PROCESSTEC ViscoTwin 130 G8 Manuel

Address: 345 E. Tulare Avenue Unit E | Visalia, CA 93277 | Phone: +1 (559) 429-4227

Fax: +1 (559) 429-4228 | Email: [email protected] | http://processtec.com

ViscoTwin 130 G8

Operation & Maintenance Manual

Published February 23rd, 2023

TABLE OF CONTENTS

PROCESSTEC INC. 2022Page ii

TABLE OF CONTENTS

PROCESSTEC INC. 2022 Page iii

1. ABOUT VISCOTWIN SCREW PUMPS .............................. . 1

1.1 Safety Notes .............................................................. 1

1.2 Working Principle .......................................................... 3

1.3 General Overview .......................................................... 4

1.4 Opons .................................................................. 5

1.4.1 Opons for 3A or EHEDG .............................................. 5

1.4.2 Pump Face Opons................................................... 6

1.4.3 Pump Housing Opons................................................ 8

1.4.4 Elastomer Opons ................................................... 10

1.4.5 Spindle Opons...................................................... 11

1.4.6 Mechanical Seal Opons .............................................. 12

1.4.7 Bearing Housing Opons .............................................. 14

1.4.8 Motor Opons ...................................................... 17

1.4.9 Frame Opons ...................................................... 18

1.5 Performance Tables ........................................................ 19

1.5.1 Sizing Chart ......................................................... 19

1.5.2 Water Curves........................................................ 21

2. INSTALLATION............................................... 23

2.1 Unpacking ................................................................ 23

2.2 Inspecon / Technical Documentaon ......................................... 23

2.3 Hoisng and Transportaon.................................................. 24

2.4 Installaon................................................................ 26

2.5 Piping Before and Aer the Pump............................................. 27

2.5.1 Upstream Piping ..................................................... 27

2.5.2 Downstream Piping .................................................. 28

2.5.3 Piping Before and Aer the Pump....................................... 28

2.6 Mechanical Seal Connecon ................................................. 29

2.7 Pre-Installaon of Seal Water for Dual Acng Mechanical Seal ..................... 30

2.8 Electrical Installaon........................................................ 31

3. OPERATION................................................. 33

3.1 Pump Startup ............................................................. 33

3.2 So Starng the Pump ...................................................... 33

3.3 Avoiding Pump Cavitaon ................................................... 34

3.4 Pumping Sensive Products.................................................. 34

3.5 Material Selecon for Sealing Surfaces......................................... 35

3.6 Pumping Product with Large Parculates ....................................... 35

TABLE OF CONTENTS

PROCESSTEC INC. 2022Page iv

3.7 High Pressure Systems ...................................................... 35

3.8 CIP / COP Soluon.......................................................... 36

3.9 Visual Inspecon ........................................................... 37

3.10 Available Elastomer Opons ................................................ 37

3.11 Leakage ................................................................. 38

3.12 Scratches in the Pump Housing .............................................. 39

4. MAINTENANCE.............................................. 41

4.1 Maintenance Preparaon. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1.1 General Movie: HOW THE PUMP WORKS................................. 41

4.1.2 Introducon to Web Page ............................................. 41

4.1.3 Risk Assessment for Pump Maintenance ................................. 42

4.1.4 Safety Measures ..................................................... 42

4.2 Explaining Maintenance Levels ............................................... 43

4.2.1 Maintenance Level 1 (ML-1) ........................................... 43

4.2.2 Maintenance Level 2 (ML-2) ........................................... 44

4.2.3 Maintenance Level 3 (ML-3) ........................................... 45

4.3 Material at hand, Required Parts & Tools ...................................... 46

4.3.1 Recommended Spare Parts ............................................ 46

4.3.2 Recommended Tools ................................................. 47

4.3.3 Recommended Oils, Grease............................................ 47

4.4 Maintenance Instrucons for ML-2............................................ 48

4.4.1 Removing the Pump Housing .......................................... 48

4.4.2 Complete Pump Disassembly .......................................... 51

4.4.3 Complete Pump Assembly ............................................. 57

4.5 Preventave Maintenance Program ........................................... 65

4.5.1 First Oil Change ...................................................... 65

4.5.2 Oil Change Intervals .................................................. 65

4.5.3 Checking Levels on Motor Gearbox Oil................................... 65

4.5.4 Greasing Motor Bearings .............................................. 65

4.5.5 Check Condion of O-rings ............................................ 66

4.5.6 Check the Exterior Lip Seals and O-rings on the Mechanical Seals ............ 66

4.5.7 Check Oil Sha Sealing Rings ........................................... 67

4.5.8 Proper Gapping of Pump .............................................. 68

4.5.9 Changing Product Flow Direcon ....................................... 72

4.6 Failures................................................................... 73

4.6.1 Foreign Material enters Pump Housing .................................. 73

TABLE OF CONTENTS

PROCESSTEC INC. 2022 Page v

5. TOOL-BOX .................................................. 75

5.1 Tools ..................................................................... 75

5.1.1 ViscoTwin Tools...................................................... 75

5.1.2 General Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

5.2 Spare Parts................................................................ 81

5.2.1 Spare Parts for Pump Housing.......................................... 81

5.2.2 Spare Parts for Seal Housing ........................................... 85

5.2.3 Spare Parts for Bearing Housing ........................................ 87

5.2.4 Spare Parts for Gear Housing........................................... 88

5.2.5 Spare Parts for Drive Train ............................................. 90

5.3 Explosion Drawings......................................................... 92

5.4 Torque Tables ............................................................. 93

5.5 Pump Housing Conguraon ................................................. 94

5.6 Oils, Grease & Lubricaon Recommended ...................................... 102

5.7 Oil Tesng Kit (with Form) ................................................... 104

6. GEEK‘S CORNER ............................................. 105

6.1 Oil Cooler with Oil Filter ..................................................... 105

6.2 Vibraon Sensor with Oil Temperature Sensors.................................. 106

6.3 Quench Design for Recirculang Fluids in Mechanical Seals........................ 107

6.4 Maximizing Bearing Lifespan ................................................. 108

6.5 Equipment Commissioning Protocol ........................................... 118

7. APPENDIX .................................................. 119

7.1 Maintenance Movies ....................................................... 119

TABLE OF CONTENTS

PROCESSTEC INC. 2022Page vi

This page intenonally le blank.

1. ABOUT VISCOTWIN SCREW PUMPS

PROCESSTEC INC. 2022 Page 1

1. ABOUT VISCOTWIN SCREW PUMPS

1.1 Safety Notes

This manual contains instrucons which should be heeded to ensure personal safety and prevent damage

to property. These instrucons are highlighted by a warning triangle and a color to indicate the degree of

the hazard. The following warnings should be observed throughout the life cycle of the pump:

ROTATING PARTS

Indicates rotang parts that can cause injury. Only perform work on or near these parts

when it is locked to prevent rotaon. It is advised to have a protecve barrier surrounding

the rotang part to prevent injury or property damage during operaon.

HIGH VOLTAGE

Indicates high voltage and risk of shock or severe burns. No work should be performed

around high voltage parts unless they have been disconnected from the main power

supply. Any work on high voltage parts must only be performed by an electrician licensed

in the state where operaons and maintenance is being performed.

CRUSHING PARTS

Indicates moving parts that can crush and cut. Perform work with awareness of how

parts move and where these crushing parts can be encountered.

SUSPENDED LOAD

Indicates a suspended or overhung load, where parts can fall, slip, or p over if not

properly secured. Do no work on any part that is suspended and avoid being directly

under or near a suspended load. Do not stand between a staonary object and a

suspended load.

LIFTING OBJECTS

Indicates heavy objects that can cause muscle strain or back injury. Liing aids and

proper liing techniques should be used to prevent injury.

1. ABOUT VISCOTWIN SCREW PUMPS

Page 2 PROCESSTEC INC. 2022

Commissioning and operang the ViscoTwin 130 G8 may only be performed by qualied personnel.

Qualied personnel in terms of the safety instrucons in this operang and safety manual are persons

who have completely read this manual.

Furthermore, maintenance can only be performed by qualied maintenance technicians. Qualied

maintenance technicians in terms of the maintenance instrucons in this operang and safety manual are

persons who have read Chapter 4 “Maintenance” and have been trained by Processtec in the use and

maintenance of this pump. In lieu of in-person training by Processtec personnel, a qualied maintenance

technician may also review the online maintenance movies available at hp://processtec.com. WARNING:

ANY MAINTENANCE LEVEL 2 PERFORMED ON THIS PUMP BY UNTRAINED PERSONNEL WITHOUT THE

EXPRESS WRITTEN CONSENT OF PROCESSTEC WILL RELEASE PROCESSTEC OF ANY LIABILITY AND VOID

ANY WARRANTY CLAIMS ON THE PUMP..

In addion to this operang manual, general on-site regulaons as well as city, state, and federal regulaons

applicable to accident prevenon must be made available and followed.

The ViscoTwin 130 G8 may only be used in the applicaons as specied in Chapter 3 "Operaon" on page

33, and only in connecon with the spare parts recommended by Processtec, Inc.

LEAKAGES

Indicates that leaks are possible. Leaked uid can cause slip-and-fall hazards and should

be cleaned up and disposed of immediately.

HOT SURFACE

Indicates a surface is hot to the touch and can cause burn injury. Do not maintain or

touch a hot surface unl the pump is turned o and allowed to cool. If immediate repair

is necessary, it is advised to wear protecve gloves while handling a hot part.

CAUTION

When operang the ViscoTwin 130 G8, it is essenal to wear appropriate protecve

equipment.

1. ABOUT VISCOTWIN SCREW PUMPS

PROCESSTEC INC. 2022 Page 3

1.2 Working Principle

Screw pumps are rotary posive displacement pumps for conveying low to high viscosity media. The

ViscoTwin G8 is a posive displacement pump characterized by a double screw, or spindle, design. The

pump ulizes very close tolerances to create a series of “sealed” chambers between spindle windings.

This allows the pump to more eciently transport highly viscous product with minimal slippage and

precision owrate control as well as gentle handling of solid parculates already mixed into the product.

The precision crasmanship of the ViscoTwin G8 means it can generate a very high pressure dierenal,

even with a low inlet pressure.

The pump is also highly customizable, with several sizes and inlet/outlet variaons to suit the needs of

the product and the space available. Addionally, the pump is maintenance friendly and fully CIP-able, to

ensure ease of use.

ViscoTwin G8 pumps used in the food and beverage industry are designed to meet the most stringent

sanitary design criteria (3A, EHEDG), and are built with corrosion-resistant materials in accordance with

recommendaons from US Food and Drug Administraon (FDA) and other internaonal food safety

governing bodies. Pumps are delivered with a motor, lantern, and framing as standard for easy installaon.

1. ABOUT VISCOTWIN SCREW PUMPS

Page 4 PROCESSTEC INC. 2022

1.3 General Overview

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