Pneumatic Transport System

HGRS MASTER - Maintenance
Type of Skill: Specific Technical Skill

Category : Transport Systems
Module: Pneumatic Transport Systems
Unit: Basic Principles and Terminology 1 of 13
Version: 1.0 04.11.03
Reference: Pneumatic Transport Training.ppt
Basic Principles and Terminology

Purpose:  To develop an understanding of the basic principles of pneumatic transport and the correct
use of terminology. These are needed to ensure understanding of equipment, analysis
and maintenance.
Description: Definition - A pneumatic conveyor system transports dry, free-flowing, granular material in
suspension within a pipe or duct by means of high velocity air-stream or by the energy of
expanding compressed air within a comparatively dense column of fluidized or aerated
material. Categories - There are three basic categories that pneumatic transport systems fall
under depending on how the air is used to convey the material.
1. Pressure Systems - positive force of the air "push" the material from one place to
another. Typically used in applications where there is one single pick up point and
material is conveyed to multiple end points. (e.g, Fuller Kinyon pump system)
2. Vacuum Systems - uses negative pressure to "pull" material from one point to the next.
These "suction" conveying systems are typically used in applications where there are one
or more pick-up points and material is conveyed to a single destination. (e.g, dust
collection systems)
3. Air Gravity Systems - air fluidizes the material but gravity forces it to be transported.
This system is commonly known as an "airslide" system.
Components - There are four basic components that make up pneumatic transport systems.
(See Figure 1.) Typically all systems have some form of these components. Further
classifications of pneumatic transport systems are based on differences within these
components.
1. Bulk Solid Feeder - The equipment introduces the material to the conveying air stream.
There are different types of feeders, including screw pumps, pressure vessels (or batch
systems), and airlifts.
2. Air Supply Equipment - Generates either positive or negative conditions in the system.
Typically a fan, blower, or compressor is used to supply the air. Choosing which depends
on pressure and flow requirements. Pressure is needed to overcome resistance in
ductwork, bends, lift, and material tonnage. Flow is needed to deliver the necessary
velocity to keep material suspended throughout the path.
3. Conveying Pipeline - the avenue in which material is transported. This includes any
bends, valves, or other necessary items needed along the journey.
4. Air/Solid Classifier - method of separating air from material. In a silo, the bagfilter on top
vents the air from the pneumatic line preventing product from escaping. In the case of an
airslide the air/solid classifier runs the length of the system.
Applications. There are numerous applications in the cement industry that uses pneumatic
transport systems.
 Kiln Feed Transport
 AFR Handling (wood chips, dried-sewage sludge, etc.)
 Pulverized Coal Transport
 Dust Collector Systems
 Vacuum Clean-up Systems
Training in Maintenance Page 1 of 4

 Airslide Systems
 Lab Sampling Systems
 Cement Transport
 Loading and Unloading Functions in Shipping Stations.
Advantages of Pneumatic Conveying
Pneumatic conveying offers distinct advantages over other forms of conveying:
 Low maintenance, low manpower, low installation costs - the conveying line consists of a
smooth bore, enclosed pipe with no mechanical moving parts.
 Flexibility in routing and distribution - pipe can be routed much easier than mechanical
belt/screw/chain conveyors and can be transported vertically, horizontally, around corners
and through small spaces. Distribution to many delivery points from one line using branch
valves and pick up from several feed points can be simply and easily made. Lines can be
easily extended or re-routed at later dates.
 Versatile use - one system/line can be used to transport a variety of products at different
times and virtually all powders and granules can be pneumatically conveyed.
 Clean enclosed system offers many benefits: Low cross contamination when different
products are conveyed. Hazardous or high value products can be conveyed in a sealed
system. Hygienic, food quality and pharmaceutical products can be conveyed in a sealed
& controlled environment. Gases can be sealed in and re-circulated for a controlled
environment and efficiency by re-cycling.
 Automation - pneumatic conveying systems can be easily automated and controlled.
Disadvantages of Pneumatic Conveying
Pneumatic conveying systems have some limitations and disadvantages including:
 Some systems can result in high power consumption when compared to certain forms of
mechanical conveying e.g. high capacity systems over long distances.
 Distances are limited, although it is possible to pneumatically convey more than 1000m,
most practical distances range between 5 and 500m.
 Capacities are limited, although it is possible to pneumatically convey at rates at 400 tons
per hour, most systems convey between 1 and 60 tons per hour.
 Abrasive products cause high wear and abrasion to pipeline and equipment.
 High conveying velocities can cause fragile product to break and degrade during
transportation.
Design - Targets in designing pneumatic systems are reliability and minimum power
requirements. The reliability of the system is important to not interrupt production and lower
necessary maintenance. Low power requirements help to keep operating costs low.
Standards: Parameters. In designing a pneumatic system certain parameters go into choosing the bulk
material feeder, the air supply, the pipeline, and the classifier. The following standard
parameters should be researched:
1. Coarse and Fine Particle Analysis
2. Specifications of Material to be Conveyed
3. Distance to Convey
4. Elevation to Convey
5. Capacity Required
6. Preliminary layout of conveying line (number of bends)
7. Temperature of material to be conveyed
 Some normal operating limits for various systems can be found in Figure 2.
 Standard carrying velocities for various materials are shown in Figure 3.
Impact if not  Inability to understand pneumatic systems will reduce the level of analysis and
applied: troubleshooting that can be completed.
 Improper design will lead to low availability and high costs.
Actions:  Learn basics and terminology, so communication can be used as a tool for everyone
working with pneumatic systems.
 Seek advice from experienced engineers or experts when designing a pneumatic transport
system
Unit  Proper identification of pneumatic transport systems at the plant.
Completion:  Participant understands the basic theory of pneumatic transport.
See site specific unit for additional information, respective corrective actions and applicable safety
instructions.
Figure 1. System Components

Material Conveyed
Solids Feeder
Solids Feeder
Conveying Pipe Pipe

Conveying
Supply
Air Supply Equipment Gas-Solids
Gas-Solids Separator
ipment Separator
Material Conveyed
Figure 2. Common Capabilities of Various Pneumatic Transport Systems

Figure 2. Table of Pneumatic Transport Carrying Velocities for Different Materials.
Type of Skill: Specific Technical Skills
Category : Transport Equipment
Unit: Screw Pump Design 2 of 13
Version: 1.0 04.11.03
Screw Pump Design

Purpose:  To understand the general design principles of the screw pump system. The screw pump
system is one of the different types of bulk solid feeder units that can be used in
pneumatic transport systems.
Description: General
 The task of the screw pump is to introduce the material flow into the conveying gas flow
against the pressure of the conveying line and at the same time seal the system
overpressure from the surroundings and upstream plant sections.
 The Fuller-Kinyon Screw Pumps are the most common types of screw pumps used in the
cement industry today. Commonly referred simply as an FK pump, there are two types; the
"H-Pump" and the "M-Pump". The "M-Pump" type was an advancement in technology from
the "H-Pump" by providing a bearing support at the discharge end of the screw shaft to
reduce wear caused by screw shaft deflection. This technology can also be added to
existing "H-Pumps" by the addition of the "Z-Flap Conversion" (see Figure 4).
 Claudius Peters manufactures their version of the screw pump design called the "X-
Pump". It is basically identical to the "M-Pump" by Fuller so we will not distinguish
between the two in this unit.
Basics of Screw Pump System

 The transporting of the bulk solid starts by the material entering a feed hopper.
 A rotating screw transports the material from the hopper to the mixing chamber. Its
rotational speed is typically 500 to 1500 RPM.
 The screw is made either with or without variable compression (decreasing screw pitch in
the direction of conveying) depending on material characteristics. The variable pitch is
used to help increase the material seal in the screw. As material is transported along the
screw it is compacted and the density is increased. This is needed if material to be
conveyed has a very low density.
 The filling of material in the screw forms a "material seal" that prevents a reverse flow of
conveying air from the mixing chamber.
 A free-floating flapper valve (or "check valve"), located in the discharge area of the pump,
is a mechanical seal that also assists in preventing the reverse flow of air from the mixing
chamber through the pump barrel.
 The force of the material transported by the screw pushes open the check valve forcing the
material into the mixing camber.
 In the mixing chamber, the material is aerated by the introduction of compressed air.
 The fluidized material is then conveyed in the transport line by continuing action of the
impeller screw and the energy of expanding air.
 Strategically arranged valves or gates are used to divert material into proper end
destinations or silos.
 Dust collectors on the top of the silos are typically used to filter the air from the pneumatic
system before venting to atmosphere.
Typical Piping Arrangement (See Figure 3)

 Locate the blower's filter-silencer (1) to obtain clean, cool, and dry air (2) while still being
convenient for servicing.
 Intake piping can be made of lightweight welded steel or standard steel pipe and standard
flanged fittings.
 Locate the blower adjacent to the pump.
 Use piping from blower to pump of the same size as the blower outlet connection.
 For multiple units where a spare blower is installed or for duplex blower installation,
manifold this line to connect to a common line to the pump.
 Install safety valve(s) to suit connected blower capacity and pressure. Locate as close to

the pump as possible, but ahead of any stop valve in the line.
 For multiple units where pump installation involves a spare pump, manifold this line at
pumps with a valve in each pump connection.
 Add a tee with bottom connection and ½" drain in the flange for periodic oil draining. Do
not connect to the sewer line if oil contamination is a problem - use a bucket to receive the
drained oil.
 See specific drawings for dimensions of blower, filter, etc.
Capabilities of Screw Pump System

 Practical distance of transportation by the system depends upon the material to be
handled, but some current systems conveying cement are up to 1500 meters in length..
 The screw pump conveying system is a dense stream system used to convey dry,
powdered materials at line pressures up to 2.4 bar (35 psig) pressure.
A full range of pump sizes is available for conveying from as low as 5 tons per hour to as high
as 400 tons per hour using various compressors as the source of air supply.
General Terminology: (See Figures 1 & 2)
Air Nozzle - A series of nozzle fastened to a plate with holes that the supply air passes
through to enter the mixing chamber
Barrel Bushing - The protective wear tube inside the pump barrel housing.
Discharge Line Pressure Gauge - Important sensor that reads the air pressure in the line
after discharge of the pump
Drive System - Either a v-belt or direct drive system that is usually 1200 RPM at 60 Hz
Feed Hopper - The section of the pump where material to be conveyed enters
Flapper Valve - A free-floating flapper valve at the discharge end of the pump barrel that is a
mechanical seal or check that assists the "material seal" in preventing air backflow. Also
provides the seal when screw is empty.
Material Seal - The pump screw compresses the conveyed material into a dense plug of
material which prevents the backward flow of air from the mixing chamber through the pump
barrel
Mixing Chamber - The section of the pump where the supply air fluidizes the material and
transfers it from the pump.
Pump Screw - The screw that transfers material from the feed hopper to the mixing chamber
through the barrel
Screw Shaft Bearings - The end bearings that support the screw shaft, most have a purge air
system to seal off bearings from the supply air and material.
Seal Purge Air - Compressed air used to help seal the screw shaft bearings
Supply Air - The compressed air supplied to the system to fluidize and transport the material
to the final destination.
Standards: Basic Start/Stop Sequence
Start:
1. Dust Collector on Receiving Vessel
2. Air compressor
3. Pump Motor
4. Pump Feed - mechanism to get material to feed hopper.
Stop:
1. Pump Feed
2. Pump Motor when current drops
3. Wait until line pressure is "0" or minimum before stopping
4. Compressor
5. Dust Collector (unless otherwise required)
Impact if not  Inability to understand and communicate problems or requirements.

applied:
Actions:  Learn and understand the general design concept for screw pump systems
Unit  Participant understands how the screw pump operates.

Completion:
instructions.
Figure 1. Components of a Screw Pump System
Supply Air
V-Belt Drive System

and Motor
Mixing Chamber
Picture: The Claudius Peters X-Pump
Discharge Line
Pressure Gauge
Figure 2. Components of a Screw Pump System (continued)
Feed Hopper
Feed Hopper
al Purge Air Air
Seal Purge
Pump Pump
ScrewScrew
w Shaft
Screw Shaft Bearings Air Nozzle
Air Nozzle
aring
s
Flapper Valve Picture: The Fuller Kinyon M-Pump
Figure 3. Typical Piping Arrangement
Figure 4. H Pump with Z-Flap Conversion

Unit: Screw Pump PMRs 3 of 13
Version: 1.0 04.11.03
Screw Pump Preventive Maintenance Routines

Purpose:  To learn what preventive maintenance routines (PMRs) are to be carried out on screw
pump systems to ensure optimal levels of availability, performance and maintenance
costs.
Description: Initial Start-up, Start-up after Major Repairs, or Start-up after PMRs:
 Assuming an individual compressor is part of the system, check the intake duct for loose
dirt or other foreign material; then check alignment, orientation, and lubrication of the
compressor. (Refer to Compressor Instructions for details)
 Ensure proper valve position, if any, in piping from compressor to pump.
 The pump is a precision piece of machinery which requires a rigid foundation. For
maximum maintenance-free operation, the pump base must be flat, true, and anchored
solidly in the foundation.
 Ensure proper alignment of the motor to pump coupling or for V-belt drives, check belt
tension and alignment of sheaves.
 Inspect pump hopper, mixing chamber and manifold for foreign material.
 Carefully observe the operating instructions furnished with the compressor and start
compressor.
 On both ends of the pump, housed in the bearing housing supports, there are seal
arrangements that require a steady flow of air or air purge for proper operation. The pump
must never be run without purge air to the seal arrangement.
 Start the screw pump motor only after air supply is entering the screw pump. Check for
proper screw rotation; typically it should be counterclockwise when viewed from the motor
end.
 Start the screw pump without feed. Note the pressure on the manifold gauge and line
gauge. For pumps utilizing manifold air for seal purge the manifold pressure gauge should
indicate 8 to 9 psi (0.56 to 0.63 kg/cm2) higher than the line pressure gauge. For pumps
utilizing plant air, the manifold pressure gauge should be 5 psi (0.35 kg/cm2) higher than
line pressure. Without feed, the line pressure should be nearly zero in each case.
 Open the feed valve or start feed conveying equipment. As the load through the screw
pump increases, the pressure on both the manifold gauge and line gauge will rise. The
pressure on the seal purge air gauge should always be higher than on the discharge line
pressure gauge throughout the full operating range.
 If, with normal full feed, the line pressure gauge fluctuates continuously from high to low
readings, the amperage of the pump motor varies through the same cycle, and the flapper
valve lever continually moves up and down, then blowback through the pump material seal
is indicated. Adjust the counterweight to a position farther out on the flapper valve lever. If
there is indication of continuous overload on the motor, remove the spacer plate (which is
located internally attached behind the flapper valve) and readjust the counterweight until
steady operation is maintained. If the blowback condition persists for a long period of time,
consult original equipment manufacturer.
 When shutting down the pump, first stop the material flow and after the pump is
completely empty, stop the driving motor.
 When the pump screw has come to a complete stop, the air should be allowed to blow
through the transport line until line gauge stabilizes at nearly zero.
Standards: Preventive Maintenance Routines:
Daily Operation Inspections: (while running)

 Check the flapper valve is free to move
 Check the condition of pressure gauges
 Check that the line pressure is within tolerances and not fluctuating too high

 Check seal purge air pressures
 Check for pump system for abnormal vibration
 Check condition of cover plate gaskets
 Check pipe lines for leaks
 Drain inlet air lines of oil/water
 Check bearing temperatures on the pump
 Check compressor amps (load and no-load)
 Check pump amps (load and no-load)
 Check pump speed if available (load and no-load)
Lubrication: (See Figure 1)

 Lubricate the flapper valve lever shaft daily.
 Lubricate air seals in the bearing housing supports on both ends of the pump daily (one to
two strokes of a grease gun).
 Excess grease will purge out through the outermost seal, on drive end it falls out of
housing, but on discharged end it remains in the housing, good practice is to remove this
during annual inspections.
 Lubricate pump bearings (while pump is running) monthly, over-greasing or under-
greasing will result in temperature change or vibration increase.
 Lubricate motor bearings as per motor supplier specifications, typically once a year.
 Flush bearings clean with suitable solvent, and repack them with fresh, suitable grease as
needed.
Vibration: (See Figure 2)

 Check vibration on the motor bearings monthly
 Check vibration on screw shaft bearings monthly
Electrical Inspections (yearly):

 Check interlock circuit and check device that triggers the interlock
 Check compressor amps when overload triggers
 Check pump motor amps when overload triggers
 Clean MCC integrity and check starter
 Test starter circuit
 Check integrity of cables and connections
 Test safety shut down feature of air purge on pneumatic pump discharge bearing. (To
test: Establish signal simulation that causes air purge on pneumatic pump discharge
bearing to operate. Isolate the supply of purge air "upstream" of safety pressure
transducer. Confirm that there is a safety shutdown sequence enacted.)
 Test safety shut down feature of air purge on pneumatic pump feed bearing. (To test:
Establish signal simulation that causes air purge on pneumatic pump feed bearing to
operate. Isolate the supply of purge air "upstream" of safety pressure transducer. Confirm
that there is a safety shutdown sequence enacted.)
Impact if not Incorrect or not carried out PMRs can lead to:
applied:  Screw pump breakdown with subsequent stop of major equipment
 Secondary damage and therefore higher maintenance cost
 Inability to handle necessary capacities due reduction in efficiencies.
Actions:  Double check the proper execution of the PMRs
 Double check the proper execution of start up steps after repairs or PMRs
Unit  Participant has carried out all PMRs types (belonging to his trade) at least one time on
Completion: their own
 Participant has carried out start up procedure at least one time on their own
 A practical application of the different PMR's is part of this training unit !!!!
Scheduling of the PMRs should be done in the maintenance management system.
For specific mechanical inspections, please see Unit 4.
See site specific unit for additional information, respective corrective actions and applicable safety instructions.
Figure 1. Lubrication Points at End Bearings Diagram
Grease Nipples for Bearing

Grease Nipple for End Seal
Figure 2. Vibration Points Diagram
3 4 5 6
4
6
1
1 2
2
Location
Location Orientation
Orientation Parameter
Parameter
Horizontal Vertical Axial
Axial Bearing Vibration
Vibration
(9 or
(9 or 33 o'clock)
o'clock) o'clock)
(12 o'clock)
condition
condition (mm/s, RMS)
(mm/s,
RMS) SPM)
(gSE, (gSE, SPM)
1
1 Motor, Ns
Motor, Ns X
X X
X X
X
2
2 Motor, Ds X X X
Motor, Ds X X X
3 Motor, Ds X X
3 Motor, Ds X X
4 Motor, Ds X X
4 Motor, Ds X X
5 Fan, Ds X X X
5 Fan,
6 Fan, Ds
Ns X
X X
X X
X
6 Fan, Ns X X X
Unit: Screw Pump Mechanical Inspections 4 of 13
Version: 1.0 04.11.03
Screw Pump Mechanical Inspections

Purpose:  To learn the mechanical inspections that are to be carried out on screw pump systems to
ensure optimal levels of availability, performance and maintenance costs.
Description:  The inspections below are to be completed at least once a year and possibly every six
months if necessary.
Standards: Mechanical Inspections:
Pump
 Internally and externally clean the pneumatic pump from any material build up.
 Inspect foundation attachment to main steel base.
 No apparent damaged, loose, or missing foundation bolts.- replace if required
 No apparent loose or missing shim stock under steel base.- replace if required
 No new foundation cracks or extension of existing cracks.
 No oil spillage on concrete foundation.- clean if required
 Inspect pneumatic pump attachment to main steel base.
 No apparent loose or missing base bolts-replace if required
 No apparent loose or missing shim stock under machinery feet.- replace if
required
 No cracks in machinery feet.
 No oil or grease spillage at machine to base attachments - clean if required
 Inspect pneumatic pump feed assembly and discharge assembly for excessive wear.
 No apparent loose or missing fasteners between all machine-to-machine
parts, feed chute to feed hopper, and "mixing chamber" and local transport
piping.
 No missing, damaged, or loose mesh wire guards.
 Replace any missing hardware
 Replace any inoperative gauges
 Inspect and clean air line traps and regulators.
 Inspect the discharge pipeline pressure transducer for loss of function.
 No partial or total blockage of transducer pipeline with transported material.
This will require the disassembly of pipeline for visual inspection.
 No partial or total blockage of transducer's pipeline by external damage to
pipe cross sectional area.
 No apparent looseness of pipeline connection(s).
 No apparent localized excessive external abrasion on pipeline or
connection(s).
 No apparent loss of containment of transport material at pipeline or
connections.
 Check bearings for lubrication and excessive wear.
 If screw pump is empty, then it should be possible to turn it by hand with the
coupling.
Pump Screw
 Inspect screw for excessive wear. If hard surface is worn through to base metal on the
flight's periphery face then replace the screw.
 Inspect screw flight inside the feed hopper, by manually rotating the screw to inspect the
condition of all the visible length of screw flight and screw shaft.
 No broken-out areas of the screw flight.
 No apparent localized "air-cut" to screw flight or screw shaft.
 No significant build-up on screw shaft or screw flights.
 After several manual rotations of the feed screw, ensure that there are no
positions where the screw is dragging on some adjacent stationary
component.

 Measure and record the screw flight to barrel bushing clearance from feed hopper side.
 Use special long feeler gauges that can measure clearance pass two flights
on the screw. (CLEARANCE NOT TO EXCEED 0.???????? ")
 Inspect screw flight inside the "mixing chamber", by manually rotating the screw to
inspect the condition of what little length of screw flight and screw shaft is visible.
 No broken-out areas of the screw flight.
 No apparent localized "air-cut" to screw flight or screw shaft.
 No significant build-up on screw shaft or screw flights.
 After several manual rotations of the feed screw, ensure that there are no
positions where the screw is dragging on some adjacent stationary
component.
 Measure and record the screw flight to barrel bushing clearance from "mixing chamber"
side.
 Use special long feeler gauges that can measure clearance pass two flights
on the screw. (CLEARANCE NOT TO EXCEED 0.???? ")
Feed hopper
 Check that the feed hopper to pneumatic pump is free from internal material build-up and
no tramp material in feed hopper bottom.
 Open hopper and remove any material or hardened build-up from hopper.
(pay attention to feed end bearing, as it can introduce oil or condensate into
this area) Build-up can affect the amount or direction of free flow of feed to
screw flights.
 Using a powerful light source and an inspection mirror to confirm that the
hopper dedusting vent pipe opening is completely open at the point of
connection to the hopper.
 Inspect the amount and type of "tramp" material found in the bottom of the
feed hopper. No mill balls, mill ball fragments, bolts, nuts, washers, or any
other metal objects should be found in the bottom of this hopper. If any metal
is found then investigations and actions must be taken to find the origin and
eliminate the cause. Tramp metal can cause serious quality issues and
damages to transport equipment (plant or customer). Tramp metal is an
indicator of problems upstream of the system.
Bearing Seal Purge Air System

 Inspect surrounding of end bearing seals for indications of material leakage.
 Inspect air purge system at pneumatic pump feed bearing.
 Pressure gauge is secure, clean, readable, with indicator needle at zero, and
no apparent other damage.
 Safety pressure transducer is secure, clean, and no other apparent damage.
 Air supply solenoid is secure, clean, and no other apparent damage.
 Air supply water trap, oiler, filter, and filters are secure, clean, and no other
apparent damage.
 Water trap is drained and appears to have been operating properly.
 Oiler is full and appears to have been working properly.
 Filter elements have been changed during this inspection period.
 All associated piping and fittings are secure, undamaged, and apparently
leak/weep free.
 Inspect air purge system at pneumatic pump discharge bearing.
 Pressure gauge is secure, clean, readable, with indicator needle at zero, and
no apparent other damage.
 Safety pressure transducer is secure, clean, and no other apparent damage.
 Air supply solenoid is secure, clean, and no other apparent damage.
 Air supply water trap, oiler, filter, and filters are secure, clean, and no other
apparent damage.
 Water trap is drained and appears to have been operating properly.
 Oiler is full and appears to have been working properly.
 Filter elements have been changed during this inspection period.
 All associated piping and fittings are secure, undamaged, and apparently
leak/weep free.
Air Nozzles
 Inspect air nozzle for excessive abrasion wear.
 No excessive, even, concentric, air nozzle bore wear as measured with a "no-
go" gauge. A "no-go" gauge can be made to judge the wear of the nozzles. By
checking if a specific width (width = maximum diameter of nozzle prior to
allowing wear on threads of nozzle plate) can pass through the nozzle, you
can judge whether nozzle should be replaced or not. Cut a piece of steel or
hard plastic to appropriate width and keep available for inspections.
 No excessive localized air nozzle bore wear (air-cut) that could in any way
affect the direction or free movement flow of compressed air.
 Inspect air nozzle for air flow blockage.
 All components of air nozzle assembly to be free of any significant material
and/or oil build up.
 No significant material build-up in bore opening that could in any way affect
the direction or free movement of flow of compressed air.
 No significant material build-up in the compressed air supply side of the
nozzle that could in any way affect the direction or free movement flow of
compressed air through the air nozzle.
 Measure diameter of nozzle outlet
 New _ Now _ Replace at
Barrel Bushing (See Figure 1)

 Check barrel bushing thickness and record measurements
 New Now Replace at
Inspect barrel bushings for excessive wear, look in hopper and behind flapper. Replace if
grooves in bushings exceed ¼".
Flapper Valve (See Figure 2)

 Check flapper valve gasket
 Inspect flapper valve for proper operation.
 Flapper and flapper valve seat makes a good positive closure seal per several
swing repetitions.
 Check for good complete circular contact of flapper valve and stationary seat
ring.
 Flapper does not exhibit abnormal looseness (side-to-side or torsional) due to
excessive bushing wear, bushing pin wear, and/or swing shaft wear.
 Free range of swing movement for flapper valve. It doesn't hit on the screw
shaft in its range of motion.
 Inspect flapper valve assembly for excessive abrasion wear. Suggestion: Use
telescoping inspection mirror or flexible borescope to see any hidden suspicious areas.
 Flapper, flapper valve seat, flapper valve seat bore, flapper valve assembly
mounting fasteners, and flapper valve arm exhibit no abrasion wear or "air
cut" damage to any visible surface.
 No apparent loss of material sealing function of the shim set under the flapper
valve stationary seat ring.
 Inspect flapper valve section of "mixing chamber" for freedom from internal
material/grease build-up.
 Entire flapper valve assembly and associated internal linkages (inside the
"mixing chamber") are free of any significant transported material build-up or
grease buildup that could affect the free movement of flapper valve system.
V-belt Drive System

 Check condition of guard
 Check condition of drive belts
 Check tension on drive belts
 Check alignment of drive sheaves
Direct Drive System

 Inspect drive coupling and guard for excessive wear.
 No apparent loose or missing coupling guard bolt(s).
 No apparent recent contact of rotating coupling and associated shafts with
any stationary object(s).
 No apparent missing, loose, or dislocated coupling hub key(s).
 No apparent loose motion between coupling hubs ands associated shafts.
 No missing, loose, or damaged coupling fasteners.
 No excessive elastomeric coupling transfer element wear as determined by
coupling O.E.M. procedure (amount of individual element wear or amount of
torsional difference).
 Coupling hubs gap within Original Equipment Manufacturing. specifications
( mm to mm)
 No other apparent function related coupling deficiencies.
Motor
 Clean off build up from motor and surrounding area.
 Check condition of motor cooling fan shroud. Shroud should be secure and in place with
no air flow obstructions.
 Check condition of cooling fan. Fan should be secure on the shaft with no damaged or
missing blades.
 Check motor stator cooling vanes. Fins are to be clean and undamaged.
 Check motor insulation
 Check connections of the motor.
 No apparent loose or missing motor foot bolt(s)
 No apparent loose or missing shim stock under motor feet.
 No damaged electric power or instrumentation cables, boxes, or devices on
the motor.
.
Impact if not Incorrect or not carried out mechanical inspections can lead to:
applied:  Screw pump breakdown with subsequent stop of major equipment
Actions:  Double check the proper execution of the mechanical inspections
Unit  Participant has carried out all of the mechanical inspections at least one time on their own (
Completion: A practical application of the different mechanical inspections is part of this training
unit ! Scheduling of the PMRs should be done in the maintenance management system)
instructions.
Figure 1. Barrel Bushing Diagram
Three Barrel Bushings
Screw Pump System

Figure 2. Flapper Valve Diagram
Unit: Screw Pump Troubleshooting 5 of 13
Version: 1.0 04.11.03
Screw Pump Troubleshooting

Purpose:  To be able to "fine tune" a screw pump transport system, so that it operates satisfactorily
with only routine maintenance and normal operating techniques.
 To be able to troubleshoot problems and eliminate their root cause
Description: There are many items that should be in place at the plant to ensure that screw pump systems
perform at the required levels of production (capacity and availability) and at the lowest
sustainable maintenance and operating costs.
1. An understanding of the design and operation of the pump system by appropriate

personnel.
2. Start-up and shutdown procedures that are recommended should be adhered to.
3. Routine preventive maintenance must be implemented so that smaller issues are

rectified before they become large problem.
4. Adjustments or fine tuning takes place to ensure the screw pump operates at optimal
levels.
5. Troubleshooting takes place to eliminate the root causes of failures.
Note: Modules 2 and 3 of Pneumatic Transport Systems deal with the first three items., This
module will cover practices of fine tuning and troubleshooting screw pump systems.
Standards: Fine Tuning Screw Pump Systems
 One of the main keys to having a reliable pneumatic system at the lowest sustainable
maintenance and operating costs is to have the pump operating at optimal conditions.
 Reasons for fine tuning the system include
 To reach design capacity
 To eliminate continual nuisance breakdowns
 To reduce maintenance needs by extending the life of components
 To reduce power requirements
 To accommodate for change in pipeline configuration
 To accommodate for changes in the material to be conveyed
 The main component of the pump system that can be adjusted to improve performance is
the "adjustment of the material seal"
Adjustments to the Material Seal

 A review of the material seal principle, and how it is affected by various influences will
eliminate some of the trial and error adjustments and make them more scientific.
 Every pump design has a material seal at the discharge end of the pump screw (see
Figure 1.) The pump screw compresses the conveyed material into a dense plug of
material which prevents reverse air flow from the conveying pipeline into the pump hopper.
Reverse air flow, commonly called blowback, reduces pump capacity and causes air
cutting of the screw shaft. To eliminate blowback, greater compression of the material seal
is required. However, greater compression requires more power and increases the
abrasion wear on the pump screw and the barrel liners (bushing). Therefore the material
seal should be adjusted to prevent blowback without over compressing. Hence the
necessity for fine tuning the screw pump system.
 The following material seal principles can be applied to all pump designs:
1. High system line pressure require greater material seal compaction than low
pressure systems.

2. The greater the material seal compression, the greater the pump power
requirements, which can lead to motor overloads. Less compression reduces the
power needed.
3. Small pitch screws make better material seals than large pitch screws, because
there are more sealing pitches in the barrel.
4. Material density, size distribution and moisture content greatly affect the material
seal. Generally, heavy materials make better seals than light materials. Large
particle size materials may provide voids in the material seal. Moisture can make
the material sticky and cause tight packing of the material seal.
 Since adjustment of the material seal affects the pump horsepower. the motor amps
should be monitored when making a seal adjustment. If the motor amps are fluctuating
and the flapper valve handle is also swinging up and down, then blowback is a problem
and the material seal must be increased. A wildly swinging flapper arm may occur at a
flow rate below design capacity, however adjustments in the seal should only be done at
design rates or actual average rates.
 Monitoring or inspecting worn pump screws can reveal important information regarding the
tuning of the pump. There are a number of different screw wear patterns, each the result
of different causes.
 An insufficient material seal permits blowback which air cuts the pump screw in a
particular manner. The blowback air flow seeks the path of least resistance or
compaction through the material seal. Since the material seal is located at the
discharge end of the screw, the air cutting occurs at the screw discharge. The
area of least compaction is on the back face of the flight and at the base of the
flight where it meets the shaft. Therefore, blowback air cutting causes a deep air
cut groove at the shaft along the back face of the discharge flight.
 Highly polished wear on the front face of the screw flight is often wrongly referred
to as blowback air cutting. This wear is caused by abrasion of the material against
the pushing face of the flight. Possibly this wear could be reduced by reducing the
amount of material seal compression.
 For actual instructions on how to increase or decrease the material seal, refer to the
supplier manual for the particular model. However, as an example, the following are the
instructions for adjusting the material seal for Type "M" Fuller-Kinyon Pumps (see Figure
3).
The Type "M" Pump Material Seal

 The seal for this particular screw pump is controlled by adjusting a restriction at the
discharge end of the pump screw.
 This restriction is controlled three ways:
 Increasing or decreasing the weighted force of the flapper valve arm.
 Moving the flapper valve closer or farther away from the pump screw by removing
or adding a spacer.
 Reducing the size of the discharge opening.
 Every "M" type pump is furnished with a one-inch thick spacer behind the flapper valve
assembly. The flapper valve arm has an adjustable weight. Initial adjustments should be
made by moving the flapper valve arm in or out.
 This adjustment can be made quickly without turning off the pump or the compressor.
 If blowback is the problem, the weights must be moved outward on the arms.
 If the flapper valve arms are bouncing up and down but the feed material has not
backed up in the feed hopper, move the weights outward until the arms are
steady.
 If blowback is the problem and the material has backed up in the feed hopper,
shut down the feed and empty out the system. Move the weights to the most
outward location and restart the feed. If this adjustment does not eliminate the
problem, try moving the weights inward to obtain satisfactory operation with a
minimum restricting force against the flapper valve.
 If the amps on the pump motor being above designed levels is a problem, move
the flapper arm weights inward. If necessary, the weights can be removed from
the arm. If this does not solve the problem, remove the spacer from behind the
flapper valve and readjust the weights if necessary.
 If pump blowback is a problem, move the flapper arm weights outward.
Sometimes additional weights are added to the arm. These additional weights
should not remain as a final adjustment. They may cause excessive wear on the
flapper valve and blowout lever. Additionally, binding or breakage of the flapper
valve shaft may occur.
 If additional weights are required or if these adjustments cause an excessive
increase in pump amps, a baffle plate should be installed behind the flapper valve.
This will permit a reduction in flapper arm weights. Refer to Figure 3 for baffle
plate sizing and installation. Normally, the baffle plate is installed with the opening
at the bottom. However, there have been installations where the opening at the top
provided better results. The baffle can be easily rotated by loosening the flapper
valve bolts and rotating the baffle. The size of the baffle opening will vary with
each installation. The smaller the opening, the tighter the material seal and the
greater the power requirements. To reduce power, increase the size opening.
 The M pump material seal can also be affected by the discharge end purge air seal.
Excessive air purge may break up the material seal and cause a blowback condition.
Insufficient purge air may cause excessive pump horsepower. The purge air
recommendations specified in the M Pump (see Figure 2) should be adhered to.
Troubleshooting Guide for Screw Pump Systems

(Guide could be consulted prior to initial start-up to help eliminate potential problems.)
A. The Pump does not Handle the System Capacity
1. Check material density and sieve analysis for proper material specifications,
since the pump is a volumetric device and changes in either property can cause
capacity problems. Coarser material feed than designed for can cause: (a) higher
pump motor amps and (b) the necessity for a reduction in capacity and line
pressure in order to sustain adequate conveying velocity.
2. Check that the pump hopper extension is vented and under a slight negative
pressure. Otherwise, a positive condition would indicate that there is blowback
from air pressure in the screw.
3. Poor material seal at pump discharge. A certain amount of material

compaction is necessary in order to provide a good seal. Too little can greatly
reduce pumping capacity by allowing blowback. Blowback occurs when an
improper seal permits conveying air to flow back through the pump. In addition to
reduced capacity, backing-up in the hopper extension and low motor amps are
major symptoms. See "Adjustments to the Material Seal" above.
4. Excessive air flow to the discharge end seal. (For "M pumps" only) This
results in aeration of material in the pump discharge housing causing reduced
capacity. On systems with plant air purge, verify that the proper size orifice is
installed in the union adjacent to the pressure regulator and that the regulator
setting is in accordance with that shown in Figure 2. Material bulk density in the
pump hopper may be reduced, with a corresponding loss in capacity if the drive
end purge air is excessive. In the case of air purge from a plant air supply system,
ensure that the pressure regulator setting and orifice size are in accordance with
data shown in the table 2 below. Systems with manifold air purge also contain an
orifice at the drive end; verify its installation and ensure the size is the same as
specified in table 2.
5. Check if a condition of excessive motor load exists on the pump. This

indicates that discharge seal is too great is causing excess power consumption
and accelerated wear on some components. See "Adjustments to the Material
Seal" above
6. Ensure constant feed to the screw pump. Surging feed condition into the pump
causes motor amp surges requiring reduction in feed to stay within motor limits.
7. Ensure that the conveying line discharge is vented via a dust collector.
Positive pressure at the conveying line discharge can result in reduced capacity.
8. Check line pressure for an abnormally high reading which would indicate that
the conveying line might be obstructed, thereby causing the higher conveying
pressure. See pump data sheet for anticipated system operating data.
9. Check diversion valves in the conveying line that may not be seating
properly.
10. Check the compressor for possible restrictions to intake that will cause lower
than required output volume.
11. Eliminate sloping conveying lines that could cause conveying problems. An
angled line, 20° to 80° from the horizontal can cause problems, such as refluxing
or re-circulating. Gravity causes the material to fall to the bottom wall and since
the air is above the material and the angle of the slope allows material to slide
back down the incline.
B. Bearing Failure - vibration analysis can assist in predicting bearing problems.
1. Ensure proper assembly as described in this manual and on general

arrangement drawings.
2. Do not over lubricate - high bearing temperatures and premature failure will
occur.
3. Do not under lubricate - see the Lubrication Section of the Screw Pump PMR
module for lubrication recommendations.
4. Use proper lubricant - consult equipment supplier for recommendations.
5. Misalignment - check drive system for proper shaft alignment or V-belt alignment.
6. Bearing Seal Failure - caused by problems in seal air, seal wear, or seal air
pressure adjustment (See Figure 2)
C. Seal Failure
1. Ensure that pump seals are installed properly, in accordance with the pump
instructions manual.
2. Ensure that newly installed pump seals are well lubricated prior to full load
system operation. Lubricate the seals while the compressor and pump are
running.
3. Check the renewable wear sleeve that the seals run on for possible damage due
to abrasion, when replacing seals in the pump. The seal wear surface must be
clean and smooth or premature seal failure will occur.
4. Ensure seal purge air piping is appropriate.
5. Check temperature of material to be transported. Material temperature in

excess of 400F (-200°C) will cause seal failure.
6. Check the delivery system of purge air to seals. (For "M pumps" only, see
Figure 2) An inadequate, or interruption of air purge caused by the following
conditions can result in seal failure:
 In the case of air purge from the pump compressor supply, the no-load
manifold pressure should be 8 to 9 psig (0.56 to 0.63 kg/cm2). A differential
lower than specified will not give proper purging upon reaching operating
pressures.
 In the case of air purge from a plant air supply, incorrect piping, regulator
settings, or orifice sizes may not provide adequate purge air.
 Emergency power failure while the conveying line is under pressure can
cause seal failure.
 Improper shutdown of conveying system (not allowing cleanout of pump

hopper) can cause seal failure.
 Permitting the pump hopper to be pressurized during the shutdown period

encourages material to enter seals when air purge is not operative.
Impact if not  Inefficient tuning or troubleshooting can lead to higher downtimes and costs.
applied:
Actions:  Study existing screw pump systems at the plant
 Review different failures (theoretical or practical)
Unit  Participant understands and can complete fine tuning and troubleshooting procedures.
Completion:
instructions.
Figure 1. Material Seal Illustration
Material Seal
Figure 2: Table for Type M Pumps - Seal Air Pressure Specifications
Figure 3. Diagram of Type M Pump - Material Seal

Unit: Screw Pump Major Repairs 6 of 13
Version: 1.0 04.11.03
Screw Pump Major Repairs

Purpose:  To provide information on repair techniques for screw pump systems.
Description: General
 Repair of screw pumps must be completed with the highest precision and accuracy.
 This unit was developed for the particular design of the "M Pump" by Fuller-Kinyon.
Although there are different specifics between pump type and manufacturers, the basics
covered here serve as a reference on all common repairs.
 Before dismantling the pump for repairs of any nature, carefully study the general
assembly drawing supplied with the pump.
 Complete all necessary actions to ensure safety during repairs. This includes but is not
limited to Lock Out/Tag Out procedures on all power supplies and compressed air
supplies.
The Pump Screw

 The pump screw is manufactured to close dimensional tolerances with fine-machined
surfaces. It is dynamically balanced in two planes to reduce vibration and ultimately
increase life. When removing or installing a new screw, handle it carefully to avoid
damage to surface finishes on its journals. Scratching these finely-machined surfaces can
cause seal failure and possible difficulty in screw removal.
 The frequency of screw replacement depends on load, operating pressures and the
physical nature of the material being handled.
 During operation, the pump screw should never touch barrel liners, and the pump should
not be operated in this condition. If this situation exists, the pump screw may be bent and
may require reconditioning or replacement
 Foreign material passing through the pump may cause imbalance; normally heavy pieces,
such as metal, collect in the bottom of the pump hopper and no damage results.
Pump Screw Removal. The pump screw can be removed from either end of the pump. It is
recommended that removal be from the discharge end on both direct drive and V-belt drive
pumps. However, on some V-belt drive installations it may be necessary to remove the screw
from the drive end due to space limitations.
 Screw Removal from Discharge End. The following steps describe screw removal from
the discharge end. See figures 1,2, and 3.
1. Remove the drive guard.
2. Remove the V-belts and pump sheave or loosen the drive coupling from the
screw shaft.
3. Loosen the setscrews (D and E). Remove the lock collar (F) and key (G) on
figure 3.
4. Remove both hopper cover plates (L, figure 1), and clean out the hopper.
5. Remove the discharge end pressurization piping and accompanying filters
and dryer. Be careful not to lose the orifice contained in the union adjacent to
the pressure regulator.
6. Remove the bearing cover (D), cap screws (E), and bearing retainer (F). See
figure 2. Reassemble the bearing cover (D); use two bolts to retain the cover
in place. This prevents the screw bushing (G) from sliding out of the seal (H)
during disassembly, of the bearing housing (M).
7. Unbolt the bearing housing (I) from the bearing support (J) shown in figure 2.
Use two bolts as jack screws in the tapped holes provided in the flange. Slide
the bearing housing assembly off the screw shaft.
8. Remove the bearing support using the same procedure as step 7.
9. Attach the screw puller to the discharge housing and screw as shown in
Figure 4. Turn the hex nut to extract the screw as far as the puller allows. On

direct drive pumps, support the drive coupling to prevent damage by falling.
10. Remove the screw puller. Provide movable support at the end of the screw.
Use crowbars, pinch bars, or other means of leverage, to pry between the
screw flights and the end of pump housing to slide the screw from the pump.
Do not pry on cast iron balance wheel! As the screw is withdrawn, reposition
the movable screw support to the approximate center of the screw or provide
additional support to the drive end of the screw for removal.
 Screw Removal from the Drive End. (See Figures 1,2, and 3.)
1. Remove the drive guard, V-belts, and pump sheave.
2. Loosen the setscrews (D and E). Remove the collar (F) and key (G), shown in
Figure 3.
3. Remove both hopper cover plates (L, figure 1) and clean out the hopper.
4. Remove the discharge end pressurization piping and accompanying filters
and dryer. Be careful not to lose the orifice contained in the union adjacent to
the pressure regulator.
5. Remove the bearing cover (D), cap screws (E), and bearing retainer (F,
Figure 2). Reassemble the bearing cover (D), using two bolts to retain the
cover in place.
6. Remove the bearing housing (H) from the bearing support (I, Figure 3). Use
two bolts as jack screws in the tapped holes provided in the flange. NOTE:
Jack the bolts evenly to prevent cocking. Due to the limited length of the jack
bolts, spacers must be inserted between the end of the jack bolt and the
support housing (I) until the bearing housing is jacked free. Remove the
bearing housing from the screw shaft.
7. Disconnect the air piping from its air purge hole in the bearing support (Figure
3). Use jack bolts to remove the bearing support from the screw shaft.
8. Provide movable support at the drive end of the screw. Insert crowbars, pinch
bars, or other means of leverage through hopper openings and pry the screw
out through the drive end of the hopper. Do not pry on cast iron balance
wheel! Support the screw as previously described in step 10 of screw removal
from the discharge end.
Replacing the Barrel Bushing. While it is not always necessary to change the barrel
bushings each time the screw is changed, a check should be made of the inside diameter of
the bushing. If it is grooved or worn to any extent, the bushing should be replaced.
 Barrel Bushing Removal
1. Remove the housings (I and J, figure 2) and the screw.
2. Remove the barrel bushing retainer screws (M and N) and the four setscrews
(P, figure 1).
3. Pull out the short barrel bushing (Q) from the discharge end of the pump.
Apply high-pressure air through the setscrew hole and rap the bushing sharply
with a hammer until all material is blown from between the barrel and bushing,
allowing the bushing to slide out freely.
4. Barrel bushings (R and S, figure 1) are also removed from the discharge end
of pump. Apply high-pressure air through the setscrew holes and rap the
bushings as explained in step 3. Use a screw jack or hydraulic jack, as shown
in figure 5, and jack the bushings out through the discharge end of the pump.
 Barrel Bushing Replacement

1. Clean barrel bushings and barrel bores thoroughly before installing bushings.
2. Insert the soft barrel bushing (R, Figure 1) into the discharge end of the pump.
Insert the as-cast face end of the bushing toward the hopper end of the barrel
(see Figure 5). Push the bushing through the barrel until the bushing extends
approximately 25 mm into the hopper. Align the ribs on the OD of the bushing
to straddle the anti-rotation setscrews (P, figure 1).
3. Insert the hard barrel bushing (S, figure 1) with the slotted end of the bushing
toward the discharge end of the pump. Push the bushing in until it contacts
the soft bushing. Position the slot in the end of the bushing on top. Assemble
the retainer bolt (N, figure 1) tightly in place. From the hopper, push both
barrel bushings forward until the retaining bolt is fully engaged in the barrel
bushing slot
4. Assemble the retaining bolt (M, figure 1) tightly in place. Insert the short
bushing (Q) into the housing with the slot engaging the retainer bolt (M).
5. Tighten the four setscrews (P, figure 1).
Pump Screw Installation. The pump screw may be installed from either end of the pump.
Install the screw from the same end of pump from which it was removed. Before installing the
screw, remove all burrs or foreign material that may hinder insertion. It is important that the
screw journals and screw bushing bores are cleaned thoroughly prior to screw insertion.
Failure to follow this suggested precaution may cause difficulty in removing the screw.
 Installation from Discharge End
1. Remove the key from the screw shaft and insert the screw into the pump until
the screw shaft journals are visible within the pump hopper. Clean the screw
shaft journals and screw-bushing bore thoroughly before further insertion.
Carefully push the screw all the way into position until the outside face of the
discharge end balance wheel is approximately flush with the end of the
discharge housing. Refer to Figure 2 and proceed as follows:
2. Clean all mating surfaces, screw journals, and screw bushing bores at the
discharge end of the pump. Apply Permatex sealant 1372 to the machined
faces of the bearing housing support (J) and carefully assemble it over the
screw shaft and bolt it tightly in place.
3. Install the O-ring (K) on the screw shaft.
4. Apply Permatex sealant 1372 to the machined faces and assemble the
bearing housing (I) over the screw shaft and bolt it tightly to the bearing
housing support (J).
5. Remove the cover (D) and assemble the bearing retainer (F) with socket head
cap screws (E). Tighten the cap screws with a torque wrench and torque each
cap screw to 180 ft.lbs (25.0 kg.m) for Type M - 250 mm pumps. Then
assemble the bearing cover (D) with Permatex sealant between the faces.
6. Assemble the key (G), lock collar (F) and tighten the set-screws (D and E)
shown in figure 3.
7. Assemble the hopper cover plates and all air purge piping with accompanying
orifice.
8. Assemble the pump drive.
9. Lubricate the lip seals located in the bearing housing supports as described in
the lubrication instructions
 Installation from Drive End

1. If bearing housing (I) and bearing support (J) in figure 2 have not been
removed from the pump, disassemble them before installing the screw.
2. Insert the screw into the hopper end of the pump. Push the screw through the
pump barrel until the balance wheel, at the discharge end of the screw, is
approximately flush with the end of the discharge housing.
3. Assemble the housing to the discharge end of the pump as described in steps
2, 3, 4, and 5 of preceding instructions. Refer to figure 3 and proceed as
follows:
4. Clean all mating surfaces, screw journals, and screw bushing bores at the
drive end of the pump. Carefully assemble the bearing housing support (I) and
the bearing housing assembly (H).
5. Finish the pump assembly as described in steps 6, 7, 8, and 9 of previous
instructions.
Pump Screw Construction

 The pump screw consists of a solid steel shaft and flights made from rolled mild steel
welded in position (see figure 6). The flights on the discharge end of the screw have
peripheral hard surfacing. In addition to the peripheral surfacing, the screw shaft and flight
faces nearest the pump discharge also have a hard surfacing layer. The hard surfacing is
always applied with gas welding. Any hairline cracks that occur in this surfacing layer are
not detrimental provided the hard surfacing has an excellent bond with the base metal.
 After the screw shaft has received flights, balance wheels, and hard surfacing, it is placed
in a lathe and straightened. The shaft is machined to accept two wear sleeves that are
mounted and held in position by a press fit. The flights and shaft are then ground to the
finished diameter.
 All screws are dynamically balanced in two planes to improve bearing life and insure
vibration-free pump operation. Determining the amount and location of the balancing
weights is performed by a balancing machine that indicates the amount of the correction
weight and its angular location. The angular location determines which balance wheel
cavity is to be used, and the amount of weight determines how much lead shot is to be
placed in this cavity.
Pump Screw Inspection Criteria

In many instances it will be possible for a Fuller-Kinyon pump screw to be repaired or
reconditioned. The following standards will allow you to inspect your pump screw. If these
criteria are carefully followed you can, in most cases, determine the screw's suitability for
repair.
 Flights - If the flight base metal is worn under the hard facing, either on the flight
periphery or face, the flight needs to be replaced. The thickness of the hard facing on the
periphery is approximately 7.5 mm and about 4 mm on the flight face (as shown on figure
6). Flights are replaced in one turn (360º) segments, and no more than three flights can be
replaced on the screw economically. If more flights must be replaced, the screw should be
scrapped.
 Hard facing Application - Screws manufactured by Fuller Company are surfaced with
Colmonoy by means of gas welding. If hard surfacing is applied with electric welding, it will
not be smooth enough on the flight faces for efficient conveying nor will it bond properly.
 Wear Sleeves - Two areas of the screw have a pressed on wear sleeve as shown in
figure 6. A damaged sleeve must be replaced.
Bearings
The type M Fuller-Kinyon pump uses angular contact bearings. The bearing located at the
discharge end of the pump screw is fixed and absorbs both radial and thrust loads. The
bearing located at the drive end is not fixed to the screw shaft and absorbs radial load only.
The 250 mm size pump utilizes a duplex pair of universally flush ground angular contact
bearings mounted back-to-back.
Bearing Replacement. To replace bearings it is not necessary to remove the pump screw
from the pump. Remove the bearing housing assemblies as described in the screw removal
instructions.
 Bearing Replacement Discharge End of Pump (Fixed). Refer to figure 2
1. Remove the bearing cover (D).
2. Slide the bearing and screw bushing (G) out of the bearing housing.
3. Support the bearing on the inner race and press the screw bushing out of the
bearing.
4. Before replacing the bearing, clean all parts thoroughly and pack the bearing
with proper lubricant. Check the seal (H) and the seal wear sleeve (L) for wear
or damage and replace them if necessary. The seal (H) is assembled as
shown in Figure 2.
Assemble the bearing on the screw bushing (G). The 250 mm size pump
uses a duplex pair of angular contact bearings mounted back-to-back.
Bearings have either the word "THRUST" or "SUPPORT" stamped on one
face of the outer ring. Assemble the bearings with the thrust faces together.
Slide the bearing and screw bushing assembly into the bearing housing.
CAUTION: Do not push the screw bushing through the seal. This could
damage the seal. Make a sleeve out of shim stock and assemble it through
the seal and over the screw bushing, see figure 7. Push the bearing assembly
into position and remove the shim stock.
5. Assemble the bearing cover with two bolts to hold the bearing in place
6. Attach the bearing housing assembly to the pump as described in pump screw
installation instructions.
 Bearing Replacement Drive End of Pump (Floating). Refer to figure 3
 For the 150 mm and 200 mm size pumps, assemble the bearing on the screw
bushing with the filling notch side of the bearing out towards the bearing locknut.
 The procedure for replacing this bearing is the same as previously described for
the discharge end bearing except that the bearing is retained on the screw
bushing (K) by a locknut (L) and lockwasher (M).
 It is most important that the locknut (L) is securely tightened to firmly clamp the
inner race of the bearing to the screw bushing (K).
 To facilitate tightening of the locknut, (L) wrench slots are provided on the screw
bushing (K).
 Using a spanner wrench to hold the screw bushing and to turn the locknut tighten
the locknut firmly by manual force.
 Then with a hammer driving the spanner wrench, tighten the locknut firmly.
 Bend a washer tab into a nut slot to retain the locknut in position.
 The firm clamping of the bearings to the screw bushing prevents rotation of
bearing on the screw bushing, and establishes proper bearing pre-load for the
Duplex bearings furnished with the 250 mm and 300 mm size pumps.
 Failure to obtain sufficient clamping of the bearings may cause bearing and seal
failures.
 There are two lip seals (N and O), which are assembled as shown in figure 3.
 Assembly of the screw bushing info these seals should be performed with caution,
utilizing the same procedure as shown in figure 7.
Seals
 At each end of the pump screw, there is a material seal arrangement housed in the bearing
housing support. This seal arrangement is identical at both ends; refer to figures 2 and 3.
This seal arrangement consists of three lip seals (P) and a grease ring spacer (Q).
 A seal failure on the drive end would be apparent by dusting to atmosphere.
 On the discharge end of the pump, if seal failure should occur, no visible dusting will
appear because of the pressure tight enclosure. Therefore, it is suggested that the
following be performed to check seal condition:
 With the pump and discharge end purge air off, remove the pipe plug on the side
of the bearing housing support (J) (figure 2), Allow the purge air to flow so that air
blows through the opening, which is now unplugged. This may require operation
of the conveying compressors for a brief time for pumps not utilizing plant air
purge to the seals. Any evidence of process material in this cavity indicates the
potential for worn seals. If material is found, or if any doubt remains, proceed to
step 2. In any case, shut off the purge air and replace the pipe plug.
 Again with the pump and purge air off, remove the nipple and cap (R) found under
the bearing housing support (J). Remove as much grease as possible and inspect
it for material contamination. This may be more easily accomplished with the
pump warm. If no contamination is found, the seals are still satisfactory. If
contaminated, the housings should be removed as previously described in the
screw removal instructions, and the seals replaced as described below. A
thorough inspection of the bearing and bearing lip seal is in order at this time. If
any material is found in the bearing or its lubricant, or if the lip seal (H) is worn, the
bearing should be thoroughly flushed and either replaced with a new bearing or
repacked and reinstalled. In any case, remove all old lubricant in the bearing
housing. Replace the lip seal if worn.
 A sudden rise in bearing operating temperature may also be indicative of seal
failure, which allows bearing contamination. A hot bearing may also be caused by
underlubrication or overlubrication, but if seal failure is suspected, proceed with
steps 1 and 2 as a check
 WARNING: Do not attempt to remove any fittings or disassemble the discharge
end housings in any way while they are pressurized!
 Procedure for replacing seals:

1. Remove the bearing housing support as previously described in the screw
removal instructions.
2. Using a hammer and punch, drive the seals out of the housing.
3. Clean all parts and assemble new seals as shown in figures 2 and 3. Pack the
grease ring (Q) and the seal cavity during assembly with the same grease
used for bearing and seal lubrication. This helps to insure adequate seal
protection upon start-up. Thereafter, follow the instructions for greasing found
in the Lubrication Section.
Wear Sleeve
There are two hard, chrome-plated, replaceable wear sleeves on the type M pump screw as
shown in Figure 8. These sleeves are located on the screw shaft adjacent to the balance
wheels where they provide a hard, smooth journal for the pump lip seals. The sleeves are
shrink fit o the shaft. The following procedure is suggested for replacing worn or damaged
sleeves.
 Sleeve Removal
 Expand the sleeve by heating with a torch. Heat the sleeve rapidly, and then drive
off the sleeve with a hammer and cold cutter. If heat is applied too slowly, the
shaft will get too hot and prevent removal of the sleeve.
 WARNING: Do not apply heat to the balance wheel. Heat can build up pressure
within the balance wheel, causing it to explode
 Sleeve Assembly
 Allow the screw shaft to cool before installing new sleeves. Heat new sleeves in
oil to approximately 300º F (150º C). Slide the sleeves over the screw shaft and
position them against the shaft shoulders.
 The drive end wear sleeve is shorter than the discharge end sleeve. The sleeves
have a chamfer on the outside diameter at both ends. The end with the smaller
outside diameter chamfer also has a chamfer on the inside diameter. The end with
the inside diameter chamfer is assembled towards the screw balance wheel.
 To obtain reasonable seal life, the outside diameter of the wear sleeve must be
concentric with the bearing journals within 0.10 mm (.004") total indicator reading.
Flapper Valve Assembly

The flapper valve assembly is a mechanical seal that prevents a flow of air from the mixing
chamber backward through the pump. The seating surfaces of the flapper valve assembly are
hard surfaced for maximum life. If these surfaces are air cut or chipped off, the flapper valve
assembly should be replaced.
Standards:  For maintenance instructions refer to the Original Equipment Manufacturer (OEM) for
details on plant specific screw pump conveyors.
Impact if not  Repetitive failures
applied:  High maintenance costs
Actions:  Review procedures prior to completing work.
 Perform work in a highly professional manner
Unit  Participant understands how to replace critical components in a screw pump system.
Completion:
See site-specific unit for additional information, respective corrective actions and applicable safety
instructions.
Figure 1. General Arrangement Drawing of the M Pump

Figure 2. Drawing of Discharge End Bearing Assembly - 250mm Type M Pump
Figure 3. Drawing of Drive End Bearing Assembly - 250 mm Type M Pump

Figure 4. Drawing of Screw Puller
Figure 5. Barrel Bushing Diagram
Figure 6. The Pump Screw

Figure 7. Seal Arrangement
Figure 8. Pump Screw Dimensions

Unit: Batch System Design 7 of 13
Version: 1.0 04.11.03
Batch System Design

Purpose:  To understand the basic design and operational parameters associated with batch system
pneumatic conveying.
Description:  A batch system (also known as a "pressure vessel" or "pressure tank" system) is used for
pneumatic conveyance of pulverized material, particularly raw meal and cement.
 The batch system transports material by alternately filling and emptying a pressure vessel
on a fixed cycle.
 The principle steps in this cycle of the pressure vessel conveyance are:
1. Filling - material to be conveyed enters the vessel at atmospheric conditions.
2. Pressurizing - the vessel is pressurized to force material into the conveying line.
3. Conveying - the vessel is emptied into the conveying line and material is
conveyed by the supply air.
4. Venting - the vessel is then vented to relieve all pressure before the filling cycle
begins again. The vessel is also vented while filling occurs
 Although there are many different suppliers of batch systems the basic steps above occur.
There may be differences in timing, air pressures, seals etc.
 Different Batch Systems
 Single pressure vessel conveying - batch conveying
 Twin pressure vessel conveying (parallel connection) - quasi-continuous
conveying, 50% reserve if one vessel fails.
 Double-story vessel conveyance (series connection) - continuous conveying.
 A pressure tank system is ideally suited for batch operations and is readily adaptable to
weighing applications.
 The tank can be mounted on a scale / load cells and one or more materials can be
weighed into it.
 The weighed batch is then transferred, under pressure, to the selected bin or silo.
Various Batch System Processes:
 In a "Blow Tank" system, the material is placed into a tank at atmospheric conditions and
the tank is then pressurized to the same pressure as the pick-up point of the conveying
line. Material then flows freely from the tank into the conveying system.
 In the Fluxo Pump System by FLS (See Figure 1), the conveying cycle begins when the
inlet valve (1) and air escape valve (2) are open, and pressure valve (3) is closed. The
tank is at atmospheric pressure and the material flows freely into the tank. When the
material reaches the level sensor, solenoid valves are activated which close the inlet valve
(1) and the air escape valve (2). The supply air for conveying then pressurizes the vessel.
For the first half of the cycle the rise in pressure exceeds the fall in tank volume and the
pressure keeps rising. Then as the expansion due to the increase of volume because of
material being transferred exceeds the incoming pressure and the tank pressure falls. At
this point the incoming pressure is closed (3) and expansion makes the pressure fall
sharply as the material completely moves out of the vessel. Finally, when the preset
pressure value is reached, inlet valve (1) and air escape valve (2) open and the next
charging cycle begins.
 The PNEUMEX pressure vessel conveying system (see Figure 2) begins with material
entering the vessel without pressure. It is then sealed. The main conveying gas is
pressed through a porous medium of the aerating floor. The behavior of the material-gas

mixture is similar to that of a liquid, flowing away through the pipeline due to the
overpressure of the system. As the pressure falls below a certain level the cycle begins
again.
 In a "MODCO Pod System" (see Figure 3), the operating cycle involves opening the pod
fill and vent valves for a predetermined length of time during which the material to be
conveyed flows into the pod. After pod is full the fill and vent valves are closed. The pod
discharge and air supply valves are then opened, and the material flows into the
"Transition Chamber". In the MODCO system only enough air is introduced to the pod
through aeration pads during the discharge cycle to insure a steady flow of material into
the Transition Chamber where it is blended with the conveying air for transport to its
destination. As one pod is being emptied the second pod is being filled, and the pods
cycle back and forth receiving and conveying a continuous flow of material.
Impact if not  If the proper cycle and design of the system is not followed, the desired capacities will not
applied: be reached.
Actions:  Understand the conveying process for the particular batch system installed at the plant.
Unit  Participant can explain how the conveying process works for their particular plant system.
Completion:
See site-specific unit for additional information, respective corrective actions and applicable safety
instructions.
Figure 1. The Fluxo Pump

Figure 2. The Pneumex Pressure Vessel Conveyor
Figure 3. The MODCO Pod System

Unit: Batch System PMRs 8 of 13
Version: 1.0 04.11.03
Batch System Preventive Maintenance Routines

Purpose:  To learn what preventive maintenance routines (PMRs) are to be carried out on batch
systems to ensure optimal levels of availability, performance, and maintenance costs.
Description:  The Preventive Maintenance Routines (PMR) play a key role in the Maintenance strategy.
 Many tasks in the plant must be performed on a frequent basis to maintain equipment (i.e.
lubrication) or to understand the condition of equipment (i.e. visual inspections).
 To achieve this goal, a proper database must be in place. The schedule of the PMRs, the
steps required by the PMR, and the results of the PMRs must be captured by the
database.
Standards: PMRs
Visual Inspections - Weekly

 General visual check for cracks, leaks, and damage
 Check the compressed - air conditioner for:
 Water level in the condensate trap
 Oil level in the oil atomizer
Instrumentation - 6 Months
 Test safety interlocks for proper operation
 Test pressure transmitters by simulated input for proper adjustment.
 Test level limit switches for proper operation
Mechanical - 6 Months
 Inspect transport vessel for excessive wear by monitoring wall thickness at defined
locations on the vessel
 Inspect transport piping for excessive wear by monitoring wall thickness at defined
locations along the piping
 Inspect vessel filling valve for excessive wear and proper functioning.
 Check the supply air piping below the batch system for penetration of the material
conveyed by opening the drain cock or the blind flange in the T elbow.
 Check the stuffing box of the expansion tube for leaks
 Inspect the conveying nozzle and the riser pipe through the manhole
Servicing - Yearly
 Check the shut-off flap for wear and leaks
 Re-tighten the stuffing boxes of the expansion tube.
 Check and calibrate the contact pressure gauge and the line pressure gauge for damage
and incorrect pressure indication.
 Remove the textile fabric belt, clean it with compressed air, check condition and remount
 Remove and check the filling level limit switch according to the instructions of the
manufacturer
Impact if not Incorrect or not carried out PMRs can lead to:
applied:  Batch system breakdown with subsequent stop of major equipment
Actions:  Double check the proper execution of the PMRs
Unit  Participant has carried out all PMRs types (belonging to their trade) at least one time on
Completion: their own
instructions.

Unit: Batch System Troubleshooting 9 of 13
Version: 1.0 04.11.03
Batch System Troubleshooting
Purpose:  To be able to "fine tune" a pressure vessel transport system so that it operates
satisfactorily with only routine maintenance and normal operating techniques.
 To be able to troubleshoot problems and eliminate the root cause of occurrences.
Description: Ensuring that the batch systems perform at the required levels of production (capacity and
availability) at the lowest sustainable maintenance and operating costs requires:
1. An understanding of the design and operation of the batch system by appropriate

personnel.
2. Start-up and shutdown procedures that are recommended to be adhered to carefully.
3. Routine preventive maintenance to be conducted to avoid issues becoming large

problems.
4. Adjustments or fine tuning being done to ensure the pressure vessel system is
operating at optimal levels.
5. Troubleshooting to eliminate the root causes of failures.
Note: Units 5 and 6 of Pneumatic Transport Systems deal with the first three items. This unit
covers fine tuning and troubleshooting batch systems.
Standards: Fine Tuning of Batch Systems:
Optimizing operation of a pressure vessel transport system requires setting the duration or
levels in the operation cycle and optimizing the amount of air needed to aerate the system.
 Operation Cycle. it is important that the filling level be optimized during each
cycle. We need to get the highest amount of material in the vessel each cycle
under the limitations of the volume of the vessel and pressure of the air
system. This minimizes number of total cycles needed for a given output and
thus increases the life of the valves.
 Aeration Air. Fine tune the amount of air required to aerate or pressurize the
system. This will optimize maintenance and energy consumption.
 Proper Valve Seating. Valves which either fail to close fully or to open fully
will rapidly wear out due to “shot blasting effects” of high velocity air streams
with material particles in-stream. Check that all valves sit fully closed and fully
open at the end of their strokes.
Troubleshooting Chart:
TROUBLE CAUSE REMEDY

I. conveying periods 1. lack of conveying air; air check air supply, reset air
are too long pressure is too low conditions
2. changing properties of the check bulk density, grain size
material being conveyed and moisture and restore
original conditions; otherwise
reset air supply
3. main, additional or bypass reset valves, replace damaged
valves out of adjustment or parts
defective
4. aerating floor is dirty check pertinent pressure
gauges; should pressure loss at

the floor be far too high, clean
the floor or, if necessary, replace
it
5. filter in additional air pipe clean filter
is dirty
6. leak in vent or inlet valve readjust set screw; replace
damaged parts; clean valves
7. conveyor pipe within the repair or replace the pipe
vessel is worn out or has
untight flange joint
8. foreign matters or material clean the vessel
clogs in the vessel
9. excessive line back Check for material build up in
pressure conveying line, restrictions, or
lack of proper de-dusting in silo
which is being conveyed to
II. vessel is not filled 1. formation of bridges above unless preliminary vessel has its
inlet valve own aerating system, remove
bridges by slightly knocking at
the wall
2. material feed is interrupted check preceding plant
III. pipe obstructions 1. insufficient air conditions blowout conveyor pipe through
blowout cock or withdraw
material into the vessel; then
reset air conditions; pressure on
back pressure manometer must
at least be 0,1 to 0,2 at under
the vessel pressure
2. additional air valve is out replace damaged parts and
of adjustment or defective reset valve; check back-
pressure gauge
3. too much material discharge pipe better; set
remained in the conveyor minimum contact a little lower
pipe from the preceding cycle
4. filter in additional air pipe clean filter; possibly reduce
is dirty moisture in compressed air
5. high pressure fluctuations reduce number of taps in the
in the compressed air network or increase air vessel
network
6. properties of the material check material properties and
being conveyed have correct them, probably reset air
changed conditions
IV. piston-controlled 1. filter in control air pipe is clean filter
valves close sluggishly dirty
2. poor lubrication of com- a) check lubricant; replace
pressed air cylinder resinifying oils by lighter ones;
clean all gaskets and moving
parts before
b) oil atomizer is obstructed;
clean control air pipes in the
case of repetition
3. gaskets in four-way valves replace gaskets; wash out
and compressed air control air pipes
cylinders are damaged
4. piston rods of compressed spray them with Teflon spray
air cylinders are dry
5. control air pressure is too increase air pressure
low
V. four-way valves blow 1. piston rings in compressed exchange piston rings
off or faulty controls air cylinders are untight
occur
2. four-way valve seats are renew valve seats
untight
VI. pressure inside the filter in the manometer pipe clean filter by operating
vessel is indicated is dirty scavenging air cock; remove
inaccurately filter and clean it should the
fouling be obstinate
VII. pressure under the water in manometer pipe let water run off and clear the
floor is indicated pipe by compressed air
inaccurately
VIII. conveying air valve the maximum contact, a) discharge the plant; switch
does not close although serving as pre-contact, it off and then on again
the minimum contact is did not respond due to b) close conveyor pipe valve
reached pressure fluctuations and re-open it after the
maximum contact has been
reached
c) in the case of higher pressure
fluctuations take the measures
as stated under III, 5; otherwise
operate PNEUMEX at higher
pressure at the same maximum
setting, yet after having reset the
air conditions
IX. dust formation when 1. the time relay is set to too increase delay on changing over
shifting from handling short a period; the residual
to filling pressure expands
into the intermediate
vessel or into the filter
2. minimum contact is set set minimum contact lower
too high
3. foreign matters are in the clean vessel
vessel
4. air supply was interrupted check air supply
temporarily
X. dust formation 1. seats of inlet valves are clean valve seats
during conveyance fouled and do not close
tightly
2. inlet valves do not close set filling level measuring device
completely as the vessel is lower
too full
XI. insufficient air flow filter is dirty clean filter
through conveyor pipe
blowout cock
XII. aerating floor is 1. compressed air contains check compressor, empty
sticky or dirty water or oil condenser traps more frequently
or install self-emptying traps;
clean oil and water separator
(fine filter) every 3 months
2. material to be conveyed is check material and dry it
moist
XIII. valve seats flutter valves are opened keep valves in opened throttle
completely position
Impact if not  Inefficient tuning or troubleshooting can lead to higher downtimes and costs.
applied:
Actions:  Study existing batch systems at the plant
 Review different failures (theoretical or practical)
Unit  Participant understands and can complete fine tuning and troubleshooting procedures.
Completion:
instructions.
Type of Skill: General Technical Skills
Category : Transport Equipment
Unit: Air Lift Operation 10 of 13
Version: 1.0 04.11.03
Air Lift Operation

Purpose:  To understand the basics on air lift system operation.
Description:  An air lift is a pneumatic elevator designed to continuously transport dry, free-flowing bulk
materials through a vertical pipe into a bin or receiving hopper at a substantially higher
elevation. Figures 1, 2, and 3 illustrate the different air lift systems from various suppliers.
 During operation there are no moving parts on the air lift system. Only the blower that
supplies the conveying air has moving machinery.
 The air lift system is simple and reliable in operation but has high air consumption, thus
energy consumption costs. It is used almost exclusively for the feed of raw meal to the
kiln preheater system.
 There are two main roles of a air lift or pneumatic elevator system
 To transport material at a specific rate using air as the transport media
 To contain material within system
How does it work?

 The material to be conveyed is continuously fed into the airlift vessel (also known as
"conveying vessel" or "airlift pot"
 The floor of the vessel is made of a porous material (e.g. textile fabric) through which air
passes and fluidizes the material.
 The material in the vessel creates a "solid" or "material" column. The pressure of the
material column forces the fluidized solids to flow into the convey line entry point.
 The main conveying air enters the airlift vessel via a nozzle just below the inlet of the
internal conveying pipe line (i.e. "entry point"). Here the stream of conveying air entrains
the material and carries it up to the final destination.
Other Items:
 The force of the solid column moving the fluidized material into the conveying line serves
as an airlock seal for the conveying line pressure in the lift pipe.
 A dedicated blower is needed to provide a stream of air moving at sufficiently high velocity
to convey it to the top of this discharge pipe.
 For conveyance and aeration purposes the conveying vessel must be charged with
compressed air which is free from dust, oil, and water.
 The totally enclosed design provides dust-free operation when vented to a dust collection
system.
 The maximum filling level in the conveying vessel is monitored by the filling limit level
switch
 A shutoff flap, located just below the nozzle in the supply air duct, serves as safety valve.
If the conveying air supply is switched off or fails, the flap will shut immediately in order to
prevent material from returning into the supply air duct.
 Expansion tubes are installed to compensate for the expansion of the conveying pipe
owing to the thermal stresses. The expansion tube consists of an internal tube with flange
and a larger external tube with transition. The space between internal and external tube of
an expansion tube is tightly sealed by a stuffing box.
 Two pressure gauges are usually installed on the system. The pressure gauges typically
indicate the pressure in the air inlet to the airlift and the material discharge pressure at the
outlet of the system. The quantity conveyed is proportional to the intensity of the pressure
generated by the material column in the conveying vessel and thus also proportional to the
conveying air pressure and the pressure at the bottom. Which means its possible to
monitor the throughput tonnages by the pressure gauges.
 Prior to longer shutdowns, empty the airlift conveyor

In operation, the airlift is a self-compensating system.
 As the product feed rate to the airlift vessel increases, the fluid bed level rises.
 This increase in bed depth results in an increase in the flow rate into the conveying line
and an increase in the conveying line pressure.
 At a given feed rate, the level in the airlift bin will automatically adjust to compensate for
the back pressure in the lift pipe, itself.
 Material feed rate should not exceed the limits of the size of vessel and the capacity of the
blower.
Standards: Start-up
 Switch on the units at the discharge end of the conveying system.
 Switch on the conveying air blower and simultaneously open the shut-off flap.
 When the OPEN limit switch of the shut-off flap is reached, activate the pressure
monitoring by means of the contact pressure gauge and start material feed.
 If the OPEN limit switch is not reached within 5 seconds, stop the blower, shut the shut-off
flap and signalize fault
Stoppage
 Stop the material feed.
 At the end of the feed lines' dead time, switch off the blower and simultaneously shut the
shut-off flap
Interlocks
 If for more than 5 seconds the filling level limit switch signalizes MAX filling level or the
contact pressure gauge signalizes max conveying air pressure, stop the material feed and
re-open after the signal is cleared. If the signal is still active after 10 seconds, switch off
the blower, shut the shut-off flap and signalize fault.
 Whenever the blower is switched off the shut-off flap must be shut.
Settings
 Set the contact pressure gauge to 0.4 bar. The final setting will be made in the test run
 Adjust the throttles at the solenoid valve such that the shut-off flap opens in 3 seconds
and shuts abruptly.
 Set the pressure regulator of the compressed-air conditioner to an initial pressure of 5 bar.
 Adjust the filling level limit switch after the first filling of the conveying vessel according to
manufacturer's instructions.
 The air quantity required for aeration of the material conveyed depends on the kind of
material conveyed and is adjusted by the throttle valve. Adjust the throttle valve after the
first filling of the conveying vessel such that the material conveyed is aerated but does not
"boil" This can be checked by touching the conveyor vessel wall
Impact if not  The desired throughput of the system is not maintained.

applied:  Unscheduled downtimes, resulting in loss of production and higher maintenance costs.
Actions:  Ensure proper setup of the plant systems regarding installation and interlocks
Unit  Participant understands operating principles and parameters of the air lift system.
Completion:
instructions.
Figure 1. Polysius - AEROPOL Vertical Conveyor
Figure 2. Fuller Company - Airlift

Figure 3. Claudius Peters - Airlift
Type of Skill: General Technical Skills
Unit: Air Lift Maintenance 11 of 13
Version: 1.0 03.11.04
Air Lift Maintenance

Purpose:  To understand the basics on air lift systems maintenance requirements.
Description:  Proper maintenance of air lift system is very important to sustaining high reliability at the
lowest sustainable maintenance costs.
 The three key elements that compose a good maintenance strategy for the system are:
 Preventive Maintenance Routines
 Repair Work
 Troubleshooting (See Figure 1)
Standards: PMRs
Weekly Visual Inspections:

 General visual check for cracks, leaks, and damage
 Check the compressed-air conditioner for:
 Water level in the condensate trap
 Oil level in the oil atomizer
Instrumentation - 6 Months
 Test pressure transmitter by simulated input for proper adjustment
 Test safety interlock for proper operation
Mechanical - 6 Months
 Inspect the aeration floor for leaks and damage to the textile fabric belt and for penetration
of material conveyed through the manhole and by opening the drain cock in the aeration
floor.
 Inspect transport vessel for excessive wear by monitoring wall thickness at defined
locations on the vessel
 Inspect transport piping for excessive wear by monitoring wall thickness at defined
locations along the piping
 Check the T-tube (the supply air piping) for penetration of the material conveyed by
opening the drain cock or the blind flange in the T-tube
 Check the stuffing box of the expansion tube for leaks
 Inspect the conveying nozzle and the riser pipe through the manhole
Servicing: Yearly
 Check the shut-off flap for wear and leaks
 Re-tighten the stuffing boxes of the expansion tube.
 Check and calibrate the contact pressure gauge and the line pressure gauge for damage
and incorrect pressure indication.
 Remove the textile fabric belt clean it with compressed air and check its condition, then
remount
 Remove and check the filling level limit switch according to the instructions of the
manufacturer
Repairs
 When maintenance work is being performed it must be ensured that all machines and
motors which could present a danger to personnel or equipment are switched off and
secured against unintentional switching on. Furthermore, it must be ensured that the whole
conveying unit is not subject to pressure and that the material feed units cannot be started.
For this purpose the blower's power supply must be disconnected and the slide valve in
the material feed pipe must be closed. The control air supply must be shut off and
the control voltage supply switched off.

 Any welding work to the conveying vessel influences the vessel's mechanical strength
properties.
 Ensure the utmost cleanliness at all times during the repair work in order to guarantee that
the bearings, the drive system or other sensitive parts are kept free of contamination
 Observe manufacturer's instructions for any repairs of flaps and valves.
Dismounting the aeration floor

1. Shut off the material feed, empty the conveying vessel.
2. Shut off the control air and conveying air supply
3. Remove the floor aeration piping and the throttle valve
4. Unscrew the control air ducts, remove the T-tube and shut-off flap unscrew the pressure
measuring-line.
5. Loosen the nuts of the conveying vessel flange, lower the aeration floor by means of the
three hoisting apparatuses of the same type.
Mounting the aeration floor

1. Clean the flange. Apply one-component joint-sealing material
2. Put on the lower perforated plate. Apply one-component joint-sealing material
3. Put on the textile fabric belt. Apply one-component joint-sealing material
4. If new textile fabric belt made of polyester is used, the screw holes may be melted through
by means of a hot mandrel.
5. DANGER When polyester fabric is molten, hydrogen cyanide is set free. Proper
precautions must be made to ensure safe working environment.
6. Put on the upper perforated plate. Apply one-component joint-sealing material.
7. Lift the aeration floor, bolt it to the conveying vessel.
Impact if not  The desired throughput of the system is not maintained.

applied:  Unscheduled downtimes, resulting in loss of production and higher maintenance costs.
Actions:  Complete necessary preventive maintenance routines regularly.
 Complete necessary repairs with precision and accuracy.
 Troubleshoot problems and eliminate the root causes
Unit  Participant has completed the standard PMRs on the airlift system at their plant on their
Completion: own.
instructions.
Figure 1. Troubleshooting Chart
Unit: Piping 12 of 13
Version: 1.0 04.11.03
Piping
Purpose:  To understand the basics of piping systems for pneumatic transport systems and hence
be able to better optimize operation or maintenance
Description:  The piping system connects the bulk solid feeder to the final destination with the least
possible loss of pressure.
 Calculations and design programs are available to determine the installed pressure
required by the air supply for a particular piping layout.
 For high velocity or low material-to-air ratio systems the line configuration is relatively
unimportant.
 Low air velocity or high material-to-air systems are greatly influenced by the configuration
of the conveying line.
 Since the movement of the solid particles ina pneumatic conveying system is
accomplished through the velocity of the conveying gas, pressure does not influence the
conveyability as much. Therefore, once material has been entrained in a conveying line,
without any changes in the system, the material should continue to accelerate to the end
of the conveying line. Another way of saying this is that as the air is expanding throughout
the system , the velocity of the conveying air increases throughout the system. If the
material was initially entrained, the material throughout the system should continued to be
entrained. Many people feel that a plugged line occurs at a downstream point in the
system. When this happens there is usually a change in the conveying line direction,
configuration, or a change at the pickup point that affects the downstream conditions.
Standards: Design and Operation:
 Piping must be either horizontal or vertical. An angled line, 20° to 80° from the
horizontal can cause problems, such as refluxing or re-circulating. Gravity causes the
material to fall to the bottom wall and since the air is above the material the angle of the
slope allows material to slide back down the incline.
 As few turns as possible. The changes cause a reduction in velocity that might allow
material to build up at elbows. This increases the resistance to flow and cause plugging
conditions.
 Distance between bends should be as long as possible. Do not use back-to-back pipe
bends regardless of location in conveying system. The effect of pipe bends multiplies when
in close proximity to each other because the re-acceleration of the material/air has not
been completed.
 Avoid changes in material direction at the system pickup point. This allows the
material to accelerate initially. No less than twenty pipe diameters should be used
between the pickup point and first pipe bend
 Terminal point must be adequately ventilated. If the pressure of the discharge receiver
becomes too high then the back pressure can cause the line to plug.
 Ensure no air leaks in the piping. The loss of velocity can cause the stream to fall
below the entrainment velocity of the system, thus allowing material to settle out and plug
the line. Leaks can be actual holes in piping or leaks past seals that are not working
properly. Plugs tend to occur 12 to 25 meters downstream of the air leak.
 Steady supply of air is required. A momentary interruption in air flow can allow material
to settle out and causing a plug to form. A sudden increase in airflow can pick up some
residual material and cause the line to plug.
 Steady supply of material. High swings in the amount of feed in a system can disrupt
the equilibrium and create a line plug.
 All connections in the conveying pipeline must be smooth, and any valves must not
reduce the area of, or protrude into the pipeline.

Pipe Bend Types: (See Figure 1)
 Long Radius - Long radius pipe bends are usually fabricated bent pipe with Radius to
Diameter (R/D) ratio of greater than or equal to 8. These historically have been the normal
pipe bends because they are the closest transition to a straight line. The long radius is
susceptible to high wear, some pressure loss, high replacement costs, and heavy lifting.
 Small Radius - The small radius pipe bends typically have a R/D ratio of 2 to 3. They
typically have a higher pressure loss across the elbow than that of a long radius elbow.
Wear is typically the same as long radius, but the small radius elbows have cheaper
replacement costs and are easier to handle during installation.
 Blind T Bend - The blinded tee bend is very effective in high wear applications, however,
there is typically an increase in pressure drop across the elbow. The tee creates a
"pocket", this dense accumulation of material absorbs the impact of the material rather
than the bend. This is a good solution to reduce maintenance costs if the system can
handle the higher pressure loss.
 Diverter Pot (cylinder bends) - Diverter pots have an inlet, a cylindrical section, and an
outlet. The inlet and outlet can form the angle required. For highly abrasive materials the
cylindrical section can be reinforced for wear. Very similar to the blind T style. The
diverter pot is the standard recommended elbow by HGRS.
 "Vortex Elbow" or "HammerTek Smart Elbow" - The principle operation of the vortex
elbow is that is has a protruding, almost spherical cavity that generates a slowly rotating
ball of self renewing material which enables incoming material to flow smoothly around the
pipe bend and exit evenly. Material impacts the "ball" rather than the wall thus eliminating
the wear on the pipe. Also, since the material within the ball is always moving the
pressure is constant. There is presently little experience with this technology.
 Rubber Pipe Bend - Situations may arise where the need for easy installation can
promote the use of a rubber pipe bend. Such pipes coated with natural rubber or similar,
are wear resistant. They can also be turned to wear out the external part.
How to clean out built up material within a pneumatic conveying line:
A line that shows higher than normal line pressure may be partially plugged. In such cases,
the following procedure may be used to help clear the some of the material hung-up in the
pipe. This helpful hint is only for lines that have become partially filled with material. Note: If
the line is completely plugged then it must be disconnected and the material removed
manually.
First, take a wooden ball or similar and wrap it with friction tape until its outside diameter is
about two inches smaller than the conveying line. Wrap tape over entire surcafce of ball.
Then, with the compressor and pump off, open the system near the charging device (the
windbox of the FK pump is a good place) and place the ball in the line, then close the system.
Next, go to the discharge end of the line and tack weld a piece a rebar or stock across the end
of the piping to stop the ball from entering the silo.
Now turn on the air supply and wait. The ball will be propelled along the line. The tape will
catch the sidewalls and make the ball spin. When the spinning ball encounters an obstruction
it will disturb the material enough for the air to re-entrain it and clean the line.
The most critical part of the procedure is to catch the ball at the end of the line. Otherwise it
could get lost in the silo and cause feeding problems or end up transferred with the material.
Impact if not  Increased downtime due to

applied:  plugged lines
 worn out piping
Actions:  Ensure that system is finely tuned
 Routinely check system components for possible air leaks
 Where pressure requirements can still be achieved use elbows that reduce wear.
Unit  Participant understands the piping concepts.
Completion:
instructions.
Figure 1. Examples of Standard Bends
R = R/D = 8 to 24
R = Radius
Radius R/D
R/D == 22to
to3
3
R/D = 8 to 24
Long Radius Elbow Short Radius Elbow Diverter Pot
Rubber Pipe Elbow

VORTEX Elbow by
Blind Tee Elbow Claudius Peters
Type of Skill: Specific Technical Skill
Unit: Valves 13 of 13
Version: 1.0 05.11.03
Valves
Purpose:  To discuss the basic on valves used in pneumatic transport systems and the associated
maintenance requirements that lead to optimum performance.
Description:  Since pneumatic transport is typically used where there is only one source point and many
terminal points multiple valves is necessary.
 The purpose of the valve is to ensure that material is contained within the system and is
directed to proper location.
 A valve is a very simple piece of equipment. It has three main components:
 The casing or housing
 The seal or gate
 The drive mechanism
 There are generally two types of valves used in the piping system for pneumatic transport,
the "knife" and the "diverter" valve.
 Drive mechanisms used for changing the position of gates. can be manually or
automatically operated. Automatic drives can be electric or pneumatic.
Standards: Installation:
 For best operation, Fuller strongly recommends that the Fuller SK valve be mounted with
the valve lever either on the side or in the top of the transport line, irrespective of whether
it is hand or motor operated. Ideally it should be mounted with the lever on the top so that
the valve disc moves across the bottom side of the transport line intersection. This avoids
moving the valve disc arm through an accumulation of material that may be located on
the bottom side of the valve body.
 In order to ensure a good seal is maintained, the valve should be supported independently
from the transport line and be free from pipe line strains. Provisions should also be made
to prevent pipe line expansion from exerting strain on the valve.
 The SK valve should be installed in a manner that will prevent any air pressure being
exerted against the disc in the closed branch of the valve.
 After the valve is installed, remove the inspection cover and check the disc for proper
seating. Operate the valve to ensure that the disc covers the port and there are no pipe
line strains. The valve is completely aligned and adjusted at the factory, but adjustments
can be made on-site to ensure a proper seal. Refer to site specific equipment instructions
for details.
Operation:
 It is preferable to operate the valves of multiple valve systems by first positioning the valve
furthest downstream from the final flow controlling valve. This avoids contamination of
continuing lines and enhances the reliability of the operation.
 Do not operate the valve while the system is conveying material because:
 The valve disc is under line pressure, and moving it under load will cause
accelerated wear and above normal torque load.
 It is important to avoid a surge in pressure and possible overloading of the air
compressor when re-entraining the re-aerated material in the original position
of the transport line beyond the valve.
 Purge the transport line prior to repositioning the valve. When the valves are moved with
the system down, it is advantageous to move the valve several times before leaving it in
the desired position. This cleans the seat and increases valve life. Longest seat life is
attained when the valves are moved periodically when the system is not in use. This
cleans the uncovered seats of deposits from dust and deposited material.
Manual Operation
To accomplish the repositioning of an SK valve, insert a bar of suitable material approximately
1.5 to 3 feet (450 to 900 mm) long in the stub lever. Pull the lock pin and move the valve to

the required position and reinsert the lock pin.
Motor Operation
Stopping the valve at the proper position is the function of the limit switches, cams, and
electric brake.
Maintenance
Periodically, remove the inspection cover and visually inspect the valve seats.
 If there is a scale build-up on the seats from the hardened material of if the seats are
scored, it is advisable to remove the valve from the system at the earliest opportunity
to prevent further damage to the seats and discs.
 If the seats have a build-up of scale, this can be repaired by lapping the disc to the
seats. More serious damage can only be repaired by grinding or replacing the seats.
Lubrication
 Operating Shaft - lubricate with grease gun on grease fitting provided. Apply sparingly as
required to avoid forcing grease into the valve body which may coat the seats and disc
with a material and grease mixture reducing the valve tightness.
 Drive Mechanism- lubricate according to drive system specifications.
.
Impact if not  Contamination of product
applied:  Housekeeping issues
 Downtime on main equipment
Actions:  Install, operate and maintain valves properly
Unit  Participant has identified the various valve used in pneumatic transport at their plant.
Completion:  Participant understands how the seal system works for their valves.
instructions.
Figure 1. Examples of SK Valves

Figure 2. Diagram of Two-Way SK Valve
Figure 3. Illustration of Valve Seat Systems

Pneumatic Transport Unit Index
Version: 1.0 05-11-03
Pneumatic Transport Systems - Unit Index
Unit 1 Basic Principle and Terminology

Unit 2 Screw Pump Design
Unit 3 Screw Pump Preventive Maintenance Routines
Unit 4 Screw Pump Mechanical Inspections
Unit 5 Screw Pump Troubleshooting
Unit 6 Screw Pump Major Repairs
Unit 7 Batch System Design
Unit 8 Batch System Preventive Maintenance Routines
Unit 9 Batch System Troubleshooting
Unit 10 Air Lift Operation
Unit 11 Air Lift Maintenance
Unit 12 Piping
Unit 13 Valves

Manufacturing Workforce Training
HGRS MASTER -
MAINTENANCE
Training Module: Pneumatic Transport Systems
Presentation: Pneumatic Transport
Training.ppt Version: 1.0
Last Update: 25-06-03
Objective
Maintenance of pneumatic transport systems is

intended to be a comprehensive training package
for all technical staff within our group companies.
It provides the basic maintenance requirements for
pneumatic transport systems.
Holcim Group Support Pneumatic Transport Systems Pneumatic Transport Training.ppt

Agenda
▪ Basics of Pneumatic Transport

▪ Screw Pump System
▪ Batch System
▪ Air Lift System
▪ Piping
▪ Valves
Definition
▪ A pneumatic conveyor system transports dry,

free-flowing, granular material in suspension within a
pipe or duct by means of high velocity air-stream or by
the energy of expanding compressed air within a
comparatively dense column of fluidized or aerated
material.( link video contoh pristiwa fluidized
https://youtu.be/lFhrpSJZzck )
Categories
▪ Pressure System – uses

positive force to “push”
material from one place
to another
▪ Vacuum System – uses
negative pressure to
“pull” material from one
point to the next.
▪ Air Gravity System – Air
fluidizes the material and
the force of gravity “slides” it
to destination
Components of Pneumatic Transport Systems

Design
▪ When designing a pneumatic transport system the

two main targets are:
4 High reliability of the system
4 Minimum power requirement
▪ Parameters used to select the right bulk material

feeder, air supply, pipeline, and classifier are:
4 Coarse and Fine Particle Analysis
4 Specifications of the Material to be Conveyed
4 Transport Distance and Elevation
4 Capacity Required
4 Preliminary Layout of Conveying Line (number of bends)
4 Temperature of Material to be Conveyed

Screw Pump
▪ The task of the screw pump is to introduce the

material into the conveying gas flow against the
pressure of the conveying line and at the same time
seal the system overpressure from its surroundings
and upstream plant sections.
Screw Pump - Operation
Material Material
Forced-in Moved to Material
against Mixing Enters
pressure of Chamber Screw
conveying
air
Material Transported
Conveying
Air
Enters
Screw
Pump
Screw Pump Components
Supply Air
V-Belt Drive System

and Motor
Mixing Chamber
Picture: The Claudius Peters X-Pump
Discharge Line
Pressure Gauge
Screw Pump Components
Feed Hopper
Seal Purge Air
Pump Screw
Screw Shaft
Bearings Air Nozzle
Flapper Valve Picture: The Fuller Kinyon M-Pump

11

Lubrication
Grease Nipplesfor Bearing

Grease Nipple for End Seal
Vibration Measurement Points
3 5 6
4
1 2
Location
Location Orientation
Orientation Parameter
Parameter
Horizontal Vertical Axial Bearing Vibration
Horizontal
(9 or 3 o'clock)
Vertical
(12 o'clock)
Axial condition
Bearing Vibration
(mm/s,
RMS)
condition
(gSE, SPM) (mm/s, RMS)
(9 or 3 o'clock) (12 o'clock)
(gSE, SPM)
1 Motor, Ns X X X
2
1 Motor, Ds
Ns X X X
3 Motor,
2 Motor, Ds
Ds X X X X
X
4 Motor, Ds X X
3 Motor, Ds X X
5 Fan, Ds X X X
4
6 Motor, Ds X X
Fan, Ns X X X 13
5 Fan, Ds X X X Transport Training.ppt
Holcim Gro up6SupportFan, Ns Pneumatic Transport Systems
X X
Pneumatic
X
3 5 6
4
Location Orientation Parameter
Horizontal Vertical Axial Bearing Vibration

(9 or
or 33 o'clock)
o'clock)
condition (mm/s, RMS)
(9 (12 o'clock) (mm/s,
RMS) SPM)
(gSE, (gSE, SPM)
1
1 Motor,
Motor, Ns
Ns X
X X
X X
X
2
2 Motor, Ds X X X
Motor, Ds X X X
3
3 Motor, Ds X X
Motor, Ds X X
4 Motor, Ds X X
4 Motor, Ds X X
5 Fan, Ds X X X
5 Fan, Ds X X X
6 Fan, Ns X X X
6 Fan, Ns X X X 14

Most Common Problem Areas
▪ There are three areas of the screw pump system

that cause the majority of the maintenance issues.
4 End Bearing Damage
4 Screw Wear
4 Flapper Valve Seating
End Bearings
▪ Contamination is the leading cause of bearing damage.

▪ Careful attention must be paid to the bearing seals, particularly
on the edges of the material.
▪ Wear and heat can reduce the effectiveness of the seal. In order
to help this, lubrication and purge air pressure is needed.
▪ The discharge bearing is particularly susceptible to
contamination due to the force of the conveying air
16

End Bearings
▪ The Type H
Pump supports
the screw at one
end.
▪ This reduces the
contamination of
bearings
because they
are not near the
force of the
conveying air
▪ However, the
cantilever screw
is more
susceptible to
deformation.
Internal Wear of System
▪ Due to the abrasiveness of the material and the

velocity of the air, wear can be a problem.
▪ Careful attention to wear rates on screw and
barrel bushings is required.
▪ Ensure air supply is shut off when the pump is empty
to avoid unnecessary wear.
Three Barrel Bushings
Screw Pump System

Flapper Valve
▪ The flapper has to be
checked regularly. Its
function is very
important to prevent
back flow of
compressed air
(pneumatic conveying
air) across the screw.
▪ Back flow can cause
high wear on the
screw. Therefore check
the flapper condition
and functionality
regularly.
19

Material Seal
1. The pump screw

compresses the
conveyed material into a
dense plug of material
which prevents reverse
air flow from the
conveying pipeline into
the pump hopper.
2. The Flapper Valve forms

a mechanical seal to
assist the material seal.
Fine Tuning the Material Seal
▪ Adjustments need to be made to the material seal

to optimize the screw pump system.
▪ Too low a pressure by the seal will allow “blowback”
which reduces capacity and causes air-cutting of
the screw shaft
▪ Too high a compression will increase the power
consumption beyond that necessary and increase
wear between screw and barrel bushings
▪ Therefore the material seal should be adjusted to
prevent blowback without over compressing. This
requires fine tuning adjustments in the field.
Batch System
▪ A batch system ( “pressure vessel” or “pressure tank”

system) is used for pneumatic conveying of
pulverized material, particularly raw meal and cement.
▪ The batch system transports material by
alternately filling and emptying on a fixed cycle.
Principle Cycle of a Batch system
1. Filling 2. Pressurizing
4. Venting 3. Conveying
23

Batch Systems Maintenance
▪ There are two main areas that require the

most maintenance attention
▪ Valve - It is good practice to make sure that all
valves (for material and air) are in good condition.
The main function is to seal and then open.
Ensure they do both properly.
▪ Instrumentation - The electrical components that
control the operation of the pressure vessel system
need to be properly maintained. This includes
pressure transmitters and level indicators.
24

Air Lift System
▪ The air lift is a pneumatic elevator designed

to continuously transport dry, free-flowing
bulk materials through a vertical pipe into a
bin or receiving hopper at a substantially
higher elevation.
▪ Thetwo main roles of an air lift or
pneumatic elevator system are:
4 To transport material at a specific rate using air
as the transport media
4 To contain material within the system
Air Lift – How does it work?
▪ The material to be conveyed is continuously fed into the

airlift vessel (also known as "conveying vessel" or "airlift
pot“).
▪ The floor of the vessel is made of a porous material (e.g.
textile fabric) through which air passes and fluidizes the
material.
▪ The material in the vessel creates a "solid" or "material" column.
The pressure of the material column forces the fluidized solids
to flow into the conveying line at the entry point.
▪ The main conveying air enters the airlift vessel via a nozzle just
below the inlet of the internal conveying pipe line (i.e. "entry point").
Here the stream of conveying air entrains the material and carries
it up to the final destination.
Air Lift System
Transport Line
Pressure Relief
or Vent Material Feed
Material Column
Internal
Conveying
Pipe
Nozzle
Aeration Floor
Supply Air
27

Piping
▪ The piping system is established to complete the route

from the bulk solid feeder to the final destination with
the least possible loss of pressure.
28

Piping Design and Operation:
▪ Piping must be either horizontal or vertical.
▪ As few turns as possible.
▪ Distance between bends should be as long as possible.
▪ Avoid changes in material direction at the system pickup point.
▪ Terminal point must be adequately ventilated.
▪ Ensure no air leaks in the piping.
▪ Steady supply of air is required.
▪ Steady supply of material is required.
▪ All connections in the conveying pipeline must be smooth
Pipe Bend Types
R/D
R/D =
= 22 to
to 3
3
Long Radius Elbow Short Radius Elbow Diverter Pot
Rubber Pipe Elbow

VORTEX Elbow by
Blind Tee Elbow Claudius Peters
Wear Protection in Piping
To help reduce wear on piping, a special lined section

should immediately follow an elbow and be 1.5 m in length.
Valves
▪ Since pneumatic transport is typically used where

there is only one source point and many terminal
points, the need for multiple valves is necessary.
▪ The purpose of the valve is to ensure that material
is contained within the system and is directed to the
proper location.
▪ The valve is a very simple piece of equipment. It
basically has three components.
4 The casing or housing
4 The seal or gate
4 The drive mechanism
Valves - Seal
▪ The critical
maintenance
item for a valve
is the seal or
gate.
▪ Ensure proper
operation
(complete seal)
▪ Ensure good
condition (no
wear damage)
33

Valves – Drive Mechanism
Motor
Manual
Pneumatic

Pneumatic Transport System

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HGRS MASTER - Maintenance

Type of Skill: Specific Technical Skill

Basic Principles and Terminology

Training in Maintenance Page 1 of 4

Advantages of Pneumatic Conveying

Pneumatic conveying offers distinct advantages over other forms of conveying:

Disadvantages of Pneumatic Conveying

Pneumatic conveying systems have some limitations and disadvantages including:

1. Coarse and Fine Particle Analysis

2. Specifications of Material to be Conveyed

6. Preliminary layout of conveying line (number of bends)

7. Temperature of material to be conveyed

Figure 1. System Components

Conveying Pipe Pipe

Figure 2. Common Capabilities of Various Pneumatic Transport Systems

Screw Pump Design

Basics of Screw Pump System

Typical Piping Arrangement (See Figure 3)

Training in Maintenance Page 1 of 4

Capabilities of Screw Pump System

General Terminology: (See Figures 1 & 2)

Standards: Basic Start/Stop Sequence

Impact if not  Inability to understand and communicate problems or requirements.

Unit  Participant understands how the screw pump operates.

Figure 1. Components of a Screw Pump System

V-Belt Drive System

Figure 2. Components of a Screw Pump System (continued)

Figure 4. H Pump with Z-Flap Conversion

Screw Pump Preventive Maintenance Routines

Standards: Preventive Maintenance Routines:

Daily Operation Inspections: (while running)

Training in Maintenance Page 1 of 3

Lubrication: (See Figure 1)

Vibration: (See Figure 2)

Electrical Inspections (yearly):

Grease Nipples for Bearing

Figure 2. Vibration Points Diagram

Screw Pump Mechanical Inspections

Training in Maintenance Page 1 of 5

Bearing Seal Purge Air System

Barrel Bushing (See Figure 1)

Flapper Valve (See Figure 2)

V-belt Drive System

Direct Drive System

Figure 1. Barrel Bushing Diagram

Three Barrel Bushings

Screw Pump System

Screw Pump Troubleshooting

1. An understanding of the design and operation of the pump system by appropriate

3. Routine preventive maintenance must be implemented so that smaller issues are

5. Troubleshooting takes place to eliminate the root causes of failures.

Adjustments to the Material Seal

Training in Maintenance Page 1 of 6

The Type "M" Pump Material Seal

Troubleshooting Guide for Screw Pump Systems

A. The Pump does not Handle the System Capacity

3. Poor material seal at pump discharge. A certain amount of material

5. Check if a condition of excessive motor load exists on the pump. This

B. Bearing Failure - vibration analysis can assist in predicting bearing problems.

1. Ensure proper assembly as described in this manual and on general

4. Use proper lubricant - consult equipment supplier for recommendations.

4. Ensure seal purge air piping is appropriate.

5. Check temperature of material to be transported. Material temperature in

 Improper shutdown of conveying system (not allowing cleanout of pump