FAQ – Grease Systems

How effective is the pumping assistance (Pressurised Follower)?

Low pressure air at 32 kPa acts on top of the 1,055 mm diameter follower. This air pressure develops up to 28 KN of force being applied to the follower to assist in force feeding the pump inlet.

This is of major benefit with high viscosity greases, tacky greases and in cold weather. Providing a positive suction minimises pump cavitation resulting in expensive pump failures.

Filling & Decanting

With an internal follower the RTM(S) series are both “bottom discharge” and “bottom fill”. This is via a 75 mm (3”) full bore ball valve fitted with a 75 mm (3”) male camloc adapter and dust cap.

The dust cap is secured to the camloc adapter with a stainless steel security cable. A label showing valve operation (open / closed is fitted).

Top and Bottom Lifting

The RTM(S) is designed to be bottom lifted with a forklift. Four way fork entry is standard, the forklift pockets are fully enclosed for operator safety. The fork pockets can accept fork tynes up to 220 mm wide.

On the front and rear fork pockets striker pads and 10 mm thick side guards are fitted to minimise damage when handled roughly and skewed around with fork trucks.

Top lifting (full) using slings / cables is via four heavy duty lifting lugs welded to doubler pads on the tank shell. These are fitted at the top of the tank and positioned to be above the fork pockets to stay within the physical envelope. Spreader bars should be utilised when lifting to protect the clamp band.

Drillings in the 10 mm thick lifting lugs are 40 mm as standard.

How does the contents indicator work?

The contents indicator provides real time level indication. A weighted poppet is placed inside a clear Perspex tube on the outside of the container. A cable is connected from the poppet to the internal follower. As the follower moves the external poppet moves in proportion.

The external sight gauge protective guard protects the Perspex tube from damage and shows contents indication, graduated F and E, notches are provided for ¼, ½ and ¾ levels.

The indicator poppet works in reverse, when at the top the unit is empty, when at the bottom the unit is full.

Indication is indicative only.

Remote indication / Pump shut down

It is possible to fit an ultrasonic sensor in the top shell, a reflector plate is mounted on the follower. The ultrasonic probe normally returns a 4-20ma signal, requiring a processor elsewhere. Typically the ultrasonic probe is mounted in a quick release coupling for maintenance, and to enable it to be swapped to other containers if needed.

A simpler method is available designed to shut down the pump when the RTM(S) is close to empty. This process utilises the steel poppet in the sight gauge assembly. A magnetic reed switch is mounted in a bracket at the top of the gauge guards. Once the sight poppet moves past this (empty position) the magnetic reed switch is triggered shutting of the pump. This can also be a 12 / 24 volt signal back to the compressor, shuts down the compressor.

How much residual grease is left?

The follower effectively wipes the side walls leaving only a very thin film of grease. Residual contents are traditionally less than 10 kg, this is retained in the sump and discharge pipe work.

Maximum Pumping Rates

This will be dependent upon the grease; viscosity, tackiness, temperature and also the pump design and connection pipe work / hoses.

Based on customer feed back flow rates of 25 – 28 l/m are comfortably achieved. Flow rates of up to 40 l/m have been reported.

Will the RTM(S) operate withour air pressure?

Yes, the vacuum vent in the top shell will allow the container to breath, the vacuum setting is -3.5 kPa (0.5 psi). However the efficiency will be greatly reduced to that of a conventional design container.

Is the RTM(S) grease container a pressure vessel?

No, based on the diameter (< 1,055 mm) and operating pressure (< 35 kPa) the container is not classified as a pressure vessel under Australian Standard AS 1210 (Unfired Pressure Vessels ) and ASME VIII div 1.

Can the grease container be over pressurised?

The integral pressure vent commences relieving at 35 kPa, fully relieving flow is 2,000 l/m at 52 kPa. The internal vent orifice size is ~ 25 mm.

Air flow in is restricted by the size of the pneumatic regulator selected, the port size of 0.25” and restrictions within the regulator ensure air flow in is less than the capacity out of the pressure vent. The regulator socket in the top shell is a 0.25” female socket.

A warning label “Do not pressurise this IBC above 35 kPa” is fitted.

What is the air consumption?

At a pumping rate of 11 l/m air requirement is ~ 19 l/m.
At a pumping rate of 25 l/m air requirement is ~ 36 l/m

Do I need filtered air?

It is expected the air to the pump and RTM(S) would be conditioned, at the minimum an automatic water drain. The RTM(S) is not overly fussy as no precision parts are encountered, the pump would however probably give problems if not clean filtered lubricated air.

What type of pneumatic regulator is required?

A low pressure regulator capable of controlling downstream pressure at 2 – 60 kPa is required. Port size no greater than 0.25” screwed. Pressure setting is 28 – 32 kPa. The RTM(S) air consumption is not great, approximately 0.04 m3/m at a flow rate of 25 l/m.

Regulators, gauges and remote air lines are available as an option, factory installed and set. It is recommended genuine parts from Trans-Tainer are used.

Where is the pressure regulator located?

The regulator and gauge are fitted in the top shell, the gauge facing outwards so as visible through the top coming.

A remote air line with a quick coupling can be fitted extending to the base for easy access. This prevents the need to access the top of the unit. The remote air line is strapped to the sight gauge guard.

Will the follower jam if the shell is dented?

The flexible follower will take up minor dents in the shell, less than 10 mm.

Valve Threads / Connections

As standard all threads are BSP (British Standard Pipe), NPT is available on request. The male 3” camloc adapter (type A) and dust cap (type DC) fitted to the ball valve are to NATO MIL specification, interchangeable world wide.

How are pumps connected?

The RTM(S) discharge point terminates in a horizontal 3” camloc adapter. As most piston style grease pumps operate most effectively in the vertical position a manifold is required.

Trans-Tainer has an extensive range of designs available on request.

RTM location / truck mounting?

Where the RTM(S) is to be mounted on a service truck or in a dedicated position mounting interfaces and tie down systems are available from Transtainer.

When being fitted to service trucks it is important that the unit is tied down from the top either using webbing straps or cables to the lifting lugs. Locating from the bottom only will result in flexing and cracking at the weld seams.

Maintenance and Cleaning

For full details refer to the RTM(S) Operating Manual. No special tools are required outside of those a fitter would be expected to have. Service is relatively simple and straight forward.

Detailed work instructions are available on request.

Routine Inspections

For routine visual inspection, generally occurs when the units are being filled, refer to Work Instruction WI-TT-40.

This covers physical damage and “fiddling with” that can be endemic on mine sites.

Service Life

The only moving component is the flexible follower, as a thin film of grease is left on the tank walls wear of the follower is extremely low. It is normal to expect the follower to have a service life in excess of 10 years.

We are aware of units that have the original follower still in use after 13 years.

Over time the RTM and enhanced heavy duty RTM(S) series have undergone continuous improvements to increase service life and operator safety, this is a result of customer feedback.

Some of these changes include; full welding instead of stitch welding, additional base gussets and striker plates, valve bracing, improved water drainage points, etc.

External and Internal Finish

The RTM(S) series are WHIP blasted internally and externally to remove mill scale internally and provide an effective bond for external coatings.

Externally a zinc rich two pack epoxy primer is applied, final coat is a re-coatable two pack polyurethane finish. Corporate colours are available on request.

Internally all surfaces are lightly oiled with a 20 / 30 grade oil. This minimises rust developing prior to first fill and eases follower movement during first fill.

Loading and Transporting

The RTM(S) are based on being smaller than a standard pallet size, the base size is 997 mm wide and 1,145 mm wide. The clamp band is 1,152 mm in diameter.

The RTM(S) are designed to load effectively two wide on standard truck trays and load effectively into shipping containers.

Custom Design

Transtainer designs and manufactures custom RTM(S) units. These may range from unique skid asemblies, dual fill / discharge points, alternative capacities, etc.

Options

A range of options to enhance field usage, safety and aesthetics are available. Some of these are as follows:

 

a) Stainless Steel Label Panels Dwg 578375
To prevent adhesive transport / shipping labels being positioned all over the unit looking ugly and leaving part labels and glue when removed a stainless steel label panel is available.
The stainless panels are removable and reversible and can be scraped clean without damaging the paint work. The panels are fitted to the front of the unit. Two panels one front and rear are available.
 
b) Remote Air Line
A 10 mm nylon line extending from the top mounted regulator to the base of the unit. This terminates in a Ryco 0.5” male snap lock air fitting. The air line is strapped to the sight gauge guard.

This prevents the need to access the top of the container, a safety aspect and speeds up connection and disconnection.
 
c) Manifest Holder Dwg 574966
A 50 mm diameter tube 200 mm long and fitted with a screw cap. The assembly stands vertically and is welded to the skid. Shipping documents are rolled up and placed in the manifest holder for protection.
 
d) Buffer Plates Dwg 578947
When transported roughly and loaded side by side the clamp bands may rub together. On the side access direction the clamp band stands proud of the base assembly.

To minimise damage caused by contact, paint loss and clamp band wear buffer plates are available. These are the point of contact and can be easily repainted.
 
e) Sump Return Point
As an additional flushing point or as a pump return point a socket and plug can be fitted in the sump. Normal size is 2” and fitted on the opposite side of the valve.