problem exists.

c.

If a condition of excessive motor load exists, the treatment requires reducing the discharge restriction. First, move the weight towards the blowout lever pivot, and if this does not sufficiently reduce motor load, then remove the spacer located behind the flapper valve. When reinstalling the valve, use the shorter bolts which are packaged with the screw puller.

d.

Generally, a combination of spacer and weight position can be found at which the pump will provide the desired capacity at the minimum required horsepower level.

4. a.

Excessive air flow to the discharge end seal results in aeration of material in the pump discharge housing causing reduced capacity. Verify that the proper size orifice is installed in the union adjacent to the pressure regulator and that the regulator setting is in accordance with that shown in figure 4.

b.

Material bulk density in the pump hopper may be reduced, with a corresponding loss in capacity, if the drive end purge air is excessive. Ensure that the pressure regulator setting and orifice size are in accordance with data shown in figure 4.

5.

Insure constant feed to the Fuller-Kinyon pump. Surging feed condition into the pump causes motor amp surges requiring reduction in feed to stay within motor limits.

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B.

C.

6.

Insure that the conveying line discharge is vented via a dust collector. Positive pressure at the conveying line discharge could result in reduced capacity.

7.

Check line pressure for an abnormally high reading which would indicate that the conveying line may be obstructed, thereby causing the higher conveying pressure. See pump data sheet for anticipated system operating data.

8.

Check diversion valves in the conveying line which may not be seating properly.

9.

Check the compressor for possible restrictions to intake which will cause lower than required output volume.

10.

Sloping conveying lines are not recommended and could cause conveying problems.

BEARING FAILURE 1.

Insure proper assembly as described in this manual and on general arrangement drawings.

2.

Do not over lubricate - high bearing temperatures and premature failure will occur.

3.

Do not under lubricate - see the Lubrication section of this manual for lubrication recommendations.

4.

Use of proper lubricant is necessary - see the Lubrication section of this manual for proper specifications.

SEAL FAILURE 1.

Verify the type M pump seals are installed in accordance with the instructions in this manual.

2.

Insure that newly installed type M pump seals are well lubricated prior to full load system operation. Lubricate the seals while the compressor and pump are running as described on the Lubrication section of this manual.

3.

Upon replacing seals in the type M pump, check the renewable wear sleeve that the seals run on for possible damage due to abrasion. The seal wear surface must be clean and smooth or premature seal failure will occur.

4.

Insure seal purge air piping is as shown in figure 4 and described on the Installation section “Purge Air Piping” of this manual. Also refer to A.4 of system capacity troubleshooting.

5.

Material temperature in excess of 400O F will cause seal failure.

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6.

An inadequate, or interruption of, air purge caused by the following conditions can resulting seal failure: a.

In the case of air purge from a plant air supply, incorrect piping, regulator settings, or orifice sizes may not provide adequate purge air. Verify the above in figure 4.

b.

Emergency power failure, while the conveying line is under pressure, could cause seal failure.

c.

Improper shutdown of conveying system (not allowing cleanout of pump hopper) can cause seal failure.

d.

Permitting the pump hopper to be pressurized during the shutdown period encourages material to enter seals when air purge is not operative.

TYPICAL PIPING ARRANGEMENT FLS rotary compressors are of the multivane type. Arranged in milled slots on the rotor is a series of composition blades, which are free to slide by centrifugal force against interior wall of the cylinder, as the rotor turns, forming numerous crescent-shaped cells that trap the air being compressed. FLS single-stage compressors, direct or V-belt driven, are available with capacities of 3000 scfm (84.5 m3/min). They are pulsation and vibration free. By eliminating the need for bulky air receivers, multiple power sources, and costly foundations, they can be located adjacent to the Fuller-Kinyon pump, thereby simplifying installation and reducing costs. Grouping of several compressors to use common cooling water, drain, lubrication, and power facilities is recommended. Additionally, FLS model BC intake filter can be used to achieve minimum filtration with minimum servicing requirements. This is a single-zone, multibag collector.

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Figure 10 Compressor Arrangement 1. IMPORTANT: Locate the filter-silencer (1) to obtain cleanest, cool, dry air and (2) convenient for servicing. It may be located at the compressor as shown, if these conditions are fulfilled. 2. Intake piping can be made of lightweight welded steel or standard steel pipe and standard flanged fittings. 3. Locate the compressor adjacent to the pump. 4. Use piping from compressor to pump of the same size as the compressor outlet connection. 5. For multiple units where a spare compressor is installed or for duplex compressor installation, manifold this line to connect to a common line to the pump. 6. Install safety valve(s) to suit connected compressor capacity and pressure. Locate as close to the pump as possible, but ahead of any stop valve in the line. 7. For multiple units where pump installation involves a spare pump, manifold this line at pumps with a valve in each pump connection. 8. We suggest a tee with bottom connection and ½” drain in the flange for periodic oil draining. Do not connect to sewer line if oil contamination is a problem – use a bucket to receive the drained oil. 9. See specific drawings for dimensions of compressor, filter, etc. 10.

No piping fittings or accessories are furnished unless specified in our proposal. Only shaded items are generally supplied by FLS.

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