INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR THE CONCEPT SQ RANGE OF ROTARY LOBE PUMPS SAFETY INFORMATION ___________________________________ 4 ISK ASSESSMENT RELATING TO THE USE OF RIGHT ECHNOLOGIES IMITED ONCEPT ROTARY LOBE PUMPS AND PUMP UNITS IN . ________________________ 7 POTENTIALLY EXPLOSIVE ATMOSPHERES INTRODUCTION __________________________________________ 8 ______________________________________________ 8 ENERAL...
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.
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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.
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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.
Risk assessment relating to the use of Wright Flow Technologies Limited. Concept SQ rotary lobe pumps and pump units in potentially explosive atmospheres. Note:- For a feature to be suitable for an application, The feature must be fit for its designated purpose and also suitable for the environment where it is to be installed.
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.
It is recommended that the exterior of the pump be cleaned periodically. Pump Model Designation The designation of pump models in the Concept SQ range is as follows: - SQ1/0004/12 (SQ1S) SQ3/0054/15 (SQ3S) SQ1/0007/06 (SQ1L) SQ3/0103/07 (SQ3L) SQ2/0017/15 (SQ2S) SQ4/0160/15 (SQ4S) SQ2/0030/07 (SQ2L) SQ4/0303/07 (SQ4L) This, together with the pump serial number, should be quoted when requesting...
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.
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...
General 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.
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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.
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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.
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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 Page 16...
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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.
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.
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.
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.
3.5 bar g and this should not (50 PSI) 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.
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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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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.
Concept SQ Dismantling / Assembly Before undertaking any work on the pump the recommended Shutdown Procedure should be followed, refer to section 3.5. Certain components of the pump are only usable once. It is essential to be certain that new replacement components are available for re-assembly. These are the split pins used to secure the castellated nuts, and the o-rings located between the rotors and shafts.
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When removing lipseals or o rings care should be taken to avoid cutting or tearing the sealing faces as they pass over keyways, splines, threads or other potentially sharp or abrasive edges. All lipseals and o-rings should be carefully examined and if damaged in any way, be replaced on assembly. All o-rings and sealing lips of lipseals should be lightly lubricated with a suitable lubricant before installing.
SQ1 Series Pumps - Dismantling 4.1.1 Front Cover and Rotor Removal Fig 15 Removal of the rotors will necessitate gaining access to the end of both the drive and lay shafts by removal of the coupling guard and drive coupling assembly. It will depend upon the specific arrangement of components that have been used as to whether or not the pump will need to be removed from its mounting to allow this.
4.1.2 Cartridge Removal (after completing 4.1.1) - see Fig 16 Before proceeding with cartridge removal, remove mechanical seals, see section 4.5. Remove o-rings (34) from shafts (9 &10) and discard, do not re-use. Remove drive coupling from drive shaft (9), if not already removed. Remove drive key (8).
SQ1 Series Pumps - Assembly 4.2.1 Cartridge Assembly 4.2.1.1 Drive Shaft Cartridge Assembly Install bearing (19 & 24) cups to bearing sleeve (20), see Fig 19. Fig 19 Install front bearing (24) cone onto drive shaft (9) see Fig 20. Fig 20 Install bearing sleeve (20) to drive shaft (9) with securing lugs towards the spline end of the shaft so that the bearing (24) cup locates with the...
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Fig 22 Install gear key (57) and gear (14) into position ensuring gear boss abuts with rear bearing (19) cone. Install tab washer (13) and lock nut (12). Do not secure tab washer (13). Install rotor (41) to the cartridge assembly, securing with castellated nut (81) (it’s not necessary to install springs (83) or pin (82) for this operation).
4.2.1.2 Lay shaft Cartridge Assembly Fig 23 Install bearing (19 & 24) cups to bearing sleeve (20), as in Fig 19. Install front bearing cone (24) onto lay shaft (10), as in Fig 20. Install bearing sleeve (20) to lay shaft (10) with securing lugs towards the spline end of the shaft so that the bearing (24) cup locates with the cone, as in Fig 21.
4.2.2 Cartridge/Mounting Plate/Rotorcase Assembly Fig 24 If not already installed, install feet (1) to rotorcase (40) using cap head screws (2). Note: If necessary for the hygienic requirements of the installation, the feet (1) should be sealed to the rotorcase (40) with a suitable sealing agent. If not already installed, install the mechanical seal housing (28) with gasket (27) to the rear of the rotorcase (40) and secure with screw (26).
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Install rotors (41), securing with castellated nuts (81), tightening to correct torque refer to section 5.2. Hexagonal sections are provided on the shafts (9 & 10) to allow use of an open ended wrench in association with a torque wrench on the castellated nut (81). (It is not necessary to install disc springs (83) or split-pins (82) for this operation).
Install torque lock assembly (88) to lay shaft (10). Install timing gear (14) to torque lock assembly (88) such that the timing gears (14) are fully engaged and aligned. The mating face of torque lock assembly (88) should not protrude on either side of the lay timing gear (14).
4.2.4 Gearbox Assembly Fig 28 Install lipseals (11) to gearbox cover (16). Install breather (21); drain plugs (5) and sight glass (6) in required position in gearbox cover (16). Note: The sight glass (6) must be installed in the upper tapped hole in the side of the gearbox cover (16).
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4.2.5 Rotor Assembly and Checking Clearances Fig 29 Do not install mechanical seals at this point. Install rotors (41) to shafts (9 and 10) in rotorcase (40). Install castellated nuts (81) to rotor (41) draw bolts, tightening to correct torque, refer to section 5.2. Hexagonal sections are provided on the shafts (9 &...
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Install rotors (41) to shafts (9 and 10) in rotorcase (40). Install disc springs (83) (ensuring correct orientation, see Fig 31) and castellated nuts (81) to rotor (41) draw bolts, tightening to correct torque, refer to section 5.2. Fig 31 Install joint ring (39) to front cover (38).
SQ 2, 3, 4 - Dismantling 4.3.1 Front Cover and Rotor Removal Fig 33 Removal of the rotors will necessitate gaining access to the end of both the drive and lay shafts by removal of the coupling guard and drive coupling assembly. It will depend upon the specific arrangement of components that have been used as to whether or not the pump will need to be removed from its mounting to allow this.
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4.3.2 Cartridge Removal (after completing 4.3.1) Fig 34 The following procedures assume the pump has been removed from the baseplate. Before proceeding with cartridge removal remove mechanical seals see section 4.5. Remove o-rings (34) from shafts (9 &10) and discard they are not re-useable. Remove oil drain plug (5) and breather (21), drain oil into suitable container and retain if later inspection is required.
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4.3.3 Cartridge Dismantling Fig 35 Remove o rings (25) from bearing sleeves (20) Remove locknut (12) and tab washer (13). Remove timing gear (14) noting that the drive shaft gear (stamped D) has a right hand helix and the lay shaft gear (stamped L) a left hand helix.
SQ 2, 3, 4 - Assembly 4.4.1 Cartridge Assembly Install bearing (19 & 24) cups to bearing sleeves (20), see Fig 36. Fig 36 Install front bearing (24) cones onto shafts (9 and 10) see Fig 37. Fig 37 Install bearing sleeves (20) to shafts (9 and 10) with securing lugs towards the spline end of the shaft so that the bearing (24) cup locates with the cone (24) see Fig 38.
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Fig 38 Install rear bearing (19) cones to shafts (9 and 10) see Fig 39. Do not use excessive pressure as rolling torque is achieved by adjusting rear lock nuts (12). Fig 39 Install gear keys (57) and gears (14) into position ensuring gear boss abuts with rear bearing (19) cone.
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4.4.2 Cartridge to Rotorcase Assembly Fig 40 If not installed, secure feet (1) to rotorcase (40) using cap screws (2). Note: If necessary for the hygienic requirements of the installation, the feet (1) should be sealed to the rotorcase (40) with a suitable sealing agent. If not already installed, install the mechanical seal housing (28) with gasket (27) on SQ2 models or o-ring (27) on SQ3 &...
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Assemble cartridges into rotorcase (40) rear bores ensuring that timing marks on the timing gears (14) are in mesh (single dot on drive shaft gear, two dots on lay shaft gear). The timing gears are in correct mesh when the single dot on the drive shaft gear is between the two dots on the lay shaft gear, see Fig 41.
Having determined the amount of shim (22) to be added, remove castellated nuts (81) and rotors (41). Remove cap head screws (23). Ease cartridge from rotorcase (40) using lever slots to create a gap to allow installation of shims (22). Add appropriate amount of shim between rotorcase (40) and shaft cartridge flange.
4.4.4 Final Setting of Cartridge Rolling Torque Remove lock nuts (12) and tab washers’ (13) from cartridge assemblies. To ensure that the correct final rolling torque is applied, it is necessary to remove any existing pre-load on bearings (19 & 24). This can be achieved by pressing shaft (9 or 10) through the bearing sleeve (20) by a distance of 0.5 to 1.0 mm, see Fig 44.
Install shim (22) sets, as determined in section 4.4.2, between rotorcase (40) and shaft cartridge flange. Secure cartridges to rotorcase (40) with cap head screws (23), tightening to correct torque refer to section 5.2. 4.4.5 Rotor Assembly and Setting Rotor Clearances Fig 45 Note: Spare rotors are supplied in pairs &...
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correct will cause severe pump damage. With rotors (41) installed, check all clearances, front (A), radial (C), rear against the Clearance Chart refer to section 5.1. and mesh (D), Remove castellated nuts (81) and rotors (41). Install mechanical seals; refer to section 4.5 Mechanical Seal Installation and Removal.
4.4.6 Gearbox Cover Assembly Fig 47 Install lipseals (11) to gearbox cover (16). Install breather (21); drain plugs (5) and sight glass (6) in required position in gearbox cover (16). Note: The sight glass (6) must be installed in the upper tapped hole in the side of the gearbox cover (16).
Mechanical Seal Installation and Removal 4.5.1 Procedures for Installing Mechanical Seals "Quick summary" of mechanical seal installation. Mechanical seals are precision-engineered assemblies incorporating finely lapped seal faces and seats. They must therefore be handled with care and will not give optimum performance unless installed carefully and according to instructions.
4.5.2 Single Mechanical Seal Fig 48 Read the General Procedures to prepare for seal installation, refer to section 4.5.1. If only the seal faces are being replaced, the seal housings (28) and gaskets (27) or o rings (27) will already be in place. Install seal housings (28) with gasket (27) on SQ1 and SQ2 models or o ring (27) on SQ3 and SQ4 models to rotorcase (40) ensuring arrows on seal housings (28) align, see Fig 49, securing with screws (26)
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Install rotary seal faces (33) into L-Cups (32). Install L-Cups (32) with rotary seal faces (33) into rotors (41) using tools (58A & 58B) see Fig 50. Fig 50 The correct method is as follows: Position rotary seal face (33) and L-Cup (32) assembly into place over counterbore in rotor (41).
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Remove tools (58A & 58B). Make sure the L-cups (32) are located correctly with the seal faces (33) sitting squarely in them. Install Squad rings (30) to stationary seats (31), ensuring correct orientation, see Fig 52. Fig 52 Install seal carriers (75) to seal housings (28) ensuring drive pins and slots are correctly engaged.
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Dismantling of Single Mechanical Seals Ensure pump is fully shutdown refer to section 3.5. Note: If seals are being reinstalled, ensure that seal faces remain matched. Remove rotary seal faces (33) from rotors (41) using extraction tools (58A & 58B). To dismantle, reverse above procedure using extraction tools supplied to aid in the removal of the seal faces, see Fig 53.
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The static faces (31) can be removed by use of tool (58C) see Fig 54. Note: Extreme care should be taken when carrying out these procedures to ensure that the seal faces are not damaged. No excessive force is necessary if the extraction tools are used correctly. Fig 54 Page 56...
4.5.3 Single Mechanical Seal (low-pressure flush / quench). Fig 55 Read the General Procedures to prepare for seal installation, refer to section 4.5.1 If only the seal faces are being replaced, the housings (28 & 44), lipseals (43) and o- rings (49) will already be in place.
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Make sure the L-Cups (32) are located correctly with the seal faces (33) sitting squarely in them. Install Squad rings (30) to stationary seats (31), ensuring correct orientation, see Fig 52. Install lipseals (43) to flushed housings (44), securing in place with retainers (42).
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Remove flushed housing / wave spring / lipseal (44 / 29/ 43) assemblies from shafts (9 & 10). This can be achieved by inserting the extraction tool (58C) through the drain/leakage detection holes in the sides of the rotorcase (40) and applying a twisting action, see Fig 56. Fig 56 Remove o-rings (49) from flushed housings (44).
4.5.4 Double Mechanical Seal (high-pressure flush). Fig 57 Read the General Procedures to prepare for seal installation, refer to section 4.5.1. If only the seal faces are being replaced, the seal housings (28) and gaskets (27) will already be in place. Install seal housings (28) with gasket (27) on SQ2 models or o ring (27) on SQ3 &...
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Remove tools (58A & 58B). Make sure the L-Cups (32) are located correctly with the seal faces (33) sitting squarely in them. Install housing / wave spring (47/76) assemblies to rotorcase (40) ensuring correct engagement of drive pins into slots in shafts (9 and 10).
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Dismantling of Double Mechanical Seals for Flush Ensure pump is fully shutdown refer to section 3.5. Note: If seals are being reinstalled, ensure that seal faces remain matched. Remove rotary seal faces (33) from rotors (41) using extraction tools (58A & 58B). To dismantle, reverse the above procedure using the extraction tools supplied to aid in the removal of the seal faces.
4.5.5 Mechanical Seals for Quench or Flush - Auxiliary Services Every Concept SQ pump is provided with four seal flushing connections, two on each side of the rotorcase, which are tapped 1/8" BSP. Pumps supplied with mechanical seals requiring an auxiliary flush have an elbow adapter terminating in compression joint to accept 1/4"...
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Venting of Seal Housings When starting up an SQ pump which is equipped with a quenched or flushed mechanical seal, and which is mounted with the rotorcase port connections in the horizontal plane, see Fig 59. The pump should be run for a few minutes with the quench / flush media being caused to flow at a rate of approximately 5 litres per minute.
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Single Mechanical Seal for Quench / Flush (For low-pressure Quench or Flush) Refer to section 4.3.3. This seal arrangement requires a supply of media to the outboard side of the mechanical seal to quench or flush the seal area. The nature of the pumped media and the specific duty conditions will determine whether a quench or a flush is required.
Lubricants Gearbox oil recommended for use with Concept SQ pumps is an “EP (Extreme Pressure) grade gear lube” for the following ambient temperature ranges. EP150 0 – 32° F EP220 32 – 85° F EP320 85° F and higher Approximate pump gearbox capacities for SQ pumps: Mounting Attitude Suction and Discharge ports in: Horizontal Plane...
5.10 Tool List Listed below are tools required for the maintenance of the Concept SQ pump range. TYPE SIZE OR RANGE SQ1 SQ2 COMBINATION WRENCH 10mm COMBINATION WRENCH 13mm COMBINATION WRENCH 17mm COMBINATION WRENCH 18mm COMBINATION WRENCH 19mm COMBINATION WRENCH 24mm COMBINATION WRENCH 32mm...
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