FK Pump PPT Complete 96 [PDF]

Zitiervorschau

Maintenance Seminar

Fuller-Kinyon Pumps Institute ™

F-K Pumps - Introduction

1

Agenda Maintenance of Fuller-Kinyon Pumps Part 1.

Introduction

Part 2.

M-Pump

Part 3.

H-Pump and Z- Flap Conversions

Part 4.

Auxiliary Equipment

Institute ™

F-K Pumps - Introduction

2

Introduction

• • • • •

Principles of Pneumatic Conveying Types of Fuller Kinyon-Pumps Development History Performance Tuning the F-K Pump System Troubleshooting

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F-K Pumps - Introduction

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Principles of Pneumatic Conveying

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F-K Pumps - Introduction

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Pneumatic Conveying Definition

“…the process of moving powdered material through a pipeline using air as the conveying medium”.

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F-K Pumps - Introduction

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Pneumatic Conveying Flow Material Flow

Dilute Phase

Material Flow Mixed Phase

Material Flow Dense Phase

Material flow through a pipeline can be characterized by the concentration of material in the air-stream. Institute ™

F-K Pumps - Introduction

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Pneumatic Conveying Flow particles in suspension

• • • • •

pipeline

Dilute Phase Flow Fairly even distribution over cross-section of the pipe. Pick-up velocity 15-25 m/s (3000-5000 fpm). Terminal velocity > 25 m/s (>5000 fpm). Pressure differential of nominal 1 bar. Material to air ratio up to 22:1.

Institute ™

F-K Pumps - Introduction

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Pneumatic Conveying Flow dust particles may be in suspension

• • • • •

moving "waves" of material

Dense Phase Flow (plug flow) Waves of material fill the entire cross sectional area of the pipe Pick-up velocity 2-9 m/s (400-1800 fpm) Terminal velocity < 20 m/s ( v2 particle lifts l > g particle floats

figure 3

dense phase p1

p2

particles particles contact contact particles particles pressure pressure differential differential moves moves material material velocity velocity (drag) (drag) is is unimportant unimportant and and is is normally normally aa very very low low value value

Institute ™

F-K Pumps - Introduction

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Conveying Line Pressure Drop

Pneumatic Conveying Flow Modu-dense Modu-flo mt Fullveyor

increasing solids rate

F-K™ Pump Pressure Tank dense phase

unstable surging phase medium phase

dilute phase

Airveyor Airlift

air flow rate Institute ™

F-K Pumps - Introduction

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The Problem

How to put material into a pressurized air-stream

The Solution …………. Institute ™

F-K Pumps - Introduction

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The Fuller-Kinyon Pump Feed Material Air and Material

Compressed Air

Feed material enters the hopper where the screw picks it up and forces it into the air-stream. Institute ™

F-K Pumps - Introduction

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Components of an F-K Pump discharge body

drive end bearing assembly

pump hopper screw inlet barrel

discharge end bearing assembly

external lever flapper valve

motor

air and material outlet base frame

Institute ™

air inlet

F-K Pumps - Introduction

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Pneumatic Conveying System De-dusting System Material Bin

Rotary Feeder Intake Filter

Air Compressor

Institute ™

Air Slide

Material Pipeline

F-K Pump

F-K Pumps - Introduction

15

Applications • Dry, free flowing ,fluidizable materials • Typical particle size analysis: • 100% < 50 mesh • 70% < 100 mesh • 60% < 200 mesh • 45% < 325 mesh • Long distance conveying, over 5,000 ft (1500 m) • High capacity conveying, up to 17,700 CFH (500 CMH), e.g. 400 tph @ 45 lb./cu.ft. • Material temperatures to 400ºF, special applications to 850ºF with water cooled seal. Institute ™

F-K Pumps - Introduction

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Typical Materials Handled Alumina Asphalt filler dust Barytes Bauxite Bentonite Catalysts Cement Clays (dried Coal Coke dust Copper concentrate Dolomite Dusts (baghouse, ESP) Feldspar Fluorspar Fly ash Institute ™

Gypsum Kaolin Lime Limestone Magnesite Magnetite Manganese dioxide Ores Phosphate rock Quartz Rutile Silica Soda ash Starch Talc Titanium dioxide F-K Pumps - Introduction

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Special Applications • • • • • • •

Abrasive materials Materials of construction will vary according to specific applications. Special screw hard surfacing. Tungsten carbide weld deposit (65 rc) (700 brinnel). Hardened barrel (450 brinnel). Other special materials on request. Ceramic barrel liners – optional. Ceramic lined discharge box- optional.

Institute ™

F-K Pumps - Introduction

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Special Applications High temperature materials • Type ‘M’ pump available up to 400°F • Type ‘H’ pump available up to 850°F – seal chamber cooling coils

Institute ™

F-K Pumps - Introduction

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Special Applications • Non compression screws for cohesive materials (e.g. gypsum). • Back beveled screw flights for materials that ‘bind’ (e.g. kaolin). • Half moon orifice for materials which flush. • Stainless steel screw for corrosive materials. • Other special alloys applied as required. Institute ™

F-K Pumps - Introduction

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Types of F-K Pumps

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F-K Pumps - Introduction

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Types of F-K Pumps M Pump

H Pump

Z Flap Conversion

Kompact Pump

Institute ™

F-K Pumps - Introduction

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M Pump

The M Pump has bearings on both ends of the shaft. Material discharge is perpendicular to the screw. Newer pumps are supplied with three piece screws. Institute ™

F-K Pumps - Introduction

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M Pump Sizes and Capacities Screw Diameter

Screw Pitch1

Capacity2

150 mm

150 x 100

27 tph

200 mm

190 x 120

107

250 mm

230 x 150

232

300 mm

300 x 190

491

350 mm

330 x 240

790

1 Screws

have decreasing pitch. Other pitches available.

2 Typical

capacity in short tons/hour while transporting 3600 blaine portland cement at screw speed of 1160 RPM.

Institute ™

F-K Pumps - Introduction

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M Pump

250 M pump with parallel discharge Institute ™

350 M pump with side discharge F-K Pumps - Introduction

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M Pump

left hand discharge

right hand discharge

The M Pump can be arranged for side or parallel discharge for left or right hand side. Institute ™

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M Pump

M Pump installation. Institute ™

F-K Pumps - Introduction

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H Pump

The H Pump has a cantilevered screw with bearings on one end of the shaft only. Material discharge is in line with the screw. Institute ™

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H Pump Sizes and Capacities Screw Diameter

Screw Pitch1

Capacity2

6”

6¼x4

31 tph

7”

8½x5½

80 tph

8”

8½x5½

128 tph

8 ½”

8½x5½

164 tph

9”

6¼x4¼

120 tph

9 ½”

6¼x4¼

142 tph

10”

10 x 7 ½

258 tph

10 ½”

10 x 7 ½

293 tph

1 Screws

have decreasing pitch. Other sizes available.

2 Typical

capacity in short tons/hour while transporting 3600 blaine portland cement at screw speed of 1160 RPM.

Institute ™

F-K Pumps - Introduction

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H Pump

Institute ™

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H Pump with Z Flap Conversion

The Z flap conversion adds a bearing onto the discharge end of the shaft. Discharge is in line with the screw. Two piece screws are available for ease of maintenance. Institute ™

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H Pump

H pump with Z flap installation. Institute ™

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Kompact Pump

The Kompact Pump is a light duty version for mobile, non-continuous operation. Institute ™

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Kompact Pump Sizes and Capacities Screw Diameter

Screw Pitch1

Capacity2

5½”

6x4

36 tph

6”

6x4

52 tph

1 Screws

have decreasing pitch. Other sizes available.

2 Typical

capacity in short tons/hour while transporting 3600 blaine portland cement at screw speed of 1160 RPM.

Institute ™

F-K Pumps - Introduction

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Kompact Pump • • • • • • • •

For Intermittent use (less than 8 hours per day). Short conveying distances (up to 150’). No hardened barrel. Light duty bearings. Low pressure system (up to 12-14 PSI). Floating type gland packing for hopper-screw seal. Hardened screw as standard. Low headroom, i.e. for railcar unloading.

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F-K Pumps - Introduction

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Development History

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Development History • First developed 1919 – 1926 • Type ‘H’ pump - developed in 1935, over 12,000 sold • Kompact pump - developed in 1961, over 1,000 sold • Type ‘M’ pump - developed in 1976, over 1,200 sold • Z-Flap conversion kit - developed 1984

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First Portable F-K Pump

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Performance Tuning the Fuller-Kinyon Pump

Institute ™

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The Material Seal Pump Inlet (low pressure)

Material Seal Zone

Pump Outlet (high pressure)

It is essential for system performance that a good seal exists to keep conveying air from blowing back into the hopper. This seal is formed by compacted material traveling through the pump barrel, especially at the discharge end where the screw pitch decreases. Institute ™

F-K Pumps - Introduction

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The Material Seal Compacted Material

Flap Valve

Air and Material Mixture Compressed Air Inlet

Transport Pipeline

The material in the pump barrel is compacted with the aid of a counterweighted flap valve at the pump outlet, which creates a resistance to the material flow. Increasing the counterweight makes a tighter seal, but motor amps will rise. Institute ™

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H Pump Material Seal

The H pump, in addition to a counterweighted flap valve, has an adjustable barrel which can be used to control the seal thickness (“A”). Institute ™

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System Troubleshooting

Institute ™

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System Troubleshooting Inadequate Capacity • If motor amps are abnormally low, adjust the material seal to prevent blow-back (increase the counterweight). • Check material density. The pump is a volumetric device and changes in density will affect changes in tons per hour. • Insure proper venting of pump inlet hopper. Hopper must be at a slight negative pressure. • Excessive purge air to the seals can aerate the material in the hopper, causing decreased capacity. Check the purge air pressure settings and orifice plates. Institute ™

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System Troubleshooting Inadequate Capacity (continued)

• If conveying is fast and steady, reduce air flow; if conveying is slow and slugging, increase air flow. • Check for steady material feed rate. • Check for restrictions at the discharge end of the system, i.e., silo vent dust collector not working. • Increase line diameter (stepped line or entire length). • If pump discharge pressure is higher than normal, there may be a line obstruction.

Institute ™

F-K Pumps - Introduction

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System Troubleshooting Plugged Conveying Pipeline

• Check for adequate air supply. • Check for air leaks in conveying line. • Check for non-seating diverter valves. • Eliminate sloping conveying lines. Sloping lines plug easier than horizontal or vertical runs. • Check for steady material feed rate. • Check material characteristic. Moist or sticky material can build up on inside of conveying line. Institute ™

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System Troubleshooting High Motor Amps

• The material seal may be too tight. Decrease the counterweight on the flap valve. • Check feed sieve analysis. Coarser material can cause higher motor amps. • Check for moisture in the feed material.

Institute ™

F-K Pumps - Introduction

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System Troubleshooting Cycling Pressure

• Check for steady material feed. • Check venting at terminal point of conveying line.

Institute ™

F-K Pumps - Introduction

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System Troubleshooting Inadequate Air Supply

• Check compressor inlet for restrictions (dirty inlet filter, faulty unloading valve, etc.) • Check for open pressure relief valve. • Check for piping and flanges for leaks. • Check compressor for proper operation (broken blades, etc.)

Institute ™

F-K Pumps - Introduction

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System Troubleshooting

Excessive Pipeline wear

• Reduce conveying velocity. • Replace bends with “tee” pipe fittings. • Step to larger diameter conveying line before terminal points in the system.

Institute ™

F-K Pumps - Introduction

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System Troubleshooting Material Breakage

• Reduce conveying velocity. • Eliminate all bends, cyclones, etc. • Reduce velocity before terminal point of conveying line. • Eliminate any rough sections or sharp changes in direction.

Institute ™

F-K Pumps - Introduction

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Maintenance Seminar

Fuller-Kinyon Pumps Institute ™

F-K Pumps - M-Pump

52

Agenda Maintenance of Fuller-Kinyon Pumps Part 1.

Introduction

Part 2.

M Pump

Part 3.

H Pump and Z Flap Conversions

Part 4.

Auxiliary Equipment

Institute ™

F-K Pumps - Introduction

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M Pump • • • • • • • • •

Institute ™

Overview Screw Barrel Bushings Discharge Body Bearings and Seals Lubrication Purge Air Spare Parts Disassembly and Assembly

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Overview

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Type M Pump

The M pump has side discharge, easily removable bearing and seal assemblies, and a three piece screw for easy replacement of the wear section. Institute ™

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M Pump Inlet Hopper

Discharge Body Barrel

Discharge End Bearing

Drive End Bearing Air Inlet

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Screw

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Three Piece Screw Stub Shaft

Replaceable Center Section

Stub Shaft

The three piece screw is standard on all new M pumps, and is available as a retrofit on older M pumps. When the screw wears out, only the center section is replaced. Stub shafts remain in place inside the bearing assemblies. Institute ™

F-K Pumps - Introduction

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Three Piece Screw Standard Pitch Screw Flights

Balance Wheel

Decreasing Pitch

Reverse Pitch

Paddle bars Hard-facing

The screw is hard-faced with nickel-chromium boride alloy. Decreasing screw pitch helps form a material seal to prevent blowback from the discharge line. Reverse pitch flights keep material away from the shaft seal. Paddle bars help disperse material into the air stream. Institute ™

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One Piece Screw

Hard-facing

The screw is hardfaced with Colmonoy, a nickel-chromium boride alloy, applied by gas welding. The flight periphery has 7.5 mm hardfacing, and the flight faces in compression zone is 4mm. Institute ™

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One Piece Screw Balance Wheel

Balance Wheel

After the flights are installed, hardfacing applied and the periphery ground, the screw is dynamically balanced. Balance is achieved by filling the holes in the balance wheels with lead shot. Balancing reduces vibration and extends bearing life. Institute ™

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One Piece Screw Wear Sleeve

Wear Sleeve

The screw has a hardened chrome wear sleeve at each end where the seals contact the shaft. These seals are shrunk on and have to be heated to 300ºF to install. If the sleeves are damaged, seal failure will result. Institute ™

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Screw Puller

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Barrel Bushings

Institute ™

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Barrel Bushings Inlet End Bushing

Center Bushing

Discharge End Bushing

The pump barrel is wear protected by three barrel bushings. The center bushing is hardened to resist the extra abrasion in the zone where the material seal is formed. Set screws and retaining screws keep the bushings from rotating. Institute ™

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Discharge Body

Institute ™

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Discharge Body Material Outlet

Flapper Valve

Flapper Valve Counterweight

Barrel Bushing Screw

Air and Material Outlet

Air Inlet

Nozzles

Institute ™

Mixing Chamber

F-K Pumps - Introduction

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Material Seal Spacer Plate

Flapper Valve

Valve Seat

The material seal is created by the compaction of material at the discharge end of the pump. Increasing the counterweight and/or increasing the spacer plate thickness makes a tighter seal, but motor amps will rise. Institute ™

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Flapper Valve

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Material Seal Baffle Plate

In some instances a baffle plate installed behind the flapper valve may improve the material seal. Institute ™

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350 M Pump

Institute ™

F-K Pumps - Introduction

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Bearings and Seals

Institute ™

F-K Pumps - Introduction

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Bearing Arrangements Older M Pumps with 1 Piece Screws

Newer M Pumps with 3 Piece Screws

350 M Pumps with 3 Piece Screws

There are several different M pump bearing arrangements. Institute ™

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M Pumps with 1 Piece Screw Discharge End Bearing

Bearing Bushing Retainer Plate Bearing Support

Cover Plate Bearing Housing

The discharge end bearing is the fixed bearing. The cover plate and retainer plate fix the bearing axially. Institute ™

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M Pumps with 1 Piece Screw Drive End Bearing Locknut

Bearing Bushing Locking Collar

The drive end bearing is the free bearing. The bearing is fixed on the bearing bushing. The shaft slides axially inside the bushing to accommodate expansion. Institute ™

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150 and 200 M Discharge End

Bearing Pressurization Connection

Purge Air

Grease

The 150 and 200 M pumps use a double row angular contact ball bearing. Grease is introduced through fittings on either side of the bearing. Air purge keeps dust out of the bearing housing. The bearing chamber is presurized. Institute ™

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150 and 200 M Drive End Bearing Lube

Seal Lube

Purge Air

Grease

Institute ™

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250 M Discharge End

Purge Air

Grease

The 250 M pump uses two back to back angular contact ball bearings. Grease is introduced through fittings on either side of the bearing pair. Institute ™

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250 M Drive End

Purge Air

Grease

Institute ™

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300 M Discharge End

Purge Air

Grease

The 300 M pump uses two back to back angular contact ball bearings with grease grooves. Grease is introduced into the groove and emerges between the bearings. Institute ™

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300 M Drive End

Purge Air

Grease

Institute ™

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Bearing with Grease Grooves

On 300 and 350 M Pumps grease is introduced through grooves between the two back to back bearings. Institute ™

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Discharge End Bearing Newer M Pump

Locknut with Tab Washer

Newer M pumps have their discharge bearings fixed axially with a locknut instead of a retainer plate. Institute ™

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Drive End Bearing Newer M Pump

The free bearing can slide axially within the housing to accommodate shaft expansion. The bearing is fixed on the bushing and the bushing is fixed on the shaft with a locknut. Institute ™

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Discharge End Bearing 350 M Pump Bearing Bushing Locknut with Tab Washer

On the 350 M pump the bearing housings and supports are combined into one casting. Institute ™

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Drive End Bearing 350 M Pump

The bearing is free to slide axially inside the housing. The inner ring is fixed on the bushing. The bushing is fixed to the shaft with a locknut. Institute ™

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Replacement Kits

The new bearing assemblies are available as bolt-on kits together with the screw stub shafts. In the event of a bearing or seal failure, the entire assembly is replaced and the damaged assembly is brought to the shop for rebuilding. Institute ™

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Seal Arrangement Material Seals

Spacer Ring

Bearing Seal

O-ring

Seals must face in direction shown. Institute ™

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Seal

When installing a bearing housing over the shaft, use a piece of shim stock to guide the seal over the bushing. This avoids damaging the seal. Institute ™

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Lubrication

Institute ™

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Lubrication Bearings

Bearings Seals

Flapper Valve Shaft

Seals

• Bearings -

Monthly or 700 hours

• Seals -

Daily

• Flapper Valve Shaft -

Daily

Use a high temperature EP grease at all lubrication points. Institute ™

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Drive End Bearing Lubrication

Drain Plugs

Grease bearings when pump is running. Do not overgrease. Overgreasing will cause high temperature and burning of the grease, resulting in bearing damage. Drain excess grease out of drain plug after bearing reaches operating temperature. Institute ™

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Discharge End Bearing Lubrication

Pressurization

Warning - Hot grease! Do not remove the drain plug with the pump running and the bearing pressurized. Apply 4-6 strokes with a hand gun in each bearing fitting. For the one-fitting 300 and 350 M pumps, apply 8-12 strokes. Institute ™

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Purge Air

Institute ™

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Purge Air Piping Plant Air 6-8 Bar Regulator

Regulator

Coarse and Fine Filters

Union with Orifice Seal Purge

Seal Purge

Bearing Pressurization

The unions contains orifice plates with a specific diameter holes. Pressure settings depend on transport air pressure. See the chart. Institute ™

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Purge Air Requirements

Institute ™

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Bearing Pressurization

The discharge bearing chamber is pressurized to keep dirt out. A coarse (5 micron) and fine (3 micron) filter keep the air clean. Institute ™

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Spare Parts

Institute ™

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Institute ™

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Disassembly and Assembly • Screw Removal from Discharge End • Screw Removal from Drive End • Barrel Bushing Removal • Barrel Bushing Replacement • Screw Replacement • Screw Replacement from Drive End • Bearing and Seal Replacement

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Screw Removal from Discharge End

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Screw Removal

Remove the purge air piping. Do not lose the orifice plate inside the pipe union. Institute ™

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Screw Removal

Loosen the set screws on the locking collar at the drive end. Institute ™

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Screw Removal

Remove the locking collar. Institute ™

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Screw Removal

Remove the key. Institute ™

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Screw Removal

Remove the inlet hopper access door. Institute ™

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Screw Removal

Clean out the inlet hopper and screw. Institute ™

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Screw Removal

Remove the bolts from the discharge end bearing cover. Institute ™

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Screw Removal

Remove the discharge end bearing cover. Institute ™

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Screw Removal

Remove the two bearing retainer screws. Institute ™

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Screw Removal

Remove the bearing retainer. Institute ™

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Screw Removal

Reassemble the cover with two screws. This prevents the screw bushing from sliding out of the seal during disassembly. Institute ™

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Screw Removal

Unbolt the bearing housing and, using two jackscrews in the threaded holes, remove the housing from the bearing support. Institute ™

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Screw Removal

Remove the bearing housing from the bearing support. Institute ™

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Screw Removal

Remove the bolts from the bearing support and insert two jackbolts in the threaded holes provided. Institute ™

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Screw Removal

Remove the bearing support from the pump discharge body. Institute ™

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Screw Removal

Institute ™

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Screw Removal

Attach the screw puller.

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Screw Removal

Turn the hexnut to extract the screw.

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Screw Removal

Extract the screw as far as the puller allows.

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Screw Removal

Remove the puller.

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Screw Removal

With the screw end supported, pry the screw out the rest of the way. Do not pry on the balance wheel! Institute ™

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Screw Removal

Reposition the supporting sling near the screw center of gravity as the screw is withdrawn. Institute ™

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Screw Removal from Drive End (The screw is normally removed from the discharge end, however, it may also be removed from the drive end when space for removal is limited.)

Institute ™

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Removal from Drive End

Remove the discharge end bearing retainer and replace the cover with two screws as previously described. Proceed to remove the drive end bearing housing. Institute ™

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Removal from Drive End

It is necessary to use spacers under the jackbolts to completely free the bearing housing, due to the limited length of the bolts. Institute ™

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Removal from Drive End

Remove the drive end bearing housing from the support.

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Removal from Drive End

Remove the bearing support. Institute ™

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Removal from Drive End

Support the screw end with a sling. Institute ™

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Removal from Drive End

Pry out the screw. Do not pry on the balance wheel! Institute ™

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Removal from Drive End

Keep the sling near the center of gravity and remove the screw. Institute ™

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Barrel Bushing Removal

Institute ™

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Barrel Bushing Removal

With the discharge bearing and support housings and the screw removed, the barrel bushings are accessible. Institute ™

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Barrel Bushing Removal

Remove the two barrel bushing retainer screws.

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Barrel Bushing Removal

Remove the four barrel bushing set screws. Institute ™

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Barrel Bushing Removal

Remove the short barrel bushing. Rap the bushing with a hammer to loosen material until the bushing slides freely. Institute ™

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Barrel Bushing Removal

Use compressed air to blow out material stuck between the barrel and pump housing. Blow air into set screw holes. Institute ™

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Barrel Bushing Removal

Remove the short barrel bushing. Institute ™

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Barrel Bushing Removal

Use a jack to push out the remaining two bushings.

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Barrel Bushing Removal

Use a circular steel plate to push against the O.D. of the bushing . Institute ™

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Barrel Bushing Replacement

Institute ™

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Barrel Bushing Replacement

Clean and de-burr the bushings and barrel bores thoroughly before installation. Institute ™

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Barrel Bushing Replacement

Install the soft bushing with the machined face towards the discharge end. Align the ribs to straddle the set screws. Institute ™

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Barrel Bushing Replacement

Install the hard bushing with the slot towards the discharge end. Institute ™

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Barrel Bushing Replacement

The slot must be on top to engage the retaining bolt.

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Barrel Bushing Replacement

Install the retainer bolt, positioning the bushing until the bolt fits in the slot. Institute ™

F-K Pumps - Introduction

147

Barrel Bushing Replacement

From inside the hopper, push both bushings toward the discharge until the retaining bolt is fully engaged. Institute ™

F-K Pumps - Introduction

148

Barrel Bushing Removal

Insert the short barrel bushing until the retaining bolt is fully engaged. Institute ™

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149

Barrel Bushing Replacement

Tighten the four set screws.

Institute ™

F-K Pumps - Introduction

150

Screw Replacement

Institute ™

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151

Screw Replacement

Before installing the screw thoroughly clean and deburr all machined surfaces. Institute ™

F-K Pumps - Introduction

152

Screw Replacement

Seal sleeves must be perfectly smooth to prevent seal damage. If necessary, install new sleeves. Institute ™

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153

Screw Replacement

Insert the screw until the journal appears in the pump inlet hopper. Institute ™

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154

Screw Replacement

Before further insertion clean the journal and sleeve once again. Institute ™

F-K Pumps - Introduction

155

Screw Replacement

Carefully push the screw all the way into position until the outside face of the discharge end balance wheel is approximately flush with the end of the discharge housing. Institute ™

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156

Screw Replacement

Clean the mating surfaces and apply Permatex. Install the bearing housing support. Institute ™

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157

Screw Replacement

Clean the screw journal and sleeve.

Institute ™

F-K Pumps - Introduction

158

Screw Replacement

Install the O-ring.

Institute ™

F-K Pumps - Introduction

159

Screw Replacement

Seat the O-ring against the shaft sleeve .

Institute ™

F-K Pumps - Introduction

160

Screw Replacement

Apply Permatex and install the bearing housing.

Institute ™

F-K Pumps - Introduction

161

Screw Replacement

Remove the end cover to reinstall the retainer. Apply LocTite to the retainer screws. Institute ™

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162

Screw Replacement

Install retainer and screws. Institute ™

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163

Screw Replacement

Torque the retainer screws (180 ft-lbs for 250 and 300 pumps, 80 ft-lbs for 200 pumps or 40 ft-lbs for 150 pumps). Institute ™

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164

Screw Replacement

Apply Permatex and re-install the cover. Institute ™

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165

Screw Replacement from Drive End

Institute ™

F-K Pumps - Introduction

166

Screw Replacement from Drive End

The screw may be installed from the drive end. Institute ™

F-K Pumps - Introduction

167

Screw Replacement from Drive End

It is first necessary to remove the discharge end bearing housing and support. Once the screw is in place, assemble the support and bearing housing as previously described. Institute ™

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168

Screw Replacement from Drive End

Clean the screw journal and sleeve at the drive end. Assemble the drive end support and bearing housings. Institute ™

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169

Screw Replacement from Drive End

Reassemble the key and locking collar. Institute ™

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170

Bearing Replacement

Institute ™

F-K Pumps - Introduction

171

Bearing Replacement

On the discharge end, remove the bearing housing and remove the locknut. Then slide the bearing out of the housing. Institute ™

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172

Bearing Replacement

On the drive end, remove the bearing housing. Remove the locknut, and slide the bearing out of the housing and off the bushing. Institute ™

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173

Seal Replacement

Institute ™

F-K Pumps - Introduction

174

Seal Replacement

On the drive end, remove the cover. Institute ™

F-K Pumps - Introduction

175

Seal Replacement

Drive the seal out of the cover.

Institute ™

F-K Pumps - Introduction

176

Seal Replacement

To access the material seals, remove the bearing supports. Institute ™

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177

Seal Replacement

Be sure the seals face in the proper direction, as shown on the drawings in the manual. Institute ™

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178

Seal Replacement

Institute ™

F-K Pumps - Introduction

179

Seal Replacement

Grease the seals and grease ring before reassembly. After assembly, apply additional grease through the fittings. Institute ™

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180

Institute ™

F-K Pumps - Introduction

181

Questions?

Institute ™

F-K Pumps - Introduction

182

Maintenance Seminar

Fuller-Kinyon Pumps Institute ™

F-K Pumps - Introduction

183

Agenda Maintenance of Fuller-Kinyon Pumps Part 1.

Introduction

Part 2.

M-Pump

Part 3.

H-Pump and Z- Flap Conversions

Part 4.

Auxiliary Equipment

Institute ™

F-K Pumps - Introduction

184

H Pump • • • • • • • •

Institute ™

Overview Screw Barrel Bushings Discharge Body Bearings and Seals Lubrication Purge Air Spare Parts

F-K Pumps - Introduction

185

Overview

Institute ™

F-K Pumps - Introduction

186

H Pump

The H pump discharges in-line with the screw. There are two bearings on the drive end. New H pumps have a bearing on the discharge end, while on older pumps the screw is cantilevered without a bearing. Institute ™

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187

H Pump Air Inlet Manifold Drive Shaft

Bearing Housing

Screw

Seal Ring Assembly

Institute ™

Flapper Valve

Inlet Hopper Barrel

Discharge Body

Air and Material Outlet

F-K Pumps - Introduction

188

H Pump

H pump installation. Institute ™

F-K Pumps - Introduction

189

H Pump

Older H Pumps have a cantilevered screw with bearings on one end of the shaft only. Institute ™

F-K Pumps - Introduction

190

H-Pump with Z-Flap Conversion

The Z flap conversion kit (in blue) adds a bearing at the discharge end of the shaft. The screw runs truer, and screw, barrel and bearing and seal life are extended. Institute ™

F-K Pumps - Introduction

191

Screw

Institute ™

F-K Pumps - Introduction

192

Two Piece Screw

A two piece screw is used on newer H pumps and pumps with Z Flap conversions. The screw flight shaft can be replaced without disturbing the drive. Institute ™

F-K Pumps - Introduction

193

Two Piece Screw Seal Area Wear Sleeve

Bearing Journals

Shrink Coupling and Bolted Flange

Institute ™

Colmonoy Hardfacing on Flight Periphery

Colmonoy Hardfacing on Flight Periphery, Face and Shaft

F-K Pumps - Introduction

194

Screw Coupling

Torque to 70 ft-lbs

The two piece screw is connected with a shrink coupling. Tighten the coupling screws gradually in a circular pattern until proper torque is achieved. Make sure the shaft and coupling bore are free of grease before assembly. Institute ™

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195

One Piece Screw

Institute ™

F-K Pumps - Introduction

196

One Piece Screw

The bearing journals are bronzed using a spray-on application. Journals can be re-built to specified diameter. Institute ™

F-K Pumps - Introduction

197

One Piece Screw

Screws are balanced in two planes. The balance wheel holes are filled with lead shot as required. Institute ™

F-K Pumps - Introduction

198

Screw Balance Holes

Balancing is necessary to keep the screw from wobbling. Institute ™

F-K Pumps - Introduction

199

Screw Removal

The screw is pried out through the discharge end. Institute ™

F-K Pumps - Introduction

200

Screw Removal

After removal of the flap valve the screw can be extracted. Institute ™

F-K Pumps - Introduction

201

Screw Hard-facing

Hard-facing is applied by gas welding. Do not apply by electric arc welding. Institute ™

F-K Pumps - Introduction

202

Grinding the Screw

After hard-facing, the screw periphery is precision-ground. Institute ™

F-K Pumps - Introduction

203

Screw

Checking the O.D. after grinding. Institute ™

F-K Pumps - Introduction

204

Barrel Bushings

Institute ™

F-K Pumps - Introduction

205

Barrel Bushings

When changing a screw, barrel bushings should be inspected for air-cutting (grooving caused by air blow-back from the conveying line into the hopper) and replaced if necessary. Front bushings wear out sooner. It may be possible to reverse the front and rear bushings to extend bushing life. Institute ™

F-K Pumps - Introduction

206

Barrel Assembly

Institute ™

F-K Pumps - Introduction

207

Barrel Bushings

Barrel with front and back barrel bushings.

Institute ™

F-K Pumps - Introduction

208

Barrel Bushings

Inserting the bushing into the barrel. Institute ™

F-K Pumps - Introduction

209

Barrel Bushings

Inserting the barrel into the inlet hopper.

Institute ™

F-K Pumps - Introduction

210

Discharge Body

Institute ™

F-K Pumps - Introduction

211

H Pump Discharge Body Air Outlet Pressure Gage

Air Inlet Pressure Gage

Flapper Valve

Air Inlet

Counterweight Bearing Housing Air and Material Outlet

Air Manifold Air Nozzles Institute ™

F-K Pumps - Introduction

212

Flapper Valve Shaft

The flapper valve shaft should be greased weekly.

Institute ™

F-K Pumps - Introduction

213

H Pump Discharge Body

This discharge body is used for older H pumps without Z-flap conversions. Institute ™

F-K Pumps - Introduction

214

H Pump Discharge Body

This discharge body is used for older H pumps without Z-flap conversions. Institute ™

F-K Pumps - Introduction

215

Flapper Valve

Institute ™

F-K Pumps - Introduction

216

Material Seal

To prevent blowback of compressed air into the feed hopper it is essential that a proper seal of compacted material is formed. Sealing depends on the distance “A” and on the counterweight applied to the flap valve lever arm. Institute ™

F-K Pumps - Introduction

217

Material Seal

Adjust the barrel to achieve the results above. If blowback still results, increase the distance “A” and increase the counterweight. Note that this will increase motor amps. Find the best balance between good sealing and low amps. Institute ™

F-K Pumps - Introduction

218

Material Seal

Gap

The material seal is adjusted by changing the gap. Institute ™

F-K Pumps - Introduction

219

Bearings and Seals

Institute ™

F-K Pumps - Introduction

220

Drive End Arrangement

The drive end arrangement features two double row angular contact bearings. The motor side is the fixed bearing. The pump side bearing is free to move axially. Institute ™

F-K Pumps - Introduction

221

Discharge End Bearing

The discharge end bearing is a double row spherical roller bearing mounted on a tapered sleeve. Proper bearing clearance is achieved by giving the locknut one half turn after initial hand tightening. Institute ™

F-K Pumps - Introduction

222

Air Cooled Seal Ring Assembly Fan

Purge Air

Springs

Graphite Seal

Renewable Sleeve

The material seal is air cooled by the fan. Purge air keeps material away from the graphite ring. Institute ™

F-K Pumps - Introduction

223

Air Cooled Seal Ring Assembly

An earlier version of the air cooled seal. Institute ™

F-K Pumps - Introduction

224

Air Cooled Seal Ring Assembly

Institute ™

F-K Pumps - Introduction

225

Air Cooled Seal Ring Assembly

Institute ™

F-K Pumps - Introduction

226

Air Cooled Seal Ring Assembly

Institute ™

F-K Pumps - Introduction

227

Air Cooled Seal Ring Assembly

Institute ™

F-K Pumps - Introduction

228

Air Cooled Seal Ring Assembly

Institute ™

F-K Pumps - Introduction

229

Renewable Sleeve

Institute ™

F-K Pumps - Introduction

230

Bearing Housing

Institute ™

F-K Pumps - Introduction

231

Bearing Installation

Institute ™

F-K Pumps - Introduction

232

Bearing Installation

Institute ™

F-K Pumps - Introduction

233

Bearings and Sleeve

Institute ™

F-K Pumps - Introduction

234

Bearing and Sleeve

Institute ™

F-K Pumps - Introduction

235

Locking Collar

Institute ™

F-K Pumps - Introduction

236

Purge Air

Institute ™

F-K Pumps - Introduction

237

Z-Flap Purge Air Plant Air 6-8 Bar

Pressure Regulator Union with Orifice

Coarse and Fine Filters

Seal Purge

Bearing Pressurization

Check Valve

The unions contains orifice plates with a specific diameter holes. Pressure settings depend on transport air pressure. See the chart. Institute ™

F-K Pumps - Introduction

238

Z-Flap Purge Air Requirements Transport Air Supply Pressure Regulator Pressure PSIG Setting PSIG 5-15

35

16-24

55

25-39

75

40-45

85

The above settings apply to 9”, 9.5” and 10” Z-Flap pumps with .140” (3.6 mm) diameter orifice plates. Institute ™

F-K Pumps - Introduction

239

H Pump

Purge air and bearing pressurization on the discharge bearing of an H pump. Institute ™

F-K Pumps - Introduction

240

Lubrication

Institute ™

F-K Pumps - Introduction

241

H Pump Lubrication

Use high-temperature EP grease: • bearings - 700 hours or monthly Do not over-grease! • seals -

3 to 4 strokes every 150 hours or weekly

• flap valve - 3 to 4 strokes every 150 hours or weekly Institute ™

F-K Pumps - Introduction

242

Spare Parts

Institute ™

F-K Pumps - Introduction

243

Institute ™

F-K Pumps - Introduction

244

Questions?

Institute ™

F-K Pumps - Introduction

245

Maintenance Seminar

Fuller-Kinyon Pumps Institute ™

F-K Pumps - Introduction

246

Agenda Maintenance of Fuller-Kinyon Pumps Part 1.

Introduction

Part 2.

M-Pump

Part 3.

H-Pump and Z- Flap Conversions

Part 4.

Auxiliary Equipment

Institute ™

F-K Pumps - Introduction

247

Auxiliary Equipment • Feed Arrangements • Diverter Valves • Pipeline Bends • Couplings • Rolling Contact Bearings • Airline Filter Regulator Lubricator

Institute ™

F-K Pumps - Introduction

248

Feed Arrangements

Institute ™

F-K Pumps - Introduction

249

Hopper Aeration System

Solenoid Valve

Orifice plate

For pumps with un-controlled feed, an automatic hopper aeration system is used. When motor amps rise, the solenoid valve opens and the silo is aerated. Purge air through the orifice plate keeps the nozzle clean. Institute ™

F-K Pumps - Introduction

250

Hopper Aeration System

Aeration air may be taken from the transport air supply line, as above, or from an independent plant air source. Institute ™

F-K Pumps - Introduction

251

Feed Hopper Baffle

The baffle plate diverts feed to the down-turning side of the screw, and promotes proper venting. Institute ™

F-K Pumps - Introduction

252

Seal Protection Baffle

On certain installations where feed material drops into the hopper from a great height, the material can enter the seal area. This modification my help extend seal life. Institute ™

F-K Pumps - Introduction

253

Diverter Valves

Institute ™

F-K Pumps - Introduction

254

Diverter / Cutoff Valves Two-Way SK Valve

ZWR - Zero Leakage

45o Diverter

ZWS - 2-way Zero Leakage

Institute ™

90o Diverter

1-way SK Valve

F-K Pumps - Introduction

255

Diverter Valves • • • • • • • • • • • • • • • •

Two-way Hose-type Diverter Valves Type ZWS Three-way Hose-type Diverter Valve Type DWS Type ZWR Zero Leakage Diverter Valve Two-way Diverter Valve Zero Leakage (‘ZL’) Diverter Valve Zero Leakage (‘ZL’) Diverter Valve Cutaway Diverters: ‘FA’, 45o, 90o 45o Diverter Valve ‘FA’ / 45o / 90o Diverter Valve 90o Diverter Valve SK Valves: Two-way SK SK Diverter Valve SK Valves: One-way SK Rotary Cutoff Valve - Photo Rotary Cutoff Valves Rotary Cutoff Valve - Expanded View

Institute ™

F-K Pumps - Introduction

256

Two-way Hose-type Diverter Valves Type ZWS •

•

Applications – Powders – Pellets Features – 2 - 3 positions – Vacuum / pressure – Pressure tight up to 4 bar (58 psi) – Low diverting angle – Cast aluminum housing & slide plate • Slide plate hard coated • PTFE lined – Flange connections – Controls wired to terminal box – Wetted surfaces in stainless steel as an option – Metal hose and rubber hose are options Institute ™

Normally completely enclosed controls

Models: ZWS: Two-way DWS: Three-way (2” to 6” line size)

F-K Pumps - Introduction

257

Three-way Hose-type Diverter Valve Type DWS • Features – 2 - 3 positions – Vacuum / pressure – Pressure tight up to 4 bar (58 psi) – Low diverting angle – Cast aluminum housing & slide plate • Slide plate hard coated • PTFE lined – Flange connections • – Controls wired to terminal box – Wetted surfaces in stainless steel as an option – Metal hose and rubber hose are options Institute ™

Advantage: – Omits one two-way vane or plug-type diverter – Gentle angle of diversion F-K Pumps - Introduction

258

Type ZWR Zero Leakage Diverter Valve Features:
Pressurized seals
Cast aluminum housing and plug
Stainless steel internal sleeves optional
Reduced I/O to operate
Bi-directional design
4 Bar pressure capability

Institute ™

F-K Pumps - Introduction

259

ZWR Two-way Diverter Valve Features:
Minimal areas for cross contamination.
No corners or edges of impingement
In-the-field valve hand reversal design
In-the-field liner sleeves replacement design
Zero leakage of gas to dead leg

Institute ™

Silicon Sealing Air Channel Sealing Pressure Chamber

F-K Pumps - Introduction

260

Zero Leakage (‘ZL’) Diverter Valve • • • • • • • • •

Zero leakage of material and air 45 psi pressures Pressurized rotor shoe Peripheral rotor seal Automatic operation Pre-piped and pre-wired NEMA 4, 7, 9 standard Standard sizes Standard 150lb. drilled flanges

Institute ™

F-K Pumps - Introduction

261

Zero Leakage (‘ZL’) Diverter Valve A

Body with Standard 150 lb drilled flanges

Peripheral Seals End Plate

Pressurized Nylon Sealing Shoe

High Pressure Lip Seal

Shoe-Type Rotor

Section A-A

Institute ™

Sealed Ball Bearing

A

F-K Pumps - Introduction

262

Diverters: ‘FA’, 450, 900 •

•

Advantages • – Available in aluminum – Stainless steel – Simple construction – 7 sizes (2”, 4”, 5”, 6”, 8”, 10”, 12”) – 3 methods of operation: hand, air, electric – Left or right mounting – Explosion proof operators – Abrasion resistant coatings ZL 45º diverter – Positive seal between ports air and material – same as above

Note: – Must stop material flow before actuating except with 90º design – Maximum operating pressure is 15 psi

90o Diverter

45o Diverter

Institute ™

F-K Pumps - Introduction

263

45o Diverter Valve

Body with Standard 150 lb drilled flanges 15 psig rated End Plate High Pressure Lip Seal Sealed Ball Bearing

Plug-Type Rotor

Section A-A

Institute ™

A

F-K Pumps - Introduction

264

o

o

‘FA’ / 45 / 90 Diverter Valve Valve

Mounting Bracket

Air Cylinder

Switch Box

Coupling

Institute ™

Dual Solenoid

F-K Pumps - Introduction

265

o

90 Diverter Valve Rotor

Body with Standard 150lb. Drilled Flanges 15 psig rated

Institute ™

F-K Pumps - Introduction

266

SK Valves: Two-way SK •

Advantages – Hand, motor, air operators are standard – Sizes 3” to 14” – Special applications: aluminum, stainless steel design in 4”, 6” and 8” – Left or right hand mounting – 450 diverter leg – Heavy cast iron construction – 50 psi seal tested – Standard flange drilling – High temperatures to 8500 – Abrasion resistant design – Explosion proof operators – NFPA 85F version available Institute ™

•

Note: – Must stop material flow before actuating – Heavy weight - valve must be carefully supported

F-K Pumps - Introduction

267

SK Diverter Valve Valve Body

Colmonoy Insert Discharge Branch

Gasket Valve Disc Arm Cover Plate for maintenance access.

Adjusting Pin Spring

Disc Arm Shaft Valve Disc

Valve Lever w/ Stops

3/8” Sq. Packing (Discharge Branch) Lock Pin and Chain

Institute ™

F-K Pumps - Introduction

268

SK Valves: One-way SK • Advantages – Heavy cast iron construction – 50 psi seal tested – Air operator standard – Hand / motor operators optional – NFPA version available – Standard flange drilling – High temperature to 8500 – Abrasion resistant design – Explosion proof operators – Sizes 3” to 12” Institute ™

• Note: – Limited materials of construction – Limited applications

F-K Pumps - Introduction

269

Rotary Cutoff Valve Advantages: • • • • •

Heavy cast iron construction Dual rotor seal Simple construction Inspection panel 5 sizes available (8x10, 12x12, 14x14, 12x24, & 16x20)

• 3 methods of operation: air, hand, motor • Special applications: • Explosion proof operators • High temperatures to 700ºF • Modulating design with V-notch rotor

Institute ™

F-K Pumps - Introduction

270

Rotary Cutoff Valve End Cover

Valve Body

Cylinder (Rotor)

End Cover Cover Plate

Lever Hub

Lever

Institute ™

F-K Pumps - Introduction

271

Pipeline Bends

Institute ™

F-K Pumps - Introduction

272

Long Radius Bend

Long radius bend with radius/pipe diameter ratios of 8 or more were the traditional method of running pipelines. Institute ™

F-K Pumps - Introduction

273

Long Radius Bend Wear Pattern

Analysis of the long radius bend indicates a ricochetting flow, rather than a smooth flow. This results in unanticipated wear. Institute ™

F-K Pumps - Introduction

274

Concrete Wear-Back

Concrete-filled wear backs made of oversized pipe or rolled channel can be used to extend the life of a bend. Institute ™

F-K Pumps - Introduction

275

Blinded Tee

The blinded tee has been shown to significantly reduce wear, thanks largely to a dead layer of material at the main wear zone. A blinded tee will have a lower pressure drop than a long radius bend, and this will reduce compressed air cost. Institute ™

F-K Pumps - Introduction

276

Short Radius Elbow

The short radius bend has a lower pressure drop than the blinded tee, and only a slightly higher wear rate.

Institute ™

F-K Pumps - Introduction

277

Resistance to Flow

This graph shows the lowest resistance (pressure drop) for a bend with R/D = 2 to 4, i.e., a short radius bend. Institute ™

F-K Pumps - Introduction

278

Bend Service Life

Bend Type

Service Life (h)

Long Radius R/D = 12

14

Blind Tee

487

The above illustrates a comparison of bend service life between blinded tees and long radius sweeps in a severe test when handling zirconium-sodium. Institute ™

F-K Pumps - Introduction

279

Bend Cost Comparison

The above illustrates the relative costs for different types of bends.

Institute ™

F-K Pumps - Introduction

280

Couplings

Institute ™

F-K Pumps - Introduction

281

Coupling Alignment

Couplings must be precisely aligned to minimize parallel and angular misalignment. Institute ™

F-K Pumps - Introduction

282

Coupling Alignment

Imprecise alignment will cause shock and vibrations to be transmitted to motor and machine bearings, resulting in reduced bearing life and possible equipment damage. Institute ™

F-K Pumps - Introduction

283

Coupling Alignment

Couplings are usually aligned with a dial indicator. Institute ™

F-K Pumps - Introduction

284

Coupling Alignment

Align the coupling as accurately as possible to promote long bearing life (not just to within coupling manufacturer’s specs). Institute ™

F-K Pumps - Introduction

285

Coupling Alignment

Feeler Gage

The coupling gap can be checked with a feeler gage. Gap specifications are normally found on the equipment foundation drawing, or in the coupling manufacturer’s data. Institute ™

F-K Pumps - Introduction

286

Laser Alignment

Laser alignment offers the most accurate and easiest coupling alignment. Institute ™

F-K Pumps - Introduction

287

Laser Alignment

A laser beam on one coupling half reflects back onto a sensor from a mirror on the other half. Misalignment is read on a hand-held computer. Institute ™

F-K Pumps - Introduction

288

Maintenance Seminar

Rolling Contact Bearings Institute ™

F-K Pumps - Introduction

289

Agenda Rolling Contact Bearings • Bearing Components • Bearing Types • FLS Applications • Installation • Lubrication

Institute ™

F-K Pumps - Introduction

290

Bearing Components

Institute ™

F-K Pumps - Introduction

291

Bearing Components

Institute ™

F-K Pumps - Introduction

292

Bearing Types

Institute ™

F-K Pumps - Introduction

293

Rolling Elements

Bearings are characterized by their various types of rolling elements.

Institute ™

F-K Pumps - Introduction

294

Bearing Selection Criteria • Radial Loadability • Axial Loadability • Speed Capability • Misalignment Capability

A bearings type is selected for a particular machine application based on the above major requirements.

Institute ™

F-K Pumps - Introduction

295

Bearing Loadability

A machine may impose a radial load, an axial load in one or both directions, or a combination of radial and axial loads on the bearing, depending on the machine’s function. Institute ™

F-K Pumps - Introduction

296

Bearing Misalignment

Misaligned Bearings or Bearing Housing

Shaft Deflection under load

Bearings have limits as to the degree of misalignment.

Institute ™

F-K Pumps - Introduction

297

Ball Bearing

Institute ™

• Radial Loadability -

Good

• Axial Loadability -

Good

• Speed -

Best

• Misalignment -

Poor

F-K Pumps - Introduction

298

Ball Bearing

Institute ™

F-K Pumps - Introduction

299

Ball Bearing with Filling Notch

A ball bearing is limited as to the number of balls that can be installed, but this may be increased by the use of a filling notch. Institute ™

F-K Pumps - Introduction

300

Angular Contact Ball Bearing • Radial Loadability -

Good

• Axial Loadability -

Very Good (one direction only)

Institute ™

• Speed -

Good

• Misalignment -

Poor

F-K Pumps - Introduction

301

Angular Contact Ball Bearing

An axial load in the wrong direction will cause the bearing to disassemble. Institute ™

F-K Pumps - Introduction

302

Angular Contact Ball Bearing

An angular contact bearing, by virtue of its ability to disassemble, allows a maximum amount of load-carrying balls to be installed. Institute ™

F-K Pumps - Introduction

303

Angular Contact Ball Bearing

Angular contact ball bearings are often arranged in pairs, to provide bi-direction axial loadability or to provide increased axial loadability in one direction only. Institute ™

F-K Pumps - Introduction

304

Double Row Angular Contact Ball Bearing

Double row angular contact ball bearings are available to provide bi-directional axial loadability. Institute ™

F-K Pumps - Introduction

305

Double Row Angular Contact Ball Bearing

Institute ™

F-K Pumps - Introduction

306

Cylindrical Roller Bearing

Institute ™

• Radial Loadability -

Very Good

• Axial Loadability -

Poor

• Speed -

good

• Misalignment -

Poor

F-K Pumps - Introduction

307

Cylindrical Roller Bearing

Institute ™

F-K Pumps - Introduction

308

Cylindrical Roller Bearing

Institute ™

F-K Pumps - Introduction

309

Cylindrical Roller Bearing

Cylindrical bearings may allow minor axial movement, or they may be axially fixed. Axial loadability, however, is limited in the cylindrical roller bearing. Institute ™

F-K Pumps - Introduction

310

Cylindrical Roller Bearings

Cylindrical roller bearings are available in many different configurations. Make sure the correct bearing is installed.

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Spherical Roller Bearing

Institute ™

• Radial Loadability -

Very Good

• Axial Loadability -

Good

• Speed -

Good

• Misalignment -

Best

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Spherical Roller Bearing

Because of the spherical shape of the rollers and races, the spherical roller bearing can accommodate the most misalignment of any bearing type. Institute ™

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Tapered Roller Bearing • Radial Loadability -

Very Good

• Axial Loadability -

Very Good (one direction only)

Institute ™

• Speed -

Good

• Misalignment -

Poor

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Tapered Roller Bearing Spacer Ring

“X” Arrangemen t

“O” Arrangemen t

Tapered roller bearings are often combined in pairs with spacer rings to provide bi-directional loadability. Institute ™

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Spherical Roller Thrust Bearing

• Radial Loadability -

Very Good

• Axial Loadability -

Best (one direction only)

• Speed -

Good

• Misalignment -

Best

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Spherical Roller Thrust Bearing

This bearing has the highest axial loadability. It is often used to suspend a rotating shaft, where the load is always downward. Institute ™

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Linear Re-circulating Ball Bearing

When linear motion is required, a linear recirculating ball bearing may be used. Balls re-circulate through passageways in the carriage as they roll along the raceway. Institute ™

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Cooper Split Roller Bearing

A split roller bearing may avoid shaft removal and extensive installation time in certain circumstances. This cylindrical roller bearing rests in a self-aligning housing. Institute ™

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Four Point Bearing

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Speed Radial Loadability Axial Loadability Misalignment

Comparison of Bearing Capabilities

Ball Bearing

Institute ™

Angular Contact Ball Bearing

Cylindrical Roller Bearing

Spherical Roller Bearing

Spherical Roller Thrust Bearing

Tapered Roller Bearing

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FLS Applications

Institute ™

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Double Row Angular Contact Ball Bearing Used on FLS Equipment: • Fuller-Kinyon Type M Pumps 150 mm and 200 mm

Institute ™

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Angular Contact Ball Bearing

Used on FLS Equipment: • Fuller-Kinyon Type M Pumps 250, 300 and 350 mm (“O” arrangement)

Institute ™

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Cylindrical Roller Bearing

Used on FLS Equipment:

• Ful-Vane Rotary Compressors • Grinding Mill Roller Assemblies

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Spherical Roller Bearing Used on FLS Equipment: • F-K Pump Z-Flap Conversions • O-Sepa Separator Lower Bearing • Kiln Thrust Roller Assembly • Kiln and Mill Pinion Bearings • Symetro Gears • Fans • Pillow Block Housings (various)

Institute ™

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Tapered Roller Bearings

Used on FLS Equipment: • Grinding Mill Roller Assemblies (“X” Arrangement)

Institute ™

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Spherical Roller Thrust Bearing

Used on FLS Equipment: • Rotary Kiln Thrust Roller • O-Sepa Separator Upper Bearing

Institute ™

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Linear Re-circulating Ball Bearing

Used on FLS Equipment: • CrossBar Cooler Institute ™

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Cooper Split Roller Bearing

Used on FLS Equipment: • Clinker Cooler Repairs

Institute ™

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Bearing Installation

Institute ™

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Bearing Clearance

Bearing internal clearance is critical to bearing life. Clearance is necessary to accommodate expansion caused by relative temperature changes of the inner and outer bearing rings. Institute ™

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Bearing Clearance

Excessive clearance results in the shaft load being spread over too few rollers. Too little clearance results in the rollers receiving additional, unnecessary internal loading when the bearing is at operating temperature. Institute ™

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Bearing Clearance

Feeler Gage

Total internal clearance can be checked with a feeler gage inserted above the top roller with the machine at rest. Institute ™

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Bearing Clearance Designations • • • • • •

C2 CN C3 C4 C5 R __.__

Small Clearance Normal Clearance Large Clearance Larger Clearance Largest Clearance Special Clearance

Bearings are available with various internal clearances.

Institute ™

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Checking Bearing Clearance

Cold clearance must be within specifications after installation. After the machine has reached normal operating temperature, clearance will be reduced. Institute ™

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Compressor Bearing Clearances Bearing Bore (MM) Before Mounting (in.)

After Mounting (in.)

30

.0020/.0024

.0012/.0022

35

.0022/.0028

.0013/.0025

40

.0022/.0028

.0013/.0028

45

.0026/.0032

.0017/.0028

55

.0030/.0035

.0019/.0032

65

.0030/.0035

.0019/.0032

70

.0035/.0043

.0024/.0040

80

.0035/.0043

.0024/.0040

95

.0041/.0049

.0028/.0045

105

.0047/.0057

.0029/.0051

120

.0071/.0081

.0053/.0075

130

.0093/.0109

.0075/.0103

Institute ™

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Bearing Axial Clearance

Bearings also have inherent axial clearance. This end play must sometimes be taken into consideration when setting up a machines shaft position. Institute ™

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Bearing Installation

Bearing inner rings are a shrink fit on the shaft (outer rings are a sliding fit inside the bore in the cylinder head. The bearing must be heated to install it on the shaft. Institute ™

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Bearing Installation Internal Clearance Reduced After Installation

The bearing inner ring is stretched after installation, reducing the bearing’s internal clearance. The clearance is controlled by maintaining the shaft diameter between limits when machining. Institute ™

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Bearing Clearance

Clearance in bearings with tapered bores is controlled by the distance the bearing is pushed up the taper. The further up, the more the inner ring will stretch and the less will be the clearance after installation. Institute ™

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Tapered Sleeve Pillow Block

Often a tapered sleeve is used instead of tapering the shaft. Institute ™

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Shrink-Fitting of Bearings

animation

Rule of thumb: The ring that sees the load over its entire circumference is the tight-fitting ring. In this animation the inner ring gets loaded over its entire circumference, while the outer ring is loaded at one point only. Institute ™

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Bearing Creep

animation

If the bearing ring is not tight, it will creep and damage the shaft. Institute ™

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Bearing Installation

Bearings are best heated with an induction heater. If this is not available, use an oil bath. Never heat a bearing with a torch. Heating to more than 250ºF (120ºC) will damage the temper of the bearing steel. Institute ™

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Induction Heating

SKF induction heating film clip Institute ™

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Bearing Installation Inner Ring

Outer Ring

Collar

This fixed cylindrical bearing comes as a matched set consisting of inner ring, fixing collar, and outer ring with rollers and cage assembled. The inner ring and collar are held in place with a locknut and tab washer. Institute ™

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Bearing Installation

Installing a pre-heated inner ring.

Institute ™

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Bearing Installation

Inner ring with locknut and tab washer. Institute ™

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Bearing Installation

Installing the collar. Institute ™

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Bearing Installation

Collar in place. Institute ™

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Bearing Installation

Installing the tab washer. Institute ™

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Bearing Installation

Installing the locknut. Institute ™

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Bearing Installation

Tightening the locknut. Institute ™

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Bearing Installation

Bending over the washer’s locking tab. Institute ™

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355

Bearing Installation

Installing the bearing retainer. Institute ™

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356

Bearing Lubrication

Institute ™

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357

Lubrication Film

Tiny surface asperities are kept from contacting each other by a good oil film. Institute ™

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358

Hydrodynamic Lubrication

As one surface slides over another, a wave of oil wedges them apart, creating an oil film. Institute ™

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359

Hydrodynamic Lubrication

When the shaft rotates, oil is drawn in between the journal and bearing. The shaft lifts and a lubrication film is established. Institute ™

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Elasto-hydrodynamic Effect

Under extreme forces, plastic deformation occurs and surface area in the contact zone increases. Lubricant viscosity multiplies under extreme pressure. The result is a thin but stable oil film capable of keeping surfaces separated. Institute ™

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361

Boundary Lubrication

When speed or oil viscosity is too low, or when loads are excessive, surfaces may contact. Boundary lubrication conditions are said to exist. Institute ™

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362

EP Additives

Extreme pressure and anti-wear additives in the oil react to the high heat and pressures at the surfaces to form a low-friction chemical film, thus preventing surfaces from seizing. Institute ™

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363

Oil Film Thickness

L=

Oil film thickness increases with viscosity and speed and decreases with load. A good film thickness is three times the surface roughness. Institute ™

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364

Viscosity

Viscosity, or the resistance of a liquid to flow, is the most important property of lubricating oil. Oil viscosity changes drastically with temperature. Institute ™

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365

Viscosity

Oil viscosity is selected based on equipment operating temperature range. Institute ™

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366

Viscosity Index

Viscosity index is a relative measurement of how viscosity changes with change in temperature. Oil with a higher viscosity index can maintain its viscosity over a wider temperature range. Institute ™

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367

ISO Viscosity Grade • International Standards Organization designation for oil viscosity grade. • Measured as Centistoke (cSt) at 40 º C. • Becoming more common than SSU (Saybolt Seconds Universal). • Multiply ISO VG by 5 to approximate SSU at 100º F.

Institute ™

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Viscosity Equivalents

Institute ™

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369

Grease

Grease = Oil + Thickener

Grease is approximately 85% base oil plus 15% thickener. Lubricating properties (viscosity, etc.) are dependent on the characteristics of the base oil, while the thickener acts as a sponge to hold the oil. Institute ™

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370

Grease Lubrication Advantages • • • • •

Seals out dirt Stays where it is put Supplies oil to the bearing as required Minimal leakage Long lasting, low maintenance

Disadvantages • Overgreasing may cause bearing damage

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Oil Lubrication • • • •

Advantages Able to clean system with recirculation Able to cool system with heat exchanger Generally better lubrication Better for high speed applications

Disadvantages • More complicated (circulating system) • More maintenance • More prone to leakage Institute ™

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Bearing Greasing (FAG recommendations)

if RPM x Diameter (in mm) is

less than 50,000

pack full

50,000 – 500,000

pack 60% full

greater than 500,000

pack 20-35% full

Excessive grease in hi-speed applications results in heat generation through churning of the grease. This can lead to burning of the grease and subsequent bearing failure. Institute ™

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Bearing Lubrication Lubrication Grooves

Bearings can be supplied with a lubrication groove. This angular contact ball bearing is used back to back with another bearing. Grease enters the groove and emerges between the two bearings. Institute ™

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374

Lubrication !

Most bearing failures are caused by lubrication problems. Institute ™

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375

Airline Filter Regulator Lubricator

Institute ™

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376

Filter Regulator Lubricator

Filter-regulator-lubricators are used to condition compressed air supply to pneumatic devices. Institute ™

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377