maintenance training module 2 - tuthill pumptuthill confidential. • for all pumps, tightening of...
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© Tuthill Corporation. All rights reserved. Tuthill confidential.
Maintenance Training Module 2 GlobalGear® with Cartridge Mechanical Seals
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Topics in Maintenance Module 2 • Reassembly of Drive Module • Reinstall Drive Module • Adjusting End Clearance • Mechanical Seal Installation • Relief Valve Disassembly & Relief Valve
Troubleshooting • Servicing High Temperature Greased Bearing Units • Replacing Bushings • Lubrication Notes
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• Reinstall the rotor into the bracket
Reassembly of the Drive Module
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• Pick up external ball bearing
Reassembly of the Drive Module
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• Reinstall bearing into bearing carrier
Reassembly of the Drive Module
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• Reinstall inner bearing cap using fasteners
Reassembly of the Drive Module
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• Move cartridge mechanical seal into position
• Have flush ports in correct orientation
• Very loosely tighten gland nuts
Reassembly of the Drive Module
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• Reinstall bearing carrier
Reassembly of the Drive Module
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• Push rotor all the way in the bracket
Reassembly of the Drive Module
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• Insert lock washer with tabs
• If there is a bearing spacer, bearing spacer goes on first
Reassembly of the Drive Module
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• Install locknut
Reassembly of the Drive Module
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Reassembly of the Drive Module Locknut Torque Requirements
Nut Size Pump Size Newton-Meters
N-05 GG15-30 68 - 95
N-07 GG120-210 136 – 176
N-08 GG250 163 – 203
KM-12 GG550 163- 203
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• Bend over tab of lock washer into slot on locknut
Reassembly of the Drive Module
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• Check and make sure that the gasket is in the correct position for flush
• Center of three holes at flush opening is correct
Reinstall Drive Module
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• Gasket must align to allow flow through internal flush drilling size GG250 & smaller
• NPT plug indicates internal flush path at this location
Reinstall Drive Module
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Reinstall Drive Module Position Drive Module Over Foot and Near Housing
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Reinstall Drive Module Push Drive Module into Housing
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Reinstall Drive Module Fasten Bolts Connecting Bracket to Housing
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Reinstall Drive Module Fasten Bolts Connecting Bearing Carrier to Foot
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• End clearance is distance between the rotor/idler end and the closest surface on the cover
Adjusting End Clearance
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• Loosen set screws on rear cover
• Slowly and gradually tighten hex nuts on rear cover until rotor touches the pump cover
Adjusting End Clearance
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• When rotor is touching cover, there will be a slight drag when turning the shaft
Key in place
Adjusting End Clearance
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• Measure the gap between the end the end cover and the bearing carrier at four places 90° apart
• Make small adjustments to set screws and/or hex nuts so that the gap is the same at all four measured points
Adjusting End Clearance
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• Record the gap measurement with the rotor touching the cover
• This is zero end clearance
Adjusting End Clearance
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• Refer to TPC 254 for Tuthill recommended end clearance
• Add the value from TPC 254 to the gap measurement for zero clearance
• This will be the target gap measurement for end clearance setting
Adjusting End Clearance
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• Loosen hex bolts, several complete turns
• Tighten set screws on rear cover, enough to achieve the target gap measurement
Adjusting End Clearance
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• Make adjustments to set screws & hex nuts so that the measured gap is the same 4 points 90° apart
• Do final even tightening of the set screws/hex nuts & measure again to confirm the same measurements of the gap at 4 points 90° apart
Adjusting End Clearance
Gap is the Same
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• Final tightening of hex bolts to secure the rear cover in place
Adjusting End Clearance
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• If adjustment is being done in the shop, clearances can be measured directly from the open flanges
Adjusting End Clearance
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• After final tightening for end clearance, rotate the shaft by hand to confirm that the shaft rotates freely
Adjusting End Clearance
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• With cover removed, check clearance between rotor outer diameter and housing inner diameter at 4 points, 90° apart
Adjusting Radial Clearance
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• Hex nuts can be adjusted to change radial rotor position
• Set screws may also need adjustment
Adjusting Radial Clearance
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Final Tightening of Fasteners Recommend Using a Torque Wrench
Fastener Size Newton-meters
M6 8 – 12
M8 19 – 28
M10 41 – 54
M12 75 – 88
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• For all pumps, tightening of the mechanical seal is the last step for reassembling pump
• Gland nuts should only be barely started tightened, and seal cartridge left loosely in place until the final seal tightening
Final Tightening of Mechanical Seals
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• Mechanical seal has a limited travel range for self alignment, and it is best to reserve the travel range for end clearance adjustments done in the field
Final Tightening of Mechanical Seals
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• Have flush ports in the correct position for piping
• Install the mechanical seal flush and square to the stuffing box
• Support the seal weight to center the seal cartridge on the shaft
Final Tightening of Mechanical Seals
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• Tighten gland nuts in an even alternating pattern
Final Tightening of Mechanical Seals
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• Tighten mechanical seal set screws in an even alternating pattern
Final Tightening of Mechanical Seals
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• Remove fasteners securing the relief valve
Removal of the Relief Valve
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• Relief valve and gasket removed
Removal of the Relief Valve
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Disassembly of the Relief Valve
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• Use large wrench to remove cap
Disassembly of the Relief Valve
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• Relief valve cap removed
Disassembly of the Relief Valve
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• Loosen jam nut using large wrench
• Remove bonnet using large wrench
Disassembly of the Relief Valve
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• Bonnet removed
Disassembly of the Relief Valve
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• Spring guide removed
Disassembly of the Relief Valve
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• Remove spring
Disassembly of the Relief Valve
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• Orange paint on spring indicates high pressure spring, range 10-17 bar for full bypass
• No orange bands indicates standard pressure range 3-10 bar for full bypass
Disassembly of the Relief Valve
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• Remove poppet
Disassembly of the Relief Valve
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Potential Problems with Relief Valves
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• Poppet sealing edge and/or poppet seat not clean
• Result will be bypassing
• Corrective action is to clean the poppet and seat
Potential Problems with Relief Valves
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• Relief valve chattering • Relief valve bypassing
flow • Cause is relief valve set
too low
Potential Problems with Relief Valves
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• Correction is to increase the setting for full bypass pressure
• Higher pressure spring may be required
Potential Problems with Relief Valves
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• Remove cap • Start pump • Slowly close discharge
valve completely • Read pressure gauge
on pump discharge • This is current full
bypass pressure setting
Setting Relief Valve in the Field
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• Must know highest normal differential pressure
• Set relief valve to 50% higher than highest normal differential pressure
Setting Relief Valve in the Field
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1. Loosen jam nut 2. Use adjusting nut to
set pressure on gauge to target setting
Setting Relief Valve in the Field
2. 1.
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3. Once desired pressure setting is achieved, tighten jam nut
4. Replace cap
5. Open discharge valve
Setting Relief Valve in the Field
4. 3.
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• Setting Relief Valve in the field should be accomplished in ten minutes or less
• Do not run the pump in full bypass for extended periods to avoid overheating
Setting Relief Valve in the Field
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1. Hold relief valve inverted as shown
2. Drop in poppet, feet
down
Reassemble Relief Valve
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3. Drop in spring 4. Drop in spring guide
Setting Relief Valve in the Field
4. 3.
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• Holding relief valve inverted
Reassemble Relief Valve
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• Reinstall bonnet using Teflon pipe dope on threads
• Reinstall cap using pipe dope on threads
Reassemble Relief Valve
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• Remove bearing cover fasteners
Removing High Temp. Greased Bearings
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• Greased bearings have a special bearing cover
• Greased bearings have a grease fitting
Removing High Temp. Greased Bearings
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• Remove bearing cover
• Remove outer bearing cap hex nuts
• Remove outer bearing cap
Removing High Temp. Greased Bearings
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• Remove inner bearing cap fasteners
Removing High Temp. Greased Bearings
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• Push Back Inner Bearing Cap Toward Mechanical Seal Cartridge
Removing High Temp. Greased Bearings
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• Greased bearings are shrunk onto the shaft for interference fit
• Must be pulled off with a bearing puller
• Best practice is not to reuse a bearing that has been pulled off a shaft
Removing High Temp. Greased Bearings
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• Use recommended lubricant or equivalent
• Add grease to the grease fitting using a grease gun
Greasing High Temperature Bearings
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• Old grease will come out here
• Old grease will slip under the lip seal
• Add new grease until a color change is observed with the old grease
Greasing High Temperature Bearings
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• Can be pressed out with a hydraulic press
• Need to be pressed in with one forceful movement with no stops or hesitation
• Stopping mid way or hesitation may result in breaking the carbon bushing
Helpful Hint Carbon Bushings
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• Tungsten Carbide Bushings can be pressed out with a hydraulic press
• Bracket or idler needs to be heated to 425° C before installing tungsten carbide bushings
• Safety provisions for handling hot materials required
Helpful Hint Tungsten Carbide Bushings
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• Grease and oils designed to take years to break down
• Contaminants of moisture and particulate from dust and dirt degrade grease and oils
• Cleanliness is critical • Tips of grease guns need to be clean
Lubrication Helpful Hints
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• Grease fittings should be cleaned before using • Work environment should be clean so as to avoid
introducing particulate into grease or oil • Use manufacturer recommend lubricants or cross-
over equivalents
Lubrication Helpful Hints
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• Concept of predictive maintenance is to identify the need for equipment overhaul before a breakdown
• Planned maintenance is less expensive than responding to break-downs
• Planned maintenance has much less impact on potential loss of production or disruption to production schedules
Predictive Maintenance
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• Significant increases from baseline recordings for temperature and/or vibration are indicators of coming maintenance requirements.
• Bearing temperature increases of 10 °C from baseline is an alarm level, 20 °C increase over baseline is an immediate action level.
• Vibration level increases by a factor of 2 above baseline is an alarm level, vibration increase of 2.5 times baseline is an immediate action level.
Predictive Maintenance How to know when maintenance is necessary?
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• Record temperatures as degrees above ambient • Bearing temperature from the pump, gear
reducer, and motor
Predictive Maintenance Suggestion is to record monthly bearing temp. and vibration readings
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