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SCREW PUMP

Operating Manual

ATTENTION!

This operating manual


only applies to :

Machine no. :

Contract no. : 0

Item no. :

Size :

Type: Standard Wear bushing type

IBAU HAMBURG Rödingsmarkt 35 20459 Hamburg (Germany)

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SCREW PUMP IBAU HAMBURG


TECHNICAL SPECIFICATIONS

Material specifications

Material :

Apparent density : kg/dm3

Temperature : max. °C

Conveyance specifications

Conveying capacity : t/h

Conveying distance : longest conveying path m, incl.


vertical and
horizontal.

Number of deflections : x 90° x 45° x 30°

Number of valves :

Dimension of conveying line : Ø x mm wall thickness

Theoretic conveying line back pressure


at max. conveying capacity : bar

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SCREW PUMP IBAU HAMBURG


Technical data for the screw pump

Screw incline : %
End flight incline : %
Max. volumetric capacity : m3/h
Screw speed : min-1
Power requirement of screw pump : kW
Nozzle hole : mm
End flight material : Wear-resistant cast
Densit application
Welded plating
Special execution in accordance with
drawing no.:

Special execution of the screw : Welded plating


Feeding helix in the inlet area
Double helix
Progressive screw %- %
Design of the cone : Standard
Wear bushing type
Special length mm
Coupling : Type
Supplementary bearing unit equipment at material temperatures > 130° C:
water-cooled oil cooler
air-cooled oil cooler

Technical data for the air compressor

Scope of delivery : IBAU Customer


Make :
Type :
Suction volumetric flow
(based on 1 bar and 20° C : m3/h
Suction pressure : bar abs
End pressure : bar abs

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SCREW PUMP IBAU HAMBURG


Screw pump motor data

Scope of delivery : IBAU Customer


Make :
Type / size :
Output : kW
Speed : min-1
Voltage / frequency : V Hz
Type of protection /
insulation material category :
Special design :

Pulse generator speed monitor Yes No

Scope of delivery : IBAU Customer


Make :
Type :
Number of pulses per revolution :

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SCREW PUMP IBAU HAMBURG


SCREW PUMP
SIZE IB-D100 - 350

TABLE OF CONTENTS Page

1.0.0 Labelling of instructions in the operating manual 7

1.1.0 General instructions 8

1.1.1 Safety instructions for plant 9

1.1.2 Safety requirements at the works 9

1.1.3 Safety measures prior to start-up 10

1.1.4 Safety measures during operation 10

2.0.0 Description 11

2.1.0 Construction and function 11

2.1.1 Construction 11

2.1.1.1 Standard design 12

2.1.1.2 Wear bushing type 12

2.1.2 Function 12

2.2.0 Compressed air supply 14

3.0.0 Installation 16

3.1.0 General instructions for assembly 16

3.2.0 Installation 17

3.2.1 Installation instructions for concrete 18

3.2.2 Installation instructions for steel construction 19

3.2.3 Instructions for assembling the screw pump on the steel construction 19

© 10/2007

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SCREW PUMP IBAU HAMBURG


3.2.4 Motor layout and coupling alignment 20

3.2.5 Assembling the sealing air system 21

3.2.6 Space required for dismounting the screw 24

3.3.0 Instructions prior to start-up of the screw pump 25

3.4.0 Safety regulations for accident prevention 25

3.4.1 Transport and storage 29

4.0.0 Start-up and maintenance 30

4.1.0 Start-up 30

4.2.0 Maintenance 32

4.2.1 Maintenance table 37

4.2.1.1 Grease quantities 38

4.2.1.2 Wear limits 39

4.2.2 General instructions for the installation of stuffing box packagings and
the starting torque of the stuffing box gland 41

4.2.3 Dismounting and inspecting the stuffing box (size 100) 41

4.2.4 Dismounting of wear parts 47

4.2.4.1 Dismounting of the wear plate, end flight and nozzles 47

4.2.4.2 Dismounting of the cone and wear bushings 47

4.2.5 Instructions for O-ring packings 50

4.2.6 Dismounting of the screw 51

4.2.7 Dismounting of the main components of the screw pump 54

5.0.0 Troubleshooting 55

6.0.0 Spare parts / wear parts 57

7.0.0 Coupling 63

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SCREW PUMP IBAU HAMBURG


1.0.0 Labelling of instructions in the operating manual

This symbol means an immediate danger for the life and health
of people.

Danger! Ignoring this symbol will lead to serious damage to your health
and even cause fatal injuries.

This symbol means a possible danger for the life and health of
people.

Warning! Ignoring this symbol may lead to serious damage to your health
and even cause fatal injuries.

This symbol means a possibly dangerous situation.

Ignoring this symbol may lead to minor injuries or damage to


Caution! property.

This symbol gives important instructions for operating the

i machine correctly.

Note Ignoring these instructions may lead to malfunctions in the


machine or its environment.

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SCREW PUMP IBAU HAMBURG


1.1.0 General instructions

This operating manual contains important information with regard to assembly,

i start-up, maintenance and accident prevention. This knowledge is essential to avoid


mistakes and omissions which could have potentially serious consequences. This
operating manual must therefore be read fully before assembly or initial start-up by
Note all persons who are involved with installation, operation, maintenance or repair of
the screw pump, and the instructions contained in the manual must be observed.

The screw pump may only be operated by personnel who are trained and authorised
to do so. It is the responsibility of the machine operator to make sure that the persons
in charge of operation and maintenance of the machinery are familiar with the rules
and regulations.
Responsibility for operating the screw pump must be precisely defined and specified
so that no-one is assigned duties for which they do not have the necessary skills.

IBAU HAMBURG does not accept any liability for damage that occurs as a result of
non-compliance with the operating manual.

The machine must be used for the purpose designated in this operating manual and
the technical specifications in the order confirmation. Otherwise, it will not function
properly and and safely.

The installation of parts or add-on units and the use of parts that are not original
IBAU HAMBURG parts or accessories may influence the given design
characteristics. As the manufacturer, we do not accept any liability for damage
resulting from the use of non-original parts or accessories.

Use for designated purpose

This screw pump is solely designed to convey non combustible dusts like cement,
lime, etc. If it is used for other materials, the responsible engineer at IBAU
HAMBURG should be consulted. The screw pump is not to be set up in rooms in
which an explosive gas/air mixture may form. The screw pump is not suitable for
other pulverized materials, which can form with air an explosive mixture.

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SCREW PUMP IBAU HAMBURG


1.1.1 Safety instructions for plant

Lockable cut-off device


In order to allow hazard-free work on the screw pump, a yellow-red main switch
with an emergency stop lever which can be locked in the OFF position must be
attached immediately next to the pump with 3 padlocks. This main switch is used to
interrupt the energy supply to the screw pump motor - manually as well, when an
emergency stop is made. The use of a padlock prevents the screw pump from being
switched on unintentionally. Screw pump operation must only be approved again
once operational safety has been ensured.

Protective measures for the screw pump motors


Motor guards and motor safety switches – with a PTC thermistor detector and / or
residual-current-operated circuit-breaker if necessary – are to be provided to ensure
electrical safety in accordance with IEC 204 and VDE 0113.

1.1.2 Safety requirements at the works


We cannot be aware of any dependence on other systems at the plant unless we were
entirely responsible for planning. Such dependency must be checked by the operator
separately.

In addition, the following requirements must be fulfilled in order to ensure regular


operation of the plant:

• Installation must be completed properly


• Test run completed successfully including all necessary adjustments
• Safety equipment and electrical interlocking systems installed properly
• The operating personnel must be trained in the proper operation of the plant and
the relevant safety regulations
• Use of the machinery for its intended purpose, and proper maintenance of the
machinery

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SCREW PUMP IBAU HAMBURG


1.1.3 Safety measures prior to start-up
Before every start-up, the operator must ensure that

• no persons or obstacles are in the danger zone of the plant

• the plant has no visible faults

• all signalling and alarm equipment is functioning properly.

1.1.4 Safety measures during operation

ATTENTION! During operation, the inspection covers (Fig. 1, item 15 and 22)
may not be opened under any circumstances! Inspection covers
may only be opened after a complete shutdown of the screw
pump and the conveying air blower / compressor.
Danger!

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SCREW PUMP IBAU HAMBURG


2.0.0 Description

Screw pumps are used for the pneumatic transport of cement, raw meal, various
types of lime, pulverised coal, fly ash, alumina and many other pulverised materials.
No other conveying unit is able to continuously feed large quantities of pulverised
goods into a pneumatic conveying line without an air blow-back. A further
advantage of screw pumps is that they require little space and are particularly low in
height. In special cases (e.g. screw pumps for unloading ships), screw pumps can
operate against conveying line back pressures of up to 2.5 bar. They come in sizes
100 to 350, with capacities ranging from approx. 3 m³/h to approx. 370 m³/h.

2.1.0 Construction and function

2.1.1 Construction

Item Designation
1 Screw
2 Fixed bearing
3 Floating bearing
4 Shaft bushing
5 Motor
6 Coupling
7 Oil level indicator
8 Oil paddle
9 Inlet box
10 Stuffing box
11 Sealing air piping
12 Wear bushings
13 Cone
14 Wear ring
15 Discharge box
16 Counterweight
17 Valve lever
18 Non-return valve
19 Nozzles
20 Conveying line
21 Blind flange
22 Inspection cover
23 Screw pipe

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2.1.1.1 Standard design

The screw pump (Fig. 1) consists of the inlet box (9), the screw pipe (23), the
discharge box (15) and the bearing unit with two bearings and the screw (1).
The fixed bearing (2) and the floating bearing (3) are mounted on the same shaft
bushing (4). This bushing is equipped inside with a centring cone and a feather key
connection to the screw. The screw (1) is actuated by a separately installed motor (5)
via a coupling (6).
The oil level in the bearing unit is shown by the oil level indicator (7). The oil
paddles (8) mounted on the shaft bushing provide the bearings with a steady supply
of oil.
The screw pump is sealed against the inlet box by a stuffing box (10). The additional
supply of sealing air (11) prevents dust from penetrating into the stuffing box (10),
but only if the material inlet space of the screw pump has been dusted. To ensure the
stuffing box functions properly, a negative pressure of min. – 20 to –50 daPa should
be ensured.
At the front section of the screw pump, facing the conveying direction, the screw
rotates in the wear bushings (12), which are mounted in the screw pipe. After the last
wear bushing there is a conically enlarged space (13), the so-called cone. At the end
of the cone there is the wear ring (14). In the discharge box of the screw pump the
counterweight (16) presses the non-return valve (18) against this wear ring (14) via
the lever (17), so sealing off the pressure-free material inlet from the pressurised
conveying chamber. The three nozzles (19) installed at the bottom of the discharge
box (15) are used to blow in the compressed air, which is mixed with the bulk
material. The mixture of air/solids so produced is thus transported to the conveying
line (20) downstream of the discharge box of the screw pump.

2.1.1.2 Wear bushing type

The design of the wear bushing type differs from that of the standard type in the
following respect:
instead of the conical space (13) with a wear ring (14), there is a cylindrical wear
bushing with a conical outlet. This wear bushing is bedded in a cone. This version
does not have a wear ring (see also fig. 16).

2.1.2 Function

The main element of the screw pump is a high-speed screw (1), with speeds of 750
and 1,000 min-1 at 50 Hz operation and speeds of 900 or 1,200 min-1 at 60 Hz
operation.
The purpose of the high-speed screw is to continuously convey bulk material from a
pressure-free material inlet (9) into the pressure chamber of the discharge box (15)
and the downstream conveying line (20). Together with the cone and non-return
valve, the screw and the material flow act as a seal between these two areas.
During operation the non-return valve (18) is made to open by the continuous supply
of material, which then falls into the discharge box (15). There it is mixed with
compressed air via the nozzles (19) and so transported to the conveying line (20).

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Fig. 1
i
Note

SCREW PUMP
ATTENTION!

The direction of rotation of screw


pumps powered by electric motors is
clockwise, facing the drive shaft, while
for screw pumps powered by a
combustion motor it is anti-clockwise!

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IBAU HAMBURG
2.2.0 Compressed air supply

The compressed air required for pneumatic conveying via a screw pump is generally
supplied by blowers or screw compressors. The quantity of compressed air required
for the specific case and the piping diameter of the conveying line are calculated by
IBAU HAMBURG.

Alternatively, compressed air from an air supply network can also be used for
pneumatic conveying.

If you are using compressed air from an air supply network, you are advised to
construct the compressed air device as shown in Fig. 2a order to ensure pneumatic
transport functions perfectly. Alternatively, you can also use a special combined
pressure throughput control valve which greatly reduces the extent of the valves
shown.

Air supply
either right

or left

Fig. 2

The air supply lines can be connected either on the left-hand or the right-hand side of
the discharge box (Fig. 2). The air connection is fitted at the factory with a blind
flange, seal and screws (see also Fig. 1, item 21). This can be bored as specified by
the customer according to the compressed air supply line. The max. diameter of the
air connection line for the relevant size of the screw pumps is given in the
appropriate IBAU dimensional sheet.

The sealing air piping (normally installed in conveying direction left) in the screw
pump is installed opposite the conveying air connection at the factory. However, it
can also be moved to the other side at any time if this proves to be necessary on site.

Attention!
The tightness of the entire conveying air system must be verified following
installation on site!
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Fig. 2a

SCREW PUMP
Legend
1 Main shutoff valve 6 Measuring flange
2 Air pressure measurement 7 Differential pressure regulator
3 Dirt trap 8 High-pressure valve
4 Pressure reducer 9 Needle valve
5 Pressure measurement 10 Differential-pressure
manometer

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IBAU HAMBURG
3.0.0 Installation
3.1.0 General instructions for assembly
The material is normally fed into the screw pump through a surge hopper installed
on the inlet box of the screw pump. The surge hopper must be sufficiently vented.

NOTE!
In the pump surge hopper there should always be a negative pressure of min. -20 to
-50 daPa under all operating conditions to ensure proper venting of the material
flow and proper functioning the stuffing box seal.

Overpressure in the pump surge hopper results in reduced volumetric capacity of the
screw pump and to escape of the bulk material via the stuffing box seal of the screw
shaft.
Always avoid using horizontal venting lines as they become blocked with dust
contained in the outgoing air over time, and this prevents sufficient ventilation of the
surge hopper.
Alternatively, the bulk material can also be fed to the material inlet space of the
screw pump laterally, e.g. via a fluidslide. The material inlet space (Fig. 1, item 9) is
equipped at the side with two inspection covers (Fig. 1, item 22). In this case one
should be removed and the flange connected to a counterflange of the conveying unit
for the supply of material. The lateral connection should preferably be right-handed
in the conveying direction for screw pumps powered by an electric motor (the screw
is clockwise), and for screw pumps powered by a combustion motor preferably left-
handed in the conveying direction (the screw is anticlockwise)! Should the position
of the material inlet described above prove impossible, the matter must be clarified
with the person responsible at IBAU HAMBURG at all events as the volumetric
capacity of the screw pump may be greatly reduced in such a case!
A surge hopper with venting should also be provided with the lateral feed of material
to the screw pump!
When material is conveyed pneumatically to silos or bins using a screw pump,
negative pressure filters must be present at the material transfer point to ensure
sufficient venting of the conveying air.
If several silos or bins have to be filled, the conveying line has to be equipped with
two-way valves leading the material flow into the corresponding silo.
The conveying lines for pneumatic conveying via the screw pump can be laid either
vertically or horizontally. However, under no circumstances should the conveying
lines run up in a slanting conveying direction as this may cause pneumatic conveying
to malfunction. Such piping sections may cause the separation of coarse particles
from the material flow, which then move down along the bottom of the slanting
conveying pipe against the conveying direction. These particles then collect at the
lowest point of the piping section, causing localised pipe blockages which generally
become apparent beforehand by throbbing conveying line back pressure at the screw
pump.
If there is any doubt about the piping route, please consult the person responsible at
IBAU HAMBURG.

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The piping bends used in the pneumatic conveying line should have a minimum
radius of 10 x di (internal diameter of the conveying pipes). In other types of
conveying pipe deflections, clarification must always be sought from the responsible
person at IBAU HAMBURG whether the resistance from this type of deflection
must be allowed for when calculating the pneumatic conveyance.

i
Note
ATTENTION!
If the above points are not observed, IBAU HAMBURG will not guarantee
that pneumatic conveying functions properly.

3.2.0 Installation

Prior to installation of the screw pump check whether all parts are available on site in
accordance with the relevant parts lists. If any parts are missing, then also check the
shipping advices and packing lists. The plant drawings provide further useful
information about possible missing parts.

If parts are found to be missing, the supplier of the screw pump and the person
responsible at IBAU HAMBURG should be notified immediately.

Minor transport damage to the screw pump, e.g. damage to paintwork, should be
repaired on site. More serious damage should be reported to the person responsible
at IBAU HAMBURG. If possible, take photographs and send in to IBAU
HAMBURG so that the damage can be assessed.

ATTENTION!
For screw pumps which are pressure surge-resistant to 10 bar the following
instructions must be observed without fail:
Warning!
Should damage have occurred to the following components during transport or
subsequent installation, these items may not be installed:

• inlet box
• screw pipe
• inlet box with screw pipe (only with screw pump type 151 and 251)
• discharge box.

This also applies to damage of the contacting thermometer or the resistance


thermometer used to monitor the oil temperature of the bearing unit and all other
electrical equipment installed on the screw pump and approved for the ambient zone
(21 or 22).

Once all necessary parts are available and without defects, check that all
requirements are satisfied for proper installation.

• Does the installation situation comply with that of the installation drawing?
• Does the available height comply with that in the drawing?

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3.2.1 Installation instructions for concrete

Fig. 3.1
1.1 Prepare the foundation according to the drawing or dimensional sheet
1.2 Construct the foundation on grown soil or existing concrete sole.
1.3 Fill in the gap between foundation and soil with bitumen (n/a with concrete
sole!).
1.4 Do not forget the measurement for dismounting the screw (group 3.2.2 or
Fig. 6)!

Fig. 3.2
2.1 Insert anchor bolts.
2.2 Position screw pump.
2.3 Align the pump by means of spacers using a water-level.
2.4 For test purposes, turn the screw at the coupling and ensure that the screw
rotates without contact.

Fig. 3.3
3.1 Fit the shuttering.
3.2 Pour in around 5 cm of casting concrete beneath the shuttering strength class
C30/37 with additive (swelling agent).
3.3 Allow to set.
3.4 Remove shuttering.
3.5 Tighten the anchor bolt nuts to a maximum torque of 120 Nm.
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3.2.2 Installation instructions for steel construction

Instructions for dimensioning the steel construction used for setting up the pump.

• To ensure that the steel construction can oscillate safely, it is essential that the
natural frequencies of the steel construction are sufficiently outside the exciting
frequencies of the screw pump.

• The deflection of the displacement carriers on which the screw pump is carried
must not exceed 1/1000 of the span when they have to bear their own load and
the live load! In addition, sheet metal discs or bonds must be provided to brace
the horizontal displacement of the carriers.

• The load factor given covers the dead weight of the screw pump, attached parts
(e.g. motor, pump surge hopper), the weight of the filling and the necessary
safety allowances for additional loads and vibrations which may arise.

• Screw pump weight including


attached parts and filling : see order specific
load data in load plans

• Screw pump speed : see order specific speed

• Critical natural frequency range


of screw pump : 13 to 20 Hz at 1000 min-1
: 10 to 15 Hz at 750 min-1

3.2.3 Instructions for assembling the screw pump on the steel construction

1. The base frame, the screw pump, the motor, the motor console and the
fastening screws are delivered separately.

2. Mount the screw pump and the motor with the motor console on the base frame
according to the installation drawing. Then align the coupling in accordance with the
instructions.

3. Position the entire assembly (base frame with screw pump and motor) on the steel
construction in the location provided and align with a water-level.
To align you may have to place extra spacers at certain locations.

4. Screw the base frame to the steel construction or weld together at places
(relevant procedure to be specified by customer).
Then turn the coupling manually to see if the screw rotates without contact in the
wear bushings.
If the screw does not rotate without contact, unscrew the screwed connections
holding the screw pump and base frame together once again. Place extra lining plates
under the appropriate points to realign the screw pump so the screw rotates without
contact. Finally realign the coupling.

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3.2.4 Motor layout and coupling alignment

In case of V-belt drive the motor has to be mounted to the side of the screw pump on

i slide rails according to the manufacturer’s instructions.

With direct drive of the screw pump the motor should be positioned so it can be
Note
moved back slightly to dismount the screw! Take the dismounting dimensions given
by the manufacturer of the coupling into consideration here.

The coupling is aligned by means of a dial indicator, a shaft ruler and a thickness
gauge according to the instructions of the coupling manufacturer. The coupling gap
(Fig. 4) to be adjusted is shown in the operating manual for the coupling.

Straigh
t edge
Note the direction of the arrow!

The direction of rotation for screw


pumps powered by an electric motor is
clockwise! Screw pumps powered by a
combustion motor run anti-clockwise,
Spacer facing the drive shaft end.
bar
Radial Axial and
alignment height alignment

Fig. 4
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3.2.5 Assembling the sealing air system

Screw pumps are delivered with the sealing air piping, designed to a pressure rating
of PN 10, already mounted.
However, if this was dismantled before transport for packaging reasons, the sealing
air piping should be reassembled according to Fig. 5 on installation of the screw
pump at the installation site.

1- diaphragm pressure gauge DIN 837-3, housing Ø 160,


indicating range 0 - 2.5 bar, to be fitted with flange DN 50 - PN 10

2- diaphragm pressure gauge DIN 837-3, housing Ø 160,


indicating range 0 - 2.5 bar, fitting R ½“

3- spring tube pressure gauge DIN 837-1, housing Ø 100, indicating


range 0 - 1 bar, fitting R ½“

4- spherical cock R ½“

5 and 6 - spherical cock R ½“ with screw pump size 100


spherical cock R ¾“ with screw pump size 151 – 200
spherical cock 1“ with screw pump size 251 and 300
spherical cock 1 ½ “ with screw pump size 350.

i The tightness of the sealing air system must be verified following installation of the
sealing air piping on site!

Note

Note
The above parts relate to the standard screw pump. In some cases deviations may
occur.

In some cases it may prove necessary on site to extract the sealing air slightly away

i from the screw pump directly from the conveying air supply line or from the works
network.
This is for example the case when on the basis of the customer's process control
Note responsibility or with constant power failures at the works, the air compressor is
suddenly switched off during conveying. In such a case there is the risk of the
material flowing back in the stuffing box of the screw pump due to the back pressure
still present in the conveying line via the nozzles and sealing air piping. When the air
compressor is switched back on, the material flows through the stuffing box housing
with the sealing air at high speed. The resulting "sandblasting effect" then causes
damage to the stuffing box housing.

Should such improper mode of operation constantly occur during operation of the
screw pump, the person responsible at IBAU HAMBURG should be informed
immediately to jointly seek possible solutions to prevent further damage to the screw
pump.
In such a case IBAU HAMBURG shall accept no warranty liability for any damage
that has already occurred!

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For the extraction of sealing air from the works network a pressure regulator and a
volume flow controller should be provided to ensure the following adjustment
values:

• Pressure should be adjustable in the range 0.02 to 0.2 bar (see. item 4.1.0 page 31)

• The sealing air volume should be adjustable according to the following table

Pump size Sealing air volume [m³/min]


100 1,0
151 1,0
200 1,0
251 3,0
300 3,0
350 3,0

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Cross-section A - C

Fig. 5

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3.2.6 Space required for dismounting the screw

Note
How to dismount the screw is described in item 4.2.5.

Screw pump
Type IB-D

Screw pump
Type IB-DV

Fig. 6

Table II

Size Type IB-D Type IB-DV

100 A = 1250 B = 1600


151 A = 1650 B = 2000
200 A = 2000 B = 2400
251 A = 2600 B = 3100
300 A = 2950 B = 3500
350 A = 3400 B = 4000

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3.3.0 Instructions prior to start-up of the screw pump

Every delivered screw pump has undergone an 8-hour test run and is normally filled
i
Note
with the right type and quantity of oil.

However, for safety reasons it is advisable to recheck the oil level at the oil level
indicator (Fig. 1, item 7) provided for this purpose prior to start-up.

ATTENTION!
The correct oil level can only be checked when the screw pump is at a standstill!

If however in an exceptional case the pump is delivered without oil , the correct
quantity of oil according to the oil level table on page 36 must be added.

The stuffing box at the shaft exit to the inlet box of the screw pump is adjustable and
is equipped with 3 packing rings and a grease ring.

The stuffing box packagings are made of the material "Arochem S" and have already
been provided with sufficient grease at the factory during the test run.

ATTENTION!

i As there may have been a lengthy period of time between delivery of the screw
pump and its start-up, the stuffing box must be regreased without fail prior to start-
up, and the correct starting torque for the stuffing box gland also checked
Note (see item 4.2.2 on page 40.)

During start-up and proper operation of the screw pump the following outside
temperatures for the housing are within the acceptable range:

• bearing unit at bearing max. 80° C


• stuffing box max. 80° C

ATTENTION!
If the above temperatures are greatly exceeded, the screw pump should be taken out
of service and the cause for the rise in temperature determined!

3.4.0 Safety regulations for accident prevention

The coupling protection (Fig. 7), the protective cover (Fig. 7 a) in the area between
the bearing unit and the stuffing box and the belt guard for V-belt-driven screw
pumps may only be removed when the machine is at a standstill. Before the machine
is restarted, the above protection devices must be properly fitted again.

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SCREW PUMP IBAU HAMBURG


ATTENTION!
Before removing the coupling protection and the protective cover, the machine
must be secured against being switched on unintentionally!
Danger!
The inspection covers on the inlet box and the discharge box of the screw pump
should only be opened using tools! Before the inspection covers are removed, the
screw pump must always come to a proper standstill and be secured against being
switched back on unintentionally!
Inspection covers on the pump surge hopper may only be opened using tools
Danger! ! Should they be located less than 850 mm from the rotating screw, the screw pump
must always come to a proper standstill and be secured against being switched back
on unintentionally before being opened.

Existing emergency operating facilities, for example emergency operating elements,


as well as possible sources of danger during operation of the screw pump must be
clearly indicated by written warning signs.

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Coupling protection

Fig. 7
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Protective cover

Fig. 7 a

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3.4.1 Transport and storage

Screw pumps must be protected against external influences such as rain, impact or
i
Note
breaking.

The screw pump must be stored prior to installation in a dry place under cover!

The screw pump must be transported on its frame as shown (see Fig. 8). Here the
rope must never be fastened to the screw shaft at point (A) and (E), the coupling (B),
the cone (C) or the stuffing box (D).

Fig. 8

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4.0.0 Start-up and maintenance
4.1.0 Start-up
ATTENTION
Prior to initial start-up of the screw pump the inspection cover on the discharge box
should be opened and the non-return valve lifted and secured so that the gap between
the end flight and the wear bushings can be checked.
Afterwards this procedure is repeated for the inlet area of the screw pump by
opening an inspection cover on the inlet box and checking the gap between the screw
and the wear bushing at the entry to the screw pipe.
The factory-set dimensions for the radial gap can be found in the test record for the
pump in both cases.
Should the radial gaps greatly diverge from the factory-set dimensions, or if the end
flight or screw knock against the wear bushings, alignment of the screw pump and/or
bearing unit should be carried out on site to correct the gaps.
IMPORTANT!
In case of any doubt a screw pump specialist should be consulted at IBAU
HAMBURG regarding performance of the above work!
Before start-up of the pneumatic conveyor installation via the screw pump make sure
that there is sufficient take-up capacity for the material flow in the receiving silos!
Before proceeding further with start-up first start the outgoing air filter on the
receiving silo selected. The air compressor / blower and the screw pump are then
switched on and the material feed started after a delay.
In order to monitor the pressure during transport each screw pump is supplied with
three pressure gauges:
• 1 diaphragm pressure gauge, which is positioned on the sealing air piping
opposite the air supply. This gauge indicates the pressure upstream of the nozzles
in the discharge box of the screw pump, i.e. before the conveying air is mixed
with the material flow. It is thus also referred to as the air pressure gauge (Fig. 5,
item 2). This pressure exceeds the back pressure by the value of the pressure
drop at the nozzles (approx. 0.2 to 0.3 bar depending on the design)!
• 1 diaphragm pressure gauge with an open measuring flange. This is mounted on
the discharge box of the screw pump. It indicates the specific conveying line
back pressure (product of the pressure loss for the equivalent conveying line
length and the quantity of material currently conveyed) and is therefore also
referred to as the back pressure gauge (Fig. 5, item 1).
• 1 spring tube pressure gauge to indicate the sealing air pressure, called the
sealing air pressure gauge (Fig. 5, item 3). The sealing air pressure is adjusted by
means of a spherical cock with the nominal conveying capacity and should fall
within the range 0.02 bar to 0.2 bar. The maximum value of 0.2 bar must not be
exceeded as this might otherwise cause damage to the stuffing box!

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IMPORTANT!
With very light bulk materials such as filter dust and pulverized coal, the sealing air
pressure should be approx. 0.02 bar as higher pressures might cause major fluidisation
of the material in the inlet area of the pump, possibly reducing the volumetric capacity
of the screw pump!

If it transpires on start-up that the difference in pressure of the nozzles is greater than
0.3 bar with the nominal conveying capacity, the person responsible at IBAU
HAMBURG should be contacted to bring about correction of the nozzle bores. Here
the existing plant parameters such as the quantity of material currently conveyed and
the actual equivalent conveying pipe length should be given so a new nozzle
calculation can be carried out.

NOTE!
In the partial load area of the pneumatic conveying the difference in pressure between
the air pressure and the back pressure may exceed the pressure of 0.3 bar given above.
This however does not represent any defect in the design of the nozzle bores!

The counterweight on the lever of the non-return valve is adjustable in its position.
In addition, it features a split design to reduce the weight if necessary.

The position and size of the counterweight depend on the material flow (e. g. wear
behaviour, bulk density and fineness) and on the specific plant parameters (e.g. level
of conveying line back pressure). On start-up of the plant the position of the
counterweight should be adjusted to ensure the seal between the pressurised discharge
box and the pressure-free inlet box of the screw pump with the nominal conveying
capacity; i.e. no conveying air should flow back to the inlet area of the screw pump.
Another criterion for adjustment of the counterweight is the drive of the screw pump.
The adjustment should be selected so that the nominal current of the drive motor is not
exceeded with the nominal conveying capacity.

NOTE!
For specific cases the screw pump type IB-D 350 is equipped with special non-
return valve damping, with two pneumatic cylinders, make Norgren Herion. They
have a damping effect on the closing direction of the non-return valve. In this
specific case a separate drawing and an operating manual for the components used
are included with this documentation.

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4.2.0 Maintenance

Maintenance of the screw pump depends on the specific operating conditions. Under
normal operating conditions maintenance should be carried out in accordance with
the table below (see 4.2.1 page 38).

Grease lubrication of the stuffing box and the non-return valve bearing must be

i carried out according to the intervals specified in the maintenance table (cf. 4.2.1
page 38) and with lubricating grease of Esso Unirex 3 quality or with an equivalent
grease as per DIN 51502 - KL 2 K. The relevant lubricating points are equipped with
Note
button head lubricating nipples as per DIN 3404 AM10x1 (Fig. 11c /item 46 page 45
and Fig. 15 between items 4 and 5 page 57)

The sealing air pressure (Fig. 5, item 3) should be adjusted according to the data

i given in item 4.1.0 and adjustment checked at regular intervals.


On the opposite side of the sealing air inlet there is a control cock which should be
opened briefly at regular intervals to check the stuffing box and remove any dust
Note which has entered.

IMPORTANT NOTE!
The control cock must not be opened while conveying material as this may damage the
stuffing box housing! However, to clean the stuffing box and remove any dust which
has entered the conveying air must be connected.

The oil for the bearing unit must be filled in via the opening in the vent socket

i (Fig. 9, item 1), with the cover unscrewed.


The bearing unit is drained through the oil drainage cock located on the opposite side
of the oil filling level indicator (Fig. 9 / item 5).
Note To lubricate the bearings oil quality SAE 15W/50 or SAE15W/40 should be used.
After initial start-up of the screw pump change the oil after 300 hours. Then change
it every 6 months or not later than 3000 operating hours.

The maximum oil temperature in operation is approx. 80° C under normal operating

i conditions and is read off the thermometer (Fig. 9, item 3) of the bearing unit.
Higher oil temperatures point to an excessively high or low oil level in the bearing
unit or to possible damage to the bearings.
Note In such cases the oil level should be corrected according to the following table on
page 36 or the defective bearings replaced!

IMPORTANT NOTE!
Inoperative thermometers should be replaced immediately to ensure correct
readoff of the permissible oil temperature of the bearing unit!

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From time to time check the tight fit of the oil paddles in the bearing unit of the
screw pump via the vent socket (Fig. 9, item 1).
When removing the oil paddles (Fig. 9, item 2) secure with wire hooks (Fig. 9,
Caution! item 4) as illustrated to prevent them from falling into the bearing unit.

IMPORTANT NOTE!
Should an oil paddle have fallen into the bearing unit in such a case, the screw pump
must not be started up under any circumstances as this might cause serious damage
Caution! to the bearing unit! In this case the complete bearing unit must be taken apart to
remove the oil paddle!

The screw pumps in sizes 100 to 200 are equipped with one oil paddle in the middle.
From size 251 to size 350 the screw pumps are equipped with four oil paddles, two
each on the floating bearing and two on the fixed bearing side.
Caution!

IMPORTANT NOTE!
When checking or performing maintenance on the oil paddles, the screw pump must
always come to a proper standstill and be secured against being switched back on
unintentionally!
Caution!

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Hook for oil paddle

Fig. 9

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i Oil level * Cross-section A-A
Note only for screw pump P151

Oil level at
standstill

Screw pump approx. litres mm "H" (max.)


P 100 ** approx. 1.25 43
P 151 * approx. 1.4 31
P 200 approx. 2.1 40
P 251 approx. 5.5 50
P 300 approx. 5.6 38
P 350 approx. 8.0 50

Note: This information applies to initial filling of the screw pump and should be used as a
guideline only. When refilling oil (only at standstill of the pump) the value
marked at the inspection glass of the oil-level indicator (see mm "H") must not be
exceeded in any case. However, falling short of the oil level by 2 mm is
admissible.

** Note on screw pump IB-D100 with oil cooler:


For the screw pump IB-D100 with oil cooler the oil filling quantity of 1.8 l is so low in
relation to the circulating oil quantity that it is not possible to read the oil filling level on the
bearing unit. For this reason there is an oil-level glass in the pressure pipe supplying the
bearing unit instead of the oil level indicator on the bearing unit. During operation of the oil
cooler it can be checked in the glass at any time if there is oil circulating. About 10 minutes
after switching off the oil cooler is possible to check the oil level via the mark shown on
the glass.

Note when changing oil:


When changing the oil, it is advisable to drain the oil when it is still hot from operation.
First the plug (Fig. 10 / item 1) on the oil drainage cock (Fig. 10 / item 2) must be removed
and this then opened. The oil drainage cock (Fig. 10 / item 2) must remain open until the
entire oil quantity has been drained off from the bottom of the bearing unit. The oil drainage
cock (Fig. 10 / item 2) is then closed and the plugFig. 10 / item 1) refitted.

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IMPORTANT NOTE!
Only when the plug is fitted can unintentional opening of the oil drainage cock be
prevented - and running dry of the bearing!

When the bearing unit is subsequently filled with oil, it must be ensured that the oil filling
quantity specified for the size of the screw pump is not exceeded. An excessive oil level
may cause the superfluous oil to escape at the felt ring seal on the coupling side at the
bearing unit!

Fig. 10

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4.2.1 Maintenance table

The following table applies for normal operating conditions:

No. Description Interval Action Note


1. Stuffing box Weekly or max. Visual Esso Unirex 3
every 100 op. inspection or
hours re-apply
lubrication as
necessary

2. Stuffing box packings Annually or Replace


max. every
8,000 op. hours
3. Oil level bearing unit Weekly Visual (see 4.2.0)
inspection
4. Oil change bearing unit Every 6 months Change oil 1 HD oil
or max. every SAE 15 W/50
3,000 op. hours
5. Non-return valve / Monthly Lubricate Esso Unirex 3
Shaft bearing
6. Wear bushing, end Every 3 months Visual (see 4.2.2)
flight and screw inspection and
check for wear
7. Bearings Every 3 years Change
or max. every bearings
24,000 op.
hours
8. Felt rings bearing unit Annually or Replace
max. every
8,000 op. hours
9. O-rings Whenever Replace
dismantled

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4.2.1.1 Grease quantities

Screw Description Quantity


pump [kg]
Size 100 Stuffing box 0,061
Size 100 Bearing non-return valve shaft / 0,004
side with counterweight
Size 100 Bearing non-return valve shaft / 0,033
side without counterweight
Size 151 Stuffing box 0,080
Size 151 Bearing non-return valve shaft / 0,006
side with counterweight
Size 151 Bearing non-return valve shaft / 0,035
side without counterweight
Size 200 Stuffing box 0,110
Size 200 Bearing non-return valve shaft / 0,008
side with counterweight
Size 200 Bearing non-return valve shaft / 0,035
side without counterweight
Size 251 Stuffing box 0,187
Size 251 Bearing non-return valve shaft / 0,011
side with counterweight
Size 251 Bearing non-return valve shaft / 0,034
side without counterweight
Size 300 Stuffing box 0,187
Size 300 Bearing non-return valve shaft / each side
both sides 0,009
Size 350 Stuffing box 0,009
Size 350 Bearing non-return valve shaft / each side
both sides 0,014

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Manufacturing mass Wear limit
End flight Screw
Screw pump de/ds db ge/gs tec ted tes tesa ts

SCREW PUMP
size: Cilld cast irion Densit Steel Steel with welded plating
4.2.1.2 Wear limits

100 99 - 100 102 - 102,1 4-6 7-8 9 - 10 5-6 10 - 11 5-6


151 152,9 - 153,6 156 - 156,5 6-8 7-8 14 - 15 6-7 12 - 13 6-7
200 204,3 - 205 208 - 208,5 6-8 7-8 14 - 15 6-7 12 - 13 6-7
251 248,5 - 250 253 - 253,5 8 - 10 7-8 14 - 15 7-8 13 - 14 8-9
300 302,5 - 303,5 308 - 308,5 8 - 10 7-8 14 - 15 9 - 10 15 - 16 8-9

350 354,5 - 355,5 360 - 360,5 10 - 12 8 - 10 18 - 19 9 - 10 15 - 16 10 - 11

Remark: The above values are indicated in mm.

Legend:
de Diameter end flight
ds Diameter screw
db Diameter wear bushing
ge/gs Maximum admissible gap between end flight / screw and wear bushing
tec Maximum admissible thickness of end flight made of chilled cast iron until exchange
ted Maximum admissible thickness of end flight with Densit application until exchange
tes Maximum admissible thickness of steel end flight until exchange
tesa Maximum admissible thickness of steel end flight with welded plating until exchange

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ts Maximum admissible thickness of the screw helix until exchange
Fig. 11:
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4.2.2 General instructions for the installation of stuffing box packagings and
the starting torque of the stuffing box gland

When installing stuffing box packagings it should be ensured that the joints of the
individual packing rings are offset 180° in relation to each other on installation in the
stuffing box housing!
The packagings and grease ring are carefully inserted in the stuffing box housing
individually by hand with the help of the stuffing box gland (see Fig. 12a to 12c)
until a noticeable resistance is felt. The nuts of the stuffing box gland are then
tightened until a noticeable resistance occurs. A marking is now made on the nuts
(e.g. using a waterproof pen), which allows correct tightening of the stuffing box
gland to be checked. With an open-jawed spanner the nuts should now be tightened
crosswise 1½ revolutions!

4.2.3 Dismounting and inspecting the stuffing box (size 100)

When dismounting and inspecting the stuffing box packagings (Fig. 12 a) it is not
necessary to remove the screw.

1. Separate and dismount the stuffing box gland (41).


2. Withdraw the grease packing (42) together with the packing rings (20) and
the grease ring (19).
3. Clean the grease packing (42), grease ring (19) and the wear bushing (21).
4. Check the O-ring packing (11) and replace if necessary.
5. Grease the wear bushing (21) thoroughly at the packing rings.
6. Mount the grease packing (42).
7. Replace the packing rings (20) if necessary. Grease the running tread of the
packing rings thoroughly before installing.
8. Mount the packing rings (20) together with the grease ring (19).
9. Mount the gland (41) and tighten the packing only manually at the nuts (43).
10. Prior to operation regrease the stuffing box at the relevant lubrication
nipples (46).
11. Before restarting the screw pump check the screw rotates smoothly. This
should move freely without running on when the coupling is just turned by
hand!
12. After a running-in period of 2 hours the correct starting torque of the stuffing
box should be adjusted as described under 4.2.2.

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Fig. 12 a: Stuffing box size 100
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Dismounting and inspecting the stuffing box (size 151)

When dismounting and inspecting the stuffing box packagings (Fig. 12 b) it is not
necessary to remove the screw.

1. Separate and dismount the stuffing box gland (41).


2. Withdraw the packing rings (20) together with the grease ring (19).
3. Clean the housing (44), grease ring (19) and the wear bushing (21).
4. Grease the wear bushing thoroughly at the packing rings.
5. Replace the packing rings (20) if necessary. Grease the running tread of the
packing rings thoroughly before installing.
6. Mount the packing rings (20) together with the grease ring (19).
7. Mount the stuffing box gland (41) and tighten the packing only manually at
the nuts (43).
8. Prior to operation regrease the stuffing box at the relevant lubrication
nipples (46).
9. Before restarting the screw pump check the screw rotates.
smoothly. This should move freely without running on when the coupling is
just turned by hand!
10. After a running-in period of 2 hours the correct starting torque of the stuffing
box should be adjusted as described under 4.2.2.

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Fig. 12 b: Stuffing box size 151

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Dismounting and inspecting the stuffing box (size 200 - 350)

When dismounting and inspecting the stuffing box (Fig. 12 c) it is not necessary to
remove the screw.

1. Separate and dismount the stuffing box gland (41).


2. Withdraw the stuffing box housing (44) using the forcing screws (45).
3. Separate the stuffing box housing (44).
4. Clean both sections of the housing.
5. If necessary replace the wear ring (18).
6. Grease the wear bushing (21) thoroughly at the packing rings.
7. Also thoroughly grease the packing rings (20) on the running treads.
8. Reassembly of the stuffing box is carried out in reverse order to
dismounting.
9. Mount the stuffing box gland (41) and tighten the packing only manually at
the nuts (43).
10. Prior to operation regrease the stuffing box at the relevant lubrication
nipples (46).
11. Before restarting the screw pump check the screw rotates.
smoothly. This should move freely without running on when the coupling is
just turned by hand!
12. After a running-in period of 2 hours the correct starting torque of the stuffing
box should be adjusted as described under 4.2.2.

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Fig. 12 c: Stuffing box size 200 - 350

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4.2.4 Dismounting of wear parts

The wear parts (Fig. 13) are dismounted in the order given via the inspection
opening (47) in the discharge box as soon as they are worn out. They should only be
replaced by original spare parts by IBAU HAMBURG as this is the only way to
ensure perfect functioning of the screw pump.
A stock of these original spare parts should therefore always be kept by the
customer.

4.2.4.1 Dismounting of the wear plate, end flight and nozzles

1. Remove the inspection cover (47), open the non-return valve (48) and secure
carefully in this position.
2. The wear plate (9) can now be removed from the non-return valve (7).
3. The end flight (13) can now be removed from the screw using the end flight
withdrawal device (49) supplied.
4. The nozzles (6) can now be replaced.

4.2.4.2 Dismounting of the cone and wear bushings

1. Remove the inspection cover (47), open the non-return valve (48) and
secure carefully in this position.
2. Take off the divided separating flange (50) from the side.
3. Remove the O-ring (11) (only applies to screw pump size 150 - 200)
4. Separate the wear ring (10) from the cone.
5. With screw pumps size IB-D100 and IB-D350 then withdraw the cone (12)
towards the inspection opening.
With screw pumps size IB-D151 / 200 / 251 and 300 the discharge box has to
be dismounted here to replace the cone and wear bushings.
6. Remove the O-rings from the cone (only applies to screw pump size 100).
7. Push out the wear bushings (15) after removing the plug (51) using a
screwdriver.

NOTE:
In some cases material penetrates in between the bearing carriers in the
screw pipe and the wear bushing due to a wear bushing already being worn
through. In this case the screw then has to be dismounted (see also item 4.2.5
on page 49).
With screw pumps size 300 and 350 it is helpful to also remove the discharge
box as this allows work to be carried out more easily on the wear bushings.
They can now be removed with a cut-off angle grinder to facilitate
dismounting. However, this should be done with great care to ensure you do
not cut too deeply and possibly damage the screw pipe!

If marks have been caused on the bearing surfaces in the screw pipe when
dismounting the wear bushings, they can be smoothed out before re-
installation with a fine-grain abrasive cloth.

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i NOTE: On assembly all O-rings removed must be replaced without exception!

Note For screw pumps size 100 and 151 the O-rings must be inserted in the cone (see 4.2.4)
before remounting.

For the screw pump size 200 the O-ring must be inserted after installation of the
cone between the housing and the separating flange (see 4.2.4). The separating
flange (50) is then affixed to the discharge box again.

For screw pumps size 251 to 350 the O-rings must be inserted the cone (see 4.2.4).
Only then is the separating flange (50) positioned and affixed to the discharge box.

When the wear parts have been mounted again as described above, check the fit of
the wear bushings through the tap hole (51) for the plug. Before starting the screw
pump again, make sure the screw with the end flight rotates smoothly and without
resistance in the wear bushings.

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Fig. 13

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4.2.5 Instructions for O-ring packings

If an O-ring has to be replaced, it can be cut to size out of a round cord with a
suitable diameter. Normally a round cord made of the material "Viton", which is
heat-resistant up to +200° C, for the screw pump. At higher operating temperatures,
special materials are used. For this reason consult IBAU HAMBURG about the
material quality used before replacing the round cord. We also recommend stocking
up with a sufficient quantity of the necessary round cord with the dimensions for
each size of pump in good time before carrying out maintenance work.
NOTE: Whenever the equipment is dismantled, the O-ring installed must be

i replaced!
When replacing the O-ring proceed as follows:
Note
• Cut the round cord to the length of the dismounted O-ring, adding another
5-10mm.
• Before installation check whether the edges of the groove for accommodating the
O-ring are broken. If they have sharp edges, the new O-ring might become
damaged, causing the O-ring packing to leak.
• Knock the round cord carefully into the groove provided using a mallet
(divergence from this see item 4.2.3 / Installation of cone and separating flange
for screw pump sizes 100 to 350).
• Cut the projecting ends of the round cord axially with a mitre of 45° so that the
cut edge is not visible from the pressure side (Fig. 14).

Fig. 14
Pressure

ATTENTION!
i If a round cord has been cut too short, never try to adjust it by stretching it to the
required length. "Stretching" will reduce the diameter of the round cord, impairing
its sealing effect!
Note

• As the adhesive for the joint between the two ends of the round cord
Loctite 101® should be used.

ATTENTION! Unsuitable adhesives may soften the round cord!

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4.2.6 Dismounting of the screw

The screw can be dismounted independently of the wear parts as follows (Fig 15):

1. Draw back the motor with the coupling half until there is sufficient space for
the screw shaft.
2. Remove the coupling half from the screw shaft.
3. Secure the shaft against uncontrolled rotation by placing the assembly aid (2,
not included in IBAU HAMBURG delivery package) in place, or by
removing the cover of the inlet box and using a wooden wedge.
4. Remove the inspection cover (3) on the discharge box, open the non-return
valve (4) and secure carefully in this position.
5. Release the nuts (5 and 6) used to secure the screw axially with an open-
ended spanner (not included in IBAU HAMBURG delivery package) (left-
hand thread). The necessary width across flats are given in the table below.
6. Take off the cup spring (7) and the thrust collar (8).
7. Loosen the screw from the conical fit of the shaft bushing by striking the
shaft end with a recoilless plastic hammer (9).
After loosening the screw, pull it out carefully from the screw pipe in the
conveying direction.

Pump type Width across flats Recommended key length


IB-D100 60 none
IB-D151 75 1.20 m
IB-D200 120 2.00 m
IB-D251 150 2.00 m
IB-D300 150 2.00 m
IB-D350 155 2.00 m

ATTENTION!
Use an open-ended spanner when unscrewing and tightening the nuts on the
screw. For accident-prevention reasons, the use of other tools such as gaspipe
pliers is forbidden.

ATTENTION!
If a plastic hammer is not used, the end of the screw should be protected from
damage by the hammer blows with a piece of hard wood or copper !

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Before reinstalling, thoroughly clean the cone of the screw (10) and apply copper
paste. Then remount the screw. Tighten the nut (6) until the cup spring (7) is lying
flat against the shoulder ring (11). Then tighten with the second nut (5).
Then mount the coupling half on the pump side (the claw of the coupling normally sits
on the screw shaft and only on the motor shaft in exceptional cases). Advance the
motor with the second coupling half and align the coupling according to item 3.2.4.
The information given by the manufacturer of the coupling (here see separate
operating manual for coupling) should be taken into consideration as regards the
coupling backlash to be adjusted.

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Fig. 15

SCREW PUMP
For screw dismounting dimension see table II on page 20

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4.2.7 Dismounting of the main components of the screw pump

Should it become necessary to replace a main component of the screw pump, e.g. the
bearing unit, inlet box, screw pipe or discharge box, proper pinning must be ensured
on subsequent installation of the new component. After alignment of the new
component perform the necessary new pinning diagonally in relation to the existing
pins.

If following an explosion it is necessary to replace one or more components in a


screw pump pressure surge-resistant to 10 bar, only original components which have
been subjected to a water pressure test by IBAU HAMBURG beforehand may be
used.

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5.0.0 Troubleshooting

1. The back pressure gauge indicates a pulsating back pressure in the conveying
line, possibly also causing obstruction of the conveying line.
Check:
a) Has anything changed in the piping system or at the receiving point?
b) Has the material quantity to be fed in been changed (e.g. greater than the
max. conveying capacity calculated)?
c) Is the compressed air supply unit of the screw pump working properly
(e.g. conveying capacity smaller than calculated)?
d) Is there a piping section slanting upwards in the conveying direction?
e) Has there been an increase in the share of coarse particles in the material
flow?
---------------------------------------------------------------------------------------------
2. The conveying capacity of the screw pump has fallen and the material flow
increases in the pump surge hopper.
Check:
a) Has the sealing air pressure been set correctly for the specific material
flow (cf. 4.1.0 - Spring tube pressure gauge for sealing air pressure)?
b) Is the venting of the pump surge hopper functioning properly? i.e. there is
a slight negative pressure in the pump surge hopper
(cf. 3.1.0 - General instructions for assembly)?
c) Are the screw and/or wear bushings heavily worn, thus causing a major
increase in the gap dimension?
d) Are the wear ring and/or valve plate of the non-return valve heavily worn
so that the tightness of the non-return valve is no longer ensured?
e) Is the quantity of material fed in greater than the conveying capacity of
the screw pump as designed?
---------------------------------------------------------------------------------------------
3. The bearings of the screw pump become too hot (temperature > +80° C).
Check:
a) Is the oil level in the bearing unit correct (cf. 4.2.0 – Maintenance)?
b) Was the right oil quality filled in? If necessary, change the oil.
c) Does the running noise of the bearings indicate damage?
d) Has material possibly got into the bearing unit when blowing out bulk
material from the stuffing box?
e) Has the temperature of the material flow increased? With material flow
temperatures > +130° C the use of an oil cooler is necessary.
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4. Oil is oozing out of the bearing unit.
Check:
a) Is the oil level in the bearing unit too high?
b) Is one of the oil drain holes in the bearing unit blocked?
c) Is the O-ring packing of the bearing covers working properly?
d) Are the felt ring seals of the bearing unit working properly?
e) If felt ring seals have been replaced, has the joint of the felt ring been
installed downwards?
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5. There is a leak in the stuffing box and dust-laden air is blown out.
Check:
a) Is there overpressure in the pump surge hopper? Check the functioning of
the dedusting system and the state of the dedusting pipe to the pump
surge hopper!
b) Determine the state of the stuffing box packagings and wear bushing (too
rough due to wear?) on the screw shaft.
NOTE:
To restore the proper functioning of the stuffing box after blowing out
material new packaging will be required here at all events!

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6.0.0 Spare parts / wear parts

When ordering spare parts, take care to indicate the data on this type plate
accurately: The type plate is fixed on the inspection cover of the screw pump. The
type designation of the screw pump is followed by the machine number
(e.g. IB-D350 / 6897). Please always give this number when ordering spare parts.

Type
Com.-No.
Item-No.

Further data can be taken from the following table (see next page):

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Table of spare parts and wear parts

Item Spare part Wear part

1 Transition piece
2 Seal
3 Back pressure gauge
4 Rotary shaft seal
5 Stuffing box packings
6 Set of nozzles
7 Non-return valve
7a Non-return valve **
8 Valve lever
9 Wear plate
9a Wear plate **
10 Wear ring
11 O-ring cord*
11 a O-ring cord*,**
12 Cone
13 End flight
14 Wear bushing (hardened)
15 Set of wear bushings
16 Air pressure gauge
17 Screw
18 Wear ring
19 Grease ring
20 Stuffing box packings
21 Wear bushing
22 Felt ring
23 Thermometer
24 Floating bearing
25 Seal-off air pressure gauge
26 Oil paddle
27 Fixed bearing
28 Cup spring
29 Hexagonal nut
30 Oil level indicator
31 Wear ring bushing **
32 Locating cone **
41 Stuffing box cover
42 Grease packing
44 Stuffing box housing

* see 4.2.4 - instructions for O-ring packing

** These spare and wear parts belong exclusively to the


wear bushing type (see Fig. 17)

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Fig. 16

SCREW PUMP
Detail see Fig.16a
page 65

Detail see Fig.16b


page 66

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Fig. 16 a: Bearing unit and stuffing box
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Fig. 16 b Standard discharge box

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Fig. 17: Detail of discharge box (wear bushing type)

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7.0.0 Coupling

For adjustment of the coupling please take note of the operating manual supplied
separately by the coupling manufacturer.

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