Related Manuals for Gardner Denver STP 125
Summary of Contents for Gardner Denver STP 125
- Page 1 125/E N1/0701 OPERATION, AINTENANCE INSTALLATION MANUAL and PARTS LIST ROTARY LOBE PUMP STP 125 STP125 VERSION: 03 February 3, 2015...
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Page 3: Table Of Contents
Page No General Pump limits of application or use Duty conditions Noise levels Utility requirements Safety precautions Health and safety information Unpacking, handling and storage Documents Unpacking Handling Pump storage Description of pump or pump unit General pump description Principle of operation Pump dimensions Pump weight Pump displacement... - Page 4 Maintenance and inspection Page No Maintenance schedule Recommended spare parts Maintenance tools Disassembly Before dismantling the pump Removing the front cover Removing the rotors Product seal removal Removing the rotorcase Removing the shaft sleeves and shims Draining the pump of lubricant Removing the front seal retainers Removing the gear housing 8.10...
- Page 5 Operation Manual Page No 11.3 Single mechanical seal fitting 12.0 Pump heating tank 12.1 Heating tank removal 12.2 Heating tank fitting 13.0 Relief valve 13.1 Disassembly - relief valve 13.2 Assembly - relief valve 14.0 Faults, causes and remedies 15.0 Torque settings/spanner sizes 16.0 Exploded view drawing and parts list...
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Page 6: General
Operation Manual 1.0 General 1.2 Duty conditions 1.1 Pump limits of application or use The pump should only be used for the duty This pump has been designed for pumping for which it has been specified. The a range of viscosities from water to semi- operating pressure, speed and temperature solid, suitable for both homogeneous liquids limits have been selected at the time of order... -
Page 7: Safety Precautions
Operation Manual 1.5 Safety precautions All warnings in this manual are summarised Operation on this page. Pay special attention to the instructions Always observe the technical data. below so that severe personal injury or damage to the pump can be avoided. Never touch the pump or the pipelines when pumping hot liquids or when Personnel performing installation, operation... -
Page 8: Health And Safety Information
Operation Manual 1.6 Health and safety information Potential safety hazards General first aid The following section gives information on If potentially hazardous substances are handling, storage and disposal of parts and accidentally inhaled, or skin or eyes materials used in the pumps which may be contaminated, then the following basic considered hazardous to health. -
Page 9: Unpacking, Handling And Storage
Operation Manual 2.0 Unpacking, handling and storage To avoid any problems, on receipt of your pump always use the following procedure:- 2.1 Documents Check the delivery note against the goods received. 2.2 Unpacking Care must be taken when unpacking the pump, and the following stages must be completed:- Inspect the packing for any possible signs of damage in transit. -
Page 10: Description Of Pump Or Pump Unit
Operation Manual 3.0 Description of pump or pump unit 3.2 Principle of operation 3.1 General pump description The pumps are of the positive displacement rotary type with trilobe rotors. The direction The pump supplied is a positive of flow is reversed by changing the direction displacement pump, which may be supplied of rotation of the pump's drive shaft. -
Page 11: Pump Dimensions
Operation Manual 3.3 Pump dimensions - horizontally ported pump The above dimensions are for guidance only 3.7 Pressure relief valve and should not be used for installation purposes. Certified dimensions are available A integral relief valve is available. It can be upon request. -
Page 12: System Design And Installation
Operation Manual 4.0 System design and installation 4.1 System design advice When designing the pumping system :- Install a non-return valve to prevent Confirm with the supplier the Net turbining when high pressures are Positive Suction Head (NPSH) applied to the pump whilst it is not requirements for the system, as in use. -
Page 13: Pipework
Operation Manual 4.3 Pipework All pipework must be supported. The pump must not be allowed to support any of the Keep - Pipework horizontal where pipework weight. applicable to reduce air locks. Include eccentric Remember - Pipework supports must also reducers on suction lines if support the weight of the required. -
Page 14: Commissioning
Operation Manual 5.0 Commissioning 5.3 Changing the oil :- The pump will not be supplied oil filled. When taking delivery of a new or refurbished First change - After 150 hours of operation pump unit it is essential to check that the or after 1 month, whichever comes first. -
Page 15: Start Up, Shut Down And Cleaning In Place
Operation Manual 6.0 Start up, shut down and Cleaning in Place 6.1 Pump Start Up Check List Has the pipework system been flushed through to purge welding slag and/or any other hard solids? Have all obstructions been removed from the pipework or pump? Are the pump connections and pipework joints tight and leak-free? Is there lubrication in the pump and... -
Page 16: Pump Shut Down Procedure
Operation Manual 6.2 Pump shut down procedure Turn the pump off. Isolate the pump/drive from all power and control supplies. Close the pipework valves to isolate the pump. Ensure all auxiliary services such as heating/cooling tanks supply etc. are isolated. If the pump is to be dismantled, refer to section 8 of this manual. -
Page 17: Cleaning In Place (Cip)
Operation Manual 6.3 Cleaning In Place (CIP) The pump can be manually cleaned or Using the ball or gate valve, (to cleaned in place(CIP). The following is an restrict liquid flow) increase the pump example of a typical CIP procedure. Specific pressure to approximately 60-75 psi requirements for each application should be while it is operating. -
Page 18: Maintenance Schedule
Operation Manual 7.0 Maintenance and inspection Part description 7.1 Maintenance schedule Quantity Description It is advisable to install pressure gauges on 'O' ring, product seal both sides of pump as close as possible to the ports so that any problems within the pump/ Mechanical seal pipework will be highlighted. -
Page 19: Disassembly
Operation Manual 8.0 Disassembly 8.1 Before dismantling the pump Before starting to dismantle the pump Always:- Purge - the pump and system if any noxious/hazardous products have been pumped. Isolate - pump/drive unit from all power and control supplies. Close - pipework valves to isolate the pump Disconnect - the pump from the drive unit. -
Page 20: Removing The
Operation Manual To aid re-assembly, note which components came off which shaft. Good engineering practise 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 Central bolt before replacing. -
Page 21: Removing The Shaft Sleeves And Shims
Operation Manual 8.10 Removing the timing gears 8.6 Removing the shaft sleeves and shims Pull the rear inner bearing races (39) off Remove the wire shaft sleeve retaining the shafts. A puller or extractor may be clip (64) from the shaft taking care not to required to do this. -
Page 22: Assembly
Operation Manual 9.0 Assembly Check the torque required to turn the shaft in the bearings. The bearings Assemble components to the shaft from which are correctly adjusted when the torque they were removed. to turn each shaft is 1.40 to 1.67 lbft for new bearings. -
Page 23: Adjusting The Rotor Timing
Operation Manual 9.4 Adjusting the rotor timing Tab washer Shim Slide rotors (13) onto the shafts (28,29), Gear locknut but do not tighten the retaining nuts (9). Turn the shaft so that the rotors are in the position shown below. Radial Clearance 9.5 Fitting the gear housing... -
Page 24: Setting The Rotor Clearances
Operation Manual 9.6 Setting the rotor clearances 10. Fit the seal sleeve retaining clips (64) onto the shafts. Incorrect setting of the rotor clearances will damage the pump. 11. Fit the rotorcase (11) and retain with four nuts (5) tightened to 30 lbft. Fit the rotorcase (11) and retain with four nuts (5) tightened to 30 lbft. -
Page 25: Replacing 'O'ring Seal
Operation Manual 10 Replacing 'O'Ring Seal 10.2 'O'ring seal fitting Press a new product 'O'ring fully into the seal housing (66), replace the rotors and rotor retention nuts. To aid seal fitting water may be used to lubricate the 'O'ring. 10.3 To remove the seal housing 1. -
Page 26: Replacing Mechanical Seal
Operation Manual 11 Replacing Mechanical Seal ITEM DESCRIPTION Shaft Sleeve ‘O’Ring Sleeve/Rotor ‘O’Ring Shaft/Sleeve Clip Shaft Sleeve Retention ‘O’Ring Seal Housing/Rotorcase Seal Housing 'O' Ring Mech Seal/Rotor 'O’Ring Mech Seal/Housing Seal Face Static Seal Face Rotary Wave Spring 11.2 Single mechanical seal removal Remove the gland guards (21). -
Page 27: Single Mechanical Seal Fitting
Operation Manual 11.3 Single mechanical seal fitting Ensure the seal housings and seal recesses are clean. Lightly lubricate the 'O'rings and springs with a silicon grease (Food quality if required). Position the wave springs (85) into the seal housing (66). Fit the static face (82) with associated 'O' ring to the seal housing recess. -
Page 28: Pump Heating Tank
Operation Manual 12 Pump heating tank 12.1 Heating tank dimensions Prior to operation a hydrostatic test of the Care should be taken when piping up and heating system is recommended. connecting to heating tanks. Hydrostatic test pressure (water) :- 90 psi Maximum working pressure :- 55 psi Heating tanks should be in operation approximately 15 minutes prior to pump start-... -
Page 29: Relief Valve
Operation Manual 13 Relief Valve The relief valve is factory set to operate at 145 psi to partially protect the pump from over pressurisation. The relief pressure can not be field adjusted. 13.1 Disassembly - Relief valve Take extreme care when removing the valve housing as the spring has been compressed. -
Page 30: Faults, Causes And Remedies
14 Faults, causes and remedies... -
Page 31: Torque Settings/Spanner Sizes
Operation Manual 15 Torque settings/spanner sizes Recommended torque settings in lbft Pump Description Tool Sizes STP125 Front cover nut 19mm Rotorcase retainer 16mm Rotor nut 41mm Bearing housing screw 8mm Allen Relief valve nut 14mm Foot screw 8mm Allen Gland guard screw 6mm Allen STP125 Page 29... -
Page 32: Exploded View Drawing And Parts List
STP125 Pump Model – Exploded View Drawing 16 Exploded view drawing and parts list , ..STP125 Page 30... - Page 33 STP125 Pump Model - Main Parts Description Qty. Part No. Dwg. Item STUD 12MM x 54 WITH CLIPHOLE 170412250 RETAINER SS PUMP CASE NUT 'R' CLIP 518101200 NUT HEX FULL S/S M12 190012200 STUD - M12 X 155MM S/S - FP2000/STP125 199121200 NUT ROTORCASE RETENTION - FP2000/STP125 518061211...
- Page 34 O-Ring Seal Parts - STP125 Pump Model Dwg. Description Qty. Part No. Item 7 bar 503187206 ROTOR, TRILOBE, O-RING - STP125 10 bar 503187205 SHIM SET, ROTOR ALIGN, S/S - STP125 1 set 516073207 SLINGER SEAL RETAINER - STP125 518080203 SETTING RING - STP125 518081209 SEAL SLEEVE, O-RING VERSION - STP125...
- Page 35 Mechanical Seal Parts - STP125 Pump Model Dwg. Description Qty. Part No. Item 5 bar 503187207 ROTOR, TRILOBE, MECH. SL. - STP125 10 bar 503187208 SHIM SET, ROTOR ALIGN, S/S - STP125 1 set 516073207 SLINGER SEAL RETAINER - STP125 518080203 SETTING RING - STP125 518081209...
- Page 36 Relief Valve Parts - STP125 Pump Model Dwg. Description Qty. Part No. Item COVER, FLAT FRONT,FOR REL. VLV. - STP125 521042215 BODY RELIEF VLV FP2000/STP125 INT. SUPP. 500074202 RELIEF VALVE HEAD/STEM - STP125 532051202 SPRING COMP 65 PSI RELIEF VALVE 517022201 ANCHOR PLATE, SS, FOR RELIEF VLV -STP125 532120201...
- Page 37 Other Optional Parts - STP125 Pump Model Dwg. Description Qty. Part No. Item COVER ASS'Y., COMP. w/RV, NBR - STP125 521042216 COVER ASS'Y., COMP. w/RV, VITON - STP125 521042217 CAPSCREW SKT HD ISO 8.8 M12 x 30mm PLTD. 130112030 KEY RND END 10MM X 8MM X 63MM 199050209 SHAFT, DRIVE, KEYED - STP125 504033216...
- Page 38 Lip Seal Parts - STP125 Pump Model (not 3A compliant) Dwg. Description Qty. Part No. Item 7 bar 503187206 ROTOR, TRILOBE, O-RING - STP125 10 bar 503187205 SHIM SET, ROTOR ALIGN, S/S - STP125 1 set 516073207 SLINGER SEAL RETAINER - STP125 518080203 SETTING RING - STP125 518081209...
- Page 40 For additional information, contact your local representative or visit: www.contactgd.com/compressors ©2015 Gardner Denver, Inc. Printed in U.S.A.