Operating Manual - Screw Pumpsinventory.powerzone.com/invimages/54695/TwoScrewPumpOperatingManual.pdf · Pump type: Operating Manual - Screw Pumps Operating Manual - Screw Pumps -

Read and carefully note the instructions in this Operating Ma-nual before unpacking and starting up the pump / assembly.

In case of non-observance of the operation manual and of thestorage instructions and maintance chart, the manufacturerwill not be liable to any guarantee claim.

Commission.No.:

Machine-No.:

Pump type:

Operating Manual - Screw Pumps

Operating Manual- Screw Pumps -

06/99 KMÜ B_DBL_E.CHP

Correct Utilization

The pump resp.pump aggregate must only be used for the application asspecified in the order confirmation and in the order related data sheet.

Any utilization other than for the intended purpose is not correct and gua-rantee claims may get lost.

The relevant performance values for this pump are to be taken from theoperating data in the order related data sheet.

Warning !If the pump is used for any purpose other thanspecified for above mentioned application, or if thepump runs at working parameters higher thanadmitted,

- danger/ damage may occur to human beings and toproperty.

Consideration of the operating manual and observance of the inspectionand maintenance instructions for the pump is the precondition for the cor-rect utilization of the product supplied.

Information

Incorrect and forbidden utilization of the productsupplied are not known to the manufacturer.

i

1. 1. Intended use Page 1

1. 2. Pump data Page 1

1. 2. 1. Manufacturer Page 1

1. 2. 2. Technical data Page 1

1. 3. Additional information Page 1

1. 3. 1. Accessories Page 1

1. 4. Your contact address Page 2

2. 1. Explanation of symbols and notes Page 3

2. 2. Qualification /training of personnel Page 3

2. 3. Dangers at non-observance of the safety rules Page 3

2. 4. Safety-conscious working Page 4

2. 5. Safety rules for the user/operator Page 4

2. 6. Safety instructions for maintenance, inspection and assembly Page 4

2. 7. Conversion or production of spare parts by the user himself Page 4

2. 8. Inadmissible operating methods Page 4

3. 1. Transport Page 5

3. 1. 1. Transit damage Page 5

3. 1. 2. Completeness of delivery Page 5

3. 1. 3. In-Plant transportation Page 5

3.1.3.1. Unpacked pumps Page 5

3.1.3.2. Unpacked pump aggregate Page 6

2. Safety Page 3

3. Transport Page 5

1. General Page 1

Bornemann Operating Manual for Contents pumps Screw Pumps

03 / 96 KMÜ 1000 98 087E

D-31682 Obernkirchen • Postfach 1162 • Telefon 0 57 24 / 390-0 • Telefax 0 57 24 / 43 44 • Telex 972 291

3.1.3.3. Packed pump or aggregate Page 6

3. 2. Storage and preservation Page 6

3. 2. 1. Transit preservation Page 6

3. 2. 2. Preservation for temporary storage (max. 3 months) Page 6

3.2.2.1. Screw pumps with soft packings Page 6

3.2.2.2. Screw pumps with mechanical seals Page 7

3.2.2.3. Maintenance during storage Page 7

3.2.2.4. Starting up after temporary storage Page 7

3. 2. 3. Preservation for max. 12 months Page 7

4. Assembly and installation of the unit/pump Page 9

4. 1. Assembly Page 9

4. 1. 1. Assembly of the coupling or pulley Page 9

4. 1. 2. Assembly of pump and motor on the baseplate Page 9

4. 1. 3. Assembly of the buffer fluid system Page 10

4. 1. 4. Assembly of the force oil lubrication system Page 10

4. 2. Installation Page 10

4. 2. 1. Foundations Page 10

4. 2. 2. Assembly of pipes Page 10

4. 2. 3. Installation of the pump aggregate Page 11

4. 2. 4. Assembly of the soft packing Page 11

4. 2. 5. Connection of drive unit Page 11

5. 1. Initial start -up Page 13

5. 1. 1. Oil level check Page 13

5. 1. 2. Prime the pump with media. Page 13

5. Commissioning Page 13

4. Assembly and installation of the unit/pump Page 9

Contents Operation Manual for BornemannScrew Pumps pumps

1000 98 087E 03 / 96 KMÜ


5. 1. 3. Pump heating Page 13

5.1.3.1. Relief valve Page 13

5. 1. 4. Pump start Page 13

5. 2. Daily starting up Page 14

5. 3. Shutting down Page 14

5. 4. Emergency Stop Page 14

6. 1. Check list maintenance Page 15

6. 2. Gear casing Page 16

6. 2. 1. Oil level check Page 16

6. 2. 2. Oil change Page 16

6.2.2.1. Refill the gear casing with oil Page 16

6.2.2.2. Draining of gear oil Page 16

6. 3. Bearings Page 16

6. 3. 1. Roller bearings, non-drive side Page 16

6. 3. 2. Roller bearings, drive-side Page 17

6. 4. Shaft sealing Page 17

6. 4. 1. Stuffing box packing Page 17

6.4.1.1. Visual inspection Page 17

6.4.1.2. Grease lubrication Page 17

6. 4. 2. Single acting mechanical seal Page 17


6. 4. 3. Double acting mechanical seals Page 17


6. 5. Buffer liquid system Page 18

6. 5. 1. Operational Test Page 18

6. Maintenance Page 15


03 / 96 KMÜ 1000 98 087E


6. 5. 2. Check level of the buffer liquid Page 18

6. 5. 3. Clean filter and vent valve Page 18

6. 5. 4. Change buffer liquid Page 18

6. 6. Force oil lubrication system Page 18

6. 6. 1. Check operation Page 18

6. 6. 2. Check tightness Page 18

6. 7. Heating Page 18

6. 7. 1. Check operation Page 18

6. 7. 2. Check tightness Page 18

6. 7. 3. Change heat transfer oil Page 18

6. 8. Coupling/ belt drive / driver/ accessories Page 18

8. 1. Lubrication Table Page 21

8. 2. Lubricating quantities Page 22

9. 1. Assembly of double-row diagonal ball bearings with filling slots Page 23

9. 2. Spare parts orders for roller bearings Page 24

9. 3. Request for Information Page 24

9. 4. Return of the pump Page 24

Safety Sheet Page 25

9. Remarks Page 23

7. Break-downs and their possible causes Page 19

8. Lubrication and Preservation Schedulefor Screw Pumps Page 21


1000 98 087E 03 / 96 KMÜ


The following chapters do not from part of this print.They are issued order related and separately attached to this documentation.

10. 1. General assembling instructions

10. 2. Removing the screw pump from the piping system

10. 3. Disassembly of the screw pump

10. 4. Labelling of assembly and disassembly direction of the liner.

10. 5. Assembly of the screw pump

10. 6. Installation of the screw pump into the piping system(pump casing)

10. 7. Pump sectional drawing

10. 8. Dismantling and assembly instructions for shaft sealing

10. 9. Dismantling and assembly instructions for relief valve

11. 1. Pump

11. 1. 1. Spare parts lists and sectional drawings

11. 1. 2. Dimensional drawings for pump or unit:

11. 2. Accessories

11. 2. 1. Documentation for coupling

11. 2. 2. Documentation for driving engine

11. 3. Miscellaneous

10. Dismantling and Assembly Instructions

11. Appendix


03 / 96 KMÜ 1000 98 087E



1000 98 087E 03 / 96 KMÜ


1. General

1. 1. Intended use

Bornemann screw pumps must only be used forpumping the medium as specified in the order rela-ted data sheet and according to the service conditi-ons prescribed therein.

Utilization other than for the intendedservice conditions, without previous con-sent of J.H. Bornemann, is not correctand excludes any liability of the manu-facturer in case of damage. The copyrightand industrial protection rights are heldby the manufacturing company.

J. H. Bornemann,Industriestraß e 2, D-31683 Obernkirchen

Germany

1. 2. Pump data

Bornemann screw pumps are self-priming, rotarypositive displacement pumps.

The pumps are almost insensitive to dry running dueto the rotating elements operating without contact.

The continuous pump operation enables smoothhandling of the medium pumped.

Bornemann screw pumps operate pulsation- and tur-bulence-free.

The capacity flow being directly proportional to thespeed, they can also be used for simple dosing applica-tions.

1. 2. 1. Manufacturer

The screw pumps are a product of

J. H. Bornemann(hereinafter called J.H.B. )

Made in Germany.

1. 2. 2. Technical data

Technical data such as:

- performance data

- load data

- consumption of energy

to be obtained from the order related data sheet..

1. 3. Additional information

In case of screw pumps, the following shaft seals areused depending on the relevant operating conditionsand pump design.

- Conventional stuffing box packings

- Radial shaft seal rings

- Single-acting mechanical seals

- Double-acting, tandem arranged mechanical sealswith buffer fluid systems.

1. 3. 1. Accessories

J.H.B. can supply an overflow-valve to protect thepump against excessive pressure increases. Thisspring-loaded disk valve is actuated at a pressure ofapprox. 1,0 bar above the maximum differentialpressure and allows the medium to flow back to thepump intake chamber.

The overflow-valves are no safety valves and notsuitable for capacity or pressure control.

On demand, the pumps can be supplied with variousintegral heating systems.

Attention

Bornemann Operating Manual for 1. Chapter pumps Screw Pumps Page 1

03/96 KMÜ 1000 98 086E


1. 4. your contact address

Joh.Heinr.Bornemann GmbH

Industriestr. 2 D-31683 Obernkirchen

P.O. Box 1162 D-31676 Obernkirchen

Germany

Tel.: 05724 / 390-0 Fax.:05724 / 390-290

1. Chapter Operating Manual for BornemannPage 2 Screw Pumps pumps

1000 98 086E 03/96 KMÜ


2. Safety

This manual contains essential instructions to be re-spected at installation, operation and maintenance.The service engineers and other competent person-nel resp. operators should carefully study these in-structions prior to assembly and commissioning andthis manual should at any time be available on site.

It is not only the general instructions referred to un-der Para Safety of this main Chapter that are to beobserved, but in addition hereto all those specific in-structions added to further chapters, e.g. for privateuse.

2. 1. Explanation of symbols and notes

Instructions included in this manual relating to safe-ty the non-observance of which might endanger hu-man being, are marked

and CAUTION

Any safety instructions that, if not adhered to, mightcause danger to equipment and functioning, are mar-ked

and ATTENTION

General notes, facilitating the pump operation or no-tifying something to the operator, are marked

Instructions directly applied to the pump, e.g.

direction arrowmarks for fluid connections

must imperatively be observed and be kept in welllegible condition.

2. 2. Qualification /training of personnel

The personnel for operation, maintenance, inspecti-on and assembly should be qualified for such work.

Responsibility, competence and supervising of thestaff should exactly be defined by the user.

In case of lacking technical knowledge, the person-nel is adequately to be trained and to be instructed.On demand, and if so ordered by the user, such trai-ning can be offered by the manufacturer/supplier.

Further, the user has to ensure that the contentsof this operating manual are clearly understoodby his personnel .

2. 3. Dangers at non-observance of thesafety rules

Non-observance of the safety rules may endangerpersonnel, machinery and environment.

Damage claims may get lost.

Due to non-observance, the following dangers mayarise:

- Breakdown of essential functions

- Failure of prescribed methods relating to mainten-ance and repair

- Danger to persons by electric, mechanic and che-mical influence

- Danger to the invironment due to leakage of haz-ardous products

marking acc. to DIN 4844-W9

marking acc. to DIN 4844-W9


03/96 KMÜ 1000 98 086E


2. 4. Safety-conscious working

All safety regulations contained in this manual, pre-vailing national rules for prevention of accidents aswell as possible operating/safety regulations existingon operator’s site itself, are strictly to be observed.

2. 5. Safety rules for the user/operator

Foundations for pumps and/or aggregates must bedesigned so that the arising forces and moments aresafely absorbed.

Pumps or aggregates must only be lifted resp. trans-ported by means of an adequate lifting equipment at-tached to those places mentioned in the instructionmanual resp. on the pumps or packing. Pressure loa-ded components connected to the aggregate must bedesigned for the max. operating pressure as specifiedin the pump data sheet.

In case of hot or cold machine parts causing possibledanger, such parts are to be protected against con-tact.

While in operation, do not remove any protectiondevices against contact applied to moving parts (e.g.coupling). Leakage (e.g. shaft sealings) of dangerousproducts (explosive, toxic, hot) should be drained offin a way not to endanger human beings or environ-ment.

Provisions of law are to be respected.

In case of noises being injurious to health, ear plugsmust be worn. Observe the regulations in force.

In case of danger resulting from media being proces-sed, used, thrown out or separated by the pump (e.g.injurious, toxic, corroding or caustic media), pro-tective clothes must be worn. Dangers by electricenergy are to be excluded. (For details see VDE-ru-les and local prescriptions of energy supply authori-ties).

2. 6. Safety instructions formaintenance, inspection andassembly

The user has to ensure that all maintenance, inspectionand assembly work be exclusively performed by au-thorized and qualified personnel who have carefullystudied the operating manual.

As a rule, any work on the pump is only permittedwhile the pump is at rest. Strictly observe the proce-dure for disconnecting the pump, described in the ope-rating manual.

Pessure loaded machine parts must be released priorto starting up. Pumps or aggregates handling healthhazardous products are to be decontaminated prior topump start.

On completion of all work, re-install resp. re-start allsafety and protection devices.

2. 7. Conversion or production of spareparts by the user himself

Pump conversion or alteration are only permitted onconsultation with the manufacturer. Original spareparts and auxiliaries from the maker serve for safety.When using outside parts, liability for consequentialdamage is rejected.

2. 8. Inadmissible operating methods

The operational safety of the pump can only be gua-ranteed if the technical data specified in the order re-lated data sheet are strictly adhered to (see Chapter1, General)

The limiting values stated on the data sheet must byno means by exceeded.

The pump user has to undertake appropriate safetymeasures on site.

The chapter 3. Safety includes the VDMA safetysheet 24 292 (status: Aug.1991).


1000 98 086E 03/96 KMÜ


3. Transport

3. 1. Transport

Use suitable lifting gear and observe the generallyapplicable safety regulations for lifting loads.

The pumps are delivered packed on timbers unless other-wise specified by the customer .

3. 1. 1. Transit damage

Check the pump for any externally visible transit da-mage immediately on receipt (break, bumps, cracksetc.).

Report transit damage immediately and by letter to:

- the supplying forwarding company and/or

- your insurance company in case you are self-insu-red for transport risk.

Due to delays in reporting transit dama-ge, insurance coverage may get lost.

Normal delay for reporting transit damage is 24 h(postal service) resp. 7 days after delivery (§ 81/82EVO / § 60 ADSp)!

It is imperative that you send one copy ofyour damage report to J.H. Bornemann.

3. 1. 2. Completeness of delivery

Check the delivery for completeness.

Immediately contact J.H. Bornemann oryour competent contractor if the deliverydoes not comply with the order.

3. 1. 3. In-Plant transportation

Do not lift the screw pumps by the bearing housing.Take care to ensure that assemblies do not becomedistorted by lifting.

When attaching the crane lifting tackle, make surethat pipes or attached auxiliaries are not damaged.

3. 1. 3. 1. Unpacked pumps

Unpacked pumps are lifted as follows: Attach thecrane lifting tackle on the pump as illustrated in thefollowing.

Vertical pumps: Attach crane hooks to the shackles loca-ted in the flange borings.

Caution

Attention

Attention

Attention


03/96 KMÜ 1000 98 086E


3. 1. 3. 2. Unpacked pump aggregate

To lift the pump aggregate, fasten the crane liftingtackle to the places illustrated below:

3. 1. 3. 3. Packed pump or aggregate

Attach the lifting tackle to those places marked onthe packing

3. 2. Storage and preservation

3. 2. 1. Transit preservation

J.H.B. applies preservatives to the pump for the fol-lowing means of transportation only:

- The internal pump parts, if not rust-resisting, aresprayed with a preservative.

- All exposed shaft elements and places not pro-tected by paint are coated with a preservative.

- Seawater and sea-air-resistant preservatives andpacking is used for transportation by sea.

- For specific customer’s preservation see custo-mer’s data sheet.

3. 2. 2. Preservation for temporary storage(max. 3 months)

If the pumps being preserved are used to pumpfoodstuffs or similar products, food-compatible pre-servatives must be used. (see chapter 8. Lubrication and Preservation sche-dule for screw pumps.).Only use trade-marked preservatives (see chapter 8.Lubrication and preservation schedule for screwpumps.)

3. 2. 2. 1. Screw pumps with soft packings

With few exceptions, screw pumps aresupplied with pre-assembled soft pack-ings.

Non-metallic pump parts must not be preserved.

The customer or operator must preserve the pumpsas follows:

1. Remove soft packingss (see chapter 11. AppendixAssembly and operation of soft packings).

2. Open the plastic protective covers on the suctionand pressure chambers.

3. Apply acid and resin-free grease to all exposedshaft elements and places not protected by paint.

4. Close the plastic protective covers on suction andpressure chambers.

5. Re-fasten the gland.

Store the pump and accessories in an en-closed and dry place.

Caution

Attention


1000 98 086E 03/96 KMÜ


3. 2. 2. 2. Screw pumps with mechanical seals

In case of mechanical seals, the sealing flange mustnot be loosened.

Non-metallic pump parts must no be pre-served.

The customer or operator must preserve the pumpsas follows:

1. Open the plastic protective covers in the suctionand pressure chambers

2. Apply acid and resin-free grease to all exposedshaft elements and places not protected by paint.

3. Close the plastic protective covers on suction andpressure chambers.

Store the pump and accessories in an en-closed and dry place.

3. 2. 2. 3. Maintenance during storage

Check the pump preservation every month and re-new, if necessary .

3. 2. 2. 4. Starting up after temporary storage

Check soundness and tightness of the sealings exter-nally accessible and renew, if necessary.

Further points to be respected see operating manualchapter 5. Starting up.

3. 2. 3. Preservation for max. 12 months

If long-term preservaton (max. 12 months) isnecessary, refer to the specific documents enclosedin Chapter 11. Appendix .

Attention


03/96 KMÜ 1000 98 086E



1000 98 086E 03/96 KMÜ


4. Assembly and installation of the unit/pump

4. 1. Assembly

Assembly must only be done by qualified personnel.

4. 1. 1. Assembly of the coupling or pulley

The motor torque is transmitted to the pump by aflexible shaft coupling, by timing gears or by V-belt.

The shaft coupling must be able to compensate foraxial, radial and angular offset during operation. ( Note the manufacturers’ regulations in Chap-ter11.Appendix ).

The transmission of the motor torque by pulley, V-belt or timing gears is in most cases possible withoutadditional bearings. A previous consultation with thesupplier is however recommended.

1. Remove the layer of preservative from the shaftjournal with a suitable solvent.(See chapter 8. Lubricating and PreservationSchedule for screw pumps.)

2. Assemble the coupling, pulley or timing gears by follo-wing the specific documentation of the manufacturer.

4. 1. 2. Assembly of pump and motor on thebaseplate

Secure and immobilize the motor before checkingthe direction of rotation

1. Before installing the motor and pump check thedirection of rotation by running the motor briefly.(See the specific documentation of the manufactu-rer in Chapter 11. Appendix).

2. Place pump and motor on their pedestals on the ba-seplate .

3. Exactly align motor and pump on the baseplate.

In order to avoid excessive noise and vibration andto reduce the wear on the anti-friction bearings andcouplings during operation of the pump assemblies,the angular and radial offset and the end play of thecoupling halves must be kept to a minimum.Permissible end play of coupling 2-5 mm dependingon size. It is essential to check with a ruler.( see specific documentation of the manufacturer inChapter 11. Appendix).

In case of pump assemblies with flange motors or si-milar drivers, the couplings are aligned by the flangecenterings of motor, motor lantern and casing for pumpbearings.

4. Following alignment, secure the pump and motorto the assembly baseplate.

5. Attach the coupling or belt protection to the base-plate.

6. Check free movement of the coupling or V-beltpulley.

Attention

Attention

Attention

Pump base locating and mounting holes.

Attention


03/96 KMÜ 1000 98 086E


4. 1. 3. Assembly of the buffer fluid system

If the pump is equipped with a buffer fluid system,assembly must take place according to manufactu-rers’ instructions.

4. 1. 4. Assembly of the force oil lubricationsystem

If the pump is equipped with a force oil lubricationsystem, assembly must take place according to ma-nufacturers’ instructions.

4. 2. Installation

Installation work must only be done by qualifiedpersonnel.

4. 2. 1. Foundations

Refer to the relevant dimension drawingsfor the data and dimensions required forlaying out the foundations.

The foundations must be executed so to absorbarising forces and moments and to avoid distortingof the assembly baseplate during installation.

In the case of flexible steel structures, the naturalmovements and vibrations of this type of load-bea-ring structure must be taken into account.

4. 2. 2. Assembly of pipes

Note the following when laying the suction and di-scharge pipes or other supply lines: In front of thegear casing of the screw pump, there must be an in-stallation clearance of at least 1,2 times the overallpump length (without drive unit) - See dimensionaldrawing in chapter 11. Appendix).

- The nominal diameter of the pipes must be equiva-lent to the nominal diameter of the pump unions.

1. Assemble the pipes in a way that the pump doesnot empty at standstill, i.e. the pumping elementsmust totally be surrounded by the medium pum-ped while the pump is at rest.

2. Place a filling connection into the suction line,close to the pump casing, to fill the pump withthe medium. The size of the filling connection to be adapted tothe viscosity of the medium (min. 1").

The pump and fittings must not be subjected to thetest pressure during compression trials and pipe-line flushing. In case of static pressure in the system, leakage onthe shaft sealings may occur while the pump is atrest .

3. Flush the pipes.

4. Make a pressure test at 1,5 times the operatingpressure.

5. Assemble shut-off devices in the suction and di-scharge lines of the pump.

6. A fine-mesh suction filter of as large a size aspossible must be installed in the piping to protectthe pump against foreign bodies in the medium.(The filter must be easy to monitor and clean).

Flow resistance of the filter:

The flow resistance must not exceed10 kPa (0,1 bar)

Mesh size of the filter:

- At initial starting up, at repair work or similar, usea filter of 1 mm mesh size during the startingphase.

- For continuous operation, select a filter mesh sizeaccording to the pump size:

Attention

Attention

Attention


1000 98 086E 03/96 KMÜ


Recommended suction filter:

mesh size pump size[mm] from to

2 - 5

46 7

HC/VHC 147 HC/VHC 180

67T 8

HC/VHC 232 -

8 9 10

The maximum permissible suction height must notbe exceeded, even when the filter is contaminated .

4. 2. 3. Installation of the pump aggregate

Before installing and connecting the pump to thepipeline, the pipe system and fittings must be cle-aned.This is to avoid any damage to or destruction of thepumping elements and fittings by coarse welding re-sidue or other foreign bodies.

When installing the assembly on a flexiblesubstructure, the natural movements and vibrationsof this structure are to be taken into account.

In case of excessive movements and vibrations ofthe substructure, the pipes must be connected to thepump via compensators.

When installing the screw pump assembly, makesure that it is securely attached to its foundationwithout any trapped stresses.

It is essential to check the coupling alignment afterinstallation of the baseplate. If the permissible align-ment tolerances prescribed by the relevant couplingmanufacturer are exceeded, the coupling must be re-aligend. (See specific documentation of the manu-facturer in chapter 11. Appendix. ).

Connect the suction- and discharge lines and otherpipes to the pump by using perfect sealings andwithout any trapped stresses.Note the flow direction of the medium.

Connect a pressure gauge and vacuum meter to thepump.Refer to dimension drawing for connections.

4. 2. 4. Assembly of the soft packing

Check whether the soft packings are pre-assembled. If not so, assemble the softpackings (see Chapter 11. Appendix As-sembly and starting-up of soft packings)

4. 2. 5. Connection of drive unit

The pump must not run dry.If the pump and drive unit are connected whenchecking the direction of rotation of the motor, thepump must be primed with the medium and the shaftsealing must be fitted.

At connection, comply with the direction of rotation ofthe motor and pump. (see Note the arrow indicatingthe direction of rotation on the pump).

Generally, the drivers are to be installed and con-nected according to the specific instructions of themotor manufacturer.

Attention

Attention

Attention

Attention

Attention


03/96 KMÜ 1000 98 086E



1000 98 086E 03/96 KMÜ


5. Commissioning

5. 1. Initial start -up

Ensure prior to starting up, that the pump is stop-ped, the shut-off devices closed and the pump pres-sure released in order to avoid danger to humanbeing.

The initial start-up must only be performed by quali-fied personnel.

Make sure that all points under 4. Assembly and in-stallation of the pump/aggregate have been cor-rectly performed.

5. 1. 1. Oil level check

Check the oil level of the gear casing via the oil le-vel sight glass..The oil level must be between minimum and maxi-mum.

Overfilling of gear case leads to excessive heatbuild-up.

If the gear casing is not sufficiently filled, refill withoil ( see chapter 6.Maintenance ).

5. 1. 2. Prime the pump with media.

THE PUMP MUST NOT RUN DRY

1. For pump filling, open the connection provided inthe suction line

2. Prime the pump with media

3. Close the connection in the suction line.

5. 1. 3. Pump heating

If the media pumped require a pump heating, it mustbe ensured that the pump heating is actuated earlyenough before switching-on the driver. This willavoid seizing of pumping elements and shaft sea-lings.

If the pump is equipped with a heating, observe thespecific documentation of the manufacturer underAppendix.

The data/dimension for the heating pipes are to betaken from the dimensional drawing resp. are mar-ked on the pump.

5. 1. 3. 1. Relief valve

If the pump is equipped with a relief valve, observethe specific instructions of the manufacturer underchapter 11. Appendix.

5. 1. 4. Pump start

Prior to pump start make sure that all safety deviceshave been fitted to the pump.

Caution

Attention

Attention

Attention

Attention

Caution


03/96 KMÜ 1000 98 086E


If the pump is equipped with soft packings, observechapter 11.Appendix Assembly and starting-up ofstuffing box sealings.

1. Open the shutoff devices in the suction and di-scharge line.

2. If provided with a heating,

- switch on the heating

- wait until the medium in the pump has reachedthe required temperature.

3. If the pump is equipped with a force oil lubricati-on system and/or buffer fluid system, switch onthese devices. Oberserve the specific instructionsof the manufacturer under 11.Chapter.

4. Start the pump aggregate.

If the pump fails to deliver after the first start-up,switch-off the pump, close the shut-off devices andpressure release the pump assembly in order toavoid dry running.Wait for some minutes and restart according tochapter 5.1.2 Fill the pump with medium, to restartthe pump.If the pump still does not deliver, stop the aggrega-te, close the shut-off valves and release the pump ag-gregate. Then look to Chapter 7. Pump failuresand possible reasons.

5. 2. Daily starting up

Prior to pump start make sure that all safety devicesare connected to the pump.

1. Open the shut-off devices in the suction and di-scharge line.

2. If provided with a heating:

- Switch on the heating

- Wait until the medium in the pump has reachedthe required temperature.

3. If the pump is equipped with a force oil lubricati-on and/or buffer fluid system, switch on these de-vices.

4. Start the pump aggregate.

5. 3. Shutting down

1. Stop the screw pump assembly

2. Close shutoff devices in suction and delivery lines


- Switch off the heating

- Wait until the pump has cooled down.

4. Switch off the force oil lubricating system and thebuffer fluid system, if equipped.

If the pumps are intended for pumpingfood stuff, they must be cleaned accordingto the regulations prescribed for the foodindustry.

In case of a longer lasting shutting down, the pumpmust be preserved according to chapter 3.2 Storageand Preservation

5. 4. Emergency Stop

1. Stop the screw pump or assembly immediately

2. Close all shutoff devices in the suction and deli-very lines straight away


- Switch off the heating

- Wait until the pump has cooled down

5. Switch off the force oil lubrication system and thebuffer fluid system, if equipped.

Attention

Attention

Caution

Attention


1000 98 086E 03/96 KMÜ


6. Maintenance

All maintennce work on the pump must only be carried out by qualified pesonnel

6. 1. Check list maintenance

Maintenance points Action Maintenance intervals

Gear casing(incl. non drivesideroller bearings)

Oil change 1. Oil change after approx. 250 operat. hoursfurther oil changes:at normal operation every 3000 operating hoursat irregular operation every 1000 operating hoursor every 6 months

Check oil level weekly

Renew vent filter yearly

Roller bearing drive-side Grease lubrication inspection every 800 operating hours

Stuffing box packing Grease lubrication weekly

Visual inspection daily

Shaft seal rings Visual inspection weekly

Mechanical seal Visual inspection weekly

Double actingMechanical seal

Visual inspection weekly

Buffer fluid system Check buffer fluid weekly

Change buffer fluid every 6 months

Check operation weekly

Clean filter andair relief

starting phase:every houroperation: weekly

Force oil lubricationsystem

Check operation weekly

Check tightness weekly

Heating Check operation weekly

Check tightness weekly

Change heat transfer oil see relevant instructions of manufacturer in thedata sheet for heat transfer oil or every 6 months

Coupling Check for wear see specific documentation of the manufacturer

Belt drive Check for wear see specific documentation of the manufacturer

Drive unit Operation see specific documentation of the manufacturer

Attention


03/96 KMÜ 1000 98 086E


Ensure prior to starting up that the pump aggregateis switched off, the shut-off devices closed and thepump pressure released in order not to endanger hu-man being.

In case of danger resulting from media being poces-sed, used, thrown out or separated by the pump(e.g. liquids, gas, smoke, vapour etc.), protectiveclothes must be worn.

All maintenance work on the pump must only bedone by qualified personnel.

Maintenance work on pumps for the foodindustry to be carried out according tothe specific instructions resp. regulationsfor this industry.

6. 2. Gear casing

6. 2. 1. Oil level check

Check the oil level in the gear casing via the oil levelsight glass. The oil level must be between maximumand minimum.

Overfilling of the gear casing leads to inadmissibleheat build-up.

6. 2. 2. Oil change

6. 2. 2. 1. Refill the gear casing with oil

The oil required for pump filling is de-scribed under chapter 8.Lubrication and Preservation Schedulefor screw pumps

1. Loosen the oil filler screw.

2. Fill the gear casing with oil until the oil level inthe sight glass stands beteween minimum and ma-ximum. For the oil quantity refer to chapter 8.2.Lubricating table.

3. Re-fasten the oil filler screw to the pump casing.

6. 2. 2. 2. Draining of gear oil

1. Place a collecting vessel under the pump. For theoil quantity to be drained, refer to chapter 8.2 Lu-bricating table.

2. Loosen the oil drain plug

3. Drain off the oil from the gear casing

4. Rescrew the oil drain plug to the gear casing

5. Dispose of the collected waste oil according to en-vironmental requirements.

6. 3. Bearings

6. 3. 1. Roller bearings, non-drive side

The non-drive side roller bearings are located in thegear casing and lubricated by the gear oil. A separatemaintenance is not necessary.

Caution

Caution

Attention

Attention


1000 98 086E 03/96 KMÜ


6. 3. 2. Roller bearings, drive-side

The drive side roller bearings pos. 6 and 7 are greaselubricated., via a grease gun and both grease nipples.For the grease quantity, refer to chapter 8.2. Lubri-cating table.

6. 4. Shaft sealing

6. 4. 1. Stuffing box packing

6. 4. 1. 1. Visual inspection

A slight leakage of the stuffing box packing is to beregarded as normal. In case of heavy leakage,slightly tighten the gland by hand. In case of a har-dening or permanent leakage that could not be repai-red by tightening the gland several times, the pack-ing has to be exchanged. See Chapter 11.AppendixAssembly and Starting-up of stuffing box packings.

Shafts or stuffing boxes damaged by scratches,marks etc. should be repaired or renewed.

6. 4. 1. 2. Grease lubrication

Grease the stuffing box packings pos. 2 to 5 weeklyvia the grease nipple until grease leaks from thegland.

6. 4. 2. Single acting mechanical seal


In case of momentary leakage the reason may be aforeign body crossing the sliding faces.

The reason for permanent leakage may be worn sliderings or destruction of elastomers due to chemical attack.

In such case exchange the slide rings or elastomers.(See chapter (10. Dismantling and Assembly of shaftsealings).

If necessary, check chemical and thermalresistance.

6. 4. 3. Double acting mechanical seals


In case of momentary leakage the reason may be aforeign body crossing the sliding faces of the mecha-nical seal installed to the atmosphere-side.

The reason for permanent leakage may be worn sliderings or destruction of elastomers due to chemical at-tack. In such a case exchange the slide rings or elasto-mers.(See chapter 10.Dismantling and assembly of shaftsealings ).

If necessary, check chemical and thermalresistance.


03/96 KMÜ 1000 98 086E


6. 5. Buffer liquid system

When using double acting mechanical seals, a bufferliquid system is required. Observe manufactuer’s in-structions in Chapter 11.Appendix.

6. 5. 1. Operational Test

The buffer liquid pressure in the mechanical sealhousing has continuously to be controlled. It shouldbe 1 ...2 bars higher than the pressure of the pum-ping medium in the suction branch. Control tempe-rature of the buffer liquid, at regular intervals.

The temperature of the buffer liquid at theoutlet of the mechanical seal should notexceed 40°C below the boiling point, atatmospheric pressure. (With water, thiscorresponds to 60° C.)For more details, see the manufacturer’sdocumentation in chapter 11. Appendix.

6. 5. 2. Check level of the buffer liquid

Periodically check the liquid level in the buffer fluidcontainer. If the liquid changes colour of if the liquidlevel is far from normal, a defective mechanical sealmay be the reason. For more details, see the manufacturer’s documenta-tion in chapter 11. Appendix.

6. 5. 3. Clean filter and vent valve

For this work, observe the manufacturer’s instructi-ons in chapter 11.Appendix.

6. 5. 4. Change buffer liquid


6. 6. Force oil lubrication system

6. 6. 1. Check operation


6. 6. 2. Check tightness

Periodically check tightness of the force oil lubrica-tion system. In case of leakage, follow the instructi-ons of the manufacturer in chapter 11. Appendix.

6. 7. Heating

6. 7. 1. Check operation

For more details, see manufacturer’s instruction inchapter 11. Appendix

6. 7. 2. Check tightness

Periodically check tightness of the heating. In caseof leakage, follow the instructions of the manufactu-rer under 11.Appendix.

6. 7. 3. Change heat transfer oil

For this operation, follow the instructions of the ma-nufacturer under 11.Appendix

6. 8. Coupling/ belt drive / driver/accessories

Check wear of coupling and belt drive.Apart from that, observe instructions of the manufactu-rers for couplings, belt drive, drivers and accessories11. Appendix.


1000 98 086E 03/96 KMÜ


7. Break-downs and their possible causes

All work on the pumps must exclusively be done by qualified personnel.

Break-down Possible causes Remedies

Reduced capacity Leaky shaft sealing replace shaft sealing

Leaky suction line make tight

Direct connection between suction-and discharge side

make tight

Appearance of cavitation check suction line

clean filter

enlarge filter

increase cross-section of line

Clearance between screws and casing is toolarge

repair or renew these parts

Clearance between the screws is too large repair or renew these parts

Speed is too low increase motor speed

Pump does not prime Leaky shaft sealing replace shaft sealing

Leaky suction line make tight

Direct connection between suction anddischarge line

make tight


clean filter

enlarge filter

increase cross-section of line

Clearance between screws and casing is toolarge

repair and renew these parts

Clearance between screws is too large repair and renew these parts

Wrong direction of rotation change direction of rotation ofthe motor

Suction liquid not available fill the pump with medium.

Attention


03/96 KMÜ 1000 98 086E


All work on the pumps must exclusively be carried out by qualified personnel

Break-down Possible causes Remedies

Noises in the pump Leaky suction line make tight

Direct connection between suction-and discharge side

make tight


clean filter

enlarge filter

enlarge cross-sections of line

Bearing and/or gear damage complete overhaul of the pumprequired

Shortage of oil in the gear casing complete overhaul of the pumprequired

Coupling damaged or incorrectly alinged repair and/or re-align coupling

Uncontrolled opening of the relief valve. check set pressure of the reliefvalve and re-adjust if necessary

Blocking of the pump Coarse contamination try to turn the pump contrary tothe nominal direction of rotationwith subsequent pump flushing

disassemble and clean the pump

Excessive expansion of the pump internalsdue to increased temperature

cool down the pump until it canbe turned by hand

Bearing damage complete overhaul of the pumprequired

Shortage of oil in the gear casing complete overhaul of the pumprequired

Coupling incorrectly aligned repair and/or re-align coupling

Driving motor becomes warm Coupling incorrectly aligned repair and/or re-align coupling

Deviations from the order data sheet check driver and the actualoperating data

Attention


1000 98 086E 03/96 KMÜ


8. Lubrication and Preservation Schedule for Screw Pumps

8. 1. Lubrication Table

Only use one and the same type of oil/grease because the lubricants may not be compatible one another.

Make Gear oil Bearing grease Preservatives

temperature of medium10°C - 300°C 1)



oily waxy

Agip Blasia 150 m GR MU 3 Li GR NF G Rustia TI 10W/20

Aral Degol BG 150 m Aralub HL 3 Li Aralub HTR 2 G Reselin M 46

BP EnergolGR-XP 150

m Energrease LS 3 Li Energrease HTB 2 G Energol LX 4

Elf Reductelf SP 150 m Epexa 3 Li Staterma MO 2 G Stockage

Esso Spartan EP 150 m Beacon 3 Li Norva 275 G Rust - Ban 335

Fina Giran 150 m Marson L 3 Li Bentex 3 G Rusan 20

Finke AviaticonOel EP 150

m Aviaticon MZF 3 Li Finkox AKF - 2 AL Finkox - RSO -Fluid

Finkox RSU3)

Fluid

PharmawhiteW - 00

Fuchs Renolin CLP 150PLUS

m Renolit FWA 220 Li Renogel FHT 2 G RenolinMR 15

Klüber KlüberoilGEM 1-150

m Centoplex3

Li PetamoGHY443

PHS ContraktorA40K

ContraktorHW90

Mobil Mobilgear 629 m Mobilux 3 Li Mobiltemp 75 G Mobilarma 523

Shell Omala Oel 150 m Alvania Fett R 3 Li Darina Fett 2 G EnsisMotoroel 10 W

Total Carter EP 150 m Multis Li Caloris 3 G Osyris HL - 2

Valvoline Tectyl 5063)

The preservatives lined grey are compatible for food stuff.

1) m = lubricants on mineral oil basis

2) Aluminium -complex lubricants (Al), lithium soaps (Li), polyurea- (PHS) and gels (G) must not be mixed.

3) These preservatives contain solvents.

Attention


03/96 KMÜ 1000 98 086E


8. 2. Lubricating quantities

Pump sizes Oil quantity in [l] Grease quantity in [g]

W - pumps V -pumps first filling re-filling

1.2, 1.2k 0,25 - 10 5

2.1, 2.1k 0,25 - 10 5

3.1, 3.1z, 3.2z 0,30 0,70 10 5

3.1k, 3.1zk, 3.2zk 0,30 0,70 10 5

4.1z(k), 4.2z(k) 0,40 0,80 15 5

5.1z(k), 5.2z(k), 5.3z(k) 0,70 1,60 20 5

HC / VHC 147 1,30 1,70 20 5

6.4z(k), 6.5z(k), 6.6z(k),6.7z(k), 6.8z(k)

1,30 3,30 90 1)

60 2)1510

HC / VHC 180 1,60 4,00 90 15

7.2z(k), 7.3z(k), 7.4z(k) 2,40 5,00 110 15

HC / VHC 232 3,00 - 150 20

7T.1z(k), 7T.2z(k), 7T.3z(k) 4,10 7,20 190 30

8.3z(k), 8.4z(k), 8.5z(k) 4,30 7,80 190 30

9.2z(k), 9.3z(k) 10,90 - 180 40

1) Roller bearings on the drive shaft

2) Roller bearings on the driven shaft

The above listed oil quantities have been determined by calculation and approximately correspond to themaximum oil filling in the gears, means the gears will be filled with oil up to the top edge of the colour pointin the oil level sight glass.

A visual inspection is necessary.

Attention


1000 98 086E 03/96 KMÜ


9. Remarks

9. 1. Assembly of double-row diagonalball bearings with filling slots

On assembly of double-row diagonal ball bearingsplease note that for reason of optimum machiningsome types are provided with a filling slot.

Screw pump with direction of rotation clockwise

Due to this special construction, these bearings aresuitable for absorbing radial forces and unilateralaxial loads. On assembly of these bearings take carethat the main load in axial direction be absorbed bythose raceways not provided with filling slots.

Screw pump with direction of rotation counterclockwise


03/96 KMÜ 1000 98 086E


9. 2. Spare parts orders for rollerbearings

The roller bearings in Bornemann screw pumps areprovided with special clearances.

On ordering spare parts, the roller bearings must fea-ture the following clearances:

roller bearing clearance

grooved ball bearing C3

roller bearing C3

diagonal ball bearing C4

9. 3. Request for Information

The customer must always state the following whencontacting JHB by telephone, telefax or in writing:

Order no..:_____________________________

Machine no.:___________________________

Pump type:______________________________

The above data can be found on the identificationplate of the screw pump.

Trained specialist fitters are available for installati-on, repairs and other requirements.

9. 4. Return of the pump

Note the following if a fault cannot be remediedwithout consultation and the pump has to be sent tothe works for repair:

1. Detach all parts that are not permanently securedto the pump as no liability can be accepted.

2. Drain the medium from the pump.

3. Clean the pump inside and outside.

If the pump is uncleaned, extra costs willarise for cleaning and decontamination.

4. Close all flanges and holes (e.g. flushing holes ofmechanical seal).

5. Send one copy of the attached safety sheet cor-rectly completed and filled in together with thepump to be repaired to J.H. Bornemann.

In case of further risk arising from the pump, dan-gerous to life and limb, respective information is tobe given to J.H. Bornemann.

Machines that have been in contact with radioacti-vely loaded media, will exclusively be repaired by aspecially qualified engineer within a safety area tobe provided for by the user.

Pumps returned for repair will only be disassem-bled after the correctly and completely filled in andduly signed Safety Sheet has been received by J.H.Bornemann.

Attention

Caution

Caution

Caution


1000 98 086E 03/96 KMÜ


User:

Company:

Street:

Place:

Phone / Fax::

The last medium handled by the pump was:

The pump was emptied by the user company.

The pump was carefully cleanedinside and outside, by the user company.(Costs for cleaning and decontamination arisingwith J.H.B. will be charged extra.)

The pump had contact to dangerous materials.

if so:

Consecutive number under whichthe dangerous material is registered in the GefStoffV:

or

- The CAS - Registration number (Chemical Abstract Service):

The signer confirms that a.m. information is correct and that the pump was orderly despatched.

Stamp, Date, Signature

NO

YES

NO

YES

NO

YES

Pump to be repaired:

Pump type:

Order no.:

Machine. no.:

Signer Name and position

Safety Sheet


03/96 KMÜ 1000 98 086E



1000 98 086E 03/96 KMÜ


Bornemann Subsidiaries:

Bornemann Pumps is a privately-owned company, established in 1853.Bornemann has been involved with the design and construction ofpumps and pump systems for over 75 years.

In 1934 Bornemann developed a twin screw pump with externalbearings. Since that time, manufacturing, resarch and developmentefforts have been concentrated toward advancing state-of-the-artscrew pump technology.

Today Bornemann manufactures twin-screw pumps, with internaland external bearings, progressive cavity pump, three-spindlepumps, multiphase pumps, down hole pumps along with customer-designed pumps and systems for applications in a wide range ofindustrial.

Bornemann’s world-wide network of 95 subsidiaries and local agentsprovides you quick and knowledgeable assistance wherever andwhenever you need it - in planing, engineering and installation andwith comprehensive maintenance programs.

RUECKS_E.CHP

For further information please contact:

Pumps and Systems

for Industry, EnvironmentalTechnology and Shipbuilding

Joh. Heinr. Bornemann GmbH

D-31676 ObernkirchenPostfach 1162

Germany

Tel. +49 (0) 5724/390-0

Fax +49 (0) 5724/390-290E-mail [email protected]

Internet: www.bornemannpumps.com

USA:Bornemann Pumps Inc.P.O. Box 1769,Matthews, NC,USA 28106Tel.: +1 (0)-704-849-8636Fax: +1 (0)-704-849-8637E-mail: [email protected]

The Netherlands:BornemannBenelux B.V.Ringdijk 506NL-2987 VZ RidderkerkTel.: +31 (0) 180-440144Fax: +31 (0) 180-465050E-mail: [email protected]

Singapor:Bornemann Pumps Asia25 Intern. Business ParkGerman Centre, # 04-08SGP-Singapore 609916Tel.: +65 (0) 561 6782Fax: +65 (0) 561 6784E-mail:

[email protected]

Argentina: Bombas Bornemann S.R.L.Armenia 2898RA-(1605) MunroProv. Buenos AiresTel.: +54 (0)-1-4756-8008Fax: +54 (0)-1-4756-5541E-mail: [email protected]

Switzerland:BornemannAnlagentechnik AGKirschbaumweg 39CH-4103 BottmingenTel.: +41 (0)-61-421 7754Fax: +41 (0)-61-421 0407

07/00 KMÜRev. 1 03/03

Documents

Operating Manual - Screw Pumpsinventory.powerzone.com/invimages/54695/TwoScrewPumpOperatingManual.pdf · Pump type: Operating Manual - Screw Pumps Operating Manual - Screw Pumps -