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Circor HOUTTUIN TT Twin-Screw Installation, Operation & Maintenance Manual

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TT Twin-Screw Pump
Installation, Operation
& Maintenance

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Summary of Contents for Circor HOUTTUIN TT Twin-Screw

  • Page 1 TT Twin-Screw Pump Installation, Operation & Maintenance...

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Introduction and Safety ......................3 Introduction ........................3 Safety ..........................3 Safety terminology and symbols ..................4 Environmental safety ......................5 User safety ......................... 6 Ex-approved products ......................8 Product warranty ......................15 Transportation and Storage ....................16 Inspect the delivery ......................
  • Page 4 Table of Contents Final piping checklist ..................... 44 Commissioning, Startup, Operation & Shutdown ............... 45 Preparation for startup ..................... 45 Check the rotation ......................46 Couple the pump and driver .................... 47 Bearing lubrication ......................48 Oil volume requirements ....................49 Lubricating-oil requirements ..................

  • Page 5: Introduction And Safety

    Prohibited methods include any modification to the equipment or use of parts not provided by CIRCOR. If there is any uncertainty regarding the appropriate use of the equipment, please contact an CIRCOR representative before proceeding.

  • Page 6: Safety Terminology And Symbols

    Risk of injury and/or property damage. Operating a pump in an inappropriate application can cause over pressurization, overheating, and/or unstable operation. Do not change the service application without the approval of an authorized CIRCOR representative. Safety terminology and symbols About safety messages It is extremely important that you read, understand, and follow the safety messages and regulations carefully before handling the product.

  • Page 7: Environmental Safety

    Report all environmental emissions to the appropriate authorities. WARNING: If the product has been contaminated in any way, such as from toxic/flammable chemicals or biological agents do NOT send the product to CIRCOR unless it has been properly decontaminated. Electrical installation For electrical installation recycling requirements, consult your local electric utility.

  • Page 8: User Safety

    Introduction and Safety User safety General safety rules These safety rules apply: • Always keep the work area clean. • Pay attention to the risks presented by gas and vapors in the work area. • Avoid all electrical dangers. Pay attention to risks of electric shock or arc flash hazards. •...
  • Page 9 Introduction and Safety Precautions during work Observe these safety precautions when you work with the product or are in connection with the product: CAUTION: Failure to observe the instructions contained in this manual could result in personal injury and property damage and may void the warranty. Read this manual carefully before installing and using the product.

  • Page 10: Ex-Approved Products

    Introduction and Safety Wash the skin and eyes Follow these procedures for chemicals or hazardous fluids that have come into contact with your eyes or your skin: Condition Action Chemicals or hazardous 1. Hold your eyelids apart forcibly with your fingers. fluids in eyes 2.
  • Page 11 Any maintenance for Ex-approved products must conform to international and national standards (for example, IEC/EN 60079-17). • CIRCOR disclaims all responsibility for work done by untrained and unauthorized personnel. • The yield stress of fasteners must be in accordance with the approval drawing and the product specification.
  • Page 12 Introduction and Safety 2. Explosion Protection Labeling 2.1 Temperature class and type of explosion protection marking are on nameplate. II 3G Ex h IIC T4...T1 Gc X ___________________________ CE Label ___________________________ Symbol for explosion protected equipment II _____________________________ Equipment group per Directive 2014/34/EU is other than underground 3______________________________ Equipment Category (section 2.2 below) G______________________________ Explosion Atmosphere (G = Gas)
  • Page 13 Introduction and Safety 2.3 Temperature Class – Flammable gases and vapors are divided into temperature classes for their flammability on hot surfaces. Surface temperature of pump must always be less than lowest ignition temperature in the temperature class. Classification of maximum surface temperature for Group II Equipment Temperature Class on Maximum Surface Temperature Accordance with EN 80079-36...
  • Page 14 Introduction and Safety ATEX Measures 3.1 Installation and connection of pump (Measures depend upon category.) 3.1.1 Category 3 Stay within the maximum permissible temperature of the pumped fluid on the order data sheet. Prevent overheating when operating in a circulating system by routing the return line from the safety valve to the tank not into the suction pipe For couplings with coupling guards: a.
  • Page 15 Introduction and Safety If pumped fluid is contaminated with solid particles: a. Install temperature sensor on case surface Adjust temperature monitoring device according to the manufacturer’s specifications and to the maximum allowable temperature of the housing surface by its temperature class. For pumps with separate relief valves: Install a pressure relief valve in the pressure line and adjust it accordingly b.
  • Page 16 Introduction and Safety Maintenance (Reduce maintenance intervals for more difficult operating conditions.) 3.3.1 Maintenance to perform Check at appropriate intervals: Motor and pump couplings according to manufacturer’s operating instructions Deformation of guard around coupling and spacing to rotating parts Functioning of monitoring devices Surface temperature of pump and motor Entire unit for excess vibrations Pump during operation for altered running noises...

  • Page 17: Product Warranty

    • Economic losses Warranty claim CIRCOR products are high-quality products with expected reliable operation and long life. However, should the need arise for a warranty claim, then contact your CIRCOR representative. TT Twin-Screw Pump - Installation, Operation & Maintenance Manual...

  • Page 18: Transportation And Storage

    Transportation and Storage Transportation and Storage Inspect the delivery Inspect the package 1. Inspect the package for damaged or missing items upon delivery. 2. Note any damaged or missing items on the receipt and freight bill. 3. File a claim with the shipping company if anything is out of order. 4.
  • Page 19 Transportation and Storage Precautions for lifting the pump WARNING: Dropping, rolling or tipping units, or applying other shock loads, can cause property damage and personal injury. Ensure that the unit is properly supported and secure during lifting and handling. Risk of serious personal injury or equipment damage. Proper lifting practices are critical to safe transport of heavy equipment.

  • Page 20: Storage Guidelines

    Pump openings are covered with blank flanges or special covers. A packing list is furnished itemizing the contents of the shipment. When received, check the contents against the packing list. Report any discrepancies to CIRCOR or your local CIRCOR distributor immediately.
  • Page 21 Refer to the drive unit and coupling manufacturers for their long-term storage procedures. For questions about possible long-term storage treatment services, please contact your local CIRCOR sales representative. TT Twin-Screw Pump - Installation, Operation & Maintenance Manual...

  • Page 22: Product Description

    Product Description Product Description General description Product description The TT Series Twin-Screw pump is a positive displacement pump capable of handling viscosities from 0.2cSt up to >100.000cSt. Due to the fully non-contacting rotor design (following API676 MPP requirements) this pump is perfectly suitable to handle all types of fluids, viscosities and fluid mixtures.
  • Page 23 Baseplate The fabricated steel baseplate supports the pump, driver, and accessories in accordance with CIRCOR standards or API-676 latest Edition requirements depending on application. Direction of rotation The direction of rotation is normally clockwise when viewed look at the drive end of the pump.

  • Page 24: Nameplate Information

    Product Description Nameplate information Important information for ordering Every pump has a nameplate that provides information about the pump. The nameplate is located on the pump casing. When you order spare parts, identify this pump information: • Model • Size •...
  • Page 25 Ensure that the code classifications on the pump are compatible with the specific environment in which the equipment is to be installed. If they are not compatible, do not operate the equipment and contact a CIRCOR representative before proceeding. TT Twin-Screw Pump -...

  • Page 26: Installation

    Electrical connections must be made by certified electricians in compliance with all international, national, state and local regulations Supervision by an authorized CIRCOR representative is recommended to ensure proper installation. Improper installation may result in equipment damage or decreased performance...

  • Page 27: Foundation Requirements

    Installation Foundation requirements Requirements Foundations should be of suitable mass to absorb vibration and provide a rigid support for the unit. Use reinforcing steel as necessary. For optimal vibration performance, the foundation should weigh between two and three times the weight of the pump. A flat, substantial concrete foundation is necessary in order to prevent strain and distortion when you tighten the foundation bolts.

  • Page 28: Baseplate-Mounting Procedures

    Installation Baseplate 1” to 2” (25mm to 50mm) gap for grout Notch Coupling Foundation Rubber plug Sleeve Rubber plug Sleeve Lower nut & plate Welded nut & bolt Figure 3a: Sleeve type bolt (embedded) Figure 3b: Sleeve type bolt (pocket) Baseplate-mounting procedures Prepare the baseplate for mounting This procedure assumes you have a basic knowledge of baseplate and foundation design...

  • Page 29: Prepare The Foundation For Mounting

    Installation Prepare the foundation for mounting Chip the top of the foundation to achieve a minimum of 1” (25mm) gap with the bottom of the baseplate, in order to remove any porous, cracked or low-strength concrete. If you use a pneumatic chisel or other air powered tool, make sure that it does not contaminate the surface with oil or moisture.

  • Page 30: Install The Pump, Driver, And Coupling

    Installation Lower the baseplate carefully onto the foundation bolts. The baseplate will rest on top of the foundation on the jackscrews provided on the baseplate. Adjust the leveling jackscrews, located adjacent to the foundation bolt holes, until the baseplate rests 1” to 2” (25mm to 50mm) above the foundation in order to allow adequate space for grouting.

  • Page 31: Alignment Checks

    Installation Follow the instructions from the equipment manufacturer when you use the reverse dial indicator or laser methods. Detailed instructions for using the dial indicator method are contained in this chapter. Alignment checks When to perform alignment checks You must perform alignment checks under these circumstances: •...

  • Page 32: Allowable Dial Indicator Values For Alignment Checks

    Installation Allowable dial indicator values for alignment checks NOTICE: The specified misalignment values are valid only at operating temperature. For cold settings, different values must be used to account for the expected thermal expansion. Failure to do so can result in being unable to successfully perform hot alignment. The driver shaft initial (cold) parallel vertical alignment setting should normally be lower than the pump shaft (unless the pump operates at a high process temperature, see the next section).
  • Page 33 Installation Ductile Iron 6.5 x 10 (11.7 x 10 Carbon Steel 6.5 x 10 (11.7 x 10 Austenitic Stainless Steel 8.9 x 10 (16 x 10 Temperature rise Δt = operating temperature – ambient temperature. The foot to shaft centerline distance is the distance from the bottom of the pump and driver feet to the center of their respective shafts.

  • Page 34: Alignment Measurement Guidelines

    Installation Alignment measurement guidelines Guideline Explanation Rotate the pump coupling half and the driver coupling half This prevents an incorrect together so that the indicator rods have contact with the same measurement. points on the driver coupling half. Move or shim only the driver in order to make adjustments. This prevents strain on the piping installations.

  • Page 35: Perform Angular Alignment For A Vertical Correction

    Installation Perform angular alignment for a vertical correction 1. Set the angular alignment indicator to zero at the top-center position (12 o’clock) of the driver coupling half. 2. Rotate the angular alignment indicator to the bottom-center position (6 o’clock). 3. Record the angular alignment indicator reading. 4.

  • Page 36: Perform Parallel Alignment For A Vertical Correction

    Installation When the reading Then do this. value is... Negative The coupling halves are farther apart on the right side than the left. To correct this, do one of the following: • Slide the DE of the driver to the left. •...

  • Page 37: Perform Parallel Alignment For A Horizontal Correction

    Installation When the reading Then do this value is... Negative The pump coupling half is lower than the driver coupling half. Remove shim(s) with a thickness equal to half of the indicator reading value under each driver foot. Positive The pump coupling half is higher than the driver coupling half. Add shim(s) with a thickness equal to half of the indicator reading value to each driver foot.

  • Page 38: Perform Complete Alignment For A Vertical Correction

    Installation negatively affect horizontal angular correction and may require re-performing the angular alignment step. Figure 9 Example of incorrect horizontal alignment (top view) Perform complete alignment for a vertical correction Refer to "Allowable indicator values for alignment checks" for the alignment values. A unit is in complete alignment when both the angular alignment indicator and the parallel alignment indicator do not vary by more than the table limits when measured at two points 180°...

  • Page 39: Grout The Baseplate

    Installation 4. Make corrections according to the separate instructions for angular and parallel alignment until you obtain the allowable reading values. Grout the baseplate Required equipment: • Cleaners: Do not use an oil-based cleaner, the grout will not bond to it. Refer to the instructions provided by the grout manufacturer on suitable cleaners to be used.

  • Page 40: Perform A Final "Soft Foot" Check

    Installation grout immediately followed by application of a high solids, film forming curing compound compliant with ASTM C309 or C1325. pour of grout Dam with Baseplate 45° chamfer pour of grout Foundation Figure 10: Arrangement of grout pour into baseplate 11.

  • Page 41: Pump Piping

    Installation Pump Piping General piping requirements and checklist Precautions WARNING: Risk of premature pump failure. Casing deformation can result in misalignment and contact with rotating parts, causing excess heat generation and sparks. Flange loads from the piping system, including those from the thermal expansion of the piping, must not exceed the limits of the pump.
  • Page 42 Installation Do not connect the piping to the Connecting the piping without adequate pump support pump until: increases the risk of pipe strain • The grout for the baseplate or sub-base becomes hard. Piping strain on the pump may cause distortion resulting •...

  • Page 43: Suction-Piping Checklist

    Installation Flange position criteria Acceptable position Axial The flange gasket thickness +0.010(0.25mm), +0.040” (1mm) Align the flange to be parallel within 0.3° (0.063” per 12” or 1mm per Parallel 200mm). Concentric Studs are centered in the holes or the flange bolts can be inserted and moved by hand.
  • Page 44 Installation commissioning (temporary) suction strainer can be removed. Recommended operating (permanent) strainer mesh size: • Viscosity≤450 SSU (86 cSt) use 40 mesh • Viscosity>450 SSU (86 cSt) use 20 mesh • Viscosity>1000 SSU (216 cSt) use 12 mesh If more than one pump operates from This recommendation helps you to achieve a higher the same liquid source, check that pump performance and prevent vapor locking...

  • Page 45: Discharge Piping Checklist

    Installation Discharge piping checklist Checklist Check Explanation/comment Checked Check that an isolation valve is The isolation valve is required for inspection and installed in the discharge line maintenance of the pump The location between the isolation valve and the Check that a check valve is installed in pump allows inspection of the check valve.

  • Page 46: Final Piping Checklist

    Installation When to install You may need to install auxiliary piping for gear / bearing cooling, mechanical seal flush, or other special features supplied with the pump. Consult the pump GA or outline drawing for specific auxiliary piping requirements and connection points. Checklist Check Explanation/comment...

  • Page 47: Commissioning, Startup, Operation & Shutdown

    Commissioning, Startup, Operation & Shutdown Commissioning, Startup, Operation & Shutdown Preparation for startup WARNING: • Risk of serious physical injury or death. Exceeding any of the pump operating limits (e.g. pressure, temperature, power, etc.) could result in equipment failure, such as explosion, seizure, or breach of containment.

  • Page 48: Check The Rotation

    Product Description • When a cartridge mechanical seal is used, ensure that the set screws in the seal locking ring are tightened and that the centering clips have been removed prior to startup. This prevents seal or shaft sleeve damage by ensuring that the seal is properly installed and centered on the sleeve.

  • Page 49: Couple The Pump And Driver

    Commissioning, Startup, Operation & Shutdown 7. Make sure that everyone is clear, and then jog the driver long enough to determine that the direction of rotation corresponds to the arrow on the bearing housing or close-coupled frame. 8. Lock out power to the driver. Couple the pump and driver WARNING: Failure to disconnect and lock out driver power may result in serious physical injury or death.

  • Page 50: Bearing Lubrication

    Product Description • Running a pump without safety devices exposes operators to risk of serious personal injury or death. Never operate a unit unless appropriate safety devices (guards, etc.) are properly installed. • Avoid death or serious injury. Assure mechanical seal guard is properly installed using supplied fastening hardware.

  • Page 51: Oil Volume Requirements

    Commissioning, Startup, Operation & Shutdown Oil volume requirements Pump Size Drive End Grease Volume Non-Drive End Housing Oil Volume liter ounces liter gallons TT200 0.07 TT220 0.10 TT250 0.22 TT275 0.18 12.6 TT335 0.36 12.0 19.8 TT450 0.46 15.7 41.5 11.0 Lubricating-oil requirements Oil quality requirements...

  • Page 52: Lubricate The Gear/Bearings After A Shutdown Period

    Cartridge seals installed by the user require disengagement of the holding clips prior to operation, allowing the seal to slide into place. If the seal has been installed in the pump by CIRCOR, these clips have already been disengaged.

  • Page 53: How To Prime The Pump With The Suction Supply Above The Pump

    Commissioning, Startup, Operation & Shutdown will identify the connections that need to be made and the type/quantity of liquid that must be supplied. How to prime the pump with the suction supply above the pump 1. Slowly open the suction isolation valve. 2.

  • Page 54: Pump Operation Precautions

    Product Description 4. If the pump fails to produce flow, perform these steps: a. Stop the driver. b. Prime the pump again. c. Restart the driver. 5. Monitor the pump while it is operating: 6. Check the pump for bearing temperature, excessive vibration, and noise. 7.

  • Page 55: Shut Down The Pump

    Commissioning, Startup, Operation & Shutdown Monitor all gauges to ensure that the pump is running at or near rating and that the suction screen (when used) is not clogged Operation with excessive discharge pressure WARNING: Risk of breach of containment and equipment damage. Excessive vibration levels can cause damage to bearings, gears, seal chamber, and/or mechanical seal.

  • Page 56: Make The Final Alignment Of The Pump And Driver

    Product Description Make the final alignment of the pump and driver WARNING: • Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks.

  • Page 57: Dowelling The Driver (Optional)

    If alignment is correct and unless Circor instructs otherwise, the driver should be doweled on diagonally opposite foot locations. Normally the pumps are doweled at the factory and the drivers are doweled in the field.

  • Page 58: Maintenance

    Maintenance Maintenance Maintenance schedule Maintenance inspections A maintenance schedule includes these types of inspections: • Daily routine inspections • Weekly routine inspections • Three-month inspections • Annual inspections Shorten the inspection intervals appropriately if the pumped fluid is abrasive or corrosive or if the environment is classified as potentially explosive.

  • Page 59: Bearing Maintenance

    Bearing maintenance These bearing lubrication sections list different temperatures of the pumped fluid. If the pump is ATEX-certified and the temperature of the pumped fluid exceeds the permitted temperature values, then consult your Circor representative. Bearing lubrication schedule Type of lubrication...

  • Page 60: Disassembly

    Disassembly, Inspection & Reassembly Disassembly Disassembly precautions WARNING: • Failure to disconnect and lock out driver power may result in serious physical injury or death. Always disconnect and lock out power to the driver before performing any installation or maintenance tasks. •...

  • Page 61: Prepare For Disassembly

    Disassembly, Inspection & Reassembly • Drill • Feeler gauges • Hex wrenches • Induction heater • Lifting sling • Micrometers (inside and outside) • Open end wrenches • Press • Soft face hammer • Spanner wrench • Spanning type puller •...
  • Page 62 Disassembly, Inspection & Reassembly 4. Remove the locknut (110) and ringfeder screws (114) to loosen the both spur gears (108 & 109) from the shafts (101 & 102). 5. Remove the spur gears (108 & 109) from the shafts (101 & 102). Remove the key (132) if necessary from the short shaft (102).

  • Page 63: Preassembly Inspections

    Disassembly, Inspection & Reassembly 23. Dispose all single use items like Gasket, o- ring, grease and lipseal with new parts as per safety policy. 24. Dispose the gearbox oil if the service time is completed as per safety policy. Preassembly inspections Replacement guidelines Casing check and replacement WARNING:...
  • Page 64 Disassembly, Inspection & Reassembly Body and seal housings areas Screw shaft inspection Inspect the screw shafts (101) (102). Repair or replace these parts if you notice any of these conditions: • Localized wear or grooving that is greater than 0.040” (1.0mm) deep •...
  • Page 65 Disassembly, Inspection & Reassembly Cartridge mechanical seal replacement Cartridge-type mechanical seals should be serviced by the seal manufacturer. Refer to the instructions from the mechanical seal manufacturer for assistance. Coupling guard replacement Repair or replace the coupling guard if you notice corrosion or other defects. Gaskets, O-rings, and seats replacement WARNING: Risk of death or serious injury.

  • Page 66: Screw Shaft Replacement Guidelines

    Disassembly, Inspection & Reassembly Screw shaft replacement guidelines Screw shaft measurement check Check the mechanical seal, bearing and gear wheel fits of the screw shafts (101) (102) using outside precision micrometers with a measurement sensitivity of 0.0001” (0.0025mm). If any are outside the tolerances shown in the fits and tolerances table, then replace the screw shaft.

  • Page 67: Bearings Inspection

    Disassembly, Inspection & Reassembly Bearings inspection Condition of bearings Do not reuse bearings as this is typically a false economy. The remaining life available on a bearing cannot be determined through simple inspection. The condition of the bearings will provide useful information on the operating conditions seen by the bearings in the bearing frame.

  • Page 68: Reassembly Of The Two-Piece Bracket Pump (Standard)

    Disassembly, Inspection & Reassembly Bearing housings Perform these checks when you inspect the bearing housings: • Check that the bearing housings are clean, with no burrs or other surface damage. • Check the bearing housing bores against the values in the bearing fits table. •...
  • Page 69 Disassembly, Inspection & Reassembly 2. Pair both Rotors on a flat surface and center them axial to each other (align the rotors axial so that the shoulders of the thrust-bearings are axially aligned to each other) 3. Insert rotor-package (both rotors together) into the casing (350) 8-shaped „screw-bores “(from gear or motor side) 4.
  • Page 70 Disassembly, Inspection & Reassembly 21. Install key (132) on the gear side idler shaft and install the gearwheel (109) and secure it with locknut (110). 22. Install, tighten and align gearwheel (108) along with the ring feder (113) to the shaft (101) gear side using hex head screw (114).
  • Page 71 Disassembly, Inspection & Reassembly Machinery Inspection Record Sheet TT Twin-Screw Pump - Installation, Operation, and Maintenance Manual...
  • Page 72 Disassembly, Inspection & Reassembly Twin-Screw Pump - Installation, Operation, and Maintenance Manual...

  • Page 73: Spare Parts

    Replacement parts Spare parts NOTICE: When ordering spare parts, the following information should be indicated on the purchase order. • Pump serial number (see Name plate). • Pump series (see Name plate) NOTICE: To ensure a safe and good functioning of the pump we advise to buy genuine spare parts according the specifications in the parts list.

  • Page 74: Troubleshooting

    Troubleshooting Troubleshooting Operation troubleshooting Symptom Cause Remedy The pump is not delivering The pump is not primed. Re-prime the pump and check that the pump and liquid. suction line are full of liquid. The suction lift is too high. Shorten the suction pipe and/or increase the diameter and/or reduce the number of “lossy”...
  • Page 75 Troubleshooting Symptom Cause Remedy The pump starts pumping The pump is not fully primed. Re-prime the pump and check that the pump and but then loses suction. suction line are full of liquid. The suction line has air or vapor pockets. Rearrange the piping in order to eliminate air pockets.

  • Page 76: Alignment Troubleshooting

    Troubleshooting Symptom Cause Remedy The mechanical seal is The mechanical seal parts are worn. Replace the worn parts. leaking excessively. The mechanical seal is overheating. Check the flushing and cooling lines. Suction pressure is above the rated value Reduce the suction pressure Barrier pressure is above the rated value Reduce the barrier pressure The screw shaft is scored at the mechanical...

  • Page 77: Supplemental Assembly Information

    Supplemental Assembly Information Supplemental assembly information Maximum torque values for fasteners TORQUE TABLE Torque for Torque for Torque for Torque for Torque for Torque for Thread Type 8.8 Type 8.8 Type 10.9 Type 10.9 Type 12.9 Type 12.9 (Nm) (In-lbs) (Nm) (In-lbs) (Nm)

  • Page 78: Recommended Torqueing Sequence For Bolted Joints

    Supplemental Assembly Information Recommended torqueing sequence for bolted joints 1. Always use a high-quality calibrated torque wrench 2. Work in a “Criss-Cross” star pattern for circular joints 3. Work in a Spiral pattern for non-circular joints 4. Use the Rule of 3 for tightening 5.

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