FMEA of Extruder Gear Pump

I. GEAR PUMP:

PR 25-6 The gear pump installed in the HDPE-1 plant is model no. PR 25-6, manufactured ! "##$ P%"P &'&TE"& #$ (H-)*2+ ,%R-(H and integrated ! .erner / Pfleiderer $m H 0ith the rest of the e1truder s!stem. The num er 25 in the model signifies that the gear thic2ness is 25 1 1* 3 25* mm and the num er 6 indicates that it has a timing gear 0here ! oth shafts are dri4en independentl!. The shaft centerline distance et0een the 2 gears is +6* mm. -t 0as installed on 12th 5e ruar! 2***. -ts e6uipment tag num er is $PE1-7515. The e1truder s!stem can e run 0ithout the gear pump, 0ith the t0in scre0 e1truder producing the re6uired pressure to force the pol!mer melt through the die plate. Ho0e4er, operation 0ith the gear pump installed is highl! eneficial due to the reasons listed elo08

#s seen in the pressure profile to the left, the ma1imum attaina le pressure is limited to around 25* ar at the end of the arrel 9at the throttle 4al4e:. Due to the pressure drop in the s!stem, the pol!mer melt drops to a pressure of around 15* ar ! the time it reaches the %$ under0ater pelleti;er. Ho0e4er, upon adding a gear pump ahead of the di4erter 4al4e, the ma1 pressure generated increases to +** ar. The pressure drops to around 2** ar ! the time the melt reaches the under0ater pelleti;er. This ma2es it much more efficient at o4ercoming the resistance to pol!mer flo0 offered ! the screen pac2 and the die plate. The gear pump highl! reduces the load on the e1truder motor, gear o1 and clutch coupling. This helps to ensure a longer life and reduced 0ear of these components. "oreo4er, the energ! efficienc! of the entire s!stem 0ith a gear pump is also much higher as the gear pump is added as a speciali;ed unit to de4elop pressure. The 4olumetric efficienc! of a gear pump is in the range of <*-<<= depending on the clearances 0hereas that of the e1truder scre0s is around >*->5=. .ithout the gear pump, a lot of the input energ! is con4erted to heat due to friction in the scre0s, 0hich raises the melt temperature in the arrel to appro1. 2?5 deg (. @! adding the gear pump, the ma1imum melt temperature is reduced to around 2>* deg (.

THEAR' A5 APER#T-A78 $ear pumps operate on the displacement principle. The! comprise of t0o intermeshing gear0heels of the same si;e, encased in a housing 0ith closel! defined clearance 9clearance et0een teeth and housing are in the order of *.1 mm and the clearance et0een front B ac2 of the gears and the housing is of the order of *.*25 mm:. $enerall! one of the t0o gear0heels is directl! dri4en ! a shaft protruding out of the housing through a shaft seal. The second gear0heel is dri4en ! the teeth of the first one. 5or some gear pump applications, ho0e4er, it ma! e etter for oth gear0heels to e dri4en. This reduces the friction et0een the gear teeth and distri utes forces e6uall! on oth gear0heels. 5or this purpose a special pump dri4e gear o1 is re6uired. #s the gear0heels rotate, the spaces et0een unmeshing teeth are filled 0ith the inflo0ing pumping medium. This is then transported along the inside 0alls of the housing from the suction side to the pressure side. Here the pumping medium is displaced ! the meshing teeth and eCected through the pump outlet. The gear teeth fulfill the follo0ing main functions8 Transport of pumping medium from suction to pressure side Displacement of pumping medium on the pressure side

&ealing et0een suction and pressure sides

The pol!re1 is installed as a ooster generating the necessar! pressure ehind the die plate, relie4ing the e1truder of this 0or2 and sa4ing energ!. -t is installed et0een the start up B throttle 4al4e and the screen changer unit. -t is a con4entional gear pump ha4ing t0o gear 0ith spur teeth, thus minimi;ing product degradation ensuring effecti4e self cleaning. The gears are enclosed in a steel casing 0ith heating Cac2et. The pump installed 0ith timing gear allo0s each shaft of the t0o gears to e dri4en separatel! 0ithout touching the teeth of each other. The gear o1 nominal po0er used for its operation is 6** D. allo0ing a ma1imum speed ! the gears of ++.+ rpm. The earings can e heated prior to start up and cooled 0ith 0ater during normal operation, thus pre4enting degradation of melt. -t is designed to operate 0ithin the follo0ing pressure limits8 &uction side, ma1imum pressure Discharge side, ma1imum pressure Differential pressure, ma1imum &pecific deli4er! rate 1** 2gBcm2g +5* 2gBcm2g +2* 2gBcm2g 2).> lBre4

The main parts of the pump are8

Housing The housing has an integral heating Cac2et for li6uid or gaseous heating media. The housing has an inlet opening on the suction side and an outlet opening on the discharge side. The suction side of the housing is ored 0ith t0o relief holes, one on the dri4e side and one on the non-dri4e side. The housing is ored to ta2e measuring pro e cartridges and temperature pro es for housing and earing temperatures.

Housing co4ers The t0o co4ers are made of steel and incorporate heating channels for li6uid or gaseous heating media. Each co4er has a Eee-shaped relief groo4e 9E-groo4e: on the inside pointing to0ard the suction side and matching o4er the relief hole in the housing. @oth co4ers ha4e a oring for a temperature pro e on top.

Dri4e shaft and short shaft These straight-toothed shafts are each mounted in t0o plain earings in the pump housing. The long end of the dri4e shaft is splined for mounting a hu or toothed coupling. The non-dri4e end of proCecting dri4e shafts has a oring for a shaft cooling pipe.

Plain earings The dri4e and non-dri4e sides of the housing are each fitted 0ith a top and a ottom earing facing each other. Each pair of earings is loc2ed ! a 2e! against rotation. The dri4e side top and non-dri4e side ottom earings are identical and thus interchangea le, li2e0ise the non-dri4e side top and dri4e side ottom earings. The h!drod!anmic plain earings are lu ricated ! the pumping medium. The earings are designated according to installation position8 Dri4e side earing, top @earing D&T

Dri4e side earing, ottom 7on-dri4e side earing, top 7on-dri4e side earing, ottom

@earing D&@ @earing 7D&T @earing 7D&@

The earings ha4e tapped orings for fitting steel shoulder rings and a temperature pro e oring on the outside diameter.

&haft seals Pol!mer melt lea2age is pre4ented ! 4iscoseal in the housing co4ers. The 4iscoseals are fitted 0ith cooling 0ater channels. The! are connected to the cooling 0ater piping. -n case of dou le shaft dri4e, depending on top and ottom shaft rotation, lefthand or right-hand 4iscoseals are incorporated in the dri4e and non-dri4e side housing co4ers. The dri4e side top seal and non-dri4e side ottom seal are interchangea le, li2e0ise the dri4e side ottom and non-dri4e side top seals.

APER#T-7$ "ADE&8 There are four different operating modes a4aila le for the Pol!re1 installed in an e1trusion plant 0ith t0in-scre0 2neader and the follo0ing upstream and do0nstream e6uipments8 1. &tart-up 4al4e flanged to suction side 2. Do0nstream e6uipment 0ith screen changer and die-plate, flanged on to pressure side +. &paghetti mode 9purging of die-plate:8 -mmediatel! after starting the Pol!re1, pol!mer melt is e1truded through the die-plate on to the floor. This operating mode is 2no0n as &paghetti mode.This is necessar! 0ith a ne0 or freshl! assem led Pol!re1 in order to clean out all the "ol!2ote dr! lu ricant film. #fter pauses in operation, &paghetti mode is necessar! in order to purge thermall! damaged pol!mer from the Pol!re1 and die-plate.

7ormall! it ta2es a out + to 5 minutes to flush out the "ol!2ote, ut purging should e continued until clear pol!mer emerges from the die-plate.#fter operation in &paghetti mode, then the normal operation can e resumed. >. &tart-up mode8 #fter start-up, follo0ing chec2s should e carried out8 (hec2 the pressure control s!stem "easure the Pol!re1 speed 0ith a hand tachometer, and compare 0ith the speed indicator reading on the process control s!stem. (hec2 all measuring, displa! and recording instruments. (hec2 operating data. (hec2 the 4iscoseal shaft seals for lea2age. (hec2 all heating medium suppl! connections for lea2age. (hec2 for an! lea2age of the cooling medium connections to the 4iscoseal shaft seals. -f shaft cooling is installed, chec2 the suppl! piping for an! lea2age. (hec2 all au1iliar! s!stems such as for shaft cooling and lu e oil s!stem.

7ormal mode The follo0ing operating limits should e maintained during normal operation8 7o. Pumping medium T!pe Design ation "5-21.62gB1<**( "a1. throughput "a1.speed Pol!re1 "a1.Tpumping medium FgrB1*GH F2gBhH Rpm *( 1 HDPE $" 6255 2 <*** 1> 2)* 2 HDPE $" 6255 2 15*** 2+ 2)* + HDPE $" <2>* 5.6 22*** +> 2?* > HDPE $" >?6* +2 2>*** >* 2>* 5 HDPE $" ?26* 2+ 2>*** >1 22* 6 HDPE $" <>5*5 2+*** +6 2?* ? HDPE $" 5*1* 2>*** +) 2?*

--.

GEARBOX8

The $ear o1 for the Pol!re1 is model no. &P%-+6 made ! "##$ $ears. -t is a +-stage reduction gear unit 0ith a final timing gear stage. The first reduction stage is a right angle e4el gear stage. The second reduction stage is a planetar! gear. The last stage is the timing gear. The 2 shafts of the timing gear s!nchroni;e and dri4e the 2 pump shafts. The! ensure contact free meshing of the pump rotors. The coupling used is to e pf "##$ toothed coupling ,5I-)' t!pe. TE(H7-(#J D#T#8 $ear o18 Distance et0een oth dri4en shafts8 +6* mm $ear 7ominal Po0er8 6** 2. "a1 Tor6ue8 1?2 27m 7ominal input rpm8 1*** rpm 7ominal output rpm8 ++.+ rpm Ju ricating Ail8 Ju e Ail Kualit!8 (JP lu e oils Eiscosit!8 -&A E$ +2* Ail flo0rate8 <* lBmin

---.

SHAFT TEMPERING SYSTEM 8

The shaft tempering s!stem regulates the temperature of the t0o shafts of the Pol!re1 gear pump. -n order to do this, it carries out the follo0ing tas2s8 -t heats the tempering medium up to operating temperature. -t cools the t0o shafts under certain operating conditions of the Pol!re1 gear pump.

"#-7 (A"PA7E7T&8 The shaft tempering s!stem comprises the follo0ing elements8 T0o shaft cooling pipes 0ith 1 rotar! Coint each Ane tempering unit for circulating 0ater 25 L 21* deg. ( 8 -ndirectl! heated ! electrical resistance heaterM indirectl! cooled ! 0ater 4ia heat e1changer to TE"# (, designed for pressure class P7>*. -t also consists of a centrifugal circulation pump of Dic2o0 Pumpen ma2e , 7(J t!pe. Ane pressuri;ing and ma2e up 0ater station8 5or generating asic s!stem pressure re6uired to achie4e the ma1imum circulation temperature ! means of a high pressure triple1 piston pump. The triple1 plunger pump is of t!pe P11B1+-1**, manufactured ! &pec2 Pumps. -t has a po0er consumption of +.< 2., producing a ma1 pressure of 15* ar N 1>2* rpm. The ma1. flo0rate is 12.? litBmin. Ane control unit8 5or automatic control of the heating B cooling s!stem. Temperature and pressure are controlled ! digital electronic controllers L -P 55, 2+* E B 5* H;

THEAR' A5 APER#T-A78 Tempering %nit8 The temperature control unit heats up the tempering medium to the correct temperature prior to operation and automaticall! regulates it during operation. The Pol!re1 shafts are either heated ! s0itching on the heating s!stem, or cooled ! s0itching on the cooling s!stem.

Heat is transferred ! feed 0ater, circulated ! a pump through the t0o shafts of the Pol!re1. Heating is done ! electrical resistance heating element. (ooling is done indirectl! ! heat e1changer.

(ontrol &!stem The plain earing temperature control s!stem maintains the Pol!re1 earing temperature 9controlled 4aria le: at the set-point 9reference 4aria le:. The tempering medium temperature 9manipulated 4aria le: is regulated ! the earing temperature control s!stem. -f the earing temperature changes, the tempering medium temperature is adCusted accordingl!. -f the earing temperature rises a o4e the set-point 4alue, the tempering medium is cooled accordingl!. -f the earing temperature falls elo0 the set-point 4alue, the tempering medium is heated accordingl!.