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Maintenance Seminar

Fuller-Kinyon Pumps
Institute

F-K Pumps - Introduction

Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.

Introduction

Part 2.

M-Pump

Part 3.

H-Pump and Z- Flap Conversions

Part 4.

Auxiliary Equipment

Institute

F-K Pumps - Introduction

Introduction

Principles of Pneumatic Conveying


Types of Fuller Kinyon-Pumps
Development History
Performance Tuning the F-K Pump
System Troubleshooting

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F-K Pumps - Introduction

Principles of
Pneumatic Conveying

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F-K Pumps - Introduction

Pneumatic Conveying
Definition

the process of moving powdered


material through a pipeline using air as
the conveying medium.

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F-K Pumps - Introduction

Pneumatic Conveying Flow


Material
Flow

Dilute Phase

Material
Flow
Mixed Phase

Material
Flow
Dense Phase

Material flow through a pipeline can be characterized


by the concentration of material in the air-stream.
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F-K Pumps - Introduction

Pneumatic Conveying Flow


particles in suspension

pipeline

Dilute Phase Flow


Fairly even distribution over cross-section of the pipe.
Pick-up velocity 15-25 m/s (3000-5000 fpm).
Terminal velocity > 25 m/s (>5000 fpm).
Pressure differential of nominal 1 bar.
Material to air ratio up to 22:1.

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F-K Pumps - Introduction

Pneumatic Conveying Flow


dust particles may be in suspension

moving "waves" of material

Dense Phase Flow (plug flow)


Waves of material fill the entire cross sectional area
of the pipe
Pick-up velocity 2-9 m/s (400-1800 fpm)
Terminal velocity < 20 m/s (<4000 fpm)
Conveying pressure differential 2-4.5 bar (15-35 psi)
Material to air ratio 20-200:1

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F-K Pumps - Introduction

Pneumatic Conveying Flow


Particles in Suspension

Moving Material Bed

Medium Phase Flow (dual or mixed)


Particles in suspension traveling above a moving bed
of material
Pick up velocity 2-18 m/s (400-3500 fpm)
Terminal velocity 15-25 m/s (3000-5000 fpm)
Conveying pressure differential 1-2.4 bar (15-35 psi)
Material to air ratio 15-30:1

Institute

F-K Pumps - Introduction

Pneumatic Conveying Flow


figure 2

two phase flow


stream flow over a settled layer
l
v1

figure 1

dilute phase
l

v1
drag

v2

drag = acceleration in
direction of airflow.

v2

lf: v1 > v2 particle lifts


l > g particle floats

figure 3

dense phase
p1

p2

particles
particles contact
contact particles
particles
pressure
pressure differential
differential moves
moves material
material
velocity
velocity (drag)
(drag) is
is unimportant
unimportant and
and is
is normally
normally aa very
very low
low value
value

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F-K Pumps - Introduction

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Conveying Line Pressure Drop

Pneumatic Conveying Flow


Modu-dense
Modu-flo mt
Fullveyor

increasing
solids rate

F-K Pump
Pressure Tank
dense
phase

unstable
surging phase
medium
phase

dilute
phase

Airveyor
Airlift

air flow rate


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F-K Pumps - Introduction

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The Problem

How to put material into


a pressurized air-stream

The Solution .
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F-K Pumps - Introduction

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The Fuller-Kinyon Pump


Feed
Material
Air and
Material

Compressed
Air

Feed material enters the hopper where the screw


picks it up and forces it into the air-stream.
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F-K Pumps - Introduction

13

Components of an F-K Pump


discharge body

drive end
bearing assembly

pump hopper
screw
inlet
barrel

discharge end
bearing assembly

external lever
flapper valve

motor

air and material


outlet
base frame

Institute

air inlet

F-K Pumps - Introduction

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Pneumatic Conveying System


De-dusting
System
Material Bin

Rotary Feeder
Intake
Filter

Air
Compressor

Institute

Air
Slide

Material
Pipeline

F-K Pump

F-K Pumps - Introduction

15

Applications
Dry, free flowing ,fluidizable materials
Typical particle size analysis:
100% < 50 mesh
70% < 100 mesh
60% < 200 mesh
45% < 325 mesh
Long distance conveying, over 5,000 ft (1500 m)
High capacity conveying, up to 17,700 CFH (500
CMH), e.g. 400 tph @ 45 lb./cu.ft.
Material temperatures to 400F, special
applications to 850F with water cooled seal.
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F-K Pumps - Introduction

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Typical Materials Handled


Alumina
Asphalt filler dust
Barytes
Bauxite
Bentonite
Catalysts
Cement
Clays (dried
Coal
Coke dust
Copper concentrate
Dolomite
Dusts (baghouse, ESP)
Feldspar
Fluorspar
Fly ash
Institute

Gypsum
Kaolin
Lime
Limestone
Magnesite
Magnetite
Manganese dioxide
Ores
Phosphate rock
Quartz
Rutile
Silica
Soda ash
Starch
Talc
Titanium dioxide
F-K Pumps - Introduction

17

Special Applications

Abrasive materials
Materials of construction will vary according to
specific applications.
Special screw hard surfacing.
Tungsten carbide weld deposit (65 rc) (700 brinnel).
Hardened barrel (450 brinnel).
Other special materials on request.
Ceramic barrel liners optional.
Ceramic lined discharge box- optional.

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Special Applications
High temperature materials
Type M pump available up to 400F
Type H pump available up to 850F
seal chamber cooling coils

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F-K Pumps - Introduction

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Special Applications
Non compression screws for cohesive materials
(e.g. gypsum).
Back beveled screw flights for materials that bind
(e.g. kaolin).
Half moon orifice for materials which flush.
Stainless steel screw for corrosive materials.
Other special alloys applied as required.
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Types of F-K Pumps

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F-K Pumps - Introduction

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Types of F-K Pumps


M Pump

H Pump

Z Flap Conversion

Kompact Pump

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F-K Pumps - Introduction

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M Pump

The M Pump has bearings on both ends of the shaft.


Material discharge is perpendicular to the screw. Newer
pumps are supplied with three piece screws.
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F-K Pumps - Introduction

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M Pump Sizes and Capacities


Screw Diameter

Screw Pitch1

Capacity2

150 mm

150 x 100

27 tph

200 mm

190 x 120

107

250 mm

230 x 150

232

300 mm

300 x 190

491

350 mm

330 x 240

790

1 Screws

have decreasing pitch. Other pitches available.

2 Typical

capacity in short tons/hour while transporting 3600 blaine


portland cement at screw speed of 1160 RPM.

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F-K Pumps - Introduction

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M Pump

250 M pump with


parallel discharge
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350 M pump with


side discharge
F-K Pumps - Introduction

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M Pump

left hand
discharge

right hand
discharge

The M Pump can be arranged for side or parallel


discharge for left or right hand side.
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F-K Pumps - Introduction

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M Pump

M Pump installation.
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F-K Pumps - Introduction

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H Pump

The H Pump has a cantilevered screw with


bearings on one end of the shaft only. Material
discharge is in line with the screw.
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F-K Pumps - Introduction

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H Pump Sizes and Capacities


Screw Diameter

Screw Pitch1

Capacity2

6x4

31 tph

8x5

80 tph

8x5

128 tph

8x5

164 tph

6x4

120 tph

6x4

142 tph

10

10 x 7

258 tph

10

10 x 7

293 tph

1 Screws

have decreasing pitch. Other sizes available.

2 Typical

capacity in short tons/hour while transporting 3600


blaine portland cement at screw speed of 1160 RPM.

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F-K Pumps - Introduction

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H Pump

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F-K Pumps - Introduction

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H Pump with Z Flap Conversion

The Z flap conversion adds a bearing onto the discharge


end of the shaft. Discharge is in line with the screw. Two
piece screws are available for ease of maintenance.
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F-K Pumps - Introduction

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H Pump

H pump with Z flap installation.


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F-K Pumps - Introduction

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Kompact Pump

The Kompact Pump is a light duty version for mobile,


non-continuous operation.
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F-K Pumps - Introduction

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Kompact Pump
Sizes and Capacities
Screw Diameter

Screw Pitch1

Capacity2

6x4

36 tph

6x4

52 tph

1 Screws

have decreasing pitch. Other sizes available.

2 Typical

capacity in short tons/hour while transporting 3600


blaine portland cement at screw speed of 1160 RPM.

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F-K Pumps - Introduction

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Kompact Pump

For Intermittent use (less than 8 hours per day).


Short conveying distances (up to 150).
No hardened barrel.
Light duty bearings.
Low pressure system (up to 12-14 PSI).
Floating type gland packing for hopper-screw seal.
Hardened screw as standard.
Low headroom, i.e. for railcar unloading.

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Development History

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F-K Pumps - Introduction

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Development History
First developed 1919 1926
Type H pump - developed in 1935,
over 12,000 sold
Kompact pump - developed in 1961,
over 1,000 sold
Type M pump - developed in 1976,
over 1,200 sold
Z-Flap conversion kit - developed 1984

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First Portable F-K Pump

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F-K Pumps - Introduction

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Performance Tuning the


Fuller-Kinyon Pump

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The Material Seal


Pump Inlet
(low pressure)

Material Seal Zone

Pump Outlet
(high pressure)

It is essential for system performance that a good seal


exists to keep conveying air from blowing back into the
hopper. This seal is formed by compacted material
traveling through the pump barrel, especially at the
discharge end where the screw pitch decreases.
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F-K Pumps - Introduction

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The Material Seal


Compacted Material

Flap Valve

Air and Material


Mixture
Compressed
Air Inlet

Transport
Pipeline

The material in the pump barrel is compacted with the aid of


a counterweighted flap valve at the pump outlet, which
creates a resistance to the material flow. Increasing the
counterweight makes a tighter seal, but motor amps will rise.
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F-K Pumps - Introduction

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H Pump Material Seal

The H pump, in addition to a counterweighted flap valve, has


an adjustable barrel which can be used to control the seal
thickness (A).
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F-K Pumps - Introduction

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System Troubleshooting

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F-K Pumps - Introduction

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System Troubleshooting
Inadequate Capacity
If motor amps are abnormally low, adjust the
material seal to prevent blow-back (increase the
counterweight).
Check material density. The pump is a
volumetric device and changes in density will
affect changes in tons per hour.
Insure proper venting of pump inlet hopper.
Hopper must be at a slight negative pressure.
Excessive purge air to the seals can aerate the
material in the hopper, causing decreased
capacity. Check the purge air pressure settings
and orifice plates.
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F-K Pumps - Introduction

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System Troubleshooting
Inadequate Capacity (continued)

If conveying is fast and steady, reduce air flow; if


conveying is slow and slugging, increase air flow.
Check for steady material feed rate.
Check for restrictions at the discharge end of the
system, i.e., silo vent dust collector not working.
Increase line diameter (stepped line or entire length).
If pump discharge pressure is higher than normal,
there may be a line obstruction.

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F-K Pumps - Introduction

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System Troubleshooting
Plugged Conveying Pipeline

Check for adequate air supply.


Check for air leaks in conveying line.
Check for non-seating diverter valves.
Eliminate sloping conveying lines. Sloping lines
plug easier than horizontal or vertical runs.
Check for steady material feed rate.
Check material characteristic. Moist or sticky
material can build up on inside of conveying line.
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F-K Pumps - Introduction

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System Troubleshooting
High Motor Amps

The material seal may be too tight. Decrease the


counterweight on the flap valve.
Check feed sieve analysis. Coarser material can
cause higher motor amps.
Check for moisture in the feed material.

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F-K Pumps - Introduction

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System Troubleshooting
Cycling Pressure

Check for steady material feed.


Check venting at terminal point of
conveying line.

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F-K Pumps - Introduction

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System Troubleshooting
Inadequate Air Supply

Check compressor inlet for restrictions


(dirty inlet filter, faulty unloading valve, etc.)
Check for open pressure relief valve.
Check for piping and flanges for leaks.
Check compressor for proper operation
(broken blades, etc.)

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F-K Pumps - Introduction

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System Troubleshooting

Excessive Pipeline wear

Reduce conveying velocity.


Replace bends with tee pipe fittings.
Step to larger diameter conveying line
before terminal points in the system.

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F-K Pumps - Introduction

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System Troubleshooting
Material Breakage

Reduce conveying velocity.


Eliminate all bends, cyclones, etc.
Reduce velocity before terminal point of
conveying line.
Eliminate any rough sections or sharp
changes in direction.

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F-K Pumps - Introduction

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Maintenance Seminar

Fuller-Kinyon Pumps
Institute

F-K Pumps - M-Pump

52

Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.

Introduction

Part 2.

M Pump

Part 3.

H Pump and Z Flap Conversions

Part 4.

Auxiliary Equipment

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F-K Pumps - Introduction

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M Pump

Institute

Overview
Screw
Barrel Bushings
Discharge Body
Bearings and Seals
Lubrication
Purge Air
Spare Parts
Disassembly and Assembly

F-K Pumps - Introduction

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Overview

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F-K Pumps - Introduction

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Type M Pump

The M pump has side discharge, easily removable


bearing and seal assemblies, and a three piece
screw for easy replacement of the wear section.
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F-K Pumps - Introduction

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M Pump
Inlet
Hopper

Discharge
Body
Barrel

Discharge
End Bearing

Drive End
Bearing
Air Inlet

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F-K Pumps - Introduction

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Screw

Institute

F-K Pumps - Introduction

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Three Piece Screw


Stub Shaft

Replaceable
Center Section

Stub Shaft

The three piece screw is standard on all new M pumps,


and is available as a retrofit on older M pumps. When the
screw wears out, only the center section is replaced. Stub
shafts remain in place inside the bearing assemblies.
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F-K Pumps - Introduction

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Three Piece Screw


Standard Pitch Screw Flights

Balance
Wheel

Decreasing
Pitch

Reverse
Pitch

Paddle
bars
Hard-facing

The screw is hard-faced with nickel-chromium boride


alloy. Decreasing screw pitch helps form a material seal
to prevent blowback from the discharge line. Reverse
pitch flights keep material away from the shaft seal.
Paddle bars help disperse material into the air stream.
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F-K Pumps - Introduction

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One Piece Screw

Hard-facing

The screw is hardfaced with Colmonoy, a nickel-chromium


boride alloy, applied by gas welding. The flight periphery
has 7.5 mm hardfacing, and the flight faces in compression
zone is 4mm.
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F-K Pumps - Introduction

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One Piece Screw


Balance
Wheel

Balance
Wheel

After the flights are installed, hardfacing applied and


the periphery ground, the screw is dynamically
balanced. Balance is achieved by filling the holes in
the balance wheels with lead shot. Balancing
reduces vibration and extends bearing life.
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One Piece Screw


Wear
Sleeve

Wear
Sleeve

The screw has a hardened chrome wear sleeve at each end


where the seals contact the shaft. These seals are shrunk
on and have to be heated to 300F to install. If the sleeves
are damaged, seal failure will result.
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Screw Puller

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Barrel Bushings

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Barrel Bushings
Inlet End
Bushing

Center
Bushing

Discharge End
Bushing

The pump barrel is wear protected by three barrel bushings.


The center bushing is hardened to resist the extra abrasion
in the zone where the material seal is formed. Set screws
and retaining screws keep the bushings from rotating.
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Discharge Body

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Discharge Body
Material
Outlet

Flapper
Valve

Flapper Valve
Counterweight

Barrel
Bushing
Screw

Air and
Material
Outlet

Air Inlet

Nozzles

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Mixing
Chamber

F-K Pumps - Introduction

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Material Seal
Spacer Plate

Flapper Valve

Valve Seat

The material seal is created by the compaction of material


at the discharge end of the pump. Increasing the
counterweight and/or increasing the spacer plate
thickness makes a tighter seal, but motor amps will rise.
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Flapper Valve

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Material Seal Baffle Plate

In some instances a baffle plate installed behind the


flapper valve may improve the material seal.
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350 M Pump

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Bearings and Seals

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Bearing Arrangements
Older M Pumps with
1 Piece Screws

Newer M Pumps with


3 Piece Screws

350 M Pumps with


3 Piece Screws

There are several different M pump bearing arrangements.


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M Pumps with 1 Piece Screw


Discharge End Bearing

Bearing
Bushing
Retainer Plate
Bearing
Support

Cover Plate
Bearing
Housing

The discharge end bearing is the fixed bearing. The cover


plate and retainer plate fix the bearing axially.
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F-K Pumps - Introduction

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M Pumps with 1 Piece Screw


Drive End Bearing
Locknut

Bearing
Bushing
Locking
Collar

The drive end bearing is the free bearing. The bearing is


fixed on the bearing bushing. The shaft slides axially inside
the bushing to accommodate expansion.
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150 and 200 M Discharge End

Bearing
Pressurization
Connection

Purge Air

Grease

The 150 and 200 M pumps use a double row angular contact
ball bearing. Grease is introduced through fittings on either
side of the bearing. Air purge keeps dust out of the bearing
housing. The bearing chamber is presurized.
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150 and 200 M Drive End


Bearing
Lube

Seal Lube

Purge Air

Grease

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250 M Discharge End

Purge Air

Grease

The 250 M pump uses two back to back angular contact


ball bearings. Grease is introduced through fittings on
either side of the bearing pair.
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250 M Drive End

Purge Air

Grease

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300 M Discharge End

Purge Air

Grease

The 300 M pump uses two back to back angular contact


ball bearings with grease grooves. Grease is introduced
into the groove and emerges between the bearings.
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300 M Drive End

Purge Air

Grease

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Bearing with Grease Grooves

On 300 and 350 M Pumps grease is introduced through


grooves between the two back to back bearings.
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Discharge End Bearing


Newer M Pump

Locknut with
Tab Washer

Newer M pumps have their discharge bearings fixed axially


with a locknut instead of a retainer plate.
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Drive End Bearing


Newer M Pump

The free bearing can slide axially within the housing to


accommodate shaft expansion. The bearing is fixed on the
bushing and the bushing is fixed on the shaft with a locknut.
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Discharge End Bearing


350 M Pump
Bearing
Bushing
Locknut with
Tab Washer

On the 350 M pump the bearing housings and supports are


combined into one casting.
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Drive End Bearing


350 M Pump

The bearing is free to slide axially inside the housing. The


inner ring is fixed on the bushing. The bushing is fixed to the
shaft with a locknut.
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Replacement Kits

The new bearing assemblies are available as bolt-on kits


together with the screw stub shafts. In the event of a
bearing or seal failure, the entire assembly is replaced
and the damaged assembly is brought to the shop for
rebuilding.
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Seal Arrangement
Material Seals

Spacer Ring

Bearing Seal

O-ring

Seals must face in direction shown.


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Seal

When installing a bearing housing over the shaft, use a


piece of shim stock to guide the seal over the bushing.
This avoids damaging the seal.
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Lubrication

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Lubrication
Bearings

Bearings
Seals

Flapper Valve Shaft

Seals

Bearings -

Monthly or 700 hours

Seals -

Daily

Flapper Valve Shaft -

Daily

Use a high temperature EP grease at all lubrication points.


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Drive End Bearing Lubrication

Drain Plugs

Grease bearings when pump is running. Do not overgrease.


Overgreasing will cause high temperature and burning of the
grease, resulting in bearing damage. Drain excess grease out
of drain plug after bearing reaches operating temperature.
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Discharge End Bearing Lubrication

Pressurization

Warning - Hot grease! Do not remove the drain plug with the
pump running and the bearing pressurized. Apply 4-6 strokes
with a hand gun in each bearing fitting. For the one-fitting
300 and 350 M pumps, apply 8-12 strokes.
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Purge Air

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Purge Air Piping


Plant Air 6-8 Bar
Regulator

Regulator

Coarse and Fine Filters

Union with
Orifice
Seal Purge

Seal Purge

Bearing
Pressurization

The unions contains orifice plates with a specific diameter


holes. Pressure settings depend on transport air
pressure. See the chart.
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Purge Air Requirements

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Bearing Pressurization

The discharge bearing chamber is pressurized to keep


dirt out. A coarse (5 micron) and fine (3 micron) filter keep
the air clean.
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Spare Parts

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Disassembly and Assembly


Screw Removal from Discharge End
Screw Removal from Drive End
Barrel Bushing Removal
Barrel Bushing Replacement
Screw Replacement
Screw Replacement from Drive End
Bearing and Seal Replacement

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Screw Removal from


Discharge End

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Screw Removal

Remove the purge air piping. Do not lose the orifice


plate inside the pipe union.
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Screw Removal

Loosen the set screws on the locking collar at the


drive end.
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Screw Removal

Remove the locking collar.


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Screw Removal

Remove the key.


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Screw Removal

Remove the inlet hopper access door.


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Screw Removal

Clean out the inlet hopper and screw.


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Screw Removal

Remove the bolts from the discharge end bearing


cover.
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Screw Removal

Remove the discharge end bearing cover.


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Screw Removal

Remove the two bearing retainer screws.


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Screw Removal

Remove the bearing retainer.


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Screw Removal

Reassemble the cover with two screws. This


prevents the screw bushing from sliding out of the
seal during disassembly.
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Screw Removal

Unbolt the bearing housing and, using two jackscrews in


the threaded holes, remove the housing from the
bearing support.
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Screw Removal

Remove the bearing housing from the bearing


support.
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Screw Removal

Remove the bolts from the bearing support and


insert two jackbolts in the threaded holes provided.
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Screw Removal

Remove the bearing support from the pump


discharge body.
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Screw Removal

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Screw Removal

Attach the screw puller.

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Screw Removal

Turn the hexnut to extract the screw.

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Screw Removal

Extract the screw as far as the puller allows.

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Screw Removal

Remove the puller.

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Screw Removal

With the screw end supported, pry the screw out the
rest of the way. Do not pry on the balance wheel!
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Screw Removal

Reposition the supporting sling near the screw


center of gravity as the screw is withdrawn.
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Screw Removal from


Drive End
(The screw is normally removed from
the discharge end, however, it may
also be removed from the drive end
when space for removal is limited.)

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Removal from Drive End

Remove the discharge end bearing retainer and replace the


cover with two screws as previously described. Proceed to
remove the drive end bearing housing.
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Removal from Drive End

It is necessary to use spacers under the jackbolts to


completely free the bearing housing, due to the limited
length of the bolts.
Institute

F-K Pumps - Introduction

127

Removal from Drive End

Remove the drive end bearing housing from the support.

Institute

F-K Pumps - Introduction

128

Removal from Drive End

Remove the bearing support.


Institute

F-K Pumps - Introduction

129

Removal from Drive End

Support the screw end with a sling.


Institute

F-K Pumps - Introduction

130

Removal from Drive End

Pry out the screw. Do not pry on the balance wheel!


Institute

F-K Pumps - Introduction

131

Removal from Drive End

Keep the sling near the center of gravity and


remove the screw.
Institute

F-K Pumps - Introduction

132

Barrel Bushing Removal

Institute

F-K Pumps - Introduction

133

Barrel Bushing Removal

With the discharge bearing and support housings and


the screw removed, the barrel bushings are accessible.
Institute

F-K Pumps - Introduction

134

Barrel Bushing Removal

Remove the two barrel bushing retainer screws.

Institute

F-K Pumps - Introduction

135

Barrel Bushing Removal

Remove the four barrel bushing set screws.


Institute

F-K Pumps - Introduction

136

Barrel Bushing Removal

Remove the short barrel bushing. Rap the bushing with a


hammer to loosen material until the bushing slides freely.
Institute

F-K Pumps - Introduction

137

Barrel Bushing Removal

Use compressed air to blow out material stuck between the


barrel and pump housing. Blow air into set screw holes.
Institute

F-K Pumps - Introduction

138

Barrel Bushing Removal

Remove the short barrel bushing.


Institute

F-K Pumps - Introduction

139

Barrel Bushing Removal

Use a jack to push out the remaining two bushings.

Institute

F-K Pumps - Introduction

140

Barrel Bushing Removal

Use a circular steel plate to push


against the O.D. of the bushing .
Institute

F-K Pumps - Introduction

141

Barrel Bushing Replacement

Institute

F-K Pumps - Introduction

142

Barrel Bushing Replacement

Clean and de-burr the bushings and barrel


bores thoroughly before installation.
Institute

F-K Pumps - Introduction

143

Barrel Bushing Replacement

Install the soft bushing with the machined face


towards the discharge end. Align the ribs to straddle
the set screws.
Institute

F-K Pumps - Introduction

144

Barrel Bushing Replacement

Install the hard bushing with the slot towards the


discharge end.
Institute

F-K Pumps - Introduction

145

Barrel Bushing Replacement

The slot must be on top to engage the retaining bolt.

Institute

F-K Pumps - Introduction

146

Barrel Bushing Replacement

Install the retainer bolt, positioning the bushing


until the bolt fits in the slot.
Institute

F-K Pumps - Introduction

147

Barrel Bushing Replacement

From inside the hopper, push both bushings toward


the discharge until the retaining bolt is fully engaged.
Institute

F-K Pumps - Introduction

148

Barrel Bushing Removal

Insert the short barrel bushing until the retaining bolt is


fully engaged.
Institute

F-K Pumps - Introduction

149

Barrel Bushing Replacement

Tighten the four set screws.

Institute

F-K Pumps - Introduction

150

Screw Replacement

Institute

F-K Pumps - Introduction

151

Screw Replacement

Before installing the screw thoroughly clean and deburr all machined surfaces.
Institute

F-K Pumps - Introduction

152

Screw Replacement

Seal sleeves must be perfectly smooth to prevent


seal damage. If necessary, install new sleeves.
Institute

F-K Pumps - Introduction

153

Screw Replacement

Insert the screw until the journal appears in the pump inlet
hopper.
Institute

F-K Pumps - Introduction

154

Screw Replacement

Before further insertion clean the journal and sleeve


once again.
Institute

F-K Pumps - Introduction

155

Screw Replacement

Carefully push the screw all the way into position until the
outside face of the discharge end balance wheel is
approximately flush with the end of the discharge housing.
Institute

F-K Pumps - Introduction

156

Screw Replacement

Clean the mating surfaces and apply Permatex.


Install the bearing housing support.
Institute

F-K Pumps - Introduction

157

Screw Replacement

Clean the screw journal and sleeve.

Institute

F-K Pumps - Introduction

158

Screw Replacement

Install the O-ring.

Institute

F-K Pumps - Introduction

159

Screw Replacement

Seat the O-ring against the shaft sleeve .

Institute

F-K Pumps - Introduction

160

Screw Replacement

Apply Permatex and install the bearing housing.

Institute

F-K Pumps - Introduction

161

Screw Replacement

Remove the end cover to reinstall the retainer. Apply


LocTite to the retainer screws.
Institute

F-K Pumps - Introduction

162

Screw Replacement

Install retainer and screws.


Institute

F-K Pumps - Introduction

163

Screw Replacement

Torque the retainer screws (180 ft-lbs for 250 and


300 pumps, 80 ft-lbs for 200 pumps or 40 ft-lbs for
150 pumps).
Institute

F-K Pumps - Introduction

164

Screw Replacement

Apply Permatex and re-install the cover.


Institute

F-K Pumps - Introduction

165

Screw Replacement from


Drive End

Institute

F-K Pumps - Introduction

166

Screw Replacement from


Drive End

The screw may be installed from the drive end.


Institute

F-K Pumps - Introduction

167

Screw Replacement from


Drive End

It is first necessary to remove the discharge end bearing


housing and support. Once the screw is in place, assemble
the support and bearing housing as previously described.
Institute

F-K Pumps - Introduction

168

Screw Replacement from


Drive End

Clean the screw journal and sleeve at the drive end.


Assemble the drive end support and bearing housings.
Institute

F-K Pumps - Introduction

169

Screw Replacement from


Drive End

Reassemble the key and locking collar.


Institute

F-K Pumps - Introduction

170

Bearing Replacement

Institute

F-K Pumps - Introduction

171

Bearing Replacement

On the discharge end, remove the bearing housing


and remove the locknut. Then slide the bearing out of
the housing.
Institute

F-K Pumps - Introduction

172

Bearing Replacement

On the drive end, remove the bearing housing.


Remove the locknut, and slide the bearing out of the
housing and off the bushing.
Institute

F-K Pumps - Introduction

173

Seal Replacement

Institute

F-K Pumps - Introduction

174

Seal Replacement

On the drive end, remove the cover.


Institute

F-K Pumps - Introduction

175

Seal Replacement

Drive the seal out of the cover.

Institute

F-K Pumps - Introduction

176

Seal Replacement

To access the material seals, remove the bearing


supports.
Institute

F-K Pumps - Introduction

177

Seal Replacement

Be sure the seals face in the proper direction, as


shown on the drawings in the manual.
Institute

F-K Pumps - Introduction

178

Seal Replacement

Institute

F-K Pumps - Introduction

179

Seal Replacement

Grease the seals and grease ring before reassembly.


After assembly, apply additional grease through the
fittings.
Institute

F-K Pumps - Introduction

180

Institute

F-K Pumps - Introduction

181

Questions?

Institute

F-K Pumps - Introduction

182

Maintenance Seminar

Fuller-Kinyon Pumps
Institute

F-K Pumps - Introduction

183

Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.

Introduction

Part 2.

M-Pump

Part 3.

H-Pump and Z- Flap Conversions

Part 4.

Auxiliary Equipment

Institute

F-K Pumps - Introduction

184

H Pump

Institute

Overview
Screw
Barrel Bushings
Discharge Body
Bearings and Seals
Lubrication
Purge Air
Spare Parts

F-K Pumps - Introduction

185

Overview

Institute

F-K Pumps - Introduction

186

H Pump

The H pump discharges in-line with the screw. There are


two bearings on the drive end. New H pumps have a
bearing on the discharge end, while on older pumps the
screw is cantilevered without a bearing.
Institute

F-K Pumps - Introduction

187

H Pump
Air Inlet
Manifold
Drive
Shaft

Bearing
Housing

Screw

Seal Ring
Assembly

Institute

Flapper Valve

Inlet Hopper
Barrel

Discharge
Body

Air and
Material Outlet

F-K Pumps - Introduction

188

H Pump

H pump installation.
Institute

F-K Pumps - Introduction

189

H Pump

Older H Pumps have a cantilevered screw with bearings


on one end of the shaft only.
Institute

F-K Pumps - Introduction

190

H-Pump with Z-Flap Conversion

The Z flap conversion kit (in blue) adds a bearing at the


discharge end of the shaft. The screw runs truer, and
screw, barrel and bearing and seal life are extended.
Institute

F-K Pumps - Introduction

191

Screw

Institute

F-K Pumps - Introduction

192

Two Piece Screw

A two piece screw is used on newer H pumps and pumps


with Z Flap conversions. The screw flight shaft can be
replaced without disturbing the drive.
Institute

F-K Pumps - Introduction

193

Two Piece Screw


Seal Area Wear
Sleeve

Bearing Journals

Shrink Coupling
and Bolted Flange

Institute

Colmonoy
Hardfacing on
Flight Periphery

Colmonoy
Hardfacing on Flight
Periphery, Face and
Shaft

F-K Pumps - Introduction

194

Screw Coupling

Torque to
70 ft-lbs

The two piece screw is connected with a shrink coupling.


Tighten the coupling screws gradually in a circular pattern
until proper torque is achieved. Make sure the shaft and
coupling bore are free of grease before assembly.
Institute

F-K Pumps - Introduction

195

One Piece Screw

Institute

F-K Pumps - Introduction

196

One Piece Screw

The bearing journals are bronzed using a spray-on


application. Journals can be re-built to specified diameter.
Institute

F-K Pumps - Introduction

197

One Piece Screw

Screws are balanced in two planes. The balance


wheel holes are filled with lead shot as required.
Institute

F-K Pumps - Introduction

198

Screw Balance Holes

Balancing is necessary to keep the screw from wobbling.


Institute

F-K Pumps - Introduction

199

Screw Removal

The screw is pried out through the discharge end.


Institute

F-K Pumps - Introduction

200

Screw Removal

After removal of the flap valve the screw can be


extracted.
Institute

F-K Pumps - Introduction

201

Screw Hard-facing

Hard-facing is applied by gas welding. Do not apply by


electric arc welding.
Institute

F-K Pumps - Introduction

202

Grinding the Screw

After hard-facing, the screw periphery is precision-ground.


Institute

F-K Pumps - Introduction

203

Screw

Checking the O.D. after grinding.


Institute

F-K Pumps - Introduction

204

Barrel Bushings

Institute

F-K Pumps - Introduction

205

Barrel Bushings

When changing a screw, barrel bushings should be


inspected for air-cutting (grooving caused by air blow-back
from the conveying line into the hopper) and replaced if
necessary. Front bushings wear out sooner. It may be
possible to reverse the front and rear bushings to extend
bushing life.
Institute

F-K Pumps - Introduction

206

Barrel Assembly

Institute

F-K Pumps - Introduction

207

Barrel Bushings

Barrel with front and back barrel bushings.

Institute

F-K Pumps - Introduction

208

Barrel Bushings

Inserting the bushing into the barrel.


Institute

F-K Pumps - Introduction

209

Barrel Bushings

Inserting the barrel into the inlet hopper.

Institute

F-K Pumps - Introduction

210

Discharge Body

Institute

F-K Pumps - Introduction

211

H Pump Discharge Body


Air Outlet
Pressure Gage

Air Inlet
Pressure Gage

Flapper
Valve

Air Inlet

Counterweight
Bearing
Housing
Air and
Material
Outlet

Air
Manifold
Air
Nozzles
Institute

F-K Pumps - Introduction

212

Flapper Valve Shaft

The flapper valve shaft should be greased weekly.

Institute

F-K Pumps - Introduction

213

H Pump Discharge Body

This discharge body is used for older H pumps without


Z-flap conversions.
Institute

F-K Pumps - Introduction

214

H Pump Discharge Body

This discharge body is used for older H pumps without


Z-flap conversions.
Institute

F-K Pumps - Introduction

215

Flapper Valve

Institute

F-K Pumps - Introduction

216

Material Seal

To prevent blowback of compressed air into the feed hopper


it is essential that a proper seal of compacted material is
formed. Sealing depends on the distance A and on the
counterweight applied to the flap valve lever arm.
Institute

F-K Pumps - Introduction

217

Material Seal

Adjust the barrel to achieve the results above. If blowback


still results, increase the distance A and increase the
counterweight. Note that this will increase motor amps. Find
the best balance between good sealing and low amps.
Institute

F-K Pumps - Introduction

218

Material Seal

Gap

The material seal is adjusted by changing the gap.


Institute

F-K Pumps - Introduction

219

Bearings and Seals

Institute

F-K Pumps - Introduction

220

Drive End Arrangement

The drive end arrangement features two double row


angular contact bearings. The motor side is the fixed
bearing. The pump side bearing is free to move axially.
Institute

F-K Pumps - Introduction

221

Discharge End Bearing

The discharge end bearing is a double row spherical roller


bearing mounted on a tapered sleeve. Proper bearing
clearance is achieved by giving the locknut one half turn
after initial hand tightening.
Institute

F-K Pumps - Introduction

222

Air Cooled Seal Ring Assembly


Fan

Purge
Air

Springs

Graphite
Seal

Renewable
Sleeve

The material seal is air cooled by the fan. Purge air


keeps material away from the graphite ring.
Institute

F-K Pumps - Introduction

223

Air Cooled Seal Ring Assembly

An earlier version of the air cooled seal.


Institute

F-K Pumps - Introduction

224

Air Cooled Seal Ring Assembly

Institute

F-K Pumps - Introduction

225

Air Cooled Seal Ring Assembly

Institute

F-K Pumps - Introduction

226

Air Cooled Seal Ring Assembly

Institute

F-K Pumps - Introduction

227

Air Cooled Seal Ring Assembly

Institute

F-K Pumps - Introduction

228

Air Cooled Seal Ring Assembly

Institute

F-K Pumps - Introduction

229

Renewable Sleeve

Institute

F-K Pumps - Introduction

230

Bearing Housing

Institute

F-K Pumps - Introduction

231

Bearing Installation

Institute

F-K Pumps - Introduction

232

Bearing Installation

Institute

F-K Pumps - Introduction

233

Bearings and Sleeve

Institute

F-K Pumps - Introduction

234

Bearing and Sleeve

Institute

F-K Pumps - Introduction

235

Locking Collar

Institute

F-K Pumps - Introduction

236

Purge Air

Institute

F-K Pumps - Introduction

237

Z-Flap Purge Air


Plant Air 6-8 Bar

Pressure Regulator
Union with
Orifice

Coarse and
Fine Filters

Seal Purge

Bearing
Pressurization

Check
Valve

The unions contains orifice plates with a specific diameter


holes. Pressure settings depend on transport air
pressure. See the chart.
Institute

F-K Pumps - Introduction

238

Z-Flap Purge Air Requirements


Transport Air Supply Pressure Regulator
Pressure PSIG
Setting PSIG
5-15

35

16-24

55

25-39

75

40-45

85

The above settings apply to 9, 9.5 and 10 Z-Flap


pumps with .140 (3.6 mm) diameter orifice plates.
Institute

F-K Pumps - Introduction

239

H Pump

Purge air and bearing pressurization on the discharge


bearing of an H pump.
Institute

F-K Pumps - Introduction

240

Lubrication

Institute

F-K Pumps - Introduction

241

H Pump Lubrication

Use high-temperature EP grease:


bearings - 700 hours or monthly Do not over-grease!
seals -

3 to 4 strokes every 150 hours or weekly

flap valve - 3 to 4 strokes every 150 hours or weekly


Institute

F-K Pumps - Introduction

242

Spare Parts

Institute

F-K Pumps - Introduction

243

Institute

F-K Pumps - Introduction

244

Questions?

Institute

F-K Pumps - Introduction

245

Maintenance Seminar

Fuller-Kinyon Pumps
Institute

F-K Pumps - Introduction

246

Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.

Introduction

Part 2.

M-Pump

Part 3.

H-Pump and Z- Flap Conversions

Part 4.

Auxiliary Equipment

Institute

F-K Pumps - Introduction

247

Auxiliary Equipment
Feed Arrangements
Diverter Valves
Pipeline Bends
Couplings
Rolling Contact Bearings
Airline Filter Regulator Lubricator

Institute

F-K Pumps - Introduction

248

Feed Arrangements

Institute

F-K Pumps - Introduction

249

Hopper Aeration System

Solenoid
Valve

Orifice plate

For pumps with un-controlled feed, an automatic hopper


aeration system is used. When motor amps rise, the
solenoid valve opens and the silo is aerated. Purge air
through the orifice plate keeps the nozzle clean.
Institute

F-K Pumps - Introduction

250

Hopper Aeration System

Aeration air may be taken from the transport air supply


line, as above, or from an independent plant air source.
Institute

F-K Pumps - Introduction

251

Feed Hopper Baffle

The baffle plate diverts feed to the down-turning


side of the screw, and promotes proper venting.
Institute

F-K Pumps - Introduction

252

Seal Protection Baffle

On certain installations where feed material drops into the


hopper from a great height, the material can enter the seal
area. This modification my help extend seal life.
Institute

F-K Pumps - Introduction

253

Diverter Valves

Institute

F-K Pumps - Introduction

254

Diverter / Cutoff Valves


Two-Way SK Valve

ZWR - Zero Leakage

45o Diverter

ZWS - 2-way Zero Leakage

Institute

90o Diverter

1-way SK Valve

F-K Pumps - Introduction

255

Diverter Valves

Two-way Hose-type Diverter Valves Type ZWS


Three-way Hose-type Diverter Valve Type DWS
Type ZWR Zero Leakage Diverter Valve
Two-way Diverter Valve
Zero Leakage (ZL) Diverter Valve
Zero Leakage (ZL) Diverter Valve Cutaway
Diverters: FA, 45o, 90o
45o Diverter Valve
FA / 45o / 90o Diverter Valve
90o Diverter Valve
SK Valves: Two-way SK
SK Diverter Valve
SK Valves: One-way SK
Rotary Cutoff Valve - Photo
Rotary Cutoff Valves
Rotary Cutoff Valve - Expanded View

Institute

F-K Pumps - Introduction

256

Two-way Hose-type Diverter


Valves Type ZWS

Applications
Powders
Pellets
Features
2 - 3 positions
Vacuum / pressure
Pressure tight up to 4 bar (58 psi)
Low diverting angle
Cast aluminum housing & slide
plate
Slide plate hard coated
PTFE lined
Flange connections
Controls wired to terminal box
Wetted surfaces in stainless steel
as an option
Metal hose and rubber hose are
options
Institute

Normally
completely
enclosed
controls

Models:
ZWS: Two-way
DWS: Three-way
(2 to 6 line size)

F-K Pumps - Introduction

257

Three-way Hose-type Diverter Valve


Type DWS
Features
2 - 3 positions
Vacuum / pressure
Pressure tight up to 4 bar (58
psi)
Low diverting angle
Cast aluminum housing &
slide plate
Slide plate hard coated
PTFE lined
Flange connections

Controls wired to terminal


box
Wetted surfaces in stainless
steel as an option
Metal hose and rubber hose
are options
Institute

Advantage:
Omits one two-way
vane or plug-type
diverter
Gentle angle of
diversion
F-K Pumps - Introduction

258

Type ZWR Zero Leakage


Diverter Valve
Features:
 Pressurized seals
 Cast aluminum housing
and plug
 Stainless steel internal
sleeves optional
 Reduced I/O to operate
 Bi-directional design
 4 Bar pressure capability

Institute

F-K Pumps - Introduction

259

ZWR Two-way Diverter Valve


Features:
Minimal areas for cross
contamination.
No corners or edges of
impingement
In-the-field valve hand
reversal design
In-the-field liner sleeves
replacement design
Zero leakage of gas to
dead leg

Institute

Silicon
Sealing
Air
Channel
Sealing
Pressure Chamber

F-K Pumps - Introduction

260

Zero Leakage (ZL)


Diverter Valve

Zero leakage of material and air


45 psi pressures
Pressurized rotor shoe
Peripheral rotor seal
Automatic operation
Pre-piped and pre-wired
NEMA 4, 7, 9 standard
Standard sizes
Standard 150lb. drilled flanges

Institute

F-K Pumps - Introduction

261

Zero Leakage (ZL) Diverter


Valve
A

Body with Standard


150 lb drilled flanges

Peripheral Seals
End Plate

Pressurized Nylon
Sealing Shoe

High Pressure
Lip Seal

Shoe-Type
Rotor

Section A-A

Institute

Sealed
Ball Bearing

F-K Pumps - Introduction

262

Diverters: FA, 450, 900

Advantages

Available in aluminum
Stainless steel
Simple construction
7 sizes (2, 4, 5, 6, 8, 10,
12)
3 methods of operation:
hand, air, electric
Left or right mounting
Explosion proof operators
Abrasion resistant coatings
ZL 45 diverter
Positive seal between ports air and material
same as above

Note:
Must stop material flow
before actuating except with
90 design
Maximum operating pressure
is 15 psi

90o Diverter

45o Diverter

Institute

F-K Pumps - Introduction

263

45o Diverter Valve

Body with Standard


150 lb drilled flanges
15 psig rated
End Plate
High Pressure
Lip Seal
Sealed
Ball Bearing

Plug-Type
Rotor

Section A-A

Institute

F-K Pumps - Introduction

264

FA / 45 / 90 Diverter Valve
Valve

Mounting
Bracket

Air Cylinder

Switch Box

Coupling

Institute

Dual Solenoid

F-K Pumps - Introduction

265

90 Diverter Valve
Rotor

Body with Standard 150lb. Drilled Flanges


15 psig rated

Institute

F-K Pumps - Introduction

266

SK Valves: Two-way SK

Advantages
Hand, motor, air operators are
standard
Sizes 3 to 14
Special applications:
aluminum, stainless steel
design in 4, 6 and 8
Left or right hand mounting
450 diverter leg
Heavy cast iron construction
50 psi seal tested
Standard flange drilling
High temperatures to 8500
Abrasion resistant design
Explosion proof operators
NFPA 85F version available
Institute

Note:
Must stop material flow
before actuating
Heavy weight - valve must
be carefully supported

F-K Pumps - Introduction

267

SK Diverter Valve
Valve Body

Colmonoy
Insert
Discharge Branch

Gasket
Valve Disc Arm
Cover Plate for
maintenance
access.

Adjusting
Pin Spring

Disc Arm
Shaft
Valve Disc

Valve Lever
w/ Stops

3/8 Sq. Packing


(Discharge Branch)
Lock Pin
and Chain

Institute

F-K Pumps - Introduction

268

SK Valves: One-way SK
Advantages
Heavy cast iron
construction
50 psi seal tested
Air operator standard
Hand / motor operators
optional
NFPA version available
Standard flange drilling
High temperature to 8500
Abrasion resistant design
Explosion proof
operators
Sizes 3 to 12
Institute

Note:
Limited materials of
construction
Limited applications

F-K Pumps - Introduction

269

Rotary Cutoff Valve


Advantages:

Heavy cast iron construction


Dual rotor seal
Simple construction
Inspection panel
5 sizes available (8x10, 12x12,
14x14, 12x24, & 16x20)

3 methods of operation: air,


hand, motor
Special applications:
Explosion proof operators
High temperatures to 700F
Modulating design with
V-notch rotor

Institute

F-K Pumps - Introduction

270

Rotary Cutoff Valve


End Cover

Valve Body

Cylinder (Rotor)

End Cover
Cover Plate

Lever Hub

Lever

Institute

F-K Pumps - Introduction

271

Pipeline Bends

Institute

F-K Pumps - Introduction

272

Long Radius Bend

Long radius bend with radius/pipe diameter ratios of 8 or


more were the traditional method of running pipelines.
Institute

F-K Pumps - Introduction

273

Long Radius Bend Wear Pattern

Analysis of the long radius bend indicates a ricochetting


flow, rather than a smooth flow. This results in
unanticipated wear.
Institute

F-K Pumps - Introduction

274

Concrete Wear-Back

Concrete-filled wear backs made of oversized pipe or


rolled channel can be used to extend the life of a bend.
Institute

F-K Pumps - Introduction

275

Blinded Tee

The blinded tee has been shown to significantly reduce


wear, thanks largely to a dead layer of material at the main
wear zone. A blinded tee will have a lower pressure drop
than a long radius bend, and this will reduce compressed
air cost.
Institute

F-K Pumps - Introduction

276

Short Radius Elbow

The short radius bend has a lower pressure drop than the
blinded tee, and only a slightly higher wear rate.

Institute

F-K Pumps - Introduction

277

Resistance to Flow

This graph shows the lowest resistance (pressure drop) for


a bend with R/D = 2 to 4, i.e., a short radius bend.
Institute

F-K Pumps - Introduction

278

Bend Service Life

Bend Type

Service Life (h)

Long Radius R/D = 12

14

Blind Tee

487

The above illustrates a comparison of bend service


life between blinded tees and long radius sweeps in a
severe test when handling zirconium-sodium.
Institute

F-K Pumps - Introduction

279

Bend Cost Comparison

The above illustrates the relative costs for different


types of bends.

Institute

F-K Pumps - Introduction

280

Couplings

Institute

F-K Pumps - Introduction

281

Coupling Alignment

Couplings must be precisely aligned to minimize


parallel and angular misalignment.
Institute

F-K Pumps - Introduction

282

Coupling Alignment

Imprecise alignment will cause shock and vibrations to be


transmitted to motor and machine bearings, resulting in
reduced bearing life and possible equipment damage.
Institute

F-K Pumps - Introduction

283

Coupling Alignment

Couplings are usually aligned with a dial indicator.


Institute

F-K Pumps - Introduction

284

Coupling Alignment

Align the coupling as accurately as possible to promote


long bearing life (not just to within coupling
manufacturers specs).
Institute

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285

Coupling Alignment

Feeler Gage

The coupling gap can be checked with a feeler gage. Gap


specifications are normally found on the equipment
foundation drawing, or in the coupling manufacturers data.
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286

Laser Alignment

Laser alignment offers the most accurate and easiest


coupling alignment.
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287

Laser Alignment

A laser beam on one coupling half reflects back onto a


sensor from a mirror on the other half. Misalignment is
read on a hand-held computer.
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288

Maintenance Seminar

Rolling Contact Bearings


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289

Agenda
Rolling Contact Bearings
Bearing Components
Bearing Types
FLS Applications
Installation
Lubrication

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290

Bearing Components

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291

Bearing Components

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292

Bearing Types

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293

Rolling Elements

Bearings are characterized by their various types of rolling


elements.

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Bearing Selection Criteria


Radial Loadability
Axial Loadability
Speed Capability
Misalignment Capability

A bearings type is selected for a particular machine


application based on the above major requirements.

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Bearing Loadability

A machine may impose a radial load, an axial load in one or


both directions, or a combination of radial and axial loads
on the bearing, depending on the machines function.
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296

Bearing Misalignment

Misaligned Bearings or
Bearing Housing

Shaft Deflection under load

Bearings have limits as to the degree of misalignment.

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297

Ball Bearing

Institute

Radial Loadability -

Good

Axial Loadability -

Good

Speed -

Best

Misalignment -

Poor

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298

Ball Bearing

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299

Ball Bearing with Filling Notch

A ball bearing is limited as to the number


of balls that can be installed, but this may
be increased by the use of a filling notch.
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300

Angular Contact Ball Bearing


Radial Loadability -

Good

Axial Loadability -

Very Good
(one direction only)

Institute

Speed -

Good

Misalignment -

Poor

F-K Pumps - Introduction

301

Angular Contact Ball Bearing

An axial load in the wrong direction will cause the


bearing to disassemble.
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302

Angular Contact Ball Bearing

An angular contact bearing, by virtue of its


ability to disassemble, allows a maximum
amount of load-carrying balls to be installed.
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Angular Contact Ball Bearing

Angular contact ball bearings are often arranged in pairs, to


provide bi-direction axial loadability or to provide increased
axial loadability in one direction only.
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304

Double Row
Angular Contact Ball Bearing

Double row angular contact ball bearings are available to


provide bi-directional axial loadability.
Institute

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305

Double Row
Angular Contact Ball Bearing

Institute

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306

Cylindrical Roller Bearing

Institute

Radial Loadability -

Very Good

Axial Loadability -

Poor

Speed -

good

Misalignment -

Poor

F-K Pumps - Introduction

307

Cylindrical Roller Bearing

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308

Cylindrical Roller Bearing

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309

Cylindrical Roller Bearing

Cylindrical bearings may allow minor axial movement, or


they may be axially fixed. Axial loadability, however, is
limited in the cylindrical roller bearing.
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Cylindrical Roller Bearings

Cylindrical roller bearings are available in many different


configurations. Make sure the correct bearing is installed.

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Spherical Roller Bearing

Institute

Radial Loadability -

Very Good

Axial Loadability -

Good

Speed -

Good

Misalignment -

Best

F-K Pumps - Introduction

312

Spherical Roller Bearing

Because of the spherical shape of the rollers and


races, the spherical roller bearing can accommodate
the most misalignment of any bearing type.
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313

Tapered Roller Bearing


Radial Loadability -

Very Good

Axial Loadability -

Very Good
(one direction only)

Institute

Speed -

Good

Misalignment -

Poor

F-K Pumps - Introduction

314

Tapered Roller Bearing


Spacer Ring

X
Arrangemen
t

O
Arrangemen
t

Tapered roller bearings are often combined in pairs


with spacer rings to provide bi-directional loadability.
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315

Spherical Roller Thrust Bearing

Radial Loadability -

Very Good

Axial Loadability -

Best (one direction only)

Speed -

Good

Misalignment -

Best

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316

Spherical Roller Thrust Bearing

This bearing has the highest axial loadability. It is


often used to suspend a rotating shaft, where the
load is always downward.
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317

Linear Re-circulating Ball Bearing

When linear motion is required, a linear recirculating ball


bearing may be used. Balls re-circulate through
passageways in the carriage as they roll along the raceway.
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318

Cooper Split Roller Bearing

A split roller bearing may avoid shaft removal and extensive


installation time in certain circumstances. This cylindrical
roller bearing rests in a self-aligning housing.
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319

Four Point Bearing

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320

Speed
Radial Loadability
Axial Loadability
Misalignment

Comparison of
Bearing Capabilities

Ball
Bearing

Institute

Angular
Contact
Ball
Bearing

Cylindrical
Roller
Bearing

Spherical
Roller
Bearing

Spherical
Roller
Thrust
Bearing

Tapered
Roller
Bearing

F-K Pumps - Introduction

321

FLS Applications

Institute

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322

Double Row
Angular Contact Ball Bearing
Used on FLS Equipment:
Fuller-Kinyon Type M Pumps
150 mm and 200 mm

Institute

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323

Angular Contact Ball Bearing

Used on FLS Equipment:


Fuller-Kinyon Type M Pumps
250, 300 and 350 mm
(O arrangement)

Institute

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324

Cylindrical Roller Bearing

Used on FLS Equipment:

Ful-Vane Rotary Compressors


Grinding Mill Roller Assemblies

Institute

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325

Spherical Roller Bearing


Used on FLS Equipment:
F-K Pump Z-Flap Conversions
O-Sepa Separator Lower Bearing
Kiln Thrust Roller Assembly
Kiln and Mill Pinion Bearings
Symetro Gears
Fans
Pillow Block Housings (various)

Institute

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326

Tapered Roller Bearings

Used on FLS Equipment:


Grinding Mill Roller Assemblies
(X Arrangement)

Institute

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327

Spherical Roller Thrust Bearing

Used on FLS Equipment:


Rotary Kiln Thrust Roller
O-Sepa Separator Upper Bearing

Institute

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328

Linear Re-circulating Ball Bearing

Used on FLS Equipment:


CrossBar Cooler
Institute

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329

Cooper Split Roller Bearing

Used on FLS Equipment:


Clinker Cooler Repairs

Institute

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330

Bearing Installation

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Bearing Clearance

Bearing internal clearance is critical to bearing life.


Clearance is necessary to accommodate expansion
caused by relative temperature changes of the inner
and outer bearing rings.
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Bearing Clearance

Excessive clearance results in the shaft load being


spread over too few rollers. Too little clearance results
in the rollers receiving additional, unnecessary internal
loading when the bearing is at operating temperature.
Institute

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333

Bearing Clearance

Feeler Gage

Total internal clearance can be checked with a feeler


gage inserted above the top roller with the machine at
rest.
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334

Bearing Clearance Designations

C2
CN
C3
C4
C5
R __.__

Small Clearance
Normal Clearance
Large Clearance
Larger Clearance
Largest Clearance
Special Clearance

Bearings are available with various internal clearances.

Institute

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335

Checking Bearing Clearance

Cold clearance must be within specifications after installation.


After the machine has reached normal operating temperature,
clearance will be reduced.
Institute

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336

Compressor Bearing Clearances


Bearing Bore (MM) Before Mounting (in.)

After Mounting
(in.)

30

.0020/.0024

.0012/.0022

35

.0022/.0028

.0013/.0025

40

.0022/.0028

.0013/.0028

45

.0026/.0032

.0017/.0028

55

.0030/.0035

.0019/.0032

65

.0030/.0035

.0019/.0032

70

.0035/.0043

.0024/.0040

80

.0035/.0043

.0024/.0040

95

.0041/.0049

.0028/.0045

105

.0047/.0057

.0029/.0051

120

.0071/.0081

.0053/.0075

130

.0093/.0109

.0075/.0103

Institute

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Bearing Axial Clearance

Bearings also have inherent axial clearance. This end play


must sometimes be taken into consideration when setting up
a machines shaft position.
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338

Bearing Installation

Bearing inner rings are a shrink fit on the shaft (outer


rings are a sliding fit inside the bore in the cylinder head.
The bearing must be heated to install it on the shaft.
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339

Bearing Installation
Internal Clearance
Reduced After
Installation

The bearing inner ring is stretched after installation,


reducing the bearings internal clearance. The clearance
is controlled by maintaining the shaft diameter between
limits when machining.
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340

Bearing Clearance

Clearance in bearings with tapered bores is controlled by


the distance the bearing is pushed up the taper. The
further up, the more the inner ring will stretch and the less
will be the clearance after installation.
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341

Tapered Sleeve Pillow Block

Often a tapered sleeve is used instead of tapering the


shaft.
Institute

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342

Shrink-Fitting of Bearings

animation

Rule of thumb: The ring that sees the load over its entire
circumference is the tight-fitting ring. In this animation the inner
ring gets loaded over its entire circumference, while the
outer ring is loaded at one point only.
Institute

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343

Bearing Creep

animation

If the bearing ring is not tight, it will creep and damage


the shaft.
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344

Bearing Installation

Bearings are best heated with an induction heater. If this


is not available, use an oil bath. Never heat a bearing
with a torch. Heating to more than 250F (120C) will
damage the temper of the bearing steel.
Institute

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345

Induction Heating

SKF induction heating film clip


Institute

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346

Bearing Installation
Inner
Ring

Outer
Ring

Collar

This fixed cylindrical bearing comes as a matched set


consisting of inner ring, fixing collar, and outer ring with
rollers and cage assembled. The inner ring and collar
are held in place with a locknut and tab washer.
Institute

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347

Bearing Installation

Installing a pre-heated inner ring.

Institute

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348

Bearing Installation

Inner ring with locknut and tab washer.


Institute

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349

Bearing Installation

Installing the collar.


Institute

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350

Bearing Installation

Collar in place.
Institute

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351

Bearing Installation

Installing the tab washer.


Institute

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352

Bearing Installation

Installing the locknut.


Institute

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353

Bearing Installation

Tightening the locknut.


Institute

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354

Bearing Installation

Bending over the washers locking tab.


Institute

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355

Bearing Installation

Installing the bearing retainer.


Institute

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356

Bearing Lubrication

Institute

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357

Lubrication Film

Tiny surface asperities are kept from contacting


each other by a good oil film.
Institute

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358

Hydrodynamic Lubrication

As one surface slides over another, a wave of oil


wedges them apart, creating an oil film.
Institute

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359

Hydrodynamic Lubrication

When the shaft rotates, oil is drawn in between the


journal and bearing. The shaft lifts and a lubrication
film is established.
Institute

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360

Elasto-hydrodynamic Effect

Under extreme forces, plastic deformation occurs


and surface area in the contact zone increases.
Lubricant viscosity multiplies under extreme
pressure. The result is a thin but stable oil film
capable of keeping surfaces separated.
Institute

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361

Boundary Lubrication

When speed or oil viscosity is too low, or when loads


are excessive, surfaces may contact. Boundary
lubrication conditions are said to exist.
Institute

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362

EP Additives

Extreme pressure and anti-wear additives in the oil


react to the high heat and pressures at the surfaces
to form a low-friction chemical film, thus preventing
surfaces from seizing.
Institute

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363

Oil Film Thickness

L=

Oil film thickness increases with viscosity and speed and


decreases with load. A good film thickness is three times
the surface roughness.
Institute

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364

Viscosity

Viscosity, or the resistance of a liquid to flow, is the most


important property of lubricating oil. Oil viscosity changes
drastically with temperature.
Institute

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365

Viscosity

Oil viscosity is selected based on equipment operating


temperature range.
Institute

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366

Viscosity Index

Viscosity index is a relative measurement of how viscosity


changes with change in temperature. Oil with a higher
viscosity index can maintain its viscosity over a wider
temperature range.
Institute

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367

ISO Viscosity Grade


International Standards Organization
designation for oil viscosity grade.
Measured as Centistoke (cSt) at 40 C.
Becoming more common than SSU
(Saybolt Seconds Universal).
Multiply ISO VG by 5 to approximate
SSU at 100 F.

Institute

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368

Viscosity
Equivalents

Institute

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369

Grease

Grease = Oil + Thickener

Grease is approximately 85% base oil plus 15%


thickener. Lubricating properties (viscosity, etc.) are
dependent on the characteristics of the base oil,
while the thickener acts as a sponge to hold the oil.
Institute

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370

Grease Lubrication
Advantages

Seals out dirt


Stays where it is put
Supplies oil to the bearing as required
Minimal leakage
Long lasting, low maintenance

Disadvantages
Overgreasing may cause bearing damage

Institute

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Oil Lubrication

Advantages
Able to clean system with recirculation
Able to cool system with heat exchanger
Generally better lubrication
Better for high speed applications

Disadvantages
More complicated (circulating system)
More maintenance
More prone to leakage
Institute

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Bearing Greasing
(FAG recommendations)

if RPM x Diameter (in mm) is

less than 50,000

pack full

50,000 500,000

pack 60% full

greater than 500,000

pack 20-35% full

Excessive grease in hi-speed applications results in heat


generation through churning of the grease. This can lead
to burning of the grease and subsequent bearing failure.
Institute

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373

Bearing Lubrication
Lubrication
Grooves

Bearings can be supplied with a lubrication groove. This


angular contact ball bearing is used back to back with
another bearing. Grease enters the groove and emerges
between the two bearings.
Institute

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374

Lubrication !

Most bearing failures are caused by lubrication problems.


Institute

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375

Airline Filter Regulator Lubricator

Institute

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376

Filter Regulator Lubricator

Filter-regulator-lubricators are used to condition


compressed air supply to pneumatic devices.
Institute

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377