Related Manuals for Idex Wright Flow Technologies RTP Series
Summary of Contents for Idex Wright Flow Technologies RTP Series
- Page 1 NSTALLATION PERATION AINTENANCE ANUAL ANGE OF UMPS...
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Page 2: Table Of Contents
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR RTP ROTARY LOBE PUMPS. SAFETY INFORMATION. ISK ASSESSMENT RELATING TO THE USE OF RIGHT ECHNOLOGIES IMITED ROTARY LOBE PUMPS AND PUMP UNITS IN POTENTIALLY EXPLOSIVE ATMOSPHERES INTRODUCTION. ENERAL RIGHT ECHNOLOGIES IMITED ISTRIBUTORS ECEIPT AND TORAGE LEANING ODEL... - Page 3 4.3.2.1 RTP20 O- # 61151). 39 RING EMOVAL AND INSTALLATION ORDERS 4.3.3 RTP20 M ECHANICAL 4.3.4 RTP30 C LASS YGIENIC ECHANICAL 4.3.5 RTP30 C LASS YGIENIC ECHANICAL 4.3.6 RTP30 S TANDARD ADIAL 4.3.7 RTP30 O- RING SPECIFICATIONS. LEARANCE HART & T ASTENERS ORQUE ETTINGS...
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Page 4: Safety Information
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. - Page 5 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.
- Page 6 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.
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Page 7: Risk Assessment Relating To The Use Of Wright Flow Technologies Limited Rtp Rotary Lobe Pumps And Pump Units In Potentially Explosive Atmospheres
Risk assessment relating to the use of Wright Flow Technologies Limited RTP rotary lobe pumps and pump units in potentially explosive atmospheres. -
Page 8: Introduction
Introduction. General. rotary lobe pump is manufactured by Wright Flow Technologies Limited a unit of the IDEX Corporation. This manual includes all the necessary information for RTP pumps and should be read prior to beginning installation, operation, or maintenance. Should you require any additional information regarding the RTP... -
Page 9: Cleaning
Cleaning. The RTP pump series is suitable for both manual cleaning and CIP (Cleaning In Place), refer to section 3.3.2. The product seals are mounted directly behind the rotors and are designed and positioned to minimise product entrapment and maximise the effects of cleaning. -
Page 10: Atex Information
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. - Page 11 The Atex rating is displayed on the pump nameplate see fig 2 Fig 2 Nameplate. Pump Model and Serial Number. Should you require any information regarding your RTP rotary lobe pump contact Wright Flow Technologies Limited or your Wright Flow Technologies Limited distributor, providing the pump model and serial number as stated on the pump nameplate, see Fig 2 in section 2.5.2, which is fixed to the pump gearbox cover.
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Page 12: General
General. Pumping Principle. The pumping action of the rotary lobe pump principle is generated by the contra-rotation of two pumping elements (rotors) within a chamber (rotorcase), Fig 4. The shaft assemblies comprise of, the shaft support bearings and the timing gears. The gears transfer the energy from the drive shaft to the driven shaft, synchronising the rotors such that they rotate without contact with each other. -
Page 13: Rtp Tm Operating Parameters
Operating Parameters. Fig 5 Operating Parameters RTP20 Nominal Connection Max-Diff. Maximum Theoretical Displacement Size Pressure Speed Temp Temp Imp.gal US gal / Litre/ rev inches bar psi rev/min /100 rev 100 rev 1.00 21.9 26.4 50 or 75 2 or 3 1000 RTP30 Nominal Connection... - Page 14 fittings to minimise restricting product flow to the pump. The following should be considered at the design stage of any system Be sure ample room is provided around the pump to allow for: Access to the pump and drive for routine inspection and maintenance, i.e. ...
- Page 15 Observing the following general guidelines should ensure the best possible suction condition is created. Suction piping is at least the same diameter as the pump connections. The length of suction piping is kept to the absolute minimum. The minimum number of bends, tees and pipework restrictions are used. ...
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Page 16: Installation With Cip Systems
Where motor mounting options are to be installed follow the manufactures recommended guidelines. However, when installing a pump complete with base and drive the following guidelines must be observed: The preferred drive arrangement for any rotary lobe pump is in-line direct coupled. ... -
Page 17: Start-Up Procedure
Start-Up Procedure. Check that all piping and associated equipment are clean and free from debris and that all pipe connections are secure and leak free. For pumps installed with flushed product seals check that all auxiliary services are in place and connected and provide sufficient flow and pressure for flushing purposes, refer to product seal section 4.3. -
Page 18: Shutdown Procedure
Ensure product is available at the inlet before starting the pump. This is very important for pumps installed with un-flushed product seals, as these sealing arrangements must never be allowed to run dry. Before beginning operation, it is considered a good practice to momentarily start/stop the pump to check the direction of rotation and ensure that the pump is free of obstructions. -
Page 19: Additional Routine Maintenance - Atex Units
3.6.1 Additional Routine Maintenance – Atex units. Grease Check for any signs of lubricant leakage on startup. Check for any signs of overheating. Low maintenance gearbox, factory filled with EP 00 semi-fluid grease. The grease should not require replacement during the lifetime of the bearings or until 14,000 hours of operation. -
Page 20: Heating And Cooling Devices
Heating and Cooling Devices See Fig 8. The RTP model can be supplied with a jacketed front cover and rotorcase with ports for circulation of a heating/cooling media. The jacketed front cover and rotorcase heating and cooling ports are strategically positioned such that the required thermal effect acts on the pumping chamber and product seal area. - Page 21 Where heating/cooling devices are employed, the heating/cooling media should be circulated 15-20 minutes prior to pump start-up and should be allowed to continue for a similar period of time after the pump has been shut down. Where a CIP cycle is employed as part of the process, the heating/cooling media should continue to be circulated during the cleaning cycle.
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Page 22: Integral Pressure Relief Valve
* N/A = Option not available. Note: For all other dimensions see section 5.5. Integral Pressure Relief Valve. Integral pressure relief valves are normally used to protect the pump from the effects of increases in system pressure caused, for example, by a restricted or closed discharge line. - Page 23 UMBER ESCRIPTION RV F RONT OVER (PTFE F IAPHRAGM RODUCT PRING OUSING PRING CREW ALVE RING PACER EQUIRED...
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Page 24: Rtp Tm Pump Dismantling And Assembly
ANGER Under no circumstances should any attempt be made to dismantle a pressure relief valve which has not had the spring pressure relieved (where applicable) or is mounted on a pump that is operating. Serious personal injury or pump damage may occur. Pump Dismantling and Assembly. -
Page 25: Disassembly
Under no circumstances should bearing cones or cups be hammered into position. For torque settings of fasteners and shaft rolling torque, see section 5.2. Disassembly. 4.1.1 Front Cover and Rotor Removal See Fig 10. - Follow recommended Shutdown Procedure, referring to section 3.5. - Gradually loosen front cover retaining nuts (36). -
Page 26: Gearbox Dismantling
- Remove product seals, refer to section 4.3. & & 4.1.2 Gearbox Dismantling (After Completing 4.1.1). The following procedures assume that the pump has been removed from the base-plate and that the product seals have been removed (see section 4.3). Remove drain plug (5) and the breather (21). - Page 27 Fig 11 Endplate Removal. Remove shaft assemblies from the gearbox (16, see fig 5.6). Shaft assemblies will be complete with gears (14), and bearings (24 and 19) – see fig 13. Remove Lip-seals (17) from the gearbox (16). Disassemble gearbox (16) from rotorcase (40) by removing the retaining screw (7).
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Page 28: Shaft Disassembly (Rtp30 Shown)
4.1.3 Shaft Disassembly (RTP30 Shown). Remove the rear bearing assembly (19). Remove the timing gear screws (23). Remove the timing gear (14) and locating dowel (80). Remove O-rings (26) from the rear of the shaft (9 or 10). Remove O-rings (25) from the front of the shafts (9 or 10). Remove front bearing assembly (24). -
Page 29: Assembly
& & Note Right-hand helix for drive shaft gear (stamped D), left-hand helix for driven shaft gear (stamped L). When ordering spare timing gears it is essential to purchase and install these as a pair. Assembly. 4.2.1 Gearbox & Rotorcase Assembly, See Fig 14. -
Page 30: Shaft Assembly - Rtp20
Install drain plug (5), where required in required position in gearbox cover (16). If not already installed, mount feet (1) to rotorcase (40) in the required positions using cap screws (2). Install the seal sleeve (if required) see section 4.3. Fig 14 Gearbox &... -
Page 31: Shaft Assembly - Rtp30
They should also not be tightened to the correct torque at this point, as an adjustment to the timing may still be required. place a nominal amount (0.05 mm) of shim (73) under the rear bearing cups Install rear bearing (19). Install the shaft assemblies into the gearbox (16) so that the cone and cup halves of the front bearing (24) are now one unit. -
Page 32: Timing
They should also not be tightened to the correct torque at this point, as an adjustment to the timing may still be required. Install rear bearing (19). Install the shaft assemblies into the gearbox (16) so that the cone and cup halves of the front bearing (24) are now one unit. - Page 33 Fig 17 Aligning the missing splines. Assemble the rotors (41), rotor retainers (35) and O-rings (34) onto the shafts (9 and 10). To achieve the correct timing clearance, rotate one shaft, whilst securing the other. The gear (14) will rotate on the lubricated O-rings until the correct mesh clearance is achieved.
- Page 34 Fig 18 Aligning the mesh point. Remove the shaft assemblies from the gearbox (16). Using the holes provided drill and ream both gear (14) and shaft (9 and 10) to suit Ø6.0 mm dowel (80), as shown in Fig 19. It is important to drill and ream the hole so that the dowel is positioned equally between the gears (14) and shafts (9 and 10).
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Page 35: Setting The Rolling Torque
4.2.5 Setting the rolling torque. It is important that the product seals, both front and rear lip seals are not installed until the bearing pre-load has been set and the clearances checked. The seals may give a false rolling torque reading as well as increasing the risk of damage during assembly. -
Page 36: Product Seal Fitting And Removal
Product Seal Fitting and Removal. 4.3.1 General Procedures for Installing Seals. Mechanical seals are precision-engineered assemblies incorporating finely lapped seal faces and seats. They must, therefore, be handled with care and will not give optimum performance unless installed carefully and according to instructions. - Page 37 i) Terminology. a) "Quench" To provide a liquid barrier, which is not, induced to flow through the seal area by any external means. b) "Flush" To provide a liquid barrier that is induced to flow through the seal area by an external means. ii) Quench or Flush Media.
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Page 38: Rtp20 O-Ring Seal Removal And Installation. (Above Orders # 61152)
4.3.2 RTP20 O-ring Seal Removal and installation. (above orders # 61152). Fig 20 O-ring Seal. Note: Extreme care should be taken when carrying out these procedures to ensure that the O-ring grooves, sleeve faces and O-ring are not damaged. Remove the front cover dome nuts, front cover, rotor retainer and rotor as per section 4.1.1 The seal O-rings in the rotor are now ready for inspection and replacement if needed (Fig 20). - Page 39 To remove the rotorcase sleeve remove the socket head screws and pull the sleeve out from the rotorcase (Fig 21). The sleeve and sleeve O-ring can now be inspected and replaced if needed. To install the sleeve, make sure the sleeve O-ring is in place and the location slot lines up with the drive pin When it is in place tighten up the grub screws and the assembly will be held in place.
- Page 40 4.3.2.1 RTP20 O-ring Seal Removal and installation (pre-orders # 61151). Fig 20 O-ring Seal. Note: Extreme care should be taken when carrying out these procedures to ensure that the O-ring grooves, sleeve faces and O-ring are not damaged. Remove the front cover dome nuts, front cover, rotor retainer and rotor as per section 4.1.1 The seal O-rings in the rotor are now ready for inspection and replacement if needed (Fig 20).
- Page 41 To remove the rotorcase sleeve remove the screws and pull the sleeve out from the rotorcase (Fig 21). The sleeve and sleeve O-ring can now be inspected and replaced if needed. To install the sleeve, make sure the sleeve O-ring is in place and the location slot lines up with the drive pins When it is in place tighten up the grub screws and the assembly will be held in place.
- Page 42 4.3.3 RTP20 Mechanical Seal. Remove the front cover dome nuts, front cover, rotor retainer and rotor as per section 4.1.1 Remove the rotary seal face using the seal extractor tool and inspect or replace the O-rings as required. When installing the seal face ensure correct engagement of the two drive dogs (Fig 23).
- Page 43 4.3.4 RTP30 Class 1 Hygienic Mechanical Seal. Fig 25 Class 1 Hygienic Mechanical Seal. Read the general procedures before proceeding, refer to section 4.3.1. Remove the dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover O-ring (39), see section 4.1. The seal can now be accessed for inspection.
- Page 44 4.3.5 RTP30 Class 2 Hygienic Mechanical Seal. Fig 26 Class 2 Hygienic Mechanical Seal. Read the general procedures before proceeding, refer to section 4.3.1. Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover O-ring (39), see section 4.1. The seal can now be accessed for inspection.
- Page 45 4.3.6 RTP30 Standard Radial Lip Seal. Fig 27 Standard Radial Lip Seal Cartridge. Read the general procedures before proceeding, refer to section 4.3.1. Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover O-ring (39), see section 4.1. Remove the lip seal cartridge assembly from the rotor (41).
- Page 46 4.3.7 RTP30 O-ring Seal. Fig 28 O-ring Seal Cartridge. Read the general procedures before proceeding, refer to section 4.3.1. Remove dome nuts (36), front cover (38), rotor retainers (35), rotors (41) and front cover O-ring (39), see section 4.1. Remove the O-ring seal cartridge assembly from the rotor (41). The seals can now be accessed for inspection.
- Page 47 Specifications. Clearance Chart (Radial) (Radial)
- Page 48 Fasteners & Torque Settings.
- Page 49 Lubricants. The recommended synthetic gearbox grease for use in the RTP is one that is intended for ‘sealed’ units. Suitable for operating temperatures between 20°C and 120°C (-4°F to 248°F) and a base viscosity in the region of 150 Cst at 40°C (104°F).
- Page 50 Tool List. Listed below are tools required for the maintenance of the RTP pump. RTP20 TYPE SIZE OR RANGE HEXAGON (ALLEN) KEY 3 MM HEXAGON (ALLEN) KEY 5 MM HEXAGON (ALLEN) KEY 8 MM COMBINATION SPANNER 19 MM ADJUSTABLE TO MIN. 135 NM (99.57 FT- TORQUE WRENCH DEPTH MICROMETER 0 - 25 MM (0 - 1")
- Page 51 RTP30 Foundation Dimensions – Stub Shaft Drive. 80 mm or 100 mm or 3" PORT 4" PORT...
- Page 52 5.5.1 RTP20 and 30 Foundation Dimensions – Basic Pump (Hydraulic Drive) CONNECTION SIZE 4 HOLES 'U' DIA...
- Page 53 Dimensions in millimetres Weight (kg) RTP20 RTP30 Dimensions in Inches Weight (lb) 2" 5.47 5.16 5.47 RTP20 4.61 5.16 5.59 10.83 0.87 3.46 3.46 7.72 11.77 1.65 6.85 3.54 0.55 4.61 8.74 7.68 0.43 11.93 12.99 2.13 3" 5.87 5.47 5.67 3"...
- Page 54 Typical Basic Pump Build (RTP20 Shown)
- Page 55 Trouble Shooting. Causes CTION NCORRECT IRECTION OTATION EVERSE OTOR & P RIMED XPEL UCTION HAMBER RIME NPSH A & S NSUFFICIENT VAILABLE NCREASE UCTION TATIC UCTION IAMETER & R IMPLIFY UCTION EDUCE ENGTH EDUCE & P RODUCT APORISING UCTION PEED RODUCT EMPERATURE NTERING...
- Page 56 Service History. Pump Serial No: Date Comments...
- Page 57 Notes. The information contained in this document is correct at time of print but may be subject to change without prior notice. The latest updated copies are available from our website...
- Page 58 Wright Flow Technologies Ltd. Edison Road, Eastbourne, East Sussex, BN23 6PT United Kingdom Phone: +44 1323 509211 Fax: +44 1323 507306 E-mail: wright.eu@idexcorp.com Wright Flow Technologies, Inc. 406 State Street Cedar Falls, Iowa 50613 U.S.A. Phone: (319) 268-8013 Fax: (803) 216-7686 E-mail: wright.usa@idexcorp.com www.wrightflowtechnologies.com Issue U –...