PROCESSTEC ViscoTwin 130 G8 Manual

Address: 345 E. Tulare Avenue Unit E | Visalia, CA 93277 | Phone: [phone]
Fax: [phone] | Email: [email protected] | http://processtec.com
ViscoTwin 130 G8
Operation & Maintenance Manual
Published February 23rd, 2023

TABLE OF CONTENTS
PROCESSTEC INC. 2022Page ii

TABLE OF CONTENTS
PROCESSTEC INC. 2022 Page iii
1. ABOUT VISCOTWIN SCREW PUMPS .............................. . 1
1.1 Safety Notes .............................................................. 1
1.2 Working Principle .......................................................... 3
1.3 General Overview .......................................................... 4
1.4 Opons .................................................................. 5
1.4.1 Opons for 3A or EHEDG .............................................. 5
1.4.2 Pump Face Opons................................................... 6
1.4.3 Pump Housing Opons................................................ 8
1.4.4 Elastomer Opons ................................................... 10
1.4.5 Spindle Opons...................................................... 11
1.4.6 Mechanical Seal Opons .............................................. 12
1.4.7 Bearing Housing Opons .............................................. 14
1.4.8 Motor Opons ...................................................... 17
1.4.9 Frame Opons ...................................................... 18
1.5 Performance Tables ........................................................ 19
1.5.1 Sizing Chart ......................................................... 19
1.5.2 Water Curves........................................................ 21
2. INSTALLATION............................................... 23
2.1 Unpacking ................................................................ 23
2.2 Inspecon / Technical Documentaon ......................................... 23
2.3 Hoisng and Transportaon.................................................. 24
2.4 Installaon................................................................ 26
2.5 Piping Before and Aer the Pump............................................. 27
2.5.1 Upstream Piping ..................................................... 27
2.5.2 Downstream Piping .................................................. 28
2.5.3 Piping Before and Aer the Pump....................................... 28
2.6 Mechanical Seal Connecon ................................................. 29
2.7 Pre-Installaon of Seal Water for Dual Acng Mechanical Seal ..................... 30
2.8 Electrical Installaon........................................................ 31
3. OPERATION................................................. 33
3.1 Pump Startup ............................................................. 33
3.2 So Starng the Pump ...................................................... 33
3.3 Avoiding Pump Cavitaon ................................................... 34
3.4 Pumping Sensive Products.................................................. 34
3.5 Material Selecon for Sealing Surfaces......................................... 35
3.6 Pumping Product with Large Parculates ....................................... 35

TABLE OF CONTENTS
PROCESSTEC INC. 2022Page iv
3.7 High Pressure Systems ...................................................... 35
3.8 CIP / COP Soluon.......................................................... 36
3.9 Visual Inspecon ........................................................... 37
3.10 Available Elastomer Opons ................................................ 37
3.11 Leakage ................................................................. 38
3.12 Scratches in the Pump Housing .............................................. 39
4. MAINTENANCE.............................................. 41
4.1 Maintenance Preparaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.1 General Movie: HOW THE PUMP WORKS................................. 41
4.1.2 Introducon to Web Page ............................................. 41
4.1.3 Risk Assessment for Pump Maintenance ................................. 42
4.1.4 Safety Measures ..................................................... 42
4.2 Explaining Maintenance Levels ............................................... 43
4.2.1 Maintenance Level 1 (ML-1) ........................................... 43
4.2.2 Maintenance Level 2 (ML-2) ........................................... 44
4.2.3 Maintenance Level 3 (ML-3) ........................................... 45
4.3 Material at hand, Required Parts & Tools ...................................... 46
4.3.1 Recommended Spare Parts ............................................ 46
4.3.2 Recommended Tools ................................................. 47
4.3.3 Recommended Oils, Grease............................................ 47
4.4 Maintenance Instrucons for ML-2............................................ 48
4.4.1 Removing the Pump Housing .......................................... 48
4.4.2 Complete Pump Disassembly .......................................... 51
4.4.3 Complete Pump Assembly ............................................. 57
4.5 Preventave Maintenance Program ........................................... 65
4.5.1 First Oil Change ...................................................... 65
4.5.2 Oil Change Intervals .................................................. 65
4.5.3 Checking Levels on Motor Gearbox Oil................................... 65
4.5.4 Greasing Motor Bearings .............................................. 65
4.5.5 Check Condion of O-rings ............................................ 66
4.5.6 Check the Exterior Lip Seals and O-rings on the Mechanical Seals ............ 66
4.5.7 Check Oil Sha Sealing Rings ........................................... 67
4.5.8 Proper Gapping of Pump .............................................. 68
4.5.9 Changing Product Flow Direcon ....................................... 72
4.6 Failures................................................................... 73
4.6.1 Foreign Material enters Pump Housing .................................. 73

TABLE OF CONTENTS
PROCESSTEC INC. 2022 Page v
5. TOOL-BOX .................................................. 75
5.1 Tools ..................................................................... 75
5.1.1 ViscoTwin Tools...................................................... 75
5.1.2 General Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.2 Spare Parts................................................................ 81
5.2.1 Spare Parts for Pump Housing.......................................... 81
5.2.2 Spare Parts for Seal Housing ........................................... 85
5.2.3 Spare Parts for Bearing Housing ........................................ 87
5.2.4 Spare Parts for Gear Housing........................................... 88
5.2.5 Spare Parts for Drive Train ............................................. 90
5.3 Explosion Drawings......................................................... 92
5.4 Torque Tables ............................................................. 93
5.5 Pump Housing Conguraon ................................................. 94
5.6 Oils, Grease & Lubricaon Recommended ...................................... 102
5.7 Oil Tesng Kit (with Form) ................................................... 104
6. GEEK‘S CORNER ............................................. 105
6.1 Oil Cooler with Oil Filter ..................................................... 105
6.2 Vibraon Sensor with Oil Temperature Sensors.................................. 106
6.3 Quench Design for Recirculang Fluids in Mechanical Seals........................ 107
6.4 Maximizing Bearing Lifespan ................................................. 108
6.5 Equipment Commissioning Protocol ........................................... 118
7. APPENDIX .................................................. 119
7.1 Maintenance Movies ....................................................... 119

TABLE OF CONTENTS
PROCESSTEC INC. 2022Page vi
This page intenonally le blank.

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 1
1. ABOUT VISCOTWIN SCREW PUMPS
1.1 Safety Notes
This manual contains instrucons which should be heeded to ensure personal safety and prevent damage
to property. These instrucons are highlighted by a warning triangle and a color to indicate the degree of
the hazard. The following warnings should be observed throughout the life cycle of the pump:
ROTATING PARTS
Indicates rotang parts that can cause injury. Only perform work on or near these parts
when it is locked to prevent rotaon. It is advised to have a protecve barrier surrounding
the rotang part to prevent injury or property damage during operaon.
HIGH VOLTAGE
Indicates high voltage and risk of shock or severe burns. No work should be performed
around high voltage parts unless they have been disconnected from the main power
supply. Any work on high voltage parts must only be performed by an electrician licensed
in the state where operaons and maintenance is being performed.
CRUSHING PARTS
Indicates moving parts that can crush and cut. Perform work with awareness of how
parts move and where these crushing parts can be encountered.
SUSPENDED LOAD
Indicates a suspended or overhung load, where parts can fall, slip, or p over if not
properly secured. Do no work on any part that is suspended and avoid being directly
under or near a suspended load. Do not stand between a staonary object and a
suspended load.
LIFTING OBJECTS
Indicates heavy objects that can cause muscle strain or back injury. Liing aids and
proper liing techniques should be used to prevent injury.

1. ABOUT VISCOTWIN SCREW PUMPS
Page 2 PROCESSTEC INC. 2022
Commissioning and operang the ViscoTwin 130 G8 may only be performed by qualied personnel.
Qualied personnel in terms of the safety instrucons in this operang and safety manual are persons
who have completely read this manual.
Furthermore, maintenance can only be performed by qualied maintenance technicians. Qualied
maintenance technicians in terms of the maintenance instrucons in this operang and safety manual are
persons who have read Chapter 4 “Maintenance” and have been trained by Processtec in the use and
maintenance of this pump. In lieu of in-person training by Processtec personnel, a qualied maintenance
technician may also review the online maintenance movies available at hp://processtec.com. WARNING:
ANY MAINTENANCE LEVEL 2 PERFORMED ON THIS PUMP BY UNTRAINED PERSONNEL WITHOUT THE
EXPRESS WRITTEN CONSENT OF PROCESSTEC WILL RELEASE PROCESSTEC OF ANY LIABILITY AND VOID
ANY WARRANTY CLAIMS ON THE PUMP..
In addion to this operang manual, general on-site regulaons as well as city, state, and federal regulaons
applicable to accident prevenon must be made available and followed.
The ViscoTwin 130 G8 may only be used in the applicaons as specied in Chapter 3 "Operaon" on page
33, and only in connecon with the spare parts recommended by Processtec, Inc.
LEAKAGES
Indicates that leaks are possible. Leaked uid can cause slip-and-fall hazards and should
be cleaned up and disposed of immediately.
HOT SURFACE
Indicates a surface is hot to the touch and can cause burn injury. Do not maintain or
touch a hot surface unl the pump is turned o and allowed to cool. If immediate repair
is necessary, it is advised to wear protecve gloves while handling a hot part.
CAUTION
When operang the ViscoTwin 130 G8, it is essenal to wear appropriate protecve
equipment.

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 3
1.2 Working Principle
Screw pumps are rotary posive displacement pumps for conveying low to high viscosity media. The
ViscoTwin G8 is a posive displacement pump characterized by a double screw, or spindle, design. The
pump ulizes very close tolerances to create a series of “sealed” chambers between spindle windings.
This allows the pump to more eciently transport highly viscous product with minimal slippage and
precision owrate control as well as gentle handling of solid parculates already mixed into the product.
The precision crasmanship of the ViscoTwin G8 means it can generate a very high pressure dierenal,
even with a low inlet pressure.
The pump is also highly customizable, with several sizes and inlet/outlet variaons to suit the needs of
the product and the space available. Addionally, the pump is maintenance friendly and fully CIP-able, to
ensure ease of use.
ViscoTwin G8 pumps used in the food and beverage industry are designed to meet the most stringent
sanitary design criteria (3A, EHEDG), and are built with corrosion-resistant materials in accordance with
recommendaons from US Food and Drug Administraon (FDA) and other internaonal food safety
governing bodies. Pumps are delivered with a motor, lantern, and framing as standard for easy installaon.

1. ABOUT VISCOTWIN SCREW PUMPS
Page 4 PROCESSTEC INC. 2022
1.3 General Overview

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 5
1.4 Opons
1.4.1 Opons for 3A or EHEDG
All ViscoTwin pump models including all associated
opons as listed throughout this Secon 1.4 are designed
according 3A and EHEDG guidelines. General design and
detail design consideraons like radii, O-ring grooves,
surface treatment, material, and elastomer selecon
fulll both norms.
Only pumps for the US dairy industry require the 3A symbol aached to it. The only dierence is a slight
improvement on the spindle polish. In case the spindles are hardened with the kolsterizaon process, the
spindels show a mae surface, because the spindle polishing took place before the kolsterizaon process.
All ViscoTwin Pump Housings are hardened with a
DURALOY treatment. The inside surface of the pump
housing is always mae.
The general build of all ViscoTwin pumps also fulll
OSHA guidelines.

1. ABOUT VISCOTWIN SCREW PUMPS
Page 6 PROCESSTEC INC. 2022
1.4.2 Pump Face Opons
Processtec is always on the lookout for new ways to innovate pro-
ducts in our Industry, and so we are proud to announce the NPSH
Opmized Pump Face. It was designed to transion pumped product
more eciently and gently between the pump face and the pump
housing. This design helps in many ways: it keeps the product whole
and intact, it eliminates cavitaon, and gives the customer more op-
ons for piping conguraons.
The NPSH Opmized Pump Face is designed to increase the eciency of the pump face during either
sucon or discharge. During sucon, the product has to transion from the cross-seconal area of a 4”
OD tube (or smaller) to a cross-seconal area of the pump housing. By the mass ow rate equaon and
Bernoulli’s equaon, respecvely:
The above equaons imply that:
That is, that as the product goes from the smaller inlet to the larger pump housing, the velocity decreases
thus the pressure increases. This increased pressure results in a higher NPSHa, thus increasing the pump’s
capabilies. The NPSH Opmized Pump Face also comes with a G1” sanitary port to add a pressure sensor
to see the process in acon.
Another factor considered in the NPSH design is smooth ow transion. Sudden changes in diameter
rapidly increase the Reynolds number of the ow, which can create turbulent ow that will both decrease
the pump eciency and could damage sensive product. The NPSH pump face addresses these concerns
by using a diverging nozzle to expand the ow evenly, avoiding sharp corners and sudden changes to the
ow characteriscs.
The Dual Port Pump Face uses the same principle as the NPSH
pump face. This conguraon allows for two lines to conjoin at the
pump which reduces piping system complexity, while maintaining
the eciency of the NPSH standard pump face.

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 7
There is also an Eco Pump Face. This is an economic opon pum-
ping less viscous or more robust product that can withstand the ra-
pid pressure changes and turbulent ows addressed in the NPSH
pump face.
Both the NPSH Opmized and Dual Port Pump Faces are
standardized on 4”OD and a Tri-Clamp connecon. Several other
size opons and process connecon opons exist but will require longer delivery mes. These available
opons are outlined in the tables below.
PORT SIZE OPTIONS
OD3" OD4" (Std.) OD5" OD6" DN80 DN100 DN125
PROCESS CONNECTION OPTIONS
Tri Clamp
(Standard) DIN 11851
DIN 11864-1
(Screwed Union)
DIN 11864-2
(Flange Union)
DIN 11864-3
(Clamp Union,
Feral Collar Side) Varivent Flange Bu Weld Short Pipe
NOTE: Processtec supplies the Non O-ring / Collar side; the mated O-ring Groove side & clamps are not
included with the ViscoTwin Pump.

1. ABOUT VISCOTWIN SCREW PUMPS
Page 8 PROCESSTEC INC. 2022
1.4.3 Pump Housing Opons
Flow Direcon
The ViscoTwin G8 has two general ow direcons: Face in -> Housing out (FH) and Housing in -> Face
out (HF)
It is preferred to drag the product along the boom of the housing which requires the shas to spin
“outwards”.
Spindle arrangement for shas turning “Outwards”:
Housing arrangement “FH” -> Spindle arrangement “V”
Housing arrangement “HF” -> Spindle arrangement “A”
Outwards turning shas require the PIN arrangement “3”
Spindle arrangement for shas turning “Inwards”:
Housing arrangement “FH” -> Spindle arrangement “A”
Housing arrangement “HF” -> Spindle arrangement “V”
Inwards turning shas require the PIN arrangement “1”
The most common arrangement for ViscoTwin pumps is arrangement FHO3V (see page 96).

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 9
Port Direcon
The ViscoTwin G8 also has two general port direcons: Discharge to Top, and Discharge to Boom.
Discharge to Top Discharge to Bottom

1. ABOUT VISCOTWIN SCREW PUMPS
Page 10 PROCESSTEC INC. 2022
1.4.4 Elastomer Opons
Elastomer Selecon Table
MAX. TEMP MAX. FAT TEMP / STRESS
EPDM 140° C 10% 28 bar
FKM 120° C 100% 28 bar
V70SW 200° C 100% 40 bar
PERLAST 200° C 100% 50 bar

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 11
1.4.5 Spindle Opons
Three dierent spindle pitches are available for each ViscoTwin pump size. Each individual spindle pitch
itself has the following opons:
• Standard EHEDG polish
• Standard 3A polish
• Hardened EHEDG polish
• Hardened 3A polish
• Hardened tapered EHEDG polish
• Hardened tapered 3A polish
Smaller spindle pitches are used to create high discharge pressures, especially with product at viscosies
below 2000 cps, at the cost of liming the ow rate. Larger spindle pitches can be used for high viscous
product at medium discharge pressure, and/or high owrates of low viscous media like CIP at lower
dierenal pressures.
For product with specic parculate sizes, the spindle pitch will determine the minimum pump size. For
example, if the parculate requires a cross secon of 1", then the pump would need to be a Model 104.53
or Model 130.65.
33mm 44mm 65mm
Volume per Revoluon
SIZE SCREW PITCH VOLUME PER REVOLUTION
METRIC US STANDARD
PARTICULATE SIZE
METRIC US STANDARD
ViscoTwin
130 G8
33 mm 0.317 Liter 0.084 Gal 16.5 mm 2/3"
44 mm 0.423 Liter 0.112 Gal 22.0 mm 6/7"
65 mm 0.623 Liter 0.165 Gal 32.5 mm 1-2/7"
Max Pump Head RPM: 3000 rpm.

1. ABOUT VISCOTWIN SCREW PUMPS
Page 12 PROCESSTEC INC. 2022
1.4.6 Mechanical Seal Opons
Dierent mechanical sealing surfaces and elastomers are available for the ViscoTwin G8 pumps. Material
and design are selected based on applicaon.
For easy handling, the ViscoTwin 130 G8 is designed to use a fully pre-assembled cartridge seal to prevent
assembly errors and damages to the sealing surfaces.
For a long service life, please follow the operang condions the mechanical seals are designed for.
Processtec has mechanical seals for various pressure and temperature requirements available.
Design Opons
Mechanical seals for the ViscoTwin are categorized as follows:
• Single Acng Mechanical Seals (SAMS)
• Double Acng Mechanical Seals (DAMS)
Available sealing surfaces in the product area:
• Silicon Carbide (SIC)
• Tungsten Carbide knife edge (TC)
Available Elastomers in the product area:
• FKM (standard)
• EPDM for high temperature without fat content
• FFKM (special applicaons for high temperature, fat content, and stress)
The mechanical seals are designed to withstand a product area pressure of up to 400 psi. High pressure
seals can be used when the product area pressure can reach up to 630 psi, however, these seals can
only be used in a specially designed HPHT (High Pressure, High Temperature) ViscoTwin. Please contact
Processtec for more informaon on our High-Pressure pumps.

1. ABOUT VISCOTWIN SCREW PUMPS
PROCESSTEC INC. 2022 Page 13
Single Acng Mechanical Seals (SAMS)
ViscoTwin G8 Pumps with single acng mechanical seals CANNOT run dry.
Due to the self draining capability of ViscoTwin G8 pumps, Processtec
does not recommend using single acng mechanical seals for standard
applicaons.
Double Acng Mechanical Seals (DAMS)
ViscoTwin G8 pumps with double acng mechanical seals can run dry as long
as the quench media ows through the seal. The quench media lubricates
and cools the sealing surfaces whether there is product in the pump or not.
The quench area is located between the inboard sealing surfaces (product
area) and the outboard sealing surfaces (atmosphere). The quench media
reduces fricon between the rotang sealing surface and the stac sealing
surface. The quench media, in most cases, is city water, single pass. It can be
glycerine or vegetable oil recirculated from a quench tank.
Sealing Surface:
Silicon Carbide (SIC)
Sealing Surface:
Tungsten Carbide knife edge (TC)

1. ABOUT VISCOTWIN SCREW PUMPS
Page 14 PROCESSTEC INC. 2022
1.4.7 Bearing Housing Opons
Housing Opons:
There are two housing opons available for the ViscoTwin Bearing Housing and Gear Housing. Both have
disnct advantages.
Stainless Steel
The Stainless Steel bearing housing is our standard opon.
The Stainless Steel bearing housing will not show external
wear even aer many years in operaon, and fullls the
highest sanitary standards.
The Stainless Steel bearing housing includes:
1) The Gear Housing Inspecon Port, which allows for:
• A mounng space for a vibraon sensor & oil temperature
sensor to connuously monitor pump performance.
• Easy oil sampling for gear oil quality tesng.*
• Spindle gapping without needing to remove and replace
the gear oil.
2) A second Oil Sight Gauge, which allows for:
• Oil level inspecon from either side of the pump.
• Easier gear oil visual inspecon (parculates in the oil,
discoloraon, etc.)
*oil sample tesng kits can be ordered at: [e-mail].
Powder Coated
The Powder Coated bearing housing is an economic soluon
made from cast iron. The powder coang is resilient to external
weathering, however some wear can show over me.