Wright flow Cocept SQ General instructions

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 THE CONCEPT SQ RANGE OF ROTARY LOBE PUMPS
1.0 SAFETY INFORMATION ___________________________________ 4
1.1 R ISK ASSESSMENT RELATING TO THE USE OF W RIGHT F LOW T ECHNOLOGIES
L IMITED . C ONCEPT 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 F LOW T ECHNOLOGIES L IMITED D ISTRIBUTORS _____________ 8
2.3 R ECEIPT AND S TORAGE ____________________________________ 8
2.4 C LEANING ______________________________________________ 8
2.5 P UMP M ODEL D ESIGNATION _________________________________ 9
2.5.1 ATEX I NFORMATION P LATE ________________________________ 10
2.5.2 E QUIPMENT G ROUPS & C ATEGORIES _________________________ 10
2.6 P UMP M ODEL AND S ERIAL N UMBER __________________________ 11
2.7 S TANDARD P UMP C OMPONENT T ERMS ________________________ 12
3.0 GENERAL______________________________________________ 13
3.1 C ONCEPT SQ R ANGE P UMPING P RINCIPLE _____________________ 13
3.2 C ONCEPT SQ R ANGE O PERATING P ARAMETERS _________________ 14
3.3 S YSTEM D ESIGN ________________________________________ 15
3.3.1 S YSTEM D ESIGN AND I NSTALLATION __________________________ 15
3.3.2 I NSTALLATIONS WITH CIP/SIP S YSTEMS _______________________ 18
3.4 S TART U P P ROCEDURE ___________________________________ 19
3.5 S HUTDOWN P ROCEDURE __________________________________ 20
3.6 R OUTINE M AINTENANCE ___________________________________ 20
3.7 H EATING AND C OOLING D EVICES ____________________________ 21
3.8 F RONT C OVER /R OTORCASE J OINT WITH F LUID B ARRIER ___________ 23
3.9 R OTORCASE P ORT C ONNECTIONS WITH F LUID B ARRIER ____________ 24
4.0 CONCEPT SQ DISMANTLING / ASSEMBLY __________________ 25
4.1 SQ1 S ERIES P UMPS - D ISMANTLING __________________________ 27
4.1.1 F RONT C OVER AND R OTOR R EMOVAL _________________________ 27
4.1.2 C ARTRIDGE R EMOVAL ____________________________________ 28
4.1.3 C ARTRIDGE D ISMANTLING _________________________________ 29
4.1.3.1 D RIVE S HAFT C ARTRIDGE D ISMANTLING _______________________ 29
4.1.3.2 L AY SHAFT C ARTRIDGE D ISMANTLING _________________________ 29
4.2 SQ1 S ERIES P UMPS - A SSEMBLY ____________________________ 30
4.2.1 C ARTRIDGE A SSEMBLY ___________________________________ 30
4.2.1.1 D RIVE S HAFT C ARTRIDGE A SSEMBLY _________________________ 30
4.2.1.2 L AY SHAFT C ARTRIDGE A SSEMBLY ___________________________ 32
4.2.2 C ARTRIDGE /M OUNTING P LATE /R OTORCASE A SSEMBLY ____________ 33
4.2.3 S ETTING R OTOR T IMING ___________________________________ 35
4.2.4 G EARBOX A SSEMBLY _____________________________________ 36
4.2.5 R OTOR A SSEMBLY AND C HECKING C LEARANCES _________________ 37
4.3 SQ 2, 3, 4 - D ISMANTLING _________________________________ 39
4.3.1 F RONT C OVER AND R OTOR R EMOVAL _________________________ 39

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4.3.2 C ARTRIDGE R EMOVAL ( AFTER COMPLETING 4.3.1)________________ 40
4.3.3 C ARTRIDGE D ISMANTLING _________________________________ 41
4.4 SQ 2, 3, 4 - A SSEMBLY ___________________________________ 42
4.4.1 C ARTRIDGE A SSEMBLY ___________________________________ 42
4.4.2 C ARTRIDGE TO R OTORCASE A SSEMBLY _______________________ 44
4.4.3 S ETTING R OTOR T IMING ___________________________________ 46
4.4.4 F INAL S ETTING OF C ARTRIDGE R OLLING T ORQUE ________________ 47
4.4.5 R OTOR A SSEMBLY AND S ETTING R OTOR C LEARANCES ____________ 48
4.4.6 G EARBOX C OVER A SSEMBLY _______________________________ 50
4.5 M ECHANICAL S EAL I NSTALLATION AND R EMOVAL _________________ 51
4.5.1 P ROCEDURES FOR I NSTALLING M ECHANICAL S EALS _______________ 51
4.5.2 S INGLE M ECHANICAL S EAL _________________________________ 52
4.5.3 S INGLE M ECHANICAL S EAL ( LOW - PRESSURE FLUSH / QUENCH ). ______ 57
4.5.4 D OUBLE M ECHANICAL S EAL ( HIGH - PRESSURE FLUSH ). _____________ 60
4.5.5 M ECHANICAL S EALS FOR Q UENCH OR F LUSH - A UXILIARY S ERVICES ___ 63
5.0 SPECIFICATIONS _______________________________________ 66
5.1 C LEARANCE C HART ______________________________________ 66
5.2 F IXINGS & T ORQUE S ETTINGS ______________________________ 67
5.3 L UBRICANTS ___________________________________________ 68
5.4 M ATERIAL S PECIFICATION . _________________________________ 68
5.5 C ONCEPT SQ R ANGE F OUNDATION D IMENSIONS AND W EIGHTS ______ 69
5.6 T YPICAL B ASIC P UMP B UILD ________________________________ 71
5.7 F AULT F INDING _________________________________________ 72
5.9 S ERVICE H ISTORY . ______________________________________ 74
5.10 T OOL L IST _____________________________________________ 75
5.11 N OTES _______________________________________________ 76

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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.
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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
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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, heat-
tracing, etc), bad installation, or poor maintenance can all promote high
temperatures on pumps and/or drives.
When cleaning, either manually or by CIP method, the operator must ensure
that a suitable procedure is used in accordance with the system requirements.
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.

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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.

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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/ /
P UMP
M
ODEL
D ISPLACEMENT
(L TRS / REV X
100.)
M ODEL
S
IZE
M AX . P RESSURE
(B AR )

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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:
ex II - 2 - G/D
Group
II.
Category 2
Unit is suitable for
environments
containing dust or gas
Temperature Class.