Operating Instructions WKLn Horizontal, multi-stage KSB High-pressure Centrifugal Pumps Pump sizes 32 to 150 Works Serial No. Pump Size:Contents Page 9 Genera : 0.1 Handling... ice : 1 Installation. 1.1 Foundation 12 Mounting. 43 Aligning the Pump and Driver 1.4 Connecting the Piping . 1.4.1 Auxiliary Connections 1.42. Vacuum Balance Line, . 1.4.3. Minimum Flow 1.5 Coupling Guard. 1.6 Final Check . 2 Stortup/Commissioning, Shutdown 21 Preparations... 2.1.4 Lubricant. 24.2 Shaft Seal . 2.1.3 Priming the Purp and associated Checks 2.1.4 Checking the Direction of Rotation 22 Startup 2.3 Shutdown 3 Maintenance and Lubrication 3.1 Supervision of Operation 3.2 Lubrication and Grease Change 3.2.1 Lubrication . 3.22 — Grease Change 4 Dismantling and Reasiembly 41 General 42 Dismantling... 4.2.1 Mechanical Seal. 43 Bearings... 44 Assembly, 441 Pump ..... + a 442 ShattSeal ... paee 44.2.1 Packed Gland. 4422 Mechanical Sel. 7 443 Setting Torques for the Tiebolts. 45 Cooling Liquid (HW design) 48 External Source Sealing Liauid WU o om oamamamaaTaaT Marea nea eOUOOOe (Vacuum Operation, 6... 2. 27 47 Spare Parts. 7 se 8 47.1 Recommended List of Spare Parts. 18 4.7.2 Alternatively keeping a complete Rotor in Stock. . 9 4.8 Exploded Views and List of Components... .. 10 5 Faults, Cause, Remedy area© General Centrifugal pumps will give trouble-free, satisfactory service if they are properly installed and maintsined, Follow the instructions in this manual carefully, Do net run the pumps under operating conditions which differ from those specified by us. This manual does not take into account any site safety regulations which may apply. The site menager or site Operator is responsible for notifying our erection staff of ‘any such regulations and ensuring they are complied with. ‘The type series, pump size, main operating data, product, ‘umber and serial number are all stamped on the nameplate attached to the pump. Please quote this information when- fever you have queries or repeat orders and in particular when ordering spare parts, Warning Do not operate this pumpset above the limit values for capacity, speed pressure and temperature, ete, shown on ‘the nameplate, Ensure that operation is in accordance with the instructions contained in this manual (contract documentation). It is essential that the electrical connection values areas specified ‘and that the instructions on installation and maintenance are followed. Failure to do so ean rosult in personal equipment, jury and damage to NB. ‘The instructions and descriptions in this manual refer 10 the standard pump model, This manual does not cover all sign details or eventualities which might occur during installation, operation or maintenance. The pumpset must only be handled by skilled, trained personnel, For any information and instructions not contained in this manual, please contact KSB. The manufacturer accepts no liability for the pumpset if the instructions in this manual are not complied with. 0.1 Handling When handling the complete pumpset, attach ropes to the pump and driver as shown (not through the motor eyebolt). Fig. 1 Pump and driver on common baseplate 1 Installation 1.1 Foundation Make sure the concrete foundation has set hard before ‘mounting the pumpset. The surface of the foundation must be completely horizontal and perfectly flat. 1.2 Mounting Position the pumpset on the foundation and align using a precision spirit level (on the shatt/discharge nozzle). Ensure that the gap between the two coupling halves is as given on. the general arrangement drawing, Shims should always be fitted to the left and right of the bolts in close proximity to the bolts, between the base plate/baseframe and foundation. If the bolts are mare than 800mm apart, position extra shims equi-distant between them. All shims must seat perfectly flush Fig, 2 Fitting shims Uniformly tighten up the bolts, Grout in the baseplate (nonshrinking mortar is highly recommended), ensuring no cavities rem 1.3 Alignment of Pump and Driver After the baseplate has been fixed in position carefully, ‘check the coupling and, if necessary, realign the pumpset, ‘The coupling must also be checked and the pumpset re- aligned even if the pump and driver are supplied ready ‘mounted on ¢ common baseplate. ‘The pumpset can be considered correctly aligned when the Gap (2 or b, see Fig, 3) betwean each shaft and a streight edge placed ‘axially over both half couplings is the same at all points on the circumterance, Furthermore, the gap between the two coupling halves must be the seme at all points on the circumference. This ‘can be measured with calipers or a feeler guage (see Fig. 3 and 4) Suaigntedge | T t q L, fc 1 Tu [— Lou i =) sirsniedse Tenge Fig. Aligning a non-spacer type flexible couplingStaightode pe ° t = o r 5 at i) Fig. 4 Aligning a flexible spacer coupling ‘The axial and radial deviation between the two coupling hhalves must not exceed 0,1 mm, 1.4 Connecting the Piping Never use the pump as an anchorage point for the piping. Suction lift lines should be run with a rising slope towards ‘the pump, positive suction lines with a downward slope towards the pump. ‘The pipes should be sunported very near to the pump and should be connected to the pump without transmitting any stresses and strains to it. The pump must not bear the weight of the piping. The nominal bores of the pipes should be the same as or larger than those of the pump nozzles, We recommend ingtalling non-return devices and shutoff valves, depanding ‘on the type of installation. ‘Tne thermal expansion of the pipework should be accom: modated by suitable means so as not to impose any extra Toad on the pump, Before commissioning a new instalation, thoroughly clean, flush and blow through all vessels, piping and connections ‘As welding beads, scale and other impurities frequently ‘only become dislodged after a certein period of time, itis necessary to fit a strainer in the suction line to prevent these from entering the pump. The total cross-section of the holes in the strainer should be three times the cross section of the piping in osder to avoid excessive pressure lost across the strainer due to clogging, The conical strainer consists of a coarse strainer fronted by @ fine strainer with a 2.0mm mesh and 0,5mm wire, made of corrosion-resistant ‘material. See DIN 4181, 2 5 3 4 Strainer holder Fine strainer Coarse strainer Pump suction nozzle Differentiat pressure guage Fig. § Conical strainer for suction line 1.4.1. Auxiliary Connections ‘The size and location of all auxiliary connsetions for sealing, circulation, balance and leakage liquid are shown in the ‘general arrangement drawing or piping diagram, 1.4.2 Vacuum Balance Line If the pump has to pump liquid outof a vessel under vacuum it is advisable to fit @ vacuum balance line, This line should have a minimum N.B, of 25mm and shoutd be srranged to lead back into the vacuum vessel at a pointabove the highest permissible liquid level ‘An additional ine from the pump discharge nozzle facili tates pump venting prior to startup, Main shutoff valve Vacuum balance tine Shutoff valve Vacuum-tight shut-off valve Non-return flap valve Vacuum vesse! Intermediate flange Fig. 6 Suction line and vacuum balance line Nemmoa> 1.4.3 Minimum Flow fit ls possible that the pump will have to operate against a closed aischarge valve, a manual or continuous bypass Or & bypass check valve must be pravided. 1.5 Coupling Guard Safety regulations specify that the pump must be fitted with a coupling guard. If the purchaser specifically states that he does not want us to supply a guard, this must be Provided by the operator 1.6 Final Check Ro-check alignmant as described in 1.3, It must be possible to rotate the coupling easily by hand, Check the integrity of all connections.2 Startup/Commissioning, Shutdown 2.1 Preparations 2.1.1 Lubricant ‘The grease-lubricated bearings have already been packed with grease. 2.1.2 Shaft Seal Chock seat (see 4.4.2.1) 2.1.3 Priming the Pump and associated Checks Vent and prime the pump and suction line before startup, ‘The shutoff valve in the suction line must be fully open. Fully open all auxiliary connections (flushing, sealing and Cooling Fiuids). Check the flaw. Open the shutoff vaive in the vacuum line {if fitted) and close the vecuum-tight shut off valve “E"' (Fig, 8) 2.1.4. Checking the Direction of Rotation Tho direction of rotation must correspond to the arrow on, the pump. Check this by switching the pump on, then off again immediately. Fit the coupling guard. 22 Startup Start the set up against a closed discharge valve only, Slowly open the discharge velye to obtain the required duty point after the pump has reached full speed. NB. Alter the pump has reached its working temperature and? fr if the pump leaks, shut the set down and tighten the tiebotts 2.3 Shutdown Close the discharge gate valve, The discharge gate valve can remain open if the discharge line incorporates @ non-return valve, provided there is back pressure, ‘Switch off the driver, making sure the pumpset runs smooth: ly and evenly down to a standstill, I the pumpset is to remain out of service for long periods, close the shutoff valve in the suction line. Close off the auxiliary connections. Do not shut off the flow of cooling fiuid, if applicable, until the pump has cooled down, (On pumps supplied with produet under vacuum, sealing liquid must be supplied to the shaft seal even during stand- still If there is @ danger of freezing and/or if the pump is to be ‘out of service for long periods, drein the pump oF otherwise protect against freazing. 3 Maintenance and Lubrication 3,1. Supervision of operation The pump must run quietly and evenly at al times, Avoid dry-running of the pump. Do not run the pump for a long period against a closed discharge valve. The bearing temperature may exceed ambient temperature by up to 50°C, but must not exceed 90°C {measured ex: nally on the bearing housing) ‘The shutoff valves in the auxiliary Hines must remain open while the pump is cunning If the pump has a gland packing this should \eak slightly during operation. The gland nuts should only be lightiv tightened, If the pump has a mechanical seal this experiences only ‘minor leakage or no visible leakage (flashing) during ope: ration, {tis maintenance-free. ‘Any standby pumps should be started up then shut down immediately, at least once a week, to ensure they are in ‘constant readiness for operation, Check the integrity of the auxiliary connections ‘The flexible coupling elements should be regularly checked and replaced as soon as they shovr signs of wee. 3.2 Lubrication and Grease Change 3.2.1 Lubrication The anti-riction bearings are grease-lubricated. See 4.3 for orease fi 3.2.2 Grease Change The initial fill of greaselubricated anticriction bearings should be changed after 3000 operating hours or 2 years, whichever is the sooner. Grade: Use @ high-quality lithium soap grease, resin and acid-free not liable to crumble, with good rust-preventative proper ties, It must have a penetration number between 2 and 3, corresponding to a worked penetration between 220 end 295 mm/10, Its drop point must be sbove 175°C. 4. Dismantling and Reassembly 4.1 General NB. Before dismantling, make sure the pump Is disconnected from the power supply and cannot be switched on acci dentally, ‘The suction and discharge shut off valves must be closed, ‘The pump casing must have cooled down to ambient ‘temperature. ‘The pump casing must be empty and not under pressure, 42 Dismantling 1. Detach all auxiliary supply lines. 2, Remove coupling guard, 3. Disconnect pump from driver and detach from baseplate, 4, Unscrew the socket head cap serew in the coupling hub ‘and detach half coupling from the shaft using a pull-off deviee, Remove key (940.1). If the pump has been in operation for some time it may be difficult to remove certain parts from the shaft. If this is the case use a brand name penetrating oil or suitable pull off device — Never use force! 6. Number and match-mark the stage casing 108 consecu: tively s0 that suction casing 106, stage casings 108 and the discharge casing 107 will be re-assembled in the cor- rect sequence and position 6. Support the stage casings 108 so that they do not collapse when the bearing housing (350) is removed (see Fig. 7) 7. Dismantle the pump from the discharge end in the sequence shown jn the exploded view on page 10 and 11 8, Remove all stages up to and including the last impeller.4.2.1 Mechenical Seal Pill the mechonieal sel 499 off the shatt by hand Before reassembly, clean the shaft sleeve (523), touch up. : any groove or tratehes with 9 polishing cloth. Ifthe score ‘mark il remain visible, you must fit 9 new shat sleeve lean the stationary sea rng satin the Sel cover (471) Aston i i Paogecasag 4.3 Bearings Suetion sd (floating bearing): pa ‘yinderrllr bearing | With adapter sleeve | Purp sizes DIN Sata BIN 5at5 ateningter 2 W207 Ks 1207 20 NU 207 KES #207 30 NU 208 KC 3 H 208 = 05 NU 208 KE #208 Weigoarram) 80 NU 200 KC 3 1200 2 woe a Fig,7 Axial alignment of rotor 125 NU 27 KCS Hain “Then make + groove (ste Fig. 8} on the shat inline with SE onoaees ag the outer edge of the bearing housing 360.1. Discharge side (fixed bearing): “Angular contact ball Bearing Pump sizes DIN 628 32 6306.03 ~a [BE 50. 3307 6 30 ca 3307 6 39 0 330863 00 33093 125, 331003 150 331203 1) 3307 C3 for cuties up to 300m {or duties over 300m bearing eize on request Before topping up remove old grease. Lubricent quantity approx, 10 gr to 20 gr per bearing, 44 Assembly 44.1 Pump Follow standard engineering practice when assembling the pump, Coat the fits of the various components and the screw connections with graphite or similar before assembly. Check O-rings end radial shaft seal rings for damage, Fit now gatkets throughout, ensuring that they are the same thickness as the old ones, Reassemble in the reverse order to dismantling. Itis essential that the components are fitted in the correct sequence, If new parts are fitted, realign the first stage impeller axially in relation to the diffuser, ‘After mounting the first stage diffuser 171.1, align the shaft ‘and impeller so that the centre of the impelier (outlet) cor- Fesponds to the centre of the diffuser (Inlet) (see Fig, 7) Fig. 8 a reference groove With the bell bearing 320 in position, the reference groove must be in its original position. Fit 2 spacer ring 504 (spacer ring width = y~x, Fig. 9). Fig. 9 Correctly sized spacer ring It must be possible to easily rotate the shaft by hand.442 Shaft Seal 4.4.2.1 Packed Gland ‘Thoroughly clean the box and shaft protecting sleeve before packing the gland, Fig, 10 Packing ring cut to size Insert the first packing ring and push home using the gland Fit each subsequent ring separately with its joint offset by, 90° to the preceding one using the gland cover ‘Tighten the gland nuts lightly and evenly. It must be possible to rotate the rotor without difficulty. Fig. 11. Packing rings, with their joints offset by 90° to the preceding ring Rae ae eer Discharge side (N/a design} Fig. 12 Packing compartment Suction side {N/a design} on Ep se ee ee ee ERE les (os wee ee we ice ees E focernnmoml tere as taiom cp Eee, an i PSPS Pars Be nay rice [Si isso [Sado 4.4.2.2 Mechanieal Se Reassemble in the reverse order to dismantling, When fitting a mechanical seal, bear the following points in mind: Maximum care and maximum cleanliness are mandatory. Do not remove the guard on the seal faces until just before fitting ‘The seal faces and O-rings must net be damaged. Clean or carefully remove any deposits from the shaft and, stationary seal ring seat in the bearing housing. The shaft sleeve (523) may be ciled to reduce friction when mounting the seal Ne. Epoxy rubber Osrings must not come into contact with oll or grease. Use water. Push the stationary seal ring into the seal plate with hand or finger pressure, applying pressure evenly to all sides. When fitting double Teflon-sheathed O-rings, ensure that the ridge of the sheath faces away from the dizection of nent » 9 Sheathridge Fig 13. Teflonsheathed O-ring 4.4.3 Setting Torques for the Tiebolts Pump size | 32] 40 [ 60 | 65 | 80 [100 | 125 [150 Torque Nm { 200 | 200 | 300 [300° 200 [260 [ 300 [350 * For discharge pressure ‘Above 1500 KPa ‘Torque = 350 Nm. 4.5 Cooling Liquid (HW Design) ‘Tho minimum permissible cooling liquid flow rates ~ with a cooling outlet temperature of 40°C — are as follows: Pump size [32] 40] 60 | 65 | 80 [100] 125 | 150 Cooling figuia Gimin. approx. |1,5 | 1,8 | 2.1] 2.1 | 25 | 25 | 28 | 28 Max. coolant outlet temperature 60°C ‘Max. coolant pressure 6 bar 4.6 External Source Sealing Liquis (Vacuum Operation) Flow rate of external source liquid (vacuum operation only) approx. 1Umin, sealing liquid pressure: 0.5 bar + suction pressure (p,) at least 0,1 bar above atmospheric. The sealant ‘must be compatible with the product pumped.47 Spare Parts Always give the following information w parts: Tyee: No. erdering spare WKLn Pump size/number of stages (0.9. 80/5) Product No. This information is to be found on the nameplate. 4.7.1 Recommended List of Spare Parts for 2 Vears’ continuous Operation to VOMA 24 296 Number of pumps [including standby pumps) 2/3 [4 [5 | 6and7 | @ands | 10and over PartNo. | Part designation Gianiey oF spare pare 210 | Shae with mux with so ats 920.4, cvs 092.112 an Kevs 940.1/.3/.4/.5/.6 se 7 ia 30% 230 Impeller {set = S) meas apriay2 2 3 30% 320__| Angular sonnac al bering thet 3] [50% 322 Cylinerical roller bearing with clamping sleeve 531 ajip2[2 3 4 50% 400.2 Gaskat (only on cooled packing) 4a/ahels 12 12 160% 592.172 | Oring oo afsfelel 9 | 12 | 160% 312.3 [ O-ring fonty on cooled packing) afels[e] i | 12°] 160% ai24 | Oving et =5) afs[ele| 9 | 12 | 180% 4361 [ Glend poking @fafefe[ | os | som 502") Casing wear ring (set = S x 2} 2}2]2/3 3 4 50% 521 Stage sleeve (set = S — 1) 2(2/2/.3 3 4 50% 524.1/.2 | Shaft protecting sleeve (set = suction and discharge sides) 2)2/2/3 3 4 50% 525.12 | Scacerslewve let = setion ana escnargs sides) zf2[2{s|_3 | «| 50x sleeve (only on ie 160 non-cooled paki 59 | Lenade mdse 00 towonedpmire | 212/2/3| 3 | # | 90% BRE [Soe sene envensanionwraeoeoedmsmioi] 11 T5) g | a | mom (On purgs with mechanical sel woos | Gosker apepeye] 2] 2 | 160% Ha [Compete mecharznl seat "enacanar.nt. > ajalajs} 6 | 7 | sm BERAZ] Saft loves et 2{2l2{s|_ 3 | «| so = number of tages 1) Size 60 and 65 (set = $x 1) not fitted size 32 and 404.7.2 Altern: ly Keeping a complete Rotor in Stock comprising: PartNo. Part designation 210 1 shaft with nut with 2 flats 920.4, cirelips 932.1/,2 and keys 940.1/.3/.4/.5/.6 230 1 set of impellers a2 1 set of O-rings 521 1 set of stage sleeves 526 1 set of shaft protecting sleeves or if the pump hhas a mechanical seal 523 1 set of sleeves 525 1 set of spacer slooves,Design with uncooled mechanical seal Part No. Part Designation 108 Suction casing 107 Discharge esting 108 185 ia Y712 Last stage oittuser HO Share 230 Impaler $20. Angular contact bal bearing 322. Gylindsical vole beating 2360.12. Baaring housing, 4002/31 Gasket a8. AVierr21 Gasket 28, 412.112) O-ring 3a 422.112 Fett ving (elans 125 and 150) 433.172 Mechan'cal se! 452 Gland cover 458 Lanternring 461 Glane packing a7 Seal plate 500.12 End fing lelzes 125 and 160) 5029) Coning wear sing 03 Spacer ving Part No. Part designation $07 Thrower S2t_ Stagesleeve 523.12 Shaltsleeve 824.172 Shalt protecting sleeve 525.1” Space sleeve 6252 Spacer slerve (izes 100 and 125 N and HWW, size 60~ 160 enocheaical seal 52581) Spacer ioowe (ize 160 N anc mechanical sea, size 100 — 150 AW) 52547) Spacer sieave {izes 100 ana 160 HWW) 831 Clamplag sleeve 80, ise 862 Cylindrical pin 6369) Greate nipple, ‘801.1 Hex. ad Bolt 9021172) St 3 (3szes 400-180 mechanical seal) 903.11.) Theeosed plug 34 905 Tiebote 814 Socket head serow {Gize 80 mechani 920.1/2/ Hex. nut 3 i ea) 8204 Notwith two fate " suction side, unbalanced discharge side, unbalanced Sischarge side, balanced Part No. Pert designation 932.12 Greio BAO” Key 02 Koy) 3403/4) Key ‘5/6 (Soot Fitted on sizes 125 and 150) 100.112 Connection for pressure messing Inavument 88 Product grain 8D Product prime vent 7A Cooling quis ouvler JE Cooling ti 9A] Sealing liquid outer oe) 105 seating liquid inlet WE Tiguid intet va ‘Souter 142 Balance liquid inlet 1} not lasted 8) applies only 10 pumps with drive from either nd 2) Ted on size 60 9nd 65 Zon sizes BO to 1605. Faults Faure Code number Cause — Remedy 1,2,3,4,5,6,8,9, 10, 11,28 Pump delivers insufficient liquie Driver is overloaded 12, 13, 15, 28 Excessively high pump | 15 Pee discharge pressure Excessively high bearing temperature 22, 23, 24, 25, 26 age at the pump 6 Excessive leakage ot 17, 18, 21, 28, 23, 33 shaft seal 3,6, 11, 12, 22, 23, 25, 30, 31 32 3,6,32 ‘The pump runs rough Excessive temperature rise inside the pump Numbers omitted do not apply to this type series Gouse — Remedy") 1, The pump generates an excessively high differential pressure E = Reset the duty point 2. Excessively high back pressure = Check the pump set for impurities = Ficlarger impeller(s)?) — Increase speed [applies to turbine driven or 1.C. engine driven pumps) 3, The pump andlor piping are incompletely vented or primed = Vent or prime the pump and piping completely 4, Suction line or impelier(s) clogged = Remove deposits in the pump and/or piping 5. Formation of air pockets in the piping ~ Alter piping layout — If necessary, fit a vent valve 6. Suction head too great/NPSH available too small = Check liquid level in suction vessel = Open isolating vaive in suction line fully — After suction line if necessary, if the friction losses Jn the suction line are excessive = Check suction Hine strainers/suetion aperture 2B. Ingress of air through the stuffing box = Sealing liquid passage is clogged; clean it out if faocessary, arrange a sealing liquid supply from an ‘outside source, or increase sealing liquid pressure = Fita new shaft seat 9. Reverse rotation = Change over two phases of the power supply cable 10. Rotational speed is too low 3) increase speed 11, Excessive wear of the pump internals — Replace worn components by new ones ‘Actvia Park, Germiston Yeletax (011) 822-2013, KSB PUMPS (SA) (PTY) LTD. P.O. Box 2958, Prose 1416 Gor North Reet & Activa Roads, ‘ermal: ksbsales@gbobal co za Cause ~ Remedy!) 12. Pump back pressure is lower than specified in the purchase order = Accurately set the duty point = In ease of persistent overloading, trim the impeller(s] if necessary 2) 13. Specific gravity or viscosity of the fluid pumped is higher than specified in the purchase order ="2) 18, Excessive rotational speed = Reduce speed = 2) 16. Tiebotts/O-rings = Tighten up the bolts = Fitnew O-rings 17. Worn shaft seal = Check condition of shaft seal and renew it it neces sary = Check flushing liquid or sealing liquid pressure 18. Grooving, score marks of roughness on shaft protecting sleave/shatt slaove surface — Fit new shaft protecting sleeve/shaft sleeve = Fit new shaft seat 21. The pump runs noisily = Correct the suction conditions = Check alignment of pump set and realign f necessary = Rlebalance the pump rotor — Increase the suction pressure at pump suction nozzle 22. Pump set misaligned = Check alignment at coupling and ealign the set if necessary. 23. The pump is warped or resonance vibrations in the piping = Check the piping connections and pump fixing bolts, if necessary reduce the distance between the pipe clamps — support the piping using vibration absorbing material 24, Excessive axial thrust 3) = Clean out balance holes in impetter 25, Too much, little or unsuitable lubricant quality = Reduce quantity of or top up Iubricant or change lubricant quality 26. The specified coupling gap has not been maintained = Restore correct coupling gap in accordance with the data on the installation plan 28. The motor is running on two phases only = Replace the defective fuse Check electrical connections : 30. The rotor is out of balance ~ Rebalance the roto: dynamically 31. Defective bearings — Fit new bearings 32, Ineufficient rate of flow = Increase the minimum rate of flow 33, Faults in the circulation liquid supply —"Inerease the cross-section of the circul Tine, 1 The pump should bemade prestussiess before attempting to remedy faults in parts under pressure 2] Please refer to KSB. ion liquic Johannesburg Head Offce Tal. (011) 876-8600 062 372.3710 Cope Town Branch Gal. (083) 673.3119 Durban Beanch Tal (031) 208-1111 Noteprutt Branch Tal (013) 748-70707746.7798 Port Etzabeth Branch Tel, (081) 379-1490, Secunde Tat (017) 694-1402 Veroeriging Branch ‘al (096) 421-4825 Zululand Branch Tel (038) 780-0019,