KSB RPH-V
Contents
1. Fig 3 Soleplate settle 5 4 On a nozzle of a pressure vessel In this case the pump set is supplied on a flange that will cover close the tank vessel Normal procedures recommended for flange connection should be applied i e parallelism between the contact faces smaller than 0 5 mm and leveling deviation smaller than 0 1 mm meter 5 5 Aligning the pump drive The pump unit consisting of pump coupling and drive has been mounted on a common baseplate and carefully aligned in the manufacturing works The following instructions also apply to units not mounted on a common baseplate After connecting the piping and priming the system it is essential to re check the alignment at operating temperature Incorrect alignment inadmissible coupling displacement will affect the operating behavior and may result in damage to the bearings and shaft seals as well as premature coupling wear Please note The pump set is correctly aligned if a straight edge placed axially on both coupling halves is the same distance from each shaft at all points around the circumference In addition the distance between the two coupling halves must remain the same all around the circumference Use a feeler gauge a wedge gauge or a dial micrometer to verify see figs 4 and 5 Straight edge Straight edge Gauge Fig2. KSB RPH V Vertical Process Pump according to API 610 as per Directive 94 9 EC Works N Type series These operating instructions contain fundamental information precautionary notes Please read the manual thoroughly prior to installation of unit connection to the power supply and commissioning t is imperative to comply with other operating instructions referring to components of this unit the unit s location of operation or directly This manual shall always be kept close to on the pump set KSB Bombas Hidr ulicas SA Rua Jos Rabello Portella 400 Varzea Paulista SP 13220 540 Brazil http www ksb com phone 55 11 4596 8500 Fax 55 11 4596 8580 SAK KSB Customer Service e mail gqualidade ksb com br Fax 55 11 4596 8656 KSB b Contents 1 General 2 Safety 2 1 Marking of Instructions in the manual 2 2 Personnel qualification and training 2 3 Non compliance with safety instructions 2 4 Safety awareness 2 55 Safety instructions for the operator user 2 6 Safety instructions for maintenance inspection and installation work 2 7 Unauthorized modification and manufacture of spare parts 2 8 Unauthorized modes of operation 2 9 Explosion protection 2 9 1 Unit fill 2 9 2 Marking 2 9 3 Checking the direction of rotation 2 9 4 Pump operating mode 2 9 5 Temperature limits 2 9 6 Maintenance 3 Transport and interim storage 3 1 Transport 3 2 Int
3. performed by authorized qualified specialist personnel who are thoroughly familiar with the manual pump must have cooled down to ambient temperature pump pressure must have been released and the pump must have been drained Work on the machine unit must be carried out only during standstill The shutdown procedure described in the manual for taking the unit out of service must be adhered to without fail Pumps or pump units handling fluids injurious to health must be decontaminated Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated Please observe all instructions set out in the chapter on Commissioning before returning the unit to service 2 7 Unauthorized modification and manufacture of spare parts Modifications or alterations of the equipment supplied are only permitted after consultation with the manufacturer and to the extent permitted by the manufacturer Original spare parts and accessories authorized the manufacturer ensure safety The use of other parts can invalidate liability of the manufacturer for consequential damage 2 8 Unauthorized modes of operation The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance with its designated use as described in the following sections The limits stated in the data sheet must not be exceeded
4. 6 1 4 Checking the direction of rotation Observe permissible temperature classes When the unit has been connected to the electric power supply verify the following local and national regulations have to be taken into account separately For trouble free operation of the pump the correct direction of rotation of the impeller is of paramount importance If running in the wrong direction of rotation the pump cannot reach its duty point vibrations and overheating will be the consequence The unit or the shaft seal might be damaged Correct direction of rotation The direction of rotation must correspond to the direction indicated by the arrow on the pump Never put your hands or any other objects into the pump The motor s direction of rotation must checked with the pump motor coupling removed If the motor runs in the wrong direction of rotation interchange two of the three phases in the control cabinet or motor terminal box The safety instructions set forth in section 2 9 3 must be complied with 12 kse b Fig 8 Decoupled drive 6 1 5 Cleaning the sump or pressure vessel N The cleaning operation mode and duration for flushing and pickling service must be matched to the casing and seal materials used 6 1 6 Start up Before starting the pump ensure that the shut off element in the suction line if any is fully open The pump may be started up against a closed discharge side swing
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6. 7 3 Drainage disposal Caution pump was used for handling liquids posing health hazards see to it that there is no risk to persons or the environment when draining the fluid All relevant laws must be heeded If required wear safety clothing and a protective mask If the fluids handled by the pumps leave residues which might lead to corrosion when coming into contact with atmospheric humidity or which might ignite when coming into contact with oxygen then the unit must be flushed through neutralized and then for drying purposes anhydrous gas must be blown through the pump The flushing fluid used and any liquid residues in the pump must be properly collected and disposed of without posing any risk to persons or the environment 7 4 Dismantling N Before dismantling the pump secure it so as to make sure it cannot be switched on accidentally The shut off valve in the discharge line must be closed The pump set must have cooled down to ambient temperature pump pressure must have been released and the pump must have been drained including oil of bearing housing if any Dismantling and reassembly must always be carried out in accordance with the relevant sectional drawing 15 7 4 1 Fundamental instructions and recommendations Repair and maintenance work to the pump must only be carried out by specially trained personnel using original spare parts see 2 7 Observe the safety regulations laid down i
7. in accordance with state of the art technology it is manufactured with utmost care and subject to continuous quality control These operating instructions are intended to facilitate familiarization with the unit and its designated use The manual contains important information for reliable proper and efficient operation Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the unit and to avoid any risks These operating instructions do not take into account local regulations the operator must ensure that such regulations are strictly observed by all including the personnel called in for installation This pump unit must not be operated beyond the limit values for the fluid handled capacity speed density pressure temperature motor rating specified in the technical documentation Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation Contact the manufacturer if required The nameplate indicates the type series size main operating data and works number please quote this information in all queries repeat orders and particularly when ordering spare parts If you need any additional information or instructions exceeding the scope of this manual or in case of damage please contact KSB s nearest customer service centre For noise characteristics please refer to section 4 3 7 2 Safety The
8. 18 Couple the motor 801 fixing it to the drive lantern 341 Note In the case of pumps with columns above 3 meters it should be assembled in the well and complying with the sequence already described 7 5 5 Tightening torques Stud Stud Hex Head Bolt Stud PART N 902 31 901 29 901 3 902 13 MATERIAL Steel A193 Gr B7 SAE1045 8 8 Steel A193 Gr B7 AISI 316 AISI 316 TORQUE N m 90 80 90 80 __ 80 90 80 __ 50 0 50 1 10 50 180 40 N a gt gt n 18 KSB 7 5 6 Diametral clearances Suction side Minimum Clearance gap Discharge side Minimum Clearance gap Pump size Casing wear ring clearance gap acc to AN 1501 Casing wear ring clearance gap acc to AN 1501 Nominal ID acc to API 610 Gr 2 standard Nominal ID acc to API 610 Gr 2 standard ew e os 0 6 95 0 6 40 181 95 0 35 0 35 40 230 80 0 33 0 5 0 33 0 5 5 80 s o Dem om o Dem om oe Dem om oe 50 180 120 0 4 0 6 120 0 4 0 6 50 200 110 0 38 0 6 0 35 0 6 94 All the dimensions are in milimeters The performance curves are based on the standard clearances For any change in efficiency please consult KSB 7 6 Spare parts stock When ordering spare parts please indicate pump type and size Production Order number part name and numb
9. 2 2 1 The correct function of the shaft seal must be checked regularly Any auxiliary systems installed must be monitored if necessary to make sure they function correctly Gland packings must be tightened correctly to prevent excessive temperatures due to packings running hot 3 Transport and interim storage 3 1 Transport The transport of motor pump set or only pump should be made with ability and sound sense according to safety standards By the motor eyebolt should only lift it never the motor pump set If the pump unit slips out of the suspension arrangement it may cause personal injury and damage to property Assembled unity Column up to 3 meters The unity should be transported and stored in the horizontal position Lifting cable should be placed only in the pump casing and drive lantern To introduce the pump in the well place the lifting cables in the soleplate eyebolt and lift the equipment to vertical position Fig 1 Assembled unity Single parts column above 3 meters Pump casing suspension piping shaft bearings rising pipe Pump is transported partially disassembled therefore single parts should be transported and stored in the horizontal position except for drive lantern and soleplate Fig 2 Pump casing and part of column pipe b 3 2 Interim storage
10. 212 against the pump shaft 211 with placed split rings 501 Fix them with split coupling 853 and studs 902 22 Fasten the bearing bracket lantern 344 on the soleplate 893 or flange Place the suspension piping 713 1 and bearing spider 383 15 fixing them to the bearing bracket lantern 344 and to the suspension piping 713 2 Fix the rising pipe 711 on the soleplate or flange Connect the pipings 700 to the fittings 720 7 5 3 Shaft seal assembly Check the correct variant and proceed as below 7 5 3 1 Mechanical seal installation The following rules must be observed when mounting the mechanical seal Extreme care and cleanliness during assembly are of overriding importance for trouble free operation of the mechanical seal The protective wrapping of the contact faces shall only be removed immediately before assembly takes place After inserting the seat ring check whether it is plane parallel in relation to the casing part Max deviation 0 02 mm The surface of the shaft protecting sleeve must be absolutely clean and smooth and the sleeve s mounting edge must be chamfered When sliding the rotating unit onto the shaft protecting sleeve take appropriate steps to protect the shaft protecting sleeve s surface from damage On pumps with double acting mechanical seal the mechanical seal chamber must be properly vented and the required pressure specified in the installation plan must be applied also
11. 4 Aligning the coupling with the help of a gauge and a straight edge RPH V Straight edge Gauge Fig 5 Aligning a spacer type coupling The radial and axial deviation between the two coupling halves must not exceed 0 1 mm The alignment of the pump and drive shall preferably be checked by means of a dial micrometer For this purpose remove the coupling spacer after having marked its installation position by dotting marks balancing condition At the same time check the motor s direction of rotation with the pump decoupled see 6 1 4 The direction of rotation must correspond to the direction indicated by the arrow on the pump Verify by switching the motor on and then off again immediately Fig 6 illustrates examples of possible dial micrometer arrangements Fig 6 Aligning a spacer type coupling with a dial Micrometer Admissible run out of coupling face axial max 0 1 mm Admissible radial deviation measured over the complete circumference max 0 2 mm 5 5 1 Aligning the complete unit To align the complete unit undo bolt 901 4 and fixing bolts 901 61 on the assembling aid if any Undo pump fastening elements and align pump and motor Compensate for any differences in height between pump and motor by means of approximately sized sheet packs under the feet of the drive On pump units with larger motors horizontal motor alignment shall be effected by means of alignment devices Re tighten the bolts on
12. bearing D li with the upper bearing cover 360 Before motor coupling adjust the axial clearance 55 The axial clearance between impeller 230 pressure cover 163 must be adjusted using the adjust nut 923 2 For that tight the nut until the impeller touches the pressure cover With depth gauge with depth gauge and using the reference surfaces of the shaft end and the adjust nut 7 5 4 Reassembly general above floor down the rotor in 2 5 mm Place the half part of intermediary coupling 848 on the last intermediary shaft end 212 using the key 940 3 the washer 550 11 and the bolt 901 11 Separately pre heat the bearing and inner spacer 504 2 by induction or oil bath up to 809 and slide them on the center sleeve 526 Place the lock washer 931 screw the bearing nut 923 tight and lock it with the lock washer Fix the deflector 508 Fix the bottom bearing cover 360 1 or the bearing casing 350 and gasket 400 5 to the bearing bracket lantern 344 Assemble the drive lantern 341 in the bearing bracket lantern 344 with the bolts 901 9 Place the key 940 1 and the bottom half coupling 840 fixing it to the shaft with a grub screw Lift the pump set by the eye bolts 900 2 and place it on the foundation rail 89 8 if any fixing it with the bolts 920
13. during standstill Quench liquid supply must also be ensured during pump standstill 7 5 3 2 Mounting the gland packing Always use pre stressed packing rings if possible Mount as follows Mount shaft protecting sleeve 524 02 if any onto the shaft using grub screws 904 2 Insert the first packing ring into the stuffing box housing Insert lantern ring 458 in such a way that the joint face is offset from the cut edge of the packing ring Insert other packing rings with their cut edge displaced by 90 Slip on gland cover 452 Slightly tighten gland cover by hand using the two hex nuts 920 13 Caution The gland packing has no contact with the liquid handled and only seals against splashes and slight gas pressure Therefore the gland cover shall only be tightened slightly Dimensions of the packing chamber number of packing rings 17 KSB RPH V Put the outer spacer 504 1 into the bearing housing 350 Mount the sub assembly spacer sleeve bearing into it gt Put the drive shaft 213 with key 940 2 inside the mcm xi spacer sleeve Place the slip thrower 507 if any and E bearing guard on to the bottom bearing cover Align it with the intermediary coupling 848 and lock the ring 500 Place the upper part of intermediary coupling spacer and 270 fix it with the bolts 901 12 Place the flat gasket 400 3 the slip thrower 507 if any i bearing guard 423 1 and close the support
14. indoors Preservation KSB standard storage and preservation procedures maintain the pump protected for a maximum period of 6 months in a indoor installation The unit pump should be stored in a dry room where the atmospheric humidity is as constant as possible When this period is exceeded additional storage procedure should be taken For that please use the following conservation liquids Internal parts of ferrous material in contact with pumped liquid except mechanical seal contact surfaces water repellent of mineral oil basis Bearings mineral oil for internal conservation Polished parts mineral oil for internal and external conservation Mechanical seals should be cleaned by dry air Do not apply any liquid or other conservation material in order to not damage secondary sealings O rings and flat gaskets All existing connections like plugs for external source liquid priming drainage etc should be properly covered Pump suction and discharge flanges are properly covered with adhesive in order to avoid strange contents in its interior Assembled pumps waiting for start up or installation should have their rotor manually rotated each 15 days In case of difficulty use some adjustable spanner protecting the motor shaft surface Before conservation liquids application areas should be washed with gas or kerosene until they are completely cleaned The conservative liquids can be removed from the
15. internal work operation and safety regulations Ex Ex symbol relates to additional requirements which must be adhered to when the pump is operated in hazardous areas 2 5 Safety instructions for the operator user hot or cold components that could pose a hazard must be equipped with a guard by the operator Guards which are fitted to prevent accidental contact with moving parts e g coupling must not be removed whilst the unit is operating Leakages e g at the shaft seal of hazardous fluids handled e g explosive toxic hot must be contained so as to avoid any danger to persons or the environment All relevant laws must be heeded Electrical hazards must be eliminated In this respect refer to the relevant safety regulations applicable to different countries and or the local energy supply companies Any components in contact with the fluid pumped especially in the case of abrasive fluids shall be inspected for wear at regular intervals and replaced by original spare parts see section 2 7 in due time If the pumps units are located in hazardous areas it is imperative to make sure that unauthorized modes of operation are prevented Non compliance may result in the specified temperature limits being exceeded 2 6 Safety instructions for maintenance inspection and installation work The operator is responsible for ensuring that all maintenance inspection and installation work
16. o 505 20 se 8 RPH V Troubleshooting Excessive pump discharge temperature inside the pump Pump delivers insufficient pressure flow rate Excessive leakage at the shaft seal Vibration during pump Motor is overloaded Increase in bearing Leakage at the pump operation temperature Excessive rise of Pump delivers against an excessively high discharge pressure Excessively high back pressure Pump or piping are not completely vented or primed Supply line or impeller clogged Formation of air pockets in the piping Re adjust duty point Check plant for impurities Increase the speed turbine engine Vent and or prime Remove deposits in the pump and or piping Alter piping layout Fit a vent valve Pump is warped or sympathetic vibrations in the piping Suction head is too high NPSH available positive suction head is too low Increased axial thrust Air intake at the shaft seal Reverse rotation Motor is running on two phases only Speed is too low 2 Defective bearings Insufficient rate of flow Wear of internal pump parts Pump back pressure is lower than specified in the purchase order Density or viscosity of the fluid pumped is higher than stated in the purchase order Use of unsuitable materials Speed is too high Tie bolts seals and gaskets Worn shaft seal Score marks or roughness on shaft protec
17. pump is removed from the pipe and stored Before putting the pump into storage carry out all checks specified in sections 7 1 to 7 4 Then apply appropriate preservatives Spray coat the inside wall of the pump casing and in particular the impeller clearance areas with preservative Spray the preservative through the suction and discharge nozzles It is RPH V advisable to close the pump nozzles e g with plastic caps or similar 6 4 Returning to service after storage Before returning the pump to service carry out all checks and maintenance work specified in sections 7 1 and 7 2 In addition the instructions laid down in the sections on Commissioning 6 1 and Operating Limits 6 2 must be observed i Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated 7 Servicing maintenance 7 1 General Instructions The operator is responsible for ensuring that all maintenance inspection installation work be performed by authorized qualified specialist personnel who are thoroughly familiar with the manual A regular maintenance schedule will help avoid expensive repairs and contribute to trouble free reliable operation of the pump with a minimum of maintenance expenditure and work Work on the unit must only be carried out with the electrical connections disconnected Make sure that the pump set cannot be switched on acc
18. pump shaft 211 together with the impeller 230 Take out spiral wound gasket 411 31 loosen impeller nut 922 and remove impeller 230 together with gaskets 411 Remove the key 940 5 the seal ring 400 33 and the shaft protective sleeve 524 If it is necessary to disassemble the bearing bush 545 27 of pressure cover 163 use an extractor The bearing bush 545 of spider bearing 383 can be removed by means of a press 7 4 3 Check of wears Impeller Check damage caused to impeller due to corrosion cavitation or erosion and if necessary replace the impeller When the clearance between the impeller and casing wear rings reach the double of specified value replace them Bearings Column and thrust Do not use disassembled rolling bearings again Use only specified bearings The clearances between the bearing sleeves 529 shaft protective sleeve 524 and bearing bush 545 can not exceed the values of 0 17 mm up to 0 3 mm If exceeding these values these parts should be changed Please observe methods of fixation of the bushes indicated on cross sectional drawing For certain bush materials are necessary a bonding agent and grub screws due to shrink characteristic Eventual machining in the sleeves can also be done in order to eliminate superficial defectives since the clearance is maintained Shaft Sealing Check damage at shaft protective sleeve and if it is possible machine it if not it is necess
19. the pump foot and the motor bolts If any tighten fixing bolts 901 61 as well as bolt 901 4 and re check alignment For subsequent alignment at operating temperature proceed in the same way If other couplings are used please refer to the enclosed supplementary operating instructions 5 6 Connecting the piping Never use the itself as Caution anchorage point for the piping The permissible pipeline forces must not be exceeded see section 4 3 5 The pipelines shall be anchored in close proximity to the pump and connected without transmitting any stresses or 10 se strains nominal diameters of the pipelines shall be at least equal to the nominal diameters of the pump nozzles It is recommended to install check and shut off elements in the system depending on the type of plant and pump It must be ensured however that the pump can still be drained and dismantled without problems Thermal expansions of the pipelines must be compensated by appropriate measures so as not to impose any extra loads on the pump exceeding the permissible pipeline forces and moments 4 An excessive impermissible increase in the pipeline forces may cause leaks on the pump where the fluid handled can escape into the atmosphere Danger of life when toxic or hot fluids are handled The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping After the piping has bee
20. the scope of warranty 6 1 Commissioning Before starting up the pump make sure that the following requirements have been checked and fulfilled If a constant level oiler is provided screw same into the tapping hole provided in the bearing bracket prior to adding the oil see 6 1 1 The connection between bearing bracket and constant level oiler shall be sealed with PTFE tape if necessary The operating data the oil level if applicable 6 1 1 and the direction of rotation 6 1 4 must have been checked The pump must have been primed 6 1 3 Also verify the following sure that the unit has been properly connected to the electric power supply and is equipped with all protection devices Make sure that all auxiliary lines 5 4 1 are connected and functioning f the pump has been out of service for a longer period of time proceed in accordance with section 6 4 6 1 1 Lubricants Oil lubricated bearings The bearing bracket has to be filled with lubricating oil The oil quality required is outlined in section 7 2 2 3 and the quantity in section 7 2 2 4 11 Oil levelin reservcir during filling procedure wer Vent filler plug Oil level in bearing bracket and connection elbow Position of reservoir for topping up oil Fig 7 Oil fill Procedure Remove the protective cage of the constant level oiler Unscrew vent plug Pour in the oil through the vent plug tapping hole
21. up 13 Shutdown 13 Operating limits 13 Temperature of the fluid handled ambient 13 temperature bearing temperature Switching frequency 13 Density of fluid pumped 13 Abrasive fluids 13 Minimum maximum flow 14 Shutdown storage preservation 14 Storage of new pumps 14 Measures to be taken for prolonged 14 shutdown Returning to service after storage 14 Servicing Maintenance 14 General instructions 14 Servicing inspection 14 Supervision of operation 14 Lubrication and lubricant change 15 Drainage disposal 15 Dismantling 15 Fundamental instructions and 16 recommendations Dismantling general 16 Check of wears 16 Reassembly 17 General instructions 17 Re assembly general below floor and 17 bearing bracket lantern Shaft seal assembly 17 Reassembly general above floor 18 Tightening torques 18 Diametral clearances 19 Spare parts stock 19 Recommended spare parts stock for 2 19 years operation Interchangeability of pump components 20 Troubleshooting 21 Sectional drawing 22 KSB RPH V Introduction KSB has supplied you an equipment that has been designed and manufactured with the latest technology Due to its simple and tough construction it will need few maintenance With the aim to provide our clients with a satisfactory trouble free operation we recommend to install and care our equipment according to the instructions contained in this service manual This manual has been prepared to inform the end us
22. 16WCB amp temperature lt 100 For other condition please consult KSB 4 4 Accessories Coupling flexible coupling If a complete unit is supplied coupling and coupling guard are provided by the supplier Special accessories as required 4 5 Dimensions and Weights For dimensions and weights please refer to the general arrangement drawing of the pump 5 Installation at site Pumps should be installed leveled and aligned by qualified people When this service is inappropriate executed it can have as consequence operation troubles premature wear and irreparable damage Foundation Plan drawing FU informs pump dimension weights foundation arrangement connection sizes and position of fixation elements Assure that all parameters for handling and operation access assembly area connections for assembly equipment cranes etc were perfectly established before pump installation activities 5 1 Safety regulations Ex Equipment operated in hazardous locations must comply with the relevant explosion protection regulations This is indicated on the pump name plate and motor name plate see 2 9 5 2 Checks to be carried out prior to installation All structural work required must have been prepared in accordance with the dimensions stated in the dimension table general arrangement plan In case of concrete foundations they shall have sufficient strength min class X0 to ensure safe and functional installati
23. 2 2 2 _ 2 2 2 2 2 2 A A A A A A A A A A Ms 2 2 27 2 272 2 2 216 8 27716 v Ov6 12106 27024 260027 2648 763 16106 00v 7 lt lt 106 7066 0084 2 026 27044 066 NN 022 2126 Sev 916 266 Lev 6 026 92706 208 LOSvS Main parts list Description CENTER SLEEVE o c c n Description BEARING COVER SPIDER SPIDER o c n Description VOLUTE CASING 526 529 15 360 383 15 102 BEARING SLEEVE 143 161 211 STRAINER OPTIONAL CASING COVER PUMP SHAFT 529 21 BEARING SLEEVE 383 21 638 711 1 CONSTANT LEVEL OILER RISING RISING 411 31 SPIRAL WOUND 433 452 458 461 MECHANICAL SEAL GLAND COVER LANTERN RING 212 INTERMEDIARY SHAFT DRIVE SHAFT IMPELLER BEARING 711 2 713 1 713 2 922 923 213 SUSPENSION PIPING 230 321 341 SUSPENSION PIPING IMPELLER NUT BEARING NUT GLAND PACKING WEAR RING 502 503 524 DRIVE LANTERN IMPELLER WEAR RING SHAFT PROT SLEEVE 344 350 BEARING BRACKET LANTERN BEARING CASING 23
24. Bearing bracket temperature see 7 2 1 The safety instructions set forth in section 2 9 must be complied with 6 2 2 Switching frequency To prevent high temperature increases in the motor and excessive loads on the pump coupling motor seals and bearings the switching frequency shall not exceed the following number of start ups per hour S Motor rating kW max S start ups h If the above switching frequencies are exceeded please contact the motor manufacturer or KSB 6 2 3 Density or fluid pumped The power input of the pump will increase in proportion to the density of the fluid pumped To avoid overloading of the motor pump and coupling the density of the fluid must comply with the data specified on the purchase order 6 2 4 Abrasive fluids When the pump handles liquids containing abrasive substances increased wear of the hydraulic system and 13 the shaft seal are to be expected The intervals recommended for servicing and maintenance shall be shortened 6 2 5 Minimum Maximum flow For max flow Qmax please refer to the characteristic curves Unless other limits are specified in the characteristic curves or data sheet the minimum flow for 50 Hz and p 7 1 2 kg dm 60 Hz and p 7 1 0 kg dm IS Qin 0 3 x Qopt Qopt optimum efficiency The data refer to water and water like liquids However if the physical properties of the fluids handled are different from water the calculatio
25. Sound pressure level L pA db Pump only Pump with motor 1 min 1 min 1 min 1 min 1 min 1 min 75 620 600 580 715 655 640 110 640 620 600 735 675 655 150 655 635 615 745 690 670 220 675 660 635 760 705 685 300 690 675 650 770 715 695 370 700 685 660 775 720 705 750 740 720 690 795 750 730 900 750 730 700 800 755 740 Measured at a distance of 1m from the pump outline as per DIN 45635 Part 1 and 24 Room and foundation influences have not been included The tolerance for these factors is 1 to 2 dB Increase for 60 Hz operation Pump without motor Pump with motor 3500min 1 3dB 1750min 1 1dB 1160min 1 dB se 4 3 7 Technical data table Volute type Outlet width Impeller Inlet diameter Impeller maximum diam Sealing chamber size Acc to API 682 Table 1 pearing in the sealing chamber Shaft diameter in the bearing in the coupling in the impeller Driver Maximum Value kW rpm n 1450 rpm Motor maximum 1 1750 rpm n 2900 rpm n 3500 rpm RPH V Simple 179 224 1 224 205 207 180 230 276 278 343 180 6313 112 1 Theindicated values for shaft material A434 4140 CL BB and impeller in A2
26. after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of the connection elbow Fig 7 Then fill the reservoir of the constant level oiler with oil and snap it back into operating position Screw vent plug in again After a short time check whether the oil level in the reservoir has dropped It is important to keep the reservoir properly filled at all times If access to the vent plug is difficult or impossible e g in cases where the motor is arranged above the pump piggy back arrangement the oil can be filled in through the connection elbow of the constant level oiler 8 The oil level shall always be below the level of the vent opening arranged at the top edge of the connection elbow During pump standstill the oil level can be checked at the oil level sight glass Grease lubricated bearings This option provides a bearing sealed on both sides and lubricated for life with a special grease ref SKF GJN For replacements consider this characteristic 6 1 2 Shaft seal Gland packings supplied with the pump Caution have to be installed prior to pump startup unless they were fitted prior delivery The gland packing must be tightened gently and evenly It must be easy to rotate the shaft by hand The mechanical seal has been fitted prior to delivery On variants with quench supply tank the tank must be fitted in accordance with the general arrangement drawing see a
27. areas in contact with pumped liquid polished parts and surfaces like shaft salient faces and couplings by means of solvents derived from petroleum or clean industrial liquids Drain the conservative oil from bearing bracket before fulfill it with lubricant oil 4 Description of the product and accessories 4 1 Technical specification Chemical shaft driven sump pump Fields of application Used in the chemical and petrochemical industry as well as in refineries for handling chemically aggressive media with low solids content 4 2 Designation RPH V 40 180 Type _______ Vertical execution Discharge nozzle DN Nominal impeller dia in mm For materials refer to the data sheet RPH V 4 3 Design details Vertical radially split shaft driven sump pump with volute casing in wet or dry installation single stage 4 3 1 Pump casing Radially split consisting of single volute casing and casing cover For handling combustible media the pump casing the pipe assembly and the flanged elbow must be made of ductile material with a maximum magnesium content of 7 5 see EN 13463 1 This is a standard feature in all KSB supplies 4 3 2 Impeller form Closed radial impeller with multiply curved vanes Axial thrust is balanced by means of suction and discharge side casing wear rings and balancing holes 4 3 3 Shaft seal Shaft sealing is effected by gland packing special variant or single or double acting me
28. ary to replace it Check damage of mechanical seal rotative and stationary faces and if necessary re lapping or replace them Sealings Check damages in the O rings and substitute them if necessary Substitute the flat gasket O rings and spiral wound gasket Certify that the new parts have the same size and thickness of the old ones Note In case of column above 3 meters the pump should be disassemble at the sump in the sequence already described 16 7 5 7 5 1 General instructions The pump shall be reassembled in accordance with the rules of sound engineering practice Clean all dismantled components and check them for signs of wear Verify the dimensions given in section 7 5 5 Damaged or worn components are to be replaced by original spare parts Make sure that the seal faces are clean and that the sealing elements are properly fitted Always use new sealing elements O rings gaskets whenever the pump is reassembled Make sure that new gaskets have the same thickness as the old ones Gaskets made of graphite or other asbestos free materials must always be fitted without using lubricants such as copper grease or graphite paste Avoid the use of mounting aids as far as possible Should a mounting aid be required after all use a commercially available contact adhesive e g Pattex The adhesive shall only be applied at selected points 3 to 4 spots and in thin layers Do not use c
29. chanical seals The shaft seal is located in a replaceable stuffing box housing and can be removed and re installed without having to dismantle the pump Caution It is recommended to use sealing plans with an external source plans 32 52 53 54 to lubricate the mechanical seal faces in order to avoid dry run during start up For other sealing plans and gland packing applications consult KSB Arrangement drawing examples Gland packing Mechanical seal 4 Mechanical seal double acting Mechanical seal single acting KSB RPH V 4 3 4 Bearings The shaft assembly is fixed in axial direction by means of a deep groove ball bearing The bearing can be oil or grease lubricated In the volute casing and in the pipe assemblies the shaft is supported in plain bearings lubricated by the pumped liquid If contaminated fluids are handled the bearings can be lubricated from an external source via a lubricating line special design 4 3 5 Permissible forces and moments at the discharge nozzle RPH V pumps are designed in such way that they can withstand piping forces and moments acc to API 610 The data on forces and moments apply to static pipelines only If the limits are exceeded they must be checked and verified The values are only applicable if the pump is installed on a completely grouted soleplate 4 3 6 Noise characteristics
30. check valve or slightly open shut off valve Only after the pump has reached full rotational speed shall the shut off valve in the discharge line be opened slowly and adjusted to comply with the duty point When starting up against an open discharge side shut off valve take the resulting increase in input power into account Pump operation with the shut off valves in the discharge suction pipes closed is not permitted The permissible pressure and temperature limits might be exceeded In extreme cases the pump may burst After the operating temperature has been reached and or in the vent of leakage switch off the unit and re tighten the bolts between volute casing and casing cover Permissible tightening torques see 7 5 3 Check the coupling alignment at aution operating temperature as described in section 5 3 1 and re align if necessary Immediate steps after start up After start up and with pump in process please observe the following items a Control electric power consumption amperage and voltage b Certify that the pump runs free of vibration and abnormal noises c Control support bearing temperature which can reach up to 40 C above ambient temperature however the sum of them can not exceed 82 C The above items should be controlled each 15 minutes during the first 2 hours operation If everything is normal new controls should be made each 1 hour during the first 5 up to 8 hours If there is any
31. d also exists during the installation phase the direction of rotation must never be checked by starting up the unfilled pump unit even for a short period to prevent temperature increases resulting from contact between rotating and stationary components 2 9 4 Pump operating mode Make sure that the pump is always started up with the suction side shut off valve fully open and the discharge side shut off valve slightly open However the pump can also be started up against a closed swing check valve The discharge side shut off valve shall be adjusted to comply with the duty point immediately following the run up process see 6 1 7 Pump operation with the shut off valves in the suction and or discharge pipes closed is not permitted In this condition there is a risk of the pump casing taking on high surface temperatures after a very short time due to a rapid temperature rise in the pumped fluid inside the pump Additionally the resulting rapid pressure build up inside the pump may cause excessive stresses on the pump materials or even bursting The minimum flows indicated in section 6 2 5 refer to water and water like liquids Longer operating periods with these liquids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface However if the physical properties of the fluids handled are different from water it is essential to check if an additional heat build up may occur a
32. e shaft 213 and intermediary coupling 848 Loosen the bolts 901 5 and remove the bearing casing 350 Loosen the nuts 920 13 and take out the mechanical seal 433 For gland packing undo hex nuts 920 13 and take off gland cover 452 Remove packing rings 461 lantern ring 458 if any and the packing rings behind the lantern ring from stuffing box housing 451 02 Remove the bearing bracket lantern 344 from the soleplate 893 or flange loosening the nuts 920 17 and studs 902 17 This action depends on seal plan piping tubing X arrangement Check before if any piping tubing will collide with it and remove them previously Remove the pipings 710 disconnecting them from their connections 720 Remove the rise piping 711 and discharge curve 144 loosening the nuts 920 19 and bolts 901 33 respectively RPH V Before loosening the suspension piping 713 1 from soleplate 893 or flange sustain the pump on a piece of wood Remove the nuts 920 18 and loosen the soleplate with auxiliary of a crane Loosen the suspension piping 713 1 with the spider bearings 383 Proceed removing the suspension piping 731 extracting the intermediary shaft 212 and the pump shaft 211 which are coupled together with a split coupling 853 Remove the bearing sleeves 529 from the shaft which are radially fixed by means of grub screws 904 Separate the volute casing 102 from pressure cover 163 and remove
33. e the impeller Increase the pressure at the pump suction nozzle Check the coupling re align if required Top up reduce or change lubricant Correct distance according to the G A Drawing Increase the voltage Clean the impeller Re balance the impeller 1 Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure 2 Request particulars 21 RPH V 22 8L 00 87206 VOSS 706 lt 704 8 006 V oc6 27706 126 22706 106 046 108 206 L Ov6 eic 6 lt 007 060 6 106 925 2 705 47916 226 600 179 L106 878 06 ccv 400 GL 9L6 8 68 SL106 gt C o PY O wa 555 iA 27777777727 A 2 D e N 699 2 NEAN E AAN 2 06 17 06 0 06 Z LOS ZINN VY NA STF 5 es E gt 4 2 22422 AN Ly yy KX x lt lt lt lt VG SIN nist aN
34. er These information can be obtained from the Data Sheet Sectional Drawings and Parts List 7 6 1 Recommended Spare parts for a 2 years operation to DIN 24296 NUMBER OF PUMPS including stand by pumps PART DENOMINATION 2 3141516 8 _ Parts Quantity emm Dro es fomo fee 8 mm _ If fitted 19 sb 2202 7 6 2 Interchangeability of pump components INTERMEDIARY SHAFT MECHANICAL SEAL SUCTION WEAR RING DISCHARGE WEAR RING DISCHARGE IMPELLER WEAR RING SHAFT PROTECTIVE SPIRAL CASING 143 STRAINER 4 161 CASING COVER e eoe 21 PUMP SHAFT a 25 180 2 72 7 p dz NO 43 922 IMPELLER NUT ee T courne 321 30 esame casine 380 esame cover RRRRRRRRRRRRECTAETZTIDTI RRRRRRRRRRRRECCNEZ TET afer oo 41 31 SPIRAL WOUND RRRRRRRRRRRRECINEZ TET bs oo oo oo oo oo oo 4232 BEARING GUARD RRRRRRRRRRRREENI ITA amp z 8 e e s e e o 20 IMPELLER RRRRRRRRRRRREE o o o 5024 o o o o
35. er about construction and operation of our pumps describing the proper procedures for handling and maintenance We recommend that this manual should be handled by the maintenance supervision This equipment must be used at operation conditions for which it has been selected such as flow rate total head speed voltage frequency and temperature of pumped liquid Ep KSE b BEONMDAES HORA AS inti VaR ZEA PAULISTA description of FONE 25 11 4556 8500 pump size Field for Em Field for n Field for technical 4 VERTES VI Production Order data Bearings P O Hydrost T kg em MAW TAGI p Year Fig 1 Nameplate For requests about the equipment or when ordering spare parts please mention the type of the pump and the Production Order number serial n This information can be obtained from the nameplate of each pump If the nameplate is not available the OP number is engraved in low relief on the suction flange and on the discharge flange you may find the impeller diameter Attention This manual contains very important recommendations and instructions Must be carefully read before installation electrical connection first start up and maintenance 1 Caution his KSB product has been developed
36. erating hours First oil change All subsequent oil after changes after operating hours Operating hours Temperature at the bearing up to 70 C 709 809 809 909 atleast once a year Procedure Remove screwed plug below the bearing bracket and drain off the oil After drainage of the bearing bracket screw in the plug again and fill with fresh oil as described in section 6 1 1 RPH V Please observe the local laws Caution applicable to the disposal of such substances 7 2 2 3 Oil quality Lubricating oil CLP46 DIN 51517 or HD 20W 20 SAE Symbol to DIN51502 O Designation Kinematic viscosity at 40 C 46 4 5 Flash point to Cleveland 175 Solidification point pour 15 C point higher than permissible Application temperature bearing temperature For ambient temperatures below 10 C another suitable lubricating oil type must be used Request particulars 7 2 2 4 Oil quantity 0 75 7 2 2 5 Guide bearings In the volute casing and the pipe assemblies the shaft is guided by plain bearings lubricated by the pumped liquid Periodically user should check and clean the small holes of lubricating pipes to the column bearings and mechanical seal The small holes should not be Caution clogged If the pumped liquid is contaminated the bearings are lubricated from an external source via a lubricating line special design
37. erim storage indoors preservation 4 Description of the product an accessories 4 1 Technical specification 4 2 Designation 4 3 Design details 4 3 1 Pump casing 4 3 2 Impeller form 4 3 3 Shaft seal 4 3 4 Bearings 4 3 5 Permissible forces and moments at the discharge nozzle 4 3 6 Noise characteristics 4 3 7 Technical data table 4 4 Accessories 4 5 Dimensions and Weights 5 Installation at site 5 1 Safety regulations 5 2 Checks to be carried out prior to installation 5 2 1 Place of installation 5 3 Soleplate foundation settle and leveling 5 4 On a nozzle of a pressure vessel 5 5 Aligning the pump drive 5 5 1 Aligning the complete unit 5 6 Connecting the piping 5 6 1 Auxiliary connections 5 6 2 Contact guard 5 Final check Page RA ARDEA C Ci O 222 xg 5 8 6 1 6 1 1 6 1 2 6 1 3 6 1 4 6 1 5 6 1 6 6 1 7 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 3 6 3 1 6 3 2 6 4 7 1 7 2 7 2 1 7 2 2 7 3 7 4 7 4 1 7 4 2 7 4 3 7 5 7 5 1 1 5 2 7 5 3 7 5 4 7 5 5 7 5 6 7 6 7 6 1 7 6 2 RPH V Connection to power supply 11 Commissioning start up shutdown 11 Commissioning 11 Lubricants 11 Shaft seal 12 Priming the pump and checks to be 12 carried out Checking the direction of rotation 12 Cleaning the sump or pressure vessel 13 Start
38. fluid handled In stipulating these temperatures any temperature rise in the shaft seal area has already been taken into account Temperature class to Temperature limit of EN 13463 1 fluid handled 85 C 120 C 185 C 280 C Max 400 C depending on material variant Safety note The permissible operating temperature of the pump in question is indicated on the data sheet If the pump is to be operated at a higher temperature the data sheet is missing or if the pump is part of a pool of pumps the maximum permissible operating temperature must be inquired from the pump manufacturer Based on an ambient temperature of 409 and proper maintenance and operation compliance with temperature class T4 is warranted in the area of the rolling element bearings special design is required to comply with temperature class T6 in the bearing area In such cases and if ambient temperature exceeds 40 C contact the manufacturer 2 9 6 Maintenance Only a pump unit which is properly serviced and maintained in perfect technical condition will give safe and reliable operation RPH V This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the operating mode and operating conditions Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of bearings running hot or defective bearing seals also see section 7
39. hey must be replaced in due time Re align the coupling as described in section 5 3 1 14 Supervision during Operation Depending on the labor availability and pump responsibility we recommend the following checks and in case of any abnormality the maintenance responsible should be advised immediately Weekly Supervision Check a Pump operation point Motor current consumption and tension value c Vibration and abnormal noises d Bearing housing temperature Monthly Supervision Check a Grease change interval if applicable Semestral Supervision Check a Soleplate and motor fix bolts b Pump motor set alignment Coupling lubrication when applicable Annual Supervision Disassemble the pump for maintenance After cleaning inspect bearings do it detail retainers and or bearing sealings joints O rings impeller split casing internal regions control also thickness wear areas and coupling Note In installations with good operation conditions and pumped liquid not aggressive to the pump materials the supervision can be done each 2 years 7 2 2 Lubrication and lubricant change 7 2 2 1 Lubrication The rolling element bearings are lubricated with mineral oil or grease for life The guide bearings are lubricated with the pumped fluid The lubricant change intervals as well as the required quantity and quality are specified below 7 2 2 2 Oil change op
40. identally danger to life Pumps handling liquids posing health hazards must be decontaminated When draining the fluid see to it that there is no risk to persons or environment or the environment relevant laws must be adhered to danger to life 7 2 Servicing inspection 7 2 1 Supervision of operation Caution The pump must run quietly and free from vibrations at all times The pump must never be allowed to run dry Always ensure a sufficient liquid level above the pump inlet Prolonged operation against a closed shut off valve is not permitted When operating the pump set with the shut off valve in the discharge line slightly open for short period of time the permissible pressure and temperature limits must not be exceeded A special design is required to comply with temperature class T6 in the bearing area In such cases and if ambient temperature exceeds 40 contact the manufacturer Verify correct oil level as described in section 6 1 1 The shut off elements and the auxiliary feed lines must not be closed during operation Any stand by pumps installed shall be started up regularly e g once a week to keep them operational Attention shall be paid to the correct functioning of the auxiliary connections The cooling system must be thoroughly cleaned at least once a year to ensure proper cooling Take the pump out of service for this purpose If the flexible coupling elements begin to show signs of wear t
41. iquid etc are indicated on the general arrangement drawing or piping layout These connections are required for proper functioning of the pump and are therefore of vital importance RPH V 5 6 2 Contact Guard N In compliance with the accident prevention regulations the pump must not be operated without a contact guard If the customer specifically requests not to include a contact guard in our delivery then the operator must supply one In this case it is important to make sure that the materials selected for coupling and coupling guard are non sparking in the event of mechanical contact KSB s scope of supply meets this requirement 5 7 Final check Re check the alignment as described in section 5 3 and verify the correct distance between the coupling and the coupling guard It must be easy to rotate the shaft by hand at the coupling 5 8 Connection to power supply Connection to the power supply must be effected by a trained electrician only Check available mains voltage against the data on the motor rating plate and select appropriate start up method We strongly recommend to use a motor protection device motor protection switch In hazardous areas compliance with IEC60079 14 is an additional requirement for electrical connection 6 Commissioning start up shutdown Compliance with the following requirements is paramount importance Damage resulting from non compliance shall not be covered by
42. ll personnel involved in the operation maintenance inspection and installation of the unit must be fully qualified to carry out the work involved Personnel responsibilities competence and supervision must be clearly defined by the operator If the personnel in question is not already in possession of the requisite know how appropriate training and instruction must be provided If required the operator may commission the manufacturer supplier to take care of such training In addition the operator is responsible for ensuring that the contents of the operating instructions are fully understood by the responsible personnel 2 3 Non compliance with safety instructions Non compliance with safety instructions can jeopardize the safety of personnel the environment and the machine unit itself Non compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages In particular non compliance can for example result in failure of important machine system functions failure of prescribed maintenance and servicing practices hazard to persons by electrical mechanical and chemical effects as well as explosion hazard to the environment due to leakage of hazardous substances 2 4 Safety awareness It is imperative to comply with the safety instructions contained in this manual the relevant national and international explosion protection regulations and the operators own
43. lso 6 1 3 Quench feed must also be provided during pump shutdown On variants with pressurized dual mechanical seals apply barrier pressure as specified in the general arrangement drawing prior to starting up the pump see 6 1 3 Barrier pressure must also be provided during pump shutdown RPH V For external liquid supply the quantities Caution and pressure specified in the data sheet and general arrangement drawing shall be applied 6 1 3 Priming the pump and checks to be carried out Before start up the pump suction line and thermosyphon vessel if any must be vented and primed The shut off valve in the suction line must be fully open Fully open all auxiliary lines provided flushing barrier cooling liquid etc and check the throughflow For water cooling use suitable non aggressive cooling water not liable to form deposits and not containing suspended solids Hardness on average 5dH 1 mmol l pH gt 8 or conditioned and neutral with regard to mechanical corrosion Inlet temperature te 10 to 30 C Outlet temperature ta max 45 C Caution Dry running of the pump will result in mechanical seal failure and must be avoided 6 1 3 1 Cooling Caution In general the shaft seal must be cooled if the vaporization pressure of the fluid handled is higher than the atmospheric pressure Depending on the fluid handled the system pressure and the mechanical seal material the limit may change example hot water
44. n connected it Caution must be easy to rotate the pump shaft by hand at the coupling Recommendations for suction In the pump installation please consider the following conditions a Check minimum distance from bottom well up to suction outlet or strainer according to installation see foundation plan b Check liquid minimum level above pump casing in order to avoid dry operation cavitation or vortex In case of frequent liquid level variation it should foreseen the installation of protection system against operation below the minimum level d In case of liquid with solids in suspension or with excessive dirty it should foreseen strainer in the pump inlet Recommendations for discharge piping The discharge piping assembly should comply with the following considerations a It should have disposals for water hammer control every time the overpressure values deriving from liquid return in long pipings exceeds the recommended values for piping and pump b In the points where it is necessary to extract the air it should foreseen vent valves C It is necessary to foreseen tie bolted assembly joints to absorb system reaction efforts deriving from applicable loads d Safety valves relief disposals and other operation valves besides those mentioned should foreseen when necessary 5 6 1 Auxiliary connections The dimensions and locations of the auxiliary connections cooling barrier liquid flushing l
45. n formula below must be used to check if an additional heat build up may lead to a dangerous temperature increase at the pump surface If necessary the minimum flow must be increased g H c n 1 n C Specific heat J kgK g Acceleration due to gravity m 57 H Pump head m Tt Temperature of fluid handled To Temperature of casing surface n Pump efficiency at duty point AS Temperature difference C 6 3 Shutdown storage preservation Each KSB pump leaves the factory carefully assembled If commissioning is to take place some time after delivery we recommend that the following measures be taken for pump storage 6 3 1 Storage of new pumps New pumps are supplied by our factory duly prepared for storage Maximum protection for up to 6 months if the pump is properly stored indoors Store the pump in a dry location Rotate the shaft by hand once a month 6 3 2 Measures to be taken for prolonged shutdown 1 The pump remains installed periodic check of operation In order to make sure that the pump is always ready for instant start up and to prevent the formation of deposits within the pump and the pump intake area start up the pump set regularly once a month or once every 3 months for a short time approx 5 minutes during prolonged shutdown periods Prior to an operation check run ensure that there is sufficient liquid available for operating the pump 2 The
46. n section 7 1 Any work on the motor shall be governed by the specifications and regulations of the respective motor supplier Dismantling and reassembly must always be carried out in accordance with the relevant general assembly drawing The general assembly drawing and other relevant documents are found in the annex The dismantling sequence can be derived from the general assembly drawing In case of damage you can always contact our service departments 7 4 2 Dismantling general Disconnect the auxiliary piping if any and remove the pump set and soleplate or flange from the sump or tank Put it on the horizontal position Remove coupling guard Disconnect the coupling and remove the motor Extract the half coupling of pump shaft loosening the sleeve fixing bolt before Take out the key 940 1 Remove the motor loosening it from the drive lantern 341 Extract the washer 920 17 unfastening the soleplate 893 from the foundation rail 89 8 Remove the pump from well and leave it in the horizontal position Take out the constant oil level 638 and piping 710 7 if any Remove the drive lantern 341 from bearing bracket lantern 344 loosening the bolts 901 9 Extract the adjust nut 923 2 Loosen the bolts 901 3 that fasten the bearing cover 360 and remove it Extract the center sleeve 526 with the bearing 321 using an extractor Remove the key 940 2 Loosen the bolts 901 11 to separate the driv
47. nd if the 5 minimum flow rate must therefore be increased check proceed as described in section 6 2 5 In addition the instructions given in section 6 of this operating manual must be observed Both gland packings and mechanical seals may exceed the specified temperature limits if run dry Dry running may not only result from an inadequately filled seal chamber but also from excessive gas content in the fluid handled Pump operation outside its specified operating range may also result in dry running In hazardous areas gland packings shall only be used if combined with a suitable temperature monitoring device 2 9 5 Temperature limits In normal pump operation the highest temperatures are to be expected on the surface of the pump casing at the shaft seal and in the bearing areas The surface temperature at the pump casing corresponds to the temperature of the fluid handled If the pump is heated it must be ensured that the temperature classes stipulated for the plant are observed In the bearing bracket area the unit surfaces must be freely exposed to the atmosphere In any case responsibility for compliance with the specified fluid temperature operating temperature lies with the plant operator The maximum permissible fluid temperature depends the temperature class to be complied with The table below lists the temperature classes to EN 13463 1 and the resulting theoretical temperature limits of the
48. on in accordance with DIN 1045 or equivalent standards Make sure that the concrete foundation has set firmly before placing the unit on it Its surface shall be truly horizontal and even The foundation bolts shall be inserted in the soleplate 5 2 1 Place of installation J The volute casing the pipe assembly and certain areas of the soleplate take on roughly the same temperatures as the medium handled The motor stool or bearing bracket lantern must not be insulated Take the necessary precautions to avoid burns 5 3 Soleplate foundation settle and leveling Place foundation rail in the trench done in the foundation block in accordance with Foundation Plan dimensions The foundation rail leveling should be executed with a precision level instrument and kept smaller than 0 1 mm meter since its not recommended to place chock blocks which would injure soleplate tightness After complete mortar cure it should executed an appropriate cleaning and removed concrete sparkling from foundation rail Place the gasket and soleplate over foundation block and fix it Note The tightness of the well can affect the NPSHA due to atmospheric pressure absence The user should assure that NPSHA is higher than NPSHmg at least 1 0 meter Check if soleplate is uniform arranged on the foundation rail
49. se operating instructions contain fundamental information which must be complied with during installation operation monitoring and maintenance Therefore this operating manual must be read and understood both by the installing personnel and the responsible trained personnel operators prior to installation and commissioning and it must always be kept close to the location of operation of the machine unit for easy access Not only must the general safety instructions laid down in this chapter on Safety be complied with but also the safety instructions outlined under specific headings particularly if the pump unit is operated in hazardous areas see section 2 9 2 1 Marking of instructions in the manual The safety instructions contained in this manual whose non observance might cause hazards to persons are specially marked with the symbol AN general hazard sign to ISO 7000 0434 the electrical danger warning sign is safety sign to IEC 417 5036 RPH V and special instructions concerning explosion protection are marked is used to introduce safety instructions whose non observance may lead to damage to the machine and its functions The word Instructions attached directly to the machine e g arrow indicating the direction of rotation markings for fluid connections must always be complied with and be kept in a perfectly legible condition at all times 2 2 Personnel qualification and training A
50. thing abnormal during this period please consult chapter Functioning Abnormalities and its eventual Causes RPH V 6 1 7 Shutdown Close the shut off valve in the discharge line If the discharge line is equipped with a non return or check valve the shut off valve may remain open If shut off is not possible the pump will run in reverse direction Caution This may cause damage to mechanical seals which are not bi directional The reverse runaway speed must be lower than the rated speed Switch off the drive making sure that the unit runs down smoothly to a standstill Close the auxiliary lines but do not turn off the cooling liquid supply if any until the pump has cooled down Please refer to section 6 1 2 In the event of frost and or prolonged shutdowns the pump and the cooling chambers if any must be drained or otherwise protected against freezing 6 2 Operating limits N The pump s unit s application limits regarding pressure temperature and speed are stated on the data sheet and must be strictly adhered to If a data sheet is not available contact KSB 6 2 1 Temperature of the fluid handled ambient temperature bearing temperature Do not operate the pump temperatures Caution exceeding those specified on the data sheet or the name plate unless the written consent of the manufacturer has been obtained Damage resulting from disregarding this warning will not be covered by the KSB warranty
51. ting sleeve Lack of cooling liquid or dirty cooling chamber Vibrations during pump operation The unit is misaligned Insufficient or excessive quantity of lubricant or unsuitable lubricant Non compliance with specified coupling distance Operating voltage is too low Rotor is out of balance Check pipeline connection and secure fixing of pump if required reduced the distance between the pipe clamps Fix the pipelines using anti vibration material Check alter liquid level Fully open shut off valve in the suction head line Change suction line if friction losses in the suction line are too high Check any strainers installed suction opening Observe permissible speed of pressure fall Correct rotor adjustment Fit new shaft seal Interchange two of the phases of the power supply cable Replace the defective fuse Check the electric cable connections Increase speed Fit new bearings Increase the minimum rate of flow Replace worn components by new ones Adjust duty point accurately Change the Material combination Reduce the speed 2 Tighten the bolts Fit new seals and gaskets Fit new shaft seal Fit new shaft protecting sleeve Fit new shaft seal check the balancing line Check the throttle bush throttling sleeve clearances Increase cooling liquid quantity Clean out cooling chamber Purify clean cooling liquid Improve suction conditions Re align the pump Re balanc
52. under any circumstances 2 9 Explosion protection If the pumps units are installed in hazardous areas the measures and instructions given in the following sections 2 9 1 to 2 9 6 must be adhered to without fail to ensure explosion protection RPH V 2 9 1 Unit fill It is assumed that the system of suction and discharge lines and thus the wetted pump internals are completely filled with the product to be handled at all times during pump operation so that an explosive atmosphere is prevented If the operator cannot warrant this condition appropriate monitoring devices must be used In addition it is imperative to make sure Caution that the seal chambers auxiliary systems of the shaft seal and the heating and cooling systems are properly filled 2 9 2 Marking The marking on the pump only refers to the pump part i e the coupling and motor must be regarded separately The coupling must have an EC manufacturer s declaration The driver must be regarded separately Example of marking on the pump part Ex II 2 G T1 T5 The marking indicates the theoretically available temperature range as stipulated by the respective temperature classes The temperatures permitted for the individual pump variants are outlined in section 2 9 5 Pumps RPH V are designed to meet the requirements of Zone 1 and Category 2 as per 1127 1 2 9 3 Checking the direction of rotation see also 6 1 4 If the explosion hazar
53. yanoacrylate adhesives quick setting adhesives If in certain cases mounting aids or anti adhesives other than described herein are required please contact the sealing material manufacturer Caution All graphite gaskets must only be used once Never use O rings that have been glued together from material sold by the metre Do no coat O rings with graphite or similar products Use animal fats or silicone base or PTFE base lubricants instead O rings made of ethylene propylene shall only be coated with silicone grease or soft soap never use mineral oils or greases The locating surfaces of the individual components must be coated with graphite or similar before reassembly The same applies to screwed connections 7 5 2 Reassembly general below floor and bearing bracket lantern Assemble the shaft protective sleeve 524 the sealing ring 400 33 the key 940 5 the impeller 230 gaskets 411 and impeller nut 922 at the pump shaft 211 NOTE 1 Change at every assembly the flat gaskets 400 and O ring 412 2 The impeller nut 922 has the fixing system heli coil For safety KSB recommends replacement of it each 3 or 4 disassembles Place the pump shaft set 211 in the spiral casing 102 Place the pressure cover 163 with spiral wound 411 31 Assemble successively the suspension piping 713 2 the bearing sleeve 529 21 and bearing spider 383 21 RPH V Flush off the intermediary shaft
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