Pulsafeeder Isochem RGT IOM User Manual

Regenerative Turbine Pump

Installation Operation Maintenance Instruction

Bulletin #: IOM – RGT0700 - Rev. C

Manufacturers of Quality Pumps, Controls and Systems

Engineered Pump Operations 2883 Brighton-Henrietta Townline Road Rochester, New York 14623

Telephone: (585) 292-8000 Fax: (585) 424-5619 http://www.pulsa.com pulsa@idexcorp.com

ISOCHEM RGT FACTORY SERVICE POLICY

If you are experiencing a problem with your Isochem pump, first review the troubleshooting guide. If the problem is not covered or cannot be solved, please contact your local authorized Sales Representative or our Technical Service Department at (585) 292-8000 for further assistance.

Trained individuals are available to diagnose your problem and arrange a solution. Solutions may include purchasing a replacement unit or returning the pump to the factory for inspection and repair. All returns require a Return Material Authorization (RMA) number to be issued by Pulsafeeder. Replacements purchased under a possible warranty situation may be credited after an examination of the original equipment by Pulsafeeder personnel.

All components may be purchased for field replacement. Refer to the appropriate IOM section for more information and part numbers. Parts purchased to correct a warranty issue may be credited after examination of the original parts by Pulsafeeder personnel. Parts returned for warranty consideration that test satisfactorily, will be sent back to the originator via freight collect.

Any field modifications will void the Pulsafeeder warranty. Out-of-warranty repairs will be subject to Pulsafeeder's standard bench fees and testing costs associated with replacement components.

reproduced, stored in a retrieval system or transmitted in any form or any means electronic or mechanical, including photocopying and recording for any purpose other than the purchaser’s personal use without the

written permission of Pulsafeeder.

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Table of Contents

1. INTRODUCTION.....................................................................................................................................1

2. SAFETY CONSIDERATIONS ....................................................................................................................3

3. EQUIPMENT INSPECTION.......................................................................................................................3

4. INSTALLATION REQUIREMENTS .............................................................................................................4

5. STARTUP AND OPERATION.................................................................................................................... 7

6. MAINTENANCE .....................................................................................................................................8

6.1 Maintenance Precautions....................................................................................................... 8

6.2 Disassembling the No. 10 Pump ...........................................................................................9

6.3 Disassembling the No. 12 Pump ...........................................................................................11

6.4 Inspection................................................................................................................................ 13

6.4.1 Flow Channel Inspection................................................................................................13

6.4.2 Wear Plate Inspection.....................................................................................................14

6.4.3 Shaft Bearing Inspection................................................................................................14

6.4.4 Choke Point Inspection .................................................................................................. 14

6.5 Parts Replacement.................................................................................................................. 15

6.5.1 Wear Plates ...................................................................................................................... 15

6.5.2 Bearings........................................................................................................................... 15

6.5.3 Reassembling the No. 10 Pump.....................................................................................16

6.5.4 Reassembling the No. 12 Pump ..................................................................................... 20

7. TROUBLESHOOTING GUIDE................................................................................................................... 24

APPENDIX A – SPECIFICATIONS ..................................................................................................................25

APPENDIX B – BOLT PATTERN....................................................................................................................25

APPENDIX C – EXPLODED DRAWING ...........................................................................................................26

APPENDIX D – OPTIONS..............................................................................................................................29

APPENDIX E – BILL OF MATERIALS .............................................................................................................30

APPENDIX F – POWER FRAME ASSEMBLY................................................................................................... 34

Power Frame Maintenance.................................................................................................................35

APPENDIX G – PERFORMANCE CURVES ...................................................................................................... 36

nventions

For the remainder of this bulletin, the following Conventions are in effect.

A WARNING DEFINES A CONDITION THAT COULD CAUSE DAMAGE TO BOTH

THE EQUIPMENT AND THE PERSONNEL OPERATING IT. PAY CLOSE ATTENTION TO ANY WARNING.

Notes are general information meant to make operating the equipment easier.

Change History

Rev # Date Author Section Nature of Change

A 5/22/00 B

C 6-30-2005 BMJ

7/26/00 RM 5.0 Updated Disassembly & Reassembly Procedures. 7/26/00 CA

RM Appendix E Updated Performance Curves. CA Appendix D Updated Bill of Materials.

Appendix B Updated Exploded Drawings. Appendix D Updated Bill of Materials. Appendix E Updated Performance Curves. Misc Verbiage updates Section 2 Added safety information Section 6 Updated reassembly instructions specific to shimming of

front cover for proper clearances

1. Introduction

The Isochem® Regenerative Turbine pump (RGT) is uniquely different from the more familiar types of pumps. As the pumped liquid progresses from suction to discharge, it is continuously circulated between the impeller vanes and the walls of the flow passage in a helical path, the axis of which coincides with the flow passage. This process results in a significantly higher buildup of pressure than that which occurs in the similar but simpler centrifugal pump.

Figure 1

The turbine pump is in many ways an intermediate between the centrifugal and positive displacement types. As discharge pressure increases, flow decreases and the power required to drive the pump increases.

Flow is directly controlled by discharge pressure: the greater the pressure, the lower the flow rate. This can be most readily achieved by throttling the discharge; however care must be taken to not exceed the power level of the motor. Flow can be regulated using a variable bypass system, allowing operation at reduced pressure and power draw by dumping excess flow, usually back to a supply tank.

A very small clearance is maintained between the impeller, wear plates, and other internal surfaces. Since the impeller floats freely in the axial direction relative to the pump, a film of fluid is present on either side of the impeller so that there is no contact and negligible wear between impeller and wear plates.

Isochem RGT pumps use magnetic coupled, sealless technology, which eliminates the need for a rotary mechanical seal and enables the pump to handle hazardous fluids safely with zero leakage.

Standard Isochem RGT pumps are close-coupled (motor mounted directly to the rear of the pump) which provides greater assembled strength, enclosure of moving parts, and compact design. An optional power frame unit is available if required for motor compatibility (see Appendix G).

All Isochem pumps transmit rotation from the motor shaft to the impeller shaft by means of a magnetic drive coupling. An encapsulated driven magnet assembly is installed on the end of the impeller shaft. It is surrounded by a containment can, which constitutes the rearmost part of the pump enclosure. A drive magnet installed on the motor shaft rotates around the containment can. Drive torque is transferred through the containment can by magnetic attraction between the drive and driven magnet assemblies, causing the pump shaft to rotate. The containment can acts as a fluid barrier, eliminating the need for a dynamic seal.

The magnetic coupling has an inherent characteristic that causes it to “decouple” if the coupling torque limit is exceeded. This could happen if a piece of foreign material were to jam the pump impeller or if unusually high torque was developed for any reason.

The magnets can operate decoupled for short periods of time without losing their magnetic strength provided that temperature does not exceed specified limits (refer to Appendix A – Pump Specifications).

The Isochem RGT pump is available in several different materials, and care should be taken that all pump components (housing, wearplates, bearings) are compatible with the process liquid.

Consult with the factory for applications involving a specific gravity or viscosity greater than that of water.

2. Safety Considerations

• Read and understand all related instructions and documentation before attempting to install

or maintain this equipment

• Keep this and all documents (specification sheets, shipment records, maintenance records)

in a safe place which is accessible to those who operate or maintain this equipment.

• Observe all special instructions, notes, and cautions.

• Act with care and exercise good common sense and judgment during all installation,

adjustment, and maintenance procedures.

• Ensure that all safety rules, work procedures, and standards that are applicable to your

company and facility are followed during the installation, maintenance, and operation of this equipment.

• Use for any application other than as described within this documentation is considered

unsafe and voids all certification markings and warranties.

• Always ensure that all factory supplied guards and covers are in place before operating this

equipment.

• The Isochem series of pumps relies on strong magnets to transfer power from the drive to

the pump system. Users are cautioned to keep magnetically sensitive items such as watches, credit cards and ID badges, and medical equipment away from the pump and drive mechanisms.

• See additional maintenance precautions listed in Section 6.

3. Equipment Inspection

Check all equipment for completeness against the order and for any evidence of shipping damage. Shortages or damage must be reported immediately to the carrier and to your Isochem supplier.

If immediate installation is not scheduled, the following steps should be taken:

1. Leave pump in the original shipping carton.

2. Store indoors in a dry environment. Avoid temperature variations.

3. Leave all shipping plugs in place.

4. Contact the motor manufacturer for specific motor storage information.

Occasionally during shipment, storage, or installation. misalignment or other damage can occur. For this reason it is recommended that each unit be tested with water in some convenient area prior to piping into the actual process system.

4. Installation Requirements

The pump installation site should provide easy access for routine maintenance and when possible to protect the pump from the elements and from leaks or drips from nearby process equipment.

Figure 2

IN A POWER FRAME (THAT IS, NOT CLOSE-COUPLED) INSTALLATION, THE USE OF A LOW-

BACKLASH OR RELATIVELY RIGID MOTOR COUPLING IS RECOMMENDED TO PREVENT MAGNETIC DE-COUPLING AT STARTUP OR UNDER WIDELY VARYING PROCESS CONDITIONS.

THE PROVISION OF A “SOFT-START” MOTOR STARTER WILL REDUCE THE POSSIBILITY OF

MAGNETIC DE-COUPLING AT STARTUP WITH A FAST-STARTING OR OVERSIZED MOTOR.

AS THE PUMP IS SUPPORTED BY THE MOTOR MOUNT, TAKE CARE THAT THE SUCTION AND

DISCHARGE PIPING DOES NOT APPLY FORCES OR MOMENTS (TWISTING) TO THE PUMP.

FOR OPTIMUM PERFORMANCE, A MINIMUM 1-1/2 INCH SUCTION LINE SIZE IS RECOMMENDED

1. Bolt the pump down firmly to the mounting surface. Provide for air movement over the electric

DISCHARGE PORT

SUCTION PORT

motor as required. The pump is functionally symmetrical so that the suction and discharge ports can be reversed

(with direction of rotation) and the housing (with cover) can be rotated to suit the installation if required. Refer to Figure 3, for typical installation and the required relation between rotation and direction of flow.

Figure 3

2. It is recommended to install vacuum/pressure gauges in the suction and discharge lines to monitor system operation.

3. Keep suction lines short and straight to minimize friction loss to the pump. Make sure that the pump will not starve or run dry. Flooded suction or gravity feed of fluid to the pump inlet is preferred and eliminates manual priming.

4. Use only full-bore ball valves or gate valves in the suction piping. If suction strainers are used, size them to minimize pressure drop and select a type that is easily cleaned. Strainers should be regularly inspected and cleared of debris as required during operation.

THE ISOCHEM RGT PUMP SHOULD BE USED TO PUMP CLEAN, CLEAR LIQUIDS ONLY. THIS PUMP

CANNOT HANDLE SOLIDS OR PARTICULATES IN THE PROCESS STREAM.

5. Arrange all suction piping and fittings to prevent formation of air pockets. Make sure all joints are air tight.

6. Flush all suction lines prior to mating up to the pump. Use unions or other appropriate fittings for ease of maintenance.

7. Do not spring piping, either suction or discharge, when mating up to the pump. Use supports or hangers at intervals as required. When necessary, provide for thermal expansion and contraction so that no strain is placed upon the pump.

8. Check all bolts and nuts for tightness. Correct any conditions that could cause destructive vibration or leakage.

9. When required, provide a proper system for containment can flush and/or drain.

10. If start-up screens are used, be sure they do not clog and starve the suction system. Start-up screens should be removed prior to placing the system into regular operation.

11. If a flexible suction line is used, select the materials and install them so that they do not collapse (causing a starved condition).

12. When taking suction from a tank or vessel, avoid entry of sludge, solids, etc. into the suction line by placing the suction line inlet above maximum level of solids.

13. When a bypass system is used to control flow from the pump, the bypassed fluid should be piped back to the suction vessel to prevent heat build-up due to recirculation. If it is absolutely necessary to pipe bypass back to the pump suction line, the point of entry should be at least 10 pipe diameters away from the suction inlet. Provision for cooling should be made in the event of excessive heat buildup caused by fluid recirculation.

14. Where pumped fluids may solidify, crystallize, precipitate etc., provision should be made to thoroughly flush the pump and associated piping prior to periods of shutdown. Pay particular attention to proper flushing and draining of the magnetic coupling area because this area will not self drain. There is a drain plug in the rear housing for access to this area.

5. Startup and Operation

• DO NOT DEAD-HEAD

• DO NOT RUN DRY

• DO NOT OPERATE AT FLOW RATES BELOW 2-3 GPM EXCEPT MOMENTARILY

Prior to operation, recheck the suction system to be sure NPSH available to the pump is adequate. Reference Appendix G – Performance Curves for more information. Make sure all suction piping is air tight and clean.

If the pump is equipped with a Power Frame motor mounting arrangement, consult Appendix F for oil fill instructions.

Turn the pump over by hand. If any mechanical binding or other trouble is detected, determine the cause and correct.

Check that electrical service to the motor agrees with the name plate ratings. Jog to check rotation and reconnect the motor if necessary.

THE PUMP SHOULD NEVER BE RUN DRY. DAMAGE TO IMPELLER, BEARINGS AND

WEAR PLATES WILL RESULT. PUMPS SHOULD NEVER BE OPERATED CONTINUOUSLY AT FLOW RATES BELOW 2 GPM (SIZE 10) OR 3 GPM (SIZE 12).

LOCALIZED HEATING WILL REDUCE OPERATING CLEARANCES AND CAN CAUSE

DAMAGE TO THE IMPELLER, COVER, AND/OR REAR HOUSING.

The pump must be primed before operation and any air must be vented from the casing. If foot valves are used, the valve should be of the flapper type and sized to minimize friction loss. Threaded and plugged vents in the pump casing can be provided as an option.

Do not operate the pump against a closed discharge, as this can cause the magnetic drive to decouple. Decoupled operation causes high temperatures that can boil the fluid or damage the magnet assemblies. Should de-coupling occur, stop the motor and restart after the stoppage has been cleared. As a safety precaution, a pressure relief valve bypass system is recommended. Ideally, the pressure relief valve can be set at a low-pressure trip point for startup, ensuring that fluid rapidly and fully floods the pump casing.

Start the pump with the discharge valve slightly open and check for proper operation. Excessive noise or vibration is an indication of harmful cavitation caused by insufficient NPSH. Stop the pump, and correct the issue as required.

6. Maintenance

The timing for maintenance of the pump is established primarily on past performance. Each installation is different. Therefore detailed maintenance records of past performance can be invaluable for determining future preventative maintenance intervals. During routine pump inspections pay particular attention to the bearings, wearplates, and impeller, as those areas will determine future maintenance intervals. For motor maintenance instructions consult the motor manufacturer.

Before performing any maintenance requiring pump disassembly, be sure to flush and drain pump and magnetic drive sections thoroughly with a neutralizing fluid. Wear protective clothing and handle equipment with proper care.

1. When changing a pump from one service to another, be sure to check that all wetted parts of

the pump are compatible with the fluid to be handled and that the motor is sufficiently sized for the application. If in doubt contact your Isochem supplier.

2. All magnetic drive couplings have a specific maximum torque limit. If this torque is

exceeded the drive will decouple. Operation in the decoupled mode should be avoided as high temperatures could be generated.

3. Should the pump exhibit reduced flow rate or pressure capability, noise, or otherwise

abnormal operation, first refer to the troubleshooting section. If the problem cannot be found, inspect the pump for wear or damage. It can be easily opened for partial wet end cleaning and inspection without disturbing piping connections by removing just the front cover.

6.1 Maintenance Precautions

1. Drain and flush pump and magnetic drive before any pump disassembly. Access to the

magnetic drive area is provided by a drain plug in the pump housing. Use caution as this section of the pump will not fully self-drain.

2. The exposed magnets on the drive magnet assembly are very fragile and will chip easily. Use

extreme care while handling them. Keep wristwatches, credit cards, ID badges, and other sensitive items away from the magnetic fields.

3. Take care to avoid particles or objects from attaching themselves to the drive magnets. It is

difficult to remove small particles and larger objects could be attracted with enough force to break the magnets.

4. Be careful during disassembly and re-assembly of the drive and driven magnet assemblies.

The attraction forces are high and when the magnets come close together there is a strong tendency to snap together suddenly, possibly causing pinching or worse to fingers. Get help, often two people may be required to safely separate or re-attached the drive and driven sections of the pump.

DO NOT MACHINE THE MAGNETS IN THE DRIVE OR DRIVEN MAGNET ASSEMBLIES. THE

DUST THAT WOULD BE PRODUCED IS HIGHLY FLAMMABLE.

5. The model number stamped on the pump nameplate identifies the pump type and other

details. Refer to the model number chart if you are unsure of exactly what type of pump you have. Always refer to the full model and serial number in any correspondence with your Isochem supplier.

6.2 Disassembling the No. 10 Pump

The item numbers listed in parenthesis refer to the exploded drawings found in Appendix B.

1. Close the suction and discharge valves.

2. Disconnect the power source from the motor.

3. Flush and drain the pump, and disconnect the piping.

4. Drain the containment can through the rear housing drain plug (item 27) (refer to Figure 4).

5. Remove the cover bolts (items 15) and remove the front cover (item 2) by carefully

withdrawing it straight back to avoid damage as the drive shaft (item 4) is withdrawn from the cover bearing (item 9).

6. The two housing pins (items 13) should remain in place in the rear housing (item 1).

7. Remove the thin plastic shims (item 3), if any, between the cover and the housing.

(The standard shim is plastic. Metal shims are used at higher temperatures.)

8. Remove the rear housing screws (item 26) and separate the rear housing (item 1) from the

casing (item 20). This will require physical force to overcome the magnetic attraction between the drive and driven magnet assemblies. Do not pry on one edge, but carefully withdraw it straight back to avoid damage. The magnets are fragile and easily damaged by rough handling. Two people may be required to separate the magnets safely.

9. Use a small screwdriver to remove the retaining ring (item 14) from the impeller assembly

(item 6) shaft at the rear of the driven magnet assembly (item 18) and withdraw the driven magnet assembly (item 18) from the impeller assembly shaft, taking care to retain the magnetic coupling drive key (item 8).

10. The spool is removed by removing the motor bolts (item 23) and withdrawing it back from

the motor.

11. Remove the retaining ring (item 14) at the rear of the rear housing (item 1) from the impeller

assembly (item 6) shaft.

12. Remove the impeller assembly from the front of the rear housing.

Do not remove the drive magnet assembly unless it or the motor is to be replaced.

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