HGRS MASTER - Maintenance

Type of Skill: Specific Technical Skills

Category : Transport Equipment
Module: Pneumatic Transport Systems
Unit: Screw Pump Design 2 of 13
Version: 1.0 04.11.03
Reference: Pneumatic Transport Training.ppt

Screw Pump Design

Purpose:  To understand the general design principles of the screw pump system. The screw pump
system is one of the different types of bulk solid feeder units that can be used in
pneumatic transport systems.
Description: General
 The task of the screw pump is to introduce the material flow into the conveying gas flow
against the pressure of the conveying line and at the same time seal the system
overpressure from the surroundings and upstream plant sections.
 The Fuller-Kinyon Screw Pumps are the most common types of screw pumps used in the
cement industry today. Commonly referred simply as an FK pump, there are two types;
the "H-Pump" and the "M-Pump". The "M-Pump" type was an advancement in technology
from the "H-Pump" by providing a bearing support at the discharge end of the screw shaft
to reduce wear caused by screw shaft deflection. This technology can also be added to
existing "H-Pumps" by the addition of the "Z-Flap Conversion" (see Figure 4).
 Claudius Peters manufactures their version of the screw pump design called the "X-
Pump". It is basically identical to the "M-Pump" by Fuller so we will not distinguish
between the two in this unit.

Basics of Screw Pump System

 The transporting of the bulk solid starts by the material entering a feed hopper.
 A rotating screw transports the material from the hopper to the mixing chamber. Its
rotational speed is typically 500 to 1500 RPM.
 The screw is made either with or without variable compression (decreasing screw pitch in
the direction of conveying) depending on material characteristics. The variable pitch is
used to help increase the material seal in the screw. As material is transported along the
screw it is compacted and the density is increased. This is needed if material to be
conveyed has a very low density.
 The filling of material in the screw forms a "material seal" that prevents a reverse flow of
conveying air from the mixing chamber.
 A free-floating flapper valve (or "check valve"), located in the discharge area of the pump,
is a mechanical seal that also assists in preventing the reverse flow of air from the mixing
chamber through the pump barrel.
 The force of the material transported by the screw pushes open the check valve forcing
the material into the mixing camber.
 In the mixing chamber, the material is aerated by the introduction of compressed air.
 The fluidized material is then conveyed in the transport line by continuing action of the
impeller screw and the energy of expanding air.
 Strategically arranged valves or gates are used to divert material into proper end
destinations or silos.
 Dust collectors on the top of the silos are typically used to filter the air from the pneumatic
system before venting to atmosphere.

Typical Piping Arrangement (See Figure 3)

 Locate the blower's filter-silencer (1) to obtain clean, cool, and dry air (2) while still being
convenient for servicing.
 Intake piping can be made of lightweight welded steel or standard steel pipe and standard
flanged fittings.
 Locate the blower adjacent to the pump.
 Use piping from blower to pump of the same size as the blower outlet connection.
 For multiple units where a spare blower is installed or for duplex blower installation,
manifold this line to connect to a common line to the pump.
 Install safety valve(s) to suit connected blower capacity and pressure. Locate as close to

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 the pump as possible, but ahead of any stop valve in the line.
 For multiple units where pump installation involves a spare pump, manifold this line at
pumps with a valve in each pump connection.
 Add a tee with bottom connection and ½" drain in the flange for periodic oil draining. Do
not connect to the sewer line if oil contamination is a problem - use a bucket to receive the
drained oil.
 See specific drawings for dimensions of blower, filter, etc.

Capabilities of Screw Pump System

 Practical distance of transportation by the system depends upon the material to be
handled, but some current systems conveying cement are up to 1500 meters in length..
 The screw pump conveying system is a dense stream system used to convey dry,
powdered materials at line pressures up to 2.4 bar (35 psig) pressure.
A full range of pump sizes is available for conveying from as low as 5 tons per hour to as high
as 400 tons per hour using various compressors as the source of air supply.

General Terminology: (See Figures 1 & 2)

Air Nozzle - A series of nozzle fastened to a plate with holes that the supply air passes
through to enter the mixing chamber

Barrel Bushing - The protective wear tube inside the pump barrel housing.

Discharge Line Pressure Gauge - Important sensor that reads the air pressure in the line
after discharge of the pump

Drive System - Either a v-belt or direct drive system that is usually 1200 RPM at 60 Hz

Feed Hopper - The section of the pump where material to be conveyed enters

Flapper Valve - A free-floating flapper valve at the discharge end of the pump barrel that is a
mechanical seal or check that assists the "material seal" in preventing air backflow. Also
provides the seal when screw is empty.

Material Seal - The pump screw compresses the conveyed material into a dense plug of
material which prevents the backward flow of air from the mixing chamber through the pump
barrel

Mixing Chamber - The section of the pump where the supply air fluidizes the material and
transfers it from the pump.

Pump Screw - The screw that transfers material from the feed hopper to the mixing chamber
through the barrel

Screw Shaft Bearings - The end bearings that support the screw shaft, most have a purge air
system to seal off bearings from the supply air and material.

Seal Purge Air - Compressed air used to help seal the screw shaft bearings

Supply Air - The compressed air supplied to the system to fluidize and transport the material
to the final destination.

Standards: Basic Start/Stop Sequence

Start:
1. Dust Collector on Receiving Vessel
2. Air compressor
3. Pump Motor
4. Pump Feed - mechanism to get material to feed hopper.

Stop:
1. Pump Feed
2. Pump Motor when current drops

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 3. Wait until line pressure is "0" or minimum before stopping
4. Compressor
5. Dust Collector (unless otherwise required)

Impact if not  Inability to understand and communicate problems or requirements.

applied:
Actions:  Learn and understand the general design concept for screw pump systems

Unit  Participant understands how the screw pump operates.

Completion:
See site specific unit for additional information, respective corrective actions and applicable safety
instructions.

Figure 1. Components of a Screw Pump System

Supply Air

V-Belt Drive System

and Motor

Mixing Chamber
Picture: The Claudius Peters X-Pump

Discharge Line
Pressure Gauge

Figure 2. Components of a Screw Pump System (continued)

Feed Hopper
Seal Purge Air

Pump Screw

Screw Shaft Air Nozzle

Bearings
Flapper Valve Picture: The Fuller Kinyon M-Pump

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Figure 3. Typical Piping Arrangement

Figure 4. H Pump with Z-Flap Conversion

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