RDL - KSB Brasil
Contents
1. f deb o um ou me o9 ppm o oo o pm 2m ro 12 x 12 16 x 16 20 x 20 16x16 20 x 20 25x25 20 x 20 25x25 20 x 20 25 20 25 25 16 1 125 Ib FF or 250 Ib RF Table 1 Values valid for materials A48CL30 and NI Resist See item 6 2 1 peripherical speed For material A536 60 40 18 multiply the values by 1 4 Pumps 200 620A 250 620A 300 500A 300 620 and 350 620A can operate 1750rpm Casted carbon steel multiply values by 1 7 with reinforced bearings subject to release by the KSB Product Department Casted chrome steel please consult KSB For lubrication with oil please consult KSB Product Department For higher temperatures consult KSB Maximum rotation 880rpm for hydraulic A For material SAE 1045 AJ 4 3 1 Technical data English units Units 300 280 300 340 300 400 300 500 300 620 350 500 350 620 400 390 400 440 400 480 400 540 400 620 400 850 N Tests peperere pe 500 640 500 700 500 790 500 890 600 540 600 830 700 590 700 820 800 740 allel 125 170 125 200 125 250 125 310 150 250 150 280 500 510 600 620 600 710 700 710 150 430 150 500 200 280 200 340 200 400 200 500 200 620 250 280 250 340 250 400 250 500 250 620 Constructive data SO Oooo On oO om occ como se jo x 202 so2. 19 9 Common baseplate for pump and motor 4 5 3 Coupling guard For a safety operation a coupling guard should be installed Made according to KSB standards of steel or brass Installed on the transversal beam in case of common baseplate see fig 9 or on the foundation floor see fig 10 Coupling guard does not touch the rotating elements 5 Installation at site Our pumps should be installed leveled and aligned by trained personnel If this work is done incorrectly it may cause operational problems premature wear and damage beyond repair 5 1 Safety regulations 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 ta ble G A drawing The concrete foundations shall have sufficient strength min BN 150 to ensure safe and functional installation 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 baseplate holes 14 O RDL 5 3 Installing the pump unit After placing the baseplate preferably without the pump and driver on the foundation
3. o e sa a 0 e e e o v ae e a o 202 s sw e a e ae o Lunge ro 25 eo a ze as ac oo s o hydrostatic A536 psi According to Hydraulic Institute test 60 40 18 evitem ff ee eee With H lt 164 gt 0 25 Qot single Minimum volute H gt 164 gt 0 40 Qot flow With double Maximum or 221 m Bore E rotation 3650 18003650 1800 1800 1800 1200 tr xc uM CI SER e espe poppe or oe re s e uem m e po enm o men eme eme pem noi eer nl fl lr lll eo eo oia pe UR FF GBR CER Tent af k pbk EELE PES Interchangeability Wear ring change without le ch dual impellers A simple change machining mper rm EIS ERES ES ED ES ono in the diameter 82 dt 030 033 030 em 047 047 oss 059 051 051 055 061 ss oso 063 068 Clockwise or counter clockwise according to position of drive see fig 14 and 15 Bas E DIN 1092 2 types 21 Form PN16 or DIN EN1092 2 types 21 Form B PN25 end pressure ANSI E 16 1 125 Ib FF or 250 Ib RF forces and moments in 2 Mx My Mz ft Ib 1080 1440 1980 2160 2530 2890 3610 5780 6500 Free side side 6807 6307 60 em e 6316 6320 6316 618 6320 63241631616320 632
4. 34 RDL 9 3 Sizes 600 up to 800 710 923 504 902 3 560 1 903 4 9035 903 1 234 503 902 5 902 1 321 920 3 920 6 41140 41150 411 1 741 9042 920 5 105 2 920 1 931 420 901 1 720 1 502 458 636 901 2 457 940 3 11 6052 904 1 2 920 2 902 4 ix 920 4 ra N 955027 7 Lot Ta ED EN CSI SEMI NEM S N law 1 A REZ Sy SSNS gt Vir R d 72220277 4 E E 7 ER gt Us NG TS wig sea mats N 4 Sch SU aa y 2 amp 565 N A 560 2 920 7 921 412 524 525 1 940 2 461 452 330 322 360 2 940 1 9028 350 360 1 920 8 tr 400 El FLAT GASKET Ie SR nass Trim 400 EMPTY EMPTY FLAT GASKET VIEW X 803 8 1 47 DRAIN OPPOSITE SIDE TO THE DRIVE R D E DRIVE SIDE BEARING LUBRICATED WITH CIL CPTICHAL Figure 31 Note 0 Not used for pump size 800 840 Not used for pumps with ANSI flanges 35 KSE RDL 1 Parts List Denomination 0 __ __ 9 I 0 Lower casing 105 1 A48CL30 A48CL30 Upper casing 105 2 A48CL35 A48CL35 Shaft SAE1045 Double entry impeller A48CL30 A743CF8M A48CL30 A743CF8M Radial ball bearing Rad
5. 41 42 43 44 45 46 Foreign particles in the impeller Defective or worn impeller Casing and or impeller wear rings worn Pump internal leakage from pressure chamber to the suction due to worn wear rings Misalignment of coupling Shaft vibration Shaft vibration due to absence of rotor balance Shaft runs eccentric due to wear of bearings or misalignment Impeller friction with casing parts Foundation is not rigid enough Pump is not aligned Operation conditions are not according to the indicated data of the Purchase order Incorrect assembly of shaft seal or mechanical seal Wear of shaft protective sleeve due to abrasive solids of the sealing liquid Insufficient packing lubrication due to gland cover being over tightened Excessive clearance between shaft and neck ring or between shaft and shaft passage diameter in the seal chamber Damaged mechanical seal due to dry operation High axial thrust due to defect inside the pump Worn bearings Defective assembly of bearings Excessive quantity of grease in the bearing housing Defective lubrication of the bearings Dirty bearings Oxidation of bearings due to water or moisture in bearing housings KSB has the right to change any information contained in this manual without previous notice 37 KSB Bombas Hidr ulicas SA Rua Jos Rabello Portella 400 V rzea Paulista SP 13220 540 Brasil http www ksb com br Tel 11 4596 8500 Fax
6. 11 4596 8580 SAK Servico de Atendimento KSB e mail gqualidade ksb com br Fax 114596 8656 RDL 14 05 2007 A1385 8E 3
7. 458 and neck ring 457 Loosen screwed pins 940 1 and thereafter shaft nuts 921 Extract shaft protective sleeves 524 taking care not to damage the O rings 412 Remove the keys 940 1 spacer sleeves 525 2 if any spacer sleeves 525 1 except for pumps 200 500 200 620 and 250 340 which do not have them Take out the impeller 234 from the shaft and the key 940 2 Pumps DN 600mm 24 up to DN 800mm 32 have bearing brackets 330 fixed in the lower casing which be disassembled loosening the nuts 920 8 and guide pins Fig 28 Extracting of external ring of bearing with screw Note a When extracting bearing housings avoid uneven effort or blows that can damage the bearings b If applicable extract the impeller wear rings 503 loosening threaded pins 904 2 7 6 2 Disassembly sequence for pumps with mechanical seal Loosen auxiliary piping if any and gland Apply specific instructions of mechanical seal manufacturer 7 7 Assembly sequence All parts must be cleaned and deburred before assembly 7 7 1 Pump with gasket Place the key 940 2 on the shaft 211 assemble the impeller 234 spacer sleeves 525 1 except for pumps 200 500 200 620 and 250 340 assemble spacer sleeves 525 2 if any Place the keys 940 1 and assemble shaft protective sleeves 524 with respective o rings Take to not damage o rings during assembly Mount and tighten the two shaft nuts 921 against the protecti
8. 1 oil change after 300h of service Next change after additional 2000h of service Subsequent changes each 8000h of service or after 1 year of service whichever comes first 27 KSE RDL 7 4 Shaft Seal Maintenance 7 4 1 Mechanical Seal Maintenance In case of supply of pump with mechanical seal additional instructions from seal manufacturer should be followed 7 4 2 Packing Maintenance If shaft sealing has already been tightened equivalent to a packing ring thickness and even so it presents excessive leakage it must be checked as follow Stop the pump Loosen nuts of gland cover and push it to the bearing housing direction in order to have enough space for work Extract with the help of a deflective spindle all the packing rings and lantern ring Clean all shaft seal chamber Check surface of protective sleeves If they present roughness or grooves replace them Cut new packing rings with oblique end see fig 23 To facilitate cut a disposal of easy construction can be used see fig 24 Fig 23 Oblique cut of the gasket Fig 24 Device to cut packing rings Lubricate internal diameter of each packing ring with grease Lubricate external diameter of lantern ring with Molykote paste G Proceed the assembly in the reverse sequence of the disassembly introducing each part inside the chamber with auxiliary of gland cover Packing rings should be assembled with their extremity displ
9. 6 6 5 0 0 0 6 0 0 40 16 16 25 25 40 16 16 25 25 40 16 25 AR N diameter for solid crossing 30 22 25 26 18 17 114 Interchangeability impellers A and E simple change War E dia Wear ring change with re machining EE clearance the diamet 1 2 1 5 1 7 D a 0 70 0 75 0 85 0 75 0 85 0 80 0 85 0 95 10 1 1 1 2 22 87 apa elel spo n d n e pn n nnn Rotation direction EE Clockwise or counter clockwise according to position of drive see fig 14 and 15 DIN EN 1092 2 types 21 Form B PN16 or DIN EN1092 2 types 21 Form B PN25 function of end pressure FX Fy Fz f rcesand Fx Fx Fy Fz Fz 2040 DEBERI 599 10780 1 moments in 2 Mx My Mz Nm 1470 1960 2695 2940 3430 3920 4900 7840 8820 5 Free Free side 6307 6314 6316 6320 6314 6316 6318 6320 6324 6316 6320 6322 6324 6328 6316 6318 6322 6324 6 6320 6322 6326 6322 6324 6328 Clearance C3 Drive side 6307 9308 6307 6310 6312 6314 6316 Ls Te 23 i a aa a no 112 150 170 122 150 160 170 200 150 170 180 200 230 150 160 180 200 170 200 210 E RS RO RO FR Shaft seal
10. be performed to control the axial displacement See Fig 17 Fig 16 Radial control Fig 17 Axial Control To correct the alignment loosen the driver bolts sliding it laterally or inserting shims to correct its height as necessary Axial and radial alignments should be within the tolerance of 0 1 mm 0 004 with the driver and pump fixing bolts tightened If there is no dial indicator available use a straight edge across the two parts of coupling sleeve The control should be done on the horizontal and vertical planes To control axially use a feeler gauge See Fig 18 Observe the coupling sleeve hub clearance specified by the manufacturer straight Edge Feeler Gauge Fig 18 Alignment with straight edge and feeler gauge 5 6 Connecting the piping Never use the pump itself as an anchorage point for the piping The permissible pipeline forces must not be exceeded see table 1 Suction lift lines shall be laid with a rising slope towards the pump and suction head lines with a downward slope towards the pump The pipelines shall be anchored in dose proximity to the pump and connected without transmitting any stresses or strains The nominal diameters of the pipelines shall be at least equal to the nominal diameters of the pump nozzles Connec tion flanges must be parallel to the pump flanges it is recommended to install check and shut off elements in the system depending on the type of plant and pump It must be ensure
11. causes Probable Causes 14 15 16 17 18 19 20 21 22 Pump was not appropriately primed Pump and suction piping are not totally filled with liquid to be pumped Suction is too high that means NPSHr is higher than NPSHd Pumped liquid contain air or gas Air pocket in the suction piping Air entrance in the suction piping Air entrance through shaft sealing Suction piping is not enough submerged Suction valve is closed or partially opened Foot valve or strainer of suction piping is dirty or clogged Foot valve is too small or it is clogged None or insufficient quantity of sealing lubricating liquid in the shaft seal housing Lantern ring is not located according to the designed below the sealing liquid hole this way the shaft seal chamber is irregularly feed by insufficient quantity of sealing lubricating liquid Too low speed Too high speed Speed in reverse side Total installation height counter pressure higher than head Total installation height counter pressure lower than head Liquid specific gravity is different from specified Liquid viscosity is different from specified Pump functioning with too low flow discharge of valve piping probably partially closed Parallel operation with different hydraulic characteristics 27 28 29 30 31 32 33 34 40 41 42 43 44 45 46 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
12. f operation 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 3 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 packing running hot 3 Transport and interim storage 3 1 Transport Transportation of the motor pump assembly or only pump should be performed with skill and good sense by trained personnel observing safety regulations Lift only motor with eyebolt never use it to lift motor pump assembly In the pump upper casing there are 2 hooks which should be used only for disassembly and transport of this part Do not transport the pump or motor pump assembly with these hooks The pump can be transported according to fig 2 by ropes or steel cables crossed in the neck of suction and discharge flanges For transportation of set with common baseframe for pump and motor according to figure 3 in case of baseframe deformation possibility transport pump motor and baseframe separately If the pump unit slips out of the suspension arrangement it may cau
13. level it with the help of a spirit level placed on the pump and driver pads Permissible deviation 0 2 mm m Shims should be fitted between the baseplate and the foundation itself they shall always be inserted to the left and right of the foundation bolts and in close proximity to these bolts For a bolt to bolt clearance of more than 800 mm additional shims shall be inserted halfway between the adjoining holes All shims must lie perfectly flush Insert the foundation bolts and set them into the foundation using concrete When the mortar has set level the baseplate as described in section 5 3 1 and tighten the foundation bolts evenly and firmly Then grout the baseplate see also 5 3 2 using low shrinkage concrete with a standard particle size and a water concrete ratio of 0 5 The flowability must be produced with the help of a solvent Secondary treatment of the concrete to DIN 1045 is an absolute necessity Shim Shim Shim lt 800 TARA a 9222722777777727 Foundation bolts 800 Fig 11 Fitting required shims To ensure low noise operation the unit can be mounted on vibration dampers please confirm with KSB first Expansion joints can be fitted between pump and suction discharge line 5 3 1 Base Leveling Check if the baseframe is equally leveled on its metallic shims Place and tighten uniformly the nuts on the foundation bolts Using a spirit level check the leveling of the basefram
14. other connections can be installed on the seal gland In this case complementary instructions will follow 3 Optionally connections with NPT can be supplied 19 KSE RDL 5 6 4 Coupling guard j In compliance with the accident prevention regulations the pump must not operate without a coupling guard If the customer specifically requests not to include a coupling guard our delivery then the operator must supply one 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 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 In hazardous areas compliance with EC60079 14 is an additional requirement for electrical connection 20 KSE RDL 6 Comissioning start up shutdown Commissioning Start up Shutdown Compliance with the following requirements is of paramount importance Damage resulting from non compliance shall not be covered by the scope of warranty 6 1 Commissioning Before starting up the pump make sur
15. pressure values from liquid return in long pipes exceed the recommended limits for piping and pump b Junction between discharge piping and pump flange should be made with a concentric reducer when nominal diameters are different c Install vent valves to remove the air d Install a discharge valve just after pump discharge nozzle in order to adjust of flow and pumping pressure or prevent driver overload e Check valve when installed should be placed between the pump and the discharge valve This location is preferable in relation to item d f Expansion joints with tie bolts should be considered to absorb system stresses Safety valves or relief devices and other operation valves should be installed when necessary h Same recommendations a b f gi regarding suction piping 5 6 3 Auxiliary connections The dimensions and locations of the auxiliary connections sealing liquid flushing liquid etc are indicated on the G A drawing and below These connections are required for proper functioning of the pump and are therefore of vital importance Modifications are only permitted after consulting KSB see 2 7 Description of piping and auxiliary connection 600 830 800 970 8D Leakage Fig 19 Standard piping and auxiliary connection Note 1 Suction piping for liquid of external source should have valve and sight glass to control and observe flow 2 For pumps with mechanical seal
16. 21632416328 6316 6318 6322 632416320 6322 6326 6322 6324 Bearings C3 Drive side 6307 6308 6307 6310 6312 6314 6316 Js Te se EEE eee EEE EE e eps eee Lubrication grease E EU IL E a m O AE meme foe lie fons Tes esee eT rre 0 0 o Te m e frm bcd ooo ooo 232 Wear ringchange with re machining ee B x 47 63 63 79 79 79 x 79 79 79 98 98 79 x 79 98 x 98 Net n ib 2 344 a48 53 364 531 580 584 608 743 794 745 785 822 1155 1760 025111011145 1600 2170 1530 1730 2040 2570 3340 3320 4670 2370 3030 3220 3920 4700 9920 3370 5070 6540 7680 02706010 6530 4 Values valid for materials A48CL30 and NI Resist Shaft seal housing Q See item 6 2 1 peripherical speed For material A536 60 40 18 multiply the values by 1 4 E Pumps 200 620A 250 620 300 500 300 620A and 350 620 can operate in 1750rpm Casted carbon steel multiply values by 1 7 with reinforced bearings subject to release by the KSB Product Department Casted chrome steel please consult KSB Q For lubrication with oil please consult KSB Product Department For higher temperatures consult KSB Maximum rotation 880rpm for hydraulic A For material SAE 1045 857 RDL Fig 4 Sealing clearance and impeller diameter Fig 5 Permissible forces and moments on the flanges see table 1 4 4 D
17. 26 Fig 26 Pump with upper casing removed available for inspection Fig 27 Lift and extracting of rotor from inside the lower casing 29 KSB b RDL Pass a rope around the shaft between the gland covers and bearing housings and lift the rotor to extract it from lower casing See fig 27 Take care to not damage the studs 902 1 and that the extracting is done without effort due to friction or bent position of rotor Extract coupling sleeve with a pull out device and the key 940 3 Loosen nuts 901 2 and bearing cover of drive side 360 1 For pumps with DN 400 mm or above there are two extract holes M8 5 16 in the rear part of bearing housings By means of uniform tighten of two bolts relatively long in these tapped holes remove external ring of bearing See fig 28 With a pull out device extract bearing housing for pumps DN 400 mm 16 or bigger extract also internal ring of bearing and spacer ring 504 For pumps up to 300 mm extract bearing housing and also ball bearings Loosen bolts 901 2 and bearing cover N D side 360 2 Unlock lockwasher 931 from bearing nut 923 Loosen bearing nut with key type nail or with pin Extract with pull out device shaft from bearing housing bearing 321 and spacer ring 504 Thereafter parts are symmetrical in both sides of rotating element and disassembly is similar Extract wear rings 502 sealing rings for shaft 420 gland cover 452 gasket rings 461 lantern ring
18. 3 CF8M IE E E E E 1 4 E E E 2 0 3000 3500 4000 0 50 100 150 1000 1500 2000 Peripheral speed 40m s Fig 6 Peripheral Speed 2500 200 350 Q l h Peripheral soeed 60m s Fig 7 Liquid flow of external source NO sze sze cuve sze cuve sze cuve 150 430 250 500 600620 2 125 310 150 250 150 280 125 170 125 200 200 620 3 325250 1 200340 2 300340 3 400620 4 70080 3 250 620 400 480 300 620 500 700 600 710 600880 3 C3 200 400 300 400 500510 2 700710 3 200 500 300 500 500 640 700820 3 800 740 NO 150 310 250 280 350 500 500 790 800840 2 150 340 250 340 350 620 500 890 ow 8009 0 3 150 400 250 400 400 390 6054 2 Ap P ps 4 4 5 Packing rings where P pressure of external source liquid bar ps suction pressure bar Usually shaft sealing is done with packing rings Position of neck ring packing rings and lantern ring are shown on fig 8 Dimensions of seal chamber packing rings are mentioned on table 1 The lantern ring disposed between packing rings receives the liquid from the region of pump high pressure Lantern ring makes the distribution of liquid which lubricates the packing and avoid the entrance of air in the pump Liquid flow to the lantern ring is controlled by a valve installed in the pump
19. 500 8000 8500 NU314 6314 X 5000 5500 6500 7000 7500 8000 45 NU316 6316 4000 4500 6000 6500 7000 7500 55 NU3i8 6318 3300 4000 550 6000 6500 7000 65 NU320 6320 1 2500 3000 5000 5500 6000 6500 75 NUS 632 f ooo 5500 6000 6500 85 NU34 634 J o 450 500 550 6000 105 NU6 6 6 1 400 4500 500 550 15 p ee 1 NU328 _ 6328 3000 3500 4000 4500 Table 3 Lubricating interval and grease quantity as function of rotation RDL Apply the correct grease in the indicated quantity through the grease nipple located in the upper part of the bearing housing acc to defined intervals An excessive quantity causes a harmful effect Every 2 years bearings should be disassembled and washed and all lubricant replaced We recommend use of lithium soap grease and do not mix with other types like sodium or calcium VG 68 MP2 Regal 68 Regal 46 Bardahl General PROMAX BARDAHL Maxlub 20 Maxlub MA 15 Table 4 Grease and oil specification 7 3 2 Bearings lubricated with oil optional Bearing housings must be filled with mineral oil of good quality Type ISO VG 68 for speeds below 3000 rpm and 150 VG 46 speed higher than 3000 rpm See table 4 Correct level is controlled by a constant level oiler Oil change must be done according to the following 2 3
20. Mount bearing covers 360 1 and 360 2 fixing them with screws 901 2 For pumps sizes 600 up to 800 mount the bearing brackets 330 on the lower casing positioning them to the studs 902 8 and fixing them with the nuts 920 8 Assure that the contact surfaces between the lower and upper casing are free of dirt Install studs 902 3 902 2 and 902 5 if any Mount rotating element inside the lower casing according to following steps a Place the bearing housings on the correct position of the studs 902 1 b Mount the wear rings in the lower casing c Remove gland covers 452 and lantern rings 458 towards the bearing housings in order to not cause any trouble during assembly d Leave neck rings 457 already positioned towards of shaft seal chamber e Unfasten rope which maintains the rotating element suspended during assembly Center the impeller in the lower casing according to the specific description below Apply silicone sealing adhesive 598 HB of Loctite on the contact surface of lower casing Place the upper casing lifting it through its hooks and guiding it by the studs 902 2 902 3 and 902 5 Place the guide pin 560 1 Uniformly tighten in a crosswise pattern the nuts 920 2 920 3 and 920 5 if any Fix the bearing housings through the nut 920 1 observing that the bearing housing be leveled Place the studs 902 4 and execute shaft seal according to fig 6 and instructions of chapter 11 2 2 Insta
21. OPPOSTE SIDE TO THE DRIVE N D E DRIVE SIDE D E BEARING LUBRICATED WITH OIL OFTIONAL Figure 29 Note Not used at pump sizes 125 250 310 150 430 200 340 620 300 340 400 Not used at pump sizes 200 500 620 250 340 400 Only for pump size 300 400 Not used for pumps with ANSI flanges RDL FLAT GASKET 33 RDL 9 2 Sizes 400 up to 500 710 923 504 902 3 5601 903 4 903 5 4 903 5 234 902 5 321 920 3 920 6 41140 411 5 3 414 1 741 920 5 105 2 931 420 901 1 720 1 502 458 720 3 10 E f 720 1 de _ EEE E ESA AA 2220 E w WA om 920 2 KEY lt 92 h A D 55 2 4 2 Dl SETAS NO 4 27727777 ANS 2 P 222 107 ZA L 921 412 524 525 1 360 2 525 2 4 4 903 2 H 120 f f ca mr B 14 NPT DRAIN Figure 30 Note gt FLAT GASKET Aoi OPPOSITE SIDE TO THE DRIVE M D E BEARING LUBRICATED WITH OIL OPTIONAL O Applicable for pump size 400 390 500 510 640 790 Used only for pumps 400 480 620 Not used for pumps with ANSI flanges Not used for pump size 400 480 461 DRIVE SIDE DE 2 452 902 1 920 1 901 2 940 3 211 l as 7 970 1 970 2 565 105 1 322 350 360 1
22. Operating Instructions N A1385 8E 3 Works N Type Series These operating instructions contain fundamental information and precautionary notes Please read the manual thoroughly prior to installation of unit electrical connection and commissioning It is imperative to comply with all other operating instructions referring to components of individual units This manual shall always be kept close to the unit s location of operation or directly on the pump set KSB RDL Axially split volute casing pump acc to Directive 98 37 EC KSE RDL 0 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 little maintenance With the aim to provide our clients with satisfactory trouble free operation we recommend to install and maintain our equipment according to the instructions contained in this service manual This manual has been prepared to inform the end user about construction and operation of our pumps describing the proper procedures for handling and maintenance We recommend that this manual should be handed over to the maintenance supervision The 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 Field for description of manufacturer data Field for Order number seria
23. aced about 90 from each other See fig 25 Fig 25 Position of displaced rings in 90 After assembling of all rings in the chamber there should remain about 5 mm 3 16 to gland cover guide 7 5 Maintenance of wear areas Maintenance of wear areas that means clearances between impeller 234 and casing wear ring 502 or between this and the impeller wear ring 503 should be made after reaching sealing clearance values mentioned on table 1 7 6 Instruction for Disassembly Note Part numbers indicated in parentheses after the name of each part refer to the parts lists and sectional drawings of chapter 9 28 ian A KSB RDL 7 6 1 Disassembly sequence for pumps with packing Close suction if any and discharge valves Drain pump removing threaded plugs 903 3 and 903 1 Close valves and disconnect auxiliary pipings manometers and vacuometers if any Remove coupling guard if any Disconnect coupling sleeve of driver Loosen nuts 920 4 and gland cover 452 of its studs 902 4 displacing into bearing direction Loosen nuts 920 2 920 3 and 920 5 if any Tighten nuts 920 6 to extract both guide pins 560 1 Separate upper casing 105 2 from lower casing 105 1 tightening extractor bolts uniformly 901 1 Pull extractor bolts back to not hinder during assembly Pass the string around each eyebolt of upper casing and lift it Thereafter pump inside is available for inspection See fig
24. ackets to facilitate the disassembly of rotor together with the bearing Up to size 500 890 the bearing casing is part integrated to the lower casing For bigger sizes bearing brackets are fixed to the lower casing through studs and nuts Bearings are protected by sealing rings on shaft against drop from the stuffing box Pumps up to DN 300 have ball bearings in both sides For bigger sizes bearings have cylindrical roller bearing at the drive end and a deep groove ball bearing at the N D E 4 4 4 Shaft Sealing Pump is shaft sealed by gland packing standard or optionally by mechanical seal In the sealing area the shaft is provided with easily replaceable protective sleeves Usually gland packing is lubricated by pumped liquid except on applications which the fluid is inadequate for these functions In these cases use an external source with clean liquid with a pressure of 1 5 to 3 0 bar 20 to 40 psi over the suction pressure The volume of lubrication sealing liquid of external source is obtained through the diagram according to fig 7 and for wash use the same pressure and flow 10 times higher than that used for lubricating sealing Pressure and flow refer to values for each chamber 11 Impeller diameter mm 200 ___ _ 1 __ 5 HEHEHE E E 4T E E Peripheral speed E limit for impeller in 3 A536 60 40 18 CuSn10 C GS 2 A743 CA6NM A74
25. ards to persons are specially marked with the symbol general hazard sign to ISO 7000 0434 The electrical danger warning sign is 10 417 5036 and special instructions concerning explosion protection are marked The word is used to introduce safety instructions whose non observance may lead to damage to the machine and its functions 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 perfectly legible condition at all times KSE RDL 2 2 Personnel qualification and training All personnel involved in the operation maintenance inspection and installation of the machine 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 itself Non
26. 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 plant functions failure of prescribed maintenance and servicing practices hazard to persons by electrical mechanical and chemical effects hazard to the environment due to leakage of hazardous substances Ex symbol relates to additional requirements which must be adhered to when the pump is operated in hazardous areas 2 4 Safety awareness It is imperative to comply with the safety instructions contained in this manual the relevant national health and safety regula tions and the operator s own internal work operation and safety regulations 2 5 Safety instructions for the operator user Any hotor 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 machine 15 operating Leakage e g at the shaft seal of hazardous media handled e g explosive toxic hot must be contained so as to avoid any danger to persons and the environment Pertinent legal provisions must be adhered to 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 compon
27. ction valve opened so the pumped liquid comes to the higher part of the pump Place the threaded plugs back and the pump will be primed Installation with negative suction In case of installation with negative suction that means pump is installed above the suction reservoir level for priming it is necessary to have a foot valve or to prime by partial vacuum Priming with filling and foot valve Remove threaded plugs 916 6 903 5 903 1 and 903 4 if any Fill the pump and suction piping with water or pumped liquid through the plug located in the higher point of the pump The foot valve will prevent the liquid to return to the suction reservoir When leaking through the higher point of the pump starts equipment used to fill filler hose piping with register etc must be removed and place threaded plugs back Priming with by pass of check valve In large installations pump and discharge piping can be filled Remove threaded plugs 916 6 903 5 903 1 and 903 4 Open partially the discharge valve Open by pass line of check valve until the liquid reaches the higher part of the pump Close valves place threaded plugs back and pump will be primed Priming with partial vacuum ejector The principle of ejector working is based on the pressure condition created by the passage of a pressurized flow through a piping with different sections This condition allows air extraction from the pump casing and suction piping creating a vacuum and making
28. ctive equipment must be properly refitted and or reactivated before starting the pump set 25 KSE RDL 7 Maintenance Repair 7 1 General instructions The operator is responsible for ensuring that all maintenance inspection and installation work is carried out by authorized duly qualified staff who are thoroughly familiar with these operating instructions 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 A Work on the unit must only be carried out with the electrical connections disconnected Make sure that the 4 h pump set cannot be switched on accidentally danger of life Pumps handling liquids posing health hazards must be decontaminated When draining the medium see to X it that there is no risk to persons or the environment All relevant laws must be adhered to danger of life 7 2 Supervision during operation After start up and if pump is operating consider the following items a Adjust pump for the operation point pressure and flow opening the discharge valve slowly just after driver has reached its nominal speed b Control current amperage of electric motor c Assure that pump operates free of vibration and abnormal noises d Control bearing temperature It can reach up to 50 C 122 F above ambient temperature however total temperature can not exceed 90 C 194 F e Adjust
29. d 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 AN An excessive impermissible increase in the pipeline forces may cause leaks on the pump where the medium handled can escape into the atmosphere This may lead to danger to human life when toxic or hot media are handled The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping 17 KSE RDL Please check if a strainer filter should be fitted in the suction line during the commissioning stage in 1 order to protect both the pump and the shaft seal from age due to contamination from the plant In order to avoid any marked deterioration of the NPSH available which would have an adverse effect on the pump the strainer has to be cleaned whenever required It is recommended to use a differential pressure gauge to detect any strainer clogging see 6 1 6 For installation on a foundation with vibration insulation please take into account the when connecting the piping that the flexible elements at the baseplate only compensate compressive and shearing strains within the admissible limits Tensile strains cannot be compensated for therefore the flexible elements shall only be firmly fastened to the foundation af
30. e longitudinally and transversally If the baseframe is unleveled loosen the anchor bolts nuts and insert additional shims as necessary between the metallic chocks and the baseframe so as to correct the leveling See Fig 12 Maximum leveling deviation 0 2 mm m Metallic Chocks boli Shirt Foursiaton block Fig 12 Base Leveling 5 3 2 Grouting In order to obtain a rigidity structure and vibration free operation the inner side of the baseframe should be filled with grout This grout should be prepared with specific products available in the civil construction market non shrinking type in order to avoid contraction during the hardening process and also provide sufficient fluidity to fill the baseframe and prevent from cavities formation See Fig 13 15 RDL Fig 13 Grouting 5 4 Rotation direction KSB RDL Pumps can be coupled to the drive on both shaft ends The rotation can be clockwise or counter clockwise a function of drive position and suction and discharge nozzles To determine the rotation direction be in front of the shaft drive side and look at the pump follow the pumped liquid flow which enters through the suction flange bigger diameter makes a complete turn inside the pump and goes out through the discharge flange smaller diameter See figures 14 and 15 If the shaft is assembled in one determined position it can be reversed without special adaptation Fig 14 Counter Clockwise
31. e that the following requirements have been checked and fulfilled If a constant level oiler is provided screw same into the upper tapping hole of the bearing bracket prior to adding the oil see 6 1 1 Seal with PTFE tape if necessary The operating data the oil level if required 6 1 1 and the direction of rotation 6 1 4 must have been checked The pump set must have been primed 6 1 3 Also verify the following Make 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 6 3 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 quality of oil required is outlined in section 7 3 2 Oil level in reservoir during filling procedure kc Vent filler plug Position of reservoir Oil level in bearing bracket for topping up oil and connection elbow Fig 20 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 after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of the connection elbow see Fig 20 Then fill the reservoir of the constant level oiler with oil and snap it back int
32. ents in contact with the pumped product especially in the case of abrasive products 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 A 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 be performed by authorized qualified specialist personnel who are thoroughly familiar with the manual The pump must have cooled down to ambient temperature it must be drained and its pressure must be released Work on the machine must be carried out only during standstill The shutdown procedure described in the manual for taking the machine out of service must be adhered to without fail Pumps or pump units handling media injurious to health must be decontaminated Immediately following completion of the work all safety relevant and protective devices must be re installed and or reactivated Please observe all instructions set out in the chapter on Com missioning before returning the machine to service 2 Unauthorized modification and manufacture of spare parts Modifications or alterations of the machine are only permitted after consultation with the manufactu
33. esign details 4 4 1 Casing Horizontal axially split volute casing with upper and lower casing Horizontal and opposite suction and discharge nozzle in the lower casing The surfaces between the casings are properly machined and the sealing is done with seal bandage of silicone 598 HB Loctite This design allows disassembly of the impeller shaft and sleeves without disassembly of the piping The protection of pump casing against wear caused by impeller rotation is made through replaceable wear rings fixed in machined channels in the lower casing This system prevents rotation and axial displacement of wear rings 4 4 2 Impeller Impeller is radial double suction with vanes of wide curvature fixed on the shaft by means of two symmetric parts set space sleeve shaft protecting sleeve and shaft nut Shaft nuts are out of flow area and are locked to the shaft by means of threaded screw and pins From size 600 540 inclusive the impeller is produced with replaceable wear rings In special execution up to size 500 890 inclusive impeller wear rings can also be provided Usually two different standard and interchangeable hydraulics A and B are available for each pump size Axial thrust is hydraulically compensated 4 4 2 1 Peripheral Speed When determining pump rotation always check if impeller material is appropriate for the peripheral speed Fig 6 4 4 3 Shaft Pump shaft is supported between bearings Bearing casings are fixed to their br
34. exposed to the atmosphere KSE RDL In any case responsibility for compliance with the specified fluid temperature operating temperature lies with the plant operator The maximum permissible fluid temperature depends on the temperature class to be complied with Due to its design temperature limit for pumps RDL could be acc to temperature class T4 to EN 13463 1 and the resulting theoretical temperature limit of the fluid handled is 120 C In stipulating this temperature any temperature rise in the shaft seal area has already been taken into account Note operation with liquids above 105 is permitted only after KSB approval Safety note permissible operating temperatures 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 40 C and proper maintenance and operation compliance with temperature class T4 is warranted in the area of the rolling element bearings A special design is required for compliance with temperature class T5 in the bearing area In such cases and if ambient temperature exceeds 40 C contact the manufacturer 2 9 6 Maintenance Ex ony a pump unit which is properly serviced and maintained in perfect technical condition will give safe and reliable
35. external piping 0 1 with external piping Fig 8 Shaft sealing Code Description Sealing by liquid being pumped 0 2 with external piping filter 1 1 Sealing through clean liquid of external source Sealing with mechanical seal 2 seals 0 When pumped liquid contains solid in suspension 12 9 4 4 6 Mechanical seal RDL Please refer to the mechanical seal drawing for details of the mechanical seal installed in the pump Other seal version is shown in the mechanical seal drawing After a short period of accommodation during operation there is no more leakage configurations and types may only be used exceptional cases and after consultation with KSB The relevant seal Mechanical seal is composed fundamentally of one stationary face and one rotating face which polished surfaces are kept together by spring pressure Sealing materials should be compatible with pumped liquid Condition for safety and long operation is based on a film of the liquid between the sealing faces and the generated heat being appropriately absorbed by liquid circulation Depending on the pumping condition this circulation can be of pumped liquid or liquid of external source Mechanical seals are constructed in many different materials and assembly arrangement covering almost all of chemical and physical characteristics of liquid to be pumped When requested shaft sealing by mechanical seal additiona
36. hould exist a strainer with a free passage of 3 to 4 times bigger than the piping area i when the pumped liquid is subject to high temperature variation expansion joints should be installed to avoid piping stresses caused by dilation and contraction of the pump j positive suction it is recommended to install a valve in order to close the flow as necessary During pump operation it must be totally opened Suction with only one suction header for several pumps must have one valve for each pump and the connection between the suction header and the suction piping should always be with changes of direction lower than 45 n all these cases with use of gate valve the shaft of it should be disposed horizontally or vertically down k In order to avoid turbulence air entering sand or mud in the pump suction use HI the recommendations Check coupling alignment after tightening piping m To facilitate piping assembly and parts adjustment install when necessary Dresser type assembly joint common or special type with tie bolts CONCENTRIC REDUCER ECCENTRIC REDUCER gus SX To II 1 CONCENTRIC REDUCER gt ECCENTRIC REDUCER Ms f a dq ISI Er a 2E Par 4 2 Fig 17 Negative suction Fig 18 Positive suction 18 O RDL 5 6 2 Recommendation for discharge piping Mounting of discharge piping should consider following items a Should have devices for control of water hammer when the
37. ial roller bearing 2 322 SEES Bearing bracket 3 Bearing housing Bearing cover L A 360 1 Bearing cover L B 360 2 Sealing ring 2 4 411 1 Sealing ring 4 411 2 Sealing ring 4 411 3 411 4 VOTER Sealing ring 2 4 411 5 70 Sealing ring for shaft NB50 A48CL30 Aramid packing A743CA6NM 504 SAE1035 Shaft protective sleeve 524 Spacer sleeve 7 525 1 A48CL30 AISI420 A48CL30 AISI420 Spacer sleeve 2 8 525 2 560 1 560 2 Conic Conic pin 3 Conicpin STEEL 901 1 901 2 902 1 902 2 902 3 9024 9025 902 8 903 1 903 2 9033 9034 Threaded plug 2 13 903 5 9036 904 1 Grub screw 3 904 2 SAEI 920 1 920 2 920 3 920 4 920 5 920 6 Nut 3 920 7 Nut 3 920 8 Nut 9 12 SAE1020 6 03 O oe 2 921 TM23 923 SAE1045 SPRING STEEL E 565 BRONZE STEEL GLASS STEEL STEEL Compressed fiber jointing sheet ZAMAC STEEL STEEL NB7O O ring 14 NB70 Table 6 1 Quantity 2 for pumps size 125 up to 300 9 Not applicable for pumps sizes 600 up to 800 2 Not applicable for pump size 125 up to 300 10 Applicable only for pumps sizes 125 up to 300 3 Applicable only for pump size 600 up to 800 11 Variable quantity according to pumps sizes 4 Not applicable for pumps with flanges ANSI 12 For pumps sizes 125 up to 300 not applicable for pumps 125 250 125 310 150 490 200 5 Applicable only for pum
38. ing the plant piping The cleaning operation mode and duration for flushing pickling service must be matched to the casing and seal materials used 6 1 6 Start up strainer If a start up strainer has been fitted to protect the pumps against dirt and or to retain contamination from the plant the strainer s contamination level must be monitored by measuring the differential pressure so as to ensure adequate inlet pressure for the pump For installation and monitoring see additional instruction sheet 6 1 7 Start up Before starting the pump ensure that the shut off element in the suction line is fully open The pump may be started up against a closed discharge side swing check valve or shut off element Only after the pump has reached full rotational speed shall the shut off element be opened slowly and adjusted to comply with the duty point When starting up against an open discharge side shut off element take the resulting increase in input power into account Pump operation with the shut off valves in the discharge and suction pipes closer 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 event of leakage switch off the unit allow to j cool down then re tighten the bolts between upper and lower volute casing 22 RDL 1 After the operating temperature has been reached re check the coupling alignme
39. ing to DIN or ANSI 4 1 Technical specification It is recommended for pumping clean or cloudy liquids in the following application water supply A drainage irrigation chemical and petrochemical industry air conditioning paper and cellulose industry fire fighting 4 2 Designation KSB RDL 250 500 A Trade a Model Discharge nozzle diameter mm Impeller nominal diameter mm Impeller type 4 3 Technical data Metric units 125 140 150 250 150 280 150 310 Bok oc DOE sfa sm as ne DE BODE DOES oo foe DOE 300 620 350 500 350 620 400 390 125 170 125 200 125 250 125 310 400 440 400 480 400 540 400 620 400 850 500 510 500 640 500 700 500 790 500 890 600 540 600 620 600 710 600 830 700 590 700 710 700 820 800 740 800 840 data t i A48CL30 11 18 18 25 11 13 5 18 18 10 12 18 10 11 13 pressure According to Hydraulic Institute hydrostatic A536 di test 60 40 18 RB 70 5 2 2 With lt gt 0 25 Qot single volute gt 0 40 Qot With double Maximum temperature 105 3650 1800 3650 1800 1800 1800 1200 wo Im E aea aaee OM Cec acca impeller end mm gas ECO PEGA e fn o ne oe e a fm o a fa ES DOS CC COCOO t ocan OOO OOOO OOOO OOOO OOS OOOO ec 16 6 0 0
40. l information will follow separately 4 4 7 Noise characteristics Sound pressure level L pA dB 2 Pump only Pump with motor 2900 1450 960 760 2900 1450 960 760 mno e 675 745 665 380 705 665 755 705 385 rio e 76 75 20 5 765 re _ 725 75 775 73 s ns 74 72 785 750 76 74 715 60 76 728 E 73 755 O 1 SO e O 1 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 2 Increase for 60Hz operation Pump without motor Pump with motor 3500 3dB 1750min 1dB 1160min dB 13 KSE RDL 4 5 Accessories 4 5 1 Coupling RDL pumps can be equipped with standard coupling type KSB or from other manufacturers KSB standard couplings do not require maintenance only periodical inspection every 30 days of elastic component condition and replacement if necessary Elastic component cannot be exposed to oil or grease contact For maintenance of other coupling type see manufacturer instruction 4 5 2 Baseplate KSB standard is a structural welded baseplate Common baseplate for pump and driver for sizes up to 500 890 and separated one for the pump for bigger sizes
41. l number OP Description of type and size of the pump Fig 1 Nameplate For requests about the equipment or when ordering spare parts please mention the type of pump and the Production Order number This information can be obtained from the nameplate of each pump If the nameplate is not available the OP number is stamped in low relief on the suction flange and on the discharge flange you may find the impeller diameter ATTENTION This instruction manual contains very important recommendations and instructions Must be carefully read before installation electrical connection first start up and maintenance KSE RDL This KSB pump has been developed in accordance with state of the art technology it is manufactured with utmost care and subject o continuous quality control These operating instructions are intended to facilitate familiarization with the pump 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 pump 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 his pump unit must not be operated beyond the limit values specified in the technical documentation for N The
42. ll grease nipple on the bearing housings Place the sealing rings 420 close to the bearing housings Centering impeller in the casing After placing the rotor in the lower casing and fixed the bearing housings it is important to center the impeller The clearance between the impeller and the internal walls of spiral on both sides must be the same Unequal clearance will cause higher axial thrust and excessive load on the fixed bearing N D E reducing its useful life or even damaging it For centering loosen the correct shaft nut 921 to which the set must be dislocated Tighten the shaft nut on the opposite side and the set sleeves and impeller will dislocate until the shaft nut was unscrewed When centering is ready tighten the nuts with key nail type or hook type Mark the shaft with manual drilling machine using the existents holes of the shaft nut Mount and tighten the grubscrews 904 1 which will seat on the shaft and will lock the nuts Note Before assembling lubricate internal diameter with Molykote paste G the following parts impeller protective sleeves spacer sleeves and shaft nuts 7 7 2 Assembly sequence for pumps with mechanical seal See specific instruction for detailed assembly of mechanical seals 31 KSE RDL 8 Spare Parts Recommended spare parts for 2 years operation according to DIN 24296 standard N of including stand by ones Denomination 4 5 7 8and9 10 or more Spare paris quan
43. medium handled capacity speed density pressure temperature and motor rating Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation Contact the if required The nameplate indicates the type series size main operating data and works number please quote this information in al 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 center For noise characteristics please refer to section 4 4 7 2 Safety These operating instructions contain fundamental information which must be complied with during installation operation and maintenance Therefore this operating manual must be read and understood both by the installing personnel and the re sponsible trained personnel operators prior to installation and commissioning and it must always be kept dose 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 21 Marking of instructions in the manual The safety instructions contained in this manual whose non observance might cause haz
44. must be regarded separately Example of marking on the pump part Ex 1 2 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 2 9 3 Checking the direction of rotation see also 6 1 4 If the explosion hazard also exists during the installation phase the direction of rotation must never be checked by starting 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 bestarded 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 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 product 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 mi
45. nditioned and neutral with regard to mechanical corrosion Inlet temperature tE 10 to 30 C Outlet temperature tA max 45 C Caution 6 1 4 Checking the direction of rotation Dry running will result in failure of the mechanical seal and must be avoided 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 Caution 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 This can be verified by switching the pump on and then off again immediately N Before checking the direction of rotation make sure that there is no foreign matter in the pump casing Never hold your hands or any other objects into the pump Do not run the pump without iquid while checking the direction of rotation If there is no medium handled available the motor s direction of rotation must be checked with the pump de coupled If the pump runs in the wrong direction of rotation interchange two of the three phases in the control cabinet or motor terminal box 6 1 5 Clean
46. nimum flows indicated in tables 4 3 and 4 3 1 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 and if the minimum flow rate must therefore be increased To check proceed as described in tables 4 3 and 4 3 1 In addition the instructions given in section 6 of this operating manual must be observed running may not only result from an inadequately filled seal chamber but also from excessive gas content 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 Both gland packings and mechanical seals may exceed the specified temperature limits if run dry Dry 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
47. nt as des cribed in section 5 5 and re align if necessary 6 1 7 1 Necessary steps for 1 operation uu ee gt t 7 Tighten the pump and driver on the baseplate Set suction and discharge piping Connect and run piping and auxiliary connections when required Make electric connection assuring that all motor protection devices are appropriately adjusted and working Assure that bearings are properly lubricated For details see chapter 7 3 Check drive rotation with pump not coupled to avoid pump dry operation Certify manually that rotor rotates free Assure that coupling alignment was executed according to chapter 5 5 Install the coupling guard if any Prime the pump that means fill the pump and suction piping with water or pumped liquid eliminating air from inside the pump See chapter 6 1 3 Assure that packing is not completely tightened Open totally the suction valve if any and close discharge one Check carefully above mentioned points start the drive machine and turn it off immediately Check the equipment stop which should be slow and smooth If the pump is normal start up definitely 6 1 7 1 1 Methods for pump priming Nr Installation with positive suction In case of installation with positive suction that means pump is installed below the suction reservoir level plugs 916 6 903 5 903 1 and 903 4 if any should be removed and su
48. o 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 The oil level should be checked with tie help of oillevel sight glass amp markings on bearing bracket RES when the pump is in standstill condition 6 1 2 Shaft seal Usually mechanical seals are fitted prior to delivery On variants with quench supply tank the tank must be fitted in accordance with the drawing see 6 1 3 Quench feed must also be provided during pump shutdown On variants with double acting mechanical seals apply sealing pressure as specified in the G A drawing data sheet prior to starting up the pump see 6 1 3 Sealing pressure must also be provided during pump shutdown For external liquid supply the quantities and pressures specified in the data sheet and G A drawing should be applied 21 KSE RDL 6 1 3 Priming the pump and checks to be carried out Before start up the pump the suction line and if applicable the thermosiphon tank must be vented and primed The shut off element in the suction line must be fully open Fully open all auxiliary lines provided flushing sealing cooling liquid etc and check the through flow For water cooling use suitable non aggressive cooling water not liable to form deposits and not containing suspended solids Hardness on average 5dH ca 1 mmol l pH gt 8 or co
49. ole process described above should be repeated e Grease lubricated bearings are charged with grease and do not need maintenance e Gland packing equipped pumps should have their packing removed before storage e Mechanical seals should be cleaned with dry compressed air No other liquid or material must be applied to them in order to prevent damage to the secondary sealing parts such as o rings and gaskets e All connections such as inlets for liquids from external sources priming draining flushing quench and cooling should be closed Suction and discharge flanges should be covered to prevent the entry of foreign bodies e Stored pumps should be turned by hand every 15 days If it is difficult to move them by hand use a pipe adjustable Spanner wrench protecting the shaft surface at the place of application e Wash exposed surfaces with gasoline or kerosene before applying the protecting liquids e Characteristics of the used protecting liquids KSE RDL TECTYL506 506 80 to100 003 to 004 up to 1 hour Gasoline Benzene Diesel Oil BRASCOLA E DW301 6 to 10 0002 to 0004 1 upto 2 hours Gasoline Benzene MOBILARMA 524 lt 6 0002 Does not dry MOBIL OIL Table 2 Protecting liquids 4 Description of the product Horizontal single stage axially split volute casing pump with double entry radial impeller Drive shaft end of the pump can be fitted either on the left or right end side Flanges accord
50. p size 300 400 340 250 500 250 620 300 340 and 300 400 For pumps sizes 400 up to 500 applicable 6 Applicable for pumps size from 600 540 only for pumps sizes 400 480 and 400 620 7 Not applicable for pumps sizes 200 500 200 620 250 340 and 250 400 13 Not applicable for pumps sizes 400 480 8 For pumps sizes 400 up to 500 applicable only for pumps sizes 400 390 500 14 Applicable for pump lubricated with oil 510 500 640 and 500 790 For pumps sizes 600 up to 800 not applicable for pump size 800 400 36 9 11 Trouble shooting 0 Possible causes RDL Pump fails to deliver liquid after being switched on Pump ceases to deliver liquid Pump overheat and or fails to deliver liquid Flow capacity too low Flow capacity too high Pump pressure too low Excessive leakage at shaft seal Excessive wear on gaskets Drive machine overload Pump does not run smooth noise 1 2 3 4 5 6 7 8 9 10 11 14 16 17 22 23 24 34 39 2 3 4 5 6 7 8 9 10 11 12 13 22 23 24 34 39 1 3 9 10 11 21 22 27 29 30 31 33 34 40 41 2 3 4 5 6 7 8 9 10 11 14 16 17 20 21 22 23 24 25 26 34 12 13 27 28 29 30 33 34 35 36 37 38 39 41 12 13 15 18 19 20 23 25 27 28 31 33 34 35 37 44 2 3 4 5 6 7 8 9 10 11 15 17 18 21 23 24 27 28 29 30 31 32 33 34 40 41 42 45 46 Bearings temperature too high Table 6 Faults and possible
51. 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 rotor 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 pump is removed from the pipe and stored Before putting the pump into storage carry out all checks specified in section 7 1 Then apply appropriate preservatives Spray coat the inside wall of the pump casing and in particular the impeller clearance areas with a preservative Spray the preservative through the suction and discharge nozzles It is advisable to close the nozzles for ex with plastic caps or similar 6 4 Returning to service after storage Before returning the pump to service carry out all checks an maintenance work specified in sections 7 1 and 7 2 N In addition the instructions laid down in the sections or Commissioning 6 1 and Operating Limits 6 2 mu stbe observed N Upon completion of the work all safety related and prote
52. rer Original spare parts and accessories authorized by the manufacturer ensure safety The use of other parts can invalidate any liability of the manu facturer for consequential damage 2 8 Unauthorized modes of operation The warranty relating to the operational reliability and safety of the pump unit supplied is only valid if the machine is used in accordance with its designated use as described in the following sections The limits stated in the data sheet must not be ex ceeded under any circumstances 4 KSE RDL 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 10 2 9 6 must be adhered without fail to ensure explosion protection 2 9 1 Unit fill ey It is assumed that the system of suction and discharge lines and thus the wetted pump internal are completely filled with the product to be handled at all times during pump operation so that an explosive atmosphere is prevented the operator cannot warrant this condition appropriate monitoring devices must be used In addition it is imperative to make sure 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 onthe pump only refers to the pump part i e the coupling and motor must be regarded separately The coupling must have an EC manufacture s declaration The driver
53. rotation Fig 15 Clockwise rotation 5 5 Coupling Alignment The useful life of the rotor assembly and its operation free of irregular vibrations will rely on the perfect alignment between the pump and the driver The alignment performed at the factory must be re checked due to the fact that during transportation and handling the motor pump assembly is exposed to deformations which may affect the initial alignment The following instructions also apply to units not mounted on a common baseplate z After connecting the piping and priming the system it is essential to re check the alignment at operating temperature Incorrect alignment and 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 After the grouting has set hard perform the alignment if possible with the suction and discharge pipe lines already connected 16 O RDL This alignment should be performed with the help of a dial indicator for the control of the radial and axial displacements Fix the bottom of the instrument to the periphery of one of the coupling halves adjust the position of the dial indicator perpendicular to the periphery of the another half of the coupling Move the dial to zero and move by hand the coupling half in which the instrument bottom is fixed making the dial indicator to complete a 360 turn See Fig 16 The same procedure should
54. se personal injury and damage to property RDL Boe dr Fan Ed 1 gY p ho la Li Fig 2 Transport of pump through seais Fig 3 Transport of complete set with common baseframe of bearing casings for pump and motor since there is no possibility of baseframe deformation due to its excessive length Note Take care to not lose or damage coupling guard or foundation bolts during transport 3 2 Interim Storage indoors Preservation KSB and its Dealer Network perform the following procedures of service and storage until effective delivery of the pump It is client responsibility to continue with these procedures after receiving the pump When a performance test after the pump sale is not applied the machined areas in contact with the pumped liquid which are not painted receive an application of RUSTILO DW 301 by brush When the pump is equipped with gland packing subject to a performance test it is drained after test without disassembling it and then filled up with RUSTILO DW 301 rotating its rotor assembly to improve the RUSTILO application After that the pump is drained again On the shaft exposed areas a brush application of TECTYL 506 is made On oil lubricated pump bearing brackets bearings receive a layer of MOBILARMA 524 by spray 3 2 1 Additional procedure for storage e Pumps stored for periods exceeding one year should be re protected every 12 months They must be disassembled cleaned and the wh
55. tained Damage resulting from disregarding this warning will not be covered by the KSB warranty Bearing bracket temperatures as described in section 7 2 1 must be observed safety instructions forth in section 2 9 must 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 should not exceed the following num ber of start ups per hour S Motor rating kW max S switchings h Up to 12 15 Upto 100 More than 100 24 KSE RDL 6 2 3 Density of the medium handled The power input of the pump will increase in proportion to the density of the medium handled To avoid over loading of the mo tor pump and coupling the density of the medium must comply with the data specified on the purchase order 6 2 4 Abrasive media handled When the pump handles liquids containing abrasive substances increased wear of the hydraulic system and the shaft seal are to be expected The intervals recommended for servicing and maintenance shall be shortened 6 3 Shutdown Storage Preservation Each KSB pump leaves the factory carefully assembled If commissioning is to take place some time after delivery we recom mend that the following measures be taken for indoors pump storage For others storage conditions consult KSB 6 3 1 Storage of new pumps New pumps are supplied by our factory duly
56. ter connecting the piping 5 6 1 Recommendation for suction piping Assembly of suction piping should comply with the following consideration a only after completing the grout set piping can be connected to the pump flange b suction piping as much as possible should be short and straight avoiding losses and totally drained preventing air from entering C to be free of air pockets in case of horizontal and negative suction the piping should be installed with a slope in direction to the suction d nominal diameter of pump suction flange does not determine the nominal diameter of suction piping For calculation of ideal diameter as referential use the flow speed established between 1 and 2 5 m s 3 and 8 ft s e when reducer is necessary this should be eccentric and with the flat side located on the top as fig 18 in order to avoid formation of air pockets f elbows when necessary should be designed and installed providing lower losses Ex prefer elbow of long or medium radius g piping flange should adjust to the pump suction nozzle totally free of tensions without transmitting any stress to the pump casing Pump should never be support for the piping If it is not observed misalignment can occur and its consequences like parts scratch and other serious damages h in installation where foot valve is applicable observe that the passage area should be 1 5 time bigger than the piping area Usually coupled to the foot valve s
57. the auxiliary valves and packing tight in order to avoid an excessive leakage on shaft seal Drops min Fig 22 Approximate number of drops On fig 23 V corresponds to the peripheral speed in m s calculated by formula where 60 1 10 12 Suction pressure Kp cm d external diameter of the shaft protecting sleeve in m 2 of shaft seal housing of table 1 n rotation per minute that pump is working rpm 7 3 Bearing maintenance Maintenance objective is to extend the useful life of the bearing system It includes observation of general condition of bearings cleaning lubricating and bearing detailed examination Lubricant properties decrease due to age and mechanical work besides all lubricants are contaminated during work therefore must be changed at intervals For the 1 set up assure that bearings are free of dirt and moisture 26 9 7 3 1 Bearings lubricated with grease During assembly in our factory bearings receive a grease charge and after lubricating interval number of hours of continuous functioning they must be lubricated to avoid metallic contact between rolling parts and also to protect them against corrosion and wear Lubricating interval Functioning hours Vill poles Grease qty 60Hz 50Hz 508 per bearing 3500 rpm 2900 rpm 1750 rpm 1450 rom 0 er 5500 6000 7000 7
58. the pumped liquid lift to suction reservoir When tank level starts rising it means that the main pump is already primed After start up of main pump turn the auxiliary pump off and close register 23 KSE RDL Ejector T Aire Water verter R Register Auxiliary 6 1 8 Shutdown Close the shut off element in the discharge line If the discharge line is equipped with a non return or check valve the shut off element may remain open If shut off is not possible the pump will run in reverse rotation 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 smoothly down to a standstill Close the auxiliary lines but only turn off the cooling liquid supply if applicable after the pump has cooled down Please refer to section 6 1 2 In the event of frost and or prolonged shutdowns the pump must be drained or otherwise protected against freezing 6 2 Operating limits The pumps units 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 medium handled ambient temperature bearing temperature Do not operate the pump at temperatures exceeding those specified on the data sheet unless the written consent of the KSB has been ob
59. tity pe MEE 2 s sm lawemmega o Las Packing ngs Se e 3 a pz paz 89 508 impelerwearrngtpan 3 mo LE exu 51 Spacersieevewpan 2 5252 Spacer seve ao Gp p p p s om saroso _ 2 fa 6 8 5 5 12 10 am keys 2 shaft nuts 1 or 2 bearing nuts 1 or 2 lockwashers Table 5 Recommended spare parts Notes 0 When pump uses only bearing 321 supply one pair of them When use one bearing 321 and one bearing 322 supply one of each part Q Optional for sizes up to 500 890 inclusive If any In this table it was considered necessity of some parts in duplicate 32 09 9 Sectional Drawing 9 1 Sizes 125 up to 300 902 2 902 5 560 1 921 350 9202 920 5 741 920 6 916 6 720 1 710 105 2 904 1 901 2 902 3 10 902 1 9203 720 1 901 1 720 9 234 720 8 920 1 6 5 903 4 6 ES 1 4114 4 720 2 720 2 412 636 9 Assess NN RR SS 7 q II PSD yy FLL IAS T 2 2 427 XAN WOO OG AIN VE A gt 3 412 VL 422272222 72 reta A Sst ZARA 2 80 920 4 70 1 940 3 cimo Tr da Ni a P E FLAT GASKET lEMPTY EMPTY 400 i 803 8 147 DRAIN
60. ve sleeves Shaft nuts must be only definitely positioned and locked after centering the impeller Place the casing wear rings 502 on the external diameter of impeller entrance hub Mount on the shaft neck rings 457 lantern ring 458 and gland cover placing them so as not hinder the assembly Mount sealing rings for shaft 420 For pumps sizes 125 up to 300 place radial ball bearing inside the bearing housings pressing them by the external ring In the bearing housing mount the spacer ring 504 at the bottom before bearing assembly Heat two sets in the furnace in temperature of 120 C 250 F for 30 minutes Place them heated on the shaft with the housing 821 Spacer ring 504 must touch in the shaft step Mount lockwasher 931 and bearing nut 923 Tighten bearing nut and lock it with one little tongue of lockwasher Mount also at high temperature bearing housing drive side with respective bearing 821 The exact position will be defined during the placement of the rotor on 30 KSE RDL the lower casing when fixing the studs 902 1 For pumps sizes 400 up to 800 assembly procedure for D E changes Mount spacer ring 504 on the shaft Mount heated the internal ring of bearing on the shaft 120 C 30 minutes Mount the external ring of bearing inside the bore of the bearing housing use uniform pressure and mount the set in the shaft Lock the set with lockwasher and bearing nut Lubricate the two bearings properly
Download Pdf Manuals
Related Search