yora,_7_sueers crm cover BIBLIOGRAPHY pesonprion | oave | Desicnep By APPROVED BY M-37 aS LA) (© th (( Key SHIP \\ unvesl i This drawing or document isthe propery of | Universal Shipbuilding Corporation and must in no case wholly or partially be copied, shown! lor given to a third party without the expressed consent of Universal Shipbuilding | \Corporation. S NO. 0028 TURQUOISE 150T BOLLARD PULL AHTSV APPROVED BY aa Single Rotor Pump Instruction Manual CHECKED BY 7 [One Screw Pumps] cHecKeD BY | ye ePatan vesionedey |Z /ez Sf— DRAWN BY * DATE OF DWG 23 May 2008 @ universal shipbuil Design Department Machinery Outfitting Design Section = Yokohama Japan - Keihin Shipy ding Corporation ard IREF. NO. ISCALE: - DATE OF ISSUETike ONE SCREW PUMPS INSTRUCTION MANUAL aa | TAIKO KIKAI INDUSTRIES CO.,LTD.MONE SCREW PUMPS Contents Safety Instructions Outline of Structure . Instructions and Arrangement : Piping nen Connection . Operation Maintenance «=n 7 Inspection Trouble Shooting eveeannenentnnna ). Assembly Sectional Drawing end Part Table ©MNOMaaDWH Cooarsoonn Foreword Described in this instruction manual are instructions and cautions to be followed in handling and maintenance of "Taiko Type One-Screw Pumps". The pump cen afford you long duration and services with your accurate operation and due maintenance inspection pursuant to the manual, If you have any question after looking through the description, do not hesitate to contact our business office or factory. Caution Reproduction and reprinting are strictly prohibited in any form.ONE SCREW PUMPS HNP Safety Instruction A\ CAUTIONS FOR YOUR SAFETY _ Before using this pump, read the INSTRUCTION MANUAL (§). Follow WARNING LABEL(S), INSTRUCTION(S) and CAUTION PLATE(S) in order to use it correctly. It is also highly recommended to ALWAYS KEEP the INSTRUCTION MANUAL(S) at the SAME PLACE for easy access. TRANSPORTATION, INSTALLATION, PIPING, WIRING, OPERATION, INSPECTION and MAINTENANCE WORK must be done by ONLY a LICENSED and / or AUTHORIZED PERSON(S) who has enough knowledge on health and safety rules and regulations as well as on his or her profession. In any respect, we will NOT GUARANTEE any DEATH, INJURIES, DAMAGES AND LOSSES wich are result in modification without our written authorization or using and assembling unauthorized parts. When DISPOSING a pump, any accessories.used parts and oil, they should be treated as a general INDUSTRIAL WASTE, WARNING LABEL(S) and SIGN in the instruction manual(s) are classified into WARNING. CAUTION and NOTICE as described below. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. A\CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. /\NOTICE indicates a potentially hazerdous situation which, if not avoided, may result in damaging or detecting a product. It will be only used for protecting the property, but not for personal safety. Footnote : ANSI Z 535 ___® WARNING TRANSPORTATION and INSTALLATION : TRANSPORTATION work must be carried by only a LICENSED or AUTHORIZED PERSON(S) who has enough knowledge on his or her profession : special attention and caution are required when fitting a HANGING WIRE in relation to its weight and gravity center. (DROPPING or FALLING -- DEATH or SERIOUS INJURY.) OPERATION and MANIPULATION NEVER ALLOW an UNAUTHORIZED PERSON to operate the pump. DO NOT TOUCH or contact to ROTATING parts or portion(s). (ROTATING -+ ROLLED IN, BIT, PINCHED and SPILLED (contacted things), INSPECTION and MAINTENANCE Before STARTING a MAINTENANCE work, clearly SIGN IN MAINTENANCE WORK and CUT ELECTRIC SUPPLY. (ELECTRIC SHOCK -+ DEATH UNINTNDED ROTATION = ROLLED IN. BIT and PINCHED.) ___ A\CAUTION OPERATION and MANIPULATION DO NOT TOUGH or contact to SEALING part or HOT parts while the pump. is IN OPERATION. HOT — BURNED and INJURED INSPECTION and MAINTENANCE ‘When OVERHAULING the pump, carefully handle the HEAVY weighted parts. especially, fitting a HANGING WIRE. (DROPPING or FALLING -> INJURY) A NOTICE OPERATION and MANIPULATION Without a specific purpose, do nat manipulate the valves and cocks attached to ‘or supplied for the pump. (WRONG MANIPULATION + DAMAGING or DEFECTING ‘the pump)ONE SCREW PUMPS 1. Outline of Structure 1.1 Structure The present pump consists of, as illustrated in the Assembly Sectional Drawing, @ pump-stand part for introducing liquid, packing glands of the liquid-seal part, a stator and a rotor for transferring introduced liquid, 8 fod and a pin for eccentrically driving the rotor, @ driving shaft and bearings, and en end piece, 1.2 Operation Principle The operating part of the displacement- screw type pump is, as shown in Fig.1. & simple combination of a stator'001 with a double-thread screw and a rotor 101 with single thread one, The pumping function is made In such manner that the rotor given rotation moves hypocycloidally within the stator, thus transferring liquid continuously through the rooms formed between the both devices. In this pumping function, the rooms become quite equal in volume, effecting static transference and constant discharge of liquid without being subject to any partial compression. A Fig.1 1.3 Features ‘The pump is applicable to any kind of liquid with the common structure but with partially varied quality of material depending, upon the nature of the liquid. Its structure provides ease of handling, 1.3.1 Features a. Usability for high-viscosity liquid. b. High self-priming ability. Priming is required only to pravent the stator from seizure, . Usability for slurry liquid, 4. Constant liquid transferability and no occurrence of pulsation. vortex and agitation of liquid flow. e. Free selection of the flowing directions ‘thanks to the rotatability in either regular or reverse direction. HNP f, Minimum use of parts, simple structure and ease of handling and maintenance inspection. g. Wide range of use. 2. Installation and Arrangement For accurate installation of the pump, set a rigid and sturdy pump base on a level plane and the pump on it by applying the foundation bolts perpendicularly. 2.1 Cautions in installation and Arrangement Work a. The rotor of the pump is rotatable in either direction. In case the pressure (degree of vacuum) is high at the suction side, however, direct the liquid flow from the rotor end to the driving-shaft side. Otherwise, the pump may be unable to lift liquid, drawing air from the gland-packing part. b. The location of the pump should be determined so as to minimize the suction- pipe loss. ©. Space around the installation should be wide enough for ease of handling and disassembly.ONE SCREW PUMPS 3. Pipe Arrangement In pipe arrangement, the pump should be set possibly close to the lift source of liquid to minimize lift head, fitted with a possibly small number of bents and other accessories and supported so that any distortion may not be given to it. 3.1 Cautions in Pipe Arrangement ‘a. Take care that air pocket or infiltration may not take place within the suction pipe, b. Do not give any dislocation to the pump axis by excessive tightening of the flange with the clamp bolts. Adjust the flange, connecting to the suction and the discharge port, to the correct position. ©. Take care that the pump may not be excessibely affected by thermal expansion or weighted with the pipe and valves. if this is likely to occur, pipe should be arranged with due consideration for the "expansion coupling’, the pump-base reinforcement and the pipe band, . Check to see rust within the pige may not affect operation. Otherwise, clean inside sufficiently. e. To minimize the suction loss, use a possibly small number of seams, joints and bents in the piping, 1. For protection of the displacement pump itself, the motor and the piping from abnormal-pressure damage, an safety valve should be provided in the discharge piping to act automatically as by-pass circuit at an abnormal pressure, 4. Connection with Motor Upon completion of the installation, the pump axis should be checked not to effect eccentricity after the pump is connected to the piping. At our factory, centering has been made on a surface table. If there has arisen eccentricity, nevertheless, loosen the clamping and the foundation bolts and readjust the axis. 4.1 Direct Drive Adjustment should be made of the pump and the mator axes with a liner inserted preferably between the common base and the installation base, but only in an unavoidable case, between the mator or the reduction gear and the commen base. a. To check the discrepancy of axis between ‘the pump and the motor sides, remove the Hi shaft-coupling bolts and measure the parallelism ang the angle of the both axes as shown in Fig.2 and 3. i) Measurement should be made, as shown in Fig2, of the side face of the shaft coupling with a dial gauge fixed on the shaft coupling of the motor side and measure to be obtained is the difference between the maximum and minimum values of the readings on the fixed axis after a single rotation. Adjustment should be made so that the measure is within 0.081, Fig2 Measurement should be made, as shown Fig. (a), of the end face of the shaft coupling, and adjustment should be made so that the difference between the maximum and minimum values is within 0.151, (Caution) Such a centering method as shown in Fig.3 (b) (with a scale) should be employed only at intermediate and regular inspections. For inspection atter installation and pipe arrangement. the Gial-gauge method is preferable. COTES gy 1 7 4 tA Fig.3 b. Check the direction of the mator rotation. c. Fit the shaft-coupling bolts. . Rotate manually and see smoothness. ¢. After centering, insert the knock-pin.ONE SCREW PUMPS 4.2 V-belt Drive As shown in Fig.4, apply a scale to the end face of the V-pulleys and eliminate vertical and horizontal discrepancies. (The scale should be applied abliquenly.) HNP Table-1 The Load Values on Belt Tension WNKkeh Tae Wat valies | load values A 9810] 130.3) 8 tae) | 2525) fc 3040) | sass) D 73180) | 981100) E 118020) | 147050) Fig.4 a. Most proper tension of the V-belt will be ‘obtained when it is loosened up to the maximum before getting to slip on the pulleys. #) As for a V-belt of general use (A, 8, C type), refer to Fig.5 to abtain its porper tension easily. "1 a uv wo Fig.S adjust it so that its deflection 6=0.016 minimum of the load values mentioned in Table 1 when it is perpendicularly loaded at the middle of span (distance between the contact points of the belt and the Fig b. After adjusting the axes, check the tension of the V-belt once more in the manner as described in ai or ai ¢. Then, tighten the motor-fixing bolts. 5. Operation Prior to initial operation after installation, check to see whether the pipe is completely arranged and the fixing bolts are sufficiently tightened, At the beginning stage of operation after reassembly, ascertain that ‘temperature, vibration and operation saund do not differ from those before disassembly. 5.1 Preparations of Operation 8. See the bolts and nuts of the joint and coupling parts are not loose, b. Ascertain the direction of the pump rotation. The rotation should be, when viewed from the driving-shaft side : i) To transfer liquid from the pump-stand side, counter-clockwise. ii) For transference from the end-piecee side, clockwise c. Make sure that the pump can turn smooth by hand d. Generally speaking, start of the pump having a rubber stator is samewhat heavy since a slight interference is given to the part fitting the rotor. In handling, please note Before the start switch is tumed ON, feed water with the accessory funnel, make manual rotation four or five times. and thus moisten between the rotor and the stator without fail ©. Fully open the vaivas in the suction and discharge sides. 1. See the pressure-gauge or purge cack or valve is open w wMONE SCREW PUMPS HNP 5.2 Operation , Before setting the motor in regular operation, repeat switch-ON and OFF one ‘or two times ta see that there is no abnormality in the rotating direction, operation sound, vibration and starting current. b. To prevent heat-up or seizure of the stator (rubber), coutinue feeding water with the funnel even after the start of operation until the pump begins to lift up liquid, c. When liquid comes out of the air vent. close the vent. stop feeding water and set the pump in operation. d. Operation will be made very smooth without noise when the pump is in good condition. If there occurs any noise from the pump or abnormal oscillation of the pointer in the pressure gauge, stop immediately and ‘examine the pump. 5.3 Stoppage After the motor stops, close the valves in the suction and discharge sides. In the case of long-time shutdown of operation, the inside of the pump should be cleaned sufficiently, provided that there is any possiblity of liquid-solute solidification or fixture or that the pump is used for corrosive liquid. Upon operation after such a long- period shutdown, see whether rust has arisen on the metal parts. 6 Maintenance For safety operation, it is necessary to ascertain from time to time whether there is anything wrong in vibration and temperature particularly around the rotating parts. 6.1 Cautions in Operation a. In operation, keep the pump within the range of the Plan Specification. b. Stop the pump immesiately if there is any disorder in vibration, operation sound, or indication of the pressure geuge or the ampere meter. c. Keep watch for the thermal rise of the bearings. if your hand can be kept on the bearing box, it is going well. Otherwise. measure the heat with a thermometer. Its allowable temperature is within the range of the room temperature added by 40 or liquid tempereture added by 20°C. 4. In operation with the pump-stand side as discharge room, keep a small amount of liquid unceasingly passing out of the gland part. In case the pump-stand side is used as suction roam, an the contrary, see there is no disorder in the oscillation of the gauge pointer nor air mixture in the discharge liquid, Otherwise, air is being drawn from the gland part. If the packings are excessively tight, overheat or overload may be liable to occur. e. Fully open the suction and discharge valves in operation. . Never run the pump in dry condition otherwise pump may be seized. 6.2 Other Cautions a. Jointed portions (Rod, Pin, Drive shaft, “O” Ring) shall be wear off occasionally with liquid. Therefore. overhauls and inspections are required in every 2500 hrs. Then, fill up grease to joint portions, when you reassemble, RECOMMENDED GREASE Good quality lithium Soap Grease mixed with Molybdate Bisulphide (MoSe) Showa Sekiyy SUNLIGHT MB2 »Nisseki-Mitsubishi MOLYNOK Wo2 *Esso Beacon a2 Mobil Mobiltemp 78 = CALTEX Molytex EP * CASTROL Molub-Alloy 777,860serias, b. If operation of the pump used for corrosive liquid is shut down for a long period of time, disassemble it and clean inside to prevent rust and, thus, it can be started without trouble after even such cease of operation, c. The stator and the rotor should be considered as expendables. Although their lives largely depends upon the nature of liquid being handled, keep at least each one stator and rotor in reserve. The rubber stator should be kept from deterioration. d. Fill up grease constantly as follows for pumps which are fixed with grease-nipples Tabreating partion Reda! | Shaft seal bearing 201 | BOT oF 502 Model to Surly term Oty Suply tem Qty | * SSI NRELBISN oe ae ce ON MALTINOG of) DeLUxtee ip *St2n Shel “Vong sts ALANA We Ee 15 | ekdemitsu Kosan as | DAPHNE EPONEX we Recommended ‘rand of Groase feeye [IS | Me Months) 5 | #Mabil j 18 "MOBILAX we2 15 | #E980 2 "BEACON me 15 xcaLTex 29. Petal Stak tae #CASTROL Noli Aicy BREST2ONE SCREW PUMPS HNP 7. Inspection 7.1 Regular Inspection Inspection should be made at regular intervals as described in Table 2. Please be advised to make up your own rule proper for actual states and conditions such as equipment method and location of the pump as well as nature of the liquid being handled, since the frequency of inspections should be largely varied in accordance with slurry or sludge dissolution in liquid or liquid viscosity. Table-2 [ Period Parts | Instruction | Three iA yeoror | Twoyears | months 6.600 Ms. 29 995 ng - -—— t Grease sealed state Ball androter —_| Se0 if bale of beavines are not eeparated from inner : bearings: ‘and outer orbit planes. If this part is deformed. - | replace bearings. | Chock there ie neither deflection nor slide way if riving shat er abrasion pees (sr fitting state of packings endleakage. If leokege Is large, replace. I Oil seals anc | See there is no tlaw on the surface and check | “O-rings hardening state, Replace if deformed | Check there is neithar defiection nor surtace abrasion. Replace if there is any defect. i ‘See abrasion and hardening state. Renew if there is ‘any defect. Rotor Stator ‘Shaft-coupling bolts | Check abrasion and, if any defect is discovered, jfesetee and rubber ring | renew, Aree | Check abraion and, any detect discovered Remark : “Period” in Table 2 means operation time,W“LONE SCREW PUMPS HNP 7.2 Disassembly For disassembly of the pump, clean the work site and prepare a space for arrangement of removed parts. Before proceeding to, and even during disassembly, you should be fully informed of the structure by reference to the Assembly Sectional Drawing so as to ensure complete reassembly. 7.2.1 Disassembly Procedure In disassembly, follow the below- described instructions a, Take off Nut for Tie rod ‘850 of End piece 003, and remave Stator 001) from Pump stand 002. b. Take off both Set bolts 851) by screwdriver, and move Sleeve (A) 113° for diameter of Pin, c. Pull out Seat packing 632>and Pin vio/e 4. Take out Rotor 101) with Con rod 03. ©. At first, remove Retaining ring 112), take off Sleeve (8) 114), and pull out Pin when you disassemble Rotor and Con rod. 4, To pull out Shaft “1G2 from Pump stand, Bearing case ‘(004 :and Ball bearing 201), 202, i) Take off tighten bolts on Bearing cover 005. ii) Take off tighten botts on Bearing case, ut them in the bolt hole that is for disassemble, and turn the bolts. Shaft could be pull out with Bearing il To teke off Bearing from Shaft, remove Bearing nut 150 after pull out Bearing washer 152 ; take off Bearing of Nut side 20 1), and remove the other beating 202) with Sleeve (A). g. Loose Bolts of Gland ‘504°, and take off them h, Pull out Gland packing ‘501 i, Remove Oil seal and Oring for each part. 7.2.2 Ceutions in Disassembly in disassembly, follow these cautions : a. For breakup of the fit parts and faces, use the tap bolts or a wooden hammer to prevent fiaw in the worked faces. b. In removing the rotating member, be careful not to hurt the worked faces. c. Take care not to bend slender parts such as shaft and rotor. ¢. Arrange the parts in regular order on paper or cloth with care and cover them to prevent dust. e. Put proper identification marks on parts before disassembly to avoid error in reassemly. f. In removing an oil seal, apply a metal piece to hit lightly on it on all the circumference. so that its lio may be prevented from damege. 7.3 Reassembly The disassembly process should be reversed for reassembly. The pump should be integrated in the exactly reverse order of disassembly. In this work, do not damage any part by hitting severely and do not fail to ‘supply oil to the lubrication parts before assembly. 7.3.1 Reassembly Procedure Refer to 7.2.1 Disassembly Procedure. 7.3.2 Cautions in Reassembly In reassembly, be sure to follow the cautions : a. Clean up the metal parts in wash oil Remedy if there is any flaw. b. Before proceading to overall integration, assemble the parts and fittings into component sets according to the identification marks. ¢. The gland packings should be packed one by one in regular order up to the required position, by pressing lightly with the glands, so that their sectional sides locate at angular intervals of 90-180". Cthewise, the pump may be excessively loaded to increase pumping loss and ta shorten the lives of the packings. d. Do not fix the bolts unsymmetrically, e. After completion of assembly, turn the pump by hand and see smoothness, f. To check the axis, refer to 4 Connection with Motor.ONE SCREW PUMPS 8. Troubles Shooting Take countermeasures immediately for Table 3 HNP are itemized by kind of trouble and trouble and damages. The descriptions in damages. Table-3 Troubles Causes: 1 Remedies Pump does not | Motor trouble. "| Remedy motor. ~ | start Fusing of wire breakage. Replace fuse or remedy wire, Suction or discharge port is closged. Remove clogs. The pump is clogged with foreign substances Pump starts. but liquid does not come out, Insufficient air extraction, Airis being drawn 1 Pump is not filled with liauid, Valves aro not open, Reverse rotation, Ar is being drawn, Pump starts, but capacity and pressure are not developed as prescribed, Number af rotations ere decreased Suction pipe or filter Is clogged. Liquid solute is solicified and fixed within ‘pump. Excessively high suction pressure Rotor or stator has wom Gavin Mater Is out af order Pump starts, but Tiquid nas come ut in beginning of ‘operation but soon stopped, Suction pipe is bolcked with air packets, Airis boing drawn, Pump starts, but | Rotor end stator partis clogged with foreign ‘motor is substances. coverioaded. Giend packings are excessively tightoned, Shatt is bent. Motor trouble, Dotect of bearings, Prescribed capacity is exceede in operation Pump starts, but bearings are overheated Ingufficinet lubrication ol. Centering of motor and driving shatt is nat Complete, of excessivaly high tension of batt. Shatt ie bent, Wrong bearing assembly, Pump starts, but_| Centering of motor and driving sheft is not pump is vibrating | complete. {and emitting noise. | Bearings have worn down, Pin in the shaft or rator side has wom, or pin (Gap screw or snap ring is loose. Foreign substances are drawn within pump, \Wrrong installation Bent shart. Loose besring clamp nut or packing gland, Cavitation has occurred. Pump starts, but ump i vibrating, and emitting noise, Remove clogs, and clean with pump. Open air vent cock Check suction system and gland packings and fix the letter tight. Enter liquid ance more, Open valves. Set in regular rotation, (Check suction system and gland packings {and fix the latter more tight. ‘See whether power voltage and frequency are as described on instruction plate and whether reduction ratios proper. ean. Remove rotor and clean inside of pump. ‘Adjust ta Plan Specitication. Ranew rotor or stator. Renew, Adjust pipe. CChack suction system and gland packings ‘and fix the latter more tight. Ramove end clean rotor and stator, and replace if unusable, Loosen or replace gland packings, Roplace. Remedy, Renew. Check viscacity, flaw and pressure of liquid, and adjust ta Pian Spectticatian. ‘Supply lubrication oll sufficient. Centering, or adjustment of V-belt to heve proper tension, Replace. Reedust Centering, Replace. Replace pin or tighten sufficiently pin cap ‘screw or snap ring, Remove foreign substances and clean rotor and stator part. Adjust installation Replace. Tignten, Adjust viscosity and pressure to Plan Specification Trouble may have occur due to other conditions in integration of your pump system. in this case, please inform us of 1. Type, serial number and purpose of the pump. 2. Kind, viscosity, temperature, ete. of liquid, 3. Suction pressure, location of the filter, number of meshes and bents, etc. of the piping.MONE SCREW PUMPS HNP 9. Assembly Sectional Drawing and Part Table a eee 4 ast) (91a) (oe [fT / 1} (09) 60) Go) 6 ) G9) Bon} TEND bsg iz Rae Waterar ow fa Swmbol_[ Name of material SGP Carton steel Se NBR Rubber 1 Pump stand 0200 Gast iron 1 ‘End Cast iron 1 Cast kon 1 Castiron 1 “Stainless ctect =| fae Stainloss steel ; STkM18_ | Carton steel 3 | toot ‘SUss0a | Steiniess stec! 1 key «df Sa5G | Carbon steel | Pin 8US420,2 | Stainless steo! 1 retaining ine | Susa04 | Stainioss steel i Mla stl Stainioss steel 114 | Sleeve ©) 1 1 - 150 = 1 158 | Bearng washer miidsted [1 Ballbeaing Bearing stool i Ball bearing Boarng sted “Grease rippie or Bess ot : ‘Carbon steel Brass Gland packing Carbonized fiber “Tantemn ring ~| ia stee Gland Eee Cast iron | Oil Seat Rubber a fo aioe tere EEE Rubber aa ~ | NBR ‘Rubber 7 ‘eat packing == NBR —*| uber ‘ong [NBR F ~ Teed ~~ ‘88400 He setoot _[ 8u6904 | Stainiss ctoolTAIKO KIKAI INDUSTRIES CO,, LTD. Weed Office § 209-1 Shimotabuse. Tabusecche. Kumage-gun, Yameguch pret. 742-1598 Japan Fectoy TEL: 81-20523113~4 FAX: 81-820-53-1001 Email: busnesstako tkcom Tokyo Branch 4th floor, Sucabashi MS Buicing, 3.4.9 Misek’-cho, Chigadau, Toxyo 101-0087 Jagan TEL 81-3G221-8651 FAX: 81-39021-8555 Ema toqo-tratakokiccom MOseke Branch 8th floor, KC Building, 2-4-7 Kewaremachl, Chuo-ku, Osake 547-0048 Japan TEL: 81-6-6281-6241 FAX: 61-6.6222.2295 Ema oscka-trataiko-d,com Bejing Office «Shanghai Offoo - Tako Korea (wison0) eater URL_nttp//wwautale-kk.com 2007/03, MTSU