G-B: Fuller-Kinyon (FK) Pump

G-B1: Description and Characteristics

The Fuller-Kinyon or FK Pump is one of the workhorses and mainstays of the
North American cement plant. For pneumatic conveying of dry powdered
materials in bulk, FK Pumps have been in use for decades. (Note: there are
other brands using a similar principle but since most, if not all, Lafarge North
American plants use FK Pumps, discussions shall be limited to them.) Today
there are three major versions of the FK Pump: the venerable Type H, the Type M
and the Type H with the Z-Flap conversion. All three versions use similar
components and operate on the same principle.
Bearings

Air Seal

Variable Pitch Screw

Hopper

Flapper Assembly

Airjets
Mixing Chamber

Type H pump is perhaps the most common type since it has been in production
for quite some time. Characteristically the Type H has a screw which is
cantilevered into the barrel, with the mixing chamber at its extreme end. The free
end of the screw is unsupported. These units are prone to higher wear on the
screw and barrel due to vibrations and "whip" of the screw. As a general rule
these units must never be run empty for very long. Moreover the screws must be
replaced regularly (depending on the plant / application: 8 to 18 months) so that a
tight clearance can be maintained between the flights and barrel.
The Type M is a side discharge unit which allows both ends of the screw to be
supported by bearings, thus eliminating vibrations and signifcantly reducing wear.
These units can be operated empty since clearances will always be maintained.
Some plants have found that the Type M characteristically cannot cope with a
large head of material feeding it, unlike the Type H. Provided that this pump is
not installed directly under a large bin or silo, the Type M pump has performed
well enough at other plants.

Flapper Assembly Outboard

Bearing
Hopper

Mixing Chamber
Airjets

Disc harge

The Z-Flap conversion is designed to overcome the basic design flaw of the
original Type H. (Fuller saw the wisdom of selling these conversion kits given the
large number of Type H Pumps sold over the decades). The converted pump
sports an extended screw shaft with a support bearing built into the far side of the
mixing chamber, thus eliminating the wear problem. The flap, to accommodate
the extended shaft, is especially designed to wrap around it amd looks like a
slotted cup.
Z-Flap (Cup)
Assembly

Outboard
Bearing

Hopper

Airjets
Mixing Chamber

The FK Pump receives material through a hopper located above its horizontal
variable pitch screw. During the advance of the material through the barrel, it is
compacted by the decreasing pitch of the screw flights. In the M Pump the very
end is reversed. Material density is further increased in the space between the
end of the terminal flight of the screw and the valve seat by forming a material
seal or plug. The material seal prevents the flow of air rearward from the mixing
chamber, sometimes reffered to as blowback. This is done along with the aid of a
flapper valve body. Recognize that small amounts of blowback will cause
component wear.
Large amounts of blowback will effecticely reduce or
sometimes block flow. The material seal effectively makes the FK Pump an
airlock as well as a pumping system.

The free floating flapper valve at the discharge end of the pump barrel is a
mechanical seal or check which assists in preventing the flow of air rearward
from the mixing chamber through the pump barrel. If operating conditions
require, an adjustment of the material seal this can be done by adjusting the
position of the pump barrel through the four jack screws, (Type H ONLY).
CAUTION: too large of a plug or material seal will cause pump motor amps to
rise to the point where it may trip easily. An external free floating arm is located
on the mixing chamber to indicate that the flapper valve is operating satisfactorily.
After material is discharged into the mixing chamber, compressed air enters the
mixing chamber through the nozzles located under the discharge point and
fluidizes the material enough to permit it to be conveyed in the air stream down
the transport line to its desired location. Depending on the system, up to 35 psig
line pressures are typical.

G-B2: Flapper Valve

Pressure Gage

Flapper Arm
Drain Cock

Air Header

Flapper Valve
Body
Air Nozzles

Base

Type H
Pump Cross Section looking into the mixing chamber.

On all FK Pumps, the correct seating of the flapper valve is crucial to minimizing
the likelihood of blowback occurring. On Type H and Type M Pumps, the
clearance between the flapper and the valve seat must be uniform and tight (in
the closed position). Any gaps will lead to blowback.
[Tip: with the mixing chamber door open, take a strip of writing paper and place it
between the flapper and seat in the closed position. Pull the strip around the

edge. The tugging needed should feel about the same all of the way around. If it
is loose in any spot, either the flapper needs adjusting or it's worn in that one
place (and should be replaced). In some cases, the set screws have come
loose, in which case have it re-adjusted then add Loctite or equivalent.]
Type M Pumps are reportedly more sensitive to the flapper being adjusted
correctly. However, on Z-Flap conversions focus should be on the fit of the
slotted flapper valve around the screw shaft itself and less on the valve and valve
seat. Apparently, there is a greater tendency for blowback occurring around this
area than around the seat. One useful modification is to install a tapered
deflector ring or oriface plate at the outlet of the barrel such that material is
pressed down towards the center shaft. In this way there is less of the tendency
for material to spill out at the valve seat and a greater tendency to keep it
concentrated and compacted at the shaft, thereby minimizing blowback.
Evidence of blowback will physically show itself as locallized wear in one or two
places in the flapper valve seat and barrel for Type M and H Pumps or around the
shaft in Z-Flap Conversions.
G-B3: Air seal
Next to each bearing, there is an air seal to prevent material leakage into it,
(there's only one on a standard Type H). The air seal unit consists of a graphitar
seal ring (carbon seal), a cooling fan and a series of springs to help maintain an
even tension of the seal ring against its point of contact. The seal ring should be
checked for amount of wear, leakage of material and air flow. This should be
done once a shift. The unit is kept clean of material by an air purge system,
which is regulated with an in-line regulator to maintain a set amount of air. The
correct air pressure setting is vital to ensuring that bearings remain clean,
(consult the Pump manual for correct settings). Set slightly higher than the
internal working pressure, the air enters the seal through the side and exits the
seal into the barrel in order to keep material from entering the seal. Air flow
failure will lead to rapid bearing seizure. Some plants will go as far as to install a
low pressure switch that causes the unit to shut itself off on a low pressure trip
point and thus protecting the pump bearings.

Flow is direc ted towards the shaft

to maintain a tighter plug around it

S haft Wear due to blowbac k

thru the Z-Flap slot

S c rew S haft

Barrel

Tapered
Deflec tor
Ring

Z-Flap in c losed Z-Flap in partially

position
open position

Z-Flap Conversion Modified with Tapered Deflector Ring

To check for air flow during a walk through inspection, a petcock valve is located
on the opposite side where the air enters the seal. Place your thumb over the
petcock and open the valve. When you feel pressure against your thumb close
the valve do not open the valve without covering the opening, as it will break the
seal between the pump and the barrel housing.

G-B4: Bearings
G-B4.1: Cantilever Bearings (Type H)
The pump screw is supported by two roller bearings. In the Type H Pump, they
are mounted in a bearing housing near the drive end. This housing should be
checked once a shift for heat, noise and vibration. The pump screw is driven by
an electric motor. The two are connected by a para flex coupling.
If the air seal on the pump hopper fails and starts to leak, material can be forced
into the bearings and cause premature bearing failure.
G-B4.2: Supported Bearings (Type M and Z-Flaps)
This bearing is kept clean of material by an air purge system similar to that used
for the graphitar seal. The air supply is regulated and filtered to keep impurities
and moisture out. The air pressure is regulated slightly higher then the mixing
chamber to keep material from entering the bearing. Air entering the bearing
exits into the mixing chamber. As before the correct setting is vital to protecting
the bearing.
G-B5: FK Pump Venting and Material Compaction
Recognize that all FK Pumps are volumetric devices. In other words it delivers a
set volume flow rate and no more. However mill circuits are normally balanced
with respect to weight or mass flows and this balance can be upset if the FK
Pump cannot cope. Delivery rates (mass flow) can be affected significantly on
FK Pumps due to a change in density. Thus for this reason feeding an FK pump
with an airslide is not always wise since the aeration air can dramatically alter
bulk densities. Good venting is important to relieving this air out of the hopper as
the material enters the screw.
In cases where FK Pump capacity is marginal with respect to the circuit, venting
become crucial to ensuring that the bulk density is as high as possible to
maximize tonnage. To help out, an extra venting box or baffle plate can be added
to the hopper as shown in the diagram. Recognize that the variable pitch screw
compacts the material which in effect squeezes any air out. This air escapes out
into the hopper which will aerate the incoming material further. The baffle plate

provides a easy escape route for this air without re-entraining it, thus maximizing
the feed bulk density.
Pump Feed

To Dust Collector
Baffle plate or box
Air pressed out by screw

Hopper
Barrel

Flapper
Valve

Mixing Chamber

Outlet
Variable Pitch Screw
Air Seal

Air Header
Nozzles

Roller Bearing

Occasionally in some installations, for reasons not fully understood, material can
become over-compacted which causes the pump to draw high motor amps and
trip suddenly. Fuller, in many installations, (but not all, consult Fuller if you wish
to modify a particular pump) has provided a small threaded port located midway
in the pump barrel. This is a compressed air injection port. Typically it is hooked
up to a solenoid which in turn is activated by a high motor amp switch. As the
motor suddenly rises in current, the switch causes the solenoid to open which
fires compressed air into the barrel momentarily. This fluidized the compacted
material, relieving the binding on the screw and hence motor amps.

G-B6: Troubleshooting - Pumps

Condition:
Dusting from feed hopper, pump running
1. Check flapper arm for movement. If movement is minimal or none, hold the arm
down by hand to try and feel if there is material coming out of the pump. If there is
no material flow or the load seems light, check flow to the pump hopper for possible
obstructions. If none, check the airslide air valve setting and the dedusting line.

2. If the load seems normal continue to hold arm down to attempt to make a material
seal. If the seal is achieved observe operation of the pump and monitor the
operation periodically.
3. Of the seal is still not achieved, check to see if there is enough manifold pressure, it
should be 25 to 30 PSI. If air pressure is low, start another compressor and attempt
to make a seal by holding down on the flapper arm. If a seal is achieved observe
and monitor the operation of the pump.
4. If all of the above attempts to make a seal fail, contact the control room and advise
him of the problem. Contact the Coordinator or Mechanical Maintenance.
G-B7: Safety - Pumps
1. Follow equipment lock out procedures.
2. Avoid contact with moving parts.
3. Be aware of pinch points.
4. Close header valve before working on equipment, if possible lock out compressor.
G-B8: Walk Through Inspection - Pumps
1. Check for air to the air seal and bearings.
2. Check air seal for amount of wear and leaks.
3. Look and listen for unusual noise and vibration.
4. Watch flapper arm (s) for movement.
5. Feel bearing housing for temperature.
6. Feel drive motor for temperature and smell for odor.
7. On the Z-flap air pressure to the screw discharge end bearing should be at least 5
lbs. Greater than the hopper pressure.