Gardner Denver STP 125 User manual

MIS TP 125/E N1/07 0 1
OPERATION,
AINTENANCE
and
INSTALLATION
MANUAL and
PARTS LIST
ROTARY
LOBE
PUMP
STP 125
STP125
VERSION: 03
February 3, 2015

1.0 General Page No
1.1 Pump limits of application or use
1
1.
2
Duty
conditions
1
1.
3
Noise
levels
1
1.
4
Utility
requirements
1
1.
5
Safety
precautions
2
1.
6
Health
and
safety
information
3
2.0 Unpacking, handlingand storage
2.1 Documents
4
2.2
Unpacking
4
2.3
Handling
4
2.
4
Pump
storage
4
3.0 Description ofpump or pump unit
3.1 General pump description
5
3.
2
Principle
of
operation
5
3.
3
Pump
dimensions
6
3.
4
Pump
weight
6
3.
5
Pump
displacement
6
3.
6
Pump
information
chart
6
3.
7
Pressure
relief
valve
6
4.0 System Design and Installation
4.1 System design advice
7
4.
2
Direction
of
rotation
7
4.3
Pipework
8
4.
4
Port
orientation
8
5.0 Commissioning
5.1 Lubricating the pump 9
5.2 Recommended lubricants 9
5.3 Changing the oil 9
5.4 Oil capacity 9
6.0 Start Up, Shut Down and Cleaning in Place
6.1 Pump start up checklist 10
6.2 Pump shut down procedure 11
6.3 Cleaning in Place (CIP) 12
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7.0 Maintenance and inspection Page No
7.1 Maintenance schedule
13
7.
2
Recommended
spare
parts
13
7.
3
Maintenance
tools
13
8.0 Disassembly
8.1 Before dismantling the pump
14
8.
2
Removing
the
front
cover
15
8.
3
Removing
the
rotors
15
8.
4
Product
seal
removal
15
8.
5
Removing
the
rotorcase
15
8.
6
Removing
the
shaft
sleeves
and
shims
16
8.
7
Draining
the
pump
of
lubricant
16
8.
8
Removing
the
front
seal
retainers
16
8.
9
Removing
the
gear
housing
16
8.10
Removing
the
timing
gears
16
8.11
Shaft
and
bearing
removal
16
9.0 Assembly
9.1 Fitting shafts into the bearing housing
17
9.
2
Fitting
the
front
seal
retainers
17
9.
3
Fitting
timing
gears
and
setting
rotor
timing
17
9.
4
Adjusting
the
rotor
timing
18
9.
5
Fitting
the
gear
housing
18
9.
6
Setting
the
rotor
clearances
19
9.
7
Fitting
the
seal
19
9.
8
Fitting
the
rotors
19
9.
9
Fitting
the
front
cover
19
10.0 Replacing 'O' ring seal
10.1 Product 'O' ring seal replacement 20
10.2 'O' ring seal fitting 20
10.3 To remove the seal housing 20
10.4 Seal housing fitting 20
11.0 Replacing mechanical seal
11.1 Singlemechanicalseal 21
11.2 Singlemechanicalsealremoval 21
.
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Page No
11.3 Singlemechanicalsealfitting 22
12.0 Pump heating tank
12.1 Heatingtankremoval 23
12.2 Heatingtankfitting 23
13.0 Relief valve
13.1 Disassembly-reliefvalve 24
13.2 Assembly-reliefvalve 24
14.0 Faults, causes and remedies 25
15.0 Torque settings/spanner sizes 26
16.0 Exploded view drawing and parts list 28
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1.0 General
1.1 Pump limits of application or use
This pump has been designed for pumping
a range of viscosities from water to semi-
solid, suitable for both homogeneous liquids
and liquids with non abrasive particles/
solids in suspension.
Speeds to 1000rpmand temperatures to
158°F can be accomodated on this pump.
Theseconditionscannotalwaysbe
accomodatedsimultaneously.
The STP125 has been designed to operate
atamaximumcontinuousdischargepressure
of 145 psi. However the STP125 is capable
ofwithstandingdischarge pressuresuptoa
maximumof160psiintermittently.At
pressures above145 psithere is the
possibilityofleakagefromthe primaryseal,if
this occursandthesealcontinues to leakat
pressures below 145 psi it is an indication
thattheprimarysealmayhavebeen
permanentlydamagedandshouldtherefore
bereplacedattheearliestopportunity.
Continous operationatpressuresabove145
psi willresultinprematurefailureof the
pump.
If the user has not specified the pumping
application or needs to change it, it is
important to confirm that the materials of
construction and product seals are
compatible with the pumping application
and that adequate NPSH is available.
Forspecificguidelinescontactyoursupplier
quotingpumpserial number,systemandduty
details.(e.g.media,pressure(s),flowrate,
pumping temperaturesetc).
1.2 Duty conditions
The pump should only be used for the duty
for which it has been specified. The
operating pressure, speed and temperature
limits have been selected at the time of order
andMUSTNOTbeexceeded.
These details arestatedontheoriginal
documentationandif notavailablemaybe
obtainedfrom yoursupplierquotingpump
serialnumber.
1.3 Noise levels
Under certain operating conditions pumps
and/or drives and/or the systems within
which they are installed can produce sound
pressure levels in excess of 85dBA. When
necessary personal protection against noise
should be taken to safeguard the hearing of
persons who are likely to be in close
proximity to the equipment.
1.4 Utility requirements
Electricalsupply:-
This pump may be supplied bareshaft or
coupledtoanelectricmotor.
Hydraulicsupply:-
This pump may be coupled to a hydraulic
motor.
Temperaturecontrol:-
Temperature control jackets will require
appropriate hot or cold media supply i.e. oil/
water/steam.
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1.5 Safety precautions
All warnings in this manual are summarised
on this page.
Pay special attention to the instructions
below so that severe personal injury or
damage to the pump can be avoided.
Personnel performing installation, operation
and maintenance of the pump must have the
relevant experience required.
WarningSigns
General safety instructions are
preceded by this symbol.
Electrical safety instructions
are preceded by this symbol.
Take great care when using
caustic agents.
Installation
Always observethetechnicaldata.
The pump must be electrically
connectedbyauthorisedpersonnel.
(Seethemotorinstructionssupplied
with the drive unit).
Never startinthewrongdirectionof
rotation with liquid in the pump.
Never put your hands or fingers
inside the port connections
Operation
Always observe the technical data.
Never touchthepumporthepipelines
when pumping hot liquids or when
sterilising.
Neverstandonthepumporpipelines.
Never run the pump with the suction
sideand/orthepressuresideblocked.
Always handletoxicandacidicliquids
with great care.
Never putyourhandsorfingersinside
the pump or port connections.
Maintenance
Always observe the technical data.
Always secure the pump during
maintenance and transportation.
Always disconnectthepumpfromthe
drive unit and power supply when
servicing thepump.
The pump must never be hot when
servicing it.
The pump and pipelines must never
be pressurised when servicing the
pump.
Never putyourhandsorfingersinside
the port connections.
Studythismanualcarefully

Operatio
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Manual
1.6 Health and safety information
Potentialsafetyhazards
The following section gives information on
handling, storage and disposal of parts and
materials used in the pumps which may be
considered hazardous to health.
Please pass this information on to your
Safety Officer, he may need it to comply with
Health and Safety, and COSHH regulations.
Generalfirstaid
If potentially hazardous substances are
accidentally inhaled, or skin or eyes
contaminated, then the following basic
precautions should be taken
Inhalation - Movetofreshair
Skin - Wash with soap and water
Eyes - Flushwithwater,seekmedical
attention
In all cases, if symptoms persist, seek medical
attention.
Material
Use Major hazard
SILICONE SEALANT GEARBOX SEAL RETAINERS,
GENERAL SEALANT. RELEASES VAPOUR AT ROOM TEMPERATURE.
ANTI-SEIZE COMPOUNDS BEARINGS APPLIED FROM AEROSOL.
RELEASESVAPOUR. DISPOSE
OF CONTAINER AS IF
PRESSURISED.
OIL AND GREASE OIL - GENERAL LUBRICATION
GREASE - PRODUCT SEALS,
TIMING GEARS, GENERAL
LUBRICATION.
SKIN AND EYE IRRITANT.
PLASTIC COMPOUNDS (PTFE,
POLYPROPLYENE, PVC)
PTFE - 'O' RINGS, LIP SEALS RELEASES FUMES WHEN
HEATED.
ELASTOMERIC COMPOUNDS
(EP, VITON, NITRILES, PTFE)
'O' RINGS, LIP SEALS RELEASES FUMES WHEN
HEATED.
PAINT EXTERNAL PUMP SURFACES. RELEASES DUST AND FUMES
IF MACHINED. TREAT AS A
FIRE HAZARD.
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2.0Unpacking,handling andstorage
Toavoidanyproblems,onreceiptofyourpump
always use the following procedure:-
2.1 Documents
1. Checkthedeliverynoteagainstthegoods
received.
2.2 Unpacking
Caremustbetakenwhenunpackingthepump,
and the following stages must be completed:-
1. Inspectthepackingforanypossiblesigns
of damage in transit.
2. Carefullyremovethepacking.
3. Inspect the pump for any visible signs of
damage.
4. Remove packing from the pump port
connections.
5. Ensurethatanyadditionalequipmentsuch
assealflushingpipeworkisnotdamaged.
2.3 Handling
Refertothepumpweightsguide,priortousing
anyliftinggear. Usethecorrectliftingslings
forthepumpweight.
An M10 x 15 tapping has been provided
suitable for the fitting of an eyebolt to enable
the pump to be lifted either with or without
the hydraulic drive fitted. Alternatively slings
should be wrapped around the ports and the
hydraulic drive flange.
Note : Tostop theslingsslipping always cross
the slings at the lifting hooks.
Bareshaftpump
2.4 Pump storage
After receipt and inspection if the pump is not
to be installed immediately the pump should
be repacked and placed in suitable storage.
The following points should be noted:-
1. Plastic or gasket type port covers
should be left in place.
2. Pumps received wrapped with
corrosion inhibiting treatment material
should be re-wrapped.
3. A clean, dry storage location, free from
vibration should be selected. When a
moist dusty atmosphere must be used
for storage, further protect the pump or
unit with a moisture repellent cover until
it is to be installed.
4. Rotate pump by hand, weekly, to
prevent bearing damage.
5. All associated ancillary equipment
should be treated similarly.
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3.0 Description of pump or pump unit
3.1 General pump description
The pump supplied is a positive
displacement pump, which may be supplied
bare shaft (see below) or with a drive unit .
The drawing below indicates various parts of
the pump.
3.2 Principle of operation
The pumps are of the positive displacement
rotary type with trilobe rotors. The direction
of flow is reversed by changing the direction
of rotation of the pump's drive shaft. The
pumping principle is as follows.
The volume at the inlet increases when the
rotors rotate and the product is drawn into
B D the pump. It is then transported in the space
betweenthelobesandtheperipheryofthe
A rotorcase to the dischargeside, where volume
between the rotors is reduced and the product
is discharged.
E C
Bareshaftpump
Item Description
A
B
C
D
E
Rotors
Rotorcase
Bearing Housing
Gear Housing
Feet
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3.3 Pump dimensions - horizontally ported pump
The above dimensions are for guidance only
and should not be used for installation
purposes. Certified dimensions are available
upon request.
3.4 Pump weight
Pump weight (dry)withplaincover 139lb.
Pumpweight(dry)withreliefvalve147lb.
The above weights are for guidance only
and will vary depending upon the
specification of the pump.
3.5 Pump displacement
Pumpdisplacement perrevolutionis
0.28 USgall.
3.6 Pump information chart
3.7 Pressure relief valve
A integral relief valve is available. It can be
used regardless of the direction of rotation. A
manual override is also available.
The relief valve is designed to partially
protect the pump from damage caused by
over-pressurisation. The relief valve is preset
at 145 psi.
Over pressurisation can occur if :-
1. A valve is closed against the pump
discharge.
2. The productviscosityin thesystemis
significantlyincreased.
3. The pump speed is increased.
Pump Max flowrate
(US gall/min)
Max pressure
(psi) Max speed (rev/min) Max Pressure at
max CIP Temp
of 2660F (psi)
STP125 280 145 1000 45
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4.0 System design and installation
4.1 System design advice
When designing the pumping system :-
Do - ConfirmwiththesuppliertheNet
Positive Suction Head (NPSH)
requirements for the system, as
this is crucial for ensuring the
smooth operation of the pump and
preventing cavitation.
Do - Avoidsuctionlifts andmanifold/
common suction lines for two
pumps running in parallel, as this
may cause vibration or cavitation.
DischargeLine
Do - Installanon-returnvalvetoprevent
turbining when high pressures are
applied to the pump whilst it is not
in use.
Do - Installvalvesiftwopumpsaretobe
usedonmanifold/common
dischargelines.
Do - Make the necessarypiping
arrangements if steam is required
for heating /cooling tanks.
Plan View
SuctionLine
Do not- Subjectthe pumptorapid
temperature changes during C.I.P.
(Cleaning in Place) procedures.
Pump seizure can result from
thermal shock. Asuitableby-pass
is recommended.
Do - Protectthepumpagainst blockage
from hard solid objects e.g. nuts,
bolts etc. Also protect the pump
from accidental operation against
a closed valve by the use of relief
valve,pressureswitch,etc..
Do - Fitsuctionanddischarge pressure
monitor points asclose tothe pump
ports as possible for diagnostic
purposes.
4.2 Direction of rotation
The direction of flow is dictated by the
direction of rotation of the drive shaft.
Reversing the direction of rotation will
reverse the flow direction.
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4.3 Pipework
All pipework must be supported. The pump
must not be allowed to support any of the
pipework weight.
Remember - Pipework supports must also
support the weight of the
product being pumped.
Always:-
Have - Suitably sized short straight
suction lines to reduce
friction losses in the
pipework thereby improving
the NPSH available.
Avoid - Bends, tees and any
restraints close to either
suction or discharge side of
pump. Use long radius
bends wherever possible.
Provide - Valves on eachsideofthe
pumpto isolatethepump
whennecessary.
Keep - Pipework horizontal where
applicable to reduce air
locks. Include eccentric
reducers on suction lines if
required.
Check - Coupling alignment during
installation.
Use - Flexible connections between
tank pipework and suction
port where conditions allow.
Pipework
support
Pipework
support
4.4 Port Orientation
The pump can be mounted in either horizontal
or vertical port orientation by changing the
pump mounting feet and its position. Pump
should not be side mounted when fitted with
vertically ported feet.
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5.0Commissioning
When taking delivery of a new or refurbished
pump unit it is essential to check that the
gearboxisfilledwiththecorrectquantityofoil
to thecentreof thesight glass, with oneof the
recommended grades of lubricant inthe table
below. Failuretohavethecorrect gradeand
levelof oilinthegearbox prior toinstallation
andstart-up, couldresultinseriousdamage
totheinternalcomponents.
The oil filler cap does not require to have
vent/breather hole. Using this type of solid
filler cap prevents the ingress of dirt and
cleaning solutions that would contaminate
the lubricant and reduce or destroy its
effectiveness . If this cap is lost at any time it
is important that a replacement of the same
type is fitted immediately.
5.1 Lubricatingthepump
The gearbox should be filled to the mid point
of the sight level glass. This requires
approximately 0.4US gallofoil fora
Horizontallyportedpumpand0.25USgallfor
aVerticallyportedpump.
5.3 Changing the oil :-
The pump will not be supplied oil filled.
First change - After 150 hours of operation
or after 1 month, whichever comes first.
Subsequent changes - Every 3000 hours of
operation or annually, whichever comes first.
Only use the recommended oil types.
5.4 Oil capacity
5.2 Recommended lubricants
Make Grade
-4°F +266°F
BP Energol
Castrol Alpha
Mobil Gear
Shell Omala
Texaco Meropa
Esso Spartan
GR-XP150
SP150
629
150
150
150
If none of the above manufacturers grades
are obtainable a suitable alternative high
grade 80-90 gear lubricant may be used
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6.0 Start up, shut down and Cleaning in Place
6.1 Pump Start Up Check List
Yes No
1. Has the pipework system been flushed
through to purge welding slag and/or
any other hard solids?
2. Have all obstructions been removed
from the pipework or pump?
3. Are the pump connections and
pipework joints tight and leak-free?
4. Is there lubrication in the pump and
drive unit?
5. Are the pipework valves open?
6. Are all safety guards in place?
7. Start then stop the pump to check that
the product is flowing in the correct
direction?
8. Are the pump speed/pressure and
temperature settings below the pump
maximum limitations?
When all answers are 'yes', the pump
may be used.
If there are any pumping problems referto the fault finding chart
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6.2 Pump shut downprocedure
1. Turn the pump off.
2. Isolate the pump/drive from all power
and control supplies.
3. Close the pipework valves to isolate
the pump.
4. Ensureallauxiliaryservicessuchas
heating/cooling tanks supply etc. are
isolated.
5. If thepump is to be dismantled, refer to
section8ofthismanual.
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6.3 Cleaning In Place (CIP)
The pump can be manually cleaned or
cleaned in place(CIP). The following is an
example of a typical CIP procedure. Specific
requirements for each application should be
dictated by the carrier/shipper.
Determine last product handled by the
pump
Remove the dust caps and/or fittings
from the pump, rinse any residue from
them with hot water.
Connect hot water hose to the pump
inlet or connect pump inlet to the tank
trailer outlet valve during the tank’s
hot water cleaning cycle.
When not fitted connect a ball or gate
valve (to restrict liquid flow) to the
pump discharge outlet.
If driven hydraulically, ensure that the
hydraulic proportional control valve is
in the neutral position.
If driven hydraulically or electric/
hydraulically, start system and run at
normal operating speed. Open the
ball or gate valve on the pump
cleaning system so the hot water or
cleaning solution from the tank flows
intothepump.(hotwatershouldbe
176°Fto194°F) Ifhydraulicallydriven,
selectforwardontheproportional
controlvalveandslowlyincrease(by
pushingthehandle)tofullpumpspeed.
Whendrivenelectricallystartthe
systemandslowlyincreasethespeed
withthehandwheelonthebeltvariator.
Using the ball or gate valve, (to
restrict liquid flow) increase the pump
pressureto approximately60-75 psi
while it is operating. Apressure gauge
atthedischargeoutletwillberequired.
Thiswillensurethatthecleaning
solutioniscleaningthepumpunder
highpressureconditions.
Run the pump for 15 minutes under this
pressure.
Relief Valve Pumps Only
WARNING: Do not complete this next
step if your pump does not have a
relief valve !!
Close the ball or gate valve (to restrict
liquid flow) until the pump relief valve
actuates. Open the valve and close it
again.Openvalve onceagain-this
shouldhavenowcleanedanyresidue
frombehindthereliefvalvediaphragm
andanyotherclosetoleranceareas
insidethepump.
Shut down pump system in reverse
order of above.
Clean all external fittings from the
fittings box with hot water and return.
Remove all hose and fittings from the
pump, bag ends and seal the ports.
IMPORTANT
Do not subject the pump to rapid temperature
changesaspumpseizurecanresult fromthermal
shock.
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Description Quantity
'O'ring,productseal
or
Mechanicalseal
'O'ring,sealhousing
'O'ring,sleeve/shaft
'O'ring,sleeve/rotor
'O'ring,rotornuts
'O' ring, front cover
Oil seal drive end
Oil seal gland end
2
2
2
2
2
2
1
1
2
7.0 Maintenance and inspection
Part description
7.1 Maintenance schedule
Itis advisableto installpressuregauges on
both sidesof pump as closeas possible to the
portssothatanyproblemswithinthepump/
pipeworkwillbehighlighted.
Your weekly schedule should include:
Checkingthe oil level inthegearcase
Checkingthe product seals forleakage
and replace as necessary. The pump
has been designed to operate at a
maximum continuous discharge
pressure of 145 psi. However, it is
capableofwithstandingdischarge
pressures up to a maximumof 160 psi
intermittently.Atpressuresabove145
psi there is the possibilityof leakage
fromtheprimaryseal,ifthis occursand
thesealcontinuestoleakatpressures
below145psi, it is an indication that the
primarysealmaybepermanently
damagedandshouldthereforebe
replacedattheearliestopportunity.
Checkingtheoil seals forleakage and
replaceasnecessaryat the earliest
opportunity.
Checkpumping pressures. Incertain
operational circumstances the pump
will pose a thermal hazard and as such
should not be touched during operation.
After shutdown the pump unit should be
allowed timetocool.
7.2 Recommended spare parts
The following table details the recommended
spare parts that should be retained within
your maintenance schedule. (Refer to the
Exploded drawings andparts list insection 16
ofthismanual).
Refertosparepartsmanualfor
itemnumbers.
7.3 Maintenance tools
The following lists the maintenance tools
required when working on the pump.
Dismantling the pump head
You will need:
Spanners
Socket set
Plastic block
Soft mallet
Cleaning hose
Rotorremovaltool(supplied
withpump)
6" Prybar(i.e.Snap-OnPt.
650)
Dismantling the gearbox
You will need - A fully equipped work shop in
addition to the above.
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8.0Disassembly
8.1 Before dismantling the pump
Before starting to dismantle the pump
Always:-
Purge -
thepumpandsystemifanynoxious/hazardous
productshavebeenpumped.
Isolate -
pump/drive unit from all power and control
supplies.
Close -
pipework valves to isolate the pump
Disconnect -
the pump from the drive unit.
Secure -
The pump must be securely held during
maintenancetomaintainstability.
Read this section before continuing to dismantle the pump
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To aid re-assembly, note which components
cameoff whichshaft.Goodengineeringpractise
suggests that components removed from a
shaft should be assembled on the same shaft.
If removing the front cover for any reason
check that rotorcase retaining nuts are tight
before replacing.
8.2 Removing the front cover
1. Remove the 'R' clips (2) and carefully
loosen the front cover retaining nuts (3)
as there may still be residual pressure in
the system.
2. Remove the front cover nuts and take off
the cover (6). If stuck, loosen by tapping
with soft mallet at overlap at sides.
Do not lever off.
3. Flush out the pump head before
continuing.
4. Remove the 'O' ring (7) from the front
cover.
8.3 Removing the rotors
1. Insert a plastic block between the two
rotors (13) to stop them turning.
2. Using a spanner remove the rotor nuts
(9). These nuts have right hand threads.
3. Therotorscanberemovedfromtheshafts
(28,29) by hand or by using the extractor
tool supplied with the pump to aid
disassembly. Unscrew the central bolt
untilflushontheinside,screwthetooltwo
full turns into the rotor. Whilst preventing
the tool from turning screw in the central
bolt. The rotor is jacked off the shaft for
hand removal.
Central bolt
8.4 Product seal removal
1. 'O' ring- Refer to section 10
2. MechanicalSeal-Refertosection 11
8.5 Removing the rotorcase
1. Removetherotorcaseretainingnuts.(5).
2. Gentlytaptherotorcase(11)oneachside
with a soft mallet to release it from the
bearing housing. (18)
3. Therotorcasewillbesupportedon
thestuds(4)duringremoval.
4. The rotorcase and seal housing (66) can
be removed as an assembly.
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