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Operating Manual
ATTENTION!
Machine no. :
Contract no. : 0
Item no. :
Size :
1/63
Material specifications
Material :
Temperature : max. °C
Conveyance specifications
Number of valves :
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Screw incline : %
End flight incline : %
Max. volumetric capacity : m3/h
Screw speed : min-1
Power requirement of screw pump : kW
Nozzle hole : mm
End flight material : Wear-resistant cast
Densit application
Welded plating
Special execution in accordance with
drawing no.:
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2.0.0 Description 11
2.1.1 Construction 11
2.1.2 Function 12
3.0.0 Installation 16
3.2.0 Installation 17
3.2.3 Instructions for assembling the screw pump on the steel construction 19
© 10/2007
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4.1.0 Start-up 30
4.2.0 Maintenance 32
4.2.2 General instructions for the installation of stuffing box packagings and
the starting torque of the stuffing box gland 41
5.0.0 Troubleshooting 55
7.0.0 Coupling 63
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This symbol means an immediate danger for the life and health
of people.
Danger! Ignoring this symbol will lead to serious damage to your health
and even cause fatal injuries.
This symbol means a possible danger for the life and health of
people.
Warning! Ignoring this symbol may lead to serious damage to your health
and even cause fatal injuries.
i machine correctly.
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The screw pump may only be operated by personnel who are trained and authorised
to do so. It is the responsibility of the machine operator to make sure that the persons
in charge of operation and maintenance of the machinery are familiar with the rules
and regulations.
Responsibility for operating the screw pump must be precisely defined and specified
so that no-one is assigned duties for which they do not have the necessary skills.
IBAU HAMBURG does not accept any liability for damage that occurs as a result of
non-compliance with the operating manual.
The machine must be used for the purpose designated in this operating manual and
the technical specifications in the order confirmation. Otherwise, it will not function
properly and and safely.
The installation of parts or add-on units and the use of parts that are not original
IBAU HAMBURG parts or accessories may influence the given design
characteristics. As the manufacturer, we do not accept any liability for damage
resulting from the use of non-original parts or accessories.
This screw pump is solely designed to convey non combustible dusts like cement,
lime, etc. If it is used for other materials, the responsible engineer at IBAU
HAMBURG should be consulted. The screw pump is not to be set up in rooms in
which an explosive gas/air mixture may form. The screw pump is not suitable for
other pulverized materials, which can form with air an explosive mixture.
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ATTENTION! During operation, the inspection covers (Fig. 1, item 15 and 22)
may not be opened under any circumstances! Inspection covers
may only be opened after a complete shutdown of the screw
pump and the conveying air blower / compressor.
Danger!
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Screw pumps are used for the pneumatic transport of cement, raw meal, various
types of lime, pulverised coal, fly ash, alumina and many other pulverised materials.
No other conveying unit is able to continuously feed large quantities of pulverised
goods into a pneumatic conveying line without an air blow-back. A further
advantage of screw pumps is that they require little space and are particularly low in
height. In special cases (e.g. screw pumps for unloading ships), screw pumps can
operate against conveying line back pressures of up to 2.5 bar. They come in sizes
100 to 350, with capacities ranging from approx. 3 m³/h to approx. 370 m³/h.
2.1.1 Construction
Item Designation
1 Screw
2 Fixed bearing
3 Floating bearing
4 Shaft bushing
5 Motor
6 Coupling
7 Oil level indicator
8 Oil paddle
9 Inlet box
10 Stuffing box
11 Sealing air piping
12 Wear bushings
13 Cone
14 Wear ring
15 Discharge box
16 Counterweight
17 Valve lever
18 Non-return valve
19 Nozzles
20 Conveying line
21 Blind flange
22 Inspection cover
23 Screw pipe
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The screw pump (Fig. 1) consists of the inlet box (9), the screw pipe (23), the
discharge box (15) and the bearing unit with two bearings and the screw (1).
The fixed bearing (2) and the floating bearing (3) are mounted on the same shaft
bushing (4). This bushing is equipped inside with a centring cone and a feather key
connection to the screw. The screw (1) is actuated by a separately installed motor (5)
via a coupling (6).
The oil level in the bearing unit is shown by the oil level indicator (7). The oil
paddles (8) mounted on the shaft bushing provide the bearings with a steady supply
of oil.
The screw pump is sealed against the inlet box by a stuffing box (10). The additional
supply of sealing air (11) prevents dust from penetrating into the stuffing box (10),
but only if the material inlet space of the screw pump has been dusted. To ensure the
stuffing box functions properly, a negative pressure of min. – 20 to –50 daPa should
be ensured.
At the front section of the screw pump, facing the conveying direction, the screw
rotates in the wear bushings (12), which are mounted in the screw pipe. After the last
wear bushing there is a conically enlarged space (13), the so-called cone. At the end
of the cone there is the wear ring (14). In the discharge box of the screw pump the
counterweight (16) presses the non-return valve (18) against this wear ring (14) via
the lever (17), so sealing off the pressure-free material inlet from the pressurised
conveying chamber. The three nozzles (19) installed at the bottom of the discharge
box (15) are used to blow in the compressed air, which is mixed with the bulk
material. The mixture of air/solids so produced is thus transported to the conveying
line (20) downstream of the discharge box of the screw pump.
The design of the wear bushing type differs from that of the standard type in the
following respect:
instead of the conical space (13) with a wear ring (14), there is a cylindrical wear
bushing with a conical outlet. This wear bushing is bedded in a cone. This version
does not have a wear ring (see also fig. 16).
2.1.2 Function
The main element of the screw pump is a high-speed screw (1), with speeds of 750
and 1,000 min-1 at 50 Hz operation and speeds of 900 or 1,200 min-1 at 60 Hz
operation.
The purpose of the high-speed screw is to continuously convey bulk material from a
pressure-free material inlet (9) into the pressure chamber of the discharge box (15)
and the downstream conveying line (20). Together with the cone and non-return
valve, the screw and the material flow act as a seal between these two areas.
During operation the non-return valve (18) is made to open by the continuous supply
of material, which then falls into the discharge box (15). There it is mixed with
compressed air via the nozzles (19) and so transported to the conveying line (20).
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SCREW PUMP
ATTENTION!
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IBAU HAMBURG
2.2.0 Compressed air supply
The compressed air required for pneumatic conveying via a screw pump is generally
supplied by blowers or screw compressors. The quantity of compressed air required
for the specific case and the piping diameter of the conveying line are calculated by
IBAU HAMBURG.
Alternatively, compressed air from an air supply network can also be used for
pneumatic conveying.
If you are using compressed air from an air supply network, you are advised to
construct the compressed air device as shown in Fig. 2a order to ensure pneumatic
transport functions perfectly. Alternatively, you can also use a special combined
pressure throughput control valve which greatly reduces the extent of the valves
shown.
Air supply
either right
or left
Fig. 2
The air supply lines can be connected either on the left-hand or the right-hand side of
the discharge box (Fig. 2). The air connection is fitted at the factory with a blind
flange, seal and screws (see also Fig. 1, item 21). This can be bored as specified by
the customer according to the compressed air supply line. The max. diameter of the
air connection line for the relevant size of the screw pumps is given in the
appropriate IBAU dimensional sheet.
The sealing air piping (normally installed in conveying direction left) in the screw
pump is installed opposite the conveying air connection at the factory. However, it
can also be moved to the other side at any time if this proves to be necessary on site.
Attention!
The tightness of the entire conveying air system must be verified following
installation on site!
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SCREW PUMP
Legend
1 Main shutoff valve 6 Measuring flange
2 Air pressure measurement 7 Differential pressure regulator
3 Dirt trap 8 High-pressure valve
4 Pressure reducer 9 Needle valve
5 Pressure measurement 10 Differential-pressure
manometer
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IBAU HAMBURG
3.0.0 Installation
3.1.0 General instructions for assembly
The material is normally fed into the screw pump through a surge hopper installed
on the inlet box of the screw pump. The surge hopper must be sufficiently vented.
NOTE!
In the pump surge hopper there should always be a negative pressure of min. -20 to
-50 daPa under all operating conditions to ensure proper venting of the material
flow and proper functioning the stuffing box seal.
Overpressure in the pump surge hopper results in reduced volumetric capacity of the
screw pump and to escape of the bulk material via the stuffing box seal of the screw
shaft.
Always avoid using horizontal venting lines as they become blocked with dust
contained in the outgoing air over time, and this prevents sufficient ventilation of the
surge hopper.
Alternatively, the bulk material can also be fed to the material inlet space of the
screw pump laterally, e.g. via a fluidslide. The material inlet space (Fig. 1, item 9) is
equipped at the side with two inspection covers (Fig. 1, item 22). In this case one
should be removed and the flange connected to a counterflange of the conveying unit
for the supply of material. The lateral connection should preferably be right-handed
in the conveying direction for screw pumps powered by an electric motor (the screw
is clockwise), and for screw pumps powered by a combustion motor preferably left-
handed in the conveying direction (the screw is anticlockwise)! Should the position
of the material inlet described above prove impossible, the matter must be clarified
with the person responsible at IBAU HAMBURG at all events as the volumetric
capacity of the screw pump may be greatly reduced in such a case!
A surge hopper with venting should also be provided with the lateral feed of material
to the screw pump!
When material is conveyed pneumatically to silos or bins using a screw pump,
negative pressure filters must be present at the material transfer point to ensure
sufficient venting of the conveying air.
If several silos or bins have to be filled, the conveying line has to be equipped with
two-way valves leading the material flow into the corresponding silo.
The conveying lines for pneumatic conveying via the screw pump can be laid either
vertically or horizontally. However, under no circumstances should the conveying
lines run up in a slanting conveying direction as this may cause pneumatic conveying
to malfunction. Such piping sections may cause the separation of coarse particles
from the material flow, which then move down along the bottom of the slanting
conveying pipe against the conveying direction. These particles then collect at the
lowest point of the piping section, causing localised pipe blockages which generally
become apparent beforehand by throbbing conveying line back pressure at the screw
pump.
If there is any doubt about the piping route, please consult the person responsible at
IBAU HAMBURG.
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i
Note
ATTENTION!
If the above points are not observed, IBAU HAMBURG will not guarantee
that pneumatic conveying functions properly.
3.2.0 Installation
Prior to installation of the screw pump check whether all parts are available on site in
accordance with the relevant parts lists. If any parts are missing, then also check the
shipping advices and packing lists. The plant drawings provide further useful
information about possible missing parts.
If parts are found to be missing, the supplier of the screw pump and the person
responsible at IBAU HAMBURG should be notified immediately.
Minor transport damage to the screw pump, e.g. damage to paintwork, should be
repaired on site. More serious damage should be reported to the person responsible
at IBAU HAMBURG. If possible, take photographs and send in to IBAU
HAMBURG so that the damage can be assessed.
ATTENTION!
For screw pumps which are pressure surge-resistant to 10 bar the following
instructions must be observed without fail:
Warning!
Should damage have occurred to the following components during transport or
subsequent installation, these items may not be installed:
• inlet box
• screw pipe
• inlet box with screw pipe (only with screw pump type 151 and 251)
• discharge box.
Once all necessary parts are available and without defects, check that all
requirements are satisfied for proper installation.
• Does the installation situation comply with that of the installation drawing?
• Does the available height comply with that in the drawing?
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Fig. 3.1
1.1 Prepare the foundation according to the drawing or dimensional sheet
1.2 Construct the foundation on grown soil or existing concrete sole.
1.3 Fill in the gap between foundation and soil with bitumen (n/a with concrete
sole!).
1.4 Do not forget the measurement for dismounting the screw (group 3.2.2 or
Fig. 6)!
Fig. 3.2
2.1 Insert anchor bolts.
2.2 Position screw pump.
2.3 Align the pump by means of spacers using a water-level.
2.4 For test purposes, turn the screw at the coupling and ensure that the screw
rotates without contact.
Fig. 3.3
3.1 Fit the shuttering.
3.2 Pour in around 5 cm of casting concrete beneath the shuttering strength class
C30/37 with additive (swelling agent).
3.3 Allow to set.
3.4 Remove shuttering.
3.5 Tighten the anchor bolt nuts to a maximum torque of 120 Nm.
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Instructions for dimensioning the steel construction used for setting up the pump.
• To ensure that the steel construction can oscillate safely, it is essential that the
natural frequencies of the steel construction are sufficiently outside the exciting
frequencies of the screw pump.
• The deflection of the displacement carriers on which the screw pump is carried
must not exceed 1/1000 of the span when they have to bear their own load and
the live load! In addition, sheet metal discs or bonds must be provided to brace
the horizontal displacement of the carriers.
• The load factor given covers the dead weight of the screw pump, attached parts
(e.g. motor, pump surge hopper), the weight of the filling and the necessary
safety allowances for additional loads and vibrations which may arise.
3.2.3 Instructions for assembling the screw pump on the steel construction
1. The base frame, the screw pump, the motor, the motor console and the
fastening screws are delivered separately.
2. Mount the screw pump and the motor with the motor console on the base frame
according to the installation drawing. Then align the coupling in accordance with the
instructions.
3. Position the entire assembly (base frame with screw pump and motor) on the steel
construction in the location provided and align with a water-level.
To align you may have to place extra spacers at certain locations.
4. Screw the base frame to the steel construction or weld together at places
(relevant procedure to be specified by customer).
Then turn the coupling manually to see if the screw rotates without contact in the
wear bushings.
If the screw does not rotate without contact, unscrew the screwed connections
holding the screw pump and base frame together once again. Place extra lining plates
under the appropriate points to realign the screw pump so the screw rotates without
contact. Finally realign the coupling.
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In case of V-belt drive the motor has to be mounted to the side of the screw pump on
With direct drive of the screw pump the motor should be positioned so it can be
Note
moved back slightly to dismount the screw! Take the dismounting dimensions given
by the manufacturer of the coupling into consideration here.
The coupling is aligned by means of a dial indicator, a shaft ruler and a thickness
gauge according to the instructions of the coupling manufacturer. The coupling gap
(Fig. 4) to be adjusted is shown in the operating manual for the coupling.
Straigh
t edge
Note the direction of the arrow!
Fig. 4
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Screw pumps are delivered with the sealing air piping, designed to a pressure rating
of PN 10, already mounted.
However, if this was dismantled before transport for packaging reasons, the sealing
air piping should be reassembled according to Fig. 5 on installation of the screw
pump at the installation site.
4- spherical cock R ½“
i The tightness of the sealing air system must be verified following installation of the
sealing air piping on site!
Note
Note
The above parts relate to the standard screw pump. In some cases deviations may
occur.
In some cases it may prove necessary on site to extract the sealing air slightly away
i from the screw pump directly from the conveying air supply line or from the works
network.
This is for example the case when on the basis of the customer's process control
Note responsibility or with constant power failures at the works, the air compressor is
suddenly switched off during conveying. In such a case there is the risk of the
material flowing back in the stuffing box of the screw pump due to the back pressure
still present in the conveying line via the nozzles and sealing air piping. When the air
compressor is switched back on, the material flows through the stuffing box housing
with the sealing air at high speed. The resulting "sandblasting effect" then causes
damage to the stuffing box housing.
Should such improper mode of operation constantly occur during operation of the
screw pump, the person responsible at IBAU HAMBURG should be informed
immediately to jointly seek possible solutions to prevent further damage to the screw
pump.
In such a case IBAU HAMBURG shall accept no warranty liability for any damage
that has already occurred!
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• Pressure should be adjustable in the range 0.02 to 0.2 bar (see. item 4.1.0 page 31)
• The sealing air volume should be adjustable according to the following table
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Fig. 5
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Note
How to dismount the screw is described in item 4.2.5.
Screw pump
Type IB-D
Screw pump
Type IB-DV
Fig. 6
Table II
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Every delivered screw pump has undergone an 8-hour test run and is normally filled
i
Note
with the right type and quantity of oil.
However, for safety reasons it is advisable to recheck the oil level at the oil level
indicator (Fig. 1, item 7) provided for this purpose prior to start-up.
ATTENTION!
The correct oil level can only be checked when the screw pump is at a standstill!
If however in an exceptional case the pump is delivered without oil , the correct
quantity of oil according to the oil level table on page 36 must be added.
The stuffing box at the shaft exit to the inlet box of the screw pump is adjustable and
is equipped with 3 packing rings and a grease ring.
The stuffing box packagings are made of the material "Arochem S" and have already
been provided with sufficient grease at the factory during the test run.
ATTENTION!
i As there may have been a lengthy period of time between delivery of the screw
pump and its start-up, the stuffing box must be regreased without fail prior to start-
up, and the correct starting torque for the stuffing box gland also checked
Note (see item 4.2.2 on page 40.)
During start-up and proper operation of the screw pump the following outside
temperatures for the housing are within the acceptable range:
ATTENTION!
If the above temperatures are greatly exceeded, the screw pump should be taken out
of service and the cause for the rise in temperature determined!
The coupling protection (Fig. 7), the protective cover (Fig. 7 a) in the area between
the bearing unit and the stuffing box and the belt guard for V-belt-driven screw
pumps may only be removed when the machine is at a standstill. Before the machine
is restarted, the above protection devices must be properly fitted again.
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Fig. 7
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Fig. 7 a
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Screw pumps must be protected against external influences such as rain, impact or
i
Note
breaking.
The screw pump must be stored prior to installation in a dry place under cover!
The screw pump must be transported on its frame as shown (see Fig. 8). Here the
rope must never be fastened to the screw shaft at point (A) and (E), the coupling (B),
the cone (C) or the stuffing box (D).
Fig. 8
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If it transpires on start-up that the difference in pressure of the nozzles is greater than
0.3 bar with the nominal conveying capacity, the person responsible at IBAU
HAMBURG should be contacted to bring about correction of the nozzle bores. Here
the existing plant parameters such as the quantity of material currently conveyed and
the actual equivalent conveying pipe length should be given so a new nozzle
calculation can be carried out.
NOTE!
In the partial load area of the pneumatic conveying the difference in pressure between
the air pressure and the back pressure may exceed the pressure of 0.3 bar given above.
This however does not represent any defect in the design of the nozzle bores!
The counterweight on the lever of the non-return valve is adjustable in its position.
In addition, it features a split design to reduce the weight if necessary.
The position and size of the counterweight depend on the material flow (e. g. wear
behaviour, bulk density and fineness) and on the specific plant parameters (e.g. level
of conveying line back pressure). On start-up of the plant the position of the
counterweight should be adjusted to ensure the seal between the pressurised discharge
box and the pressure-free inlet box of the screw pump with the nominal conveying
capacity; i.e. no conveying air should flow back to the inlet area of the screw pump.
Another criterion for adjustment of the counterweight is the drive of the screw pump.
The adjustment should be selected so that the nominal current of the drive motor is not
exceeded with the nominal conveying capacity.
NOTE!
For specific cases the screw pump type IB-D 350 is equipped with special non-
return valve damping, with two pneumatic cylinders, make Norgren Herion. They
have a damping effect on the closing direction of the non-return valve. In this
specific case a separate drawing and an operating manual for the components used
are included with this documentation.
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Maintenance of the screw pump depends on the specific operating conditions. Under
normal operating conditions maintenance should be carried out in accordance with
the table below (see 4.2.1 page 38).
Grease lubrication of the stuffing box and the non-return valve bearing must be
i carried out according to the intervals specified in the maintenance table (cf. 4.2.1
page 38) and with lubricating grease of Esso Unirex 3 quality or with an equivalent
grease as per DIN 51502 - KL 2 K. The relevant lubricating points are equipped with
Note
button head lubricating nipples as per DIN 3404 AM10x1 (Fig. 11c /item 46 page 45
and Fig. 15 between items 4 and 5 page 57)
The sealing air pressure (Fig. 5, item 3) should be adjusted according to the data
IMPORTANT NOTE!
The control cock must not be opened while conveying material as this may damage the
stuffing box housing! However, to clean the stuffing box and remove any dust which
has entered the conveying air must be connected.
The oil for the bearing unit must be filled in via the opening in the vent socket
The maximum oil temperature in operation is approx. 80° C under normal operating
i conditions and is read off the thermometer (Fig. 9, item 3) of the bearing unit.
Higher oil temperatures point to an excessively high or low oil level in the bearing
unit or to possible damage to the bearings.
Note In such cases the oil level should be corrected according to the following table on
page 36 or the defective bearings replaced!
IMPORTANT NOTE!
Inoperative thermometers should be replaced immediately to ensure correct
readoff of the permissible oil temperature of the bearing unit!
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IMPORTANT NOTE!
Should an oil paddle have fallen into the bearing unit in such a case, the screw pump
must not be started up under any circumstances as this might cause serious damage
Caution! to the bearing unit! In this case the complete bearing unit must be taken apart to
remove the oil paddle!
The screw pumps in sizes 100 to 200 are equipped with one oil paddle in the middle.
From size 251 to size 350 the screw pumps are equipped with four oil paddles, two
each on the floating bearing and two on the fixed bearing side.
Caution!
IMPORTANT NOTE!
When checking or performing maintenance on the oil paddles, the screw pump must
always come to a proper standstill and be secured against being switched back on
unintentionally!
Caution!
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Fig. 9
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Oil level at
standstill
Note: This information applies to initial filling of the screw pump and should be used as a
guideline only. When refilling oil (only at standstill of the pump) the value
marked at the inspection glass of the oil-level indicator (see mm "H") must not be
exceeded in any case. However, falling short of the oil level by 2 mm is
admissible.
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When the bearing unit is subsequently filled with oil, it must be ensured that the oil filling
quantity specified for the size of the screw pump is not exceeded. An excessive oil level
may cause the superfluous oil to escape at the felt ring seal on the coupling side at the
bearing unit!
Fig. 10
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SCREW PUMP
size: Cilld cast irion Densit Steel Steel with welded plating
4.2.1.2 Wear limits
Legend:
de Diameter end flight
ds Diameter screw
db Diameter wear bushing
ge/gs Maximum admissible gap between end flight / screw and wear bushing
tec Maximum admissible thickness of end flight made of chilled cast iron until exchange
ted Maximum admissible thickness of end flight with Densit application until exchange
tes Maximum admissible thickness of steel end flight until exchange
tesa Maximum admissible thickness of steel end flight with welded plating until exchange
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IBAU HAMBURG
ts Maximum admissible thickness of the screw helix until exchange
Fig. 11:
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When installing stuffing box packagings it should be ensured that the joints of the
individual packing rings are offset 180° in relation to each other on installation in the
stuffing box housing!
The packagings and grease ring are carefully inserted in the stuffing box housing
individually by hand with the help of the stuffing box gland (see Fig. 12a to 12c)
until a noticeable resistance is felt. The nuts of the stuffing box gland are then
tightened until a noticeable resistance occurs. A marking is now made on the nuts
(e.g. using a waterproof pen), which allows correct tightening of the stuffing box
gland to be checked. With an open-jawed spanner the nuts should now be tightened
crosswise 1½ revolutions!
When dismounting and inspecting the stuffing box packagings (Fig. 12 a) it is not
necessary to remove the screw.
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When dismounting and inspecting the stuffing box packagings (Fig. 12 b) it is not
necessary to remove the screw.
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When dismounting and inspecting the stuffing box (Fig. 12 c) it is not necessary to
remove the screw.
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46/63
The wear parts (Fig. 13) are dismounted in the order given via the inspection
opening (47) in the discharge box as soon as they are worn out. They should only be
replaced by original spare parts by IBAU HAMBURG as this is the only way to
ensure perfect functioning of the screw pump.
A stock of these original spare parts should therefore always be kept by the
customer.
1. Remove the inspection cover (47), open the non-return valve (48) and secure
carefully in this position.
2. The wear plate (9) can now be removed from the non-return valve (7).
3. The end flight (13) can now be removed from the screw using the end flight
withdrawal device (49) supplied.
4. The nozzles (6) can now be replaced.
1. Remove the inspection cover (47), open the non-return valve (48) and
secure carefully in this position.
2. Take off the divided separating flange (50) from the side.
3. Remove the O-ring (11) (only applies to screw pump size 150 - 200)
4. Separate the wear ring (10) from the cone.
5. With screw pumps size IB-D100 and IB-D350 then withdraw the cone (12)
towards the inspection opening.
With screw pumps size IB-D151 / 200 / 251 and 300 the discharge box has to
be dismounted here to replace the cone and wear bushings.
6. Remove the O-rings from the cone (only applies to screw pump size 100).
7. Push out the wear bushings (15) after removing the plug (51) using a
screwdriver.
NOTE:
In some cases material penetrates in between the bearing carriers in the
screw pipe and the wear bushing due to a wear bushing already being worn
through. In this case the screw then has to be dismounted (see also item 4.2.5
on page 49).
With screw pumps size 300 and 350 it is helpful to also remove the discharge
box as this allows work to be carried out more easily on the wear bushings.
They can now be removed with a cut-off angle grinder to facilitate
dismounting. However, this should be done with great care to ensure you do
not cut too deeply and possibly damage the screw pipe!
If marks have been caused on the bearing surfaces in the screw pipe when
dismounting the wear bushings, they can be smoothed out before re-
installation with a fine-grain abrasive cloth.
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Note For screw pumps size 100 and 151 the O-rings must be inserted in the cone (see 4.2.4)
before remounting.
For the screw pump size 200 the O-ring must be inserted after installation of the
cone between the housing and the separating flange (see 4.2.4). The separating
flange (50) is then affixed to the discharge box again.
For screw pumps size 251 to 350 the O-rings must be inserted the cone (see 4.2.4).
Only then is the separating flange (50) positioned and affixed to the discharge box.
When the wear parts have been mounted again as described above, check the fit of
the wear bushings through the tap hole (51) for the plug. Before starting the screw
pump again, make sure the screw with the end flight rotates smoothly and without
resistance in the wear bushings.
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If an O-ring has to be replaced, it can be cut to size out of a round cord with a
suitable diameter. Normally a round cord made of the material "Viton", which is
heat-resistant up to +200° C, for the screw pump. At higher operating temperatures,
special materials are used. For this reason consult IBAU HAMBURG about the
material quality used before replacing the round cord. We also recommend stocking
up with a sufficient quantity of the necessary round cord with the dimensions for
each size of pump in good time before carrying out maintenance work.
NOTE: Whenever the equipment is dismantled, the O-ring installed must be
i replaced!
When replacing the O-ring proceed as follows:
Note
• Cut the round cord to the length of the dismounted O-ring, adding another
5-10mm.
• Before installation check whether the edges of the groove for accommodating the
O-ring are broken. If they have sharp edges, the new O-ring might become
damaged, causing the O-ring packing to leak.
• Knock the round cord carefully into the groove provided using a mallet
(divergence from this see item 4.2.3 / Installation of cone and separating flange
for screw pump sizes 100 to 350).
• Cut the projecting ends of the round cord axially with a mitre of 45° so that the
cut edge is not visible from the pressure side (Fig. 14).
Fig. 14
Pressure
ATTENTION!
i If a round cord has been cut too short, never try to adjust it by stretching it to the
required length. "Stretching" will reduce the diameter of the round cord, impairing
its sealing effect!
Note
• As the adhesive for the joint between the two ends of the round cord
Loctite 101® should be used.
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The screw can be dismounted independently of the wear parts as follows (Fig 15):
1. Draw back the motor with the coupling half until there is sufficient space for
the screw shaft.
2. Remove the coupling half from the screw shaft.
3. Secure the shaft against uncontrolled rotation by placing the assembly aid (2,
not included in IBAU HAMBURG delivery package) in place, or by
removing the cover of the inlet box and using a wooden wedge.
4. Remove the inspection cover (3) on the discharge box, open the non-return
valve (4) and secure carefully in this position.
5. Release the nuts (5 and 6) used to secure the screw axially with an open-
ended spanner (not included in IBAU HAMBURG delivery package) (left-
hand thread). The necessary width across flats are given in the table below.
6. Take off the cup spring (7) and the thrust collar (8).
7. Loosen the screw from the conical fit of the shaft bushing by striking the
shaft end with a recoilless plastic hammer (9).
After loosening the screw, pull it out carefully from the screw pipe in the
conveying direction.
ATTENTION!
Use an open-ended spanner when unscrewing and tightening the nuts on the
screw. For accident-prevention reasons, the use of other tools such as gaspipe
pliers is forbidden.
ATTENTION!
If a plastic hammer is not used, the end of the screw should be protected from
damage by the hammer blows with a piece of hard wood or copper !
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SCREW PUMP
For screw dismounting dimension see table II on page 20
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IBAU HAMBURG
4.2.7 Dismounting of the main components of the screw pump
Should it become necessary to replace a main component of the screw pump, e.g. the
bearing unit, inlet box, screw pipe or discharge box, proper pinning must be ensured
on subsequent installation of the new component. After alignment of the new
component perform the necessary new pinning diagonally in relation to the existing
pins.
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1. The back pressure gauge indicates a pulsating back pressure in the conveying
line, possibly also causing obstruction of the conveying line.
Check:
a) Has anything changed in the piping system or at the receiving point?
b) Has the material quantity to be fed in been changed (e.g. greater than the
max. conveying capacity calculated)?
c) Is the compressed air supply unit of the screw pump working properly
(e.g. conveying capacity smaller than calculated)?
d) Is there a piping section slanting upwards in the conveying direction?
e) Has there been an increase in the share of coarse particles in the material
flow?
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2. The conveying capacity of the screw pump has fallen and the material flow
increases in the pump surge hopper.
Check:
a) Has the sealing air pressure been set correctly for the specific material
flow (cf. 4.1.0 - Spring tube pressure gauge for sealing air pressure)?
b) Is the venting of the pump surge hopper functioning properly? i.e. there is
a slight negative pressure in the pump surge hopper
(cf. 3.1.0 - General instructions for assembly)?
c) Are the screw and/or wear bushings heavily worn, thus causing a major
increase in the gap dimension?
d) Are the wear ring and/or valve plate of the non-return valve heavily worn
so that the tightness of the non-return valve is no longer ensured?
e) Is the quantity of material fed in greater than the conveying capacity of
the screw pump as designed?
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3. The bearings of the screw pump become too hot (temperature > +80° C).
Check:
a) Is the oil level in the bearing unit correct (cf. 4.2.0 – Maintenance)?
b) Was the right oil quality filled in? If necessary, change the oil.
c) Does the running noise of the bearings indicate damage?
d) Has material possibly got into the bearing unit when blowing out bulk
material from the stuffing box?
e) Has the temperature of the material flow increased? With material flow
temperatures > +130° C the use of an oil cooler is necessary.
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When ordering spare parts, take care to indicate the data on this type plate
accurately: The type plate is fixed on the inspection cover of the screw pump. The
type designation of the screw pump is followed by the machine number
(e.g. IB-D350 / 6897). Please always give this number when ordering spare parts.
Type
Com.-No.
Item-No.
Further data can be taken from the following table (see next page):
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1 Transition piece
2 Seal
3 Back pressure gauge
4 Rotary shaft seal
5 Stuffing box packings
6 Set of nozzles
7 Non-return valve
7a Non-return valve **
8 Valve lever
9 Wear plate
9a Wear plate **
10 Wear ring
11 O-ring cord*
11 a O-ring cord*,**
12 Cone
13 End flight
14 Wear bushing (hardened)
15 Set of wear bushings
16 Air pressure gauge
17 Screw
18 Wear ring
19 Grease ring
20 Stuffing box packings
21 Wear bushing
22 Felt ring
23 Thermometer
24 Floating bearing
25 Seal-off air pressure gauge
26 Oil paddle
27 Fixed bearing
28 Cup spring
29 Hexagonal nut
30 Oil level indicator
31 Wear ring bushing **
32 Locating cone **
41 Stuffing box cover
42 Grease packing
44 Stuffing box housing
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SCREW PUMP
Detail see Fig.16a
page 65
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IBAU HAMBURG
Fig. 16 a: Bearing unit and stuffing box
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For adjustment of the coupling please take note of the operating manual supplied
separately by the coupling manufacturer.
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