1

EVEREST® ESP-HP

™ SERIES

Dry Vacuum pumps

Models: ESP-HP150 ESP-HP300 ESP-HP400 ESP-HP800

� INSTALLATION

� OPERATION

� MAINTAINANCE

� REPAIR

MANUAL

EVEREST® ESP

™ SERIES MANUAL Ver.2.0.1

EVEREST BLOWER SYSTEMS Innovative Solutions

Head Office: B-44, Mayapuri Industrial Area, Phase-1, New Delhi-110064, India.

TEL: +91-11-45457777 Fax: +91-11-45457718

Email: ebs@everestblowers.com ; Web: www.everestblowers.com

WARNING

DO NOT OPERATE BEFORE

READING THIS MANUAL.

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EVEREST® ESP-HP™ SERIES MANUAL Ver.2.0.1

2012 Everest Group EVEREST VACUUM PUMPS AND SYSTEMS ARE DESIGNED FOR INDOOR INSTALLATION AND SHALL

BE PROTECTED FROM DIRECT SUNLIGHT, RAIN & DUST.

Below IEC warning marks are attached on the pump’s surface.

Warning Risk of Electric Shock Hot Surface

SAFETY PRECAUTIONS FOR DRY VACUUM PUMPS Please read the following safety information on this page before operating your vacuum pump.

• Do not operate the pump without the belt guard properly attached. Disconnect the pump motor from the electrical supply at

the main disconnect before removing the belt guard. Replace the belt guard before reconnecting the power supply to the

pump motor. Operating the pump without the belt guard properly installed exposes personnel in the vicinity of the pump to

risk from rotating drive components.

• Do not operate the pump with oxygen-enriched gas (greater than 21% by volume) in the suction line, unless the pump has

been prepared with an inert fluid suitable for the application and equipped with seal and start/stop purge system.

Pumping oxygen-enriched gases with mineral oil or other non-inert fluids and without proper purges can cause fire

or explosion in the pump, resulting in damage or serious bodily injury.

• 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. Where process vapour contains

environmentally unfriendly chemical vapour, pump discharge must be connected to the properly sized scrubber system to

neutralize the harmful chemicals prior to the discharge to the atmosphere. Laws and ordinances may pertain to your local

area regarding discharge of oil mist, oil vapour, and chemical vapour to atmosphere. Check local laws and ordinances prior to

operation of the pump with discharge to outside atmosphere.

• 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 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 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 damage or serious bodily injury.

• Lift pump only by the lifting lugs supplied with the pump. 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)

NOTICE

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Screw Vacuum Pumps Page No

Table of Contents:

1. Introduction 5

Principal of Operation 5

Construction 6

a) Timing Gear 6

b) Bearings 6

c) Oil Level Gauge 6

2. Materials of Construction 6

3. Specifications Table 7

4. Piping Diagram 8

a) Fresh Water-Cooling 8

b) Re-Circulating Colling 8-9

5. Purges 9-10

6. Steam Flushing 11

a) Steam Flushing 11

b) Steam Flushing Method (After Pump Operation) 11-12

7. Handling Procedure 12

a) Assembly of Piping 12

b) Piping Work 13-14

8. Operation 14

a) Preparation For Operation 14-15

b) Operation 15-16

c) Pump Shutdown 16

9. Lubrication 16

10. Maintenance and Inspection 17

a) General 17

b) Periodic Inspection Schedule 17

i) Daily 17

ii) Monthly 18

iii) Quarterly 18

iv) Every Six Months 18

v) Yearly 18

c) Dry Vacuum Pump Maintenance & Inspection Schedule 19

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d) Coupling Drive 20

e) Cleaning by Solvent 20

i) Introduction 20

ii) Pump Cleaning in Operation 20-21

iii) Stuck Pump Cleaning 21

11. Maintenance and Repair 22

a) General 22

b) Disassembly Procedure 22-25

c) Reassembly Procedure 26-31

d) Clean & Overhaul Kit 32-33

12. Troubleshooting 34

13. Vacuum System Checklist 35

14. Special Tool List 36

15. Exploded View Drawings and Parts Lists 37-38

16. Warranty-Vacuum Products 39-40

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1.0) INTRODUCTION:

CONGRATULATIONS on purchase of your EVEREST Dry Screw Vacuum Pump from Everest Blower Systems. You may

please examine the pump for any shipping damage, and if any shipping damage is found report it immediately to the carrier. If

the pump is to be installed at a later date than purchased, please make sure that it is stored in a clean, dry location and rotated

periodically. If the pump is being stored outdoors, please ensure it is protected from weather and corrosion.

EVEREST® ESP-HP

™ series vacuum pumps are built to exacting standards and properly installed and maintained shall provide

many years of reliable service. We request 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 simple 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 inside of the back cover 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.

This instruction manual describes instructions and precautions to be observed in the handling and maintenance of EVEREST

Dry Vacuum Pump. It is strongly recommended that those who operate or maintain the pump read this manual carefully prior to

pump operation, to ensure longevity of pump life.

PRINCIPAL OF OPERATION:

The EVEREST® ESP-HP

™ Dry Screw Vacuum Pump is a single stage, dry running, non-contact, type vacuum pump.

The design principle of the ESP is simple. Two parallel screws, having a highly sophisticated surface profile consisting of an

Archimedean and Quimby curve and an arc, rotate in opposite directions. Drive shaft rotation is Clock Wise (CW) when viewed

from the motor end (drive end) of the pump. Helical cut timing gears position these screws relative to each other.

The pumped gas is compressed into the discharged port by the rotation of the screws. A specific amount of clearance for each

pump size is maintained between the two screws and between screws and housing in order to avoid any metal to metal contact.

The power of the motor is transmitted to the main shaft through a coupling or belt pulley.

Because the EVEREST® ESP-HP

™ has a special pitch screw design, the compression process is more efficient and the pump

runs cooler.

For simplicity and space saving, the models ESP-HP™ -150 through ESP-HP

™ -800 are provided as standard with flanged

adaptors for mounting a C-flange motor directly to the Vacuum Pump, eliminating the need for a separate base frame mounted

assembly and coupling guard for the vacuum pumps.

The power of the motor is transmitted to the drive screw shaft through a V-Pulley or a coupling, and further to the driven Screw

shaft through the timing gears.

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1.0) CONSTRUCTION:

a. Timing Gear: The timing gear is an important part of the screw vacuum pump. The tooth surface is heat cured, and polished with a

special high precision tooth-polishing machine for reduced noise during the pump operation.

b. Bearings: The bearings on the fixed side of the ESP pump (discharge end) are angular contact ball bearings and on the

expansion side (inlet end) are roller bearings of heavy load capacity. These bearings have been selected to withstand

high speed and heavy load service and to assure the accurate clearances between gears and between screws.

c. Oil Level Gauge: An oil level gauge (sight glass type) is located on the front end cover. Oil should be filled to the top level of the Upper

Mark.

WARNING: If the oil level is too low, gears, bearings and mechanical seals will be damaged as a result of

improper lubrication.

If the pump were operated with low oil level, the gears and bearings would seize by lack of lubrications. If the oil is

overfilled, the oil temperature would get elevated and cause high gear noise and may affect integrities of the other

parts within the DE (Drive End) Casing. When pump is not in use, be sure to check the oil level and oil contamination,

and then refill or change the oil when needed. The oil is splashed by rotation of the timing gears and lubricates the

Bearings and Mechanical Seals.

2.0) MATERIALS OF CONSTRUCTION:

Housing & Screw Ductile Iron (GCD 400)

Various optional corrosion protection coatings (Teflon®, PFA, NiFlon & NIFA) are

available when requested.

Front end plate and Rear end

Plate: Ductile Iron (GCD400)

Grease Cover/Bearing

Cover Ductile Iron (GCD250)

Lip Seals: PTFE and Carbon mix (Turcon) in Stainless Steel body

Slip Sleeve: Ceramic coated Stainless Steel sleeve with an O-ring for serial numbers up to:

Oil Seal: Viton

Double Lip Seal: Polyamide in Stainless Steel / Tucron –T40 / CAT- T25 (Carbon Filled PTFE)

Mechanical Rotor - Stainless Steel Body with Carbon #5 face

Seals: Stator - Stainless Steel with Tungsten Carbide/ Silicon coating.

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3.0) TECHNICAL SPECIFICATION: Table-1 Specification:

Model

Description ESP-HP150 ESP-HP300 ESP-HP400 ESP-HP800

Nominal Capacity 50/60HZ(m3/h)

110/130

250/300 330/400 660/800

Ultimate Pressure (Torr) 7.5 x 10-3 7.5 x 10-3 7.5 x 10-3 7.5 x 10-3

Standard Motor Power Requirement (Kw) 50/60Hz

2.2/3.7 5.5/7.5 7.5/11 11/15

Noise Level (dB) 79/85

79/85

79/85

79/85

Rotating Speed 50/60Hz(rpm)

2,900/3,500

2,900/3,500

2,900/3,500

2,900/3,500

Inlet/Outlet Standard JIS40/40 JIS50/40 JIS65/50 JIS100/65

Oil Capacity (Liter) 1 2 2 2.5

Seal Purge Consumption (1/min)

5~15

Colling Water Flow Rate

(1/min) 5~10 10~15 10~15 15~20

Seal Type

Standard

HV(Suction): Double Lip Seal + Double Lip Seal LV(Discharge): Only Lip Seal & Mechanical Sea (with Gas Purge)

Drive end : Oil Seal

Option

HV(Suction): Double Lip Seal + Double Lip Seal LV(Discharge): Only Lip Seal & Mechanical Sea (with Gas Purge)

Drive end : Oil Seal

Gross Weight (kg) 200 300 380 600

Note: 1) This table is based on the condition of “Cooling water temperature 30

o C, Air temperature 30

o C”.

2) In case of adopting ESP-HP 300, ESP-HP 800 for processing a polymer and/or polymer By-product, one-step upper

Power capacity of motor is recommended to overcome overloading due to a polymer and/or polymer by-product in

Chemical process.

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4.0) PIPING DIAGRAM:

The vacuum pump casing and the front end plate have an integrated cooling water jacket. The EVEREST® ESP-HP

™ series

pumps can be configured with two different types of cooling systems, Fresh Water Cooling and Re-Circulating Cooling.

A) FRESH WATER-COOLING: The fresh water cooling system consists of a “once through” cooling water circuit. A flow indicator, flow switch on the cooling

water supply line and temperature gauge (or switch) at the cooling water discharge line should be installed to monitor the

adequacy of the cooling water flow and the cooling water discharge temperature. (Switch and Temp. gauge are optional)

The cooling water circuit is extended to the process exhaust silencer.

B) Re-Circulating Cooling: This system is a water cooled version with a cooling water total recovery system. A centrifugal pump circulates the cooling water

from the ESP vacuum pump to a Heat Exchange unit. A flow indicator, flow switch on the cooling water supply line and

temperature gauge (or switch) at the cooling water discharge line should be installed to monitor the adequacy of the cooling

water flow and the cooling water discharge temperature.

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5.0) PURGES:

Cooling Purge — Cooling Purge is to cool the inside of the casing and the screws. During the operation of the pump, the

process gas introduced into the casing through the suction nozzle is compressed by the rotation of the screws and transferred to

the discharge side. Temperature of the process gas gets increased by the heat of compression and this heat energy should be

removed in order to prevent the pump from seizure.

Normally this purge is done by atmospheric air. Where the process gas is not compatible with the atmospheric air, a different

cooling medium should be used, such as, Nitrogen, CDA (Clean Dry Air) etc. For a standard pump, an air filter is provided near

the discharge side of the casing.

Notes:

• Cooling Purge: is not required for EVEREST® ESP-HP

™ 150.

• Flow rates: shown below should be applied when the end-user decides to supply Cooling Purge to the pump.

• Purge Pressure: Atmospheric pressure for process inlet pressure (operating pressure) 150 Torr or below, and 0.5

kg/cm2g (7.11 psi (g)) minimum for process inlet pressure (operating pressure) 150 Torr or higher.

• Flow Rates: Cooling purge flow rate can vary depending on the process inlet pressure (operating pressure) and

the discharge gas temperature.

Seal Purge — Depending on the application, SDV pump may require Seal Purges. If Seal Purge is specified on your system,

it is intended to provide a pressurized barrier within the Front End Plate (FEP) and/or Rear End Plate (REP) with gas which

should be compatible with the process gas and the lubrication oil/grease or inert gas such as Nitrogen or Argon, so that the

contamination of the lubrication oil and/or the grease within the Front End Cover (FEC) and/or the Rear End Plate (REP) is

prevented.

Drive End (DE) Seal Purge should be connected to two purge connection nozzles on the Front End Cover. Non Drive End

(NDE) Seal Purge should be connected to two purge connection nozzles on the Rear End Plate (REP). (For ESP-P-150, there’s

only one Non Drive End (NDE) Seal Purge connection nozzle.) Both Drive End (DE) and Non Drive End (NDE) Seal Purges can

be branched from a single source of purge gas supply.

Seal Purge pressure should be below 1.0 kg/cm2g (14.2 psig). Leak rate of the mechanical seals is below 3 cc/hr (5.3 x 10-6

CFM) and they can sustain pressure up to 3 kg/cm2g (42.7 psig).

Please note that EVEREST does not recommend NDE (Non Drive End) Seal Purge unless it is absolutely required. Providing

NDE (Non Drive End) Seal Purge slightly increases the inlet pressure due to the additional mass flow into the pump. Please

consult factory for further assistance if you require seal purges.

Notes:

• Start/Stop (Cleaning) Purges should last for 20 to 30 minutes with the process isolation valve closed, prior to the

start of the process operation and immediately after the completion of the process operation.

• Seal Purge Pressure: 0.5 kg/cm2g (7.11 psig) Maximum

• Flow Rates: Standard Litters per minute.(splm)

Cooling Purge ESP-P150 ESP-P-300 ESP-P-400 ESP-P-800

SLPM 30 40 40 60

MODEL ESP-P-150 ESP-P-300 ESP-P-400 ESP-P-800

DE (Drive End) Seal Purge 5~10 10~15 10~15 15~20

NDE (Non Drive End) Seal Purge 1 2 2 5

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Start/Stop (Cleaning) Purges — Start/Stop (Cleaning) Purge is to remove residual process gas or any incompatible

substances such as moisture, atmospheric air etc. from the inside of the pump prior to or after the pump operations. Start/Stop

(Cleaning) Purge should be done with gas which is compatible with the process gas or inert gas such as Nitrogen or Argon. This

Start/Stop (Cleaning) Purge is especially important when pumping corrosive gases, toxic gases or polymeric process materials

such as film resin etc.

Start (Cleaning) Purge: With the inlet process isolation valve of the pump closed, operate the pump with purge gas to

the Pump for 20 to 30 minutes to remove any undesired residual gases from the pump’s internal. The inlet process isolation

valve should be open to start process pumping operation upon completion of the Start (Cleaning) Purge.

Notes:

• Start/Stop (Cleaning) Purges should last for 20 to 30 minutes with the process isolation valve closed, prior to the

start of the process operation and immediately after the completion of the process operation.

• Purge Pressure: 1.5 kg/cm2g (21.3 psig) Max.

• Flow Rates: Standard Litters per minute.(splm)

6.0) STEAM FLUSING :

A) STEAM FLUSHING:

The EVEREST® ESP-HP

™ pump should be operated for 10 to 20 minutes upon completion of process batch cycle with

the process isolation valve closed where there’s no Start/Stop (Cleaning) Purge system and sequence in place. This

duration of dry operation without process load is to remove any residual process gas or condensed process vapours

from the inside of the pump that may have accumulated during the process operation. These residual process

materials could be a source of pump motor overload when the pump is re-started. If this residual process material has

not been removed by the dry operation after the process operation and the pump is re-started the residual process

material inside of the pump could cause a pump seizure by excessive frictional load to the motor or damage the screws

and/or the casing.

In such case there’s enough amount of the residual process material build-up within the pump, the pump internal

should be cleaned out. Steam Flushing is one way to clean the residual process material build-up from the pump

internal. When there is enough residual process material build-up, please ensure that the pump is not forced to

rotate by the motor. Especially for the processes that have a high potential for build-up and are aggressive in

nature, such as, processes with Oligomer, Monomer, Polymer, Resin, etc; should be cleaned out regularly by

Steam Flushing.

i) Steam pressure: Approximately 1 kg/cm2g (14.22 psig)

ii) System Isolation: Disconnect all electrical and control powers and place lockout tags on the MCC and/or Control

Panel to ensure no one accidentally starts the pump during the Steam Flushing. The process isolation valve should

be closed. Discharge valve (if applicable) and silencer drain valve should be open.

iii) Inject steam for 10 to 20 minutes through the pump’s process inlet (suction) nozzle or one of the nozzles located at

the side of the pump’s process inlet (suction) nozzle. Injection time can be varied based on the types and amount of

residual process material built-up within the pump.

iv) Rotate the pump shaft by HAND to check whether the pump rotates without much friction or not.

Start/Stop (Cleaning) Purge ESP-P-150 ESP-P-300 ESP-P-400 ESP-P-800

SLPM 25 25 40 65

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v) If the pump rotates smoothly by hand rotation, stop the steam injection and start the pump motor with process

isolation valve closed.

vi) If the pump does not rotate smoothly by hand rotation, repeat steps 3 and 4 until the pump rotates smoothly by

hand. Depending on the severity of the residual process material build-up, it may require repeating steps 3 and 4

several times.

B) Steam Flushing Method (After Pump Operation)

a. Process materials that require Steam flushing: Oligomer, Monomer, Polymer, Resin, etc.

b. Steam pressure: approx. 1 Kg/cm2g (14.22 psig)

c. Flushing Procedure: Close Suction valve, Open discharge valve or Silencer/Separator’s Drain valve

d. Inject Steam for 10 to 20 minutes (the injection time varies with the process material being removed) through pump

suction line or through a plug in suction flange

e. Try to rotate the pump shaft (Pulley or Coupling) by hand to see whether the pump rotates smoothly (during this time,

be careful not to start the motor and observe all lock out/tag out procedures).

f. If the pump rotates smoothly, stop injecting steam.

g. Then, start the motor and check if the pump runs normally.

h. If pump does not turn after performing this procedure, it may be necessary to repeat this procedure 2 to 3 times. If still

no result is achieved please consult factory.

NOTES:

• PURGE PRESSURE: 0.5 to 1.5 kg/cm2 (7.1 to 21.3 psig).

• Flow rates listed are Minimum.

• FLUSHING PURGE should last for 30 minutes with the pump suction valve closed, after process operation is ended.

• All PURGE work except for flushing should be done at the same time as the process starts up.

• Sealing purge at NON-DRIVE END can vary a little according to the type of process and operating condition.

• The COOLING PURGE amount can vary with the vacuum level.

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7.0) HANDLING PROCEDURE

A) Assembly of Piping:

Location:

a. The pump should be mounted on a base frame with sufficient rigidity and placed on a flat and level surface.

b. If it is to be installed outdoors, please ensure the motor, painting, peripheral equipment, and parts, etc. are suitable for

the outdoor operations in case it is planned that the pump be installed outdoors.

c. There should be enough space around the pump to allow for safe maintenance work and periodic inspections.

Foundation:

a. Foundation for the pump assembly and it’s base frame should be flat, levelled, and have adequate load bearing

capacity. (Foundation drawings can be made available in case required.)

b. Pump and its base frame, peripheral equipment and piping should be installed when the foundation concrete has been

cured.

Installation:

a. EVEREST® ESP-HP

™ pumps should always be operated in a horizontal and level position. EVEREST

® ESP-HP

™

pumps should never be installed in an upright (vertical) or angled position, and should be installed on a rigid base

frame.

b. Pump assembly with the base frame should be placed on a foundation and should be supported evenly. Metal shims

should be inserted between the base frame and the foundation, if required for levelling. Pump assembly with the base

frame should be levelled to within 0.5 mm (0.02”) in any 1 meter (3.28 ft.)

c. Use adequately sized anchor bolts.

d. Upon completion of the setting of the pump assembly on the foundation and anchor bolts, the base frame should be

adequately grouted prior to tightening the anchor bolt nuts. Anchor bolt nuts should be tightened after the grout is firmly

cured. Anchor bolts should be tightened evenly to ensure the previously set level is not changed.

B) Piping Work:

Main Piping:

a. Process piping internals should be clean and free from rust, dust, foreign materials, weld slag’s etc.

b. A 40-mesh strainer supplied along with the EVEREST® ESP-HP

™ pump should be placed at the pump process inlet

nozzle. After initial start-up and continued operation of the pump for several hours, disassemble the process inlet piping

from the pump and check the strainer for cleanliness. If there are any particulates strained such as weld slags etc,

clean the mesh strainer and replace to the pump process inlet nozzle. It is highly recommended to check this

strainer regularly for its integrity and cleanness.

c. It is required to install expansion joints on the suction side of the pump as well as the discharge side of the pump.

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These expansion joints are to prevent direct application of any excessive load (primary and secondary load) to the

pump assembly from the process piping structures. Process piping must be supported and guided such that the pump

assembly is relatively free from any excessive load imposed from the process piping structures.

d. Where process exhaust silencer is provided, it should be installed on or as near to the pump discharge nozzle as

possible.

e. A check valve should be installed as close to the process inlet nozzle as possible, which is used to isolate the

pump from the process during the pump shut down. The pump will turn in reverse direction if check valve is not present

at the process inlet nozzle by the pressure differentials. Where a check valve installation is not permitted for any

reason, a process isolation valve, such as a gate valve, should be installed. However, operational procedures must

include a pump shut down procedure that includes closure of this process isolation valve prior to pump shut down. It is

highly recommended to install a process inlet isolation valve whether a process inlet check valve is installed or not.

f. Where the process gas contains high condensable vapours, a condensate recovery tank should be installed. The tank

should be designed to collect the condensates and disposed or drained, as it required.

Cooling Water Piping:

EVEREST® ESP-HP

™ pumps are equipped with an integrated cooling liquid jackets. A cooling medium, typically water,

must be supplied to the cooling liquid supply nozzle located at the FEC (Front End Plate) which will be circulated to the

pump Casing and discharged from the discharge nozzle located on the Casing. Where water-jacketed discharge silencer

or after cooler is supplied with the pump, the silencer or after cooler should also receive the cooling liquid as well. A

single loop cooling liquid supply line can by employed by installing piping between the cooling liquid discharge nozzle at

the pump Casing to the cooling liquid supply connection nozzle on the silencer or the after cooler. Cooling medium

supply piping should include the instruments listed below:

Note: If a Water Jacket type Silencer or After Cooler is installed, this Silencer / After Cooler also require cooling

water piping.

Cooling Liquid Supply Line:

� Manual isolation valve

� Strainer

� Pressure gauge with an isolation valve. (Optional)

� Liquid flow meter. (Optional)

� Liquid flow switch (Or, combined cooling liquid flow meter/switch) (Optional)

� On/Off solenoid valve.(Optional)

� Flow regulating valve. (Optional)

� Temperature gauge. (Optional)

Cooling Liquid Discharge Line

� Temperature gauge. (Optional)

� Temperature switch (Optional)

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8.0) OPERATION:

A) Preparation for Operation

a. Ensure the pump internal and process piping is thoroughly cleaned and free from weld slags, metal chips, particulates,

rusts, dusts etc.

b. Ensure all the process piping connections and utility piping connections are properly installed / tightened and

supported.

c. Ensure the lubrication oil at the Drive End oil reservoir of the pump is filled up to the top level of RED Mark or OL Mark

while the pump is NOT in operation.

d. Adjust and set the cooling liquid flow rate listed on the “ESP Technical Data” table.

e. Ensure the electrical power connection to the motor or electrical/control panel is completed and is ready to supply

power to the motor.

NOTE: Remember that the right oil level is crucial for the pump performance. If the pump were operated with

Low oil level, the gears and bearings would seize by lack of lubrications. If the oil is overfilled, the oil temperature gets

elevated and would cause high gear noise and may affect integrity of the other parts within the DE (Drive End) casing.

Warning

Pre-warm up pump until temperature reaches to normal operating temperature and carry out Maximum

gas inlet purge before pumping condensate. Otherwise steam can be condensed and damage or rust

pump.

B) Operation:

a. Ensure the direction of the pump rotation is correct; CW (Clockwise) direction, looking from the motor. A pump

rotational direction check can be done by jogging the pump a brief moment while checking the rotational direction of

the motor fan. If the motor rotates CCW (Counter-Clockwise), correct the power cable connections and check the

rotational direction again to ensure the pump rotates in correct CW direction. Pump rotational direction check should be

done with the process inlet isolation valve open.

b. With the process inlet isolation valve open, operate the pump for 20 to 30 minutes. At this stage, all pump operating

parameters should be checked for any abnormality; such as excessive vibration, high oil/grease temperatures, high

cooling liquid discharge temperature, high process discharge temperature noise, over current draw etc. In case of

observation of any abnormality, stop the pump and investigate for the cause of the abnormality. Typical causes of

abnormalities come from improper lubrication and/or improper installation of the pump.

c. Upon completion of the above step, operate the pump for 2 to 3 hours under normal process load condition and check

the pump operating parameters again.

d. If an abnormality is found during the initial operation with normal process load, shutdown the pump immediately and

ensure the problem is corrected prior to re-start-up of the pump.

e. Pump operating conditions should be within the limits shown on the “Specifications Table” on page 7.

a. Max. Process Inlet Temperature

b. Process Discharge Temperature

c. Oil Temperature

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d. Grease Temperature

f. Cooling Medium Differential Temperature is determined by subtracting the Supply temperature from the Discharge

temperature. For water, differential temperature must be within 10°C.

g. Observe other operating conditions as well, such as: noise, vibration, and motor current (amps).

C) Pump Shutdown:

a. Prior to disconnection of the motor power, ensure to close the process inlet isolation valve.

b. Where the process gas or vapour is in corrosive or hazardous nature, introduce inert gas, such as Nitrogen or Argon,

into the pump inlet for 20 to 30 minutes to purge out the residual process gas or vapour from the pump internals prior to

disconnecting the motor power. Please see Start/Stop (Clean) Purge section for more information.

c. Shutdown the pump.

d. Shut off the cooling liquid supply.

If the pump needs to be shut down for a long period of time when freezing weather is expected, and water is used as a

cooling liquid, the pump cooling jacket should be drained through the cooling jacket nozzles.

9.0) LUBRICATION:

Lubricants for ESP pumps must be a

high-grade petroleum products

containing oxidation (and/or rust)

inhibitor, extreme-pressure additives

etc. Lubricants containing water,

sulphate resin, or tar should not be

used with ESP pumps.

Turbine oil (ISO VG46/ T46) is readily

obtainable in the market and would

generally satisfy these requirements.

Warning

Warm up pump and carry out maximum purge to gas inlet. Otherwise pump can be damaged or corroded

by condensed water vapour accumulated inside the pump

GEAR & BEARING OIL GREASE

LUBRICANTS

For General BP, Energol THHT 46 /

THB 46

Mobile 1 Synthetic Grease (Standard)

Regal, R&O 46 SHINETSU, G 40M

Applications Shell, Turbo 46 Nok-KLUBER, HFE 552

Mobil, DTE Oil Medium FAG, Arcanol L74V

For Special Fomblin, RT-15

Fomblin, 25/6 Nok-KLUBER, Barrerta L55/2

Applications

Krytox 1525

16

10.0) MAINTENANCE AND INSPECTION:

A) General:

a. During normal operation, the temperature in the pump will increase in homogeneous matter as a result of

compression work done on the process gas or vapour. It is abnormal if the temperature rise is localized in the pump

and/or the external painting becomes scorched, however, the localized hot spots are typically due to the inadequate

cooling liquid supply or cooling liquid cut-off, interference of the screws with casing, or pump has ingested foreign

material, such as sold particulates, metal chips, process material build up etc. If a localized hot spot is observed,

the pump must be shut down immediately for inspection. In some cases, the screws and the casing may have

become corroded. This corrosion will cause the clearance between the screws and casings to increase and

increase the “slip” (internal reverse flow: flow of gas from the pump discharge to the suction). The pumping capacity

of the pump is then decreased. In this case, the pump must be shut down and clearances must be measured and

verified in order to determine required corrective actions.

b. Most of pump abnormalities can be noted by routine checks of bearing temperatures, vibration and noise etc.

Daily inspection of the pump is highly recommended as a preventative maintenance.

c. Interference between the pump screws or between the screws and the casing can be detected by listening

through stethoscope on the pump casing.

d. Whenever the pump is stopped, completely drain the cooling liquid if the pump is located in a cold region or in the

winter to prevent freezing of the cooling liquid.

B) Periodic Inspection Schedule:

I) Daily:

a. Check the electrical current load on the motor (Amps): An increase in the motor current load indicates abnormality

of the pump operation.

b. Check whether pump rotates smoothly and in correct direction (CW).

c. Check process inlet and discharge pressures.

d. Check for the pump for any excessive noise and vibrations.

e. Check NDE (Non Drive End) grease cover temperature.

f. Check DE (Drive End), oil reservoir cover temperature.

g. Check for any sign of cooling liquid leakage.

h. Check oil level. High or low oil level can damage gears and bearings.

i. Check for any sign of external oil leakage.

j. Check cooling liquid supply flow rate and pressure.

17

II) Monthly:

a. Check the oil colour: If the oil colour is too dark, replace the oil.

b. Check oil level: If the oil level drops in a short period of time, check the integrity of mechanical seals.

c. Check grease.

III) Quarterly:

a. Check the cooling liquid flow and discharge cooling liquid colour. May require periodic cleaning of the cooling

jackets and water piping.

b. Replace grease at NDE (Non Drive End).

IV) Every 6 Months:

a. Check all process and utility piping and their supports.

V) Yearly

a. Check the pump internal surfaces, casing and screws surfaces for any sign of rust and flaws.

b. Check all mechanical seals and lip seals

C) DRY VACUUM PUMP MAINTENANCE & INSPECTION SCHEDULE

18

Item Check Point Daily Monthly QUARTERLY 6 Mos. Yearly

Motor Amperage Any Change? Amperage as specified? ×

Rotation Is the rotation smooth and direction correct? ×

Suction & Discharge Pressure Is the pressure as specified? ×

Noise & Vibration Any abnormal sound or vibration? ×

Temperatures Any excessive oil or water temperature? ×

Cooling Liquid Leak Check for leakage of the cooling liquid. ×

Oil Level Gauge Is oil at proper level? ×

Water contamination on free What is the colour? Has it changed to reddish ×

end cover Brown?

Cooling Water Pressure Is the pressure as specified or too high? ×

Grease Is grease colour dark, contaminated or broken ×

Down?

Oil Leaks Any signs of oil leaks? ×

Reverse Cooling Filter (Cooler) Any heat on suction pipe? ×

Belt Tension / Coupling Alignment

Check V-Belt Tension /Coupling Alignment and Bolt tightness. ×

Lubricant Colour Check colour; if dark, replace lubricant ×

Oil Level If oil level drops drastically check mechanical

×

Seal.

Oil/Grease change ×

Suction & Discharge Piping Is there any accumulated scale or dirt? ×

Process and Utility piping and

×

supports

Pump casing internal and Any signs of rust and flaw found?

×

screws surfaces

Mech. Seal, Oil Seal, Bearing, Inspect for damage & replace as needed.

×

O-Ring, V-Belt & Packing

Timing Gears Inspect for damage ×

19

D) Coupling Drive: Align coupling by using Dial Gauge. The concentricity should be as follows:

E) Cleaning by Solvent:

i) Introduction:

Choose suitable solvent for pumping material. For cleaning, suitable amount of solvent

Is needed. (Approx. 10L~20l, or as per requirement).

a. Close pump out let or silence drain valve.

b. Clean the Pump: If you want to remove precipitates from which operate well, follow the below procedure.

ii) Pump Cleaning in Operation:

Note: In case of that pump is full of solvent, shut off the pump. It can bring serious damage to the pumps or lead to an

accident.

a. Separate the exhaust pipeline from pump outlet and put suitable container under pump exhaust.

b. If the system has pump suction isolation valve, close it. In the other case, separate pump inlet from process system

and fix blind flange to pump suction line.

c. To separate motor, turn off power and loosen bolts for fixing. Turn coupling three of four times clockwise by chain

wrench after separating the motor.

d. If it is necessary, repeat above three steps until pump rotate freely.

e. Separate blind flange in pump suction line. Then, reconnect pump suction line to process system. Assemble pump

exhaust hole to discharge line again and discard all precipitates from pump.

Motor Pump Motor Pump side side side side

Feeler gauge

Class of motor On side of coupling

M180 less than 0.05

M200M and above less than 0.08 Class of motor At end of coupling

M132M and under less than 0.1

M160M and above less than 0.18

20

iii) Stuck Pump Cleaning:

Note: In case of that pump is full of solvent, shut off the pump. It can bring serious damage of the pumps or accident.

a. If the system has pump suction isolation valve, close it. In the other case, separate pump inlet from process

system and fix blind flange to pump suction line.

b. Pour suitable solvent slowly into suction flush port. Wait about few minutes until that pump is full of solvent.

c. Repeat previous steps until pump cannot get more solvent. Leave the pump at least one hour until that precipitate

can act enough with solvent.

d. Insert chain wrench into running device hub. Then, rotate pump to clockwise

e. If you cannot rotate it, keep step four. (Leave pump more with solvent).

f. If you can rotate it, keep going to next step.

g. Put suitable container under the pump exhaust then remove the blind flange.

h. Rotate pump three or four times completely by chain wrench. It is possible that pump can’t rotate due to pressure

lock of pump.

i. If necessary, repeat from step 5) to step 6).

j. Separate blind flange in pump suction line. Then, reconnect pump suction line to process system or open the

suction valve.

k. Reconnect pump discharge line to discharge port.

l. If necessary, turn on power of pump motor.

m. Remove used solvent and precipitate.

21

11.0) MAINTAINANCE AND REPAIR:

A) General:

The operating temperature in the pump will increase by the compression work done on the process product. However, if

the temperature increase locally and/or the external painting become scorched, this indicates a faulty symptom of the

pump. The localized hot spot are typically due to the poor cooling water supply or cooling water cut off, interference of

screws with casing, or foreign material ingestion, such as process material built-up, metal chips, solid particulates. In this

case, shut down the pump immediately for inspection. In certain cases, the screws and the casing may have been

corroded. This corrosion induces to increase the clearance between the screws and casing. This will increase the

reversal flow of gas from the pump discharge to the suction, and the pumping capacity is decreased. In this case, shut

down pump and inspect the clearance to determine the required corrective actions. Request for appropriate technical

support to your pump supplier or manufacturer.

1) Unusual bearing temperature, vibration or noise can be detected by routine inspection. Thus, daily routine

inspection of the pump is highly recommended.

2) Abnormal interference between screws or between screw and casing can be detected by using the

stethoscope.

3) If the pump is located in a cold region or in the winter, whenever the pump is stopped, drain cooling water

completely to prevent freezing of the cooling water.

B) Disassembly Procedure (Refer to 7. Disassembly Drawing)

1) Precautions:

1) Check the clearance between the screws through the inlet nozzle at the point E in Figure 2.

The allowable clearance between the screws is listed on the Table 3.

Figure-2 Screw clearance

22

Table-3 Allowable Clearance between the Screws

Model

ESP-HP-150 ESP-HP-300 ESP-HP-400 ESP-HP-800

E (um)

0.05~0.07 0.08~0.1 0.1~0.12 0.18~0.2

2) All fittings and connections shall be placed match marks.

3) Care should be taken not to damage the gasket in connection.

4) Keep all disassembled parts in a dust free space, especially Mech. Seal, Lip Seal and Bearing.

2) Disassembly Procedure (Standard: Refer to Seal Type in Table “Technical

Specification”)

1) Disconnect all process and utility pipeline and electrical connections. Remove motor, coupling, and key.

2) Open the cooling water drain valve in Casing, and drain cooling water completely.

3) Open Oil Drain Plug in Front End Cover 4 and drain oil from pump.

4) Loosen Socket Bolts 61 for fixing Seal Adaptor Housing 15 using hexagonal wrench and separate Seal

Adaptor Housing 15 from Front End Cove 4. Care should be taken during the disassembly without applying

any damage of the Oil Seal 48 which attached to Seal Adaptor Housing 15.

5) Remove Locknuts in Stud bolts 55 and separate Front End Cover 4.

6) Separate Power Lock 18 in Timing Gear 17 using the hexagonal wrench. Remove Locknut 28 (Left-hand

Thread) using Locknut wrench to separate the Timing Gear 17.

7) Separate Grease Cover 18 in Casing Read End by removing the Socket Bolt 60.

8) Separate Rear End Plate 3 using the pull out tool after removing the Lock Washer and Luck Nut 26 (Left-hand

Thread) is using the Lock Nut Wrench.

9) Separate Roller bearing 21, Rear End Plate Slinger 36, Slip Sleeve 35, Double Lip Seal 33, and Rear End

Plate Spacer 37 from the Rear End Plate 3.

10) Loosen the Wrench Bolt 62 and separate Plate Guide 11 from the Rear End Plate.

11) This is the final Step for disassembling Rear End Plate 4.

12) Lift up the pump casing 1 after installing two Eye Bolts to the Front End Plate 3 using the lifting device (Hoist,

Chain block) and reposition the pump with Front End Plate on top on the work bench. Adjust the height of

supporting fixture on the workbench to prevent contacting the Screw rotor shaft 6 and 7 with the top surface of

the workbench.

13) Remove Wrench Bolt 63 to separate Front End Plate 2 from Casing 1. After fastening one eye bolt to the

Front End Plate 2, separate Front End Plate 2 from Casing 1 using the lifting device. Relocate the Front End

Plate with Screw rotor shaft 6 & 7 to the screw rotor shaft supporting fixture.

14) Separate bearing Stopper 14 after removing Wrench Bolt 59.

15) Remove Lock Nut 24 using Lock Nut Wrench and separate Lock Washer 25.

16) Separate Bearing Holder 12 and 13 from the Front End Plate after fastening hexagonal bolts to the pull out tap

in Bearing Holder.

23

17) Pull out Angular Contact Bearing 20 from the disassembled Bearing Holder 12 and 13. Then, separates

Spacer (FEP) 38, Mechanical Seal Rotator 23, and Mechanical Seal Stator 22 from Screw Rotor Shaft.

18) Remove Plate Guide (9, 10) and Oil Lip Seal 32 after separating from the Screw Rotor Shaft 6, 7 using the

Eye bolt assembled in Front End Plate 2 with the Hoist.

19) Separate cover, plate and blind plate of water jacket from casing

# Pay attention to the thread direction of Lock Nut 24, 26, 28 during the disassembly and dis-Assembly. The Drive

Rotor Shaft 7 has two threads with right-hand direction while The Drive Rotor Shaft 6 has three threads with left hand.

All disassembled part is cleaned by solvent and parts which have abrasion or damage should be changed with

factory approved parts which is indicated by manufacturer.

Every disassembly and assembly, new Bearing, Seals, gasket and O-rings should be used.

3) Disassembly Procedure (Option: Double Lip Seal: Refer to Seal Type in “Technical

Specification”.)

1) Disconnect all process and utility pipeline and electrical connections. Remove motor, coupling, and key

2) Open the cooling water drain valve in Casing, and drain cooling water completely.

3) Open Oil Drain Plug in Front End Cover 4 and drain oil from pump.

4) Loosen Socket Bolts 61 for fixing Seal Adaptor Housing 15 using hexagonal wrench and separate Seal

Adaptor Housing 15 from Front End Cove 4. Care should be taken during the disassembly without applying

any damage of the Oil Seal 48 which attached to Seal Adaptor Housing 15.

5) Remove Locknuts in Stud bolts 55 and separate Front End Cover 4.

6) Separate Power Lock 18 in Timing Gear 17 using the hexagonal wrench. Remove Locknut 28 (Left-hand

Thread) using Locknut wrench to separate the Timing Gear 17.

7) Separate Grease Cover 18 in Casing Read End by removing the Socket Bolt 60.

8) Separate Rear End Plate 3 using the pull out tool after removing the Lock Washer and Lock Nut 26 (Left-hand

Thread) is using the Lock Nut Wrench.

9) Separate Roller bearing 21, Rear End Plate Slinger 36, Slip Sleeve 35, Double Lip Seal 33, and Rear End

Plate Spacer 37 from the Rear End Plate 3.

10) Loosen the Wrench Bolt 62 and separate Plate Guide 11 from the Rear End Plate.

11) This is the final Step for disassembling Rear End Plate 4.

12) Lift up the pump casing 1 after installing two Eye Bolts to the Front End Plate 3 using the lifting device (Hoist,

Chain block) and reposition the pump with Front End Plate on top on the work bench. Adjust the height of

supporting fixture on the workbench to prevent contacting the Screw rotor shaft 6 and 7 with the top surface of

the workbench.

13) Remove Wrench Bolt 63 to separate Front End Plate 2 from Casing 1. After fastening one eye bolt to the

Front End Plate 2, separate Front Plate 2 from Casing 1 using the lifting device. Relocate the Front End Plate

with Screw rotor shaft 6 & 7 to the screw rotor shaft supporting fixture.

14) Separate bearing Stopper 14 after removing Wrench Bolt 59.

15) Remove Lock Nut 24 using Lock Nut Wrench and separate Lock Washer 25.

24

16) Separate Bearing Holder 12 and 13 from the Front End Plate after fastening hexagonal bolts to the pull out tap

in Bearing Holder.

17) Pull out Angular Contact Bearing 20 from the disassembled Bearing Holder 12 and 13. Then, separate

Double Lip Seal 23, Lanterning Ring 22, O-ring 64, and Slip Sleeve in sequence.

18) Remove Plate Guide (9, 10) and Oil Lip Seal 32 after separating from the Screw Rotor Shaft 6, 7 using the

Eye bolt assembled in Front End Plate 2 with the Hoist.

19) Separate cover, plate and blind plate of water jacket from casing.

# Pay attention to the thread direction of Lock Nut 24, 26, 28 during the disassembly and dis-Assembly.

The Drive Rotor Shaft 7 has threads with right-hand direction while The Drive Rotor Shaft 6 has three

Threads with left hand.

All disassembled part are cleaned by solvent and parts which has abrasion or damage should be changed with

factory approved parts which in indicated by manufacturer.

Every disassembly and assembly, new Bearing, Seals, gasket and O-rings should be used.

C) Reassembly Procedure (Refer to 7. Disassembly Drawing)

1) Precautions:

1) Check all parts for wear or damage during assembly. Especially, damage of mating parts or sub-

assembly which join or fit together will deteriorate the proper operation of the pump after it is assembled.

Therefore, Utmost care must be taken for inspection of those parts, joints, fittings, and sub-assembly. If

found worn or damaged, then changed or repaired.

2) Clean bearing with light oil. Then, apply lubricant. Always clean hands and tools before handling

bearing.

3) Remove dust from fittings by solvent or soft and clean cloth. Then apply oil. In case key or shaft has rust

and it is too difficult to separate, apply Molybdenum Disulphide (Clean the inside of gear by solvent or

clean cloth).

4) Use new packing when packing is damaged. Measure the thickness of new packing and ensure it is

same as old packing.

2) Reassembly Procedure (Standard: Refer to Seal Type in Technical

Specification)

1) Assemble Gasket and Blind Plate to Casing 1 and Front End Plate 2 using Hexagonal Bolt.

2) Assemble Guide Plate 9 and 10 to Front End 2 using Wrench Bolt on the workbench or proper Pipe Stand.

3) Place the Screw rotor shaft supporting fixture on the workbench and Secure firmly. The Key way Slot in the

Drive and Driven Screw Shafts 7 and 6 should be located in Top position when upright Screw Shafts.

25

4) Starts assemble from the Gear side (Front End Plate).

Standard (Mechanical Seal)

Figure-3 Mechanical Seal Assembly

5) Assemble the Front End Plate to the Screw Rotor Shaft 6 and 7 using the Lifting Device after fastening the

Eye Bolt. During this step. Front End Plate 23 should be tightly contacted with the said surface of the Screw

Rotor Shaft.

6) After install Bearing Holder 12 and 13, inject few drops of oil into O-ring of Mech. Seal Stator 22, then press fit

to the Drive and Driven Shaft 7 and 6 and secure the Mechanical Seal Stator 22 using the Installation Tool

Next, install Mech. Seal Rotator 23 to the Drive 7 & Driven Shaft 6 after oil injection to the carbon in Mechanical Seal

Rotator. Secure firmly Mechanical Seal Rotator 23 on the Drive 7 & Driven Shaft 6 using the Installation Tool.

Remove the Installation Tool and press the mechanical seal by finger to check the proper tension of the spring

in Mechanical Seal. Then, check whether o-ring is positioned in proper place by rotating the seal a little bit.

7) Place Spacer 38 in Drive & Driven Shaft. The Spacer 38 was made specially to meet the required allowable

tolerance of the drive and driven side. Care should be taken not to change.

8) Insert Ball Bearing 20 into the Bearing Holder 12 and 13.

9) Secure Ball Bearing on Driven Shaft 7 and 6 with Lock Washer 25, Lock Nut 24 using the Lock Nut Wrench

and bend one edge of Lock Washer 24 to fix the locations. Prior to securing Lock Nuts, insert a copper plate

or soft metal shim between the Screws to protect the Drive & Driven Shaft 7 and 6 from rotating.

10) Secure Bearing Stopper 14 to Bearing Holder 12 and 13 with Socket Bolt 59.

11) Lift the Sub-Assembly of Front End Plate and Screw Rotor Shaft using the Eye Bolt with hoist to separate from

the supporting fixture on workbench. Check the Clearance between side surface of Screw and surface of

Plate Guide 9 and 10. After that insert O-ring into the Front End Plate 32.

O-ring

Mech.

Seal

O-ring

Mech.

Seal

Gear Side Gear Side

26

12) Insert Dowel Pin 31 and O-ring 50 into the Casing 1 at the supporting fixture on the workbench. Secure

Wrench Bolt 63 after attached the Sub-Assembly of Front End Plate and Screw Rotor Shaft to Casing 1 with

care to prevent casing from any internal damage. Locate the Pump Assembly in horizon position with facing

the rear end of pump on front side.

13) Replace Plate Guide 11 into Rear End Plate 3 and secure with Wrench Bolt 62.

14) Replace Double Lip Seal 33 and Spacer 37 into Rear End Plate.

15) Replace Dowel Pin 30 and O-ring 50 into the Casing 1. Insert Slip Sleeve 35 with O-ring 66 into the Screw

Shaft.

16) Attach the Rear End Plate 3 to Casing and secure them with Hexagonal Bolt 57.

17) Replace REP Slinger 36 and Roller Bearing 21 into the Rear Plate 2 after injecting a large amount of the

grease for vacuum application into the bearing.

18) Insert O-ring on sealing groove of Rear End Plate 3 and Replace Grease Cover 8. Then, secure with Wrench

Bolt 60.

Figuire-4 Rear End Plate

19) Lift up the Pump Assembly and Place it on the workbench horizontally with pointing the discharge side to the

worker.

20) Insert key into the Driven Shaft 6 and replace Timing Gear 16 onto the Driven Shaft 6. Next, Replace Timing

Gear 17 and Power Lock 18 onto the Drive Shaft 7.

.

Process Side

Double Lip

Seal

Grease

27

Figure 5 Suction Area

Insert Thickness Gauge (Feeler Gauge with 01 mm thickness) into the suction port as shown in Figure5. Then, rotate

the Timing Gear 17 to secure the Thickness gauge. After that secure the Timing gear 17 using the Wrench Bolt at

Power Lock and remove the Thickness Gauge. The Timing Gear run-out or flatness should be within 0.05 mm.

21) Replace Stud Bolt 55, Dowel Pin 30, and O-ring 51 in sequence into the Front End Plate 2.

22) Attach Front End Cover 4 to Front End Plate 2 and Secure the Nut to the Stud Bolt 55.

23) Replace Ball Bearing 19 into the Driven Shaft 7, and replace Speedy Sleeve 34.

24) Attach Oil Seal 48 into the Seal Adapter Housing 48, and insert O-ring 54 into the groove. Then, Replace the

Seal Adapter Housing to Front End Cover 4.

25) Attach Front End Cover 4 and Replace keys, coupling and Motor.

26) Fill oil up to the green line on Oil Level Gauge in the Front End Plate. Then, attach Air Vent 65.

3) Reassembly Procedure (Option: Refer to Double Lip Seal Type in

“Technical Specification”.)

1) Assemble Gasket and Blind Plate to Casing 1 and Front End Plate 2 using Hexagonal Bolt.

2) Assemble Guide Plate 9 and 10 to Front End Plate 2 using Wrench Bolt on the workbench or proper Pipe

Stand.

3) Place the Screw rotor shaft supporting fixture on the workbench and Secure firmly. The Key way Slot in the

Drive and Driven Screw Shafts 7 and 6 should be located in Top position when upright Screw Shafts.

4) Starts assemble from the Gear side (Front End Plate).

28

Figure 3-1 Double Lip Seal

5) Assemble the Front End Plate to the Screw Rotor Shaft 6 and 7 using the Lifting Device after fasterning the

Eye Bolt. During this step. Front End Plate 23 should be tightly contacted with the side surface of the Screw

Rotor Shaft.

6) After replacing Bearing Holder 12 and 13 into Front End Plate 2, insert O-ring 68, Slip Sleeve 66 into the

Screw Shaft. Next, replace Double Lip Seal 23 and Lantern Ring in sequence.

7) Place Spacer 38 in Drive & Driven Shaft. The Spacer 38 was made specially to meet the required allowable

tolerance of the drive and driven side. Care should be taken not to change the assembling position as was

before.

8) Insert Ball Bearing 20 into the Bearing Holder 12 and 13.

9) Secure Ball Bearings on Drive & Driven Shaft 7 and 6 with Lock Washer 25, Lock Nut 24 using the Lock Nut

Wrench and bend one edge of Lock Washer 24 to fix the locations. Prior to securing Lock Nuts, insert a

copper plate or soft metal shim between the Screws to protect the Drive & Driven Shaft 7 and 6 from rotating.

10) Secure Bearing Stopper 14 to Bearing Holder 12 and 13 with Socket Ball 59.

11) Lift the Sub-Assembly of Front End Plate and Screw Rotor Shaft using the Eye Bolt with hoist to separate from

the supporting fixture on workbench. Check the Clearance between side surface of Screw and surface of

Plate Guide 9 and 10. After that insert O-ring into the Front End Plate 32.

12) Insert Dowel Pin 31 and O-ring 50 into the Casing 1 at the supporting fixture on the workbench. Secure

Wrench Bolt 63 after attached the Sub-Assembly of Front End Plate and Screw Rotor Shaft to Casing 1 with

care to prevent casing from any internal damage. Locate the Pump Assembly in horizon position with facing

the rear end of pump on front side.

29

13) Replace Plate Guide 11 into Rear End Plate 3 and secure with Wrench Bolt 62.

14) Replace Double Lip Seal 33 and Spacer 37 into Rear End Plate.

15) Replace Dowel Pin 30 and O-ring 50 into the Casing 1. Insert Slip Sleeve 35 with O-ring 66 into the Screw

Shaft.

16) Attach the Rear End Plate 3 to Casing and secure them with Hexagonal Bolt 57.

17) Replace REP Slinger 36 and Roller Bearing 21 into the Rear Plate 2 after injecting a large amount of the

grease for vacuum application into the bearing.

18) Insert O-ring on sealing groove of Rear End Plate 3 and Replace Grease Cover 8. Then, secure with Wrench

Bolt 60.

19) Lift up the Pump Assembly and Place it on the workbench horizontally with pointing the discharge side to the

worker.

20) Insert key into the Driven Shaft 6 and replace Timing Gear 16 onto the Driven Shaft 6. Next, Replace Timing

Gear 17 and Power Lock 18 onto the Drive Shaft 7.

Insert Thickness Gauge (Feeler Gauge with 01 mm thickness) into the suction port as shown in Figure 5. Then, rotate the Timing Gear 17 to secure the Thickness gauge. After that secure the Timing gear 17 using the Wrench Bolt at Power Lock and remove the Thickness Gauge. The Timing Gear run-out or flatness should be within 0.05 mm.

21) Replace Stud Bolt 55, Dowel Pin 30, and O-ring 51 in sequence into the Front End Plate 2.

22) Attach Front End Cover 4 to Front End Plate 2 and Secure the Nut to the Stud Bolt 55.

Process Side

Double Lip

Seal

Grease

30

23) Replace Ball Bearing 19 into the Driven Shaft 7, and replace Speedy Sleeve 34.

24) Attach Oil Seal 48 into the Seal Adapter Housing 48, and insert O-ring 54 into the groove. Then, Replace the

Seal Adapter Housing to Front End Cover 4.

25) Attach Front End Cover 4 and Replace keys, coupling and Motor.

26) Fill oil up to the green line on Oil Level Gauge in the Front End Plate. Then, attach Air Vent 65.

D) Clean & Overhaul Kit

Clean & Overhaul Kit includes general spare parts for disassembly and assembly such as seals, bearings and O-rings. These spare parts are recommended not to reuse after disassembly. These spare parts can be purchased as “Kit” or separately.

Table 4-1 Clean & Overhaul Kit Standard Type (Mechanical Seal).

Model

Description

ESP-HP150, ESP-HP 300, ESP-HP 400, ESP-HP 800

Kit: ESH-HP-RSK-MS 150, 300, 400, 800

Quantity

Mechanical Seal Assembly

2

Only Lip Seal (FEP)

2

Double Lip Seal (REP)

4

Slip Sleeve (REP)

2

Oil Seal (Gear Box Side)

1

Ball Bearing (FEP)

2

Roller Bearing (REP)

2

Ball Bearing (FEP)

1

O-ring (REP)

1

O-ring (Casing)

2

O-ring (FEP)

1

O-ring (Suction Port)

1

O-ring (FEP Cooling Water Jacket)

1

O-ring (Seal Adaptor Housing

1

O-ring (Slip Sleeve/REP)

2

31

Table 4-1 Clean & Overhaul Kit Option (Double Lip Seal)

Model

Description

ESP-HP150, ESP-HP 300, ESP-HP 400, ESP-HP 800

Kit: ESP-HP RSK-DL 150, 300, 400, 800

Quantity

Double Lip Seal (FEP)

4

Double Lip Seal (REP)

4

Slip Sleeve (REP)

2

Oil Seal (Gear Box Side)

1

Ball Bearing (FEP)

2

Roller Bearing (REP)

2

Ball Bearing (FEP)

1

O-ring (REP)

1

O-ring (Casing)

2

O-ring (FEP)

1

O-ring (Suction Port)

1

O-ring (FEP Cooling Water Jacket)

1

O-ring (Seal Adaptor Housing

1

O-ring (Slip Sleeve/FEP)

2

O-ring (Slip Sleeve/REP)

2

Note: Timing Gears are not included in Repair Kit and can be purchased separately.

32

12.0) ) TROUBLESHOOTING:

PROBLEM CAUSES SOLUTION

Insufficient Clogged inlet filter and/or strainer Clean or change the inlet filter and/or strainer

Pumping Too much clearance Check the screw “E” clearance and reset the

Capacity

clearance (reset the timing gear)

Clogged inlet filter and/or strainer Clean or change the inlet filter and/or strainer

Check the screw “E” clearance and reset (reset the

Foreign matter is caught in the pump timing gear) if needed. If the screws and/or casing

are damaged by foreign material, replace the screw

and/or casing.

Motor Significant increase of inlet pressure Check the pressure differential between the inlet and

Overload

outlet of the pump

Interference between screws Reset the screw “E” clearance (reset the timing gear

Interference between screws and casing Reset the “D” clearance.

Blocked discharge nozzle or piping and increased Drain & clean discharge nozzle and piping

back pressure

Excessive oil in FEC Check oil level and adjust the oil level if required

High vacuum pump inlet temperature Reduce the inlet temperature

High compression ratio Check the differential pressure between inlet and

discharge nozzle

Overheat

Interference between screw and casing Search for the cause of interference

Problem with cooling liquid flow Clean cooling liquid lines and pump cooling jackets

Blocked discharge nozzle or piping and increased Drain and clean discharge nozzle and piping

back pressure

Incorrect positioning of timing gears and screws Reposition the timing gears and screws: run-out or

flatness of the timing gears should be within 0.03 mm

Knocking Improper assembly Reassemble the pump

Abnormal rise of inlet pressure Search for the cause

Damaged gear due to overload or improper Replace timing gears

lubrication

Bearing or Improper lubrications Change oil

Gear damage Low oil level Refill oil to the correct level

33

13.0) VACUUM SYSTEM CHECKLIST:

CHECK POINT CHECK

Opening Cooling water supply valve. Is flow correct? �

Close vacuum suction line. �

Before Open Discharge line. �

Operation Check lubricant colour and level. Is it acceptable?

�

Check Belt Tension (for V-belt type only) or Coupling Alignment. �

Run vacuum pump for a few minutes before opening the Suction line. �

Check vacuum level in full vacuum. Is it normal? �

During

Check electric power condition (Voltage & Amperage) in full vacuum. Is it acceptable? �

Any abnormal noise? �

Operation

Check operation temperature. Is it normal? �

Check lubricant colour and level. Is it acceptable? �

Run vacuum pump for a few minutes after closing the suction line. �

Stopping

If foreign material is introduced inside of the vacuum pump, clean it with cleaning fluid. �

Make sure that the Suction & Discharge line is closed. �

Make sure the power supply is cut off. �

34

14.0) SPECIAL TOOL LIST:

Specification

Description ESP HP150

ESP HP 300 ESP HP 400 ESP HP 800 Material

3206/NJ206

3208/NJ208 3308/6308 3309/NJ309 Teflon

1 Bearing Pusher

6207 6207, NJ208 3308/6308 Teflon

Al bar

Al bar Al bar Al bar Aluminum

2 Mech. Seal Pusher Special Aluminum

3 Lip Seal Puller Consult factory Teflon

4

Bearing Holder Puller Assembly

Consult factory

5 Hook Spanner 45/50 58/62 68/75

6 Feeler Gauge 150 MZ

(4”, 12”) 172 ME

7 Hex Wrench Fox 5 mm * 160mm

M8 * 55L M8 * 55L M10 * 150L

8 Clamp Bolt Set M8 * 100L M8 * 100L M8 * 150L S45C

M8 * 150L M10 * 100L M10 * 270L

M8 * 200L M8 * 200L M10 * 200L M8 * 270L

9 “T” Wrench 6mm

10 “L” Wrench Set In mm unit

11 Hammer (Rubber) E-060

12 Torque Wrench 450-QLK

13 Tool Box 500 * 230 * 240

14 Removable Tapered Consult factory

Slip Sleeve

15 Special Tool for push Consult factory

sleeve installation

35

DISASSEMBLY DRAWING (Mechanical Seal)

ESP-HP150, ESP-HP300, ESP-HP400, ESP-HP800

36

DISASSEMBLY DRAWING (Double Lip Seal)

ESP-HP 150, ESP-HP 300, ESP-HP 400, ESP-HP 800

37

WARRANTY – VACUUM PRODUCTS Subject to the terms and conditions hereinafter set forth and set forth in General Terms of Sale, Everest Vacuum & Blower

Systems (the seller) 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 form 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 5% 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 start-up date, whichever occurs first

Repair 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 start-up 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

DISCLAMIER.

All accessories furnished by seller but manufactured by others bear only at the manufacturer’s standard warranty.

All claims for defective products, parts, or work under this 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, or 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 neither by reason of failure to

resist erosive or corrosive action nor for 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 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, wilful

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 on

(1) year after the cause of action has occurred.

38