Idex Wright Flow Technologies RTP Series User manual

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I NSTALLATION , O PERATION
A ND
M AINTENANCE M ANUAL
F OR T HE
R ANGE OF P UMPS

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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
FOR RTP
TM
ROTARY LOBE PUMPS.
1.0 SAFETY INFORMATION. 3
1.1 R ISK ASSESSMENT RELATING TO THE USE OF W RIGHT F LOW T ECHNOLOGIES L IMITED
RTP ROTARY LOBE PUMPS AND PUMP UNITS IN POTENTIALLY EXPLOSIVE ATMOSPHERES . 6
2.0 INTRODUCTION. 7
2.1 G ENERAL . 7
2.2 W RIGHT F LOW T ECHNOLOGIES L IMITED D ISTRIBUTORS . 7
2.3 R ECEIPT AND S TORAGE . 7
2.4 C LEANING . 8
2. P UMP M ODEL D ESIGNATION . 8
2. .1 ATEX I NFORMATION 9
3.0 GENERAL. 11
3.1 RTP
TM
P UMPING P RINCIPLE . 11
3.2 RTP
TM
O PERATING P ARAMETERS . 12
3.3 S YSTEM D ESIGN AND I NSTALLATION . 12
3.3.2 I NSTALLATION WITH CIP S YSTEMS . 15
3.4 S TART -U P P ROCEDURE . 16
3. S HUTDOWN P ROCEDURE . 17
3.6 R OUTINE M AINTENANCE – N ON A TEX UNITS . 17
3.6.1 A DDITIONAL R OUTINE M AINTENANCE – A TEX UNITS . 18
3.7 H EATING AND C OOLING D EVICES 19
3.8 I NTEGRAL P RESSURE R ELIEF V ALVE . 21
4.0 RTP
TM
PUMP DISMANTLING AND ASSEMBLY. 23
4.1 D ISASSEMBLY . 24
4.1.1 F RONT C OVER AND R OTOR R EMOVAL 24
4.1.2 G EARBOX D ISMANTLING 25
4.1.3 S HAFT D ISASSEMBLY (RTP30 S HOWN ). 27
4.2 A SSEMBLY . 28
4.2.1 G EARBOX & R OTORCASE A SSEMBLY , 28
4.2.2 S HAFT A SSEMBLY – RTP20 29
4.2.3 S HAFT A SSEMBLY – RTP30 30
4.2.4 T IMING . 31
4.2. S ETTING THE ROLLING TORQUE . 34
4.2.6 R OTOR C LEARANCES . 34
4.3 P RODUCT S EAL F ITTING AND R EMOVAL . 35
4.3.1 G ENERAL P ROCEDURES FOR I NSTALLING S EALS . 35
4.3.2 RTP20 O- RING S EAL R EMOVAL AND INSTALLATION . ( ABOVE ORDERS # 611 2). 37

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4.3.2.1 RTP20 O- RING S EAL R EMOVAL AND INSTALLATION ( PRE - ORDERS # 611 1). 39
4.3.3 RTP20 M ECHANICAL S EAL . 41
4.3.4 RTP30 C LASS 1 H YGIENIC M ECHANICAL S EAL . 42
4.3. RTP30 C LASS 2 H YGIENIC M ECHANICAL S EAL . 43
4.3.6 RTP30 S TANDARD R ADIAL L IP S EAL . 44
4.3.7 RTP30 O- RING S EAL . 45
.0 SPECIFICATIONS. 46
.1 C LEARANCE C HART 46
.2 F ASTENERS & T ORQUE S ETTINGS . 47
.3 L UBRICANTS . 48
.4 T OOL L IST . 49
. RTP30 F OUNDATION D IMENSIONS – S TUB S HAFT D RIVE . 50
. .1 RTP20 AND 30 F OUNDATION D IMENSIONS – B ASIC P UMP (H YDRAULIC D RIVE ) 51
.6 T YPICAL B ASIC P UMP B UILD (RTP20 S HOWN ) 53
.7 T ROUBLE S HOOTING . 54
.8 RTP
TM
S ERVICE H ISTORY . 55
.9 N OTES . 56

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1.0 Safety Information.
INCORRECT INSTALLATION, OPERATION, OR MAINTENANCE OF
EQUIPMENT MAY CAUSE SEVERE PERSONAL INJURY OR DEATH
AND/OR EQUIPMENT DAMAGE THAT MAY INVALIDATE THE
ARRANTY.
THIS INFORMATION MUST BE READ FULLY BEFORE BEGINNING
INSTALLATION, OPERATION, OR MAINTENANCE AND MUST BE KEPT
ITH THE PUMP. ONLY SUITABLY TRAINED OR QUALIFIED PERSONS
SHOULD UNDERTAKE INSTALLATION AND MAINTENANCE.
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. A 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 operations envelope can cause mechanical contact,
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 from exceeding its stated duty pressure. It must be suitable for both
directions of pump rotation where applicable. Do not allow the pump to
operate 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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Da an ng ge er r - - F Fa ai il lu ur re e t to o f fo ol ll lo ow w t th he e
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de ea at th h. . A Ar re ea as s o of f p po ot te en nt ti ia al l r ri is sk k a ar re e
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id de en nt ti if fi ie ed d b by y t th he e f fo ol ll lo ow wi in ng g s sy ym mb bo ol l: :
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Wa ar rn ni in ng g - - S Sa af fe et ty y i in ns st tr ru uc ct ti io on ns s
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wh hi ic ch h s sh ha al ll l b be e c co on ns si id de er re ed d f fo or r
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pr ro ot te ec ct ti io on n o of f t th he e p pu um mp p o or r p pu um mp p
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un ni it t i it ts se el lf f a ar re e m ma ar rk ke ed d b by y t th he e s si ig gn n: :
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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, 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 head to avoid the build-up of a potential charge 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 5.3). Beware of over/under filling the gearbox as this could
cause the pump to overheat and severe 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 3.1).
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 will 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 baseplate. If the pump is
baseplate 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 the 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 depressurised and purged.
- Any temperature control devices (jackets, heat-tracing, etc.) are fully
isolated, that they are depressurised and purged, and components are
allowed to reach a safe handling temperature.
Use only genuine right Flow Technologies parts.
All certification, standards, guarantees & warranties originally supplied with
this pump will be invalidated by the use of non-genuine Service Parts.
DO NOT attempt to dismantle a pressure relief valve which has not had the
spring pressure relieved, is still connected to a pressurised gas/air supply or is
mounted on a pump that is operating. Serious personal injury or death and/or
pump damage may occur.
Use only genuine right Flow Technologies parts.
All certification, standards, guarantees & warranties originally supplied
with this pump will be invalidated by the use of non-genuine Service
Parts.
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 pressurised media.
Pumps and/or drives can produce sound power levels exceeding 85-dB (A)
under certain operating conditions. hen necessary, personal protection
against noise must be taken.
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.
hen cleaning, either manually or by CIP method, the operator must ensure
that a suitable procedure is used in accordance with the system requirements.
During a CIP cleaning cycle, a pump differential pressure of between 2 and 3
bar (30 to 45 psi) is recommended to ensure suitable velocities are reached
within the pump head. The exterior of the pump should be cleaned
periodically.
The surface temperature of the pump is also dependent on the temperature of
the pumped medium.
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1.1 Risk assessment relating to the use of right Flow Technologies Limited RTP
rotary lobe pumps and pump units in potentially explosive atmospheres.
N
No ot te e: :- - F Fo or r a a f fe ea at tu ur re e t to o b be e s su ui it ta ab bl le e f fo or r a an n a ap pp pl li ic ca at ti io on n, , T Th he e f fe ea at tu ur re e m mu us st t b be e f fi it t f fo or r i it ts s
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2.0 Introduction.
2.1 General.
RTP
TM
rotary lobe pump is manufactured by right Flow Technologies Limited
a unit of the IDEX Corporation.
This manual includes all the necessary information for RTP
TM
pumps and
should be read prior to beginning installation, operation, or maintenance.
Should you require any additional information regarding the RTP
TM
pumps
contact right Flow Technologies Limited or their local authorised distributor
(refer to section 2.2).
hen 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, see fig 2. Should the
nameplate be unreadable or missing, the pump serial number is also stamped
on either side of the rotorcase, see fig 3.
If the system or product characteristics are to be changed from the original
application for which the pump was selected, right Flow Technologies
Limited or their authorised distributor should be consulted to ensure the pump
is suitable for the new application.
2.2 right Flow Technologies Limited Distributors.
right Flow Technologies Limited distributes its products internationally via a
network of authorised distributors. Throughout this manual where reference is
made to right Flow Technologies Limited, service and assistance will also be
provided by any right Flow Technologies Limited authorised distributor for
RTP
TM
pumps.
2.3 Receipt and Storage.
Upon receipt of the pump, immediately examine it for any signs of visible
damage. If any damage is noted, contact right Flow Technologies Limited or
your right Flow Technologies Limited distributor and clearly mark upon the
carriers paperwork that the goods have been received in a damaged condition,
with a brief description of the 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 –10°C and 40°C (14°F and 105°F).

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2.4 Cleaning.
The RTP
TM
pump series is suitable for both manual cleaning and CIP
(Cleaning In Place), refer to section 3.3.2.
The product seals are mounted directly behind the rotors and are designed
and positioned to minimise product entrapment and maximise the effects of
cleaning.
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 be cleaned periodically.
2.5 Pump Model Designation.
Fig 1 Designation of pump models
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.
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Page 9
2.5.1 ATEX Information
ATEX Pump Requirements
Mechanical seals are a source of heat and must never be allowed to run dry.
e would recommend provision be made to ensure that there is always flow
or fluid around the pump seals. If there is a risk of the supply being
interrupted, then a temperature monitoring system must be applied to ensure
the pump does not exceed the Atex rating. The surface temperature of the
pump is dependent on the temperature of the pumped fluid and a due account
of this should be taken whilst undertaking your risk assessment of the
installation. These pumps are Atex rated T3.
Only use genuine spare parts that have been designed and verified Atex
compliant by right Flow Technologies, failure to use genuine spare parts will
invalidate the Atex certification.
Pumps that have the Atex certification will have an earthing point on the front
cover, this needs to be electrically earthed before use.
The service and maintenance intervals are increased on certified Atex units,
refer to section 3.6.1 for the required routine maintenance. Failure to maintain
the pumps to these intervals will result in the Atex certification being
invalidated.
hen installing the unit make sure so far as reasonably practicable that the
pump is aligned within 5 degrees to the horizontal – failure to align the unit
could adversely affect the gearbox lubrication and could cause heat to build
up.
It is the end user’s responsibility to ensure that the Atex rating of the
equipment supplied meets the requirements of the installation.
2.5.2 Equipment Groups & Categories
The pump range has been rated as
ARNING
ARNING
ARNING
Category 2
Temperature Class T3
Unit is suitable for environments
con
taining dust or gas G/D
Group II.
ARNING