Series TD OPERATING AND MAINTENANCE INSTRUCTIONS

TWIN SCREW PUMPS SERIES TD

--------------------------------------------------------------------------------------TO : JINDAL POWER LTD

--------------------------------------------------------------------------------------Pump Model . Pump Sr. No. Quantity OKE No. . : Your Order No. Order Date Item Number Destination Project Name : TDSH 088/052 : 092051/0712, 0713, 0714, 0715 : 4Nos : 092051

--------------------------------------------------------------------------------------: : : : : JSPL -ANGUL

--------------------------------------------------------------------------------------TUSHACO PUMPS PVT. LTD

HEAD OFFICE :
601,6TH Floor,Raheja Plaza A Wing, L.B.S. Marg, Ghatkopar (w) Mumbai 400 086. TEL.: 91-22-2519 7300. FAX.: 91-22-2519 7360 EMAIL: salesho@tushacopumps.com EMAIL: tushacohyd@tushacopumps.com: mahesh.prasad@tushacopumps.com

MANUFACTURING UNIT
653/1 ,SOMNATH CO-OP. INDL. SOCIETY LTD. KACHIGAM ROAD , DABHEL, DAMAN 396 210 Phone : +91-0260 -2252076 Fax : +91-0260 -2242075

f:\swati\216.doc

Series TD
TABLE OF CONTENTS
1. 2. ... ... ... ... ... ... ... ... 3. ... ... ... ... ... ... ... ... ... ... 4 ... ... ... ... ... ... 5. ... ... ... ... ... ... ... ... 6. ... TABLE OF CONTENTS.... INTRODUCTION description.. application.. advantages.. relief valve.. shaft sealing arrangement heating of pump casing.. general pump data.. available designs. INSTALLATION.. preparation for installation. transport.. location.. foundation.. aligning of pump and motor horizontal alignment.. alignment - sub 1,2,3. piping design.. pipe accessories.. suction strainers.. check valve. OPERATION general before start-up start-up after the pump is in operation after long term shut down.. fault find chart MAINTENANCE.. schedule.. bearings.. timing gear.. spare parts.. lubrication table. lubrication chart.. shaft dimensions TD S & TD L ..... bearing chart LONG TERM STORAGE.. conservation prescription 1.0 2.0 2.0 2.0 2.0 2.1 2.1 2.1 2.1 2.1 3.0 3.0 3.0 3.1 3.1 3.2 3.2 3.2.1 3.3 3.3 3.3 3.3 4.0 4.0 4.1 4.1 4.2 4.2 4.3 5.0 5.0 5.1 5.1 5.1 5.2 5.3 5.4 5.4 6.0 6.0

1.0

7. ... ... ... ... ... ... ... ...

DOCUMENTS AND DRAWINGS. pump data sheet . makers test certificate. cross sectional view dimensional view mechanical seal drawing GA drawing.. dismantling instructions TD SH ___/10. dismantling instructions TD S/L H ___/40 dismantling instructions TD LH ___/00. Assembly. Assembly.

7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.10.1

Series TD
INTRODUCTION 2.0

TUSHACO TWIN SCREW `TD series is a Positive Displacement screw pump with a pair of timing gears - a unique construction that prevents metal to metal contact of rotating elements while in operation - Thus preventing serious damages - and considered as an ideal choice for many duties where dry running can occur sometimes. TWIN SCREW pumps - as in case of other screw pump class - deliver uniform pulsation free - smooth flow conveying the product gently without agitation/churning or shearing. TD is a double flow design - the liquid enters from both the ends of screw pairs and travels towards the center where it is discharged. NPSHR is low, pump is capable of handling a wide range of viscosities and run direct at motor speed for most applications. Description ...

Screws with timing gears

Application ...
The screw pumps, series TD are specially designed for handling light and heavy fluids, both lubricating and non-lubricating under low to medium pressures. Designed to operate with a wide range of flows, these pumps are used for a wide range of applications. A B C Loading and unloading, storage tanks, barges and ships Lube Oil Circulation systems. General Transfer applications

Advantages
A B C D E F G H I J K

...
High efficiency. No metal to metal contacts between the screws shaft High suction lift capability Can handle a wide range of fluids with superior volumetric efficiency The pump is capable of DRY running for short periods. High speed operation - direct motor speeds eliminate the need for gear reduction. The pumps are self priming. The pump can handle air in the suction line without loss of prime. Non-Pulsating Flow No emulsification of the fluid being pumped. Very low noise and vibration levels.

Series TD
INTRODUCTION 2.1

Relief Valve ...

The safety valve connects discharge and the suction side of the pump to protect the pump against over pressure if ordered with the pump. If not, separate line mounted Relief Valve should be fitted. Relief valve can be utilized to reduce the starting torque. Hand wheel feature permits opening of the valve to lower the pressure and the starting torque during start-up.

Shaft Sealing Arrangement ...

Due to their specific design, these pumps can be supplied with mechanical seals or stuffing box packing. The selection of these seals depends on temperature and nature of the liquid handled as well as on the specific operating conditions.

Heating of Pump Casing ...

The pump has provision for foot heating and has to be specified while ordering. - Heating the pump prior to its use in order to protect the hot product from cooling down w hen entering the pump. - It is necessary to start heating atleast one hour prior to starting the pump. This system is not intended for heating the liquid, but to keep it hot when the pump is not in use to prevent congealing/solidifying of product within the casing. It is thus necessary that the product to be pumped is heated to the required temperature beforehand, so that it is pumped in the best possible conditions. Once the pump is started, product temperature will be such that it may not be necessary to continue heating the pump.

General pump data ...

TUSHACO Twin screw TD Series pumps are offered with the following limitations : -------------------------------------------------------------------------------------------------------Capacities Pressure Range Viscosities Speeds of Rotation Motor power From from from from from 20 1 1 500 2 to to to to to 1000 M3/Hr 16/24 BAR 15000 cSt or more 1760 RPM 500 kW

Available designs ...

Pumps with internal or external bearing, mechanical seal or stuffing box, horizontal foot mounted with or without foot heating, with or without built in relief valve. Standard construction in Cast Iron casing parts - screws AISI C1045/4140/420 or 431. Special construction in FABRICATED STEEL with or without jacket. Long shaft design for special applications with above features. Vertical designs for space saving applications.

Series TD
INSTALLATION
Preparation for Installation ...
After receipt of the pump, it should be stored in a dry area. The shipping crate is only suitable to protect the pump for maximum of 90 days after shipment from the factory. The period may be shorter in the case of poor atmospheric conditions. Special packing for long term storage can be supplied upon request. After receipt, each pump should be thoroughly checked. Damage must be reported to the TUSHACO office or representative, and the transportation company immediately. Any claims for damage must be known within one week after receipt of the goods.

3.0

Transport ...
Take care when moving the pump. Rough treatment or lifting in an unsuitable way may cause permanent damage. The safe lifting methods are illustrated below. The pump should never be lifted by the shaftend. Relief valve handwheel may have to be removed to accommodate the lifting straps.

Series TD
INSTALLATION
Location ...
Position the pump as close as possible to the tank. Ideally the pump should be located in a well-ventilated room with sufficient space on all sides for easy maintenance. If it is necessary to place the pump in a pit, care should be taken to prevent flooding.

3.1

Foundation ...
The foundation should be designed in such a way that it can support the weight of pump and motor.

When concrete is poured, holes should be kept open at the positions indicated on the base plate drawing for placing the bolts later. The surface of the concrete should be left rough in order to permit the application of a thin layer of mortar, which serves to support the entire baseplate. After the concrete has set hard, place the pump unit together with the bolts in its place. With levelling wedges the unit can be levelled. The holes can now be filled, and this goes also for the void between the base plate and the concrete. If a concrete floor is already available, use can be made of wedge bolts.

Series TD
INSTALLATION
Aligning of pump and motor ...
The accuracy of aligning of pump and motor is of great importance for the working life of coupling and bearings. A flexible coupling is not designed to absorb a mis-alignment. The purpose of the coupling is to permit some radial movement between pump and motor shafts during power transfer. A major mis-alignment will cause a shorter life for the coupling and excessive bearing wear. It will also result in vibration. Alignment is best done with a dial gauge. Axial or radial deviations may not exceed 0.25 mm/0.010. After having the pump in operation for about a week, it is essential to recheck the alignment. This should take place after switching off the motor before the pump has had time to cool down. For good operation it is necessary to mount the pump securely. Nuts must be tightened evenly to prevent distortion. Alignment can be carried out as follows.

3.2

Procedure for horizontal mount pumps ...

1) Align motorshaft abd pumpshaft vertically by using shims.

2) Now align motorshaft and pumpshaft horizontally by pushing. 3) Align the coupling halves.

Series TD
INSTALLATION
Sub 1) Horizontal Alignment [dismounted coupling piece(s)]. Connect the dial gauge to the coupling half of the motor. A B C Rotate the shaft through a 1/4 revolution. Adjust the gauge to zero. Rotate the shaft through a 1/2 revolution. The difference between the gauge reading now and before should not exceed 0.25. If the deviation is larger, the motor shaft is to be adjusted and the check should be carried out again.

3.2.1

Sub 2) Check of horizontal alignment [dismounted coupling piece(s)]. Connect the dia gauge to the coupling half of the motor. A B Rotate the shaft several times through 90 Deg. and read the gauge. The two readings in opposite position should not differ more than 0.25 mm. If it is more, the parallellity of the pump-motor combination must be realigned.

Sub 3) Alignment of coupling [mounted coupling piece(s)]. A The next thing to be done is to check whether the coupling halves are parallel. A micrometer should be placed at 4 places between the coupling halves; at top, bottom and at both sides. If the variation in reading is less than 0.25 mm the pump motor combination can be considered parallel and the motor can be anchored down. If the variation is larger than 0.25 mm the motor must be adjusted.

Series TD
INSTALLATION
Piping design ...
Because the screw pump has close clearance between its working parts, it is essential that the suction line is carefully and thoroughly cleaned before the connection is made. If the pump has a suction lift, the suction line should be adequately sized to reduce friction losses. Errors in the pipe layout, such as excessively long or small diameter suction lines, too may bends, valves, and elevated parts in the line cannot be overcome by the pump since the limiting factor is the atmospheric pressure. This pressure is a physical phenomenon independent of any pump. The result will inevitably be cavitation, noise, vibration, and faulty operation. After installing the pump unit on foundation, the pipelines can be connected. For correct location of pipes, refer to the pump drawing. Pipe adaptors should be short and direct. Bends should be laid out with the largest possible radius. All pipes should be fixed independent from the pump flanges. Pipelines which may have to withstand elevated temperature must be provided with expansion joints to absorb expansion of the pipe. Tensional or compressing loads on the pump could result in distortions causing wear or even seizure. To check whether the pipes are correctly aligned, bolts should be inserted through the bolt holes of pump flange and pipe flange. If these bolts can be pushed by hand and the flanges are parallel, the pipelines are fitted stress free. Some clearance between the pump and the pipe flange should be maintained to allow for the flange gaskets.

3.3

Pipe Accessories ... Suction Strainers ...

TUSHACO recommends the use of a strainer at the suction side to ensure that no dirt or welding beads remain in the system. The strainer should be made of reinforced 30 Mesh wire(~ 500 Microns). The total free flow area must be 4 to 5 times bigger than the cross sectional free flow area of the suction line. If the medium has a viscosity above 20 cSt, the area should be enlarged to 5 or 6 times the size of the pipe.
Manometers should be placed before and behind the strainer to check when cleaning is to be carried out. The pressure loss over the strainer should be no more than 0.5 BAR. In general, suction strainers can be used with any liquid except when the viscosity is very high. In these cases, the strainer should be eliminated and careful cleaning of the suction line is advised to remove all foreign particles.

Check Valve ...

If the discharge head is high and the viscosity of the liquid is low, it is recommended to install a check valve in the discharge line. This is to protect the pump from reverse rotation in the event of backflow when the pump is shut down. This also allows parallel operation of another pump in the same system.

Series TD
OPERATION
General ...
For all TUSHACO TWIN-SCREW pumps, the operating principle remains the same. The TUSHACO twin screw pump series is a Rotary Positive Displacement pump which consists of two counter-rotating screws. The screws mesh together with very small clearance between flanks (due to precision timing gears) and rotate freely in the casing bores. Before start up, the pump is filled with liquid. The air in the suction line will be removed by the pumping action. This creates a vacuum (negative pressure) enabling the liquid to enter into the pump. The fluid gets trapped between the thread profiles and moves axially from one end to the other with least turbulence. Internal pressure losses is the lowest in Twin screw pumps thus giving excellent suction capability. Opposed screw construction eliminates axial thrust. Both shafts are supported by bearings and are fixed axially at the driven end of the shafts. Shaft sealing can be accomplished by two methods : - Soft packed stuffing boxes External bearings and long shaft(L) - Mechanical seals Short or long shaft (S) or (L) A variety of designs and/or materials can be offered for both versions.

4.0

Series TD
OPERATION
Before start-up ...
A Inspect all pipelines, check for any leakage or stress in the system. Clean all pipes, valves, tanks and filters to be sure all foreign materials have been removed. Check all valves and meters. All casing bolts should be tightened. Check to be sure the pump shaft can rotate without difficulty; if not, the cause of blockage or friction should be corrected. Each pump is tested before leaving the factory, but transport could have some effect. Resistance in turning the shaft must be expected with pumps equipped with mechanical seals. The pumps equipped with soft packed stuffing boxes will not have this resistance. Check the direction of rotation of pump and motor to be sure they are the same. An arrow to indicate the direction of rotation is always fixed on the pump. In case the pump has external bearings; fill the timing gear box with oil. Refer to the lubrication table for type and quality of the oil. The pumps should always be filled with liquid before starting. If the pump is fitted with mechanical seals it is most important to fill the pump before start-up either with the pumped liquid or with a neutral compatible liquid to protect the seal faces from running dry. This is very important. Auxiliary flushing or lubrication lines should be examined for any damage or distortions. Open all valves. Read the driver instruction manual to determine if a special coupling is required. If the pump has a suction lift, the deairation valve in the discharge line should be opened and the pipe filled with liquid. This is only necessary for new installations or for reinstalled pumps.

4.1

H I

Start-up ...
A If the pump is provided with a heating feature, this heating should be turned on until pump has reached its normal operation temperature, after that heating must be turned off and motor can be started. As soon as the pump has reached the rated speed, the safety valve should be closed. The absorbed power, and the suction and discharge pressure should be checked against the data sheet.

Series TD
OPERATION 4.2

After the pump is in operation ...

A If the pump has soft packed stuffing boxes, tighten the packing gland bolts, until the leakage is reduced to 40 - 60 drops per hour, per box. If it is not possible to reduce the leakage by tightening the gland bolts, the soft packing must be worn and should be replaced. Mechanical seal usually do not require any attention. Slight seepage/leakage after 1st commissioning may eventually stop after a few hours of running when the seal faces get beded in. B Check the temperature of bearings, timing gearbox and soft packing if provided. It is to be expected that this temperature will be high in these areas at start-up, and after a short period of time the temperatures will settle down to the product temperature. If the pump is part of a closed system, the discharge line should be derated during operation.

After long term shut down ...

The pump should not stand unused for long periods. The pump should be operated once a week if possible. If the pump will be idle for longer periods, it is advisable to rotate the shaft by hand if possible, on a weekly schedule. It is easy to detect if any of the internal parts are contacting by rotating the shaft by hand. When starting, let the pump run for a short period without pressure to allow proper wetting of all rotating parts.

Series TD
OPERATION 4.3

Fault finding chart

Pump fails to prime Lack of output Hydraulic noise Motor overloading Irregular delivery Pump Seizes Pump becomes warm Cause: Rotation incorrect Pump is not filled Air leaks in suction system Shaft seal(s) leaking Vacuum too high Relief valve leaking Viscosity too high Motor speed too low Vapour pressure of the medium too high Suction pipe too close to the tank bottom Retention time of fluid in tank too short to separate the air Incorrect alignment Motor speed too high Velocity in pipeline too high Discharge pressure too high Foreign matter in screw clearances Damaged ball bearings Pipe work incorrectly aligned to pump casing Suction pipe too small

Series TD
MAINTENANCE
Schedule ...
Daily (only for pumps with external bearings) : 1. Check the level of the oil in the timing gearbox (it should cover half the sight glass. Check the leakage from the stuffing boxes if these are applied; it should remain at 40 to 60 drops per hour per box. Mechanical seal do not require routine maintenance.

5.0

2.

Weekly : 1. 2. Yearly : 1. Check the alignment of the coupling halves, preferably immediately after ending the pumping operation, while the temperature is still at operating level. Check capacity and absorbed horse power. Capacity - and power loss will indicate wear. Check the screw flank clearance, as well as the play between the timing gears. Let unused pump run for 30 minutes at full load. Check any automatic controls and/or regulating valves.

2.

3.

Series TD
MAINTENANCE
Bearings ...
After every 4000 to 5000 working hours the axial clearance of the bearings is to be checked. The axial clearance of the shafts should not exceed 0.2 mm.

5.1

Timing gears ...

If the clearance is more than 0.5 mm the timing gears should be replaced. For pumps with external bearings : Refer to the lubrication table and chart (pages 5.5 and 5.6) for the quantity and quality of lubricating oil to be used and the schedule for changing the lubrication (page 5.1). After the first 50 working hours of pump operation the lubrication oil should be changed. Subsequent renewals are to be made in accordance with the lubrication chart.

Spare parts ...

In order to reduce the time the pump is out of order in case of break down, it is advisable to keep the following parts in stock.

1 1 1 1 1

Set of screwshafts complete with timing gears Set of bearings Set of gaskets Set of mechanical seals or Set of stuffing box packing.

When ordering spare parts, the following information should be indicated on the purchase order :

Pump serial number (see title page). Pump type (see title pate). Code number of required spares as given in the parts list (page 7.3).

Series TD
MAINTENANCE
Lubrication
Pump series TD (External Bearing) Lubrication of gears and ball bearings driven side : oil Lubrication of gears and ball bearings non driven side : greased for life

5.2

PUMP SERIES TD S (SHORT SHAFT) and TD L (LONG SHAFT)

Required amount of oil in gear box in liters. Series 088 105 118 135 150 165 180 195 210 235 TD S 1.1 1.5 2.6 2.6 4.4 5.1 6.6 8.1 11.1 14.1 TD L 1.3 1.7 2.1 2.3 3.7 4.2 5.7 6.3 8.3 11.6

Series TD
MAINTENANCE
Lubrication chart ..... Recommended Oils Temp. of the pumped liquid Max. temp. of the gear box Drain interval for working hours ISO standard Make BP CHEVRON ELF ESSO Marine ESSO Industrial GULF Marine GULF Industrial MOBIL 100 C 80 C 4000 160 C 120 C 4000 240 C 160 C 2000 300 C 200 C 1000 350 C 250 C 500 ONLY FOR EXTERNAL BEARING CONSTRUCTION

5.3

VG 100

VG 150

VG 680

VG 680

1000

Energol OE 175 Energol CS 200 OC Turbine Oil 24 Orites 125 MS Tromar 30 Teresso 100

Energol OE 225 Energol CS 300 OC Turbine Oil 36 Orites 125 MS Tromar 30 Teresso 150

Energol OE 225 Energol CS 300 Cylinder Oil 90 Orites 270 MS

Energol OE 325 Energol CS 425 Cylinder Oil 190 Orites 270 MS

Energol CS 550 Cylinder Oil 190 Orites 270 MS

Cyclesso 680

Cyclesso 680

Cyclesso 680

Veritas V9 Harmony 61

Veritas HDV 17 Harmony 97 Harmony 204 Harmony 204

SHELL TOTAL IOCL HPCL

DTE Oil No 3 DTE Oil Extra heavy Omala 150 Carter EP 100 N Servo System 121 Enklo 120

DTE Oil HH

Glygoyle 30

Glygoyle 30

Omala 220 Carter EP 220 Servo System 220 Enklo 220

Omala 320 Carter EP 220 Servo System 220 Enklo 220

Trivela WA Cortusa SY 150 Cyndol 680 Cortusa SY 150 Cyndol 680

BPCL

Hydrol 150

Hydrol 220

Hydrol 220

Engoil 680

Series TD
UPDATE

TITLE :SERIES :MODEL :-

18/07/02

MAINTENANCE MASTER TWIN SCREW TD

0.02

OPEN TOL. 0.1 UNLESS SPECIFIED.

NO SHARP CORNERS. ALL DIM. ARE IN MM UNLESS SPECIFIED.

DRN. CODE:-

MUKESH

APP. DRG.NO.:-

P001 4378

d1

d1 D
= =

d4

d3

SHAFT DIMENSION REPAIR PURPOSES SERIES-TD. BEARING AND SEAL SIZES : SEE CROSS SECTIONAL DRAWINGS ENCLOSED. ALL DIMENSIONS IN MM.
Tolerance

Single row Bearing

Tolerance

SERIES 88 105 118 135 150 165 180 210 235 244 265 275

D 88 105 118 135 150 165 180 210 235 244 265 275

d1 35 40 45 50 55 60 65 80 100 100 110 110

d2 30 30 35 40 45

Tolerance

d3 30 30 35 40 45

d4 28 28 32 38 42

h6

50 55 65 85 85 100 100

k5

50 55 65 85 85 100 100

k5

45 50 60 65 65 75 75

h6

Tolerance

Double row Bearing

d2

Series TD
LONG TERM STORAGE 6.0

When pumps are stored or unused for long periods, rust my occur. Since rust has an adverse effect on the working life of the pump, it is advisable to apply protection to the bare metal surfaces.

Conservation prescription ...

The inside of the timing gear box, the bearings, pump casing and screwshafts should be filled with : Exxon RS 335 Shell Ensis Oil 1 Valvoline Ritzol R6 Mobil Arma 523/524

The shaft seals should be greased with a grease which can be removed later. The internal machined parts must be protected with for example : Exxon RS 335 Shell Ensis Oil 1 Valvoline Ritzol R6 Mobil Arma 523/524 All drilled holes and screw taps are to be plugged. Flanges are to be covered with blanks. Periodical checks of the stored pump should be made. The screwshafts are to be turned once per 14 days. After rotation the position of the shafts must be different from what they were before the rotation.

Series TD
DOCUMENTS AND DRAWINGS 7.0

Cross sectional view ...

enclosed : = Cross sectional view no.: POO1 4572/1

Additional information ...

enclosed : = = = Dimensional drawing no.: Mechanical seal drawing : G.A. drawing of pump and motor assembly : P661 5844/4

Dismantling : Tick 4 any one, as per customer requirement External bearing, 4 mechanical seal Internal bearing, 1 mechanical seal External bearing, 4 stuffing box TD SH _ _ _ / 40 TD SH _ _ _ / 10 TD SH _ _ _ / 00

See attached drawings

Series TD
PUMP DATA SHEET 7.1

TO BE INSERTED ACCORDING TO THE PUMP MODEL, WHEN GIVING TO THE CONCERNED PARTY.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

BRAND NAME PUMP TYPE MODEL PUMP SERIAL NO. OUR FILE REF LIQUID KINEMATIC VISCOCITY CAPACITY DIFF. PRESSURE SPEED DRIVE TYPE OF COUPLING DIRECTION OF ROTATION CASING ROTOR SHAFT SHAFT SEAL MOUNTING TYPE OF BEARING SUCTION DISCHARGE RELIF VALVE RECOMMENDED MOTOR MOTOR FRAME

TUSHACO

Series TD
MAKERS TEST CERTIFICATE
ENCLOSED

7.2

Series TD
CROSS SECTIONAL DRAWING 7.3

ENCLOSED

Series TD
DIMENSIONAL DRAWING 7.4

SEE GA DRAWING

Series TD
MECHANICAL SEAL DRAWING 7.5

N. A.

Series TD
GA DRAWING OF PUMP & MOTOR ASSEMBLY 7.6

ENCLOSED

Series TD
DISMANTLING INSTRUCTION FOR TD SH __/10
Internal bearing with one mechanical seal. Refer drawings attached in the manual Dismantling a twin screw pump requires clean open space as in a workshop rather than at the place where the pump is installed and connected to piping system. The pump will have to be removed from the base frame after disconnecting power supply and shutting off inlet/outlet/steam in/condensate out valves and disconnecting the pipelines. Drain all the fluid from the pump and clean the pump externally. All bolts/screws and fasteners are in metric sizes - keep standard tools - Spanner sets, Allenkey sets and other conventional maintenance tools like puller, hammer etc. DISMANTLING PROCEDURE Keep the above referred drawings ready for quick reference. First remove the coupling from the shaft and also shaft key (133). Mark for identification on all covers and parts with respect to one another by numbers/letters. Remove bolts (309) and pull out gear box. The timing gears are visible for inspection as well as to check the backlash. Mechanical seal, rotating part will be on the shaft. This can be pulled out. Stationery part, will be fixed inside the gearbox. This can be removed for checking. Remove cover non drive end (407) together with bearings (103) by removing bolts(310). The cover can be removed by using jack screws using threaded holes. Now remove bolts. Now unscrew bolts (310) drive end and jack off cover drive end (401) carefully. The entire screw assembly alongwith shafts bearings (105) etc. will come off as a cartridge. There will be a tendency for the assembly to drop in the bores as soon as screws are out of the bores while pulling out the assembly. This will damage the shafts. If further disassembly is required then you may proceed. Remove lock nuts (110) and lock washer (111). The timing gears (108) can be pulled out. Make sure to mark the timing gears with respect to the shafts and positions. Distance piece (124) (very important) can also be removed but positions must be market to prevent interchanging of locations as these spaces determine the clearance between screws and timings. The bearings (105) can also be removed and also the oil seal (721). Similarly bearings (103) and oil seal (721) from cover (407) can also be removed. Rotating parts mechanical seals (702) see makers drawing, can be pulled out of shaft stationery part of seal will be in segment (498 and 494) and can be removed. Replace seals if damaged. Clean all parts thoroughly by kerosene/solvent.

7.7

Series TD
DISMANTLING INSTRUCTION FOR TD S/L H _ _ _/40 7.8
External bearing with four mechanical seals. Refer drawings attached in the manual Dismantling a twin screw pump requires clean open space as in a workshop rather than at the place where the pump is installed and connected to piping system. The pump will have to be removed from the base frame after disconnecting power supply and shutting off inlet/outlet/steam in/condensate out valves and disconnecting the pipelines. Drain all the fluid from the pump and clean the pump externally. All bolts/screws and fasteners are in metric sizes - keep standard tools - Spanner sets, Allenkey sets and other conventional maintenance tools like puller, hammer etc. DISMANTLING PROCEDURE Keep the above referred drawings ready for quick reference. First remove the coupling from the shaft and also shaft key (133). Mark for identification on all covers and parts with respect to one another by numbers/letters. Drain the lube oil from gear box by opening drain plug 443. Remove bolts (309) and pull out gear box. The timing gears are visible for inspection as well as to check the backlash. Remove cover non drive end (407) together with bearings (103) by removing bolts(310). The cover can be removed by using jack screws using threaded holes. Now remove bolts. Now unscrew bolts (310) drive end and jack off cover drive end (401) carefully. The entire screw assembly along with shafts bearings (105) etc. will come off as a cartridge. There will be a tendency for the assembly to drop in the bores as soon as screws are out of the bores while pulling out the assembly. This will damage the shafts. If further disassembly is required then you may proceed. Remove lock nuts (110) and lock washer (111). The timing gears (108) can be pulled out. Make sure to mark the timing gears with respect to the shafts and positions. Distance piece (124) (very important) can also be removed but positions must be market to prevent interchanging of locations as these spaces determine the clearance between screws and timings. The bearings (105) can also be removed and also the oil seal (721). Similarly bearings (103) and oil seal (721) from cover (407) can also be removed. Rotating parts mechanical seals (702) see makers drawing, can be pulled out of shaft stationery part of seal will be in segment (498 and 494) and can be removed. Replace seals if damaged. Clean all parts thoroughly by kerosene/solvent.

Series TD
DISMANTLING INSTRUCTION FOR TD LH _ _ _/00
External bearing with four stuffing boxes. Refer drawings attached in the manual Dismantling a twin screw pump requires clean open space as in a workshop rather than at the place where the pump is installed and connected to piping system. The pump will have to be removed from the base frame after disconnecting power supply and shutting off inlet/outlet/steam in/condensate out valves and disconnecting the pipelines. Drain all the fluid from the pump and clean the pump externally. All bolts/screws and fasteners are in metric sizes - keep standard tools - Spanner sets, Allenkey sets and other conventional maintenance tools like puller, hammer etc. DISMANTLING PROCEDURE Keep the above referred drawings ready for quick reference. First remove the coupling from the shaft and also shaft key (133). Mark for identification on all covers and parts with respect to one another by numbers/letters. Drain the lube oil from gear box by opening drain plug 443. Remove bolts (309) and pull out gear box. The timing gears are visible for inspection as well as to check the backlash. Remove cover non drive end (407) together with bearings (103) by removing bolts(310). The cover can be removed by using jack screws using threaded holes. Now remove bolts. Now unscrew bolts (310) drive end and jack off cover drive end (401) carefully. The entire screw assembly alongwith shafts bearings (105) etc. will come off as a cartridge. There will be a tendency for the assembly to drop in the bores as soon as screws are out of the bores while pulling out the assembly. This will damage the shafts. If further disassembly is required then you may proceed. Remove lock nuts (110) and lock washer (111). The timing gears (108) can be pulled out. Make sure to mark the timing gears with respect to the shafts and positions. Distance piece (124) (very important) can also be removed but positions must be market to prevent interchanging of locations as these spaces determine the clearance between screws and timings. The bearings (105) can also be removed and also the oil seal (721). Similarly bearings (103) and oil seal (721) from cover (407) can also be removed. Remove gland, stuffing box packings and clean parts thoroughly. Use new packings while reassembly. Clean all parts thoroughly by kerosene/solvent.

7.9

Series TD
ASSEMBLY OF TD PUMPS
For assembly follow reverse procedure.

7.10

The assembly should start with screw sets assembled on drive end cover as a cartridge. See diagram.

Rotate the drive screw and check the clearances.

Axial clearances can be adjusted by putting shims between the bearing (105) and cover (401) so as to make the clearances uniform. The clearance should be checked on the convex flanks.

Series TD
ASSEMBLY OF TD PUMPS
Radial Adjustment
After the axial adjustments are carried out the timing gears can be locked with lock nut (110). Now turn the driven long shaft screw in the direction of rotation. Check for the clearances between flanks while rotating. If they are uneven it can be corrected by an offset key.

7.10.1

Offset key on short shaft

Fit the offset key in such a way so that the short shaft will rotate away from the drive screw slightly once both timing gears are installed. This procedure will prevent the concave flanks from touching. Note : The offset key is always installed on the short shaft. Rotate the driven shaft again. If the flanks still touch, a key of 0,15mm or 0,2mm must be used. Make sure, however, that the convex flank clearance remains sufficiently large. The clearance between the convex flanks must always be larger than the clearance between the sharp edges. If the sharp edges touch in some areas, some filing may be carried out until a play of 0,05mm is obtained. After assembly fill lubricating oil for the level by the recommended grade for External bearing execution. Check that the pump is free to rotate by hand. If everything is OK, the pump may be put back into operation after following the instruction in the manual for installation and operation. Contact manufacturer for any help or assistance.