Schneckenpumpe Eng 10 2007-ibau Pump Manual

SCREW PUMP Operating Manual ATTENTION! This operating manual only applies to : Machine no.

:

Contract no.

:

Item no.

:

Size

:

Type:

Standard

0

Wear bushing type

IBAU HAMBURG Rödingsmarkt 35 20459 Hamburg (Germany)

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TECHNICAL SPECIFICATIONS

Material specifications Material

:

Apparent density

: kg/dm3

Temperature

: max. °C

Conveyance specifications Conveying capacity

: t/h

Conveying distance

: longest conveying path vertical and horizontal.

Number of deflections

: x 90°

Number of valves

:

Dimension of conveying line

: Ø

x

m, incl.

x 45°

x 30°

mm wall thickness

Theoretic conveying line back pressure at max. conveying capacity : bar

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Technical data for the screw pump Screw incline End flight incline Max. volumetric capacity Screw speed Power requirement of screw pump Nozzle hole End flight material

: : : : : : :

% % m3/h min-1 kW mm Wear-resistant cast Densit application Welded plating Special execution in accordance with drawing no.:

Special execution of the screw

:

Welded plating Feeding helix in the inlet area Double helix Progressive screw %%

Design of the cone

:

Standard Wear bushing type Special length mm

Coupling

: Type

Supplementary bearing unit equipment at material temperatures > 130° C: water-cooled oil cooler air-cooled oil cooler Technical data for the air compressor Scope of delivery Make Type Suction volumetric flow (based on 1 bar and 20° C Suction pressure End pressure

: : : : : :

IBAU

Customer

m3/h bar abs bar abs

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Screw pump motor data Scope of delivery Make Type / size Output Speed Voltage / frequency Type of protection / insulation material category Special design

: : : : : :

kW min-1 V

Customer

Hz

: :

Pulse generator speed monitor Scope of delivery Make Type Number of pulses per revolution

IBAU

: : : :

Yes

No

IBAU

Customer

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SCREW PUMP SIZE IB-D100 - 350 TABLE OF CONTENTS

Page

1.0.0

Labelling of instructions in the operating manual

7

1.1.0

General instructions

8

1.1.1

Safety instructions for plant

9

1.1.2

Safety requirements at the works

9

1.1.3

Safety measures prior to start-up

10

1.1.4

Safety measures during operation

10

2.0.0

Description

11

2.1.0

Construction and function

11

2.1.1

Construction

11

2.1.1.1

Standard design

12

2.1.1.2

Wear bushing type

12

2.1.2

Function

12

2.2.0

Compressed air supply

14

3.0.0

Installation

16

3.1.0

General instructions for assembly

16

3.2.0

Installation

17

3.2.1

Installation instructions for concrete

18

3.2.2

Installation instructions for steel construction

19

3.2.3

Instructions for assembling the screw pump on the steel construction

19

© 10/2007

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3.2.4

Motor layout and coupling alignment

20

3.2.5

Assembling the sealing air system

21

3.2.6

Space required for dismounting the screw

24

3.3.0

Instructions prior to start-up of the screw pump

25

3.4.0

Safety regulations for accident prevention

25

3.4.1

Transport and storage

29

4.0.0

Start-up and maintenance

30

4.1.0

Start-up

30

4.2.0

Maintenance

32

4.2.1

Maintenance table

37

4.2.1.1

Grease quantities

38

4.2.1.2

Wear limits

39

4.2.2

General instructions for the installation of stuffing box packagings and the starting torque of the stuffing box gland

41

4.2.3

Dismounting and inspecting the stuffing box (size 100)

41

4.2.4

Dismounting of wear parts

47

4.2.4.1

Dismounting of the wear plate, end flight and nozzles

47

4.2.4.2

Dismounting of the cone and wear bushings

47

4.2.5

Instructions for O-ring packings

50

4.2.6

Dismounting of the screw

51

4.2.7

Dismounting of the main components of the screw pump

54

5.0.0

Troubleshooting

55

6.0.0

Spare parts / wear parts

57

7.0.0

Coupling

63

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1.0.0 Labelling of instructions in the operating manual

This symbol means an immediate danger for the life and health of people.

Danger!

Ignoring this symbol will lead to serious damage to your health and even cause fatal injuries. This symbol means a possible danger for the life and health of people.

Warning!

Ignoring this symbol may lead to serious damage to your health and even cause fatal injuries. This symbol means a possibly dangerous situation.

Caution!

i Note

Ignoring this symbol may lead to minor injuries or damage to property. This symbol gives important instructions for operating the machine correctly.

Ignoring these instructions may lead to malfunctions in the machine or its environment.

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1.1.0 General instructions

i Note

This operating manual contains important information with regard to assembly, start-up, maintenance and accident prevention. This knowledge is essential to avoid mistakes and omissions which could have potentially serious consequences. This operating manual must therefore be read fully before assembly or initial start-up by all persons who are involved with installation, operation, maintenance or repair of the screw pump, and the instructions contained in the manual must be observed. The screw pump may only be operated by personnel who are trained and authorised to do so. It is the responsibility of the machine operator to make sure that the persons in charge of operation and maintenance of the machinery are familiar with the rules and regulations. Responsibility for operating the screw pump must be precisely defined and specified so that no-one is assigned duties for which they do not have the necessary skills. IBAU HAMBURG does not accept any liability for damage that occurs as a result of non-compliance with the operating manual. The machine must be used for the purpose designated in this operating manual and the technical specifications in the order confirmation. Otherwise, it will not function properly and and safely. The installation of parts or add-on units and the use of parts that are not original IBAU HAMBURG parts or accessories may influence the given design characteristics. As the manufacturer, we do not accept any liability for damage resulting from the use of non-original parts or accessories. Use for designated purpose This screw pump is solely designed to convey non combustible dusts like cement, lime, etc. If it is used for other materials, the responsible engineer at IBAU HAMBURG should be consulted. The screw pump is not to be set up in rooms in which an explosive gas/air mixture may form. The screw pump is not suitable for other pulverized materials, which can form with air an explosive mixture.

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1.1.1 Safety instructions for plant Lockable cut-off device In order to allow hazard-free work on the screw pump, a yellow-red main switch with an emergency stop lever which can be locked in the OFF position must be attached immediately next to the pump with 3 padlocks. This main switch is used to interrupt the energy supply to the screw pump motor - manually as well, when an emergency stop is made. The use of a padlock prevents the screw pump from being switched on unintentionally. Screw pump operation must only be approved again once operational safety has been ensured. Protective measures for the screw pump motors Motor guards and motor safety switches – with a PTC thermistor detector and / or residual-current-operated circuit-breaker if necessary – are to be provided to ensure electrical safety in accordance with IEC 204 and VDE 0113. 1.1.2 Safety requirements at the works We cannot be aware of any dependence on other systems at the plant unless we were entirely responsible for planning. Such dependency must be checked by the operator separately. In addition, the following requirements must be fulfilled in order to ensure regular operation of the plant: • Installation must be completed properly • Test run completed successfully including all necessary adjustments • Safety equipment and electrical interlocking systems installed properly • The operating personnel must be trained in the proper operation of the plant and the relevant safety regulations • Use of the machinery for its intended purpose, and proper maintenance of the machinery

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1.1.3 Safety measures prior to start-up Before every start-up, the operator must ensure that • no persons or obstacles are in the danger zone of the plant • the plant has no visible faults • all signalling and alarm equipment is functioning properly.

1.1.4 Safety measures during operation ATTENTION! During operation, the inspection covers (Fig. 1, item 15 and 22) may not be opened under any circumstances! Inspection covers may only be opened after a complete shutdown of the screw pump and the conveying air blower / compressor. Danger!

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2.0.0 Description Screw pumps are used for the pneumatic transport of cement, raw meal, various types of lime, pulverised coal, fly ash, alumina and many other pulverised materials. No other conveying unit is able to continuously feed large quantities of pulverised goods into a pneumatic conveying line without an air blow-back. A further advantage of screw pumps is that they require little space and are particularly low in height. In special cases (e.g. screw pumps for unloading ships), screw pumps can operate against conveying line back pressures of up to 2.5 bar. They come in sizes 100 to 350, with capacities ranging from approx. 3 m³/h to approx. 370 m³/h.

2.1.0 Construction and function 2.1.1 Construction Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Designation Screw Fixed bearing Floating bearing Shaft bushing Motor Coupling Oil level indicator Oil paddle Inlet box Stuffing box Sealing air piping Wear bushings Cone Wear ring Discharge box Counterweight Valve lever Non-return valve Nozzles Conveying line Blind flange Inspection cover Screw pipe

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2.1.1.1 Standard design The screw pump (Fig. 1) consists of the inlet box (9), the screw pipe (23), the discharge box (15) and the bearing unit with two bearings and the screw (1). The fixed bearing (2) and the floating bearing (3) are mounted on the same shaft bushing (4). This bushing is equipped inside with a centring cone and a feather key connection to the screw. The screw (1) is actuated by a separately installed motor (5) via a coupling (6). The oil level in the bearing unit is shown by the oil level indicator (7). The oil paddles (8) mounted on the shaft bushing provide the bearings with a steady supply of oil. The screw pump is sealed against the inlet box by a stuffing box (10). The additional supply of sealing air (11) prevents dust from penetrating into the stuffing box (10), but only if the material inlet space of the screw pump has been dusted. To ensure the stuffing box functions properly, a negative pressure of min. – 20 to –50 daPa should be ensured. At the front section of the screw pump, facing the conveying direction, the screw rotates in the wear bushings (12), which are mounted in the screw pipe. After the last wear bushing there is a conically enlarged space (13), the so-called cone. At the end of the cone there is the wear ring (14). In the discharge box of the screw pump the counterweight (16) presses the non-return valve (18) against this wear ring (14) via the lever (17), so sealing off the pressure-free material inlet from the pressurised conveying chamber. The three nozzles (19) installed at the bottom of the discharge box (15) are used to blow in the compressed air, which is mixed with the bulk material. The mixture of air/solids so produced is thus transported to the conveying line (20) downstream of the discharge box of the screw pump. 2.1.1.2 Wear bushing type The design of the wear bushing type differs from that of the standard type in the following respect: instead of the conical space (13) with a wear ring (14), there is a cylindrical wear bushing with a conical outlet. This wear bushing is bedded in a cone. This version does not have a wear ring (see also fig. 16).

2.1.2 Function The main element of the screw pump is a high-speed screw (1), with speeds of 750 and 1,000 min-1 at 50 Hz operation and speeds of 900 or 1,200 min-1 at 60 Hz operation. The purpose of the high-speed screw is to continuously convey bulk material from a pressure-free material inlet (9) into the pressure chamber of the discharge box (15) and the downstream conveying line (20). Together with the cone and non-return valve, the screw and the material flow act as a seal between these two areas. During operation the non-return valve (18) is made to open by the continuous supply of material, which then falls into the discharge box (15). There it is mixed with compressed air via the nozzles (19) and so transported to the conveying line (20).

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Fig. 1

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The direction of rotation of screw pumps powered by electric motors is clockwise, facing the drive shaft, while for screw pumps powered by a combustion motor it is anti-clockwise!

ATTENTION!

Note

i

2.2.0 Compressed air supply The compressed air required for pneumatic conveying via a screw pump is generally supplied by blowers or screw compressors. The quantity of compressed air required for the specific case and the piping diameter of the conveying line are calculated by IBAU HAMBURG. Alternatively, compressed air from an air supply network can also be used for pneumatic conveying. If you are using compressed air from an air supply network, you are advised to construct the compressed air device as shown in Fig. 2a order to ensure pneumatic transport functions perfectly. Alternatively, you can also use a special combined pressure throughput control valve which greatly reduces the extent of the valves shown.

Air supply either right

or left

Fig. 2

The air supply lines can be connected either on the left-hand or the right-hand side of the discharge box (Fig. 2). The air connection is fitted at the factory with a blind flange, seal and screws (see also Fig. 1, item 21). This can be bored as specified by the customer according to the compressed air supply line. The max. diameter of the air connection line for the relevant size of the screw pumps is given in the appropriate IBAU dimensional sheet. The sealing air piping (normally installed in conveying direction left) in the screw pump is installed opposite the conveying air connection at the factory. However, it can also be moved to the other side at any time if this proves to be necessary on site. Attention! The tightness of the entire conveying air system must be verified following installation on site! 14/63

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Fig. 2a

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1 Main shutoff valve 2 Air pressure measurement 3 Dirt trap 4 Pressure reducer 5 Pressure measurement manometer

Legend 6 Measuring flange 7 Differential pressure regulator 8 High-pressure valve 9 Needle valve 10 Differential-pressure

3.0.0 Installation 3.1.0 General instructions for assembly The material is normally fed into the screw pump through a surge hopper installed on the inlet box of the screw pump. The surge hopper must be sufficiently vented. NOTE! In the pump surge hopper there should always be a negative pressure of min. -20 to -50 daPa under all operating conditions to ensure proper venting of the material flow and proper functioning the stuffing box seal. Overpressure in the pump surge hopper results in reduced volumetric capacity of the screw pump and to escape of the bulk material via the stuffing box seal of the screw shaft. Always avoid using horizontal venting lines as they become blocked with dust contained in the outgoing air over time, and this prevents sufficient ventilation of the surge hopper. Alternatively, the bulk material can also be fed to the material inlet space of the screw pump laterally, e.g. via a fluidslide. The material inlet space (Fig. 1, item 9) is equipped at the side with two inspection covers (Fig. 1, item 22). In this case one should be removed and the flange connected to a counterflange of the conveying unit for the supply of material. The lateral connection should preferably be right-handed in the conveying direction for screw pumps powered by an electric motor (the screw is clockwise), and for screw pumps powered by a combustion motor preferably lefthanded in the conveying direction (the screw is anticlockwise)! Should the position of the material inlet described above prove impossible, the matter must be clarified with the person responsible at IBAU HAMBURG at all events as the volumetric capacity of the screw pump may be greatly reduced in such a case! A surge hopper with venting should also be provided with the lateral feed of material to the screw pump! When material is conveyed pneumatically to silos or bins using a screw pump, negative pressure filters must be present at the material transfer point to ensure sufficient venting of the conveying air. If several silos or bins have to be filled, the conveying line has to be equipped with two-way valves leading the material flow into the corresponding silo. The conveying lines for pneumatic conveying via the screw pump can be laid either vertically or horizontally. However, under no circumstances should the conveying lines run up in a slanting conveying direction as this may cause pneumatic conveying to malfunction. Such piping sections may cause the separation of coarse particles from the material flow, which then move down along the bottom of the slanting conveying pipe against the conveying direction. These particles then collect at the lowest point of the piping section, causing localised pipe blockages which generally become apparent beforehand by throbbing conveying line back pressure at the screw pump. If there is any doubt about the piping route, please consult the person responsible at IBAU HAMBURG.

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The piping bends used in the pneumatic conveying line should have a minimum radius of 10 x di (internal diameter of the conveying pipes). In other types of conveying pipe deflections, clarification must always be sought from the responsible person at IBAU HAMBURG whether the resistance from this type of deflection must be allowed for when calculating the pneumatic conveyance.

i

ATTENTION! If the above points are not observed, IBAU HAMBURG will not guarantee that pneumatic conveying functions properly.

Note 3.2.0 Installation Prior to installation of the screw pump check whether all parts are available on site in accordance with the relevant parts lists. If any parts are missing, then also check the shipping advices and packing lists. The plant drawings provide further useful information about possible missing parts. If parts are found to be missing, the supplier of the screw pump and the person responsible at IBAU HAMBURG should be notified immediately. Minor transport damage to the screw pump, e.g. damage to paintwork, should be repaired on site. More serious damage should be reported to the person responsible at IBAU HAMBURG. If possible, take photographs and send in to IBAU HAMBURG so that the damage can be assessed. ATTENTION! For screw pumps which are pressure surge-resistant to 10 bar the following instructions must be observed without fail: Warning!

Should damage have occurred to the following components during transport or subsequent installation, these items may not be installed: • • • •

inlet box screw pipe inlet box with screw pipe (only with screw pump type 151 and 251) discharge box.

This also applies to damage of the contacting thermometer or the resistance thermometer used to monitor the oil temperature of the bearing unit and all other electrical equipment installed on the screw pump and approved for the ambient zone (21 or 22).

Once all necessary parts are available and without defects, check that all requirements are satisfied for proper installation. • •

Does the installation situation comply with that of the installation drawing? Does the available height comply with that in the drawing? 17/63

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3.2.1 Installation instructions for concrete

Fig. 3.1 1.1 1.2 1.3 1.4

Prepare the foundation according to the drawing or dimensional sheet Construct the foundation on grown soil or existing concrete sole. Fill in the gap between foundation and soil with bitumen (n/a with concrete sole!). Do not forget the measurement for dismounting the screw (group 3.2.2 or Fig. 6)!

Fig. 3.2 2.1 2.2 2.3 2.4

Insert anchor bolts. Position screw pump. Align the pump by means of spacers using a water-level. For test purposes, turn the screw at the coupling and ensure that the screw rotates without contact.

Fig. 3.3 3.1 3.2 3.3 3.4 3.5

Fit the shuttering. Pour in around 5 cm of casting concrete beneath the shuttering strength class C30/37 with additive (swelling agent). Allow to set. Remove shuttering. Tighten the anchor bolt nuts to a maximum torque of 120 Nm. 18/63

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3.2.2 Installation instructions for steel construction Instructions for dimensioning the steel construction used for setting up the pump. •

To ensure that the steel construction can oscillate safely, it is essential that the natural frequencies of the steel construction are sufficiently outside the exciting frequencies of the screw pump.

•

The deflection of the displacement carriers on which the screw pump is carried must not exceed 1/1000 of the span when they have to bear their own load and the live load! In addition, sheet metal discs or bonds must be provided to brace the horizontal displacement of the carriers.

•

The load factor given covers the dead weight of the screw pump, attached parts (e.g. motor, pump surge hopper), the weight of the filling and the necessary safety allowances for additional loads and vibrations which may arise.

•

Screw pump weight including attached parts and filling

•

Screw pump speed

•

Critical natural frequency range of screw pump

: see order specific load data in load plans : see order specific speed : 13 to 20 Hz at 1000 min-1 : 10 to 15 Hz at 750 min-1

3.2.3 Instructions for assembling the screw pump on the steel construction 1. The base frame, the screw pump, the motor, the motor console and the fastening screws are delivered separately. 2. Mount the screw pump and the motor with the motor console on the base frame according to the installation drawing. Then align the coupling in accordance with the instructions. 3. Position the entire assembly (base frame with screw pump and motor) on the steel construction in the location provided and align with a water-level. To align you may have to place extra spacers at certain locations. 4. Screw the base frame to the steel construction or weld together at places (relevant procedure to be specified by customer). Then turn the coupling manually to see if the screw rotates without contact in the wear bushings. If the screw does not rotate without contact, unscrew the screwed connections holding the screw pump and base frame together once again. Place extra lining plates under the appropriate points to realign the screw pump so the screw rotates without contact. Finally realign the coupling.

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3.2.4 Motor layout and coupling alignment

i Note

In case of V-belt drive the motor has to be mounted to the side of the screw pump on slide rails according to the manufacturer’s instructions. With direct drive of the screw pump the motor should be positioned so it can be moved back slightly to dismount the screw! Take the dismounting dimensions given by the manufacturer of the coupling into consideration here. The coupling is aligned by means of a dial indicator, a shaft ruler and a thickness gauge according to the instructions of the coupling manufacturer. The coupling gap (Fig. 4) to be adjusted is shown in the operating manual for the coupling.

Straigh t edge

Radial alignment

Spacer bar

Note the direction of the arrow! The direction of rotation for screw pumps powered by an electric motor is clockwise! Screw pumps powered by a combustion motor run anti-clockwise, facing the drive shaft end.

Axial and height alignment

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3.2.5 Assembling the sealing air system Screw pumps are delivered with the sealing air piping, designed to a pressure rating of PN 10, already mounted. However, if this was dismantled before transport for packaging reasons, the sealing air piping should be reassembled according to Fig. 5 on installation of the screw pump at the installation site.

i

1-

diaphragm pressure gauge DIN 837-3, housing Ø 160, indicating range 0 - 2.5 bar, to be fitted with flange DN 50 - PN 10

2-

diaphragm pressure gauge DIN 837-3, housing Ø 160, indicating range 0 - 2.5 bar, fitting R ½“

3-

spring tube pressure gauge DIN 837-1, housing Ø 100, indicating range 0 - 1 bar, fitting R ½“

4-

spherical cock R ½“

5 and 6 -

spherical cock R ½“ with screw pump size 100 spherical cock R ¾“ with screw pump size 151 – 200 spherical cock 1“ with screw pump size 251 and 300 spherical cock 1 ½ “ with screw pump size 350.

The tightness of the sealing air system must be verified following installation of the sealing air piping on site!

Note Note The above parts relate to the standard screw pump. In some cases deviations may occur.

i Note

In some cases it may prove necessary on site to extract the sealing air slightly away from the screw pump directly from the conveying air supply line or from the works network. This is for example the case when on the basis of the customer's process control responsibility or with constant power failures at the works, the air compressor is suddenly switched off during conveying. In such a case there is the risk of the material flowing back in the stuffing box of the screw pump due to the back pressure still present in the conveying line via the nozzles and sealing air piping. When the air compressor is switched back on, the material flows through the stuffing box housing with the sealing air at high speed. The resulting "sandblasting effect" then causes damage to the stuffing box housing. Should such improper mode of operation constantly occur during operation of the screw pump, the person responsible at IBAU HAMBURG should be informed immediately to jointly seek possible solutions to prevent further damage to the screw pump. In such a case IBAU HAMBURG shall accept no warranty liability for any damage that has already occurred! 21/63

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For the extraction of sealing air from the works network a pressure regulator and a volume flow controller should be provided to ensure the following adjustment values: •

Pressure should be adjustable in the range 0.02 to 0.2 bar (see. item 4.1.0 page 31)

•

The sealing air volume should be adjustable according to the following table

Pump size 100 151 200 251 300 350

Sealing air volume [m³/min] 1,0 1,0 1,0 3,0 3,0 3,0

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Cross-section A - C Fig. 5

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3.2.6 Space required for dismounting the screw Note How to dismount the screw is described in item 4.2.5.

A

Screw pump Type IB-D

B

Screw pump Type IB-DV

Fig. 6 Table II Size

Type IB-D

Type IB-DV

100 151 200 251 300 350

A = 1250 A = 1650 A = 2000 A = 2600 A = 2950 A = 3400

B = 1600 B = 2000 B = 2400 B = 3100 B = 3500 B = 4000 24/63

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3.3.0 Instructions prior to start-up of the screw pump

i Note

Every delivered screw pump has undergone an 8-hour test run and is normally filled with the right type and quantity of oil. However, for safety reasons it is advisable to recheck the oil level at the oil level indicator (Fig. 1, item 7) provided for this purpose prior to start-up. ATTENTION! The correct oil level can only be checked when the screw pump is at a standstill! If however in an exceptional case the pump is delivered without oil , the correct quantity of oil according to the oil level table on page 36 must be added. The stuffing box at the shaft exit to the inlet box of the screw pump is adjustable and is equipped with 3 packing rings and a grease ring. The stuffing box packagings are made of the material "Arochem S" and have already been provided with sufficient grease at the factory during the test run.

i Note

ATTENTION! As there may have been a lengthy period of time between delivery of the screw pump and its start-up, the stuffing box must be regreased without fail prior to startup, and the correct starting torque for the stuffing box gland also checked (see item 4.2.2 on page 40.) During start-up and proper operation of the screw pump the following outside temperatures for the housing are within the acceptable range: • •

bearing unit at bearing stuffing box

max. 80° C max. 80° C

ATTENTION! If the above temperatures are greatly exceeded, the screw pump should be taken out of service and the cause for the rise in temperature determined!

3.4.0 Safety regulations for accident prevention The coupling protection (Fig. 7), the protective cover (Fig. 7 a) in the area between the bearing unit and the stuffing box and the belt guard for V-belt-driven screw pumps may only be removed when the machine is at a standstill. Before the machine is restarted, the above protection devices must be properly fitted again.

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ATTENTION! Before removing the coupling protection and the protective cover, the machine must be secured against being switched on unintentionally! Danger!

Danger!

The inspection covers on the inlet box and the discharge box of the screw pump should only be opened using tools! Before the inspection covers are removed, the screw pump must always come to a proper standstill and be secured against being switched back on unintentionally! Inspection covers on the pump surge hopper may only be opened using tools ! Should they be located less than 850 mm from the rotating screw, the screw pump must always come to a proper standstill and be secured against being switched back on unintentionally before being opened. Existing emergency operating facilities, for example emergency operating elements, as well as possible sources of danger during operation of the screw pump must be clearly indicated by written warning signs.

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Coupling protection

Fig. 7 27/63

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Protective cover

Fig. 7 a 28/63

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3.4.1 Transport and storage

i Note

Screw pumps must be protected against external influences such as rain, impact or breaking. The screw pump must be stored prior to installation in a dry place under cover! The screw pump must be transported on its frame as shown (see Fig. 8). Here the rope must never be fastened to the screw shaft at point (A) and (E), the coupling (B), the cone (C) or the stuffing box (D).

Fig. 8

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4.0.0 Start-up and maintenance 4.1.0 Start-up ATTENTION Prior to initial start-up of the screw pump the inspection cover on the discharge box should be opened and the non-return valve lifted and secured so that the gap between the end flight and the wear bushings can be checked. Afterwards this procedure is repeated for the inlet area of the screw pump by opening an inspection cover on the inlet box and checking the gap between the screw and the wear bushing at the entry to the screw pipe. The factory-set dimensions for the radial gap can be found in the test record for the pump in both cases. Should the radial gaps greatly diverge from the factory-set dimensions, or if the end flight or screw knock against the wear bushings, alignment of the screw pump and/or bearing unit should be carried out on site to correct the gaps. IMPORTANT! In case of any doubt a screw pump specialist should be consulted at IBAU HAMBURG regarding performance of the above work! Before start-up of the pneumatic conveyor installation via the screw pump make sure that there is sufficient take-up capacity for the material flow in the receiving silos! Before proceeding further with start-up first start the outgoing air filter on the receiving silo selected. The air compressor / blower and the screw pump are then switched on and the material feed started after a delay. In order to monitor the pressure during transport each screw pump is supplied with three pressure gauges: •

1 diaphragm pressure gauge, which is positioned on the sealing air piping opposite the air supply. This gauge indicates the pressure upstream of the nozzles in the discharge box of the screw pump, i.e. before the conveying air is mixed with the material flow. It is thus also referred to as the air pressure gauge (Fig. 5, item 2). This pressure exceeds the back pressure by the value of the pressure drop at the nozzles (approx. 0.2 to 0.3 bar depending on the design)!

•

1 diaphragm pressure gauge with an open measuring flange. This is mounted on the discharge box of the screw pump. It indicates the specific conveying line back pressure (product of the pressure loss for the equivalent conveying line length and the quantity of material currently conveyed) and is therefore also referred to as the back pressure gauge (Fig. 5, item 1).

•

1 spring tube pressure gauge to indicate the sealing air pressure, called the sealing air pressure gauge (Fig. 5, item 3). The sealing air pressure is adjusted by means of a spherical cock with the nominal conveying capacity and should fall within the range 0.02 bar to 0.2 bar. The maximum value of 0.2 bar must not be exceeded as this might otherwise cause damage to the stuffing box!

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IMPORTANT! With very light bulk materials such as filter dust and pulverized coal, the sealing air pressure should be approx. 0.02 bar as higher pressures might cause major fluidisation of the material in the inlet area of the pump, possibly reducing the volumetric capacity of the screw pump! If it transpires on start-up that the difference in pressure of the nozzles is greater than 0.3 bar with the nominal conveying capacity, the person responsible at IBAU HAMBURG should be contacted to bring about correction of the nozzle bores. Here the existing plant parameters such as the quantity of material currently conveyed and the actual equivalent conveying pipe length should be given so a new nozzle calculation can be carried out. NOTE! In the partial load area of the pneumatic conveying the difference in pressure between the air pressure and the back pressure may exceed the pressure of 0.3 bar given above. This however does not represent any defect in the design of the nozzle bores! The counterweight on the lever of the non-return valve is adjustable in its position. In addition, it features a split design to reduce the weight if necessary. The position and size of the counterweight depend on the material flow (e. g. wear behaviour, bulk density and fineness) and on the specific plant parameters (e.g. level of conveying line back pressure). On start-up of the plant the position of the counterweight should be adjusted to ensure the seal between the pressurised discharge box and the pressure-free inlet box of the screw pump with the nominal conveying capacity; i.e. no conveying air should flow back to the inlet area of the screw pump. Another criterion for adjustment of the counterweight is the drive of the screw pump. The adjustment should be selected so that the nominal current of the drive motor is not exceeded with the nominal conveying capacity. NOTE! For specific cases the screw pump type IB-D 350 is equipped with special nonreturn valve damping, with two pneumatic cylinders, make Norgren Herion. They have a damping effect on the closing direction of the non-return valve. In this specific case a separate drawing and an operating manual for the components used are included with this documentation.

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4.2.0 Maintenance Maintenance of the screw pump depends on the specific operating conditions. Under normal operating conditions maintenance should be carried out in accordance with the table below (see 4.2.1 page 38).

i Note

i Note

Grease lubrication of the stuffing box and the non-return valve bearing must be carried out according to the intervals specified in the maintenance table (cf. 4.2.1 page 38) and with lubricating grease of Esso Unirex 3 quality or with an equivalent grease as per DIN 51502 - KL 2 K. The relevant lubricating points are equipped with button head lubricating nipples as per DIN 3404 AM10x1 (Fig. 11c /item 46 page 45 and Fig. 15 between items 4 and 5 page 57) The sealing air pressure (Fig. 5, item 3) should be adjusted according to the data given in item 4.1.0 and adjustment checked at regular intervals. On the opposite side of the sealing air inlet there is a control cock which should be opened briefly at regular intervals to check the stuffing box and remove any dust which has entered. IMPORTANT NOTE! The control cock must not be opened while conveying material as this may damage the stuffing box housing! However, to clean the stuffing box and remove any dust which has entered the conveying air must be connected.

i Note

i Note

The oil for the bearing unit must be filled in via the opening in the vent socket (Fig. 9, item 1), with the cover unscrewed. The bearing unit is drained through the oil drainage cock located on the opposite side of the oil filling level indicator (Fig. 9 / item 5). To lubricate the bearings oil quality SAE 15W/50 or SAE15W/40 should be used. After initial start-up of the screw pump change the oil after 300 hours. Then change it every 6 months or not later than 3000 operating hours. The maximum oil temperature in operation is approx. 80° C under normal operating conditions and is read off the thermometer (Fig. 9, item 3) of the bearing unit. Higher oil temperatures point to an excessively high or low oil level in the bearing unit or to possible damage to the bearings. In such cases the oil level should be corrected according to the following table on page 36 or the defective bearings replaced! IMPORTANT NOTE! Inoperative thermometers should be replaced immediately to ensure correct readoff of the permissible oil temperature of the bearing unit!

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Caution!

Caution!

From time to time check the tight fit of the oil paddles in the bearing unit of the screw pump via the vent socket (Fig. 9, item 1). When removing the oil paddles (Fig. 9, item 2) secure with wire hooks (Fig. 9, item 4) as illustrated to prevent them from falling into the bearing unit. IMPORTANT NOTE! Should an oil paddle have fallen into the bearing unit in such a case, the screw pump must not be started up under any circumstances as this might cause serious damage to the bearing unit! In this case the complete bearing unit must be taken apart to remove the oil paddle! The screw pumps in sizes 100 to 200 are equipped with one oil paddle in the middle. From size 251 to size 350 the screw pumps are equipped with four oil paddles, two each on the floating bearing and two on the fixed bearing side.

Caution! IMPORTANT NOTE! When checking or performing maintenance on the oil paddles, the screw pump must always come to a proper standstill and be secured against being switched back on unintentionally! Caution!

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Hook for oil paddle

Fig. 9 34/63

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i

Oil level

* Cross-section A-A only for screw pump P151

Note

Oil level at standstill

Screw pump

approx. litres

mm "H" (max.)

P 100 **

approx. 1.25

43

P 151 *

approx. 1.4

31

P 200

approx. 2.1

40

P 251

approx. 5.5

50

P 300

approx. 5.6

38

P 350

approx. 8.0

50

Note: This information applies to initial filling of the screw pump and should be used as a guideline only. When refilling oil (only at standstill of the pump) the value marked at the inspection glass of the oil-level indicator (see mm "H") must not be exceeded in any case. However, falling short of the oil level by 2 mm is admissible. ** Note on screw pump IB-D100 with oil cooler: For the screw pump IB-D100 with oil cooler the oil filling quantity of 1.8 l is so low in relation to the circulating oil quantity that it is not possible to read the oil filling level on the bearing unit. For this reason there is an oil-level glass in the pressure pipe supplying the bearing unit instead of the oil level indicator on the bearing unit. During operation of the oil cooler it can be checked in the glass at any time if there is oil circulating. About 10 minutes after switching off the oil cooler is possible to check the oil level via the mark shown on the glass. Note when changing oil: When changing the oil, it is advisable to drain the oil when it is still hot from operation. First the plug (Fig. 10 / item 1) on the oil drainage cock (Fig. 10 / item 2) must be removed and this then opened. The oil drainage cock (Fig. 10 / item 2) must remain open until the entire oil quantity has been drained off from the bottom of the bearing unit. The oil drainage cock (Fig. 10 / item 2) is then closed and the plugFig. 10 / item 1) refitted. 35/63

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IMPORTANT NOTE! Only when the plug is fitted can unintentional opening of the oil drainage cock be prevented - and running dry of the bearing! When the bearing unit is subsequently filled with oil, it must be ensured that the oil filling quantity specified for the size of the screw pump is not exceeded. An excessive oil level may cause the superfluous oil to escape at the felt ring seal on the coupling side at the bearing unit!

2

1

Fig. 10

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4.2.1 Maintenance table The following table applies for normal operating conditions:

No. Description 1. Stuffing box

2.

3. 4.

5. 6.

7.

8.

9.

Interval Weekly or max. every 100 op. hours

Action Visual inspection or re-apply lubrication as necessary

Note Esso Unirex 3

Stuffing box packings

Annually or Replace max. every 8,000 op. hours Oil level bearing unit Weekly Visual inspection Oil change bearing unit Every 6 months Change oil or max. every 3,000 op. hours Non-return valve / Monthly Lubricate Shaft bearing Wear bushing, end Every 3 months Visual flight and screw inspection and check for wear Bearings Every 3 years Change or max. every bearings 24,000 op. hours Felt rings bearing unit Annually or Replace max. every 8,000 op. hours O-rings Whenever Replace dismantled

(see 4.2.0) 1 HD oil SAE 15 W/50 Esso Unirex 3 (see 4.2.2)

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4.2.1.1 Grease quantities Screw pump Size 100 Size 100 Size 100 Size 151 Size 151 Size 151 Size 200 Size 200 Size 200 Size 251 Size 251 Size 251 Size 300 Size 300 Size 350 Size 350

Description Stuffing box Bearing non-return valve shaft / side with counterweight Bearing non-return valve shaft / side without counterweight Stuffing box Bearing non-return valve shaft / side with counterweight Bearing non-return valve shaft / side without counterweight Stuffing box Bearing non-return valve shaft / side with counterweight Bearing non-return valve shaft / side without counterweight Stuffing box Bearing non-return valve shaft / side with counterweight Bearing non-return valve shaft / side without counterweight Stuffing box Bearing non-return valve shaft / both sides Stuffing box Bearing non-return valve shaft / both sides

Quantity [kg] 0,061 0,004 0,033 0,080 0,006 0,035 0,110 0,008 0,035 0,187 0,011 0,034 0,187 each side 0,009 0,009 each side 0,014

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SCREW PUMP 6-8 6-8 8 - 10 8 - 10 10 - 12

208 - 208,5

253 - 253,5

204,3 - 205

248,5 - 250

302,5 - 303,5 308 - 308,5

354,5 - 355,5 360 - 360,5

200

251

300

350

Diameter screw

Diameter wear bushing

ds

db

8 - 10

7-8

7-8

7-8

7-8

18 - 19

14 - 15

14 - 15

14 - 15

14 - 15

9 - 10

Densit

Cilld cast irion 7-8

ted

tec

Maximum admissible thickness of the screw helix until exchange

ts

Maximum admissible thickness of steel end flight until exchange

tes

Maximum admissible thickness of steel end flight with welded plating until exchange

Maximum admissible thickness of end flight with Densit application until exchange

ted

tesa

Maximum admissible thickness of end flight made of chilled cast iron until exchange

tec

9 - 10

9 - 10

7-8

6-7

6-7

5-6

Steel

tes

End flight

Wear limit

ge/gs Maximum admissible gap between end flight / screw and wear bushing

Diameter end flight

de

Legend:

Remark: The above values are indicated in mm.

100

152,9 - 153,6 156 - 156,5

ge/gs

151

db

4-6

99 - 100

de/ds

102 - 102,1

size:

Screw pump

Manufacturing mass

15 - 16

15 - 16

13 - 14

12 - 13

12 - 13

10 - 11

Steel with welded plating

tesa

10 - 11

8-9

8-9

6-7

6-7

5-6

ts

Screw

4.2.1.2 Wear limits

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4.2.2 General instructions for the installation of stuffing box packagings and the starting torque of the stuffing box gland When installing stuffing box packagings it should be ensured that the joints of the individual packing rings are offset 180° in relation to each other on installation in the stuffing box housing! The packagings and grease ring are carefully inserted in the stuffing box housing individually by hand with the help of the stuffing box gland (see Fig. 12a to 12c) until a noticeable resistance is felt. The nuts of the stuffing box gland are then tightened until a noticeable resistance occurs. A marking is now made on the nuts (e.g. using a waterproof pen), which allows correct tightening of the stuffing box gland to be checked. With an open-jawed spanner the nuts should now be tightened crosswise 1½ revolutions!

4.2.3 Dismounting and inspecting the stuffing box (size 100) When dismounting and inspecting the stuffing box packagings (Fig. 12 a) it is not necessary to remove the screw. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12.

Separate and dismount the stuffing box gland (41). Withdraw the grease packing (42) together with the packing rings (20) and the grease ring (19). Clean the grease packing (42), grease ring (19) and the wear bushing (21). Check the O-ring packing (11) and replace if necessary. Grease the wear bushing (21) thoroughly at the packing rings. Mount the grease packing (42). Replace the packing rings (20) if necessary. Grease the running tread of the packing rings thoroughly before installing. Mount the packing rings (20) together with the grease ring (19). Mount the gland (41) and tighten the packing only manually at the nuts (43). Prior to operation regrease the stuffing box at the relevant lubrication nipples (46). Before restarting the screw pump check the screw rotates smoothly. This should move freely without running on when the coupling is just turned by hand! After a running-in period of 2 hours the correct starting torque of the stuffing box should be adjusted as described under 4.2.2.

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Fig. 12 a: Stuffing box size 100 42/63

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Dismounting and inspecting the stuffing box (size 151) When dismounting and inspecting the stuffing box packagings (Fig. 12 b) it is not necessary to remove the screw. 1. 2. 3. 4. 5. 6. 7. 8. 9.

10.

Separate and dismount the stuffing box gland (41). Withdraw the packing rings (20) together with the grease ring (19). Clean the housing (44), grease ring (19) and the wear bushing (21). Grease the wear bushing thoroughly at the packing rings. Replace the packing rings (20) if necessary. Grease the running tread of the packing rings thoroughly before installing. Mount the packing rings (20) together with the grease ring (19). Mount the stuffing box gland (41) and tighten the packing only manually at the nuts (43). Prior to operation regrease the stuffing box at the relevant lubrication nipples (46). Before restarting the screw pump check the screw rotates. smoothly. This should move freely without running on when the coupling is just turned by hand! After a running-in period of 2 hours the correct starting torque of the stuffing box should be adjusted as described under 4.2.2.

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Fig. 12 b: Stuffing box size 151 44/63

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Dismounting and inspecting the stuffing box (size 200 - 350) When dismounting and inspecting the stuffing box (Fig. 12 c) it is not necessary to remove the screw. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

12.

Separate and dismount the stuffing box gland (41). Withdraw the stuffing box housing (44) using the forcing screws (45). Separate the stuffing box housing (44). Clean both sections of the housing. If necessary replace the wear ring (18). Grease the wear bushing (21) thoroughly at the packing rings. Also thoroughly grease the packing rings (20) on the running treads. Reassembly of the stuffing box is carried out in reverse order to dismounting. Mount the stuffing box gland (41) and tighten the packing only manually at the nuts (43). Prior to operation regrease the stuffing box at the relevant lubrication nipples (46). Before restarting the screw pump check the screw rotates. smoothly. This should move freely without running on when the coupling is just turned by hand! After a running-in period of 2 hours the correct starting torque of the stuffing box should be adjusted as described under 4.2.2.

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Fig. 12 c: Stuffing box size 200 - 350 46/63

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4.2.4 Dismounting of wear parts The wear parts (Fig. 13) are dismounted in the order given via the inspection opening (47) in the discharge box as soon as they are worn out. They should only be replaced by original spare parts by IBAU HAMBURG as this is the only way to ensure perfect functioning of the screw pump. A stock of these original spare parts should therefore always be kept by the customer. 4.2.4.1 Dismounting of the wear plate, end flight and nozzles 1. 2. 3. 4.

Remove the inspection cover (47), open the non-return valve (48) and secure carefully in this position. The wear plate (9) can now be removed from the non-return valve (7). The end flight (13) can now be removed from the screw using the end flight withdrawal device (49) supplied. The nozzles (6) can now be replaced.

4.2.4.2 Dismounting of the cone and wear bushings 1. 2. 3. 4. 5.

6. 7.

Remove the inspection cover (47), open the non-return valve (48) and secure carefully in this position. Take off the divided separating flange (50) from the side. Remove the O-ring (11) (only applies to screw pump size 150 - 200) Separate the wear ring (10) from the cone. With screw pumps size IB-D100 and IB-D350 then withdraw the cone (12) towards the inspection opening. With screw pumps size IB-D151 / 200 / 251 and 300 the discharge box has to be dismounted here to replace the cone and wear bushings. Remove the O-rings from the cone (only applies to screw pump size 100). Push out the wear bushings (15) after removing the plug (51) using a screwdriver. NOTE: In some cases material penetrates in between the bearing carriers in the screw pipe and the wear bushing due to a wear bushing already being worn through. In this case the screw then has to be dismounted (see also item 4.2.5 on page 49). With screw pumps size 300 and 350 it is helpful to also remove the discharge box as this allows work to be carried out more easily on the wear bushings. They can now be removed with a cut-off angle grinder to facilitate dismounting. However, this should be done with great care to ensure you do not cut too deeply and possibly damage the screw pipe! If marks have been caused on the bearing surfaces in the screw pipe when dismounting the wear bushings, they can be smoothed out before reinstallation with a fine-grain abrasive cloth.

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i

NOTE: On assembly all O-rings removed must be replaced without exception!

Note

For screw pumps size 100 and 151 the O-rings must be inserted in the cone (see 4.2.4) before remounting. For the screw pump size 200 the O-ring must be inserted after installation of the cone between the housing and the separating flange (see 4.2.4). The separating flange (50) is then affixed to the discharge box again. For screw pumps size 251 to 350 the O-rings must be inserted the cone (see 4.2.4). Only then is the separating flange (50) positioned and affixed to the discharge box. When the wear parts have been mounted again as described above, check the fit of the wear bushings through the tap hole (51) for the plug. Before starting the screw pump again, make sure the screw with the end flight rotates smoothly and without resistance in the wear bushings.

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Fig. 13 49/63

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4.2.5 Instructions for O-ring packings If an O-ring has to be replaced, it can be cut to size out of a round cord with a suitable diameter. Normally a round cord made of the material "Viton", which is heat-resistant up to +200° C, for the screw pump. At higher operating temperatures, special materials are used. For this reason consult IBAU HAMBURG about the material quality used before replacing the round cord. We also recommend stocking up with a sufficient quantity of the necessary round cord with the dimensions for each size of pump in good time before carrying out maintenance work.

i Note

NOTE: Whenever the equipment is dismantled, the O-ring installed must be replaced! When replacing the O-ring proceed as follows: •

Cut the round cord to the length of the dismounted O-ring, adding another 5-10mm.

•

Before installation check whether the edges of the groove for accommodating the O-ring are broken. If they have sharp edges, the new O-ring might become damaged, causing the O-ring packing to leak.

•

Knock the round cord carefully into the groove provided using a mallet (divergence from this see item 4.2.3 / Installation of cone and separating flange for screw pump sizes 100 to 350).

•

Cut the projecting ends of the round cord axially with a mitre of 45° so that the cut edge is not visible from the pressure side (Fig. 14).

Fig. 14 Pressure

i Note

ATTENTION! If a round cord has been cut too short, never try to adjust it by stretching it to the required length. "Stretching" will reduce the diameter of the round cord, impairing its sealing effect! •

As the adhesive for the joint between the two ends of the round cord Loctite 101® should be used. ATTENTION!

Unsuitable adhesives may soften the round cord!

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4.2.6 Dismounting of the screw The screw can be dismounted independently of the wear parts as follows (Fig 15): 1. 2. 3.

4. 5.

6. 7.

Draw back the motor with the coupling half until there is sufficient space for the screw shaft. Remove the coupling half from the screw shaft. Secure the shaft against uncontrolled rotation by placing the assembly aid (2, not included in IBAU HAMBURG delivery package) in place, or by removing the cover of the inlet box and using a wooden wedge. Remove the inspection cover (3) on the discharge box, open the non-return valve (4) and secure carefully in this position. Release the nuts (5 and 6) used to secure the screw axially with an openended spanner (not included in IBAU HAMBURG delivery package) (lefthand thread). The necessary width across flats are given in the table below. Take off the cup spring (7) and the thrust collar (8). Loosen the screw from the conical fit of the shaft bushing by striking the shaft end with a recoilless plastic hammer (9). After loosening the screw, pull it out carefully from the screw pipe in the conveying direction.

Pump type IB-D100 IB-D151 IB-D200 IB-D251 IB-D300 IB-D350

Width across flats 60 75 120 150 150 155

Recommended key length none 1.20 m 2.00 m 2.00 m 2.00 m 2.00 m

ATTENTION! Use an open-ended spanner when unscrewing and tightening the nuts on the screw. For accident-prevention reasons, the use of other tools such as gaspipe pliers is forbidden. ATTENTION! If a plastic hammer is not used, the end of the screw should be protected from damage by the hammer blows with a piece of hard wood or copper !

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Before reinstalling, thoroughly clean the cone of the screw (10) and apply copper paste. Then remount the screw. Tighten the nut (6) until the cup spring (7) is lying flat against the shoulder ring (11). Then tighten with the second nut (5). Then mount the coupling half on the pump side (the claw of the coupling normally sits on the screw shaft and only on the motor shaft in exceptional cases). Advance the motor with the second coupling half and align the coupling according to item 3.2.4. The information given by the manufacturer of the coupling (here see separate operating manual for coupling) should be taken into consideration as regards the coupling backlash to be adjusted.

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Fig. 15

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For screw dismounting dimension see table II on page 20

4.2.7 Dismounting of the main components of the screw pump Should it become necessary to replace a main component of the screw pump, e.g. the bearing unit, inlet box, screw pipe or discharge box, proper pinning must be ensured on subsequent installation of the new component. After alignment of the new component perform the necessary new pinning diagonally in relation to the existing pins. If following an explosion it is necessary to replace one or more components in a screw pump pressure surge-resistant to 10 bar, only original components which have been subjected to a water pressure test by IBAU HAMBURG beforehand may be used.

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5.0.0 Troubleshooting 1.

The back pressure gauge indicates a pulsating back pressure in the conveying line, possibly also causing obstruction of the conveying line. Check: a) Has anything changed in the piping system or at the receiving point? b) Has the material quantity to be fed in been changed (e.g. greater than the max. conveying capacity calculated)? c) Is the compressed air supply unit of the screw pump working properly (e.g. conveying capacity smaller than calculated)? d) Is there a piping section slanting upwards in the conveying direction? e) Has there been an increase in the share of coarse particles in the material flow? ---------------------------------------------------------------------------------------------

2.

The conveying capacity of the screw pump has fallen and the material flow increases in the pump surge hopper. Check: a) Has the sealing air pressure been set correctly for the specific material flow (cf. 4.1.0 - Spring tube pressure gauge for sealing air pressure)? b) Is the venting of the pump surge hopper functioning properly? i.e. there is a slight negative pressure in the pump surge hopper (cf. 3.1.0 - General instructions for assembly)? c) Are the screw and/or wear bushings heavily worn, thus causing a major increase in the gap dimension? d) Are the wear ring and/or valve plate of the non-return valve heavily worn so that the tightness of the non-return valve is no longer ensured? e) Is the quantity of material fed in greater than the conveying capacity of the screw pump as designed? ---------------------------------------------------------------------------------------------

3.

The bearings of the screw pump become too hot (temperature > +80° C). Check: a) Is the oil level in the bearing unit correct (cf. 4.2.0 – Maintenance)?

b) Was the right oil quality filled in? If necessary, change the oil. c) Does the running noise of the bearings indicate damage? d) Has material possibly got into the bearing unit when blowing out bulk material from the stuffing box? e) Has the temperature of the material flow increased? With material flow temperatures > +130° C the use of an oil cooler is necessary. ---------------------------------------------------------------------------------------------

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4.

Oil is oozing out of the bearing unit. Check: a) b) c) d) e)

Is the oil level in the bearing unit too high? Is one of the oil drain holes in the bearing unit blocked? Is the O-ring packing of the bearing covers working properly? Are the felt ring seals of the bearing unit working properly? If felt ring seals have been replaced, has the joint of the felt ring been installed downwards? ---------------------------------------------------------------------------------------------

5.

There is a leak in the stuffing box and dust-laden air is blown out. Check: a) Is there overpressure in the pump surge hopper? Check the functioning of the dedusting system and the state of the dedusting pipe to the pump surge hopper! b) Determine the state of the stuffing box packagings and wear bushing (too rough due to wear?) on the screw shaft. NOTE: To restore the proper functioning of the stuffing box after blowing out material new packaging will be required here at all events!

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6.0.0 Spare parts / wear parts When ordering spare parts, take care to indicate the data on this type plate accurately: The type plate is fixed on the inspection cover of the screw pump. The type designation of the screw pump is followed by the machine number (e.g. IB-D350 / 6897). Please always give this number when ordering spare parts.

Type Com.-No. Item-No.

Further data can be taken from the following table (see next page):

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Table of spare parts and wear parts Item

Spare part

1 2 3 4 5 6 7 7a 8 9 9a 10 11 11 a 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 41 42 44

Wear part Transition piece

Seal Back pressure gauge Rotary shaft seal Stuffing box packings Set of nozzles Non-return valve Non-return valve ** Valve lever Wear plate Wear plate ** Wear ring O-ring cord* O-ring cord*,** Cone End flight Wear bushing (hardened) Set of wear bushings Air pressure gauge Screw Wear ring Grease ring Stuffing box packings Wear bushing Felt ring Thermometer Floating bearing Seal-off air pressure gauge Oil paddle Fixed bearing Cup spring Hexagonal nut Oil level indicator Wear ring bushing ** Locating cone ** Stuffing box cover Grease packing Stuffing box housing

*

see 4.2.4 - instructions for O-ring packing

**

These spare and wear parts belong exclusively to the wear bushing type (see Fig. 17)

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Fig. 16

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Detail see Fig.16b page 66

Detail see Fig.16a page 65

Fig. 16 a: Bearing unit and stuffing box 60/63

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Fig. 16 b Standard discharge box 61/63

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Fig. 17: Detail of discharge box (wear bushing type)

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7.0.0 Coupling For adjustment of the coupling please take note of the operating manual supplied separately by the coupling manufacturer.

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