INSTALLATION, OPERATION
AND
MAINTENANCE MANUAL
FOR THE
VIKING PUMP, INC. A Unit of IDEX Corporation
Cedar Falls, Iowa 50613 U.S.A.
Issue B - Jun 03
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR DURALOBE® ROTARY LOBE PUMPS.
1.0SAFETY INFORMATION. _______________________________________ 3
RISK ASSESSMENT RELATING TO THE USE OF VIKING PUMP DURALOBE ROTARY LOBE PUMPS AND PUMP UNITS IN POTENTIALLY EXPLOSIVE ATMOSPHERES. ______________ 6
2.0INTRODUCTION. ______________________________________________ 7
2.1GENERAL. ___________________________________________________ 7
2.2VIKING PUMP DISTRIBUTORS. _____________________________________ 7
2.3RECEIPT AND STORAGE._________________________________________ 7
2.4CLEANING. __________________________________________________ 8
2.5PUMP MODEL DESIGNATION. _____________________________________ 8
2.5.1ATEX INFORMATION PLATE _____________________________________ 9
2.5.2EQUIPMENT GROUPS & CATERGORIES_____________________________ 9
2.6PUMP MODEL AND SERIAL NUMBER. _______________________________ 10
2.7STANDARD PUMP COMPONENT TERMS._____________________________ 11
3.0GENERAL. __________________________________________________ 12
3.1DURALOBE® PUMPING PRINCIPLE._________________________________ 12
3.2DURALOBE® PUMP OPERATING PARAMETERS. ________________________ 13
3.3SYSTEM DESIGN. _____________________________________________ 14
3.3.1SYSTEM DESIGN AND INSTALLATION. _____________________________ 14
3.3.2INSTALLATIONS WITH CIP SYSTEMS. _____________________________ 16
3.4START UP PROCEDURE.________________________________________ 16
3.6ROUTINE MAINTENANCE. _______________________________________ 18
3.7HEATING AND COOLING DEVICES _________________________________ 18
3.8INTEGRAL PRESSURE RELIEF VALVES ______________________________ 21
3.8.1SETTING AND OPERATING SPRING LOADED VALVES __________________ 22
3.8.2SETTING AND OPERATING AIR LOADED VALVE ______________________ 23
4.0DURALOBE® PUMP DISMANTLING AND ASSEMBLY. ______________ 30
4.1DISASSEMBLY._______________________________________________ 31
4.1.2CARTRIDGE REMOVAL _______________________________________ 33
4.1.3CARTRIDGE DISASSEMBLY ____________________________________ 34
4.2ASSEMBLY. _________________________________________________ 35
4.2.1CARTRIDGE ASSEMBLY _______________________________________ 35
4.2.2CARTRIDGE TO ROTORCASE ASSEMBLY___________________________ 39
4.2.3ROTOR ASSEMBLY AND SETTING ROTOR CLEARANCES________________ 41
4.2.4GEARBOX COVER ASSEMBLY __________________________________ 43
4.3PRODUCT SEAL FITTING AND REMOVAL. ____________________________ 44
4.3.1GENERAL PROCEDURES FOR FITTING MECHANICAL SEALS._____________ 44
4.3.2SINGLE MECHANICAL SEAL ____________________________________ 45
4.3.3SINGLE FLUSHED MECHANICAL SEAL_____________________________ 47
4.3.4DOUBLE MECHANICAL SEAL ___________________________________ 49
4.3.5SINGLE O-RING SEAL________________________________________ 51
4.3.6DOUBLE O-RING SEAL _______________________________________ 52
4.3.7TRAPPED SLEEVE___________________________________________ 53
4.3.8HYBRID DOUBLE MECHANICAL 2000 SEAL _________________________ 54
Page : 1
4.3.9HYBRID DOUBLE MECHANICAL SEAL _____________________________ 55
4.3.10HYBRID SINGLE FLUSHED MECHANICAL SEAL_______________________ 56
4.3.11STRIP CLEAN SINGLE O-RING SEAL ______________________________ 57
4.3.12DURALOBE SINGLE O-RING SEAL OL1____________________________ 58
4.3.13DURALOBE SINGLE O-RING SEAL S2, S3, S4_______________________ 59
4.3.14MK2 DOUBLE O-RING SEAL S1_________________________________ 60
4.3.15MK2 DOUBLE O-RING SEAL S2, S3, S4 __________________________ 61
4.3.16FLUSHED PRODUCT SEAL _____________________________________ 62
5.0SPECIFICATIONS.____________________________________________ 65
5.1CLEARANCE CHART ___________________________________________ 65
5.2FASTENERS & TORQUE SETTINGS. ________________________________ 66
5.3LUBRICANTS ________________________________________________ 67
5.4MATERIAL SPECIFICATION. ________________________________________ 67
Page : 2
1.0Safety 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. ALL INSTALLATION AND MAINTENANCE MUST BE
UNDERTAKEN BY SUITABLY TRAINED OR QUALIFIED PERSONS ONLY.
Danger - Failure to follow the listed precautionary measures may result in serious injury or death 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
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 the pump outside of its operating envelope can cause mechanical contact in the pump head, 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
WARNING 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).
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WARNING
WARNING
WARNING
WARNING
WARNING
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 loadings and will 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 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). Beware of over / under filling the gearbox as this could cause the pump to over heat 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 a source of ignition.
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 5.5.
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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 depressurized and purged.
-Any temperature control devices (jackets, heat-tracing, etc) are fully isolated, that they are depressurized 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 pressurized 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 pressurized 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 5.8.
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.
WARNING During a CIP cleaning cycle, a pump differential pressure of between 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.
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Risk assessment relating to the use of Viking Pump Duralobe rotary lobe pumps and pump units in potentially explosive atmospheres.
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.
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Source Of Hazards |
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Potential Hazards |
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Frequency Of |
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Recommended Measures |
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Hazards |
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Very Rare |
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Ensure that pump is totally filled. |
Unvented cavities |
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Build up of explosive gas |
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Consider mounting ports vertically. |
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See Chapter 1.0 |
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Ensure that operating pressures are |
Rotorcase / Rotors / Front |
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Unintended mechanical |
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not exceeded. Ensure that suffcient |
Cover |
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contact |
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NPSH to prevent cavitation. See |
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Chapter 1.0/3.3.1 Service plan. |
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User must ensure temperature limits. |
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excess temperature. |
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Rare |
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Do not overfill gearboxes with |
Pump external surfaces |
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lubricant. Provide a ground contact |
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for pump. See Chapter 1.0 / Service |
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plan. |
Cover 'O' ring |
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Pump liquid leakage. Build |
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Check selection of elastomers are |
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suitable for application. Ensure cover |
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up of explosive gas. |
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retaining nuts are tight. Service plan. |
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Pump casing / cover |
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Pump liquid leakage. Build |
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Stainless steel, Corrosion resistant. |
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up of explosive gas. |
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excess temperature. |
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Selection of seal system must be |
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suitable for application. See Chapter |
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Shaft seals |
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contact. |
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5.0. Service plan. Mechanical seals |
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Leakage. |
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must never run dry |
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Build up of explosive gas. |
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Auxiliary system for shaft |
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Pump liquid leakage. Build |
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Selection of auxiliary seal system |
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must be suitable for application. |
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sealing |
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up of explosive gas. |
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Mechanical seals must never run |
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dry. |
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If flushed seals are installed ensure |
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Very Rare |
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that flush is applied to seal |
Rotation direction test |
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Excess temperature |
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assemblys. Only allow pump to run |
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for minimum period - just a few |
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seconds. |
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Excess Temperature. |
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Can cause excessive pressue, heat |
Closed valve condition |
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Excess Pressure. |
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and mechanical contact. See |
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Mechanical contact. |
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Chapter 1.0 |
Shaft |
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Random induced current |
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Very Rare |
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Provide a ground contact for pump. |
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See Chapter 1.0. |
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Temperature from friction |
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Coupling selection must suit |
Mechanical shaft coupling |
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(Torque Protection) |
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shear pins. |
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application. See Chapter 1.0. |
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Electrostatic charging |
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Break up of spider. |
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application. Service plan. See |
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contact. |
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Chapter 1.0. |
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Electrostatic charging |
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2.0Introduction.
2.1General.
Duralobe® rotary lobe pumps are manufactured by Johnson Pump (UK) a unit of Viking Pump Inc., Cedar Falls, USA, herein after referred to as
Viking Pump.
This manual includes all the necessary information for Duralobe® pumps and should be read prior to beginning installation, operation or maintenance.
Should you require any additional information regarding the Duralobe® pumps contact Viking Pump or their local authorized 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 pump 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, Viking Pump or their authorized distributor should be consulted to ensure the pump is suitable for the new application.
2.2Viking Pump Distributors.
Viking Pump distributes it’s products internationally via a network of authorized distributors. Throughout this manual where reference is
made to Viking Pump, service and assistance will also be provided by any Viking Pump authorized distributor for Duralobe® pumps.
2.3Receipt and Storage.
Upon receipt of the pump, immediately examine it for any signs of visible damage. If any damage is noted, contact Viking Pump or your Viking Pump distributor and clearly mark upon the carriers paperwork that the goods have been received in a damaged condition, with a brief description of 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 14°F and 105°F.
Page : 7
2.4Cleaning.
The Duralobe® 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 minimize product entrapment and maximize the effects of cleaning.
This 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 is cleaned periodically.
2.5Pump Model Designation.
The designation of pump models are as follows:
S1S |
S3S |
S1M |
S3M |
S1L |
S3L |
S2S |
S4S |
S2M |
S4M |
S2L |
S4L |
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.
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2.5.1 Atex Information Plate
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Unit is suitable for |
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environments containing |
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Category 2 |
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dust or gas |
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Group II. |
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Temperature Class.
2.5.2 Equipment Groups & Catergories
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2.6Pump Model and Serial Number.
Should you require any information regarding your Duralobe® rotary lobe pump contact Viking Pump or your Viking Pump distributor, providing the pump model and serial number as stated on the pump nameplate, see Fig 2, which is fixed to the pump gearbox cover.
Should this be damaged or missing, the pump serial number is also stamped on opposite corners of the rotorcase, (see Fig 3).
Fig 2
VIKING PUMP
IDEX CORPORATION
FILL TO SIGHT LEVEL
RECOMMENDED LUBRICANT
MODEL |
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SERIAL NUMBER |
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BUILD CODE |
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VIKING PUMP INC. |
A Unit of IDEX Corporation |
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CEDAR FALLS , IA |
USA |
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MADE IN GREAT BRITAIN
Fig 3
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2.7Standard Pump Component Terms.
Fig 4
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3.0General.
3.1Duralobe® 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), see Fig 5. The rotors are located on shafts which in turn are held within two cartridges mounted onto the back of the rotorcase. The shaft cartridge assemblies comprise of, the shaft support bearings and the timing gears. The gears transfer the energy from the drive shaft to the driven shaft, synchronizing the rotors such that they rotate without contact with each other. As the rotors pass the suction port, Fig 5a, the cavity increases creating a pressure decrease, which induces the pumped medium to flow into the rotorcase.
The pumped medium is carried around the rotorcase by the rotors, Fig 5b and 5c, to the discharge side of the pump, Fig 5d. Here the cavity decreases and the pumped medium is discharged from the rotorcase, Fig 5e.
For pump component terms see Fig 4.
Fig 5 Rotary Lobe Pump Principle.
Page : 12
3.2Duralobe® Pump Operating Parameters.
Fig 6
Pump |
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Nominal |
Max Diff. |
Maximum |
Max |
Max |
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Theoretical Displacement |
Connection |
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Series |
Pressure |
Speed |
Temp |
Temp |
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Size |
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Liter / |
Imp.gal |
US gal |
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/100 |
mm |
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inches |
bar |
psi |
rev/min |
°C |
°F |
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rev |
/100 rev |
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rev |
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S1S |
0.04 |
0.88 |
1.06 |
25 |
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1 |
14 |
200 |
1150 |
150 |
300 |
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S1M |
0.06 |
1.32 |
1.59 |
25 |
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1 |
10 |
150 |
1150 |
150 |
300 |
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S1L |
0.08 |
1.76 |
2.11 |
25 |
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1 |
7 |
100 |
1150 |
150 |
300 |
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S2S |
0.17 |
3.74 |
4.49 |
38 |
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1.5 |
14 |
200 |
1150 |
150 |
300 |
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S2M |
0.25 |
5.50 |
6.61 |
50 |
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2 |
10 |
150 |
1150 |
150 |
300 |
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S2L |
0.34 |
7.48 |
8.98 |
50 |
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2 |
7 |
100 |
1150 |
150 |
300 |
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S3S |
0.54 |
11.88 |
14.27 |
50 |
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2 |
14 |
200 |
870 |
150 |
300 |
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S3M |
0.81 |
17.82 |
21.40 |
76 |
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3 |
10 |
150 |
870 |
150 |
300 |
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S3L |
1.08 |
23.76 |
28.53 |
76 |
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3 |
7 |
100 |
870 |
150 |
300 |
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S4S |
1.62 |
35.64 |
42.80 |
76 |
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3 |
14 |
200 |
700 |
150 |
300 |
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S4M |
2.43 |
53.46 |
64.20 |
101 |
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4 |
10 |
150 |
700 |
150 |
300 |
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S4L |
3.24 |
71.28 |
85.60 |
101 |
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4 |
7 |
100 |
700 |
150 |
300 |
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The maximum pressure and speed operating parameters are given in Fig 6. In practice these may be limited due to the nature of the product to be pumped and/or design of the system in which the pump is to be installed.
Consult Viking Pump or your Viking Pump distributor for assistance.
If the system or product characteristics are to be changed from the WARNING original application for which the pump was selected, Viking Pump or
their authorized distributor should be consulted to ensure the pump is suitable for the new application.
The pump should not be subjected to sudden temperature changes to avoid the risk of damage from sudden expansion/contraction of components. Care should be taken when selecting pumps for handling liquids containing abrasive particles as these may cause wear of pump head components. For advice or assistance contact Viking Pump or your Viking Pump distributor.
Page : 13
3.3System Design.
3.3.1System Design and Installation.
When incorporating any pump into a system it is considered good practice to minimize piping runs and the number of pipe fittings (tees, unions, bends etc.) and restrictions. Particular care should be taken in designing the suction line, which should be as short and straight as possible with a minimum of pipe fittings to minimize restricting product flow to the pump. The following should be considered at the design stage of any system:
i)Be sure ample room is provided around the pump to allow for:
a)Access to the pump and drive for routine inspection and maintenance, i.e. to replenish pump or drive lubricant or to remove pump front cover and rotors.
b)Ventilation of the drive to prevent over heating.
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The pump must not be used to support piping. All piping to and from |
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WARNING |
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the pump unit must be independently supported. Failure to observe |
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this may distort the pump head components or assembly and cause |
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serious consequential damage to the pump. |
iii)Valves should be provided adjacent to the pump suction and discharge connections to allow the pump to be isolated from the system for routine inspection and maintenance.
iv)Rotary lobe pumps are of the positive displacement type and therefore an overload protection device must be provided. This can take the form of:
a)A pressure relief valve integral with the pump where available and suited to the application, refer to section 3.8.
b)An in-line pressure relief system, i.e. external to the pump.
c)Incorporation of a torque limiting device in the drive system.
d)Rupture disc incorporated in the discharge piping.
Where pump rotation and hence flow is to be reversed during normal operation, the overload device must be capable of protection for both directions of rotation/flow. The Duralobe® integral relief valves are described in section 3.8 and are designed to operate under such conditions.
Page : 14
WARNING |
v) |
It is recommended that all piping and associated equipment from the |
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tank to the discharge point is thoroughly cleaned before installation of |
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the pump to avoid the possibility of debris entering the pump and |
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causing damage. |
WARNING
WARNING
WARNING
vi)Pressure gauges should be installed adjacent to the pump suction and
discharge connections such that system pressures can be monitored.
These gauges will provide a clear indication of changes in operating conditions and where a relief valve is incorporated in the system, will be necessary for setting and checking the functioning of the valve.
vii)It is imperative that the suction condition at the pump inlet meets the
Net Positive Suction Head Required (NPSHr) by the pump. Failure to observe this could cause cavitation, resulting in noisy operation, reduction in flow rate and mechanical damage to the pump and associated equipment.
The Net Positive Suction Head Available (NPSHa) from the system must always exceed the Net Positive Suction Head Required (NPSHr) by the pump.
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.
-That calculations to determine system NPSHa are carried out for the worst condition, see Fig 7.
Should advice on pump or system NPSH characteristics be required contact Viking Pump or your Viking Pump distributor.
Fig 7
Page : 15 |
(viii) When installing a pump complete with baseplate, motor and drive the following guidelines must be observed:
a)The preferred drive arrangement for any rotary lobe pump is in-line direct coupled. If an alternative is required please contact Viking Pump or your
Viking Pump distributor.
b)Flexible couplings must always be incorporated and correctly aligned within the limits recommended by the coupling manufacturer. To check coupling alignment rotate the shaft by at least one full revolution and ensure that the shaft rotates smoothly.
Couplings of a non flexible design must never be used.
c)Couplings must always be enclosed in a suitable guard to prevent contact with rotating parts which could result in personal injury. Guards should be of suitable material ,(see d) and of sufficiently rigid design to prevent contact with rotating parts under normal operating conditions.
d)When installing pump sets in flammable or explosive environments, or for handling flammable or explosive materials, special consideration must be given not only to the safety aspects of the drive unit enclosure but also to the materials used for both the coupling and the guard to eliminate the risk of explosion.
e)Baseplates must be secured to a flat level surface such that distortion and misalignment are avoided. Once baseplates are fastened in position the drive alignment must be re-checked, (see b).
f)When using electric motor drives, ensure that the electrical supply is compatible with the drive and controls and that the method of wiring is correct for the type of starting required by the motor i.e. Direct On Line, or other similar method. Ensure all components are correctly grounded.
3.3.2Installations with CIP Systems.
The Duralobe® has been designed to be effectively cleaned by the CIP procedures recommended for in place cleaning of process equipment. It is recommended that a differential pressure of 30 to 45 psi be developed across the pump head during cleaning in order to develop the necessary fluid velocities required for thorough cleaning.
3.4Start Up Procedure.
WARNING
WARNING
-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 section 4.3.7.
Page : 16
WARNING
WARNING
WARNING
-Ensure lubrication is provided for both pump and drive. Duralobe® pumps are shipped without oil and should be filled to the level of the oil
sight glass which must be installed in the upper tapped hole in the side of the gearbox cover, refer to section 5.3 for pump oil capacities and grades.
-If an external relief valve is incorporated in the system check that it is set correctly. For start up purposes it is considered good practice to set the relief valve lower than the system design pressure. On completion
of start up the relief valve should be reset to the required setting for the application. The required setting should never exceed the lower of either the pumps maximum pressure rating or the system design pressure. For setting integral relief valves, refer to sections 3.8.1 and 3.8.2.
-Ensure both suction and discharge valves are fully open, and pipework
is free from all obstructions. Duralobe® pumps are of the positive displacement type and should therefore never be operated against a closed valve as this would result in pressure overload, resulting in damage to the pump and possibly the system.
WARNING |
- |
Ensure rotation of the drive shaft is correct for the direction of flow |
|
|
required, see Fig 8. |
Fig 8 |
|
|
|
|
WARNING
-Ensure product is available in the tank before starting pump. This is very important for pumps installed with unflushed product seals as these sealing arrangements must never be allowed to run dry. -Before beginning operation it is considered good practice to momentarily start/stop the pump to check the direction of rotation and ensure that the pump is free of obstructions. Once this has been carried out, begin operation keeping a visual check on suction and discharge pressure gauges and monitor pump temperature and power absorbed where possible.
Page : 17
3.5Shutdown Procedure.
When shutting the pump down close both the suction and discharge valves and ensure that the necessary safety precautions are taken:
-The prime mover power source has been isolated.
-If installed, the pneumatically operated integral relief valve has been depressurized.
-If Installed, flushed product seal auxiliary services have been isolated and depressurized.
-Pump head and piping have been drained and purged.
3.6Routine Maintenance.
WARNING |
- |
Check oil levels regularly. |
|
|
|
-Change the oil every 12 months or 3000 operating hours whichever is the sooner.
-For lubricant capacities and grades refer to section 5.3.
3.7Heating and Cooling Devices see Figs 9 and 10.
All Duralobe® models except the S1 series, 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.
The pressure rating of the Duralobe® series jacketed front cover and rotorcase heating/cooling ports is 50 psi and should not be exceeded without consulting Viking Pump or your local Viking Pump distributor.
Heating/cooling of the pump head is used to maintain, rather than increase/decrease the temperature of the pumped media and should be used as part of a complete system where suction and discharge lines and vessels are also heated/cooled.
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 shutdown. Where a CIP cycle is employed as part of the process, the heating/cooling media should continue to be circulated during the cleaning cycle.
Page : 18
Fig 9 Dimensions of Front Cover Jacket for Heating/Cooling.
|
Millimeters |
|
Inches |
|
|
Model |
A6 |
M1 |
A6 |
M1 |
Y4 |
|
|
|
|
|
|
S1S |
45.0 |
52.0 |
1.77 |
2.05 |
¼ |
S1M |
45.0 |
54.0 |
1.77 |
2.13 |
¼ |
S1L |
45.0 |
54.5 |
1.77 |
2.15 |
¼ |
S2S |
70.0 |
70.0 |
2.76 |
2.76 |
½ |
S2M |
70.0 |
75.0 |
2.76 |
2.95 |
½ |
S2L |
70.0 |
76.0 |
2.76 |
2.99 |
½ |
S3S |
105.0 |
95.0 |
4.13 |
3.74 |
½ |
S3M |
105.0 |
104.0 |
4.13 |
4.09 |
½ |
S3L |
105.0 |
104.0 |
4.13 |
4.09 |
½ |
S4S |
150.0 |
113.0 |
5.91 |
4.45 |
½ |
S4M |
150.0 |
126.0 |
5.91 |
4.96 |
½ |
S4L |
150.0 |
133.0 |
5.91 |
5.24 |
½ |
Note: For all other dimensions see section 5.5, Foundation Dimensions and Weights.
Page : 19
Fig 10 Dimensions for Rotorcase Ports for Heating/Cooling.
|
|
Millimeters |
|
|
Inches |
|
||
Model |
|
|
|
|
|
|
|
|
A7 |
BF |
|
M2 |
A7 |
BF |
M2 |
Y5 |
|
S1S |
N/A |
N/A |
|
N/A |
N/A |
N/A |
N/A |
N/A |
S1M |
N/A |
N/A |
|
N/A |
N/A |
N/A |
N/A |
N/A |
S1L |
N/A |
N/A |
|
N/A |
N/A |
N/A |
N/A |
N/A |
S2S |
80.0 |
66.5 |
|
14.0 |
3.15 |
2.62 |
0.55 |
1/8 |
S2M |
80.0 |
66.5 |
|
24.5 |
3.15 |
2.62 |
0.96 |
1/8 |
S2L |
80.0 |
66.5 |
|
36.0 |
3.15 |
2.62 |
1.42 |
1/8 |
S3S |
102.5 |
90.5 |
|
16.0 |
4.04 |
3.56 |
0.63 |
1/8 |
S3M |
102.5 |
90.5 |
|
25.0 |
4.04 |
3.56 |
0.98 |
1/8 |
S3L |
102.5 |
90.5 |
|
49.0 |
4.04 |
3.56 |
1.93 |
1/8 |
S4S |
140.0 |
137.0 |
|
22.0 |
5.51 |
5.39 |
0.87 |
1/8 |
S4M |
140.0 |
137.0 |
|
35.0 |
5.51 |
5.39 |
1.38 |
1/8 |
S4L |
140.0 |
137.0 |
|
64.0 |
5.51 |
5.39 |
2.52 |
1/8 |
Note: For all other dimensions see section 5.5, Foundation Dimensions and Weights.
Page : 20
3.8Integral Pressure Relief Valves see Figs 11, 12, 13 and 14.
All models in the Duralobe® series can be supplied with integral pressure relief valves with both spring and air loaded versions available. The function of the valves can be further enhanced with the option of manual or airlift override offering particular benefits where CIP or SIP is employed. Valves incorporating this option can be opened to regulate the volume of the cleaning media within the pump chamber thereby avoiding the need for manual cleaning or external by-pass.
Where the pump is mounted onto a portable cart baseplate complete with motor and drive to be used as a mobile set, it is strongly recommended that a integral pressure relief valve is installed.
The Duralobe® integral pressure relief valves available include:
Spring Loaded - see Fig 11.
Valve can be set to required pressure relief setting.
Spring Loaded with Manual Lift - see Fig 12.
Valve can be set to required pressure relief setting. Manual lift override can be used to open valve without disturbing pressure relief setting (not available on the S4 series).
Spring Loaded with Air Lift - see Fig 13.
Valve can be set to required pressure relief setting. Air lift override, which operates on an air supply of up to 105 psi depending on pressure relief setting, can be used to open valve without disturbing pressure relief setting
(not available on the S4 series).
Air Loaded with Air Lift - see Fig 14.
Valve, which operates on an air supply of up to 105 psi for S1, S2, S3 and
150 psi for S4, can be set to required pressure relief setting. Air lift override, which operates on an air supply of up to 105 psi for S1,S2,S3 and 150 psi for S4, depending on pressure relief setting, can be used to open valve without disturbing pressure relief setting.
Air actuated relief valves can be operated remotely and interfaced with other elements of the system or process control.
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. In response to a pressure increase the valve opens and internally circulates the pumped media within the pump chamber.
Page : 21
WHEN THE VALVE OPENS, BECAUSE THE VOLUME OF FLUID
WARNING CIRCULATING IS RELATIVELY SMALL, THE TEMPERATURE OF THE FLUID IN THE PUMP CHAMBER MAY RISE IF THE PUMP CONTINUES TO
OPERATE FOR AN EXTENDED PERIOD. IN SEVERE CASES THIS MAY RESULT IN TEMPERATURES IN EXCESS OF THE PUMPS OPERATING LIMITS OR VAPORIZATION OF THE FLUID, BOTH OF WHICH SHOULD BE AVOIDED. FOR THESE REASONS WHEN THE VALVE IS ACTIVATED THE CAUSE OF THE SYSTEM PRESSURE INCREASE SHOULD BE ELIMINATED AS CONTINUOUS OPERATION OF THE PUMP WITH THE VALVE OPEN IS NOT RECOMMENDED AND MAY CAUSE SEVERE DAMAGE TO THE PUMP.
If the pump on which the valve is installed is to be installed in either a pressurized system or one incorporating a vessel under vacuum, the application of the valve should be referred to Viking Pump or their authorized distributor.
The selection, setting and application of integral relief valves is influenced by the viscosity and nature of the pumped media, the pump operating speed and the required pressure relief setting and mode of operation. For these reasons, and to cover the diverse range of products, the conditions under which they are pumped, and application demands, it is not practical to factory set integral relief valves. The setting of the valve should be carried out on site under the proposed duty conditions for which the pump and valve were selected.
For setting and operating Duralobe® integral relief valves refer to sections
3.8.1 and 3.8.2. Before beginning the relief valve setting procedure the pump should be installed, refer to section 3.3.1, with a pressure gauge in the discharge line adjacent to the pump discharge port.
3.8.1Setting and Operating Spring Loaded Valves see Figs 11, 12 and 13.
-Remove cover (108). For integral relief valve with manual lift, see Fig 12, first remove nut (129) and handwheel (111).
-Loosen nut (107) using a pry bar in the holes provided, to relieve spring compression. For integral relief valve with air lift, see Fig 13, the air cylinder must be exhausted prior to unscrewing the nut (107).
-Start pump, refer to section 3.4.
-Screw in nut (107) using pry bar in holes provided until required pressure relief setting is reached.
|
Note: Care should be taken not to exceed the lower of either the pumps |
|
WARNING |
||
maximum pressure rating or the system design pressure. |
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||
|
- Reinstall cover (108). For integral relief valve with manual lift, see Fig 12, |
|
|
reinstall handwheel (111) and nut (129). |
Page : 22
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