Wright flow Classic+ Manual de usuario

NSTALLATION

PERATION

AINTENANCE

ANUAL

Range of Pumps

Page 2

Installation, Operation & Maintenance Manual

For The Classic+ Range Of Rotary Lobe Pumps

1.0

Safety Information. 5

1.1

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

Classic+ rotary lobe pumps and pump units in potentially explosive

atmospheres. 8

2.0

Introduction. 9

2.1

General. 9

2.2

Wright Flow Technologies Limited Distributors. 9

2.3

Receipts and Storage. 9

2.4

Cleaning. 10

2.5

Pump Model Designation. 10

2.5.1

ATEX Information 11

2.5.2

Equipment Groups & Categories 11

2.6

Pump Model and Serial Number. 12

3.0

General. 14

3.1

Classic+ Pumping Principal. 14

3.2

Classic+ Range Operating Parameters. 15

3.3

System Design. 17

3.3.1

System Design and Installation. 17

3.3.2

Installations with CIP Systems. 19

3.4

Start Up Procedure. 20

3.5

Shutdown Procedure. 21

3.6

Routine Maintenance. 22

3.7

Heating and Cooling Jackets 22

3.8

Integral Pressure Relief Valves 25

3.8.1

Setting and Operating Spring Loaded Valves 26

3.8.2

Setting and Operating Air Loaded Integral Pressure Relief Valves 27

4.0

Classic+ Disassembly and Assembly. 30

4.1

CP10, CP20 and CP30 Pump - Disassembly and Assembly. 32

4.1.1

CP10, CP20 and CP30 Front Cover and Rotor Removal 32

4.1.2

CP10, CP20 and CP30 Rotorcase Removal 35

4.1.2.1

CP10, CP20 and CP30 Rotorcase Removal for Pumps fitted with Single Un-

Flushed Mechanical Seals and Single O-Ring Seals 35

4.1.2.2

CP10, CP20 and CP30 Rotorcase Removal for Pumps Fitted with Single

Flushed or Double Flushed Mechanical Seals. 37

4.1.3

CP10, CP20 and CP30 Gearbox Disassembly 38

4.1.3

CP10, CP20 and CP30 Gearbox Assembly 42

4.1.4

CP10, CP20 and CP30 Rotorcase, Rotor and Front Cover Assembly 46

4.2

CP40 Pumps - Disassembly and Assembly 48

Page 3

4.2.1

CP40 Front Cover and Rotor Removal 48

4.2.2

CP40 Rotorcase Removal 50

4.2.2.1

CP40 Rotorcase Removal for Pumps fitted with Single Un-flushed

Mechanical Seals and O-Ring Seals 50

4.2.2.2

CP40 Rotorcase Removal for Pumps Fitted with Single Flushed or Double

Flushed Mechanical Seals. 52

4.2.4

CP40 Gearbox Assembly 55

4.2.5

CP40 Rotorcase, Rotor and Front Cover Assembly 58

4.3

CP50 Pumps - Disassembly and Assembly 59

4.3.1

CP50 Front Cover and Rotor Removal 59

4.3.2

CP50 Rotorcase Removal 61

4.3.2.1

CP50 Rotorcase Removal for Pumps fitted with Single Un-flushed

Mechanical Seals and O-Ring Seals 61

4.3.2.2

CP50 Rotorcase Removal for Pumps fitted with Single Flushed and Double

Flushed Mechanical Seals 63

4.3.3

CP50 Gearbox Disassembly 64

4.3.4

CP50 Gearbox Assembly 66

4.3.5

CP50 Rotorcase, Rotor and Front Cover Assembly 69

5.0

Classic+ Mechanical Seal Removal & Replacement. 71

5.1

General Procedures for Installing Mechanical Seals. 71

5.2

CP10, CP20, CP30 and CP40 Mechanical Seals 72

5.2.1

CP10, CP20, CP30 and CP40 Single Mechanical Seal Removal 72

5.2.2

CP10, CP20, CP30 and CP40 Single Mechanical Seal Replacement 73

5.2.3

CP10, CP20, CP30 and CP40 Single Flushed Mechanical Seal Removal 74

5.2.4

CP10, CP20, CP30 and CP40 Single Flushed Mechanical Seal Replacement 75

5.2.5

CP10 Double Flushed Mechanical Seal Removal 76

5.2.6

CP10 Double Flushed Mechanical Seal Replacement 77

5.2.7

CP20, CP30 and CP40 Double Flushed Mechanical Seal Removal 78

5.2.8

CP20, CP30 and CP40 Double Flushed Mechanical Seal Replacement 79

5.3

CP50 Mechanical Seals 80

5.3.1

CP50 Single Mechanical Seal Removal 80

5.3.2

CP50 Single Mechanical Seal Replacement 80

5.3.3

CP50 Single Flushed Mechanical Seal Removal 81

5.3.4

CP50 Single Flushed Mechanical Seal Replacement 81

5.3.5

CP50 Double Flushed Mechanical Seal Removal 82

5.3.6

CP50 Double Flushed Mechanical Seal Replacement 83

6.0

Classic+ Single O-Ring Seals 84

6.1

General Procedures for Fitting Single O-Ring Seals 84

6.2

Oring Seals for CP10, CP20, CP30 and CP40 Pumps 85

6.2.1

CP10, CP20, CP30 and CP40 Oring Seal Assembly and Removal 85

6.3

O-Ring Seal for CP50 Pump 86

6.3.1

CP50 O-Ring Seal Assembly and Removal 86

Page 4

6.4

Classic+ Packed Gland Seals 87

6.4.1

General Procedures For Fitting Packed Gland Seals 87

6.5

Packed Gland Seals - CP10, CP20, CP30 and CP40 Series Pumps 88

6.5.1

Packed Gland Seal Removal 88

6.5.2

Packed Gland Seal Replacement 89

6.5.3

Flushed Packed Gland Seal Removal 89

6.5.4

Flushed Packed Gland Seal Replacement 90

6.6

Packed Gland Seals - CP50 Series Pumps. 91

6.6.1

Packed Gland Seal Removal 91

6.6.2

Packed Gland Seal Replacement 91

6.6.3

Flushed Packed Gland Seal Removal 92

6.6.4

Flushed Packed Gland Seal Replacement 93

6.6.5

Seal Conversion to Packed Gland (With Shaft Sleeve) 93

6.6.6

Seal Conversion to Flushed Packed Gland (With Shaft Sleeve) 94

7.0

Flushed Product Seals Auxiliary Services 95

7.1

Single Mechanical Seal (for Low-Pressure Quench or Flush) 95

7.2

Double Mechanical Seal (for High Pressure Flush) 96

7.3

Flushed Packed Gland Seal 96

8.0

Specifications 97

8.1

Clearance Chart 97

8.2

Fasteners & Torque Settings. 99

8.3

Lubricants. 100

8.4

Material Specifications. 100

8.5

Foundation Dimensions and Weights. 101

8.6

Rectangular Inlet 103

8.7

Trouble Shooting. 104

8.8

Typical Noise Emission Data - CP10, CP20 and CP30 Pumps. 105

8.9

Typical Noise Emission Data – CP40 and CP50 Pumps. 106

8.10

Service History. 107

8.11

Tool List. 108

9.0

Notes. 110

Page 5

1.0 Safety Information.

INCORRECT INSTALLATION, OPERATION, OR MAINTENANCE OF

EQUIPMENT MAY CAUSE SEVERE PERSONAL INJURY OR DEATH

AND/OR EQUIPMENT DAMAGE AND MAY INVALIDATE THE WARRANTY.

THIS INFORMATION MUST BE READ FULLY BEFORE BEGINNING

INSTALLATION, OPERATION, OR MAINTENANCE AND MUST BE KEPT

WITH THE PUMP. SUITABLY TRAINED OR QUALIFIED PERSONS MUST

UNDERTAKE ALL INSTALLATION AND MAINTENANCE ONLY.

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. 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

of the pump outside of its operation 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 exceeding its stated duty pressure. It must be suitable for both

directions of pump rotation where applicable. Do not allow 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 3.8).

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

Danger - Failure to follow the listed

precautionary measures may result

in serious injury or death are

identified by the following symbol:

WARNING

Page 6

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

Pump orientation must be considered in relation to drainage/cavity

ventilation 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 and will create high temperatures and

increased noise emissions. It may also be necessary to earth the pump

head to avoid the build up of a potential charge difference 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 3.4 and 8.3). Beware of over/under filling the gearbox as this

could cause the pump to overheat and 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 an ignition source.

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

section 3.4).

Do not install the pump into a system where it will run dry (i.e. without a supply

of pumped media) unless it is equipped with a flushed shaft seal arrangement

complete with a fully operational flushing system. Mechanical seals require a

thin fluid film to lubricate the seal faces. Dry running can cause excessive heat

and seal failure.

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 base plate. If pump is base plate

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 bare

shaft pumps refer to section 8.5.

WARNING

Page 7

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.

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.

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. Typical noise emission data can be found in

section 8.8 and 8.9.

Avoid any contact with hot parts of pumps and/or drives that 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 and 45 psi) is recommended to ensure suitable velocities are reached

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

periodically.

Surface temperature of pump is also dependent on the temperature of

pumped medium.

WARNING

Page 8

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

Classic+ rotary lobe pumps and pump units in potentially explosive

atmospheres.

Source Of Hazards Potential Hazards

Frequency Of

Hazards Recommended Measures

Unvented cavities Build up of explosive gas

Very Rare

Ensure that pump is totally filled.

Consider mounting ports vertically.

See Chapter 1.0

Rotorcase / Rotors / Front

Cover Unintended mechanical

contact

Rare

Ensure that operating pressures are

not exceeded. Ensure that suffcient

NPSH to prevent cavitation. See

Chapter 1.0/3.3.1 Service plan.

Pump external surfaces excess temperature.

Electrostatic charging

Rare

User must ensure temperature limits.

Do not overfill gearboxes with

lubricant. Provide a ground contact

for pump. See Chapter 1.0 /

Service

plan.

Cover 'O' ring

Pump liquid leakage. Build

up of explosive gas.

Very Rare

Check selection of elastomers are

suitable for application. Ensure cover

retaining nuts are tight. Service plan.

Pump casing / cover

Pump liquid leakage. Build

up of explosive gas.

Very Rare

Stainless steel, Corrosion resistant.

Shaft seals

excess temperature.

Unintended mechanical

contact.

Leakage.

Build up of explosive gas.

Rare

Selection of seal system must be

suitable for application.

See Chapter

5.0. Service plan. Seals must never

run dry.

Auxiliary system for shaft

sealing

Pump liquid leakage. Build

up of explosive gas.

Rare

Selection of auxiliary seal system

must be suitable for application.

Seals must never run dry.

Rotation direction test Excess temperature

Very Rare

If flushed seals are installed ensure

that flush is applied to seal

assemblys. Only allow pump to run

for minimum period - just a few

seconds.

Closed valve condition Excess Temperature.

Excess Pressure.

Mechanical contact.

Rare

Can cause excessive pressue, heat

and mechanical contact. See

Chapter 1.0

Shaft Random induced current

Very Rare

Provide a ground contact for pump.

See Chapter 1.0.

Mechanical shaft coupling

(Torque Protection)

Temperature from friction

Sparks from break up of

shear pins.

Electrostatic charging

Rare

Coupling selection must suit

application. See Chapter 1.0.

Mechanical shaft coupling

(standard)

Break up of spider.

Unintended mechanical

contact.

Electrostatic charging

Rare

Coupling selection must suit

application. Service plan. See

Chapter 1.0.

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 9

2.0 Introduction.

2.1 General.

Classic+ rotary lobe pumps are manufactured by Wright Flow Technologies

Limited, a unit of the IDEX Corporation.

This manual includes all the necessary information for the Classic+ and

should be read prior to beginning installation, operation, or

maintenance.

Should you require any additional information regarding the Classic+

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 cover, refer to section

2.6.

Should the nameplate be unreadable or missing, the serial number is also

stamped on either side of the rotorcase refer to section 2.6.

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 Classic+.

2.3 Receipts 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

damage.

Page 10

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°and 40°C (14°F and 105°F).

Further to the above, if the pump is not intended for installation or use within

18 months or more then refer to Wright Flow Technologies Limited, or the

Wright Flow Technologies Limited authourised distributor for storage

recommendations.

2.4 Cleaning.

The Classic+ pump series is suitable for both manual cleaning and CIP

(Cleaning In Place), refer to section 3.3.2.

It is recommended that the exterior of the pump be cleaned periodically with a

non-aggressive, non-abrasive cleaning solution.

2.5 Pump Model Designation.

The designations of pump models in the Classic+ range are as follows:

CP10/0005/12 CP20/0020/12 CP30/0069/12 CP40/0180/12 CP50/0351/12

CP10/0008/08 CP20/0031/07 CP30/0113/07 CP40/0250/07 CP50/0525/08

CP10/0011/05

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 and the rotorcase, (refer to section 2.6, Figs 2 and 3).

For the maximum operating pressures, temperatures and speeds refer

to section 3.2, Fig 6.

Fig 1 CP designated models only.

0069

UMP

ANGE

ISPLACEMENT

(

LTRS

REV

)

ODEL

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RESSURE

(

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