FK Pump PPT Complete 96

Maintenance Seminar
Fuller-Kinyon Pumps
Institute
F-K Pumps - Introduction
Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.
Introduction
Part 2.
M-Pump
Part 3.
H-Pump and Z- Flap Conversions
Part 4.
Auxiliary Equipment
Institute
Introduction
Principles of Pneumatic Conveying

Types of Fuller Kinyon-Pumps
Development History
Performance Tuning the F-K Pump
System Troubleshooting
Institute
Principles of
Pneumatic Conveying
Institute
Pneumatic Conveying
Definition
the process of moving powdered

material through a pipeline using air as
the conveying medium.
Institute
Pneumatic Conveying Flow

Material
Flow
Dilute Phase
Material
Flow
Mixed Phase
Material
Flow
Dense Phase
Material flow through a pipeline can be characterized

by the concentration of material in the air-stream.
Institute

particles in suspension
pipeline
Dilute Phase Flow

Fairly even distribution over cross-section of the pipe.
Pick-up velocity 15-25 m/s (3000-5000 fpm).
Terminal velocity > 25 m/s (>5000 fpm).
Pressure differential of nominal 1 bar.
Material to air ratio up to 22:1.
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dust particles may be in suspension
moving "waves" of material
Dense Phase Flow (plug flow)

Waves of material fill the entire cross sectional area
of the pipe
Pick-up velocity 2-9 m/s (400-1800 fpm)
Terminal velocity < 20 m/s (<4000 fpm)
Conveying pressure differential 2-4.5 bar (15-35 psi)
Material to air ratio 20-200:1
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Particles in Suspension
Moving Material Bed
Medium Phase Flow (dual or mixed)

Particles in suspension traveling above a moving bed
of material
Pick up velocity 2-18 m/s (400-3500 fpm)
Terminal velocity 15-25 m/s (3000-5000 fpm)
Conveying pressure differential 1-2.4 bar (15-35 psi)
Material to air ratio 15-30:1
Institute

figure 2
two phase flow

stream flow over a settled layer
l
v1
figure 1
dilute phase
l
v1
drag
v2
drag = acceleration in
direction of airflow.
v2
lf: v1 > v2 particle lifts

l > g particle floats
figure 3
dense phase
p1
p2
particles
particles contact
contact particles
particles
pressure
pressure differential
differential moves
moves material
material
velocity
velocity (drag)
(drag) is
is unimportant
unimportant and
and is
is normally
normally aa very
very low
low value
value
Institute
10
Conveying Line Pressure Drop

Modu-dense
Modu-flo mt
Fullveyor
increasing
solids rate
F-K Pump
Pressure Tank
dense
phase
unstable
surging phase
medium
phase
dilute
phase
Airveyor
Airlift
air flow rate

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11
The Problem
How to put material into

a pressurized air-stream
The Solution .
Institute
12
The Fuller-Kinyon Pump

Feed
Material
Air and
Material
Compressed
Air
Feed material enters the hopper where the screw

picks it up and forces it into the air-stream.
Institute
13
Components of an F-K Pump

discharge body
drive end
bearing assembly
pump hopper
screw
inlet
barrel
discharge end
bearing assembly
external lever
flapper valve
motor
air and material

outlet
base frame
Institute
air inlet
14
Pneumatic Conveying System

De-dusting
System
Material Bin
Rotary Feeder
Intake
Filter
Air
Compressor
Institute
Air
Slide
Material
Pipeline
F-K Pump
15
Applications
Dry, free flowing ,fluidizable materials
Typical particle size analysis:
100% < 50 mesh
70% < 100 mesh
60% < 200 mesh
45% < 325 mesh
Long distance conveying, over 5,000 ft (1500 m)
High capacity conveying, up to 17,700 CFH (500
CMH), e.g. 400 tph @ 45 lb./cu.ft.
Material temperatures to 400F, special
applications to 850F with water cooled seal.
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16
Typical Materials Handled

Alumina
Asphalt filler dust
Barytes
Bauxite
Bentonite
Catalysts
Cement
Clays (dried
Coal
Coke dust
Copper concentrate
Dolomite
Dusts (baghouse, ESP)
Feldspar
Fluorspar
Fly ash
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Gypsum
Kaolin
Lime
Limestone
Magnesite
Magnetite
Manganese dioxide
Ores
Phosphate rock
Quartz
Rutile
Silica
Soda ash
Starch
Talc
Titanium dioxide
17
Special Applications
Abrasive materials
Materials of construction will vary according to
specific applications.
Special screw hard surfacing.
Tungsten carbide weld deposit (65 rc) (700 brinnel).
Hardened barrel (450 brinnel).
Other special materials on request.
Ceramic barrel liners optional.
Ceramic lined discharge box- optional.
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18
High temperature materials
Type M pump available up to 400F
Type H pump available up to 850F
seal chamber cooling coils
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19
Non compression screws for cohesive materials
(e.g. gypsum).
Back beveled screw flights for materials that bind
(e.g. kaolin).
Half moon orifice for materials which flush.
Stainless steel screw for corrosive materials.
Other special alloys applied as required.
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20
Types of F-K Pumps
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21
Types of F-K Pumps

M Pump
H Pump
Z Flap Conversion
Kompact Pump
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22
M Pump
The M Pump has bearings on both ends of the shaft.

Material discharge is perpendicular to the screw. Newer
pumps are supplied with three piece screws.
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23
M Pump Sizes and Capacities

Screw Diameter
Screw Pitch1
Capacity2
150 mm
150 x 100
27 tph
200 mm
190 x 120
107
250 mm
230 x 150
232
300 mm
300 x 190
491
350 mm
330 x 240
790
1 Screws
have decreasing pitch. Other pitches available.
2 Typical
capacity in short tons/hour while transporting 3600 blaine

portland cement at screw speed of 1160 RPM.
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24
M Pump
250 M pump with

parallel discharge
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350 M pump with

side discharge
25
M Pump
left hand
discharge
right hand
discharge
The M Pump can be arranged for side or parallel

discharge for left or right hand side.
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26
M Pump
M Pump installation.
Institute
27
H Pump
The H Pump has a cantilevered screw with

bearings on one end of the shaft only. Material
discharge is in line with the screw.
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28
H Pump Sizes and Capacities

Screw Diameter
Screw Pitch1
Capacity2
6x4
31 tph
8x5
80 tph
8x5
128 tph
8x5
164 tph
6x4
120 tph
6x4
142 tph
10
10 x 7
258 tph
10
10 x 7
293 tph
1 Screws
have decreasing pitch. Other sizes available.
2 Typical
capacity in short tons/hour while transporting 3600

blaine portland cement at screw speed of 1160 RPM.
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29
H Pump
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30
H Pump with Z Flap Conversion
The Z flap conversion adds a bearing onto the discharge

end of the shaft. Discharge is in line with the screw. Two
piece screws are available for ease of maintenance.
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31
H Pump
H pump with Z flap installation.

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32
Kompact Pump
The Kompact Pump is a light duty version for mobile,

non-continuous operation.
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33
Kompact Pump
Sizes and Capacities
Screw Diameter
Screw Pitch1
Capacity2
6x4
36 tph
6x4
52 tph
1 Screws
have decreasing pitch. Other sizes available.
2 Typical
capacity in short tons/hour while transporting 3600

blaine portland cement at screw speed of 1160 RPM.
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34
Kompact Pump
For Intermittent use (less than 8 hours per day).

Short conveying distances (up to 150).
No hardened barrel.
Light duty bearings.
Low pressure system (up to 12-14 PSI).
Floating type gland packing for hopper-screw seal.
Hardened screw as standard.
Low headroom, i.e. for railcar unloading.
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35
Development History
Institute
36
Development History
First developed 1919 1926
Type H pump - developed in 1935,
over 12,000 sold
Kompact pump - developed in 1961,
over 1,000 sold
Type M pump - developed in 1976,
over 1,200 sold
Z-Flap conversion kit - developed 1984
Institute
37
First Portable F-K Pump
Institute
38
Performance Tuning the

Fuller-Kinyon Pump
Institute
39
The Material Seal

Pump Inlet
(low pressure)
Material Seal Zone
Pump Outlet
(high pressure)
It is essential for system performance that a good seal

exists to keep conveying air from blowing back into the
hopper. This seal is formed by compacted material
traveling through the pump barrel, especially at the
discharge end where the screw pitch decreases.
Institute
40
The Material Seal

Compacted Material
Flap Valve
Air and Material

Mixture
Compressed
Air Inlet
Transport
Pipeline
The material in the pump barrel is compacted with the aid of

a counterweighted flap valve at the pump outlet, which
creates a resistance to the material flow. Increasing the
counterweight makes a tighter seal, but motor amps will rise.
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41
H Pump Material Seal
The H pump, in addition to a counterweighted flap valve, has

an adjustable barrel which can be used to control the seal
thickness (A).
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42
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43
Inadequate Capacity
If motor amps are abnormally low, adjust the
material seal to prevent blow-back (increase the
counterweight).
Check material density. The pump is a
volumetric device and changes in density will
affect changes in tons per hour.
Insure proper venting of pump inlet hopper.
Hopper must be at a slight negative pressure.
Excessive purge air to the seals can aerate the
material in the hopper, causing decreased
capacity. Check the purge air pressure settings
and orifice plates.
Institute
44
Inadequate Capacity (continued)
If conveying is fast and steady, reduce air flow; if

conveying is slow and slugging, increase air flow.
Check for steady material feed rate.
Check for restrictions at the discharge end of the
system, i.e., silo vent dust collector not working.
Increase line diameter (stepped line or entire length).
If pump discharge pressure is higher than normal,
there may be a line obstruction.
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45
Plugged Conveying Pipeline
Check for adequate air supply.

Check for air leaks in conveying line.
Check for non-seating diverter valves.
Eliminate sloping conveying lines. Sloping lines
plug easier than horizontal or vertical runs.
Check for steady material feed rate.
Check material characteristic. Moist or sticky
material can build up on inside of conveying line.
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46
High Motor Amps
The material seal may be too tight. Decrease the

counterweight on the flap valve.
Check feed sieve analysis. Coarser material can
cause higher motor amps.
Check for moisture in the feed material.
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47
Cycling Pressure
Check for steady material feed.

Check venting at terminal point of
conveying line.
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48
Inadequate Air Supply
Check compressor inlet for restrictions

(dirty inlet filter, faulty unloading valve, etc.)
Check for open pressure relief valve.
Check for piping and flanges for leaks.
Check compressor for proper operation
(broken blades, etc.)
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49
Excessive Pipeline wear
Reduce conveying velocity.

Replace bends with tee pipe fittings.
Step to larger diameter conveying line
before terminal points in the system.
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50
Material Breakage
Reduce conveying velocity.

Eliminate all bends, cyclones, etc.
Reduce velocity before terminal point of
conveying line.
Eliminate any rough sections or sharp
changes in direction.
Institute
51
Maintenance Seminar
Fuller-Kinyon Pumps
Institute
F-K Pumps - M-Pump
52
Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.
Introduction
Part 2.
M Pump
Part 3.
H Pump and Z Flap Conversions
Part 4.
Auxiliary Equipment
Institute
53
M Pump
Institute
Overview
Screw
Barrel Bushings
Discharge Body
Bearings and Seals
Lubrication
Purge Air
Spare Parts
Disassembly and Assembly
54
Overview
Institute
55
Type M Pump
The M pump has side discharge, easily removable

bearing and seal assemblies, and a three piece
screw for easy replacement of the wear section.
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56
M Pump
Inlet
Hopper
Discharge
Body
Barrel
Discharge
End Bearing
Drive End
Bearing
Air Inlet
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57
Screw
Institute
58
Three Piece Screw

Stub Shaft
Replaceable
Center Section
Stub Shaft
The three piece screw is standard on all new M pumps,

and is available as a retrofit on older M pumps. When the
screw wears out, only the center section is replaced. Stub
shafts remain in place inside the bearing assemblies.
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59
Three Piece Screw

Standard Pitch Screw Flights
Balance
Wheel
Decreasing
Pitch
Reverse
Pitch
Paddle
bars
Hard-facing
The screw is hard-faced with nickel-chromium boride

alloy. Decreasing screw pitch helps form a material seal
to prevent blowback from the discharge line. Reverse
pitch flights keep material away from the shaft seal.
Paddle bars help disperse material into the air stream.
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60
One Piece Screw
Hard-facing
The screw is hardfaced with Colmonoy, a nickel-chromium

boride alloy, applied by gas welding. The flight periphery
has 7.5 mm hardfacing, and the flight faces in compression
zone is 4mm.
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61
One Piece Screw

Balance
Wheel
Balance
Wheel
After the flights are installed, hardfacing applied and

the periphery ground, the screw is dynamically
balanced. Balance is achieved by filling the holes in
the balance wheels with lead shot. Balancing
reduces vibration and extends bearing life.
Institute
62
One Piece Screw

Wear
Sleeve
Wear
Sleeve
The screw has a hardened chrome wear sleeve at each end

where the seals contact the shaft. These seals are shrunk
on and have to be heated to 300F to install. If the sleeves
are damaged, seal failure will result.
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63
Screw Puller
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64
Barrel Bushings
Institute
65
Barrel Bushings
Inlet End
Bushing
Center
Bushing
Discharge End
Bushing
The pump barrel is wear protected by three barrel bushings.

The center bushing is hardened to resist the extra abrasion
in the zone where the material seal is formed. Set screws
and retaining screws keep the bushings from rotating.
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66
Discharge Body
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67
Discharge Body
Material
Outlet
Flapper
Valve
Flapper Valve
Counterweight
Barrel
Bushing
Screw
Air and
Material
Outlet
Air Inlet
Nozzles
Institute
Mixing
Chamber
68
Material Seal
Spacer Plate
Flapper Valve
Valve Seat
The material seal is created by the compaction of material

at the discharge end of the pump. Increasing the
counterweight and/or increasing the spacer plate
thickness makes a tighter seal, but motor amps will rise.
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69
Flapper Valve
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70
Material Seal Baffle Plate
In some instances a baffle plate installed behind the

flapper valve may improve the material seal.
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71
350 M Pump
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72
Bearings and Seals
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73
Bearing Arrangements
Older M Pumps with
1 Piece Screws
Newer M Pumps with

3 Piece Screws
350 M Pumps with

3 Piece Screws
There are several different M pump bearing arrangements.

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74
M Pumps with 1 Piece Screw

Discharge End Bearing
Bearing
Bushing
Retainer Plate
Bearing
Support
Cover Plate
Bearing
Housing
The discharge end bearing is the fixed bearing. The cover

plate and retainer plate fix the bearing axially.
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75
M Pumps with 1 Piece Screw

Drive End Bearing
Locknut
Bearing
Bushing
Locking
Collar
The drive end bearing is the free bearing. The bearing is

fixed on the bearing bushing. The shaft slides axially inside
the bushing to accommodate expansion.
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76
150 and 200 M Discharge End
Bearing
Pressurization
Connection
Purge Air
Grease
The 150 and 200 M pumps use a double row angular contact
ball bearing. Grease is introduced through fittings on either
side of the bearing. Air purge keeps dust out of the bearing
housing. The bearing chamber is presurized.
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77
150 and 200 M Drive End

Bearing
Lube
Seal Lube
Purge Air
Grease
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78
250 M Discharge End
Purge Air
Grease
The 250 M pump uses two back to back angular contact

ball bearings. Grease is introduced through fittings on
either side of the bearing pair.
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79
250 M Drive End
Purge Air
Grease
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80
300 M Discharge End
Purge Air
Grease
The 300 M pump uses two back to back angular contact

ball bearings with grease grooves. Grease is introduced
into the groove and emerges between the bearings.
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81
300 M Drive End
Purge Air
Grease
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82
Bearing with Grease Grooves
On 300 and 350 M Pumps grease is introduced through

grooves between the two back to back bearings.
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83

Newer M Pump
Locknut with
Tab Washer
Newer M pumps have their discharge bearings fixed axially

with a locknut instead of a retainer plate.
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84
Drive End Bearing

Newer M Pump
The free bearing can slide axially within the housing to

accommodate shaft expansion. The bearing is fixed on the
bushing and the bushing is fixed on the shaft with a locknut.
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85

350 M Pump
Bearing
Bushing
Locknut with
Tab Washer
On the 350 M pump the bearing housings and supports are

combined into one casting.
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86
Drive End Bearing

350 M Pump
The bearing is free to slide axially inside the housing. The

inner ring is fixed on the bushing. The bushing is fixed to the
shaft with a locknut.
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87
Replacement Kits
The new bearing assemblies are available as bolt-on kits

together with the screw stub shafts. In the event of a
bearing or seal failure, the entire assembly is replaced
and the damaged assembly is brought to the shop for
rebuilding.
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88
Seal Arrangement
Material Seals
Spacer Ring
Bearing Seal
O-ring
Seals must face in direction shown.

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89
Seal
When installing a bearing housing over the shaft, use a

piece of shim stock to guide the seal over the bushing.
This avoids damaging the seal.
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90
Lubrication
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91
Lubrication
Bearings
Bearings
Seals
Flapper Valve Shaft
Seals
Bearings -
Monthly or 700 hours
Seals -
Daily
Flapper Valve Shaft -
Daily
Use a high temperature EP grease at all lubrication points.

Institute
92
Drive End Bearing Lubrication
Drain Plugs
Grease bearings when pump is running. Do not overgrease.

Overgreasing will cause high temperature and burning of the
grease, resulting in bearing damage. Drain excess grease out
of drain plug after bearing reaches operating temperature.
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93
Discharge End Bearing Lubrication
Pressurization
Warning - Hot grease! Do not remove the drain plug with the
pump running and the bearing pressurized. Apply 4-6 strokes
with a hand gun in each bearing fitting. For the one-fitting
300 and 350 M pumps, apply 8-12 strokes.
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94
Purge Air
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95
Purge Air Piping

Plant Air 6-8 Bar
Regulator
Regulator
Coarse and Fine Filters
Union with
Orifice
Seal Purge
Seal Purge
Bearing
Pressurization
The unions contains orifice plates with a specific diameter

holes. Pressure settings depend on transport air
pressure. See the chart.
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96
Purge Air Requirements
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97
Bearing Pressurization
The discharge bearing chamber is pressurized to keep

dirt out. A coarse (5 micron) and fine (3 micron) filter keep
the air clean.
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98
Spare Parts
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99
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100
Disassembly and Assembly

Screw Removal from Discharge End
Screw Removal from Drive End
Barrel Bushing Removal
Barrel Bushing Replacement
Screw Replacement
Screw Replacement from Drive End
Bearing and Seal Replacement
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101
Screw Removal from

Discharge End
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102
Screw Removal
Remove the purge air piping. Do not lose the orifice

plate inside the pipe union.
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103
Screw Removal
Loosen the set screws on the locking collar at the

drive end.
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104
Screw Removal
Remove the locking collar.

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105
Screw Removal
Remove the key.

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106
Screw Removal
Remove the inlet hopper access door.

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107
Screw Removal
Clean out the inlet hopper and screw.

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108
Screw Removal
Remove the bolts from the discharge end bearing

cover.
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109
Screw Removal
Remove the discharge end bearing cover.

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110
Screw Removal
Remove the two bearing retainer screws.

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111
Screw Removal
Remove the bearing retainer.

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112
Screw Removal
Reassemble the cover with two screws. This

prevents the screw bushing from sliding out of the
seal during disassembly.
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113
Screw Removal
Unbolt the bearing housing and, using two jackscrews in

the threaded holes, remove the housing from the
bearing support.
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114
Screw Removal
Remove the bearing housing from the bearing

support.
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115
Screw Removal
Remove the bolts from the bearing support and

insert two jackbolts in the threaded holes provided.
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116
Screw Removal
Remove the bearing support from the pump

discharge body.
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117
Screw Removal
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118
Screw Removal
Attach the screw puller.
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119
Screw Removal
Turn the hexnut to extract the screw.
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120
Screw Removal
Extract the screw as far as the puller allows.
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121
Screw Removal
Remove the puller.
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122
Screw Removal
With the screw end supported, pry the screw out the
rest of the way. Do not pry on the balance wheel!
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123
Screw Removal
Reposition the supporting sling near the screw

center of gravity as the screw is withdrawn.
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124
Screw Removal from

Drive End
(The screw is normally removed from
the discharge end, however, it may
also be removed from the drive end
when space for removal is limited.)
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125
Removal from Drive End
Remove the discharge end bearing retainer and replace the

cover with two screws as previously described. Proceed to
remove the drive end bearing housing.
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126
It is necessary to use spacers under the jackbolts to

completely free the bearing housing, due to the limited
length of the bolts.
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127
Remove the drive end bearing housing from the support.
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128
Remove the bearing support.

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129
Support the screw end with a sling.

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130
Pry out the screw. Do not pry on the balance wheel!

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131
Keep the sling near the center of gravity and

remove the screw.
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132
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133
With the discharge bearing and support housings and

the screw removed, the barrel bushings are accessible.
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134
Remove the two barrel bushing retainer screws.
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135
Remove the four barrel bushing set screws.

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136
Remove the short barrel bushing. Rap the bushing with a

hammer to loosen material until the bushing slides freely.
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137
Use compressed air to blow out material stuck between the

barrel and pump housing. Blow air into set screw holes.
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138
Remove the short barrel bushing.

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139
Use a jack to push out the remaining two bushings.
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140
Use a circular steel plate to push

against the O.D. of the bushing .
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141
Institute
142
Clean and de-burr the bushings and barrel

bores thoroughly before installation.
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143
Install the soft bushing with the machined face

towards the discharge end. Align the ribs to straddle
the set screws.
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144
Install the hard bushing with the slot towards the

discharge end.
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145
The slot must be on top to engage the retaining bolt.
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146
Install the retainer bolt, positioning the bushing

until the bolt fits in the slot.
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147
From inside the hopper, push both bushings toward

the discharge until the retaining bolt is fully engaged.
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148
Insert the short barrel bushing until the retaining bolt is

fully engaged.
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149
Tighten the four set screws.
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150
Screw Replacement
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151
Screw Replacement
Before installing the screw thoroughly clean and deburr all machined surfaces.
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152
Screw Replacement
Seal sleeves must be perfectly smooth to prevent

seal damage. If necessary, install new sleeves.
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153
Screw Replacement
Insert the screw until the journal appears in the pump inlet
hopper.
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154
Screw Replacement
Before further insertion clean the journal and sleeve

once again.
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155
Screw Replacement
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.
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156
Screw Replacement
Clean the mating surfaces and apply Permatex.

Install the bearing housing support.
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157
Screw Replacement
Clean the screw journal and sleeve.
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158
Screw Replacement
Install the O-ring.
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159
Screw Replacement
Seat the O-ring against the shaft sleeve .
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160
Screw Replacement
Apply Permatex and install the bearing housing.
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161
Screw Replacement
Remove the end cover to reinstall the retainer. Apply

LocTite to the retainer screws.
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162
Screw Replacement
Install retainer and screws.

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163
Screw Replacement
Torque the retainer screws (180 ft-lbs for 250 and

300 pumps, 80 ft-lbs for 200 pumps or 40 ft-lbs for
150 pumps).
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164
Screw Replacement
Apply Permatex and re-install the cover.

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165
Screw Replacement from

Drive End
Institute
166

Drive End
The screw may be installed from the drive end.

Institute
167

Drive End
It is first necessary to remove the discharge end bearing

housing and support. Once the screw is in place, assemble
the support and bearing housing as previously described.
Institute
168

Drive End
Clean the screw journal and sleeve at the drive end.

Assemble the drive end support and bearing housings.
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169

Drive End
Reassemble the key and locking collar.

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170
Bearing Replacement
Institute
171
Bearing Replacement
On the discharge end, remove the bearing housing

and remove the locknut. Then slide the bearing out of
the housing.
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172
Bearing Replacement
On the drive end, remove the bearing housing.

Remove the locknut, and slide the bearing out of the
housing and off the bushing.
Institute
173
Seal Replacement
Institute
174
Seal Replacement
On the drive end, remove the cover.

Institute
175
Seal Replacement
Drive the seal out of the cover.
Institute
176
Seal Replacement
To access the material seals, remove the bearing

supports.
Institute
177
Seal Replacement
Be sure the seals face in the proper direction, as

shown on the drawings in the manual.
Institute
178
Seal Replacement
Institute
179
Seal Replacement
Grease the seals and grease ring before reassembly.

After assembly, apply additional grease through the
fittings.
Institute
180
Institute
181
Questions?
Institute
182
Maintenance Seminar
Fuller-Kinyon Pumps
Institute
183
Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.
Introduction
Part 2.
M-Pump
Part 3.
Part 4.
Auxiliary Equipment
Institute
184
H Pump
Institute
Overview
Screw
Barrel Bushings
Discharge Body
Bearings and Seals
Lubrication
Purge Air
Spare Parts
185
Overview
Institute
186
H Pump
The H pump discharges in-line with the screw. There are

two bearings on the drive end. New H pumps have a
bearing on the discharge end, while on older pumps the
screw is cantilevered without a bearing.
Institute
187
H Pump
Air Inlet
Manifold
Drive
Shaft
Bearing
Housing
Screw
Seal Ring
Assembly
Institute
Flapper Valve
Inlet Hopper
Barrel
Discharge
Body
Air and
Material Outlet
188
H Pump
H pump installation.
Institute
189
H Pump
Older H Pumps have a cantilevered screw with bearings

on one end of the shaft only.
Institute
190
H-Pump with Z-Flap Conversion
The Z flap conversion kit (in blue) adds a bearing at the

discharge end of the shaft. The screw runs truer, and
screw, barrel and bearing and seal life are extended.
Institute
191
Screw
Institute
192
Two Piece Screw
A two piece screw is used on newer H pumps and pumps

with Z Flap conversions. The screw flight shaft can be
replaced without disturbing the drive.
Institute
193
Two Piece Screw

Seal Area Wear
Sleeve
Bearing Journals
Shrink Coupling
and Bolted Flange
Institute
Colmonoy
Hardfacing on
Flight Periphery
Colmonoy
Hardfacing on Flight
Periphery, Face and
Shaft
194
Screw Coupling
Torque to
70 ft-lbs
The two piece screw is connected with a shrink coupling.

Tighten the coupling screws gradually in a circular pattern
until proper torque is achieved. Make sure the shaft and
coupling bore are free of grease before assembly.
Institute
195
One Piece Screw
Institute
196
One Piece Screw
The bearing journals are bronzed using a spray-on

application. Journals can be re-built to specified diameter.
Institute
197
One Piece Screw
Screws are balanced in two planes. The balance

wheel holes are filled with lead shot as required.
Institute
198
Screw Balance Holes
Balancing is necessary to keep the screw from wobbling.

Institute
199
Screw Removal
The screw is pried out through the discharge end.

Institute
200
Screw Removal
After removal of the flap valve the screw can be

extracted.
Institute
201
Screw Hard-facing
Hard-facing is applied by gas welding. Do not apply by

electric arc welding.
Institute
202
Grinding the Screw
After hard-facing, the screw periphery is precision-ground.

Institute
203
Screw
Checking the O.D. after grinding.

Institute
204
Barrel Bushings
Institute
205
Barrel Bushings
When changing a screw, barrel bushings should be

inspected for air-cutting (grooving caused by air blow-back
from the conveying line into the hopper) and replaced if
necessary. Front bushings wear out sooner. It may be
possible to reverse the front and rear bushings to extend
bushing life.
Institute
206
Barrel Assembly
Institute
207
Barrel Bushings
Barrel with front and back barrel bushings.
Institute
208
Barrel Bushings
Inserting the bushing into the barrel.

Institute
209
Barrel Bushings
Inserting the barrel into the inlet hopper.
Institute
210
Discharge Body
Institute
211
H Pump Discharge Body

Air Outlet
Pressure Gage
Air Inlet
Pressure Gage
Flapper
Valve
Air Inlet
Counterweight
Bearing
Housing
Air and
Material
Outlet
Air
Manifold
Air
Nozzles
Institute
212
Flapper Valve Shaft
The flapper valve shaft should be greased weekly.
Institute
213
This discharge body is used for older H pumps without

Z-flap conversions.
Institute
214
This discharge body is used for older H pumps without

Z-flap conversions.
Institute
215
Flapper Valve
Institute
216
Material Seal
To prevent blowback of compressed air into the feed hopper

it is essential that a proper seal of compacted material is
formed. Sealing depends on the distance A and on the
counterweight applied to the flap valve lever arm.
Institute
217
Material Seal
Adjust the barrel to achieve the results above. If blowback

still results, increase the distance A and increase the
counterweight. Note that this will increase motor amps. Find
the best balance between good sealing and low amps.
Institute
218
Material Seal
Gap
The material seal is adjusted by changing the gap.

Institute
219
Bearings and Seals
Institute
220
Drive End Arrangement
The drive end arrangement features two double row

angular contact bearings. The motor side is the fixed
bearing. The pump side bearing is free to move axially.
Institute
221
The discharge end bearing is a double row spherical roller

bearing mounted on a tapered sleeve. Proper bearing
clearance is achieved by giving the locknut one half turn
after initial hand tightening.
Institute
222
Air Cooled Seal Ring Assembly

Fan
Purge
Air
Springs
Graphite
Seal
Renewable
Sleeve
The material seal is air cooled by the fan. Purge air

keeps material away from the graphite ring.
Institute
223
An earlier version of the air cooled seal.

Institute
224
Institute
225
Institute
226
Institute
227
Institute
228
Institute
229
Renewable Sleeve
Institute
230
Bearing Housing
Institute
231
Bearing Installation
Institute
232
Institute
233
Bearings and Sleeve
Institute
234
Bearing and Sleeve
Institute
235
Locking Collar
Institute
236
Purge Air
Institute
237
Z-Flap Purge Air

Plant Air 6-8 Bar
Pressure Regulator
Union with
Orifice
Coarse and
Fine Filters
Seal Purge
Bearing
Pressurization
Check
Valve
The unions contains orifice plates with a specific diameter

holes. Pressure settings depend on transport air
pressure. See the chart.
Institute
238
Z-Flap Purge Air Requirements

Transport Air Supply Pressure Regulator
Pressure PSIG
Setting PSIG
5-15
35
16-24
55
25-39
75
40-45
85
The above settings apply to 9, 9.5 and 10 Z-Flap

pumps with .140 (3.6 mm) diameter orifice plates.
Institute
239
H Pump
Purge air and bearing pressurization on the discharge

bearing of an H pump.
Institute
240
Lubrication
Institute
241
H Pump Lubrication
Use high-temperature EP grease:

bearings - 700 hours or monthly Do not over-grease!
seals -
3 to 4 strokes every 150 hours or weekly
flap valve - 3 to 4 strokes every 150 hours or weekly

Institute
242
Spare Parts
Institute
243
Institute
244
Questions?
Institute
245
Maintenance Seminar
Fuller-Kinyon Pumps
Institute
246
Agenda
Maintenance of
Fuller-Kinyon Pumps
Part 1.
Introduction
Part 2.
M-Pump
Part 3.
Part 4.
Auxiliary Equipment
Institute
247
Auxiliary Equipment
Feed Arrangements
Diverter Valves
Pipeline Bends
Couplings
Rolling Contact Bearings
Airline Filter Regulator Lubricator
Institute
248
Feed Arrangements
Institute
249
Hopper Aeration System
Solenoid
Valve
Orifice plate
For pumps with un-controlled feed, an automatic hopper

aeration system is used. When motor amps rise, the
solenoid valve opens and the silo is aerated. Purge air
through the orifice plate keeps the nozzle clean.
Institute
250
Hopper Aeration System
Aeration air may be taken from the transport air supply

line, as above, or from an independent plant air source.
Institute
251
Feed Hopper Baffle
The baffle plate diverts feed to the down-turning

side of the screw, and promotes proper venting.
Institute
252
Seal Protection Baffle
On certain installations where feed material drops into the

hopper from a great height, the material can enter the seal
area. This modification my help extend seal life.
Institute
253
Diverter Valves
Institute
254
Diverter / Cutoff Valves

Two-Way SK Valve
ZWR - Zero Leakage
45o Diverter
ZWS - 2-way Zero Leakage
Institute
90o Diverter
1-way SK Valve
255
Diverter Valves
Two-way Hose-type Diverter Valves Type ZWS

Three-way Hose-type Diverter Valve Type DWS
Type ZWR Zero Leakage Diverter Valve
Two-way Diverter Valve
Zero Leakage (ZL) Diverter Valve
Zero Leakage (ZL) Diverter Valve Cutaway
Diverters: FA, 45o, 90o
45o Diverter Valve
FA / 45o / 90o Diverter Valve
90o Diverter Valve
SK Valves: Two-way SK
SK Diverter Valve
SK Valves: One-way SK
Rotary Cutoff Valve - Photo
Rotary Cutoff Valves
Rotary Cutoff Valve - Expanded View
Institute
256
Two-way Hose-type Diverter

Valves Type ZWS
Applications
Powders
Pellets
Features
2 - 3 positions
Vacuum / pressure
Pressure tight up to 4 bar (58 psi)
Low diverting angle
Cast aluminum housing & slide
plate
Slide plate hard coated
PTFE lined
Flange connections
Controls wired to terminal box
Wetted surfaces in stainless steel
as an option
Metal hose and rubber hose are
options
Institute
Normally
completely
enclosed
controls
Models:
ZWS: Two-way
DWS: Three-way
(2 to 6 line size)
257
Three-way Hose-type Diverter Valve

Type DWS
Features
2 - 3 positions
Vacuum / pressure
Pressure tight up to 4 bar (58
psi)
Low diverting angle
Cast aluminum housing &
slide plate
Slide plate hard coated
PTFE lined
Flange connections
Controls wired to terminal

box
Wetted surfaces in stainless
steel as an option
Metal hose and rubber hose
are options
Institute
Advantage:
Omits one two-way
vane or plug-type
diverter
Gentle angle of
diversion
258
Type ZWR Zero Leakage

Diverter Valve
Features:
Pressurized seals
Cast aluminum housing
and plug
Stainless steel internal
sleeves optional
Reduced I/O to operate
Bi-directional design
4 Bar pressure capability
Institute
259
ZWR Two-way Diverter Valve

Features:
Minimal areas for cross
contamination.
No corners or edges of
impingement
In-the-field valve hand
reversal design
In-the-field liner sleeves
replacement design
Zero leakage of gas to
dead leg
Institute
Silicon
Sealing
Air
Channel
Sealing
Pressure Chamber
260
Zero Leakage (ZL)

Diverter Valve
Zero leakage of material and air

45 psi pressures
Pressurized rotor shoe
Peripheral rotor seal
Automatic operation
Pre-piped and pre-wired
NEMA 4, 7, 9 standard
Standard sizes
Standard 150lb. drilled flanges
Institute
261
Zero Leakage (ZL) Diverter

Valve
A
Body with Standard

150 lb drilled flanges
Peripheral Seals
End Plate
Pressurized Nylon
Sealing Shoe
High Pressure
Lip Seal
Shoe-Type
Rotor
Section A-A
Institute
Sealed
Ball Bearing
262
Diverters: FA, 450, 900
Advantages
Available in aluminum
Stainless steel
Simple construction
7 sizes (2, 4, 5, 6, 8, 10,
12)
3 methods of operation:
hand, air, electric
Left or right mounting
Explosion proof operators
Abrasion resistant coatings
ZL 45 diverter
Positive seal between ports air and material
same as above
Note:
Must stop material flow
before actuating except with
90 design
Maximum operating pressure
is 15 psi
90o Diverter
45o Diverter
Institute
263
45o Diverter Valve
Body with Standard

150 lb drilled flanges
15 psig rated
End Plate
High Pressure
Lip Seal
Sealed
Ball Bearing
Plug-Type
Rotor
Section A-A
Institute
264
FA / 45 / 90 Diverter Valve
Valve
Mounting
Bracket
Air Cylinder
Switch Box
Coupling
Institute
Dual Solenoid
265
90 Diverter Valve
Rotor
Body with Standard 150lb. Drilled Flanges

15 psig rated
Institute
266
SK Valves: Two-way SK
Advantages
Hand, motor, air operators are
standard
Sizes 3 to 14
Special applications:
aluminum, stainless steel
design in 4, 6 and 8
Left or right hand mounting
450 diverter leg
Heavy cast iron construction
50 psi seal tested
Standard flange drilling
High temperatures to 8500
Abrasion resistant design
NFPA 85F version available
Institute
Note:
Must stop material flow
before actuating
Heavy weight - valve must
be carefully supported
267
SK Diverter Valve
Valve Body
Colmonoy
Insert
Discharge Branch
Gasket
Valve Disc Arm
Cover Plate for
maintenance
access.
Adjusting
Pin Spring
Disc Arm
Shaft
Valve Disc
Valve Lever
w/ Stops
3/8 Sq. Packing

(Discharge Branch)
Lock Pin
and Chain
Institute
268
SK Valves: One-way SK
Advantages
Heavy cast iron
construction
50 psi seal tested
Air operator standard
Hand / motor operators
optional
NFPA version available
Standard flange drilling
High temperature to 8500
Abrasion resistant design
Explosion proof
operators
Sizes 3 to 12
Institute
Note:
Limited materials of
construction
Limited applications
269
Rotary Cutoff Valve

Advantages:
Heavy cast iron construction

Dual rotor seal
Simple construction
Inspection panel
5 sizes available (8x10, 12x12,
14x14, 12x24, & 16x20)
3 methods of operation: air,

hand, motor
Special applications:
High temperatures to 700F
Modulating design with
V-notch rotor
Institute
270
Rotary Cutoff Valve

End Cover
Valve Body
Cylinder (Rotor)
End Cover
Cover Plate
Lever Hub
Lever
Institute
271
Pipeline Bends
Institute
272
Long Radius Bend
Long radius bend with radius/pipe diameter ratios of 8 or

more were the traditional method of running pipelines.
Institute
273
Long Radius Bend Wear Pattern
Analysis of the long radius bend indicates a ricochetting

flow, rather than a smooth flow. This results in
unanticipated wear.
Institute
274
Concrete Wear-Back
Concrete-filled wear backs made of oversized pipe or

rolled channel can be used to extend the life of a bend.
Institute
275
Blinded Tee
The blinded tee has been shown to significantly reduce

wear, thanks largely to a dead layer of material at the main
wear zone. A blinded tee will have a lower pressure drop
than a long radius bend, and this will reduce compressed
air cost.
Institute
276
Short Radius Elbow
The short radius bend has a lower pressure drop than the
blinded tee, and only a slightly higher wear rate.
Institute
277
Resistance to Flow
This graph shows the lowest resistance (pressure drop) for

a bend with R/D = 2 to 4, i.e., a short radius bend.
Institute
278
Bend Service Life
Bend Type
Service Life (h)
Long Radius R/D = 12
14
Blind Tee
487
The above illustrates a comparison of bend service

life between blinded tees and long radius sweeps in a
severe test when handling zirconium-sodium.
Institute
279
Bend Cost Comparison
The above illustrates the relative costs for different

types of bends.
Institute
280
Couplings
Institute
281
Coupling Alignment
Couplings must be precisely aligned to minimize

parallel and angular misalignment.
Institute
282
Coupling Alignment
Imprecise alignment will cause shock and vibrations to be

transmitted to motor and machine bearings, resulting in
reduced bearing life and possible equipment damage.
Institute
283
Coupling Alignment
Couplings are usually aligned with a dial indicator.

Institute
284
Coupling Alignment
Align the coupling as accurately as possible to promote

long bearing life (not just to within coupling
manufacturers specs).
Institute
285
Coupling Alignment
Feeler Gage
The coupling gap can be checked with a feeler gage. Gap

specifications are normally found on the equipment
foundation drawing, or in the coupling manufacturers data.
Institute
286
Laser Alignment
Laser alignment offers the most accurate and easiest

coupling alignment.
Institute
287
Laser Alignment
A laser beam on one coupling half reflects back onto a

sensor from a mirror on the other half. Misalignment is
read on a hand-held computer.
Institute
288
Maintenance Seminar

Institute
289
Agenda
Bearing Components
Bearing Types
FLS Applications
Installation
Lubrication
Institute
290
Bearing Components
Institute
291
Bearing Components
Institute
292
Bearing Types
Institute
293
Rolling Elements
Bearings are characterized by their various types of rolling

elements.
Institute
294
Bearing Selection Criteria

Radial Loadability
Axial Loadability
Speed Capability
Misalignment Capability
A bearings type is selected for a particular machine

application based on the above major requirements.
Institute
295
Bearing Loadability
A machine may impose a radial load, an axial load in one or

both directions, or a combination of radial and axial loads
on the bearing, depending on the machines function.
Institute
296
Bearing Misalignment
Misaligned Bearings or
Bearing Housing
Shaft Deflection under load
Bearings have limits as to the degree of misalignment.
Institute
297
Ball Bearing
Institute
Radial Loadability -
Good
Axial Loadability -
Good
Speed -
Best
Misalignment -
Poor
298
Ball Bearing
Institute
299
Ball Bearing with Filling Notch
A ball bearing is limited as to the number

of balls that can be installed, but this may
be increased by the use of a filling notch.
Institute
300
Angular Contact Ball Bearing

Good
Axial Loadability -
Very Good
(one direction only)
Institute
Speed -
Good
Misalignment -
Poor
301
An axial load in the wrong direction will cause the

bearing to disassemble.
Institute
302
An angular contact bearing, by virtue of its

ability to disassemble, allows a maximum
amount of load-carrying balls to be installed.
Institute
303
Angular contact ball bearings are often arranged in pairs, to

provide bi-direction axial loadability or to provide increased
axial loadability in one direction only.
Institute
304
Double Row
Double row angular contact ball bearings are available to

provide bi-directional axial loadability.
Institute
305
Double Row
Institute
306
Cylindrical Roller Bearing
Institute
Very Good
Axial Loadability -
Poor
Speed -
good
Misalignment -
Poor
307
Institute
308
Institute
309
Cylindrical bearings may allow minor axial movement, or

they may be axially fixed. Axial loadability, however, is
limited in the cylindrical roller bearing.
Institute
310
Cylindrical Roller Bearings
Cylindrical roller bearings are available in many different

configurations. Make sure the correct bearing is installed.
Institute
311
Spherical Roller Bearing
Institute
Very Good
Axial Loadability -
Good
Speed -
Good
Misalignment -
Best
312
Because of the spherical shape of the rollers and

races, the spherical roller bearing can accommodate
the most misalignment of any bearing type.
Institute
313
Tapered Roller Bearing

Very Good
Axial Loadability -
Very Good
(one direction only)
Institute
Speed -
Good
Misalignment -
Poor
314
Tapered Roller Bearing

Spacer Ring
X
Arrangemen
t
O
Arrangemen
t
Tapered roller bearings are often combined in pairs

with spacer rings to provide bi-directional loadability.
Institute
315
Spherical Roller Thrust Bearing
Very Good
Axial Loadability -
Best (one direction only)
Speed -
Good
Misalignment -
Best
Institute
316
This bearing has the highest axial loadability. It is

often used to suspend a rotating shaft, where the
load is always downward.
Institute
317
Linear Re-circulating Ball Bearing
When linear motion is required, a linear recirculating ball

bearing may be used. Balls re-circulate through
passageways in the carriage as they roll along the raceway.
Institute
318
Cooper Split Roller Bearing
A split roller bearing may avoid shaft removal and extensive

installation time in certain circumstances. This cylindrical
roller bearing rests in a self-aligning housing.
Institute
319
Four Point Bearing
Institute
320
Speed
Radial Loadability
Axial Loadability
Misalignment
Comparison of
Bearing Capabilities
Ball
Bearing
Institute
Angular
Contact
Ball
Bearing
Cylindrical
Roller
Bearing
Spherical
Roller
Bearing
Spherical
Roller
Thrust
Bearing
Tapered
Roller
Bearing
321
FLS Applications
Institute
322
Double Row
Used on FLS Equipment:
Fuller-Kinyon Type M Pumps
150 mm and 200 mm
Institute
323

Fuller-Kinyon Type M Pumps
250, 300 and 350 mm
(O arrangement)
Institute
324
Ful-Vane Rotary Compressors

Grinding Mill Roller Assemblies
Institute
325

F-K Pump Z-Flap Conversions
O-Sepa Separator Lower Bearing
Kiln Thrust Roller Assembly
Kiln and Mill Pinion Bearings
Symetro Gears
Fans
Pillow Block Housings (various)
Institute
326
Tapered Roller Bearings

Grinding Mill Roller Assemblies
(X Arrangement)
Institute
327

Rotary Kiln Thrust Roller
O-Sepa Separator Upper Bearing
Institute
328
Linear Re-circulating Ball Bearing

CrossBar Cooler
Institute
329
Cooper Split Roller Bearing

Clinker Cooler Repairs
Institute
330
Institute
331
Bearing Clearance
Bearing internal clearance is critical to bearing life.

Clearance is necessary to accommodate expansion
caused by relative temperature changes of the inner
and outer bearing rings.
Institute
332
Bearing Clearance
Excessive clearance results in the shaft load being

spread over too few rollers. Too little clearance results
in the rollers receiving additional, unnecessary internal
loading when the bearing is at operating temperature.
Institute
333
Bearing Clearance
Feeler Gage
Total internal clearance can be checked with a feeler

gage inserted above the top roller with the machine at
rest.
Institute
334
Bearing Clearance Designations
C2
CN
C3
C4
C5
R __.__
Small Clearance
Normal Clearance
Large Clearance
Larger Clearance
Largest Clearance
Special Clearance
Bearings are available with various internal clearances.
Institute
335
Checking Bearing Clearance
Cold clearance must be within specifications after installation.

After the machine has reached normal operating temperature,
clearance will be reduced.
Institute
336
Compressor Bearing Clearances

Bearing Bore (MM) Before Mounting (in.)
After Mounting
(in.)
30
.0020/.0024
.0012/.0022
35
.0022/.0028
.0013/.0025
40
.0022/.0028
.0013/.0028
45
.0026/.0032
.0017/.0028
55
.0030/.0035
.0019/.0032
65
.0030/.0035
.0019/.0032
70
.0035/.0043
.0024/.0040
80
.0035/.0043
.0024/.0040
95
.0041/.0049
.0028/.0045
105
.0047/.0057
.0029/.0051
120
.0071/.0081
.0053/.0075
130
.0093/.0109
.0075/.0103
Institute
337
Bearing Axial Clearance
Bearings also have inherent axial clearance. This end play

must sometimes be taken into consideration when setting up
a machines shaft position.
Institute
338
Bearing inner rings are a shrink fit on the shaft (outer

rings are a sliding fit inside the bore in the cylinder head.
The bearing must be heated to install it on the shaft.
Institute
339
Internal Clearance
Reduced After
Installation
The bearing inner ring is stretched after installation,

reducing the bearings internal clearance. The clearance
is controlled by maintaining the shaft diameter between
limits when machining.
Institute
340
Bearing Clearance
Clearance in bearings with tapered bores is controlled by

the distance the bearing is pushed up the taper. The
further up, the more the inner ring will stretch and the less
will be the clearance after installation.
Institute
341
Tapered Sleeve Pillow Block
Often a tapered sleeve is used instead of tapering the

shaft.
Institute
342
Shrink-Fitting of Bearings
animation
Rule of thumb: The ring that sees the load over its entire
circumference is the tight-fitting ring. In this animation the inner
ring gets loaded over its entire circumference, while the
outer ring is loaded at one point only.
Institute
343
Bearing Creep
animation
If the bearing ring is not tight, it will creep and damage

the shaft.
Institute
344
Bearings are best heated with an induction heater. If this

is not available, use an oil bath. Never heat a bearing
with a torch. Heating to more than 250F (120C) will
damage the temper of the bearing steel.
Institute
345
Induction Heating
SKF induction heating film clip

Institute
346
Inner
Ring
Outer
Ring
Collar
This fixed cylindrical bearing comes as a matched set

consisting of inner ring, fixing collar, and outer ring with
rollers and cage assembled. The inner ring and collar
are held in place with a locknut and tab washer.
Institute
347
Installing a pre-heated inner ring.
Institute
348
Inner ring with locknut and tab washer.

Institute
349
Installing the collar.

Institute
350
Collar in place.
Institute
351
Installing the tab washer.

Institute
352
Installing the locknut.

Institute
353
Tightening the locknut.

Institute
354
Bending over the washers locking tab.

Institute
355
Installing the bearing retainer.

Institute
356
Bearing Lubrication
Institute
357
Lubrication Film
Tiny surface asperities are kept from contacting

each other by a good oil film.
Institute
358
Hydrodynamic Lubrication
As one surface slides over another, a wave of oil

wedges them apart, creating an oil film.
Institute
359
Hydrodynamic Lubrication
When the shaft rotates, oil is drawn in between the

journal and bearing. The shaft lifts and a lubrication
film is established.
Institute
360
Elasto-hydrodynamic Effect
Under extreme forces, plastic deformation occurs

and surface area in the contact zone increases.
Lubricant viscosity multiplies under extreme
pressure. The result is a thin but stable oil film
capable of keeping surfaces separated.
Institute
361
Boundary Lubrication
When speed or oil viscosity is too low, or when loads

are excessive, surfaces may contact. Boundary
lubrication conditions are said to exist.
Institute
362
EP Additives
Extreme pressure and anti-wear additives in the oil

react to the high heat and pressures at the surfaces
to form a low-friction chemical film, thus preventing
surfaces from seizing.
Institute
363
Oil Film Thickness
L=
Oil film thickness increases with viscosity and speed and

decreases with load. A good film thickness is three times
the surface roughness.
Institute
364
Viscosity
Viscosity, or the resistance of a liquid to flow, is the most

important property of lubricating oil. Oil viscosity changes
drastically with temperature.
Institute
365
Viscosity
Oil viscosity is selected based on equipment operating

temperature range.
Institute
366
Viscosity Index
Viscosity index is a relative measurement of how viscosity

changes with change in temperature. Oil with a higher
viscosity index can maintain its viscosity over a wider
temperature range.
Institute
367
ISO Viscosity Grade

International Standards Organization
designation for oil viscosity grade.
Measured as Centistoke (cSt) at 40 C.
Becoming more common than SSU
(Saybolt Seconds Universal).
Multiply ISO VG by 5 to approximate
SSU at 100 F.
Institute
368
Viscosity
Equivalents
Institute
369
Grease
Grease = Oil + Thickener
Grease is approximately 85% base oil plus 15%

thickener. Lubricating properties (viscosity, etc.) are
dependent on the characteristics of the base oil,
while the thickener acts as a sponge to hold the oil.
Institute
370
Grease Lubrication
Advantages
Seals out dirt

Stays where it is put
Supplies oil to the bearing as required
Minimal leakage
Long lasting, low maintenance
Disadvantages
Overgreasing may cause bearing damage
Institute
371
Oil Lubrication
Advantages
Able to clean system with recirculation
Able to cool system with heat exchanger
Generally better lubrication
Better for high speed applications
Disadvantages
More complicated (circulating system)
More maintenance
More prone to leakage
Institute
372
Bearing Greasing
(FAG recommendations)
if RPM x Diameter (in mm) is
less than 50,000
pack full
50,000 500,000
pack 60% full
greater than 500,000
pack 20-35% full
Excessive grease in hi-speed applications results in heat

generation through churning of the grease. This can lead
to burning of the grease and subsequent bearing failure.
Institute
373
Bearing Lubrication
Lubrication
Grooves
Bearings can be supplied with a lubrication groove. This

angular contact ball bearing is used back to back with
another bearing. Grease enters the groove and emerges
between the two bearings.
Institute
374
Lubrication !
Most bearing failures are caused by lubrication problems.

Institute
375
Airline Filter Regulator Lubricator
Institute
376
Filter Regulator Lubricator
Filter-regulator-lubricators are used to condition

compressed air supply to pneumatic devices.
Institute
377

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Maintenance Seminar

F-K Pumps - Introduction

H-Pump and Z- Flap Conversions

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Principles of Pneumatic Conveying

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the process of moving powdered

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Pneumatic Conveying Flow

Material flow through a pipeline can be characterized

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Pneumatic Conveying Flow

Dilute Phase Flow

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Pneumatic Conveying Flow

moving "waves" of material

Dense Phase Flow (plug flow)

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Pneumatic Conveying Flow

Moving Material Bed

Medium Phase Flow (dual or mixed)

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Pneumatic Conveying Flow

two phase flow

lf: v1 > v2 particle lifts

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Conveying Line Pressure Drop

Pneumatic Conveying Flow

air flow rate

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How to put material into

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The Fuller-Kinyon Pump

Feed material enters the hopper where the screw

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Components of an F-K Pump

air and material

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Pneumatic Conveying System

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F-K Pumps - Introduction

Typical Materials Handled

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F-K Pumps - Introduction

F-K Pumps - Introduction

Types of F-K Pumps

F-K Pumps - Introduction

Types of F-K Pumps

F-K Pumps - Introduction

The M Pump has bearings on both ends of the shaft.

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M Pump Sizes and Capacities

have decreasing pitch. Other pitches available.

capacity in short tons/hour while transporting 3600 blaine

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250 M pump with

350 M pump with

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F-K Pumps - Introduction

The H Pump has a cantilevered screw with

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H Pump Sizes and Capacities