Wright flow Cocept SQ, SQ1/0004/12, SQ1S, SQ1/0007/06, SQ1L Installation, Operation And Maintanance Manual

...

NSTALLATION,

PERATION

AINTENANCE

ANUAL

OR THE

ANGE OF PUMPS

Page 2

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FOR THE CONCEPT SQ RANGE OF ROTARY LOBE PUMPS

1.0 SAFETY INFORMATION ___________________________________ 4

1.1 R

ISK ASSESSMENT RELATING TO THE USE OF WRIGHT FLOW TECHNOLOGIES

IMITED. CONCEPT SQ ROTARY LOBE PUMPS AND PUMP UNITS IN

POTENTIALLY EXPLOSIVE ATMOSPHERES

. ________________________ 7

2.0 INTRODUCTION __________________________________________ 8

2.1 G

ENERAL

______________________________________________ 8

2.2 W

RIGHT FLOW TECHNOLOGIES LIMITED DISTRIBUTORS

_____________ 8

2.3 R

ECEIPT AND STORAGE

____________________________________ 8

2.4 C

LEANING

______________________________________________ 8

2.5 P

UMP MODEL DESIGNATION

_________________________________ 9

2.5.1 ATEX I

NFORMATION PLATE

________________________________ 10

2.5.2 E

QUIPMENT GROUPS & CATEGORIES

_________________________ 10

2.6 P

UMP MODEL AND SERIAL NUMBER

__________________________ 11

2.7 S

TANDARD PUMP COMPONENT TERMS

________________________ 12

3.0 GENERAL ______________________________________________ 13

3.1 C

ONCEPT SQ RANGE PUMPING PRINCIPLE

_____________________ 13

3.2 C

ONCEPT SQ RANGE OPERATING PARAMETERS

_________________ 14

3.3 S

YSTEM DESIGN

________________________________________ 15

3.3.1 S

YSTEM DESIGN AND INSTALLATION

__________________________ 15

3.3.2 I

NSTALLATIONS WITH

CIP/SIP S

YSTEMS

_______________________ 18

3.4 S

TART UP PROCEDURE

___________________________________ 19

3.5 S

HUTDOWN PROCEDURE

__________________________________ 20

3.6 R

OUTINE MAINTENANCE

___________________________________ 20

3.7 H

EATING AND COOLING DEVICES

____________________________ 21

3.8 F

RONT COVER/ROTORCASE JOINT WITH FLUID BARRIER

___________ 23

3.9 R

OTORCASE PORT CONNECTIONS WITH FLUID BARRIER

____________ 24

4.0 CONCEPT SQ DISMANTLING / ASSEMBLY __________________ 25

4.1 SQ1 S

ERIES PUMPS - DISMANTLING

__________________________ 27

4.1.1 F

RONT COVER AND ROTOR REMOVAL

_________________________ 27

4.1.2 C

ARTRIDGE REMOVAL

____________________________________ 28

4.1.3 C

ARTRIDGE DISMANTLING

_________________________________ 29

4.1.3.1 D

RIVE SHAFT CARTRIDGE DISMANTLING

_______________________ 29

4.1.3.2 L

AY SHAFT CARTRIDGE DISMANTLING

_________________________ 29

4.2 SQ1 S

ERIES PUMPS - ASSEMBLY

____________________________ 30

4.2.1 C

ARTRIDGE ASSEMBLY

___________________________________ 30

4.2.1.1 D

RIVE SHAFT CARTRIDGE ASSEMBLY

_________________________ 30

4.2.1.2 L

AY SHAFT CARTRIDGE ASSEMBLY

___________________________ 32

4.2.2 C

ARTRIDGE/MOUNTING PLATE/ROTORCASE ASSEMBLY

____________ 33

4.2.3 S

ETTING ROTOR TIMING

___________________________________ 35

4.2.4 G

EARBOX ASSEMBLY

_____________________________________ 36

4.2.5 R

OTOR ASSEMBLY AND CHECKING CLEARANCES

_________________ 37

4.3 SQ 2, 3, 4 - D

ISMANTLING

_________________________________ 39

4.3.1 F

RONT COVER AND ROTOR REMOVAL

_________________________ 39

Page 3

4.3.2 C

ARTRIDGE REMOVAL (AFTER COMPLETING

4.3.1) ________________ 40

4.3.3 C

ARTRIDGE DISMANTLING

_________________________________ 41

4.4 SQ 2, 3, 4 - A

SSEMBLY

___________________________________ 42

4.4.1 C

ARTRIDGE ASSEMBLY

___________________________________ 42

4.4.2 C

ARTRIDGE TO ROTORCASE ASSEMBLY

_______________________ 44

4.4.3 S

ETTING ROTOR TIMING

___________________________________ 46

4.4.4 F

INAL SETTING OF CARTRIDGE ROLLING TORQUE

________________ 47

4.4.5 R

OTOR ASSEMBLY AND SETTING ROTOR CLEARANCES

____________ 48

4.4.6 G

EARBOX COVER ASSEMBLY

_______________________________ 50

4.5 M

ECHANICAL SEAL INSTALLATION AND REMOVAL

_________________ 51

4.5.1 P

ROCEDURES FOR INSTALLING MECHANICAL SEALS

_______________ 51

4.5.2 S

INGLE MECHANICAL SEAL

_________________________________ 52

4.5.3 S

INGLE MECHANICAL SEAL (LOW-PRESSURE FLUSH / QUENCH

). ______ 57

4.5.4 D

OUBLE MECHANICAL SEAL (HIGH-PRESSURE FLUSH

). _____________ 60

4.5.5 M

ECHANICAL SEALS FOR QUENCH OR FLUSH - AUXILIARY SERVICES

___ 63

5.0 SPECIFICATIONS _______________________________________ 66

5.1 C

LEARANCE CHART

______________________________________ 66

5.2 F

IXINGS & TORQUE SETTINGS

______________________________ 67

5.3 L

UBRICANTS

___________________________________________ 68

5.4 M

ATERIAL SPECIFICATION

. _________________________________ 68

5.5 C

ONCEPT SQ RANGE FOUNDATION DIMENSIONS AND WEIGHTS

______ 69

5.6 T

YPICAL BASIC PUMP BUILD

________________________________ 71

5.7 F

AULT FINDING

_________________________________________ 72

5.9 S

ERVICE HISTORY

. ______________________________________ 74

5.10 T

OOL LIST

_____________________________________________ 75

5.11 N

OTES

_______________________________________________ 76

Page 4

1.0 Safety Information

INCORRECT INSTALLATION, OPERATION OR MAINTENANCE OF EQUIPMENT

MAY CAUSE SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE AND

MAY INVALIDATE THE WARRANTY.

THIS INFORMATION MUST BE READ FULLY BEFORE COMMENCING

INSTALLATION, OPERATION OR MAINTENANCE AND MUST BE KEPT WITH

THE PUMP. SUITABLY TRAINED OR QUALIFIED PERSONS MUST UNDERTAKE

ALL INSTALLATION AND MAINTENANCE ONLY.

Safety instructions given in this

manual non-compliance with which

would affect safety are identified by

the symbol:

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:

DANGER

DO NOT OPERATE PUMP IF:

- THE FRONT COVER IS NOT INSTALLED CORRECTLY.

- ANY GUARDS ARE MISSING OR INCORRECTLY INSTALLED.

- THE SUCTION OR DISCHARGE PIPEWORK 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 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 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.

WWAARRNNIINNGG

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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 and will create high temperatures and increased noise emissions. 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 with the recommended grades and quantities of lubricant see section 3.4. Beware of over/under filling the gearbox as this could cause the pump to overheat and mechanical damage to occur.

Before operating the pump, ensure 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 pipe work connecting to the pump is fully supported and 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.

Ensure that pump rotation is correct for the desired direction of flow; (see 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.

Install pressure gauges/sensors 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. If pump is baseplate mounted, the base plate must be used for all lifting purposes, not any part of the pump. If slings are used for lifting, they must be safely and securely attached. For weights of bare shaft pumps refer to section 5.5.

DO NOT attempt any maintenance or disassembly of the pump or pump unit without first ensuring that:

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

- The pumping chamber and any shaft seal support system, front cover barrier support system, and rotorcase port barrier support system are de-pressurised and purged.

- Any temperature control devices (jackets, heat-tracing, etc) are fully isolated, that they are de-pressurised and purged, and components allowed to reach a safe handling temperature.

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

WWAARRNNIINNGG

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seal housings, barrier support systems, 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 pressure levels exceeding 85-dB (A) under certain operating conditions. When necessary, personal protection against noise must be taken. See section 5.8 for typical noise emission data.

Avoid any contact with hot parts of pumps and/or drives, which may cause injury. Certain operating conditions, temperature control devices (jackets, heattracing, 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. For CIP cleaning requirements, refer to section 3.3.2. The exterior of the pump should be cleaned periodically.

Surface temperature of pump is also dependent on the temperature of pumped medium.

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

1.0 / 4.5

. 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 applic

ation, The feature must be fit for its

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

Page 8

2.0 Introduction

2.1 General

The range of Concept SQ rotary lobe pumps are manufactured and distributed, refer to section 2.2, by Wright Flow Technologies Limited, Eastbourne, England.

This manual includes all the necessary information for the Concept SQ pump range and should be read prior to commencing installation, operation or maintenance.

When asking for assistance please quote the pump model and serial number. This information can be obtained from the pump nameplate which is located on the top 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 the rear face of the rotorcase, refer to section 2.6, Figs 2 & 3.

If it is proposed to modify the system or change the characteristics of the product to be pumped from that for which the pump was originally selected, Wright Flow Technologies Limited or their authorised distributor should be consulted.

2.2 Wright Flow Technologies Limited Distributors

Wright Flow Technologies Limited distributes their products internationally via a network of authorised distributors. Throughout this manual where reference is made to Wright Flow Technologies Limited, any authorised distributor will also provide service and assistance. Should you require any additional information regarding the Concept SQ range of pumps contact Wright Flow Technologies Limited or their local authorised distributor.

2.3 Receipt and Storage

On receipt of the pump, immediately examine for any signs of visible damage. If any damage is noted, contact Wright Flow Technologies Limited and clearly mark upon the carriers paperwork that the goods have been received in a damaged condition, with brief description of damage.

If the pump is not required for immediate installation then it should be stored within a suitable environment.

2.4 Cleaning

The Concept SQ pump range is suitable for manual cleaning, CIP (Cleaning In Place) and SIP (Sterilisation In Place) refer to section 3.3.2.

The mechanical seals are mounted directly behind the rotor and are designed and to minimise product entrapment and maximise the effects of cleaning.

This strategic positioning of the mechanical seals, combined with their ease of access provides an arrangement that can be more effectively cleaned by both manual and CIP/SIP procedures.

Page 9

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

2.5 Pump Model Designation

The designation of pump models in the Concept SQ range is as follows: -

SQ1/0004/12 (SQ1S) SQ1/0007/06 (SQ1L) SQ2/0017/15 (SQ2S) SQ2/0030/07 (SQ2L)

SQ3/0054/15 (SQ3S) SQ3/0103/07 (SQ3L) SQ4/0160/15 (SQ4S) SQ4/0303/07 (SQ4L)

This, together with the pump serial number, should be quoted when requesting additional information on the pump or when ordering spare parts. The pump serial number is stamped on the pump nameplate and the rear face of the rotorcase, refer to section 2.6, Figs 2 and 3.

For an explanation of pump model designations see Fig 1. For the maximum operating pressures, temperatures and speeds refer to

section 3.2, Fig 6.

Fig 1 (European Designation)

SQ 3 0054 15 / /

UMP

ODEL

ISPLACEMENT

TRS/REV X

ODEL

IZE

MAX. P

RESSURE

(BAR)

Page 10

2.5.1 ATEX Information

ATEX Pump Requirements Please be aware that 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 a flow of fluid around the pump seals at all times. If there is a risk of the supply being interrupted, we would recommend that the flush on the seals be fitted with a flow detection device. The surface temperature of the pump is dependent on the temperature of the pumped fluid and due account of this should be taken whilst undertaking your risk assessment of the installation. These pumps are rated to T3.

2.5.2 Equipment Groups & Categories

TEMP - T3

SERIAL NO:

II - 2 - G/D

Group

II.

Category 2

Unit is suitable for

environments

containing dust or gas

Temperature Class.

Page 11

2.6 Pump Model and Serial Number

Should you require any information regarding your Concept SQ rotary lobe pump contact Wright Flow Technologies Limited quoting 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 the rear face of the rotorcase, see Fig 3.

Fig 2

Fig 3

12345 / A / 99

Page 12

2.7 Standard Pump Component Terms

Fig 4

Page 13

3.0 General

3.1 Concept SQ Range Pumping Principle see Fig 5

Fig 5

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 cartridge assemblies. The shaft cartridge assemblies comprise the shaft support bearings and the timing gears. The timing gears transfer the drive from the driven shaft to the lay shaft, synchronising the rotors such that they rotate without contact with each other.

As the rotors pass the suction port, see Fig 5a, the cavity generated increases creating a pressure decrease, which induces the media to be pumped to flow into the rotorcase.

The pumped media is carried around the rotorcase by the rotors, see 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.

Page 14

3.2 Concept SQ Range Operating Parameters

Fig 6

Concept SQ

Model

ISPLACEMENT

ONNECTION SIZE

(International

Standards)

IFFERENTIAL

RESSURE

(Maximum)

AXIMUM

PEED

(Continuous)

AXIMUM

EMPERATURE

(Continuous)

litres / rev

I gal /

100 rev

US gal /

100 rev

mm Inches Bar

lbf/in² rev / min

°C

°F

SQ1/0004/12 0.04 0.88 1.06

1.0

175

1000

150 300

SQ1/0007/06 0.07 1.76 2.11

1.0

1000

150 300

SQ2/0017/15 0.17 3.74 4.49

1.5

215

850

150 300

SQ2/0030/07 0.30 6.60 7.93

2.0

100

850

150 300

SQ3/0054/15 0.54 11.88 14.27

2.0

215

700

150 300

SQ3/0103/07 1.03 22.66 27.21

3.0

100

700

150 300

SQ4/0160/15 1.60 35.20 42.27

3.0

215

600

150 300

SQ4/0303/07 3.03 66.66 80.06 100

4.0

100

600

150 300

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 and / or the process.

If it is proposed to modify the system/duty, or change the characteristics of the product to be pumped from that for which the pump was originally selected Wright Flow Technologies Limited should be consulted.

The pump should not be subjected to sudden temperature changes to avoid the risk of damage through 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 and assistance contact Wright Flow Technologies Limited.

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3.3 System Design

3.3.1 System Design and Installation When incorporating any pump into a system it is considered good

practice to minimise pipework 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 the minimum of pipefittings to minimise restricting product flow to the pump. The following should be considered at the design stage of any system.

a) Ensure ample room is provided around the pump to allow for: -

ii) Access to the pump and drive for routine inspection and

maintenance, for example to replenish pump or drive lubricant, remove pump front cover and rotors.

iii) Ventilation of the drive to prevent over heating.

b) The pump must not be used to support pipework; all pipework to

and from the pump unit must be independently supported. Failure to observe this may cause distortion of the pump head components or assembly and serious consequential damage to the pump.

c) 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.

d) Rotary lobe pumps are of the positive displacement type and

therefore an overload protection device must be provided. This can take the form of:i) An in-line pressure relief system, i.e. external to the pump. ii) Inclusion of a torque limiting device in the drive system. iii) Rupture disc incorporated in the discharge pipework.

e) 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.

f) It is considered good practice to ensure all pipework and

associated plant from the suction vessel to the discharge point is thoroughly cleaned before installation of the pump to avoid the possibility of debris entering the pump and causing damage.

g) 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.

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h) Suction Conditions

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 pipework is at least the same diameter as the pump

connections.

- Suction pipework is straight for a distance of at least the

equivalent of 10 pipe diameters immediately before pump.

- The length of suction pipework 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 Wright Flow Technologies Limited.

Fig 7

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i) When installing a pump complete with baseplate, motor and drive

the following guidelines must be observed:

- The preferred drive arrangement for any rotary lobe pump is in-line direct coupled. If an alternative is required please contact Wright Flow Technologies Limited.

- Flexible couplings must always be incorporated and correctly aligned. To check coupling alignment rotate the shaft by at least one full revolution and ensure that the shaft rotates smoothly.

Fig 8

To check for and correct angular misalignment, use a calliper to check the measurement across the hubs. Adjust position of pump or drive as necessary until the measurement is the same at all points around the hubs.

Fig 9

To check for and correct parallel offset, place a straightedge across the hub flanges in two positions at 90 Degrees to each other. Adjust position of pump or drive as necessary until the straightedge lays flat on both sides.

Note:

Some couplings are able to withstand gross angular and/or parallel

misalignment. However, the above methods of reduce these effect to an

absolute minimum is required to avoid placing excessive loads onto

pump and/or drive components. The table below gives details of

maximum parallel and angular misalignments allowed.

ONCEPT SQ

ODEL

AXIMUM PARALLEL

ISALIGNMENT (MM

AXIMUM ANGULAR

ISALIGNMENT (DEGREES

)

SQ1 0.05 0.5 SQ2 0.075 0.5 SQ3 0.10 1.0 SQ4 0.15 1.0

Couplings of a non-flexible design must never be used.

Page 18

- 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 below and of sufficiently rigid design to prevent contact with rotating parts under normal operating conditions.

Note: The guard must be designed such that it fully covers the projecting part of the lay shaft of the pump.

- When installing pump sets in flammable or explosive environments, or for handling flammable or explosive materials. Special consideration must be given to the safety aspects of the drive unit enclosure and also to the materials used for both the coupling and the guard to eliminate the risk of producing sparks.

- 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.

- 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, Star Delta etc. Ensure all components are correctly earthed.

3.3.2 Installations with CIP/SIP Systems The Concept SQ pump range has been designed to be effectively

cleaned by the CIP procedures recommended for in place cleaning of process plant. To assist in maximising the effectiveness of cleaning within the pump head it is recommended that during the cleaning cycle a flow rate equivalent to a velocity of 1.5 metres per second; in a pipe of equal diameter to the rotorcase connections is achieved. With a differential pressure of 2 to 3 bar being developed across the pump head.

For applications where maximum drainage of the pump head is required, for example in the handling of ‘Agri-Foodstuffs’ and / or where CIP is employed, the pump should be mounted with the rotorcase connections in the vertical orientation. A procedure must be determined to ensure that the pump is effectively cleaned. It is recommended that this cycle would typically include a combination of some or all of the following: Acidic or Caustic based Detergents, ‘Sanitisers’, Disinfectants and Water rinses. These must be appropriate to both the products being handled and the materials of construction of the pump.

The Concept SQ pump range is also suitable for SIP treatment.

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3.4 Start Up Procedure

- Check all pipework and associated equipment is clean and free

from debris and that pipe connections are secure and leak free.

- For pumps installed with flushed mechanical seals check all

auxiliary services are in place and connected and provide sufficient flow and pressure for flushing purposes, refer to section

4.5.7.

- For pumps installed with Fluid Barrier devices on Front Cover /

Rotorcase joint and Rotorcase port connections, check all auxiliary services are in place and connected and provide sufficient flow and pressure, refer to sections 3.8 and 3.9.

- Ensure lubrication is provided for both pump and drive. Concept

SQ pumps are despatched 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.

- Check that, if an external relief valve is incorporated in the

system, it is set correctly. For commissioning purposes it is considered good practice to set the relief valve lower than the system design pressure. On completion of commissioning 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.

- Ensure both suction and discharge valves are fully open, and

pipework is free from all obstructions. Concept SQ 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.

- Ensure rotation of the drive shaft is correct for the direction of flow

required (see Fig 10).

Fig 10

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- Ensure product is available in the suction vessel before starting

pump, this is very important for pumps installed with single mechanical seals not being serviced with a quench or flush as these sealing arrangements must never be allowed to run dry.

- Before commencing 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 commence operation keeping a visual check on suction and discharge pressure gauges and monitor pump temperature and power absorbed where possible.

3.5 Shutdown 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.

- That, where employed, mechanical seal flush, rotorcase port

connection barrier flush and front cover barrier flush auxiliary services have been isolated, de-pressurised and fully drained.

- That, where employed, heating / cooling devices have been

isolated, de-pressurised and fully drained.

- Pump head and pipework have been drained and purged.

3.6 Routine Maintenance

- Check mechanical shaft seals for leakage.

- 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.

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Page 21

3.7 Heating and Cooling Devices See Figs 11 & 12

All models in the Concept SQ range can be supplied with a jacketed front cover and, with the exception of the SQ1 series pumps, rotorcase with ports for circulation of a heating/cooling media. The jacketed cover and rotorcase heating and cooling ports are strategically positioned such that the thermal effect acts on the pump chamber and seal area.

The pressure rating of the Concept SQ range jacketed front cover and rotorcase heating/cooling ports is 3.5 bar g

(50 PSI)

and this should not be exceeded without first making reference to Wright Flow Technologies Limited.

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 also for a similar period of time after the pump has been shutdown. Where a CIP or SIP cycle is employed as part of the process, the heating/cooling media should continue to be circulated during the cleaning cycle.

Fig 11 Dimensions of Front Cover Jacket for Heating/Cooling

Concept SQ

Model

Millimetres Inches

A6 M1

(Inches)

A6 M1 Y4

SQ1/0004/12 38.0 58.0 ¼ 1.50 2.28 ¼ SQ1/0007/06 38.0 60.5 ¼ 1.50 2.38 ¼ SQ2/0017/15 54.0 77.5 ½ 2.13 3.05 ½ SQ2/0030/07 54.0 82.0 ½ 2.13 3.23 ½ SQ3/0054/15 90.0 101.0 ½ 3.54 3.98 ½ SQ3/0103/07 90.0 110.0 ½ 3.54 4.33 ½ SQ4/0160/15 142.5 120.0 ½ 5.61 4.72 ½ SQ4/0303/07 142.5 140.0 ½ 5.61 5.51 ½

Note:

For all other dimensions see section 5.5, Foundation Dimensions

Page 22

Fig 12 Dimensions for Rotorcase Ports for Heating/Cooling

Concept SQ

Model

Millimetres Inches

A7 BF M2

(Inches)

A7 BF M2 Y5

SQ1/0004/12 N/A N/A N/A N/A N/A N/A N/A N/A SQ1/0007/06 N/A N/A N/A N/A N/A N/A N/A N/A SQ2/0017/15 80 66.5 14 1/8 3.15 2.62 0.55 1/8 SQ2/0030/07 80 66.5 36 1/8 3.15 2.62 1.42 1/8 SQ3/0054/15 102.5 90.5 16 1/8 4.04 3.56 0.63 1/8 SQ3/0103/07 102.5 90.5 49 1/8 4.04 3.56 1.93 1/8 SQ4/0160/15 140 137 22 1/8 5.51 5.39 0.87 1/8 SQ4/0303/07 140 137 64 1/8 5.51 5.39 2.52 1/8

Note: For all other dimensions see section 5.5, Foundation Dimensions and Weights.

Y4 BSP Female Connections

Page 23

3.8 Front Cover/Rotorcase Joint with Fluid Barrier

Fig 13

The product to atmosphere interface between front cover and rotorcase can be provided with a fluid barrier to prevent either the ingress of microbiological and other contaminants, or the egress of pumped media to atmosphere. The fluid must be compatible with the media being pumped and the materials of construction of any pump components with which it comes into contact.

Where pumps are equipped with this feature, two tapped holes are located in the front cover forming the connections for the supply of the barrier fluid, see fig 13. The position of the holes is dependant upon the orientation of the pump, but in either case, the lower tapped hole must be used for the fluid inlet so that air is naturally vented out via the upper tapped hole. Barrier liquids should be supplied at a flow rate of approximately 0.5 to 1 litres per minute. Barrier gasses can be either static or flowing as applicable.

The pressure rating of the Concept SQ range front cover / rotorcase joint with fluid barrier is 3.0 bar g (43.5 PSI) and this should not be exceeded without first making reference to Wright Flow Technologies Limited.

The position of the holes is dependent upon the orientation of the pump.

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Page 24

3.9 Rotorcase Port Connections with Fluid Barrier

Fig 14

The product to atmosphere interface between the rotorcase port connections and the suction and discharge pipework can be provided with a fluid barrier to prevent either the ingress of microbiological and other contaminants, or the egress of pumped media to atmosphere, when the applicable port connections are installed.

Where pumps are equipped with this feature, two tapped holes are located on each of the connection male parts which are welded to the rotorcase forming the connections for the supply of the barrier fluid, see Fig 14.

In the standard orientation, which is with the rotorcase ports in the vertical plane, either tapped hole can be used as the fluid inlet. If the barrier media is a liquid, the flow should be raised to approximately 2 litres per minute for the first few minutes to allow venting of any gas or air trapped in the barrier chamber of the lower connection assembly. The flow can then be reduced to zero if required, or maintained at a value between 0 and 1 litres per minute. If the barrier media is a gas, it should be made to flow for the first few minutes to allow removal of air, and then the flow can be reduced to zero if required.

In the optional orientation, which is with the connection ports in the horizontal plane, the lower tapped hole should be used for the fluid inlet so that air or gas trapped in the barrier chambers is naturally vented out via the upper tapped hole. If the barrier media is a liquid, the flow should be raised to approximately 2 litres per minute for the first few minutes to allow venting of any air or gas. The flow can then be reduced to zero if required, or maintained at a value between 0 and 1 litres per minute. If the barrier media is a gas, it should be made to flow for the first few minutes to allow removal of air, and then the flow can be reduced to zero if required

The pressure rating for the fluid barrier of these port connections is 3.0 Bar g (43.5 PSI) and this must not be exceeded under any circumstances.

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+ 53 hidden pages

Wright flow Cocept SQ, SQ1/0004/12, SQ1S, SQ1/0007/06, SQ1L Installation, Operation And Maintanance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual