KLRC Manual - Tuthill Vacuum & Blower
Contents
1. a d KLRC 40 AND 75 O V FI p LRC 40 AND 75 ONLY or 2 i o 223 2 2 HE ATTE Figure 4 Piping Schematic Full Sealant Recoverv Svstem with Circulating Pump 9 mar YJLMNALMINI 1 II ONNO 5 Piping Schematic Full Sealant Recoverv Svstem Without Circulating Pump See the Specification Table on page 5 for size of connections Figures 2 3 4 and 5 show the connection locations for suction discharge gas sealant water and shaft seal cooling water of different pump models Note that connections are different for KLRC 40 75 compared to the KLRC I00 to 950 Also shown are the valves and gauges as they should generally be located for any of the piping arrangements Piping must be no smaller than the pump connection and must be aligned and may have to be supported so as not to place a strain on the pump Normally it is not necessary to drain a pump to shaft level prior to starting provided that the incoming sealant flow was stopped simultaneously with stopping the pump during the last shutdown An automatic solenoid valve normally closed is convenient for this use The pump may be manually drained to shaft level by use of the attenuation valve As the pump creates its own vacuum it will draw in the required amount of sealant so that the sealant need not be under pressure when pumping below 400 Torr From 400 to 760 T2. REASSEMBLY PROCEDURE 1 NDE IMPELLER SHAFT 1 1 If the NDE impeller was removed from shaft install drive key and impeller on shaft looking at the NDE of shaft the curvature of the impeller blades must be Clockwise on models 40 75 and counterclockwise on models 100 525 Note a Install and wrench tighten the impeller nut and when seated apply one hammer blow to the wrench Then install the impeller lock nut and again when seated apply one hammer blow to the wrench b If a dummy NDE bearing is not available assure that the ball bearing fits on the shaft bearing journal with a very light tap or slip fit 1 2 Temporarily install a dummy or ball bearing and a bearing cap in the NDE bearing housing then attach it to the NDE end casing Note a To differentiate end casings note the DE casing for models 300 525K has the fluid sealant supply port centrally located under the bearing housing In models 40 75K the supply port is located on the outside periphery of the NDE end casing at centerline height 2 NDE STAGE 2 1 Position the NDE end casing bearing housing assembly on the assembly stand If the NDE endplate with shaped suction port for models 40 75 and smaller discharge port for models 100 525 was removed apply sealing compound to the counter bored sealing face Note for stainless steel models use the PTFE glass filled gasket in lieu of sealant Install the plate full face up slightly rotating it to distrib
3. 2912 SPRINGFIELD MO uu K Gw POSTAGE WILL BE PAID BV ADDRESSEE m m ATTN CUSTOMER SERVICE VACUUM PRODUCTS TUTHILL VACUUM amp BLOWER SYSTEMS ww PO BOX 2877 SPRINGFIELD MO 65890 2150
4. BALL BRG SINGLE ROW BRG LOCKNUT KEY DE IMPELLER KEY NDE IMPELLER KEY DRIVE SHAFT HEX HD CAP SCR BRG HSG HEX HD CAP SCR BRG HSG CAP HEX SOC CAP SCR END PLATES HEX NUT TIE RODS PLAIN WASHER TIE RODS LOCKWASHER BRG HSG LOCKWASHER BRG HSG CAP O OO A Oo HEX HD BSHG ATTENUATION VALVE PPG CTSK CTR HSG PIPE PLUG SQ DRAIN PIPE PLUG HEX SOC DRAIN PPG HEXS SHAFT SEALS PPG CTSK DE END CASING NN Q ITEMSNOT SHOWN RECOMMENDED SPARE PARTS 23 Twat 1d4vHS fi il hae fib 06 dt Chh QX 004 MEE BF m m Ned bex hr dee ER ITI LE M Eom zv M gpl Need 58 JAA EE emi N pa iii BSS ra A mae 4 IX z 7 4 22 SIE Mi i suy X ex i OSE OLE BEL OEE 821 NOLLONE 55 16 GISZ DYT ADOP DYTN uon3 s 5503 AM IJ 24 STAINLESS STEEL 40 75 KLRC GASKETED ASSEMBLY PARTS LIST DESCRIPTION END CASING NDE END CASING DE END PLATE DE END PLATE NDE CTR HOUSING GASKETED IMPELLER DE IMPELLER NDE IMPELLER HSG GASKETED DE IMPELLER HSG GASKETED NDE GASKET SET 015 THICK PTFE SHAFT BEARING HOUSING OIL S
5. 3 5 Remove shaft seal same as step 1 5 Note a For DE shaft seal replacement only continue with Reassembly Step 4 0 b For disassembly of DE stage or complete disassembly continue with the next step 4 DE STAGE 4 1 Remove the crossover pipe at connecting flanges if not already removed 4 2 Remove the DE tie rod nuts and lift off the DE end casing Remove the endplate from the end casing only if it needs to be replaced 4 3 Remove the impeller housing 4 4 Remove shaft lock nut and impeller nut Same as Step 2 4 except note that nut threading is in the opposite direction on this end of the respective pump models KLRC 40 amp 75 Left Hand Thread CW toloosen KLRC 100 950 Right Hand Thread CCW to loosen 4 5 Remove impeller and note direction of blade for reassembly 5 CENTER HOUSING AND NDE STAGE 5 1 Remove NDE tie rod nuts and lift off the center housing with both sets of tie rods 5 2 Lift off the NDE impeller housing 5 3 Lift the shaft with NDE impeller attached from the NDE end casing 5 4 Disassemble the shaft impeller only if the impeller locknut is not securely fastened and indicates fuller inspection or if either part needs to be replaced REASSEMBLY GENERAL All pans must be clean Clean off old sealant film at housing interfaces and removed with an effective solvent All joint and impeller faces must be free of any nicks Note a Standard cast iron construction FA and BA pump housing joints are sealed with
6. Check heat exchanger cleanliness Incorrect sealant flow rate Defective bearing See Sealant flow rate Replace Too much sealant liquid Decrease flow rate Coupling misaligned Align Cavitation defined on pg 13 Defective bearing Open attenuating valve or reset vacuum relief valve to increase flow Replace High sealant temperature Check coolant flow and temperature Suction open to atmosphere Coupling misaligned Adjust isolation valve Align Pump not properly anchored Anchor See excessive noise Excessive back pressure Check inlet pressure and gas flow Reduce height of pump discharge Too much sealant liquid See table for proper flow rate Misalignment Realign motor and pump Defective bearing Misaligned pump assembly Replace bearing Impeller binding or will not turn Accumulation of rust or scale See Operation and Maintenance Foreign object in pump Dismantle pump and remove foreign object Mechanical Seals squeal MAINTENANCE GENERAL WARNING TO ANY ELECTRIC COMPONENTS OF THE UNIT Insufficient cooling liquid Increase coolant flow to seal check compatibility of sealant DISCONNECT PUMP FROM ELECTRICAL POWER SOURCE PRIOR TO MAKING REPAIRS OR ADJUSTMENTS Elementary rules of cleanliness periodic inspections and preventative maintenance policy of the pump will produce optimum performance and prolong the life
7. 2 11 2 ANSI Inlet Outlet Flange 150 11 2 11 2 11 2 11 2 2 2 3 3 4 4 55 22 6 24 1 25 8 28 1 29 7 33 6 41 41 56 5 56 5 Overall Length mm 573 613 654 713 754 852 1041 1041 1435 1435 12 6 12 6 16 16 19 1 19 1 23 5 23 5 30 56 30 56 Overall Height mm 321 321 406 406 486 486 597 597 776 776 Width in 11 9 11 9 12 8 12 8 16 9 16 9 18 9 18 9 25 32 25 32 mm 302 302 324 324 429 429 479 479 643 643 in 6 5 6 5 6 9 6 9 8 3 8 3 9 8 9 8 12 59 12 59 Shaft Height mm 165 165 175 175 210 210 249 249 320 320 15 155 200 230 255 360 405 800 800 1590 1590 Weight Net Pump only kg 70 91 104 116 163 184 363 363 721 721 The cooling fluid flow rates are based on sealant fluid entering the HX at 80 F and exiting at 65 F Cooler or warmer fluid than 60 will effect the flow rate ANSI American National Standards Institute THEORY OF OPERATION When the pump is in operation a continuous flow of sealant liquid is entering the pump and forms a seal between the impeller and casing see Figure 1 The impeller is off set above center of the pump casing and as the impeller rotates pumping action begins in the space between the impeller and casing by filling and emptying similar to 1 1 reciprocating compressor engine Gas inlet and discharge ports positioned so as to draw gas into the cavitv inside the liquid sealed ring during the expansion segment and discharge gas along with some liquid during the compre
8. 5 Deep Slot A B D MATERIAL ITEM 1 MATERIAL ITEM 42 BASE 14 12 1 4 1 7 SCHEDULE 40 PIPE STEEL HRS LOW CARBON PLATE 14 12 3 8 1 8 SCHEDULE 40 PIPE STEEL HRS LOW CARBON PLATE 16 16 1 2 1 12 SCHEDULE 40 PIPE STEEL HRS LOW CARBON PLATE NOTES UNLESS OTHERWISE SPECIFIED 2 WELDED CONSTRUCTION REMOVE BURRS AND SHARP EDGES 20 00 Figure 8 MATERIAL CS HOT ROLLED LOW CARBON L ANGLE STRUCTURAL 3 x 3 x 1 4 C CHANNEL STRUCTURAL C 8 x 11 5 FT LB Recommended Assembly Stands 19 BEARING INSERTING TOOL Stamp pump size on this i face 1 47 high Era J 1 10 13 146 gt 1 gt Radius AI TYP TAB x 45 Chamfer 1118 Radius 1 6 x 45 M Chamier 13x30 M Cr INCHES PUMP MODEL BEARING SIZE A B C D E F G H J K 40 amp 75 205 25 x 52 mm 2 027 1 87 1 233 1 03 0 88 13 8 5 8 5 3 25 4 5 100 125 206 30 x 62 mm 2 42 2 272 1 423 1 226 0 942 11 2 13 16 5 3 25 4 5 200 300 207 35 x 72 mm 2 814 2 608 1 67 1 423 1 255 11 2 11 16 5 3 25 4 5 525 310 50x 110mm 4 31 3 937 2 375 2 01 1 755 2 11 16 5 3 25 4 5 950 1314 70x 150 mm 5 885 5 25 3 5 2 8 2 255 2 75 1 1 8 11 9 25 10 512 MATERIAL Figure 9 Bear
9. an inch maximum when measured around the periphery of the coupling halves V BELT DRIVE Before attempting to tension any V belt drive it is imperative that the sheaves be properly aligned V belts should be replaced in sets and the sheaves should be positioned so as to allow the belts to be placed in the grooves without rolling them onto the sheaves The following tensioning steps can be safely followed for all belt types 1 With belts properly in their grooves adjust the sheaves until all slack has been taken up 2 Start the drive and continue to tension the V belt s until only a slight bow on the slack side of the drive appears while operating under load conditions 3 After 24 to 48 hours of operation the belts will seat themselves in the sheave grooves Further tensioning may be necessary as described in Step 2 Slipping squealing at start up is often evidence of insufficient tensioning Belt dressing should not be used on V belts Sheaves 6 belts should remain free of oil grease Tension should removed from belts if the drive is to inactive for extended period of time WARNING The belt guard or coupling guard must be properlv secured in place at all times while the pump is running SEALANT RECOVERV SVSTEMS Figures 2 through 5 illustrate sealant configurations Once Through Fig 2 Partial Recovery Fig 3 Full Recovery with Circulating Pump Fig 4 Full Recovery withou
10. atmosphere Check local laws and ordinances prior to operation of the pump with discharge to outside atmosphere Venting of the discharge of an oil mist eliminator to outside atmosphere is highly recommended Do not restrict the pump discharge in any way or place valves in the discharge line The vacuum pump is a compressor and will generate high pressures without stalling the motor when operated at low suction pressures Excessive pressure could cause pump damage or serious bodily injury Disconnect the pump motor from the electrical supply at the main disconnect before disassembling or servicing the pump Make sure pump is completely reassembled the coupling or belt guard is properly installed and that all fill and drain valves are installed and closed before reconnecting the power supply Accidental starting or operation of the pump while maintenance is in progress could cause pump damage or serious bodily injury Lift pump only by strapping the crossover pipe DO NOT lift equipment attached to pump by the pump lifting lugs Do not touch hot surfaces on the pump In normal operation at low pressures surface temperatures will not normally exceed 180 F 82 C Prolonged operation at 200 Torr 267 mbar a may cause surface temperatures as high as 220 F 104 C TABLE 5 SECTION PAGE INTRODUCTIO
11. energizing the motor to determine that the impeller is free to turn 12 PRESTART 5 1 Check that the proper electrical power is connected to the control panel via the fusible disconnect 2 Check that the sealant water supply to the vacuum system is adequate in terms of flow rate temperature and supply temperature 3 Checkthat the proper sized inlet and outlet piping is connected to the vacuum system Flexible connectors should be used between the pumps and piping to prevent external stresses from being applied to the equipment On large diameter piping pipe supports should be used to prevent the weight of the piping from stressing the equipment 4 Fillthe separator tank if applicable of the liquid ring pump with the correct sealant liquid to the level which corresponds appropriately to the shaft level of the liquid ring pump At no time should the liquid level be allowed to drop below the sealant outlet connection which would allow gas to enter the suction of the circulation pump Maximum sealant level would coincide with the top of liquid ring pump bearing housing 5 Aliquid level gauge is installed to allow visual monitoring of the sealant level NOTE The limitations on what sealant can be used in the liquid ring pump are based upon the following considerations a The sealant should be compatible with the materials of construction and the process stream so that corrosion polymerization or some adverse chemical reaction
12. outboard ball bearings bearing end caps and steel trim The second suffix letter designates the standard type of shaft seal A John Crane Type 21 seal Carbon Ceramic Viton D Flow Serve RO Dura Seal Carbon Durchrome Viton L PTFE encapsulated Viton O Rings DD Flow Serve Double RO Dura Seal Consult factory for alternate seal configurations When the nameplate model designation is followed by the letters HT the pump has an operating temperature limit of 220 F Inquiries should be referred to Tuthill Vacuum amp Blower Systems referencing model and serial number of the pump SUITABLE APPLICATIONS Kinney Liquid Ring Vacuum Pumps KLRC are reliable non pulsating pumps KLRC pumps are two stage configuration suitable for operation down to 30 Torr absolute approximately 29 inches Hg vacuum reference 30 inch barometer when sealed with 60 F water Standard pumps with stainless steel impellers designated with material codes F or C are suitable for operation with sealant temperatures up to 160 F Bronze impeller pumps designated with material code B and pumps with HT following the Model designation on the nameplate are suitable for operation with sealant temperatures up to 220 F Consult Tuthill Vacuum amp Blower Systems for applications requiring operations above 220 F AVOID DAMAGE TO THE PUMP Unpack the pump carefully and handle only by methods that will not damage or misalign the pump Do not run the pump dry Make sure
13. sealant is piped to both seals see Figures 2 through 5 Donotallow sealant in the pump to freeze Donot place any valves or restrictions in the discharge line If the pump and motor are mounted on a base the unit should only be lifted from the base or by attaching to the base Lifting the unit by attaching to the pump or motor could disturb the alignment The crossover manifolding on the KLRC series pumps should never be used as an attaching area for lifting SPECIFICATION TABLE TABLE 1 UNIT KLRC KLRC KLRC KLRC KLRC KLRC KLRC KLRC KLRC KLRC 40 75 100 125 200 300 525 526 950 951 Speed RPM 1750 1750 1750 1750 1750 1750 1750 1450 1150 860 Drive Tvpe Direct Direct Direct Direct Direct Direct Direct Belt Direct Belt HP 5 5 7 5 10 15 25 50 40 100 75 Standard motor kW 38 38 5 6 76 114 19 38 304 746 55 9 Sealant liquid required GPM 5 5 6 7 8 12 18 18 26 26 at 60 F w sealant recovery L min 19 19 23 26 30 45 70 70 98 98 Sealant liquid required GPM 3 3 4 4 4 6 9 9 13 13 at 60 F w partial sealant recovery L min 11 11 15 15 23 30 45 45 49 49 Liquid required to fill a US Gal 4 6 5 6 6 3 7 5 9 24 24 2 gt Full Sealant Recovery FSR System Liters 18 19 23 24 28 34 91 91 Cooling fluid at 60 F GPM 5 5 7 10 15 25 50 50 52 52 required for HX L min 19 19 27 28 57 95 190 190 197 197 Sealant Liquid Connections NPT 1 2 1 2 3 4 3 4 1 1 11 4 1 1 4 11
14. upon desired vacuum setting and pump size INLET CHECK VALVE Used to automatically isolate pump from process chamber when the vacuum pump is shut down by blocking the back flow of air and sealant Valve must be installed in a horizontal position FLEXIBLE CONNECTOR Used to accommodate some motion and misalignment between pump and system Kinney Flexible Vacuum Connectors with steel flanges and stainless steel bellows are recommended INLET SHUT OFF VALVE Used to positively isolate pump from process chamber Ball valves are supplied up to 2 NPT Butterfly valves are supplied for connections larger than 2 NPT SEALANT SOLENOID VALVE Used to establish sealant flow open when motor is energized and return to closed position when motor is de energized FLOW CONTROLLERS Used to establish the sealant flow rate to the vacuum pump and shaft seals Recommended flow controllers are shown on page 10 SEALANT CIRCULATING PUMP Used to circulate recovered sealant Required for use when operation at high pressure such as frequent cycling or when operating for prolonged periods above 400 Torr STRAINER Used to filter solid particles from the sealant HEAT EXCHANGER Used to cool circulated sealant 11 INLET AIR EJECTORS Motive Air In An air ejector may be added to the inlet of a liguid ring vacuum pump to provide an additional pumping stage The air ejector can achieve significantly lower pressure than is possible with the compound ligu
15. DS LOCKWASHER BRG HSG LOCKWASHER BRG HSG CAP PIPE PLUG HEX SOC DRAINS PPG HEXS VACUUM RELIEF VALVE PPG CTSK CTR HSG PIPE NIPPLE SEALANT INLET PIPE NIPPLE ATTENUATION ELB 90 SEALANT INLET ELB 90 STREET ATTENUATION HHBSHG ATTENUATION ITEMS NOT SHOWN RECOMMENDED SPARE PARTS 0 29 RI mm N N IN N ose 081 Ort 06 01 OS 067 07 08 011 0 5 OL 09 087 ite 086 ove 06 o 6 H jis 29 m STi H LUE 1 2 225 jal 1 AL mi s Ts 2 2 008 2117 A 0 22772 by zzZzzzzZZzzzzzzz PUN M ose TA TIET MAMMA 228 ja d Oz 022 OL OLE OLE 09 0 027 0 2 021 152022 00 092 06 002 it l e e e ci 8 e V U Ze i a 056 DY TM uon2as 55042 5 AMBIH 950 KLRC ASSEMBLY PARTS LIST DESCRIPTION END CASING DE END CASING
16. E END CASING NDE END PLATE DE END PLATE NDE CTR HOUSING IMPELLER DE IMPELLER NDE IMPELLER HSG DE IMPELLER HSG NDE SHAFT LH THR D BRG HSG GRSBL BRG OIL SEAL BRG HSG GREASE FITTING BRG HSG CAP END DE GRSBL CAP END GRSBL NDE CROSSOVER PIPE TIE ROD DE TIE ROD NDE IMP LK NUT LH THD IMP NUT LH THD IMP LK NUT RH THD IMP NUT RH THD FLINGER SPACER BRG SPACER SHAFT SEAL GASKET FLANGE CROSSOVER SHAFT SEAL LR ATTENUATION VALVE O RING BRG HSG BRG DOUBLE ROW ANGULAR CONTACT BRG SINGLE ROW CONRAD BRG LOCKNUT KEY DE IMPELLER KEY NDE IMPELLER KEY DRIVE SHAFT STUD CROSSOVER HEX HD CAP SCR BRG HSG HEX HD CAP SCR BRG HSG CAP HEX SOC CAP SCR END PLATES s HEX NUT RODS amp CROSSOVER PLAIN WASHER TIE RODS amp CROSSOVER LOCKWASHER BRG HSG LOCKWASHER BRG HSG CAP HHBSHG ATTENUATION PPG CTSK CTR HSG PPG HEXS VACUUM RELIEF VALVE PIPE NIPPLE SEALANT INLET PIPE NIPPLE ATTENUATION ELB 90 SEALANT ELB 90 ATTENUATION 00 ITEMS NOT SHOWN R
17. E DISASSEMBLY ASSEMBLY If the pump is to be idle for an extended period of time it should be preserved internally to prevent rust if the sealant liquid is water or water soluble liquids The pump can be preserved temporarily 2 to 3 months by adding a water soluble rust inhibitor into the DE Shaft seal replacement pump For longer periods of preservation drain the pump by Stage only removing the drain plugs When the draining is completed and all Total Disassembly drain plugs have been replaced fill the pump to 1 3 to 1 4 full using Shell Oil Company VSI SAE 25 SAE 33 or SAE 37 be used or Antifreeze Rotate the pump by hand to coat the interior of the pump with oil NDE Shaft seal replacement NDE Stage only SPARE PARTS Figures 11 12 13 and 14 are cross section views of the pumps represented in this manual A set of recommended spare parts for each pump model operating should be available as initial spare parts When ordering parts the pump nameplate information must accompany the order along with the part reference number and name DISASSEMBLY GENERAL KLRC liquid ring pumps incorporate two sets of tie rods which fasten either stages or ends of the pump to the center housing This allows independent work on each stage The stages are referred to as drive end DE and non drive end NDE For models 100 through 525 the suction flange and the longer first stage are located at the drive end and th
18. EAL GREASE FITTING CAP BRG HSG DE CAP BRG HSG NDE TIE ROD DE TIE ROD NDE DE IMPELLER NUT LH DE IMPELLER LOCK NUT LH NDE IMPELLER NUT RH NDE IMPELLER LOCK NUT RH FLINGER SPACER BRG SHAFT SEAL LR ATTENUATION VALVE 1 4 NPT O RING VITON BALL BRG DOUBLE ROW BALL BRG SINGLE ROW BRG LOCKNUT KEY DE IMPELLER KEY NDE IMPELLER KEY DRIVE SHAFT HEX HD CAP SCR BRG HSG HEX HD CAP SCR BRG HSG CAP HEX SOC CAP SCR ENDPLATES HEX NUT TIE RODS PLAIN WASHER TIE RODS LOCKWASHER BRG HSG LOCKWASHER BRG HSG CAP PIPE PLUG SQ DRAIN PPG CTSK CTR HSG PPG HEX SOC IMPELLER HOISINGS PPG HEX SOC SHAFT SEALS PPG CTSK DE END CASING HEX HD BSHG ATTENUATION VALVE ITEMS NOT SHOWN RECOMMENDED SPARE PARTS 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 4 4 1 1 1 1 2 1 2 1 2 1 1 1 1 1 1 8 6 4 8 8 8 6 3 2 2 2 1 1 25 ME vk ut a mp RR 2 E 4 T p TAT mH WESCE T J J o IIIT eos oa oe oo serene 11 1 M P vm WE pbi l IINA GAL Me NI SF N r STS DHTM 01 001 2813 UOHJ9S 5501 1 26 CAST IRON 100 525 KLRC ASSEMBLY PARTS LIST DESCRIPTION END CASING D
19. ECOMMENDED SPARE PARTS 27 aa Ne k 1 ea la paon N AE um THE js a W lie E alla n PE e ar o amat un god ong was el rar ara E ie bero et ast i tt DEN f 77 B i pu oaa ria Nas c gt ow a f a E E EA ssi j 3 fil Met Tu 4 H iw M E la m nni E ET _ 3 a Pe diii 5 4 21 L i g m IL 13 1 827 H 11 AP F XXX c z ORE ODE 08 007 082 55 1 lt STS 01 001 2H 1M uonoes SSOID pL 28 STAINLESS STEEL 100 525 KLRC GASKETED ASSEMBLY PARTS LIST DESCRIPTION END CASING DE END CASING NDE END PLATE DE END PLATE NDE CTR HOUSING IMP DE IMP NDE IMPELLER HSG DE IMPELLER HSG NDE GASKET SET SHAFT LH THR D BRG HSG GRSBL BRG OIL SEAL BRG HSG GREASE FITTING BRG HSG CAP END DE GRSBL CAP END GRSBL NDE CROSSOVER PIPE TIE ROD DE TIE ROD NDE IMP LK NUT LH THD IMP NUT LH THD IMP LK NUT RH THD IMP NUT RH THD FLINGER SPACER BRG GASKET FLANGE CROSSOVER SHAFT SEAL LR ATTENUATION VALVE O RING BRG HSG BRG DOUBLE ROW ANGULAR CONTACT BRG SINGLE ROW CONRAD BRG LOCKNUT KEY DE IMPELLER KEY NDE IMPELLER KEY DRIVE SHAFT STUD CROSSOVER HEX HD CAP SCR BRG HSG HEX HD CAP SCR BRG HSG CAP HEX SOC CAP SCR END PLATES HEX NUT TIE RODS amp CROSSOVR PLAIN WASHER TIE RO
20. Loctite Corp Permatex Aviation Form A gasket liquid sealant 3H thinning solvent Denatured Alcohol b Stainless steel pumps CD3 are assembled with PTFE glass filled gaskets in lieu of sealant 16 Note Iron pumps designated for Hot Operation 220 F Limit assembled with paper shims and Gasket liquid sealant 3H c Sealant when used must be applied lightly on one surface of joint with a small stiff brush The sealant can must be capped when not used to avoid solvent evaporation If needed use listed thinner to maintain original fluid consistency d Assembly should proceed without interruption until tie rods for the pump are half tightened to prevent early setting of sealant e The following torque values ft Ibs apply for fasteners Always replace the end plate screws use new stainless steel cap screws with nylon locking inserts DO NOT REUSE THE OLD SCREWS f For installation with multiple pumps and in house repair it is helpful to have cast iron dummy bearings with outside diameter 001 smaller than inside diameter 001 larger than and width equal to the NDE ball bearing g Ball bearings for pump models HT as shown on the nameplate prior to August 1998 are lubricated with special high temperature grease and are etched on the outside diameter Spec lube They should not be replaced with standard bearings PUMP MODEL END PL SCREWS TIE ROD NUTS BRG HSG SCREWS 40 75 100 125 200 300 525 950
21. Manual 4804 2 KINNEY KLRC SERIES Liquid Ring Vacuum Pumps M d KLRC 40 KLRC 75 KLRC 100 KLRC 125 KLRC 200 OQEIS KLRC 300 KLRC 525 KLRC 526 KLRC 950 KLRC 951 INSTALLATION OPERATION MAINTENANCE REPAIR MANUAL WARNING DO NOT OPERATE BEFORE READING MANUAL ws ID Tuthill WA Ne 4840 West Street O Box 2877 ML Springfield Missouri USA 65801 2877 AL Qua Tel 417 865 8715 800 825 6937 Fax 417 865 2950 www tuthillvacuumblower com 08 2012 e DO NOT VALVE OR RESTRICT PUMP DISCHARGE OPENING USE OIL MIST ELIMINATOR WHEN OPERATING PUMP ENSURE ADEQUATE VENTILATION WHEN DISCHARGING INDOORS sill DO NOT OPERATE WITHOUT BELT GUARD REFER TO MANUAL SAFETY INSTRUCTIONS NOTICE The above safety instruction tags were permanently affixed to your pump prior to shipment Do not remove paint over or obscure in any manner Failure to heed these warnings could result in serious bodily injury to the personnel operating and maintaining this equipment SAFETY PRECAUTIONS FOR LIQUID RING PUMPS Please read the following safety information on this page before operating your vacuum pump Please read the following safety information on this page before operating your vacuum pump Do not operate the pump without the coupling or belt guard properly attached Disconnect the pump motor from the electrical supply at the main disconnect
22. N 4 MODELS COVERED BV THIS MANUAL 4 NAMEPLATE DATA 4 SUITABLE APPLICATIONS 4 AVOID DAMAGE TO THE PUMP 4 SPECIFICATION TABLE TABLE 1 5 THEORY OF OPERATION 5 PROPERTIES OF SEALANTS 5 SEALANT TEMPERATURE 6 INSTALLATION 6 GENERAL 6 DIRECT COUPLED DRIVE 6 V BELT DRIVE 6 SEALANT RECOVERY SYSTEMS 7 ONCE THROUGH RECOVERY 7 PARTIAL SEALANT RECOVERY PSR 8 SEALANT PIPING 10 SEALANT FLOW CONTROL 10 COOLING PIPING FOR MECHANICAL SEALS 10 MANIFOLD PIPING 11 ELECTRICAL CONNECTIONS 11 SYSTEM COMPONENTS 11 INLET AIR EJECTORS 12 OPERATION 12 STARTING THE PUMP 12 PRESTART CHECKS 13 INITIAL START UP 13 PROCEDURE FOR MINIMUM SEALANT FLOW RATE 13 STOPPING THE PUMP 14 MAINTENANCE 14 GENERAL 14 SHAFT BEARINGS 14 SCALE OR RUST ACCUMULATION 15 MECHANICAL SHAFT SEALS 15 PREPARATION FOR STORAGE 15 SPARE PARTS 15 DISASSEMBLY 15 GENERAL 15 DISASSEMBLY PROCEDURE 15 REASSEMBLY 16 GENERAL 16 REASSEMBLY PROCEDURE 17 ASSEMBLY DRAWINGS amp PARTS LISTS 23 31 WARRANTY VACUUM PRODUCTS 32 INTRODUCTION CONGRATULATIONS on your purchase of a new KINNEV KLRC Liquid Ring Vacuum Pump from Tuthill Vacuum amp Blower Systems Please examine the pump for shipping damage and if any damage is found report it immediately to the carrier If the pump is to be installed at a later date make sure it is stored in a clean dry location and rotated regularly Make sure covers are kept on all openings If the pump is stored outdoors be sure to protect it fro
23. NDE ENDPLATE DE ENDPLATE NDE CENTER HOUSING IMPELLER DE IMPELLER NDE IMPELLER HOUSING DE IMPELLER HOUSING NDE SHAFT BEARING HOUSING LIP SEAL GREASE FITTING END CAP DE END CAP NDE CROSSOVER PIPE TIE ROD DE TIE ROD NDE IMPELLER LOCK NUT LH M80X1 5 IMPELLER NUT LH M80X1 5 IMPELLER LOCK NUT RH M80X1 5 IMP NUT RHTHD FLINGER BEARING SPACER 4 RING GASKET MECHANICAL SEAL BALL VALVE 75 O RING BEARING BEARINGLOCKNUT IMPELLER KEY SQUARE KEY 5 X 3 25 IN 100 HEXBOLT 625 11 X 2 5 HEXBOLT 625 11 X 2 HEXBOLT 375 16 X 1 25 HEX SOCK CAPSCREW 375 16 X 1 HEXNUT 75 FLATWASHER 75 LOCKWASHER 625 LOCKWASHER 375 HEX REDUCING BUSHING FLATWASHER 625 PIPE PLUG SQUARE SOCK 1 25 PIPE PLUG HEX SOCK 5 PIPE PLUG SQUARE SOCK 1 5 NIPPLE 1 5 NIPPLE 75 ELBOW 1 50 NPT STREET ELBOW HEXNUT 625 ITEMS NOT SHOWN 31 NOTES 32 NOTES 33 WARRANTY VACUUM PRODUCTS Subject to the terms and conditions hereinafter set forth and set forth in General Terms of Sale Tuthill Vacuum amp Blower Systems the sell
24. Table 2 chemical content should be evaluated since certain conditions will affect the service life of the WATER VAPOR pump Generally if water is suitable to drink it is suitable for pump use Hardness greater than SEALANT PRESSURE 500 PPM will result in internal plating and fouling of pump parts Service with hardness of less TEMPERATURE F TORR than 500 PPM depends upon operating temperature and the nature of the mineral deposit Naturally occurring well water with organic acid of pH 5 or higher is generally suitable however pH of 7 or higher is preferred Chemically treated water with sulfur content requires pH 7 or more Water which has a pH less than 5 should be treated or the pump should have special materials of construction If internal scaling affects performance a water treatment specialist should be consulted Tuthill Vacuum amp Blower Systems recommends that sealants and sealant systems be carefully evaluated and we invite you to discuss them with your Tuthill Vacuum amp Blower Systems Sales Professional or our Application Engineers SEALANT TEMPERATURE The rated capacity ACFM of a pump is based upon the use of incoming seal water at 60c F Seal water temperature affects the pump capacity Table 2 provides data which when applied to the below formula will give the pumping capacity on dry air at water temperature other than 60 F To calculate pumping capacity or to approximate the capacity
25. and tight then hammer tap until solid resistance is felt Install DE bearing cap with lock washers and screws NOTE On atypical KLRC repair the factory shim setting should be reused In the event that the shim is damaged a shim of the same size can be ordered from the factory of that exact size see Section 9 0 NDE ASSEMBLY PREPARATION Invert the pump assembly on the assembly stand Remove the temporarily installed bearing housing bearing cap and dummy or ball bearing Note If continuing with a complete reassembly skip to Step 7 if only reassembling the NDE side go to Step 6 0 below If the center housing and DE impeller housing were removed follow assembly steps 3 2 3 5 to reinstall Position the NDE impeller housing for correct match with center housing and DE impeller housing then apply sealing compound to the matching end and install with a slight rotating movement while aligning the cast in index marks Note if If the NDE endplate was removed from the NDE end casing reassemble it as in Step 2 1 Place the NDE end casing plate assembly on top of the impeller housing with tie rods entering the bolt holes and align the index marks Assemble washers and nuts to tie rods and lightly tighten them Install the single row ball bearing on shaft and seat into bearing housing To avoid relative displacement of inner and outer bearing races with slight interference fit use a bearing driver as shown in Figure 13 Then install NDE bear
26. arge separator Conversely if the system has a large amount of condensables and is adding liquid to the gas liquid discharge separator the above valve and switch can be used to activate a drain valve to lower the liquid level in the discharge gas liquid separator When sustained operation is required above 400 Torr or with rapid cycling on small volumes an optional circulating pump is recommended This will also apply for long roughing cycles Also if the pump RPM is below standard 1750 RPM the use of a circulating pump should be considered High sealant viscosity and low specific heat and density may require a greater sealant recirculation rate and the use of a circulating pump COOLING PIPING FOR MECHANICAL SEALS Sealant must be piped to the mechanical seals in order to keep the seal faces cooled and lubricated The seals will fail if a suitable flow of sealant is not supplied The sealant must be clean and free of particulates dirt or grit will cause the seal faces to wear and fail prematurely Connect the sealant piping to the seals as shown in Figures 2 to 5 Note that the connections to the pump are different for KLRC 40 and 75 compared to the KLRC 100 to 950 MANIFOLD PIPING 10 The suction and discharge ports distinguishable arrows on the pump also shown Figures 2 to 5 Note that the discharge port on the KLRC 40 and KLRC 75 are at the shaft drive end whereas on the KLRC 100 to KLRC 950 the discharg
27. before removing the coupling or belt guard Replace the coupling or belt guard before reconnecting the power supply to the pump motor Operating the pump without the coupling or belt guard properly installed exposes personnel in the vicinity of the pump to risk from rotating drive components CAUTION Do not operate the pump with oxygen enriched gas in the suction line unless the pump has been properly cleaned inspected and certified to be free of hydrocarbon presence and prepared with an inert fluid suitable for the application Oxygen enriched gas is defined as gas of which the constituents include by volume mol 96 an amount of oxygen greater than that of standard atmospheric air typically 20 2196 by volume If the oxygen content in the gas stream exceeds the proportions found in standard atmospheric air then it is considered an oxygen enriched gas and standard mineral oil synthetic hydrocarbon oil or other non inert fluids should not be used WARNING Pumping oxygen enriched gases with mineral oil synthetic hydrocarbon oil or other non inert fluids can cause fire or explosion in the pump resulting in damage or serious bodily injury or death Take precautions to avoid prolonged or excessive exposure to oil mist or process materials emanating from the discharge of the pump Do not allow the pump to discharge into a closed or inadequately ventilated room Laws and ordinances may pertain to your local area regarding discharge of vapor to
28. d ring pump should start immediately Turn on the sealant water Adjust the anti cavitation valve to obtain best vacuum level without cavitating the liquid ring vacuum pump Check that the sealant flow to the mechanical seals is adequate Check that the cooling water flow to the liquid ring heat exchanger is adequate by checking the sealant temperature Check the sealant level in the separator tank If necessary add remove fluid PROCEDURE FOR MINIMUM SEALANT FLOW RATE The requirements for sealant flow as shown in Specification Table on Page 5 are the maximum GPM for once through partial and full recovery systems To determine the minimum quantity of sealant flow required for a specific application proceed as follows For once through and partial sealant recovery systems with the pump on a system and operating at the desired operating inlet pressure slowly decrease the flow of sealant liquid until the inlet pressure begins to fluctuate and then gradually increase the flow until the pressure again becomes steady This is the setting to be used for minimum seal flow as long as operating conditions remain constant Cavitation occurs when there is localized boiling of the sealant This boiling action causes the formation and collapse of vapor bubbles and the resultant shock forces cause erosion by tearing out metal particles The damage can be especially severe in corrosive environments A loud rumbling sound i
29. does not occur b The vapor pressure of the sealant must be compatible with the desired process pressure c Specific gravity should be between 0 5 and 2 d Specific heat should be between 0 3 and 1 e Viscosity should be 45 cst at sealant operating temperature 6 After filling the liquid ring pump and recovery system with sealant to the proper level position the manual valves for start up a Check that the globe valve located in the sealant line between the heat exchanger and the liquid sealant b Check that the two small valves located in the seal cooling lines leading to the mechanical seals on the liquid ring pump are both fully opened These valves may be throttled down to halfway open later if slightly higher vacuum is desired or if sealant pressure is high Under no circumstances should the valves be closed more than one half way 7 On initial start up or if the pumps have been sitting idle for several weeks rotate the pumps by hand several rotations to be sure that they are mechanically free 8 the motor to check the proper direction of rotation Facing the drive shaft of each pump The KLRC 40 amp KLRC 75 liquid ring pumps rotate counter clockwise All other models rotate clockwise INITIAL START UP 1 Turnon the main power by closing the external fusible disconnect switch or circuit breaker Check that all isolation and discharge valves if fitted are in the proper position Push the START button The liqui
30. e discharge flange and shorter second stage are located at the non drive end For models 40 and 75 which do not have a crossover pipe the suction flange and first stage are located at the non drive end and the discharge flange and second stage are located at the drive end Repair on the pump is most easily accomplished with the pump axis in a vertical position Adequate support is provided by pump stands as shown in Figure 8 Disassemble a pump only to the extent necessary for repair Applicable disassembly assembly steps are as follows DISASSEMBLY PROCEDURE Remove pump from installation and drive coupling with drive key from pump shaft Drain sealant fluid from pump by removing all 1 4 NPT drain plugs 1 NDE SHAFTSEAL 1 1 Position pump vertically on support stand NDE up 1 2 Remove NDE bearing housing 1 3 Remove bearing housing flange screws and use two in threaded holes to push off bearing housing 1 4 Remove the loose elastomer flinger the shaft seal seat and the ball bearing from the bearing housing 1 5 Remove the shaft seal head from the shaft Because various shaft seal tvpes with different length can be used in the seal cavitv some seals require the use of seal spacer washers between seal head and impeller locknut For identical seal replacement these spacers must be reused 15 Note a For NDE shaftseal replacement only continue with Reassembly Step 7 b For disassembly of the NDE stage only or cornp
31. e impeller nut for use with the John Crane shaft seal standard in cast iron pumps Kinney version FA and BA No spacer is used with Flowserve shaft seal standard in stainless steel pumps Kinney version CD or optionally in cast iron pumps for example FD2 models Remove carbon from seal head Kinney style A only John Crane Type 21 and push seal elastomers boot onto a very lightly greased vacuum grease shaft against the washer then re install carbon with proper notch alignment When installing Kinney style D Flowserve type RO assure that the drive dowel pin is aligned with and enters the clearance hole in the impeller locknut Install the shaftseal seat with lightly greased vacuum grease seal element and lapped surface facing out into the DE bearing housing with attached pump narneplate Place O ring into bearing housing flange groove Insert flinger into housing gap and install both on shaft and against end housing assure proper seating the shaftseal spring compression will give some resistance and install bolts with lockwashers torque per the Specification Table on Page 5 Install bearing spacer washer on shaft Washer thickness is stamped on front of DE bearing housing for example 57 would indicate 057 thick bearing washer Install the double row ball bearing on shaft and into housing using proper tooling Install bearing locknut with spanner wrench while holding shaft with another spanner wrench in the drive keyway until h
32. e port is at the non drive end The discharge leg should not have more than 24 inches of elevation from the pump discharge flange Too much elevation in this line would cause a build up of back pressure overload the motor and reduce the efficiencv of the pump During initial operation a screen should be installed across the incoming port of the suction end casing to prevent abrasive particles from entering the pump The accumulation in the screen should be removed often enough to prevent restriction of gas flow and the screen can be removed when particulate accumulation no longer occurs CAUTION Newly installed manifolding must be clean leak free and free of any weld slag When the process produces particulates which could damage the pump a suitable suction line filter must be used CAUTION The pump liquid sealant must not be allowed to freeze in the piping or pump ELECTRICAL CONNECTIONS Standard electrical motors supplied with Kinney Liquid Ring Pumps are three phase 230 460 volts 60 Hz across the line operation Pump starting loads are low as null load is developed at maximum RPM Reduced voltage when starting is not required unless the power use is restricted by the plant power supply Connect the pump motor and all applicable electrical accessories to a motor controller that has over current protection heaters or fuses based on the full load current multiplied by the service factor as stamped on the nameplate There should also be a sui
33. er warrants products and parts of its manufacture when shipped and its work including installation and start up when performed will be of good quality and will be free from defects in material and workmanship This warranty applies only to Seller s equipment under use and service in accordance with seller s written instructions recommendations and ratings for installation operating maintenance and service of products for a period as stated in the table below Because of varying conditions of installation and operation all guarantees of performance are subject to plus or minus 596 variation Non standard materials are subject to a plus or minus 10 variation PRODUCT TYPE WARRANTY DURATION New 15 months after date of shipment or 12 months after initial startup date whichever occurs first 6 months after date of shipment or remaining warranty period whichever is greater Remanufactured 9 months after date of shipment or 6 months after initial startup date whichever occurs first THIS WARRANTY EXTENDS ONLY TO BUYER AND OR ORIGINAL END USER AND IN NO EVENT SHALL THE SELLER BE LIABLE FOR PROPERTY DAMAGE SUSTAINED BY A PERSON DESIGNATED BY THE LAW OF ANY JURISDICTION AS A THIRD PARTY BENEFICIARY OF THIS WARRANTY OR ANY OTHER WARRANTY HELD TO SURVIVE SELLER S DISCLAIMER All accessories furnished by Seller but manufactured by others bear only that manufacturer s standard warranty claims for defective products parts or work under thi
34. he svstem This information is also helpful when ordering spare parts Model No V Belt Size Length Serial No Tvpe of Lubrication Startup Date Pump RPM Operating Vacuum Pump Sheave Diameter Anv other special accessories supplied or in use Motor Sheave Diameter Motor RPM HP NOTES IMPORTANT All vacuum pumps manufactured by Tuthill Vacuum amp Blower Systems are date coded at time of shipment In order to assure you of the full benefits of the product warranty please complete tear out and return the product registration card below or you can visit our product registration web page at http vacuum tuthill com product registration r IMPORTANT vacuum pumps manufactured Tuthill Vacuum Blower Svstems are date coded at time of shipment In order to assure vou of the full benefits of the product warrantv please complete tear out and return this product registration card Location City State Province ZIP Postal Code Country Telephone PLEASE CHECK ONE E mail Vacuum Furnace o Model Vacuum Coating Pharmaceutical Serial Number Semiconductor Electronics o Food Meat Packing Gas Petrochemical o Other Date of Purchase Date of Startup NO POSTAGE NECESSARV IF MAILED INTHE UNITED STATES BUSINESS REPLV MAIL FIRST CLASS MAIL PERMIT
35. id ring pump alone with no increase in horsepower The operation of the air ejector is similar to that of a water eductor except that ambient air or recirculated discharge gas is used to provide the motive force for compressing the process gas from system pressure to the liguid ring pump inlet pressure The liguid ring pump handles both the process gas and the motive gas m 5 5 z With an air ejector a suction pressure as low as 3 Torr can be achieved Using an air ejector the pumping capacity between cut in and 10 Torr is about 60 of the pumping capacity at 100 Torr without the air ejector To increase the pumping capacity above 30 Torr an air shutoff valve may be added To achieve the full pumping capacity of the liquid ring pump above 30 Torr a valved by pass may also be added Thus the inlet air ejector can be combined with a liquid ring pump in three ways e Air ejector only Air ejector with motive air shutoff valve manual or solenoid Air ejector with motive air shutoff valve and bypass manifold with valve The standard air ejector is cast iron with a series 300 stainless steel nozzle All stainless steel ejectors are available upon request OPERATION CAUTION Standard pumps with stainless steel impellers designated with material codes F or C are suitable for operation with sealant temperatures up to 160 F Bronze impeller pumps designated with material code B and pumps with HT following the m
36. ing Driver Tool INCHES KLRC 40 12 3 8 16 KLRC 75 100 139 16 3 8x16 KLRC 125 15 15 16 3 8x16 KLRC 200 Cold Rolled Steel 1411 16 3 8 16 KLRC 300 18 5 8 3 8x16 KLRC 525 25 1 4 1 2x 13 20 KLRC 950 35 5 8x 11 Figure 10 Foot Alignment Tool NOTES AlHNJES Y Tw3ELIJWHS OLE 057 DEE 0 4 OF LE 08 OFF 008028 05 08 DOE OE T E 111 An 06 ore OFF PUE s 5 58 25 BI OCF te DEL OSE OL OF OF USE 58 08 lt 8 OV DHIM 55042711 9061 22 CAST IRON 40 75 KLRC ASSEMBLY PARTS LIST DESCRIPTION END CASING NDE END CASING DE END PLATE DE END PLATE NDE CTR HOUSING IMPELLER DE IMPELLER NDE IMPELLER HSG DE IMPELLER HSG NDE SHAFT BEARING HOUSING OIL SEAL GREASE FITTING CAP BRG HSG DE CAP BRG HSG NDE TIE ROD DE TIE ROD NDE DE IMPELLER NUT LH DE IMPELLER LOCK NUT LH NDE IMPELLER NUT RH NDE IMPELLER LOCK NUT RH FLINGER SPACER BRG SPACER SHAFT SEAL SHAFT SEAL LR ATTENUATION VALVE 1 4 NPT O RING VITON BALL BRG DOUBLE ROW
37. ing cap 6 CENTER HOUSING AND NDE STAGE 6 1 6 2 If the NDE impeller was removed from shaft reassemble as in Step 1 1 6 3 the unit is stainless steel use PTFE glass filled gaskets in lieu of sealant 6 4 6 5 6 6 For alignment of feet and tie rod torque nuts follow Steps 2 5 and 3 5 7 NDE SHAFTSEAL AND BEARING HOUSING 7 1 Shaft seal spacer washers follow Step 4 2 7 2 For seal head assembly follow Step 4 3 7 3 For NDE bearing housing assembly follow step 4 4 7 4 with lock washers and screws 8 CROSSOVER PIPE 8 1 18 Assemble crossover pipe with gaskets to both end casings facing the drive end to the left DE end casing flange and the diagonal NDE end casing flange Within the available play of the studs in the flange holes match the flange outside diameters as best as possible 9 CLEARANCE CHECK AND ADJUSTMENT If replacement of casings or housings end center or bearing occur during the repair of a KLRC pump shim thickness will need to be re checked Included in the KLRC repair kits is one shim of the largest size this can be ground to the dimension to achieve the same result Dummy bearings will be required to accomplish this task dummy bearings should be made based on the dimensions of the bearings supplied for the pump model less 002 OD and increased by 002 in ID Mild steel or an equivalent material is acceptable for this It may be advantageous to provide threaded holes to aid in removal of the dummy bea
38. lete disassembly continue with Disassembly Step 2 0 2 NDE STAGE 2 1 Remove the crossover pipe at connecting flanges 2 2 Remove NDE tie rod nuts and lift off the NDE end casing Remove the endplate from the end casing only if it needs to be replaced 23 Remove the impeller housing Note Verify that further disassembly is necessary if a The impeller nut and locknut are not secure b The impeller has to be replaced or requires a major cleaning c If the center housing has to be replaced it can be removed by following steps 2 4 2 6 However if a complete pump disassembly is required temporarily reassemble the impeller housing and end casing with three or four tie rod nuts then invert the pump and continue with step 3 2 4 Loosen and remove the impeller lock nut then loosen and remove the impeller nut thin nut Note the threading KLRC 40 amp 75 Left Hand Thread CW toloosen KLRC 100 950 Right Hand Thread CCW to loosen 2 5 Lift off the impeller and note the direction of the blade for reassembly 2 6 Remove center housing by disassembling tie rod nuts at the DE end casing 3 DE SHAFTSEAL 3 1 Position pump vertically on support stand DE up 3 2 Remove DE bearing housing cap and bearing lock nut with a spanner wrench 3 3 Remove DE bearing housing with nameplate Same as Step 1 3 3 4 Remove the loose elastomer flinger the shaft seal seat the double row ball bearing and bearing spacer from the bearing housing
39. losed loop sealing configuration that employs a heat exchanger water or air cooled to maintain proper sealing fluid temperature See Figure 4 for piping arrangement This arrangement is not suitable for prolonged operation at pressure above 400 Torr unless a circulating pump is installed Full liquid recovery systems often operate under conditions where condensation would cause the liquid level to rise making it necessary to drain liquid from the unit in order to maintain the liquid level The opposite condition can exist whereby liquid evaporation makes it necessary to add makeup liquid to maintain the liquid level If there are extensive piping fittings and valves and other restrictive devices in the sealant line on a full recovery system that does not use a circulation pump the sealant liquid is induced into the pump under pump suction entirely For sustained operation above 400 Torr on rapid cycling of pump down from atmosphere a circulation pump may be required A circulation pump when added to a full recovery system maintains proper sealant flow at all inlet pressure conditions The pressure on the sealant gauge will vary depending upon the inlet pressure from several inches of vacuum to a slightly positive pressure The optional components are described on pages 14 and 15 Normally a common supply line is used for both seal liquid and mechanical seal cooling The optional components are described on page 11 0 KLRC 100 TO 950
40. m weather and corrosion KINNEY KLRC vacuum pumps are built to exacting standards and if properly installed and maintained will provide many years of reliable service We urge you to take time to read and follow every step of these instructions when installing and maintaining your pump We have tried to make these instructions as straightforward as possible We realize getting any new piece of equipment up and running in as little time as possible is imperative to production WARNING Serious injury can result from operating or repairing this machine without first reading the service manual and taking adequate safety precautions IMPORTANT Record the pump model and serial numbers in the OPERATING DATA form on the last page of this manual You will save time and expense by including this reference identification on any replacement part orders or if you require service or application assistance MODELS COVERED BY THIS MANUAL This manual contains installation operation and maintenance procedures for KLRC 40K to KLRC 951K The nameplate on the pumps provides a letter coding for pump material and shaft seal type in the suffix following the KLRC model number NAMEPLATE DATA The first letter designates the standard materials of construction B Cast Iron casing bronze impellers 316 stainless steel shaft and steel trim F Cast iron casing with stainless steel 316L impellers and 316 Shaft and steel trim C All stainless steel 316L pump except for the
41. ocking bend as at step 1 1 Shaft rotation should be prevented 17 32 3 3 3 4 3 5 3 6 with spanner wrench at the drive end keyway This washer is found on the old style KLRC pump only Apply sealing compound to the matching end of the DE impeller housing for 100 525 models with two male ends align tooling tabs with those on the NDE impeller housing and install it aligning the top index marks on the center housing Note for stainless steel models use PTFE glass filled gaskets in lieu of sealant If the DE endplate with shaped suction and discharge ports for models 100 525 and one discharge port for models 40 75 was removed from the DE end casing follow Step 2 1 for its assembly Place the DE end casing plate assembly on top of the impeller housing with tie rods entering the bolt holes and align index marks Assemble washers and nuts to tie rods and lightly tighten them To assure correct alignment of the feet of both end casings an alignment bar as shown in Figure 14 can be bolted to the end casing feet to get correct radial alignment Then loosen one bolt lightly and tighten the tie rod nuts as in Step 2 5 The sealant fluid supply pipe elbow must be installed if it was removed DE SHAFT SEAL AND BEARING HOUSING 4 1 4 2 4 3 44 4 5 If the lip oil seal has been damaged during the disassembly process replace it at this time using the proper tooling Install shaft seal spacer washer on the shaft against th
42. odel designation on the nameplate are suitable for operation with sealant temperatures to 220 F Operation with sealant at higher temperatures reduces internal clearances and will cause the pump to fail Alr Valve The pump performance curves are shown on the KLRC series data in ren sheets which can be viewed at our site http vacuum tuthill com The Manifold fox temperature of the sealant is a major factor determining the base Roughing pressure influences the pumping speed At lower temperatures the pump capacitv increases and at higher temperatures the pump Optional capacity decreases The temperature efficiency ratio is not linear and v lil the most pronounced effect is at low pump pressures Valve with Vacuum Switch When the pump is supplied with sealant water directly from a water main the water regulating valve must be adjusted so that the water enters the pump casing in the order of zero gauge pressure If however the pump operates at a holding pressure above 400 Torr the sealant water pressure should be increased to about 7 PSIG It is generally not recommended to run a liquid pump with the suction open to atmosphere for any period of time as the pump will heat up due to the inability to draw in sealant to dissipate the heat Figure 7 Air Ejector Installation STARTING THE PUMP If the pump has been idle for an extended period of time it is advisable to turn the pump by hand prior to
43. of the pump SHAFT BEARINGS The two shaft bearings should be lubricated every 1500 hours of operation or every two months A high temperature grease with an extreme pressure EP additive is recommended Grease should be added through the grease fitting while the shaft is turning The temperature of the bearings should not exceed 140 F hot to touch unless special grease is being used after consulting Tuthill Vacuum amp Blower Systems 14 SCALE OR RUST ACCUMULATION If scale or rust accumulates and hampers the efficiencv of the pump remove the scale or rust bv circulating an inhibitor selected according to the nature of the buildup MECHANICAL SHAFT SEALS If the mechanical seals leaking they should be replaced or reconditioned Some mechanical shaft seal manufacturers have seal reconditioning program which we recommend where available When replacing the mechanical seal clean the shaft thoroughly where the previous seal may have bonded to the shaft Figures 9 10 11 amp 12 show the mechanical shaft seals that are commonly used on Kinney liquid ring pumps The seal faces must be protected during installation from particles that may scratch the surfaces Before installing the elastomers the shaft and elastomers should be lubricated with a lubricant compatible with the pumping process for ease in installing and better positioning on the shaft CAUTION Do not run the mechanical seal without coolant PREPARATION FOR STORAG
44. orr if the pump should operate for an extended period of time a minimum of 7 PSI pressurized sealant would be required The Specification Table on Page 5 provides the flow rates of water at 60 F required for standard pumps at standard conditions Recommended flow rates should provide an overall temperature rise of 10 F in a water sealed pump Sealant flow rates and temperatures represent important considerations because of their effect on the heat balance of the pump If the pump must operate over a broad vacuum range flow rates are especially important With too little water the unit will not pump at full capacity at higher vacuums and with too much water the horsepower requirement will be excessive in the low vacuum range Acceptable variations in flow rates shown in the Specification Table on Page 5 are on the order of 10 with no sealant recover system to 25 to 5096 with partial sealant recovery systems Full recovery systems have an optional sealant circulating pump that may be necessary if sustained operation above 400 Torr is anticipated SEALANT FLOW CONTROL Sealant flow Shaft Seal flow The types of devices used to control the sealant flow depend upon orifice controller A orifice controller B the sealant arrangement used the size of the pump and individual NPT preference A low cost constant flow control device is generally used for no recovery systems and for the supply branch of partial recovery systems Another method i
45. r problems resulting from build up of material within the unit nor for problems due to incompatibility with the materials of construction Any improper use operation beyond capacity substitution of parts not approved by Seller or any alteration or repair by others in such manner as in Seller s judgment affects the product materially and adversely shall void this warranty No employee or representative of Seller other than an Officer of the Company is authorized to change this warranty in any way or grant any other warranty Any such change by an Officer of the Company must be in writing The foregoing is Seller s only obligation and Buyer s only remedy for breach of warranty and except for gross negligence willful misconduct and remedies permitted under the General Terms of Sale in the sections on CONTRACT PERFORMANCE INSPECTION AND ACCEPTANCE and the PATENTS Clause hereof the foregoing is BUYER S ONLY REMEDY HEREUNDER BY WAY OF BREACH OF CONTRACT TORT OR OTHERWISE WITHOUT REGARD TO WHETHER ANY DEFECT WAS DISCOVERED OR LATENT AT THE TIME OF DELIVERY OF THE PRODUCT OR WORK In no event shall Buyer be entitled to incidental or consequential damages Any action for breach of this agreement must commence within one 1 year after the cause of action has occurred January 2002 34 OPERATING DATA It is to the user s advantage to have the requested data filled in below and available in the event a problem should develop in the vacuum pump or t
46. ring NOTE If a shim change is required on a hot pump or stainless steel pump please contact the factory for further information The required shim dimension can be found as follows 1 Move the shaft of the assembled pump fully towards the NDE of the pump 2 With the bearing cap removed using a depth micrometer measure to the dummy bearing from the bearing housing surface Record the reading With the assistance of a gear puller push the shaft completely towards the DE of the pump 3 Using a depth micrometer measure to the dummy bearing and record the reading gt Subtract the smaller reading from the larger this number is the total clearance of the pump 5 The shim size is one half of the total clearance within the pump 4 B KLRC 40 through fore KLRC 525 ITEM 1 ITEM 2 Cut or burn slot s on this of the pipe i R 0 375 A i j 5 Ldn RAD i TVP 2 Places all around pipe KLRC 950 Siot TYPA Places SLOT S CUTOUT S 7 SCH 40 L 28 4 Wide x 2 Deep 2 E Slot TYP 2 Places 3 Wide x 2 Deep Slot TYP 2 Places 12 SCH 40 B 22 lt hd 3 wide x 1 Deep Slot 174 Wide x 1 Deep Slot TYP 2 Places 7 8 SCH 40 Pipe 1 Wide x 2 Deep 4 Wide x 8 Deep Slot Slot TYP 2 Places 3 wide x
47. s a sign that cavitation is occurring It is easily suppressed by raising the inlet pressure above the vapor pressure of the sealant at its operating temperature by bleeding air or another comparable gas into the suction if opening the attentuation valce cannot be used or does not bleed in enough air 13 When cavitation occurs the pump sounds as though it has gravel in it This noise will commonly occur when the pressure is low and the air or non condensable gas flow is slight Cavitation should be reduced or eliminated by bleeding air into the pump through the attenuation valve If enough air can not be bled into the pump to satisfactorily quiet the pump an air bleed valve should be installed Non condensable gas may be recirculated by adding a return line from the discharge separator tank to the pump inlet bleed valve STOPPING THE PUMP 1 Isolate the pump from the process chamber gt W N Stop pump TROUBLESHOOTING CONDITION Seals Leaking Reduced capacity Excessive noise Overheating Excessive vibration Motor overloaded Abnormal bearing wear Shut off sealant liguid supply See Starting the Pump Shut off cooling sealant to the mechanical shaft seals CAUSE Seal incorrectly installed REMEDY Re install seal Seal worn or damaged Rotational speed too low Replace seal Check supply voltage Vacuum leak Locate and repair High sealant temperature Check coolant flow and temperature
48. s to install an upstream adjusting valve and KLRC 75 an intermediate pressure gauge The valve can then be adjusted to KLRC 100 obtain a specified pressure thus producing the desired sealing flow rate KLRC 125 and gas inlet pressure The latter procedure generallv provides the most economical sealing flow rate To achieve greater water conservation the partial recoverv svstem can be used with optional water miser and the fresh water flow adjusted for the highest operating temperature KLRC 525 1 compatible with the process KLRC 950 1 1 4 GPM L min NPT GPM L min KLRC 40 KLRC 200 KLRC 300 1 With a partial recovery system an optional sealant flow control valve Table 3 Recommended Flow Controllers actuated by sealant discharge temperature may be used to automatically reduce fresh sealant flow when water temperatures are low This will reduce sealant consumption below normal partial recovery flow rates Fresh sealant flow may also be increased to achieve desired cooling and improve pump performance In order to reduce sealant water consumption in once through and partial recovery systems a solenoid valve may be fitted to the sealant supply line This valve will be integral with pump start stop operation thereby opening the sealant supply line during pump start up An automatic sealant make up valve and level switch will allow make up water to be added to maintain a predetermined level in the disch
49. s warranty must be made in writing immediately upon discovery and in any event within one 1 year from date of shipment of the applicable item and all claims for defective work must be made in writing immediately upon discovery and in any event within one 1 year from date of completion thereof by Seller Unless done with prior written consent of Seller any repairs alterations or disassembly of Seller s equipment shall void warranty Installation and transportation costs are not included and defective items must be held for Seller s inspection and returned to Seller s Ex works point upon request THERE ARE NO WARRANTIES EXPRESSED IMPLIED OR STATUTORY WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS OF PURPOSE After Buyer s submission of a claim as provided above and its approval Seller shall at its option either repair or replace its product part or work at the original Ex works point of shipment or refund an equitable portion of the purchase price The products and parts sold hereunder are not warranted for operation with erosive or corrosive material or those which may lead to build up of material within the product supplied nor those which are incompatible with the materials of construction The Buyer shall have no claim whatsoever and no product or part shall be deemed to be defective by reason of failure to resist erosive or corrosive action nor fo
50. ssion segment Gas Inlet Liquid 8 Gas Out The discharged liquid can be recovered and recirculated through the use of a gas liquid separator An attenuation valve is provided to drain sealant from the pump before Gas Entering 3 starting and to bleed air into the purnp to prevent cavitation which occurs Cavitv within Gas Leaving when the pressure is low and the airflow is minimal To additionally protect HiguidRing _ es JI aig against cavitation an optional air bleed valve and or vacuum relief valve can be installed in the suction line Water is normally used as a liquid seal but may be unsuitable for some pump applications Tuthill Vacuum amp Blower Systems should be consulted a Seal Liquid Inlet before changing to a different liquid in the pump Figure 1 Cross Section Liquid Ring Pump PROPERTIES OF SEALANTS Water is the most commonly used sealant in liquid ring vacuum pumps Other fluids may be used to obtain process compatibility In these applications special consideration should be given to the properties of the sealant which may affect pump performance Some of the properties of sealant which should be considered are Specific Gravity Specific Heat e Viscosity e Vapor Pressure Additionally the solubility of process gas in the sealant be of significance and should be VAPOR PRESSURE evaluated especially if the partial or full recovery system is used When water is the sealant its OF WATER
51. t Circulating Fig 5 CAUTION Do not run the pump dry ONCE THROUGH RECOVERY This arrangement takes water directly from the water supply through the pump and discharges it directly through a gas liquid separator tank to an approved drain This arrangement is most common on small pumps in installations where water conservation is not a factor or where contamination of sealant is not a factor Optional valving arrangement is designed to conserve sealant flow and power and when pump is operating at high pressure low vacuum The optional components are described on page 17 KLRC 100 TO 950 er O A UP TIDAL VALM PAINTZ DM SCHEMATIC AI UPPER LEFT Figure 2 Piping Schematic Once Through Recovery System PARTIAL SEALANT RECOVERY PSR The partial recovery arrangement has the pump discharging water and gas into a gas liquid separator tank releasing the gas to atmosphere and retaining the water Some water is disposed through an overflow and the remainder is retained in the separator tank for recirculation Makeup water is added in quantity necessary to maintain proper sealing water temperature This is the most commonly used arrangement where sealing liquid conservation is required The optional components are described on page 11 KLRC 100 TO 950 B a 1 KLRC 40 AND 75 ONLY Figure 3 Piping Schematic Partial Sealant Recovery System FULL SEALANT RECOVERY FSR A full sealant recovery system is a c
52. table disconnect switch between the controller and the power supply After the motor starter and disconnect switch have been installed turn the pump by hand to determine that the impeller s is free to rotate Check the rotation by jogging the motor An arrow on the drive end casing indicates the direction that the pump must rotate If after wiring the motor the pump turns in the wrong direction reverse any two of the power leads to the motor SYSTEM COMPONENTS The following are some of the components available for installation either when the pump is ordered or later to be installed in the field Accessories such as solenoid valves and flow switches can be added to meet particular needs The air liquid separator tank can be either the design that is mounted to the floor or the type that is suspended by the pump manifolding depending upon the application INLET ELBOW Used to adapt vertical pump inlet to horizontal for mounting inlet check valve etc A similar elbow may be used to connect pump discharge separator tank INLET VACUUM GAUGE Used to measure pump inlet vacuum Standard 3 W dial gauge has brass bourdon tube and reads 0 30 Hg The gauge is mounted at the pump suction Stainless is available at an additional cost INLET VACUUM RELIEF VALVE Used to control pump inlet vacuum If pump capacity exceeds the system requirements at a preset vacuum then the valve will open and admit ambient air or connected gas Valve selection is dependent
53. ute sealant if used while lining up the bolt holes Fasten with Nylon pellet or patch screws torque per the Specification Table on Page 5 2 2 Insert the NDE of shaft impeller assembly into the bearing so that the impeller face rests on the end plate A dummy bearing is helpful for an easy fit at this step 23 sealing compound to the male end of the NDE impeller housing for 40 75 models with two male check the cross sectional drawing for correct end and install it aligning the cast in index marks on top of housing and end casing Tap it with a soft hammer for proper searing Then applv sealing compound to the top end face Note for stainless steel models use the PTFE glass filled gasket in lieu of sealant 2 4 Place the center housing with rods drain holes at bottom onto the impeller housing with tie rods entering the end casing holes Align the indexing marks and tap it down 2 5 Assemble washers and nuts to tie rods and tighten in a crisscross pattern in several incremental steps with a clicker torque wrench For example 30 40 ft Ibs The assembly position does not allow easy reading of a dial torque wrench Finally torque per the Specification Table on Page 5 3 DE STAGE 3 1 Install impeller drive key and impeller on shaft looking at the DE of shaft end the impeller blades must be pointing KLRC 40 amp 75 Counterclockwise KLRC 100 950 Clockwise Proceed with retaining washer impeller nut and washer l
54. when using water at other than 60 F the following formulas apply 5 5 133 Where S Actual capacity in at P 5 Pump capacity with 60 F sealant at This data is shown on Data Sheet 4703 P Inlet pressure in Torr P Vapor pressure of sealant at actual sealant temperature INSTALLATION GENERAL Pumps are partially filled with a water soluble rust inhibitor prior to shipment This solution should be drained or flushed from the pump Drain pump by removing drain plugs Liquid ring pump units with pump and motor on a common base can be located on any flat and level flooring suitable for their weight The pumps are almost vibration free and foundation bolting is not normally required Using elastomer machine mounting pads Vibration Controls is helpful to eliminate minor floor vibrations When the base must be bolted to the floor it should be shimmed as necessary to avoid any base distortion DIRECT COUPLED DRIVE Pumps shipped with the pump and motor directly coupled and mounted on a common base have been aligned prior to shipment and normally no further alignment is necessary However alignment should be checked and adjustments made if necessary prior to starting unit Generally when installing flexible couplings the two shafts must be aligned to within 020 of an inch maximum and the coupling halves must be positioned on the shafts to be parallel to each other within 030 of
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