Idex Wright Flow Technologies RTPe Series Manual de usuario

INSTALLATION,OPERATION

AND

MAINTENANCE MANUAL

FOR THE

RANGE OF PUMPS

Page | 1 
 
 
INSTALLATION, OPERATION AND MAINTENANCE MANUAL 
FOR RTPeTM ROTARY LOBE PUMPS. 
0 SAFETY INFORMATION. 3 
1 RISK ASSESSMENT RELATING TO THE USE OF WRIGHT FLOW TECHNOLOGIES LIMITED RTPETM 
ROTARY LOBE PUMPS. 6 
0 INTRODUCTION. 7 
1 GENERAL. 7 
2 WRIGHT FLOW TECHNOLOGIES LIMITED DISTRIBUTORS. 7 
3 RECEIPT AND STORAGE. 7 
4 CLEANING. 8 
5 PUMP MODEL DESIGNATION. 8 
5.1 ATEX INFORMATION 9 
0 GENERAL. 11 
1 RTPETM PUMPING PRINCIPLE. 11 
2 RTPETM OPERATING PARAMETERS. 12 
3 SYSTEM DESIGN AND INSTALLATION. 12 
3.2 CLEANING IN PLACE. 15 
4 START-UP PROCEDURE. 16 
5 SHUTDOWN PROCEDURE. 17 
6 ROUTINE MAINTENANCE –NON ATEX UNITS. 17 
6.1 ADDITIONAL ROUTINE MAINTENANCE –ATEX UNITS. 18 
7 INTEGRAL PRESSURE RELIEF VALVE. 19 
0 RTPETM PUMP DISASSEMBLY AND ASSEMBLY. 21 
1 DISASSEMBLY. 22 
1.1 FRONT COVER AND ROTOR REMOVAL 22 
1.2 GEARBOX DISASSEMBLY 23 
1.3 SHAFT DISASSEMBLY. 25 
2 ASSEMBLY. 26 
2.1 GEARBOX &ROTORCASE ASSEMBLY, 26 
2.2 SHAFT ASSEMBLY –RTPE20 27 
2.3 TIMING. 28 
2.4 SETTING THE ROLLING TORQUE. 30 
2.5 ROTOR CLEARANCES. 30 
3 PRODUCT SEAL FITTING AND REMOVAL. 31 
3.1 GENERAL PROCEDURES FOR INSTALLING SEALS. 31 
3.2 RTPE20 COMPOSITE O-RING SEAL REMOVAL AND INSTALLATION. 32 
3.3 RTPE20 MECHANICAL SEAL. 34 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Page | 2

5.0 SPECIFICATIONS. 35

5.1 CLEARANCE CHART 35

5.2 FASTENERS &TORQUE SETTINGS. 36

5.3 LUBRICANTS. 37

5.4 TOOL LIST. 37

5.5.1 RTPE20 FOUNDATION DIMENSIONS –BASIC PUMP METRIC (1” FEMALE DRIVE) 38

5.5.2 RTPE20 FOUNDATION DIMENSIONS –BASIC PUMP INCH (1” FEMALE DRIVE) 39

5.6 TYPICAL BASIC PUMP BUILD (RTPE20 SHOWN) 40

5.7 TROUBLE SHOOTING. 41

5.8 RTPETM SERVICE HISTORY. 43

5.9 NOTES. 44

Page | 3

1.0 Safety Information.

INCORRECT INSTALLATION, OPERATION, OR MAINTENANCE OF

EQUIPMENT MAY CAUSE SEVERE PERSONAL INJURY OR DEATH

AND/OR EQUIPMENT DAMAGE THAT MAY INVALIDATE THE

WARRANTY.

THIS INFORMATION MUST BE READ FULLY BEFORE BEGINNING

INSTALLATION, OPERATION, OR MAINTENANCE AND MUST BE KEPT

WITH THE PUMP. ONLY SUITABLY TRAINED OR QUALIFIED PERSONS

SHOULD UNDERTAKE INSTALLATION AND MAINTENANCE.

DANGER

DO NOT OPERATE PUMP IF:

- The front cover is not installed correctly.

- Any guards are missing or incorrectly installed.

- The suction or discharge piping is not connected.

DO NOT place fingers, etc. into the pumping chamber or its connection ports

or into any part of the gearbox if there is ANY possibility of the pump shafts

being rotated. A severe injury will occur.

DO NOT exceed the pumps rated pressure, speed, and temperature, or

change the system/duty parameters from those for which the pump was

originally supplied, without confirming its suitability for the new duty. Running

the pump outside of its operations envelope can cause mechanical contact,

excessive heat and can represent a serious risk to health and safety.

Installation and operation of the pump must always comply with health and

safety regulations.

A device must be incorporated into the pump, system, or drive to prevent the

pump from exceeding its stated duty pressure. It must be suitable for both

directions of pump rotation where applicable. Do not allow the pump to

operate with a closed/blocked discharge unless a pressure relief device is

incorporated. If an integral relief valve is incorporated into the pump, do not

allow re-circulation through the relief valve for extended periods; (refer to

section 3.7).

Danger - Failure to follow the listed

precautionary measures may result in

serious injury or death. Areas of

potential risk are identified by the

following symbol:

Warning - Safety instructions which shall

be considered for reasons of safe

operation of the pump or pump unit and/or

protection of the pump or pump unit itself

are marked by the sign:

WARNING

Page | 4

The mounting of the pump or pump unit should be solid and stable. Pump

orientation must be considered in relation to drainage requirements. Once

mounted, shaft drive elements must be checked for correct alignment. Rotate

pump shaft by at least one full revolution to ensure smoothness of operation.

Incorrect alignment will produce excessive loading, create high temperatures

and increased noise emissions. Do not use any drive arrangements, which

cause side loading of the drive shaft. It may also be necessary to earth the

pump head to avoid the build-up of a potential charge that could cause a

spark.

The installation must allow safe routine maintenance and inspection (to

replenish lubricants, check for leakage, monitor pressures, etc.) and provide

adequate ventilation necessary to prevent overheating.

Fill all gearboxes with the recommended grades and quantities of lubricant;

(refer to section 5.3). Beware of over/under filling the gearbox as this could

cause the pump to overheat and severe mechanical damage to occur.

Before operating the pump, be sure that it and all parts of the system to which

it is connected are clean and free from debris and that all valves in the suction

and discharge pipelines are fully opened. Ensure that all piping connecting to

the pump is fully supported and correctly aligned with its relevant connections.

Misalignment and/or excess loads will cause severe pump damage. This

could result in unexpected mechanical contact in the pump head and has the

potential to be a source of ignition.

Be sure that pump rotation is correct for the desired direction of flow; (refer to

section 3.1).

Do not install the pump into a system where prolonged run dry will occur (i.e.

without a supply of pumped media). Mechanical seals require a thin fluid film

to lubricate the seal faces. Dry running will cause excessive heat and seal

failure. Composite O-ring are dry run capable for a limited time.

Pressure gauges/sensors are recommended, next to the pump suction and

discharge connections to monitor pressures.

Caution must be taken when lifting the pump. Suitable lifting devices should

be used as appropriate. Lifting eyes installed on the pump must only be used

to lift the pump, not pump with drive and/or baseplate. If the pump is

baseplate mounted, the base plate must be used for all lifting purposes. If

slings are used for lifting, they must be safely and securely attached. For

weights of the bare shaft, pumps refer to section 5.5.1 & 5.5.2

WARNING

Page | 5

DO NOT attempt any maintenance or disassembly of the pump or pump unit

without first ensuring that:

-The pump is fully isolated from the power source (electric, hydraulic,

pneumatic).

- The pumping chamber, pneumatic relief valve and any shaft seal

support system are depressurised and purged.

- Any temperature control devices (jackets, heat-tracing, etc.) are fully

isolated, that they are depressurised and purged, and components are

allowed to reach a safe handling temperature.

Use only genuine Wright Flow Technologies parts.

All certification, standards, guarantees & warranties originally supplied with

this pump will be invalidated by the use of non-genuine Service Parts.

DO NOT attempt to dismantle a pressure relief valve which has not had the

spring pressure relieved, is still connected to a pressurised gas/air supply or is

mounted on a pump that is operating. Serious personal injury or death and/or

pump damage may occur.

Use only genuine Wright Flow Technologies parts.

All certification, standards, guarantees & warranties originally supplied

with this pump will be invalidated by the use of non-genuine Service

Parts.

DO NOT loosen or undo the front cover, any connections to the pump, shaft

seal housings, temperature control devices, or other components, until sure

that such action will not allow the unsafe escape of any pressurised media.

Pumps and/or drives can produce sound power levels exceeding 85-dB (A)

under certain operating conditions. When necessary, personal protection

against noise must be taken.

Avoid any contact with hot parts of pumps and/or drives, which may cause

injury. Certain operating conditions, temperature control devices (jackets,

heat-tracing, etc.), bad installation, or poor maintenance can all promote high

temperatures on pumps and/or drives.

When cleaning, either manually or by CIP method, the operator must ensure

that a suitable procedure is used in accordance with the system requirements.

During a CIP cleaning cycle, a pump differential pressure of between 2 and 3

bar (30 to 45 psi) is recommended to ensure suitable velocities are reached

within the pump head. The exterior of the pump should be cleaned

periodically.

The surface temperature of the pump is also dependent on the temperature of

the pumped medium.

WARNING

Page | 6

1.1 Risk assessment relating to the use of Wright Flow Technologies Limited

RTPeTM rotary lobe pumps.

Note:- For a feature to be suitable for an application, The feature must be fit for its

designated purpose and also suitable for the environment where it is to be installed.

Page | 7

2.0 Introduction.

2.1 General.

RTPeTM rotary lobe pump is manufactured by Wright Flow Technologies

Limited a unit of the IDEX Corporation.

This manual includes all the necessary information for RTPeTM pumps and

should be read prior to beginning installation, operation and maintenance.

Should you require any additional information regarding the RTPeTM pumps

contact Wright Flow Technologies Limited or their local authorised distributor

(refer to section 2.2).

When asking for assistance, please provide the pump model and serial

number. This information can be obtained from the pump nameplate, which is

located on the side of the pump gearbox, see fig 2. Should the nameplate be

unreadable or missing, the pump serial number is also stamped on either side

of the rotorcase, see fig 3.

If the system or product characteristics are to be changed from the original

application for which the pump was selected, Wright Flow Technologies

Limited or their authorised distributor should be consulted to ensure the pump

is suitable for the new application.

2.2 Wright Flow Technologies Limited Distributors.

Wright Flow Technologies Limited distributes its products internationally via a

network of authorised distributors. Throughout this manual where reference is

made to Wright Flow Technologies Limited, service and assistance will also be

provided by any Wright Flow Technologies Limited authorised distributor for

RTPeTM pumps.

2.3 Receipt and Storage.

Upon receipt of the pump, immediately examine it for any signs of visible

damage. If any damage is noted, contact Wright Flow Technologies Limited or

your Wright Flow Technologies Limited distributor and clearly mark upon the

carriers paperwork that the goods have been received in a damaged condition,

with a brief description of the damage.

If the pump is not required for immediate installation then it should be stored

in a clean, dry environment. It is recommended that storage temperature

should be between –10°C and 40°C (14°F and 105°F).

Page | 8

2.4 Cleaning.

The RTPeTM pump series is suitable for both manual cleaning and CIP

(Cleaning In Place), refer to section 3.3.2.

The strategic positioning of the product seals, combined with their ease of

access provides an arrangement that can be more effectively cleaned by both

manual and CIP procedures.

It is recommended that the exterior of the pump be cleaned periodically.

2.5 Pump Model Designation.

Fig 1 Designation of pump models

This information, together with the pump serial number, should be provided

when requesting additional information on the pump or when ordering spare

parts. The pump serial number is stamped on the pump nameplate(Fig 2) and

the rotorcase, (Fig 3). For the maximum operating pressures, temperatures

and speeds refer to section 3.2.

RTPe

0100

PUMP

MODEL

DISPLACEMENT

(1 LTRS/REV.)

MODEL

SIZE

MAX.PRESSURE

(BAR)

Page | 9

Page 9

2.5.1 ATEX Information

ATEX Pump Requirements

Mechanical seals are a source of heat and must never be allowed to run dry.

We would recommend provision be made to ensure that there is always flow

or fluid around the pump seals. If there is a risk of the supply being

interrupted, then a temperature monitoring system must be applied to ensure

the pump does not exceed the Atex rating. The surface temperature of the

pump is dependent on the temperature of the pumped fluid and a due account

of this should be taken whilst undertaking your risk assessment of the

installation. These pumps are Atex rated T3.

Only use genuine spare parts that have been designed and verified Atex

compliant by Wright Flow Technologies, failure to use genuine spare parts will

invalidate the Atex certification.

Pumps that have the Atex certification will have an earthing point on the front

cover, this needs to be electrically earthed before use.

The service and maintenance intervals are increased on certified Atex units,

refer to section 3.6.1 for the required routine maintenance. Failure to maintain

the pumps to these intervals will result in the Atex certification being

invalidated.

When installing the unit make sure so far as reasonably practicable that the

pump is aligned within 5 degrees to the horizontal –failure to align the unit

could adversely affect the gearbox lubrication and could cause heat to build

up.

It is the end user’s responsibility to ensure that the Atex rating of the

equipment supplied meets the requirements of the installation.

2.5.2 Equipment Groups & Categories

The RTP pump range has been rated as

WARNING

Category 2

Temperature Class T3

Unit is suitable for environments

containing dust or gas G/D

Group II.

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