KSB HDA
Contents
1. Reverse rotation Interchange two of the phases of the power supply cable Motor is running on two phases only Replace the defective fuse Check the electric cable connections Speed is too low 2 Increase speed Defective bearings Fit new bearings Insufficient rate of flow Increase the minimum rate of flow Wear of internal pump parts Replace worn components by new ones Pump back pressure is lower than specified in the purchase order Adjust duty point accurately Trim the impellers Density or viscosity of the fluid pumped is higher than stated in the purchase order 2 Use of unsuitable materials Change the Material combination Speed is too high Reduce the speed 2 applies to turbine driven or I C engine driven pumps 2 3 Tie bolts seals and gaskets Tighten the bolts Fit new seals and gaskets Worn shaft seal Fit new shaft seal Score marks or roughness on shaft protecting sleeve Fit new shaft protecting sleeve Fit new shaft seal check the balancing line Check the throttle bush throttling sleeve clearances Lack of cooling liquid or dirty cooling chamber Increase cooling liquid quantity Clean out cooling chamber Purify clean cooling liquid Vibrations during pump operation Improve suction conditions Re align2. 15 20 25 30 35 40 45 50 55 60 70 Clearance mm 4 4 4 5 5 6 8 9 9 9 9 13 Dimension x mm 2 2 2 2 2 3 3 4 4 4 4 5 Max Parallel 0 13 0 13 0 25 0 25 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 Alignment limits for functioning mm Max Angular 0 13 0 13 0 25 0 25 0 40 0 40 0 30 0 50 0 50 0 80 0 80 0 80 G 31 and G 51 85 155 155 380 380 765 765 765 1350 1350 Bolt tighteness with torque Kg x cm G 32 and G 52 80 160 330 650 650 1170 1170 1170 1300 1300 1300 1960 Fig 20 Coupling each end 0 015 0 03 0 09 0 12 0 17 0 23 0 40 0 54 0 79 0 96 1 68 3 15 Fig 20 Spacer in lenght Kg x m 0 015 0 015 0 015 0 03 0 03 0 06 0 09 0 09 0 09 0 09 0 09 0 09 Grease Weight Kg Fig 20 Coupling without spacer 0 03 0 06 0 17 0 23 0 34 0 45 0 79 1 07 1 58 1 58 3 45 6 30 Extraction bolt size of gear hub UNC pol 5 16 18 3 8 16 1 2 13 5 8 11 3 4 10 3 4 10 3 4 10 3 4 10 7 8 9 1 8 Table 02 Data of coupling installation ATENTTION Alignment limits of pump and drive are indicated on items 5 4 4 till 5 4 8 2 7 Startup comissioning shutdown 7 1 Comissioning preliminary check In order to avoid any failure before start up we recommend analyze and check list fulfillment of attachment I 7 1 1 Lubrication Check bearing and lubrication and apply the required lubricant t
3. 25 HDA Figure 39 Rotor adjustment distance a Then measure distance b from the contact face of the balance disc 601 dismantled to the end of the spacer 525 2 Fig 40 Figure 40 Rotor adjustment distance b Shorten the spacer 525 2 so that the measures are equivalents a b Pump sizes 40 and 50 Consult item 9 4 1 1 General and Fig 34 Pump sizes 65 to 150 Shorten spacer ring 504 1 ensuring that plane parallelism is maintained so that there is axial clearance between the split ring 501 and the spacer ring 504 1 of 0 3 mm on sizes 65 to 125 0 5 mm on size 150 Deviation from absolute plane parallelism must not exceed 0 005 mm For details of final assembly see section Mounting the balance device 9 4 5 Fitting the shaft seal Pump sizes 65 to 150 1 Insert the key and slipt the shaft protecting sleeve 524 with O ring 412 5 onto the shaft Pump sizes 40 to 150 2 Mount the stuffing box housing 451 and gasket 400 3 3 Insert O ring 412 5 Mount the cooling cover 165 and gasket 400 2 and insert the studs for the gland cover 4 Slide the gland cover 452 1 over the shaft protecting sleeve 524 1 do not insert it in the stuffing box 5 Slip thrower 507 1 and or bearing cover 423 bearing internal side onto the shaft if they are part of the supply ATTENTION Do not pack the gland until just before commissioning after final alignment
4. 5 2 2 1 The dimensions comply with those in the installation plan 5 2 2 2 The foundation as a whole and in particular the area surrounding the foundation holes is truly horizontal and even 5 2 2 3 If these criteria are not fulfilled the requisite corrections must be reviewed with the site management and initiated 5 2 3 Transport the pump set components to the place of installation 5 2 4 If the pump set components are packaged the packaging should not be removed until immediately before the installation work starts When doing so the pump set must not be damaged The consignee of the components 5 HDA supplied is responsible for disposal of the packaging Caution All openings of the mounted pump set components are closed and must not be opened until they are needed during installation 5 2 5 Completely cover the pump set components to protect them for the full duration of the installation work on site against construction site dirt spark discharge grinding dust and other harmful ambient influences Take special care to adequately protect instruments electric cables and wiring ducts Spare parts and parts which are not immediately needed must be stored 5 2 6 Dismantle and store the coupling guards or coupling covers mounted on the pump set Figure 04 5 2 6 1 Disconnect the coupling guard 5 2 6 2 Dismantle and store the spacer of the mounted connecting coupling as described in the manufacturer s documentatio
5. Applied layer thickness m Drying time Removal Manufacturer TECTYL 506 80 up to 100 up to 1 hour Gasoline benzol diesel oil BRASCOLA RUSTILO DW 301 6 up to 10 1 up to 2 hours Gasoline benzol CASTROL MOBILARMA 524 6 Liquid Not necessary MOBIL OIL Table 01 5 Installation Pumps should be installed leveled and aligned by qualified people When this service is inappropriate executed it can have as consequence operational troubles premature wear and irreparable damage 5 1 Pre requisites 5 1 1 The foundation has been prepared and the concrete has set 5 1 2 The place of installation and the route thereto have been cleared and are suitable for transport of the pump set components 5 1 3 Adequate means of transport and hoisting tackle including personnel are available until completion of the installation work 5 1 4 Adequate alignment devices are available 5 1 5 The installation may be performed without interruptions 5 1 6 If welding work is performed on the pump set we recommend to earth all baseplates of the pump set 5 2 Preparations 5 2 1 In addition to this operating instruction the technical documents on the other pump set components are also needed for the installation and alignment work If these components are included in KSB s scope of supply the relevant documents are contained in product s data book 5 2 2 Check the foundation for compliance with the following criteria
6. Pump sizes 65 to 125 3 Fit the spacer sleeve 525 1 insert the key fit the shaft protecting sleeve 524 1 securing it using the circlip 923 3 Pump size 150 4 Insert key fit the shaft protecting sleeve 524 1 securing it using the circlip 923 3 Pump sizes 40 to 150 5 Insert the key for the coupling hub in the shaft 210 and fit the coupling hub using a suitable device From the non drive end Pump sizes 65 to 150 1 Fit the 1st stage impeller key 231 in the shaft 210 Pump sizes 40 to 150 2 Fit the impellers and the stage sleeves of the subsequent stages in the appropriate sequence on the shaft Slide the spacer sleeve 525 2 and balance disc 601 without O rings Pump sizes 40 and 50 3 Screw the shaft protecting sleeve 524 2 onto the shaft and tighten Check that the axial clearance between the impeller 230 and shaft protecting sleeve 524 2 is 0 3 mm Adjust if necessary by remachining the spacer sleeve 525 1 see fig 35 Pump sizes 65 to 150 4 Slip the spacer ring 504 1 onto the shaft insert the split ring 501 in the shaft groove and secure it with the collar 505 1 Check that the axial clearance between impeller 230 and spacer sleeve 525 2 is 0 3 mm 5 Fit key in the shaft 210 mount the shaft protecting sleeve 524 1 without O ring securing it with circlip 932 2 NOTE On pumps with a lifting device tilting pad thrust bearings type slide the spacer sleeve 525 3 onto
7. anti friction bearings Pump plain bearings with ring oil lubrication 27 HDA Figure 42 Lift off device segmental thrust bearing Pump sizes 40 to 125 plain bearings with force oil lubrication Figure 43 Lift off device segmental thrust bearing Pump size 150 plain bearing with force oil lubrication 28 HDA Figure 44 Gear pump Gear pump parts 9 4 7 Coupling See item 8 3 Wherever possible use a special device to fit and pull off couplings see Fig 45 and 46 To mount the coupling hubs when warm heat them in an oil bath or on an electric hotplate temperature between 80 100 C Figure 45 Pulling off the coupling hub Figure 46 Mounting the coupling hub Part Qtty Description 400 29 1 Gasket 525 4 1 Spacer sleeve 87 1 1 Pinion 872 1 Gear 99 3 1 Gear pump 902 29 2 Stud 904 29 1 Threaded pin 916 29 1 Threaded plug 920 29 2 Nut View X 29 HDA 9 4 8 Rotor lift Only carry out this check when the pump has cooled down and with the coupling hub mounted temperature a nozzles 50 C Laterally align bottom half of the bearing housing 350 1 Horizontal adjusting screws 901 4 in the bearing housing flange are used for the lateral alignment of the bearing housing The lateral alignment of the pump can be considered satisfactory if the lower bearing shell 370 can be moved in its seating by hand without undue effort from either end between the sh
8. a unfavorable effect to the disc system and counter disc of pump axial compensation Therefore in this situation it is recommended to the turbine manufacturer to dispose a way to maintain the turbine heated which do not rotate the pump in low rotations With the turbine heated and ready for startup it will increase the rotation up to the pump nominal rotation or at least up to it s minimum rotation 7 2 3 Startup with electrical motor If the driver is an electric motor pay attention to the startup type in order to avoid that the pump operates in a rotation below the minimum indicated The best condition is to startup the electrical motor until the rotation is fast completed If frequency inverter is used should observe the minimum indicated rotation for the pump to be directly reached In the case of startup with soft starter compensated key or star delta an adjust should be made in order to reach the nominal rotation in no less than 5 seconds 7 3 Shutdown Close the shut off valve if applicable close also intermediate extraction valve It is essential that a non return valve is fitted in the discharge line and that sufficient back pressure is available Switch off the driver checking that it runs down smoothly to a standstill In case the pump shutdown takes a long time close the valve in the suction line In pumps which handle liquid from a vessel under vacuum the shaft seal must be fed with sealant even when the p
9. and take off the stuffing box housing 451 with the cooling cover 165 19 HDA Size 40 and 50 3 Undo the shaft protecting sleeve 524 1 2 and withdraw it from the shaft 210 Remember threads can be left hand or right hand Size 65 and 150 4 Remove circlip 932 3 and pull the shaft protecting sleeve 524 1 off the shaft Size 65 under 125 5 Remove the suction side key and pull the spacer sleeve 525 1 off the shaft 9 3 2 4 Balance device Pump sizes 40 and 50 1 Remove the balance disc 601 using the extractor Pump sizes 65 a 150 2 Remove collar 505 1 and remove split ring 501 3 Pull off spacer ring 504 1 4 Remove the balance disc 601 using the extractor 5 If necessary loosen retaining bolts of the balance counter disc 602 and withdraw this from the discharge casing 107 using the extractor and pull spacer 525 2 off the shaft ATTENTION If you do not intend to dismantle the hydraulic parts of the pump measure the approximate total radial play Attach a dial indicator to a fixed support e g flange or discharge nozzle and place its tipo against the seat of the balance disc Fig 29 Carefully raise the shaft to its upper dead centre ensuring that here is no additional sagging of the shaft as this could give an incorrect measurement The clearance measured here should not exceed 0 8 mm if it does the pump must be dismantled and overhauled The rotor clearances can only be measured com
10. control and monitoring devices pressure switches and gages temperature switches and gages flow switches etc are correct set up and running 3 4 In case of multistage pump HDB with gear pump directly coupled to the shaft it is required to check the pressure delivered on lubrication lines during operation 3 5 For others accessories electric motor turbine mechanical seals valves couplings speed variable drivers etc is recommended to verify the specific requirements of operation maintenance of each one HDA KSB Bombas Hidr ulicas SA Rua Jos Rabello Portella 400 V rzea 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 A1826 8E 1 25 03 2010
11. cover and bearing bracket receive an application of TECTYL 506 by brush Bearings assembled in pump support lubricated with oil receive MOBILARMA 524 by spray The pump must be protected against physical damage humidity dust and aggressive ambient indoor 4 1 Preservation and storage additional procedures Pumps stored for periods over 6 months must have the preservative process done each 12 month The pumps must be disassembled cleaned and the storage process must be done again For pumps assembled with packing they must be removed from the equipment before storage Mechanical seals must be cleaned with dry air Do not apply liquids or other preservative materials in order to not damage the secondary sealings O rings and flat gaskets All the existent connections like plugs for liquids of external source vent drainage etc should be properly closed The pump suction and discharge nozzles are properly closed with tape in order to avoid strange bodies inside the pump Before conservation liquids application areas should be washed with gasoline or kerosene until they are completely cleaned Assembled pumps waiting for start up or installation should have their rotor manually rotated each 15 days In case of difficulty use a box spanner protecting the motor shaft surface at the point of application The main characteristics of preservative liquids mentioned in this manual are Protecting liquid
12. has been carried out If the pump is supplied with mechanical seals consider the manufacturer recommendation or specific documentation to install them 9 4 6 Bearing assembly 1 Insert the bearing isolator 423 2 and 423 3 on the shaft 2 Fit the bottom part of the bearing housing 350 3 Screw in the lower bearing shells 370 between shaft 210 and bearing housing Insert the bearing isolator 423 1 on the shaft Mount the coupling hub using a suitable device see Fig 46 4 Raise the rotor see section 9 4 8 Rotor lift 5 Mount the upper bearing shell 370 bearing end cover 361 and upper bearing housing 350 Fasten the bearing housing using tapered pins Bore and ream the holes if necessary 6 Mount the rotor position indicator 623 1 plus actuating pin 624 on the discharge end 7 Check the markings on the rotor position indicator with the balance disc 601 in contact with the balance counter disc 602 if necessary make a new marking see section 9 1 1 Rotor position indicator 8 If the pump is supplied with lift off device in the bearing casing according to figures 41A 41B 42 and 43 and follow sequence of items 5 and 6 above If also a gear pump directly connected to the pump shaft is supplied consider for assembly the details indicated in the figure 44 26 HDA Figure 41A Lift off device anti friction bearings Pump anti friction bearings Figure 41B Lift off device
13. mca Figure 12 5 7 Vacuum balance line If the pump has to pump liquid out of a vessel under vacuum it is advisable to fit a vacuum balance line This line should have a minimum N B of 25 mm and should be arranged to lead back into the vacuum vessel at a point above the highest permissible liquid level An additional line with shut off valve from the pump discharge nozzle facilitates pump venting prior to startup see Fig 13 A Main shut off valve suction side B Vacuum balance line C Vacuum tight shut off valve E Vacuum tight shut off valve R Non return valve discharge side V Vacuum vessel Z Intermediate flange Fig 13 Suction line and vacuum line 5 8 Auxiliary connections The auxiliary connections cooling sealing etc necessary to the perfect functioning of the pump should be checked and executed according to the set drawings piping plan and other supplied documents 5 9 Balance liquid The balance liquid flow rates QE are given as mean values of various measurements They relate to a pump speed of 2900 1 min 50Hz and can be converted linearly for other speeds The return of the balance liquid to the suction branch or tank is dependent on the product temperature the number of stages and the NPSH available With dropping de aerator pressure the balance liquid must always be fed back to the suction tank If a booster pump is used this liquid must be returned to the suction chamber The flow velocity in the bal
14. quality Designation Lubricating oil CLP 46 DIN 51 517 Or HD 20W 20 SAE Symbol to DIN 51 502 Kinematic viscosity at 40 C 46 4 mm2 s Flash point to Cleveland 175 C Solidification point pour point 15 C Application temperature 1 Higher than permissible bearing temperature 1 For ambient temperatures below 10 C another suitable lubricating oil type must be used 9 1 3 3 Oil Quantity Plain bearing Design with lift off device 3 With ball bearing Constructive size Bearings drive end and non drive end Oil volume per bearing l Inner diameter x lenght mm Oil fill per bearing l 1 Oil consumption l min 2 Bearing design See fig 41A 4 Bearing design See fig 41B DIN 628 Oil fill l Additional oil consumption for segmental thrust bearing with forced oil lubrication l min See figs 42 and 43 40 50 NU208K H208 DIN5412 DIN5415 0 2 35 x 50 0 40 2 7305 BUA Angular contact ball bearing 3309 C3 0 02 6 65 NU210K H210 DIN5412 DIN5415 0 2 45 x 60 0 40 3 7306 BUA 6 80 NU210K H210 DIN5412 DIN5415 0 2 45 x 60 0 40 3 7307 BUA 6 100 NU211K H211 DIN5412 DIN5415 0 3 50 x 60 0 50 4 8 125 50 x 70 0 70 6 10 150 75 x 85 1 30 8 Angular contact ball bearing 3310 BTNG C3 0 05 10 Table 03 bearing sizes and volume oil consumption Notes 1 For lubrication with oil bath a
15. switched on accidentally The suction and discharge shut off valves must be closed The pump casing must have cooled down to ambient temperature The pump casing must be empty and not under pressure Drain off the oil remove the coupling guard Separate the half couplings removing the spacer if fitted see 6 3 Coupling Remove the gland packing Check pump alignment at the coupling and note the reading see section 5 4 4 till 5 4 8 2 Disconnect the supply lines as far as necessary Always refer to the relevant sectional drawing during dismantling and assembly 9 3 Dismantling 9 3 1 Rolling bearings execution 1 Remove coupling hub using suitable device fig 28 2 Remove drive side bearing cover 360 and non drive side bearing end cover 361 including rotor position indicator 623 1 3 Bend up lock washer between ring nut of clamping sleeve and radial roller bearing 322 4 Screw ring nut backwards several turns 5 Gently tap front face of ring nut to loosen clamping sleeve 531 on the shaft 210 6 Withdraw clamping sleeve and bearing inner race from the shaft 7 Extract bearing outer race from the bearing housing 350 1 8 Undo and remove the nuts 920 2 of the studs 902 1 in the discharge casing 107 to allow access to the bearing housing and stuffing box housing 9 Remove bearing housing 350 1 10 Pull thrower 507 1 off the shaft 210 9 3 2 Sliding bearings execution 9 3 2 1 Non
16. the pump Re balance the impeller Increase the pressure at the pump suction nozzle The unit is misaligned Check the coupling re align if required Insufficient or excessive quantity of lubricant or unsuitable lubricant Top up reduce or change lubricant Non compliance with specified coupling distance Correct distance according to the G A Drawing Operating voltage is too low Increase the voltage Rotor is out of balance Clean the impeller Re balance the impeller Check balance liquid line Check mode of pump running Check return line Check pump pressures Chech rotor clearances and balancing device 1 The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure 2 Contact KSB 3 This fault can also overcome by modifying the impeller diameter 32 HDA ATTACHMENT I START UP CHECK LIST YES NO N A Rev 1 CUSTOMER PUMP DRIVER OP TAG SERVICE SEAL PLAN 1 Hydraulic check list 1 1 Is the suction valve fully open And are all blanking plates removed 1 2 Is there liquid available to pump suction valve is opened 1 3 Is the liquid in a condition to flow freely 1 4 Is the suction flow path complete 1 5 Is the suction line connection to the supply vessel submerged enough to prevent the formation of air entraining vortices 1 6 Are the suc
17. the spacer sleeve 525 2 over the shaft and key until it abuts against the impeller The key of the final stage must engage with the groove of the spacer sleeve 525 2 6 Insert the O ring 412 3 in the groove of the balance disc 601 Fit the key in the shaft groove and slide the balance disc over the shaft until it abuts against the spacer sleeve 525 2 7 Dimension the spacer ring 504 1 as per item 9 4 4 Rotor adjustment 8 Slip the spacer ring 504 1 onto the shaft insert the split ring 501 in the shaft groove and slide the collar 505 1 over it NOTE See section 9 3 3 6 1 Bluing ink check Pump sizes 40 and 50 Figure 37A Pump sizes 65 to 100 Figure 37B Pump sizes 125 and 150 Figure 37C 9 4 4 Adjusting the rotor Preparations Sizes 40 to 150 Suction discharge and stage casings are held together with tiebolts the balance counter disc 602 is fitted into the discharge casing 107 and perfectly clean gasket 400 1 The gasket 400 1 is not used on sizes 125 and 150 Lean the set preliminarily towards the pump discharge end pressure and then push it back 2 mm in the suction side according to figure 38 ATTENTION This rotor position must not be altered during the measurements which follow Figure 38 Rotor position at start of measurements Rotor adjustment Measure the distance a from the contact face of the balance counter disc 602 to the final stage impeller hub Fig 39
18. 8 9 3 Dismantling 18 5 9 Balance liquid 8 9 4 Assembly 22 5 10 Extracting piping 8 9 5 Spare parts 29 5 11 Coupling guard 8 10 Faults and causes 31 Start up check list 32 1 Introduction KSB has supplied you with equipment that has been designed and manufactured with the most advanced technology Due to its simple and tough construction it will not need much maintenance With the aim of providing 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 user about the construction and operation of our pumps describing the adequate procedures for handling and maintenance We recommend that this manual should be handled by the maintenance supervision This equipment should be used in the operational conditions for which it was selected as to flow rate total head speed voltage frequency and temperature of pumped liquid 3 HDA 2 Nameplate Figure 01 Nameplate For requests about the product or when ordering spare parts please indicate the type of pump and the Production Order n serial n This information can be obtained from the nameplate on the actual pump If the nameplate is not available the PO n 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 im
19. LER 1 ONLY ON PUMP SIZE 150 370 BEARING SHELL 2 ON PUMP SIZE 150 PART N 370 1 2 400 1 GASKET 1 400 2 GASKET 2 400 3 GASKET 2 412 1 O RING n 412 2 O RING 1 412 3 O RING 1 ON PUMP SIZES 65 TO 150 ONLY 412 4 O RING 2 412 5 O RING 2 412 6 O RING 1 412 9 O RING 2 461 GLAND PACKING 2 501 SPLIT RING 1 502 1 CASING WEAR RING 1 502 2 CASING WEAR RING n 1 503 1 IMPELLER WEAR RING 1 ONLY ON PUMP SIZE 150 IF FITTED 503 2 IMPELLER WEAR RING 5 IF FITTED AND ON PUMP SIZE 150 QTTY n 1 504 1 SPACER RING 1 ONLY ON PUMP SIZES 65 TO 150 505 1 COLLAR 1 ONLY ON PUMP SIZES 65 TO 150 521 STAGE SLEEVE n 1 524 1 SHAFT PROTECTING SLEEVE 2 1 1 ONLY ON PUMP SIZES 40 AND 50 524 2 SHAFT PROTECTING SLEEVE 1 ONLY ON PUMP SIZES 40 AND 50 525 1 SPACER SLEEVE 1 525 2 SPACER SLEEVE 1 540 BUSH 1 ONLY ON PUMP SIZES 125 AND 150 541 STAGE BUSH n 1 IF FITTED 601 BALANCE DISC 1 602 BALANCE COUNTER DISC 1 932 3 CIRCLIP 2 ONLY ON PUMP SIZES 65 TO 150 n N of stages 9 6 Sectional drawing and part list please see the drawing and part list sent together with product data book 31 HDA 10 Faults and causes Pump delivers insufficient flow rate Motor is overloaded Excessive pump discharge pressure Increase in bearing temperature Leakage at the pump Excessive leakage at the shaft seal Vibration during p
20. Operating instructions A1826 8E 1 KSB HDA HDA Horizontal multi stage high pressure centrifugal pumps Work number OP _____________________________ Type series ___________________________________ These operating instructions contain fundamental information and precautionary notes Please read the manual thoroughly prior to installation of unit connection to the power supply and commissioning It is imperative to comply with all other operating instructions referring to components of this unit This manual shall always be kept close to the unit s location of operation or directly on the pump set 2 HDA Contents Page Page 1 Introduction 2 6 Accessories 8 2 Name plate 3 6 1 Minimum flow valve 8 3 Transport 3 6 2 Measuring instruments 9 4 Preservation and storage 4 6 3 Coupling 9 4 1 Preservation and storage additional 4 7 Startup comissioning shutdown 10 procedures 7 1 Comissioning preliminary check 10 5 Installation 4 7 2 Startup 11 5 1 Pre requisites 4 7 3 Shutdown 11 5 2 Preparations 4 8 Maintenance 11 5 3 Installation of the pump set 5 8 1 Operation supervision 11 5 4 Pre alignment of pump set 5 8 2 Lubrification 12 5 5 Fastening the baseplate on the foundation 7 9 Dismantling and reassembly 12 5 6 Pipings 7 9 1 Technical data and description 12 5 7 Vacuum balance line 8 9 2 Dismantling and reassembly 18 5 8 Auxiliary connections
21. RVICE SEAL PLAN 2 Mechanical check list 2 1 Is foundation block sufficiently massive 2 2 Is the baseplate pedestal cooling turned on where fitted 2 3 Is the warm up system where installed functioning correctly 2 4 Does the alignment change when the pump and pipes are filled with liquid 2 5 Does the alignment change significantly after the pump has warmed to its operating temperature 2 6 Was the flange alignment checked before and after bolt up 2 7 When cold can the rotor be easily turned with relative ease and without metallic sounds 2 8 Is bump start motor to check rotation correct 2 9 If variable speed drive is used please ensure minimum speed is above first critical of multistage pump typically more than 2000 rpm 2 10 Check for any mechanical looseness 2 11 Check oil ring where fitted is located centrally and has not become dislodged 2 12 Check static oil level or constant level oiler where fitted 2 13 If grease lubricated make sure not over packed 2 14 Where fitted is grease visible from the relief valve Does the grease look old or new 2 15 If a constant level oiler is fitted is the pump in a fixed installation 2 16 Check cooling water to bearings where provided 2 17 If pump is soft packed check that gland bolts are only very slightly tight 2 18 If softy packed pump is on a suction lift ensure packing will be flooded with liquid during sta
22. add 13 grams of Brindi resin per Kg diluting the mixture in 6 additional water volume for example for 50 Kg of chloridric acid must add 650 gramms of Brindi resin and is diluted with 300 liters water Other inhibitter can be used considering the quantities of composition dependent of inhibitor class The deburring process takes approximately 4 hours at 20 C Thereafter remove the acid and wash the pipings with cold water The rest of acid is neutralized with a sodium solution at 0 5 500 grams sodium 100 liter water After 1 up to 2 hours reaction remove the sodium solution and wash again with water Immediately after that blow with hot air dry and line with oil to be used in service ATTENTION When working with chloridric acid it is imperative to use protective masks and protective sleeves and in case of concentrated acid it is necessary to use respiratory mask Carefully mix the chloridric acid in the water no contrary b Oil circuit wash Before first startup after repair works or after long standstill provide with oil pump oil piping wash during many hours cleaning the circuit filters This washing must be done with bearing shells 370 disassembled After finish washing control the oil in the reservoir regarding cleanness and if necessary clean or change it Carefully clean the bearing casings with wash oil after finishing to wash the circuit and before mounting the bearing shells The oil must be washed immediat
23. aft 210 and bottom half of the bearing housing 350 If the check reveals increased clearances between pump rotor and pump casing within the permitted limits add half the radial increase to the lift dimension shown on the upper part of the bearing housing Fit dial indicators on the shaft 210 suction and discharge sides with the rotor in zero position zero position means with both radial bearings removed lift is based on this condition Insert the lower bearing shells 370 at the suction and discharge sides and read off the vertical rise of the rotor on the dial indicators The rotor should move upwards by half the radial rotor clearance 0 05 to 0 1 mm Check the measurement by taking out and re inserting the bottom bearing shells 370 The measurement should correspond to the initial value Use a piece of wood to facilitate insertion of the bottom bearing shells Note the lift values The rotor can be aligned vertically by means of the adjusting screw 901 4 at the top of the bearing housing flange 9 5 Spare parts When ordering spare parts always quote the part n and serial number The serial number is shown on the front page of this manual and on the pump nameplate Fig 47 Dial indicator arrangement for shaft lift Device n 0089F0115 Device n 0089F0116 30 HDA 9 5 1 Spare parts PART DENOMINATION QTTY REMARKS 210 SHAFT 1 230 IMPELLER n 231 SUCTION STAGE IMPEL
24. ance line must not exceed 5 m s When returning the balance liquid to the suction tank the balance liquid pressure must be at least 0 5 kgf cm2 higher than the suction pressure at the pump inlet the build up pressure must not exceed 2 5 of the pump discharge pressure If when liquid is fed back to the suction tank the line is longer than 10 m increase the N B of the return line to the next size up See sectional drawing attached on product data book for location of the connections 14A and E Figure 14 Balance liquid flow rates 5 10 Extracting piping If the pump has flow extraction flange in one or more stage casings it should be assured that it or they are always opened during the operation in order to guarantee part of minimum necessary operation flow for the pump 5 11 Coupling guard Safety regulations stipulate that the pump must be fitted with a coupling guard If the purchaser specifically states that he does not want us to supply a coupling guard it must be provided by the operator 6 Accessories 6 1 Minimum flow valve When the pump work flow is reduced the necessary Power is not reduced in the same proportion on the contrary it is relatively high inclusive with a zero flow This absorbed power transform into heat inside the pump that means the liquid is heated in it s interior With 1 Strainer holder 2 Fine strainer 3 Coarse strainer 4 Pump suction branch 9 HDA the purpose not to produce ev
25. aporation the minimum flow must be re circulated The minimum flow value of continuous operation is of 50 of BEP flow point of better efficiency and it is found in the pump data sheet Generally the minimum flow will be assured by an automatic valve Fig 15 If the minimum flow valve has been supplied please consult respective operation instruction which will be together with the supply documents Figure 15 Minimum flow valve 6 2 Measuring instruments Our supply scope normally comprehend the following measuring instruments Suction pressure manometer Discharge pressure manometer Balance liquid circuit manometer Minimum flow circuit manometer Intermediate extraction manometer If applicable Bearing temperature control manometer 6 3 Coupling The gear couplings are recommended for high speed fluctuant shafts and high pressure pumps The models with gap disc are recommended for applications with motors with sliding bearings 6 3 1 Assembly 6 3 1 1 Care Carefully clean all the coupling surfaces specially joint surfaces and biting surfaces Heat the hub in an oil bath or stove up to 135 C Do not rest teeth gear at the recipient bottom or apply flame directly to the gear teeth Use recommended lubricant by the elastic sleeve manufacturer Fulfill the cover teeth with grease and bent the sealings softly with grease before assembly 6 3 1 2 Coupling parts assembly Place the teeth cover with Seal rings over the
26. checked and replaced as soon as they show signs of wear Measuring equipment The suction and discharge nozzles of each pump should be equipped with a pressure gauge thermometer having a suitable range for the pressure temperature involved plus a pressure gauge cock or valve Where the suction conditions dictate the suction nozzle should be equipped with a mano vacuometer additional measuring equipment is available on request 8 2 Lubrication Check the quality and quantity of the bearing and lubrication according to item 9 1 3 9 Dismantling and reassembly See Sectional drawings on data book for part n 9 1 Technical data and description 9 1 1 Rotor position indicator The indicator sleeve 623 1 which is screwed into the bearing end cover 361 has two markings at right angles to the pump axis The non drive end marking indicates the position of the pump rotor when operating with a new balance device 601 and 602 The pump side marking 2 0 mm away from the non drive end marking indicates the permissible amount of balance device wear If the end of the pin 624 in line with the pump side marking this means the balance device 601 and 602 is so worn that it must be replaced see Figs 21 and 22 Figure 21 Rotor position pump operation normally Figure 22 Rotor position shut pump down 13 HDA 9 1 2 Bearings Figure 23A Bearing arrangement with rolling bearings Part n Denomination 422 1 Fel
27. clearance specified in the table 05 Figure 33 Remachining the balance device 9 3 3 6 1 Checking the balance device with bluing ink After remachining the balance device or fitting new components 601 602 525 2 carry out a check with bluing ink Coat the axial contact face of the balance disc 601 thinly with bluing ink Thoroughly clean the axial contact face of the balance counter disc 602 Assemble the balance device as per item 9 4 3 points 1 to 8 shaft protective sleeve stuffing Box and bearings as per item 9 4 6 points 1 to 3 ATTENTION Do not fit O rings Raise the rotor as per item 4 3 8 Slowly rotate the rotor pushing it towards the suction side Then pull the rotor back towards the discharge end of the pump and dismantle all components up to the balance counter disc 602 The contact face of the counter disc should bear an even impression of the bluing ink over its entire area or at least over the outer of this area If not the balance counter disc 602 must be remachined and the ink test repeated 9 3 3 6 Balancing the rotor Fitting new rotor components or remachining existing ones means the rotor has to be dynamically balanced at max operating speed Max Residual eccentricity 5 m Rotor assembly From the drive end Pump sizes 40 and 50 1 Fit the 1st stage key slide the spacer sleeve 525 1 onto the shaft and over the key 2 Screw the shaft protecting sleeve 524 1 without O ring onto the shaft
28. ding to the section 5 4 from item 5 4 4 5 5 1 5 After final alignment the pump feet and the guide casing must be pinned to avoid lost the alignment of pump set 5 5 2 Extract of standard DIN 1045 1 5 5 2 1 Admixtures for concrete Admixtures are substances which are added to the concrete and which by chemical or physical action or both change the concrete properties e g its workability hardening or setting They provide negligible bulk 5 5 2 2 Strength class Cylinder compressive strength Cube compressive strength Exposure class Minimum compressive N mm2 N mm2 XC4 C25 30 25 30 5 5 3 Addition agents 5 5 3 1 For concrete and grouting also for placing any reinforcement in position only admixtures as per item 5 5 2 1 and exhibiting valid test symbol and only under the conditions stated in the test certificate 5 5 3 2 Chlorides chlorid or other substances expediting the corrosion of steel must not be added to reinforced concrete as well as concrete and grouting coming into contact with reinforced concrete 5 5 4 Minimum cement content According to DIN 1045 2 Allowable for admixtures Minimum compressive strength class Minimum cement content in kg m3 of compacted concrete Water cement value WZ for thickness up to 0 40 m C 25 30 270 W Z lt 0 60 5 5 5 After complete hardening of the grouting repeat the alignment from item 5 4 4 5 6 Pipings N
29. drive end bearing 1 Unscrew rotor indicator 623 1 and pin 624 regarding the position of rotor if applicable Execution with lift off device and gear pump coupled to the shaft this indicator and pin do not exist 2 If applicable remove the gear pump 632 and joint part 145 from the pump shaft loosening nuts 920 9 3 Remove the lift off device antifriction bearings loosening the studs 902 4 from bearing casing 350 2 when this accessory is included with the pump 4 Loosen and remove the nuts on the fixing bolts of the top half bearing housing 350 1 5 Remove the top halves of the bearing housing 350 1 6 Loosen and remove the bearing clamp 733 7 Remove the bearing end cover 361 if applicable 8 Remove the top bearing shell 370 lubrication rings 644 and maintain the bearing isolator 423 on the shaft 9 Check the rotor lift as per 9 4 8 Rotor lift 10 Remove bottom bearing shells 370 11 Loosen the nuts 920 2 and studs 902 1 take out the tapered pins 560 2 and remove the bottom halves bearing housings 350 1 12 Maintain the throwers 507 1 on the shaft Figure 28 Extraction of coupling hub 9 3 2 2 Drive end bearing 1 Proceed as per above items 4 5 6 7 8 9 10 11 and 12 2 Remove half of coupling hub using suitable device fig 28 9 3 2 3 Shaft seal 1 Remove the gland cover 452 1 2 or gland if the sealing is provided by mechanical seals 2 Pull back
30. e shaft protecting sleeve 524 into position and secure with the circlip 932 3 Check that the axial clearance between shaft shoulder and spacer sleeve 525 1 is 0 5 mm adjust if necessary Pump size 150 4 Insert drive end key slide the shaft protecting sleeve 524 onto the shaft and fasten with the circlip 932 3 Check that the axial clearance between the shaft protecting sleeve 524 1 and shaft shoulder is 1 0 mm Pump sizes 65 to 150 5 Insert the key for 1st stage impeller slide the impeller 230 and stage sleeve 521 onto the shaft from the non drive end and insert the shaft in the suction casing 106 Pump sizes 40 to 150 6 Insert the diffuser 171 1 in the stage casing 108 Mount the stage casing on the suction casing 106 Mount the stage casings in the correct sequence 7 Mount the other stages in the same way stage impeller stage sleeve and stage casing in succession after assembly 8 After mounting each stage check the overall axial clearance Sa1 Sa2 of the impeller min 5 mm Fig 36 Figure 36 Total axial clearance 9 Insert final stage diffuser 171 2 in the discharge casing 107 10 Mount the discharge casing 107 complete with final stage diffuser 171 2 and wear ring 512 11 Slip discs 550 1 onto the suction end tiebolts 905 screw on and centre nuts 920 1 Insert tiebolts 905 into the casing from the suction side 12 On the discharge side coat the threads and sh
31. ely before comissioning 9 1 4 Shaft sealing Packed glands are used to Seal the shaft outlets Subsequent conversion to a different type of seal is possible In such cases consult the pump manufacturer for details of the components required and necessary machining work 9 1 4 1 Packed glands HW hot water type packed glands need not be cooled where product temperature is less than 105 C With product temperatures of 106 C up to 150 C cooling is necessary connections 7E 1 7A 1 where the product temperature exceeds 150 C the gland cover must also be cooled connections 7E 2 7A 2 See Fig 25 and 26 Figure 24 shows the necessary cooling water flow rate In this monogram the heating up of the coolant was assumed to be t 10 C If there is any deviation from the assumed temperature differential t the coolant flow rate changes according to the formula 10 Q effective coolant flow rate t The temperature of the coolant at the cooling point outlet must not exceed 50 C The nomogram values include approx 10 for gland cover cooling For bearing cooling add 10 17 HDA Fig 24 Cooling liquid requirement Fig 25 Packed gland type HW Fig 26 Packed gland type HW with cooled gland cover 9 1 4 2 Packing the stuffing box Ensure that the packing material selected is compatible with the product Always use new packing material which has preferably been stored for some time If the suction pres
32. er wear rings 503 to a common diameter basing this on the most heavily scored impeller wear ring Individual deep grooves can be left untouched 4 Calculate the average actual diameter of all smoothed down impeller wear rings Adding this to the as new clearance as per table 05 gives to bore diameter for the casing wear rings tolerance 0 04 mm 5 Align the stage casing 108 and suction casing 106 with fitted casing wear ring to the outer fit and machine the wear ring in one machine tool setting Figure 32 9 3 3 3 Ball bearings 322 The bearings must be replaced by new ones if there are any sign of discolour and or rust or damage Use gasoline for cleaning of bearings that might be still used After cleaning these bearings must be immediately sprinkled with lubricant oil or greased 9 3 3 4 Plain bearings 370 Check the contact picture of the bore and eliminate any slight indentations using a scraper Check the fits of the plain bearings 370 with the bearing housing 350 When fitted with the bearing clamp 571 tightened it must be impossible to move the bearing shell in its seat If the fit is too loose uniformly remachine both faces of the bearing clamp 571 until the bearing shell will sit firmly in its seat without moving When fitting new bearing shells always adjust the seat as described above 21 HDA 9 3 3 5 Shaft seal Shaft protective sleeves 524 1 2 should only be re ground very lightly Dama
33. ever use the pump as an anchorage point for the piping Suction lift lines should be run with a rising slope towards the pump positive suction lines with a downwards slope towards the pump The pipes should be supported very near the pump and should be connected to the pump without transmitting any stresses and strains to it The pump must not bear the weight of the piping The nominal bores of the pipes should be the same as or greater than those of the pump nozzles We recommend installing non return valves and shut off valves according to the type of installation Thermal expansion of the pipework should be accommodated by suitable means so as not to impose any extra load on the pump For permissible nozzle loadings see foundation plan sent together with product data book Before commissioning a new installation thoroughly clean flush and blow through all vessels piping and connections As welding beads scale and other impurities frequently only become dislodged after a certain period of time it is necessary to fit a strainer in the suction line as close as possible to the suction nozzle to stop entering the pump The total cross section of the holes in the strainer should be three times the cross section of the piping to prevent excessive 8 HDA pressure loss across the strainer caused by clogging The pressure drop in the line must not exceed 3 m Note The loss of maximum load in the suction line should not exceed 2
34. fter the last stage casing 108 has been dismantled draw the shaft 210 with first stage impeller 230 231 out of the suction casing 106 then pull the impeller 230 231 off the shaft 210 11 Stack the stage casings 108 carefully so that the seal faces cannot be damaged see fig 30 Figure 30 Stacking the stage casings 9 3 3 Examination of pump components 9 3 3 1 Shaft 210 Check the running between centres on a lathe Max permissible shaft whip 0 03mm The shaft should never be straightened either warm or cold If the maximum permissible shaft whip is exceeded fit a new shaft 20 HDA ATTENTION Make sure the shaft is accurately centred on the lathe as otherwise the readings will be inaccurate 9 3 3 2 Suction 106 discharge 107 and stage casings 108 impellers 230 231 spacer sleeves 525 1 2 stage sleeves 521 Check all seal faces are in perfect condition Check the plane parallelism of the sealing faces at four points with a micrometer The deviation should not exceed 0 005 mm Touch up any damaged surfaces preferably on a lathe The surface roughness should not exceed Ra 0 8 m superfinish turning If damaged faces cannot be touched up on a lathe they may be reground If the pump casing has been adapted to match the shaft deflection they mating faces on two adjacent stage casings will have been machined in such a way that the top gap between them is narrower than the gap at the bottom b
35. ged sleeves should be removed and new ones fitted Only use new packing material If the protective sleeves and components of mechanical seals are damaged these must be replaced by new ones For marks relatively light in the contact surface the stationary and rotative seats can be sent to the mechanical seal supplier for polishing ATTENTION Never admit that o rings of etileno propileno have contact with oil or grease 9 3 3 6 Balance device Check the balance disc 601 balance counter disc 602 and spacer sleeve 525 2 for damage If the balance disc 601 touches the balance counter disc 602 remachine the faces on a lathe with arbours this ensures the contact faces are then sufficiently true in relation to the bores Max remachining 2 h 2 mm see fig 33 Individual grooves can be allowed to remain Remachining the balance device If remachining causes 2 h to be exceeded you must fit a new balance device 601 602 The total amount trimmed off the disc 601 and counter disc 602 must also be trimmed off the spacer sleeve 525 to maintain the previous rotor position in relation to the pump casing Perfect plane parallelism of the spacer sleeve faces is essential The bottom of the remachined balance disc 601 should not press against the key Carry out a check using bluing ink as per item 9 3 3 6 1 When eliminating fouling in the radial gap between the counter disc 602 and spacer sleeve 525 2 by machining apply the
36. ims with molybdenum disulphide and tighten the nuts 920 1 by hand using a short standard spanner to ensure metal to metal contact of the stage casings 108 13 Place the pump on its baseplate ensuring the pump feet seat flush on the baseplate 14 The tie bolts should be tightened in accordance with the scale graduation marks slots on tightening nut Prior to tightening in accordance with the scale graduation marks the tie bolts have to be pre loaded with 10 Nm to make sure that the casings have metal to metal contact in the axial direction In addition the tightening nuts have to be tightened in accordance with the scale graduation marks indicated in the foundation drawing 9 4 3 Mounting the balance device Pump sizes 125 to 150 1 If used insert bush 540 fit the balance counter disc 602 and attach it to the discharge casing 107 Pump sizes 40 to 100 2 Insert the gasket 400 1 fit the balance counter disc groove 602 in the discharge casing 107 e and tighten up the socket head screws 914 1 Pump sizes 40 and 50 3 Slip the spacer sleeve 525 2 onto the shaft until it abuts Insert the key and slide the balance disc 24 HDA 601 over the shaft until it abuts against the spacer sleeve 525 2 4 Screw shaft protecting sleeve 524 2 and O ring 412 5 onto the shaft 210 and tighten it Remember the screw threads may be left hand or right hand Pump sizes 65 to 150 5 Insert O ring 412 3 slide
37. ing practice Coat the fits of the various components and screw connections with graphite or similar before assembly Check all O rings and shaft seal rings for damage and renew them if necessary Always fit new gaskets ensuring they are of the same thickness as the old ones NOTE Always moisten O rings before final assembly with silicon fluid or if not available with soapy water Never fit dry O rings The tightening torques indicated for nuts and bolts shall be observed The table below indicates the tightening torques for threads depending on the materials used Property class Material 8 8 10 9 A 50 A 70 1 4462 1 4462 Tigges A 80 450 0 2 yield stress Rp02 in N mm 2 1 640 900 210 250 450 624 Metric ISO threads Tightening torque MA in Nm M6 10 4 14 9 3 40 7 30 10 3 M8 25 2 36 1 8 30 17 7 25 0 M10 49 5 71 0 16 2 34 8 49 2 M12 85 2 122 2 28 0 59 9 84 8 M16 211 302 7 69 2 148 209 9 M20 412 591 9 135 290 410 4 1 Nominal values to DIN ISO 898 Part 1 DIN 267 Part 11 and DIN 267 Part 18 Table 06 9 4 1 1 General Prior to assembly measure the axial length E of the stage casing 108 and the appertaining impeller 230 with stage sleeve 521 Any differences in length must be compensated for solely by machining the stage sleeve 521 so that E1 E2 Fig 34 If remachining is necessary reduce the length of the stage sleeve at both end faces in a s
38. ingle macine tool setting The permissible deviation from absolute plane parallelistm is 5 m Pump sizes 40 and 50 Check the axial clearance of the rotor components before mounting the rotor Slip the impellers stage sleeves balance disc and spacer sleeves 525 1 2 onto the shaft and tighten both shaft protecting sleeves The axial clearance should be 0 3 mm see Fig 35 if necessary machine the spacer sleeve 525 1 to achieve this This is generally necessary if replacement spacer sleeves have been fitted ATTENTION Take care not to damage the contact faces on the stage casings 108 impellers 230 231 and stage sleeves 521 Thoroughly clean all pump components particularly the end contact faces 23 HDA Figure 34 Measuring stages Figure 35 Axial rotor clearance sizes 40 and 50 9 4 2 Assembling the pump 1 Coat the shaft 210 with molybdenum disulphide or a similar approved liquid Pump sizes 40 and 50 2 Fit the key for the first stage impeller and slide the spacer sleeve 525 1 onto the shaft and over the key Screw the shaft protecting sleeve 524 1 with O ring 412 5 onto the shaft drive end and tighten checking whether the thread is right or left hand Slide the 1st stage impeller and stage sleeve 521 onto the shaft from the front and insert the shaft into the suction casing 106 Pump sizes 65 to 125 3 Slip the spacer sleeve 525 1 onto the shaft drive end fit key slide th
39. le misalignment of the coupling hubs KSB requirement 5 4 8 1 The radial displacement kr must not exceed 0 03 mm measured in planes displaced by 90 Figure 09 Radial displacement examples 5 4 8 2 The angular misalignment kA may be 0 03 mm in horizontal and vertical direction Figure 10 Angular misalignment examples 5 4 9 Alignment corrections on the pump 5 4 9 1 In case corrections are necessary should add shims to the driver feet by means of metal sheet of corresponding thickness In the case of drive by turbine alignment should be executed considering that the turbine will be dislocated determining the value in the vertical position thermal dilation that means the turbine should be positioned below the pump center line with the same value it will dislocate We recommend re check of alignment by hot after 30 min of functioning 5 4 9 2 Lateral correction of the pump 5 4 9 2 1 Loosen the nuts of the studs used for fastening the feet 5 4 9 2 2 For pump sizes HDA 100 125 and 150 loosen the nuts of the relevant adjusting screws and perform the lateral correction by means of the adjusting screws 2 which stay at the casing guide 1 in the casing lower part For pump sizes below from HDA 100 guide casing must be pinned by parallel pins after final alignment Figure 11 Lateral correction example 1 guide casing 2 adjusting screw 7 HDA 5 4 9 3 Do not tighten the nuts of the adjusting scre
40. n 5 3 Installation of the pump set 5 3 1 Levelling the baseplate 5 3 1 1 Remove all the components pump motor etc from the baseplate placing it the installation local according to the installation plan 5 3 1 2 With the help of the spirit level start the baseplate levelling repeatedly under 180 from the support machined surface of the pump and driver These surfaces must be leveled transversal and longitudinal in the 0 2 mm m Levelling corrections should be done through the screws supplied in the baseplate In order to help in the baseplate levelling carbon steel wedge should be placed between the baseplate and the foundation at the left and the right of the anchor bolt fix point The levelling wedge height should be as sufficient as to permit a minimum height of the grouting of 25 mm Figure 05 5 4 Pre alignment of pump set Secure the drive against unintentional starting 5 4 1 Place the pump and driver over the metallic baseplate and start alignment of pump set 5 4 2 In the case of electric motors with axial tolerance their rotors must be placed in the magnetic centre as described in the manufacturer s documentation This rotor position must not be altered during the full duration of alignment work 5 4 3 Check the distance between the coupling hubs for compliance with the installation plan and adjust it if required 5 4 4 Run out check Check each coupling hub for run out using a dial gauge
41. nd lubrication ring 2 For lubrication with forced oil lubrication 3 If fitted see sectional drawing on product data book 4 Applicable for pumps with ball bearing 16 HDA 9 1 3 4 Lubrication schedules and oil change For execution with ball bearing it is recommended to change the oil after about 300 hours of operation and then after every further 8000 hours or each year For lubrication in oil bath with lubrication ring the first oil change should be made with approximately 300 hours of operation and then after every further 3000 hours operation For lubrication with forced oil lubrication the quantity and quality of oil in the reservoir of lubrication unit should be controlled each month Change each 8000 hours operation 9 1 3 5 Oil piping with forced oil lubrication The oil feeding piping should be connected to the inlet and outlet connections from the pump bearings at the plant during installation and following supply drawings The return piping should be installed with inclination of approximately 2 degrees in direction of the reservoir ATTENTION The piping connection should be executed without stress a Cleaning oil pipings Uscrew all the connections points and close one side of oil piping Fulfill with caution pipings with inhibited chloridric acid Attention The acid is heated and can sprinkle or form scum Preparation of inhibited chloridric acid To the technical chloridric acid of 30 37 found in the market should
42. on the pump 8 Follow startup instructions for turbine drive 7 2 Startup 7 2 1 General Open the shut off valve in the minimum flow line Only switch on the pump motor with the discharge valve closed Slowly open the discharge valve to obtain the required duty point after the pump has reached full speed Check the pressure loss in the suction line by differential pressure measurements this should not exceed 2m 7 2 2 Start up with turbine In the case the driver is a steam turbine certain recommendations must be observed Turbines with fast startup Turbines prepared for immediately startup that means they are heated through by pass line from escape or other way and are ready to start operation When put in action they should increase it s rotation up to the pump nominal rotation or at least up to it s minimum rotation Turbines with slow startup Turbines that need to be pre heated for startup that means don t have condition to maintain heated when in the stand by position In this situation the pre heat or 1 turbine startup should be made not coupled to the pump and can this way increasing gradually it s rotation until it reaches the desired temperature Never couple the pump and maintain the turbine at the slow turn in order to maintain the turbine heated and ready for startup The slow turn is an operation condition of the turbine in very low rotation and below the minimum indicated rotation for the pump and has
43. pletely accurately when the pump is dismantled Figure 29 Measuring the rotor clearance 9 3 2 5 Pump casing 1 Loosen the nuts 920 1 on the discharge side tiebolts 905 cross wise until they are only slightly pr tensioned 2 Loosen anchor bolts on pump feet pedestals and lift the pump off the baseplate onto chocks If the pump suction and discharge nozzles both face the same way the pump can also be set down on its nozzles for dismantling ATTENTION Take care not to damage the contact faces of the pump nozzles Do not sling ropes under the pump shaft 3 Remove cladding 680 4 Unscrew nuts 920 1 on the discharge end of the pump and withdraw the tiebolts 905 5 Chock up the stage casings 108 with blocks of wood or a stand so that the next components are accessible 6 Press discharge casing 107 together with diffuser 171 2 from the stage casing 108 Do not damage seal faces ATTENTION Before dismantling match mark the stage casings 108 so they can be reassembled in the same order and position see fig 30 7 Pull spacer sleeve 525 2 off the shaft 8 Pull last stage impeller 230 off the shaft 9 Remove the stage casings 108 together with the diffusers 171 1 stage sleeves 521 and impellers 230 231 off the following stages The impellers 230 231 and stage sleeves 521 are secured against twisting by a common key on the shaft 210 and are stamped with matching numbers 10 A
44. portant instructions and recommendations Its careful reading is an obligation before installation electrical connections first starting and maintenance 3 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 In the case of motor pump set the lifting cables must be disposed as shown on Fig 02 On pumps with a short baseplate or without a baseplate attach the ropes as shown in Fig 03 Figure 02 Figure 03 4 HDA 4 Preservation and storage KSB standard storage and preservation procedures maintain the pump protected for a maximum period of 6 months in an indoor installation It is client responsibility to keep these procedures after receiving the pump The unit pump should be stored in a dry room where the atmospheric humidity is as constant as possible After sale if performance test is not executed the areas that have contact with the pumped liquid and are not painted for example stuffing box wear rings flanges sealing area etc receive an application of RUSTILO DW 301 by brush When the pump contain packing and performance test is executed after test the pump is drained without disassemble Afterwards the pump is fulfilled with RUSTILO DW 301 moving the rotor to optimize the application Thereafter the RUSTILO is drained The shaft exposed areas end and region between gland
45. rt up and operation 2 19 Is the coupling guard secure 2 20 Was it verified that the seal chamber is vented 2 21 Pumps handling hot liquids must be warmed up before starting 2 22 In case of dual seals can the barrier liquid pressure be monitored As an aid to diagnosis a failure on primary seal 2 23 In case of dual seals can the barrier liquid temperature in and out be monitored As an aid to diagnosis a failure on primary seal 2 24 In case of dual seals can it be proven that the barrier liquid pressure exceeds the suction pressure BEFORE start up 2 25 Verify oil mist venting from bearings of oil mist system if applicable 2 26 In case of multistage pumps HDA HDB with extraction lines they should be always opened if recommended on pump data sheet 34 HDA YES NO N A Rev 1 CUSTOMER PUMP DRIVER OP TAG SERVICE SEAL PLAN 3 Accessories check list 3 1 In case of ARC valve are they correctly fitted 3 2 In case of multistage pumps HDA HDB WL with balancing lines returning to the suction tank is the safety relief valve correctly set up 3 3 In case of pressurized lube oil system ULF to the bearings following items should be checked is outlet pressure of ULF correct Check driver rotation direction are leakages on supply and return lines of ULF and bearings if applicable check inlet and outlet temperatures of water cooling of heat exchanger
46. see figure Run out check The run out must not exceed 0 03 mm if it is exceeded KSB must be informed Figure 06 Run out check example 5 4 5 In the case of electric motor drive the alignment starts with the pump In the case of turbine drive the alignment starts with it Thereafter alignment of all the other components should be done 5 4 6 Perform the alignment with dial gauges in accordance with the manufacturer s documentation The figures 07 and 08 are examples of alignment with dial gauges Caution The coupling must not be turned by means of the alignment device 6 HDA Caution Both coupling hubs must be turned together in the same direction by 90 each in order to ensure that the measuring points are the same A coupling hub used as a reference point for alignment B coupling hub to be aligned Figure 07 Connecting coupling alignment with spacer example A coupling hub used as a reference point for alignment B coupling hub to be aligned Figure 08 Connecting coupling alignment without spacer example 5 4 7 As an alternative the coupling may be aligned using a laser device Caution Only use laser devices where unintentional radiation is avoided and no injury to health is caused by the optical device for setting and observing Injuries to health by reflection and effective leakage or secondary radiation must be prevented by protective screens 5 4 8 Permissib
47. shafts before hubs assembly as shown on Fig 16 Install the hubs in it s respective shaft the way the face of each hub remain close to the shaft end Position the equipment in approximately alignment with approximately distance between the shafts Figure 16 6 3 1 3 Clearance and angular alignment Use a internal micrometer as shown on Fig 17 measure the distance between the shafts at intervals of 90 The difference between the minimum and maximum measure should not exceed the angular limit specified in table 1 Figure 17 6 3 1 4 Parallel alignment Align until a ruler seat in a square or within the limits specified in table 02 Over both hubs as shown on Fig 18 and also at intervals of 90 Check with lamina gauge The interspace could not exceed the limit deviation specified in table 02 Strongly tight all the bolts and repeat steps 3 and 4 Re align the coupling if necessary Grease the hub teeth Figure 18 10 HDA 6 3 1 5 Assembly and lubrication Check on table 02 the necessary grease quantity Fulfill the teeth with grease softly bent the sealings with grease and insert post Screw cover and post in the rigid hub and apply torque in the bolts Remove threaded plug of each cover and complete with grease both covers until overflow through the opened hole place the threaded plugs Figure 19 To determine the distance between shafts measure all the fluctuant shaft and spacer length flange to flange Figure 20 Size 10
48. sure exceeds 15 bar we recommend die forming the individual packing rings before insertion We can supply this press on request The pressing pressure should be approx 10 bar Before inserting the packing thoroughly clean the box and the shaft protecting sleeve and coat them with molybdenum disulphide or another approved lubricant Insert the packing rings one at a time pushing them home with the gland cover Each ring should have its joint offset by 90 to the preceding one See Fig 27 Make sure there is a large enough gap at the top of the box to accommodate the gland cover Lightly compress the rings using the gland nuts Loosen the nuts and re tighten them to finger pressure using a feeler gauge check that the gland cover seats correctly when under suction pressure ATTENTION All stuffing boxes must drip during operation Leakage rate approx 2 to 3 l h Collant flow Product temperature C L h 18 HDA Fig 27 Gland packing Pump sizes Stuffing box sizes mm N of rings Packing cord per box mm 40 e 50 45 65 x 45 4 10 x 10 x 850 65 e 80 66 90 x 50 4 12 x 12 x 1000 100 70 95 x 50 4 12 x 12 x 1100 125 80 105 x 50 4 12 x 12 x 1300 150 101 125 x 53 4 12 x 12 x 1450 Table 04 Measures for stuffing box and packing cord 9 2 Dismantling and reassembly ATTENTION Before dismantling make sure the pump is disconnected from the mains and cannot be
49. t ring 500 1 Ring 631 Constant level oiler 913 Vent plug Part n Denomination 210 Shaft 322 Rolling radial bearing 350 1 Bearing housing 360 Bearing end cover 361 Bearing non end cover 400 5 Flat gasket 507 1 Thrower 52 1 Conic bush 623 1 Position indicator 624 Control pin 731 8 Threaded plug 13 B Oil drain 14 HDA Figure 23B Bearing arrangement with sliding bearings Part n Denomination 210 Shaft 324 Control pin 350 1 Bearing housing 361 Bearing end cover 370 Bearing shell 370 1 2 Bearing shell 423 1 2 3 Bearing isolator 507 1 Thrower 562 2 3 Pin 571 Clamp 623 1 Rotor indicator 624 Actuating pin 62 4 Termometer 642 1 Oil level sight glass 644 Lubrication ring 913 Vent plug 4 M Connection for temperature control 7 A Cooling outlet 7 B Cooling inlet 8 B Stuffing box drain 13 A Oil drain 13 B Oil drain 13 E 1 E 2 Oil inlet Figure 23 C Cooled sliding bearing housing 15 HDA The shaft 210 runs in two plain bearings 370 The shells on these bearings are attached to the bearing housing by means of clamps 571 Use connections 13A and 13E 1 for forced oil lubrication from the external unit The oil temperature in the bearing housing may rise to 50 C above ambient temperature but should not exceed 80 C The housings 350 1 must be cooled if the product temperature exceeds 150 C and the ambient temperature simultaneously exceeds 45 C
50. the shaft Fit key slide bearing plate 384 and spacer sleeve 525 4 22 HDA onto the shaft 210 and secure with bearing nut 920 8 or fix the pinion 87 1 at the shaft end if the pump has a gear pump coupled to the shaft 6 Before carrying out dynamic balancing check the pump rotor at the impellers impeller wear rings stage sleeves balance disc and bearing points for run out The value measured should not exceed 0 03 mm 7 Before final installation dismantle the rotor in the reverse order 9 3 3 7 Rotor clearances As new clearance Max permissible clearance Cast iron mm in Crome steel mm in Cast iron mm in Crome steel mm in 1st stage 1 Casing wear ring Impeller neck 0 45 0 55 1 1 1 1 Casing wear ring Impeller neck 2nd stage onwards 0 35 0 45 1 0 1 0 Diffuser stage sleeve 0 30 0 40 1 0 1 0 Balance counter disc spacer sleeve 0 45 0 45 1 0 1 0 Shaft suction casing 1 0 1 0 2 0 2 0 1 Suction impeller only Table 05 Rotor clearances ATTENTION If measured values exceed the max permissible clearances shown in the Rotor clearances Table 05 new wear parts must be fitted If new wear parts have to be fitted at one or more points then all other wear parts must also be renewed to re establish as new clearances throughout the pump 9 4 Assembly 9 4 1 Assembling the pump Assemble the pump in accordance with standard engineer
51. tion strainers correctly sized 1 7 Are there provisions to measure the pressure drop through the strainer as and indication of clogging 1 8 Is the suction pressure adequate to provide enough NPSH 1 9 If this pump has a suction booster pump do the suction pressure readings of this pump correct 1 10 Will the discharge line stay full once the pump shuts down 1 11 Is the pump primed 1 12 Is the pump vented and are the vent valves open Has pump been slowly turned over by hand to clear impeller passages 1 13 Pumps handling hot liquid must be warmed up before starting 1 14 Are there facilities available for measurement of pump flow and pump power consumption amps as an aid to future diagnostics 1 15 Are there tapings available for measurement of suction and discharge pressure as an aid to future diagnostics 1 16 Is the minimum flow bypass open where provided 1 17 Is the automatic re cycle valve open where provided 1 18 Is the discharge line resistance sufficient for start up As a default aim for a valve opening of less than 20 1 19 Is the discharge line empty 1 20 Is the discharge line likely to get damaged during operation 1 21 Could reverse flow take place in the system 1 22 If the pump is of the type that uses an external hydraulic balancing line are you sure that no obstructions can occur 33 HDA YES NO N A Rev 1 CUSTOMER PUMP DRIVER OP TAG SE
52. ump operation Excessive rise of temperature inside the Rough pump running Pressure quantity of balance liquid varies Cause Remedy 1 Pump delivers against an excessively high discharge pressure Re adjust duty point Excessively high back pressure Check plant for impurities Increase the speed turbine I C engine Pump or piping are not completely vented or primed Vent and or prime Supply line or impeller clogged Remove deposits in the pump and or piping Formation of air pockets in the piping Alter piping layout Fit a vent valve Pump is warped or sympathetic vibrations in the piping 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 Suction head is too high NPSH available positive suction head is too low Observe permissible speed of pressure fall Increased axial thrust 2 Correct rotor adjustment Air intake at the shaft seal Fit new shaft seal Clean liquid passage Arrange a sealing liquid supply from an outside source Or increase sealing liquid pressure
53. ump is at standstill If there is the danger of frost and or in the event of prolonged periods of standstill drain the cooling chamber or protect the pump from freezing In the case of driver with frequency inverter or soft starter the shutdown should be immediate the desaceleration ramps are extremely damage to pump balance system 8 Maintenance 8 1 Operation supervision The pump must run smoothly and evenly at all times The pump should not work dry Prolonged operation against a closed discharge valve gt 10 min must be avoided even if the minimum flow system is in operation part load cavitation wear to the minimum flow valve 12 HDA The bearing temperature may exceed ambient temperature by 50 C but not go above 80 C Check the rotor position using the indicator see item 9 1 1 The shut off valves in the supply lines must remain open during operation See item 9 1 4 for details of shaft seal monitoring Check the suction pressure and temperature and the pump the pump discharge pressure and temperature Check the cooling liquid flow rate and temperature if applicable The maximum permissible difference between inlet and outlet temperature is 10 C We recommend recording this information in a logbook Standby pumps should be started up then immediately shut down once a week to keep them operational Also check the integrity of the auxiliary connections The flexible coupling elements should be regularly
54. using connections 7E and 7A according to figure 23C At product temperatures over 200 C the bearings must always be cooled 9 1 3 Lubrication 9 1 3 1 Oil lubrication a Execution with ball bearings The bearings are submerged in oil bath and the correct level is guaranteed by the constant level oiler 638 see figure 23A b Lubrification with oil bath and lubrication oil ring execution with sliding bearings see fig 23B and 23C On bearings lubricated by lubrication ring the lower halves of the bearing housings 350 1 are filled with enough oil to guarantee that the lubrication rings 644 dip into the oil thereby ensuring the bearings are lubricated after the first few turns of the shaft An oil level sight glass 642 is provided to allow inspection on the oil fill Check table 03 to obtain oil volume per bearing c Lubrication with forced oil lubrication execution with sliding bearings The oil feeding to the bearings during the operation can be deriving from separated lubrication unit The oil pump of lubrication unit or an auxiliary oil pump lubrication should lubricate the main pump before startup and soon lubrication even after the main pump is turned off during the rotation period by inertia up to shutdown The description of separated lubrication unit if applicable is available in specific documentation supplied with the equipment data book Consult table 03 to obtain oil consumption per bearing 9 1 3 2 Oil
55. ws firmly because the connecting coupling alignment still must be repeated several times 5 5 Fastening the baseplate on the foundation 5 5 1 Foundation bolts Place the anchor bolts on the baseplate holes and screw the nuts at the ends up to the anchor bolt screw project 10 mm over the nuts Observe the position of anchor bolts in it s holes 5 5 1 1 Fill all trench of the foundation block completely with non shrinking concrete grout minimum compressive strength class C 25 30 grain size lt 5 mm according to the excerpt from DIN 1045 The flowability must be produced with the help of a fluxing agent For more details please check item 5 5 2 2 below 5 5 1 2 Baseplate grouting 5 5 1 2 1 Prepare the final grouting for the baseplate up to the planned height as shown in the installation plan 5 5 1 2 2 Make provisions for the grouting compound to bond with the foundation concrete 5 5 1 2 3 Fill all fields of the baseplate completely with non shrinking concrete grout minimum compressive strength class C 25 30 grain size lt 5 mm according to the excerpt from DIN 1045 The flow ability must be produced with the help of a fluxing agent Complete grouting without major interruptions For more details please check item 5 5 2 2 below 5 5 1 3 When the grouting compound has set check the nuts of the foundation bolts for tightness once again using a torque wrench torque of 193 N m 5 5 1 4 Provide final alignment of pump set accor
56. y a given amount The stage casings are marked with the word OBEN TOP at the top end of the periphery and with the reference number of the casing concerned If the mating faces are toughed up the difference in size between top and bottom must be maintained The grinding equipment consists of a grinding disc and centering mandrel Figure 31 Grinding the sealing faces Never regrind a sealing face by using its mating face on the next stage casing as a grinding block as this would open out the centring spigot The impellers 230 231 stage casings 108 and diffusers 171 1 2 are equipped with renewable wearing parts impellers wear rings 503 casing wear rings 502 and stage bushes 541 Examine the wearing parts for signs of wear and check the rotor clearances as per table 05 The wearing parts must only be remachined in situ within the max permissible clearance limits The increase in clearance caused by machining must also be adjusted at all the wear points in the pumps If the rotor clearances exceed the max values given in table 05 new wear parts must be fitted to re establish as new clearances Example Renewing the casing wear rings 502 1 Push the casing wear rings out of their seats taking care not to damage the seats see Fig 32 2 Press the new oversized wear rings into the bore cooling the rings makes this easier 3 Smooth down all impellers 230 231 in the region of the fitted impell
57. ype and quantities as stipulated See item 9 1 3 for details of lubricant grade and fill 7 1 2 Shaft seal Check shaft sealing see item 9 1 4 Lubrication points 11 HDA 7 1 3 Priming the pump and associated checks Vent and prime the pump and suction line before startup The shut off valve in the suction line must be fully open Fully open all auxiliary lines flush sealant coolant etc and check the flow Open the shut off valve in the vacuum balance line E if fitted and close vacuum tight C figure 13 7 1 4 Checking the direction of rotation with the pump primed The direction of rotation must match the arrow on the pump Check this by switching the pump on and then off again immediately 7 1 5 Comissioning If commissioning takes place more than 5 months after installation the following checks must be repeated 1 Ensure that the couplings are in perfect alignment 2 Check the main piping is connected stress free pretensioned as specified 3 With toothed couplings it must be possible to shift the coupling housings slightly in the axial direction 4 Remove the pump bearings clean and replace see section Dismantling the pump 5 Check shaft seal 6 Check operation of the measuring and monitoring equipment 7 If the driver is an electric motor check the direction of rotation with the pump primed by switching the pump on and then off again immediately The direction must match the arrow
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