KSB Etachrom NC Installation & Operating Manual Download Page 20

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5 Installation at Site

5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheres

Explosion hazard!

Damage to the pump set!

▷

Comply with the applicable local explosion protection regulations.

▷

Observe the information in the data sheet and on the name plates of pump and

motor.

5.2 Checks to be carried out prior to installation

Place of installation

WARNING

Installation on mounting surface which is unsecured and cannot support the load

Personal injury and damage to property!

▷

Use a concrete of compressive strength class C12/15 which meets the

requirements of exposure class XC1 to EN 206-1.

▷

The mounting surface must have set and must be completely horizontal and
even.

▷

Observe the weights indicated.

Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.

5.3 Installing the pump set

Always install the pump set in horizontal position.

DANGER

Excessive temperatures due to improper installation
Explosion hazard!

▷

Install the pump in horizontal position to ensure self-venting of the pump.

5.3.1 Installation on the foundation

Fig. 7: Fitting the shims

Bolt-to-bolt distance

Shim

Shim if (L) > 800 mm

Foundation bolt

✓

The foundation has the required strength and characteristics.

5 Installation at Site

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Etachrom NC

Summary of Contents for Etachrom NC

Page 1: ...Standardised Pump Etachrom NC Installation Operating Manual ...

Page 2: ...served The contents provided herein must neither be distributed copied reproduced edited or processed for any other purpose nor otherwise transmitted published or made available to a third party without KSB s express written consent Subject to technical modification without prior notice KSB Aktiengesellschaft Frankenthal 28 02 2013 ...

Page 3: ...s of operation 10 2 10 Explosion protection 10 3 Transport Temporary Storage Disposal 13 3 1 Checking the condition upon delivery 13 3 2 Transport 13 3 3 Storage preservation 14 3 4 Return to supplier 14 3 5 Disposal 15 4 Description of the Pump Set 16 4 1 General description 16 4 2 Product Information as per Regulation No 547 2012 for Water Pumps with a Maximum Shaft Power of 150 kW Implementing ...

Page 4: ...ing limits 34 6 3 Shutdown storage preservation 36 6 4 Returning to service 36 7 Servicing Maintenance 37 7 1 Safety regulations 37 7 2 Maintenance inspection 38 7 3 Drainage cleaning 42 7 4 Dismantling the pump set 42 7 5 Reassembling the pump set 44 7 6 Tightening torques 48 7 7 Spare parts stock 50 8 Trouble shooting 53 9 Related Documents 55 9 1 Exploded view List of components 55 10 EC Declar...

Page 5: ... any environmental and health hazards arising from components in contact with the fluid handled Discharge line The line which is connected to the discharge nozzle Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pool of pumps Pumps which are purchased and stored independently of their later use Pump Machine without drive additional components or a...

Page 6: ... applicable documents Document Contents Data sheet Description of the technical data of the pump set General arrangement drawing outline drawing Description of mating and installation dimensions for the pump set weights Drawing of auxiliary connections Description of auxiliary connections Hydraulic characteristic curve Characteristic curves showing head NPSH required efficiency and power input Gen...

Page 7: ...Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product 1 General Etachrom NC 7 of 62 ...

Page 8: ...indicates a hazard for the machine and its functions 2 2 General This manual contains general installation operating and maintenance instructions that must be observed to ensure safe pump operation and prevent personal injury and damage to property The safety information in all sections of this manual must be complied with This manual must be read and completely understood by the specialist person...

Page 9: ...tence and supervision of all personnel involved in transport installation operation maintenance and inspection must be clearly defined by the operator Deficits in knowledge must be rectified by means of training and instruction provided by sufficiently trained specialist personnel If required the operator can commission the manufacturer supplier to train the personnel Training on the pump set must...

Page 10: ...st have cooled down to ambient temperature Pump pressure must have been released and the pump must have been drained When taking the pump set out of service always adhere to the procedure described in the manual Section 6 1 7 Page 33 Section 6 3 Page 36 Decontaminate pumps which handle fluids posing a health hazard Section 7 3 Page 42 As soon as the work is completed re install and or re activate ...

Page 11: ...rating temperature of the pump in question refer to the data sheet Table 4 Temperature limits Temperature class to EN 13463 1 Maximum permissible fluid temperature T1 Temperature limit of the pump T2 280 T3 185 T4 120 T5 85 T6 Only after consultation with the manufacturer In the following cases and if ambient temperatures are higher contact the manufacturer Compliance with temperature class T5 is ...

Page 12: ...dditional increase in the temperatures at the pump surface However if the physical properties of the fluids handled are different from water it is essential to check whether an additional heat build up may occur and if the minimum flow rate must therefore be increased The calculation formula in Section 6 2 3 1 Page 35 can be used to check whether an additional heat build up may lead to a hazardous...

Page 13: ...nger to life from falling parts Always transport the pump set in the specified position Never attach the suspension arrangement to the free shaft end or the motor eyebolt Give due attention to the weight data and the centre of gravity Observe the applicable local health and safety regulations Use suitable permitted lifting accessories e g self tightening lifting tongs To transport the pump pump se...

Page 14: ...rs from the openings of the pump set at the time of installation Store the pump set in a dry protected room where the atmospheric humidity is as constant as possible Rotate the shaft by hand once a month e g via the motor fan If properly stored indoors the pump set is protected for a maximum of 12 months New pumps pump sets are supplied by our factory duly prepared for storage For storing a pump s...

Page 15: ...ed from the KSB web site at www ksb com certificate_of_decontamination 3 5 Disposal WARNING Fluids consumables and supplies which are hot or pose a health hazard Hazard to persons and the environment Collect and properly dispose of flushing fluid and any residues of the fluid handled Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posi...

Page 16: ...d characteristic curve The efficiency of a pump with a trimmed impeller is usually lower than that of a pump with full impeller diameter Trimming of the impeller will adapt the pump to a fixed duty point leading to reduced energy consumption The minimum efficiency index MEI is based on the full impeller diameter Operation of this water pump with variable duty points may be more efficient and econo...

Page 17: ...scosity of the fluid handled 6 Minimum efficiency index 7 Impeller diameter 8 Head 9 Speed 10 Year of construction 11 Efficiency see data sheet 4 5 Design details Design Annular casing pump Back pull out design Horizontal installation Single stage Dimensions and ratings to EN 733 Pump casing Annular casing with welded on or bolted on pump feet Replaceable casing wear rings Bearings Radial ball bea...

Page 18: ... to the suction nozzle At the rear side of the impeller the shaft 4 enters the casing via the casing cover 3 The shaft passage through the cover is sealed towards the atmosphere with a shaft seal 8 The shaft runs in rolling element bearings 9 and 10 which are supported by a bearing bracket 5 linked with the pump casing and or casing cover The pump is sealed by a standardised mechanical seal 4 7 No...

Page 19: ...er Coupling guard DANGER Risk of ignition by frictional sparks Risk of explosion Choose a coupling guard material that is non sparking in the event of mechanical contact see DIN EN 13463 1 If any coupling parts are made of aluminium a brass coupling guard must be used Channel section steel or folded steel plate optional Cast baseplate to ISO 3661 As required 4 9 Dimensions and weights For dimensio...

Page 20: ...posure class XC1 to EN 206 1 The mounting surface must have set and must be completely horizontal and even Observe the weights indicated 1 Check the structural requirements All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing general arrangement drawing 5 3 Installing the pump set Always install the pump set in horizontal position DAN...

Page 21: ... Wait until the concrete has set firmly then level the baseplate 6 Tighten the foundation bolts 3 evenly and firmly NOTE For baseplates more than 400 mm wide it is recommended to grout the baseplate with low shrinkage concrete NOTE For baseplates made of grey cast iron it is recommended to grout the baseplate with low shrinkage concrete NOTE For low noise operation contact KSB to check whether the...

Page 22: ...age or hinder disassembly of the pump The suction lift line has been laid with a rising slope the suction head line with a downward slope towards the pump A flow stabilisation section having a length equivalent to at least twice the diameter of the suction flange has been provided upstream of the suction flange The nominal diameters of the pipelines are equal to or greater than the nominal diamete...

Page 23: ...p Match the cleaning operation mode and duration for flushing and pickling service to the casing and seal materials used 5 4 2 Permissible forces and moments at the pump nozzles FV FVmax 2 FH FHmax 2 Mtmax Mt 2 1 FV FH FH FV FH FH Fig 10 Forces and moments at the pump nozzles The following condition must be met IFVI IFHI and IMtI are the sums of the absolute values of the respective loads acting o...

Page 24: ... 9 0 7 65 200 3 0 2 2 0 85 65 250 3 2 2 4 1 05 80 200 4 0 2 9 1 45 80 250 4 0 2 9 1 45 NOTE The indicated values apply to pumps made of chrome nickel molybdenum steel 1 4571 on non grouted baseplates 5 4 3 Vacuum balance line NOTE Where fluid has to be pumped out of a vessel under vacuum it is recommended to install a vacuum balance line The following rules apply to vacuum balance lines Minimum no...

Page 25: ...mosphere due to insufficient venting Explosion hazard Make sure the space between the casing cover discharge cover and the bearing cover is sufficiently vented Never close or cover the perforation of the bearing bracket guards e g by insulation WARNING The volute casing and casing discharge cover take on the same temperature as the fluid handled Risk of burns Insulate the volute casing Fit protect...

Page 26: ...es and strains 2 Place the straight edge axially on both coupling halves 3 Leave the straight edge in this position and turn the coupling by hand The coupling is aligned correctly if the distances A and B to the respective shafts are the same at all points around the circumference The radial and axial deviation between the two coupling halves must not exceed 0 1 mm during standstill as well as at ...

Page 27: ... baseplate 5 Check that the coupling and shaft can easily be rotated by hand WARNING Unprotected rotating coupling Risk of injury by rotating shafts Always operate the pump set with a coupling guard If the customer specifically requests not to include a coupling guard in KSB s delivery then the operator must supply one Observe all relevant regulations for selecting a coupling guard DANGER Risk of ...

Page 28: ... a coupling guard DANGER Risk of ignition by frictional sparks Explosion hazard Choose a coupling guard material that is non sparking in the event of mechanical contact see DIN EN 13463 1 6 Re install the coupling guard and the footboard for the coupling guard if any 7 Check the distance between coupling and coupling guard The coupling and coupling guard must not come into contact 5 8 Electrical c...

Page 29: ...ort as possible Table 8 Time relay settings for star delta starting Motor rating Y time to be set 30 kW 3 s 30 kW 5 s 5 8 2 Earthing DANGER Electrostatic charging Explosion hazard Damage to the pump set Connect the PE conductor to the earthing terminal provided Provide for potential equalisation between the pump set and foundation 5 8 3 Connecting the motor NOTE In compliance with IEC 60034 8 thre...

Page 30: ...seal and leakage Separate the pump from the motor to check the direction of rotation CAUTION Drive and pump running in the wrong direction of rotation Damage to the pump Refer to the arrow indicating the direction of rotation on the pump Check the direction of rotation If required check the electrical connection and correct the direction of rotation The correct direction of rotation of the motor a...

Page 31: ...the pump and prime them with the fluid to be handled CAUTION Increased wear due to dry running Damage to the pump set Never operate the pump set without liquid fill Never close the shut off element in the suction line and or supply line during pump operation 1 Vent the pump and suction line and prime both with the fluid to be handled 2 Fully open the shut off element in the suction line 3 Fully op...

Page 32: ...e the pump set without liquid fill Prime the pump as specified Always operate the pump within the permissible operating range CAUTION Abnormal noises vibrations temperatures or leakage Damage to the pump Switch off the pump set immediately Eliminate the causes before returning the pump set to service The system piping has been cleaned The pump suction line and inlet tank if any have been vented an...

Page 33: ...he fluid handled has cooled down The shut off valve in the suction line is and remains open 1 Close the shut off valve in the discharge line 2 Switch off the motor and make sure the pump set runs down smoothly to a standstill NOTE If the discharge line is equipped with a non return or check valve the shut off element in the discharge line may remain open provided the site s requirements and regula...

Page 34: ...g operation Table 9 Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 C Minimum See data sheet 6 2 2 Frequency of starts DANGER Excessive surface temperature of the motor Explosion hazard Damage to the motor In case of explosion proof motors observe the frequency of starts specified in the manufacturer s product literature The start up frequency is usually determine...

Page 35: ...proportion to the density of the fluid handled CAUTION Impermissibly high density of the fluid handled Motor overload Observe the information on fluid density indicated in the data sheet Make sure the motor has sufficient power reserves 6 2 3 3 Abrasive fluids Do not exceed the maximum permissible solids content specified in the data sheet When the pump handles fluids containing abrasive substance...

Page 36: ...or grease all exposed machined parts and surfaces of the pump with silicone free oil or grease food approved if required to protect them against corrosion Observe the additional instructions Section 3 3 Page 14 If the pump set is to be stored temporarily do not preserve the wetted components made of alloy materials Observe any additional instructions and information provided Section 3 Page 13 6 4 ...

Page 37: ...re the electrical connections are disconnected before carrying out work on the pump set WARNING Fluids and supplies posing a health hazard and or hot fluids or supplies Risk of injury Observe all relevant laws When draining the fluid take appropriate measures to protect persons and the environment Decontaminate pumps which handle fluids posing a health hazard WARNING Insufficient stability Risk of...

Page 38: ...hazard Fire hazard Damage to the pump set Regularly check the rolling element bearings for running noises DANGER Incorrectly serviced barrier fluid system Explosion hazard Fire hazard Damage to the pump set Hot and or toxic fluids could escape Service the barrier fluid system regularly Monitor the barrier fluid pressure CAUTION Increased wear due to dry running Damage to the pump set Never operate...

Page 39: ...ated rolling element bearings due to the running in process The final bearing temperature is only reached after a certain period of operation up to 48 hours depending on the conditions 7 2 2 Inspection work DANGER Excessive temperatures caused by friction impact or frictional sparks Explosion hazard Fire hazard Damage to the pump set Regularly check the coupling guard plastic components and other ...

Page 40: ...ng of axial sealing rings mounted on the shaft Only gentle contact of the sealing lip shall be established 7 2 3 Lubrication and lubricant change of rolling element bearings DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Explosion hazard Fire hazard Damage to the pump set Regularly check the condition of the lubricant 7 2 3 1 Grease lubrication The bea...

Page 41: ... bearing g Code Grease per bearing g 25 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6306 Z C3 8 32 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6306 Z C3 8 40 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6306 Z C3 8 50 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 6305 Z C3 5 630...

Page 42: ...rforming work on the pump set Risk of injury Always have repair and maintenance work performed by specially trained qualified personnel WARNING Hot surface Risk of injury Allow the pump set to cool down to ambient temperature WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to property Use suitable transport devices lifting equipment and lifting tackle t...

Page 43: ... motor NOTE On pump sets with spacer type couplings the back pull out unit can be removed while the motor remains bolted to the baseplate WARNING Motor tipping over Risk of crushing hands and feet Suspend or support the motor to prevent it from tipping over 1 Disconnect the motor from the power supply 2 Unbolt the motor from the baseplate 3 Shift the motor to separate it from the pump 7 4 4 Removi...

Page 44: ...e gasket 400 1 if any from shaft 210 and dispose of it 3 Remove discharge cover 163 from bearing bracket 330 or intermediate piece 132 4 Remove the stationary assembly of the mechanical seal consisting of the mechanical seal s mating ring and the elastomer from discharge cover 163 7 4 7 Dismantling the bearings Grease lubrication The notes and steps stated in Section 7 4 1 Page 42 to Section 7 4 6...

Page 45: ...es cyanoacrylate adhesives Coat the locating surfaces of the individual components with graphite or similar before reassembly For reassembly tighten all screws and bolts as specified in this manual Section 7 6 Page 48 7 5 2 Fitting the bearings Grease lubrication 1 2 3 4 Fig 15 Installing the radial ball bearing 1 Bearing bracket 2 Cover plate 3 Radial ball bearing 4 Shaft The individual parts hav...

Page 46: ...The sealing surfaces have been cleaned 1 Clean shaft sleeve 523 or shaft 210 and touch up any score marks or scratches with a polishing cloth If the score marks or scratches are still visible replace shaft sleeve 523 and or shaft 210 2 Push shaft sleeve 523 if any onto shaft 210 with new gasket 400 1 3 Clean the seat ring location in discharge cover 163 CAUTION Elastomers in contact with oil greas...

Page 47: ...ut unit tipping over Risk of crushing hands and feet Suspend or support the bearing bracket at the pump end The notes and steps stated in Section 7 5 1 Page 44 to Section 7 5 4 Page 47 have been observed carried out Any damaged or worn parts have been replaced by original spare parts The sealing surfaces have been cleaned For back pull out units without coupling fit the coupling in accordance with...

Page 48: ...200 A C D X B Fig 18 Tightening points for impeller diameters 250 50 200 65 200 80 200 Table 14 Tightening torques for screwed connections at the pump Position Thread size Rated torque Nm A M10 M12 38 55 B M12 x 1 5 M16 x 1 5 M24 x 1 5 M30 x 1 5 55 55 130 170 C M8 M10 20 38 D M12 125 E M8 M10 M12 M16 20 38 55 130 7 Servicing Maintenance 48 of 62 Etachrom NC ...

Page 49: ... for the pump set Position Thread size Rated torque Nm Description 1 M12 M16 M20 30 75 75 Pump on baseplate 2 M12 30 3 M24 x 1 5 M36 x 1 5 140 140 Levelling screws in baseplate 4 M6 M8 M10 M12 M16 M20 M24 10 10 15 30 75 140 140 Motor on baseplate or motor on levelling screws or shims 5 M6 M8 M10 13 18 44 Coupling only for spacer type coupling made by Flender 6 M6 10 Coupling guard 7 Servicing Main...

Page 50: ...nsecutive number Year of construction Refer to the name plate for all data Section 4 4 Page 17 Also specify the following data Part description Part No Quantity of spare parts Shipping address Mode of dispatch freight mail express freight air freight Refer to the exploded view or general assembly drawing for part numbers and descriptions Section 9 1 Page 55 7 Servicing Maintenance 50 of 62 Etachro...

Page 51: ...2 2 20 321 Radial ball bearing set 1 1 2 2 2 3 25 330 Bearing bracket 1 2 400 1 Gasket 4 6 8 8 9 10 100 412 O ring 4 6 8 8 9 12 150 433 Mechanical seal 1 1 2 2 2 3 25 502 1 Casing wear ring suction side 2 2 2 3 3 4 50 502 25 Casing wear ring discharge side 2 2 2 3 3 4 50 5236 Shaft sleeve 2 2 2 3 3 4 50 5 Not applicable for Etachrom NC 25 125 1 25 125 25 160 32 125 1 32 125 32 160 40 125 50 125 6 ...

Page 52: ... 1 25 160 5 2 2 1 3 1 1 2 1 1 1 1 2 1 1 25 200 2 3 3 1 4 1 1 3 1 1 1 1 3 1 1 1 25 250 1 3 4 2 5 1 3 4 1 3 1 3 4 2 3 32 125 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 32 125 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 32 160 5 2 2 1 3 1 1 2 1 1 1 1 2 1 1 32 200 2 3 3 1 4 1 1 3 1 1 1 1 3 1 1 1 32 250 1 3 4 2 5 1 3 4 1 3 1 3 4 2 3 40 125 1 1 1 1 1 1 1 1 1 1 1 1 2 40 160 2 2 1 1 1 2 1 1 1 1 2 1 2 2 40 200 2 3 1 1 1 3 1 1 ...

Page 53: ...layout Fit vent valve Suction lift is too high NPSHavailable positive suction head is too low Check alter fluid level Install pump at a lower level Fully open the shut off element in the suction line Change suction line if the friction losses in the suction line are too high Check any strainers installed suction opening Observe permissible speed of pressure fall Air intake at the shaft seal Fit ne...

Page 54: ...ing of pump if required reduce distances between the pipe clamps Fix the pipelines using anti vibration material Increased axial thrust8 Clean balancing holes in the impeller Replace the casing wear rings 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 general arr...

Page 55: ...ription Part No Description 101 Pump casing 330 Bearing bracket 901 1 4 Hexagon head bolt 163 Discharge cover 360 1 2 Bearing cover 903 1 Screwed plug 182 Foot 411 1 2 3 Joint ring 920 1 4 Nut 183 Support foot 412 O ring 930 Safety device 210 Shaft 433 Mechanical seal 932 1 2 Circlip 230 Impeller 502 1 29 Casing wear ring 940 1 2 Key 321 1 2 Radial ball bearing 580 2 Cap 6B Fluid drain 9 Not appli...

Page 56: ...scription 101 Pump casing 330 Bearing bracket 902 2 Stud 132 Intermediate piece 360 1 2 Bearing cover 903 1 Screwed plug 163 Discharge cover 411 1 2 3 Joint ring 920 1 4 5 Nut 183 Support foot 412 O ring 930 Safety device 210 Shaft 433 Mechanical seal 932 1 2 Circlip 230 Impeller 502 1 2 Casing wear ring 940 1 2 Key 321 1 2 Radial ball bearing 901 1 2 4 Hexagon head bolt 6B Fluid drain 9 Related D...

Page 57: ...earing cover 901 1 4 Hexagon head bolt 132 Intermediate piece 400 1 Gasket 902 2 Stud 163 Discharge cover 411 1 2 3 Joint ring 903 1 Screwed plug 183 Support foot 412 O ring 920 1 4 5 Nut 210 Shaft 433 Mechanical seal 930 Safety device 230 Impeller 502 1 2 Casing wear ring 932 1 2 3 Circlip 321 1 2 Radial ball bearing 523 Shaft sleeve 940 1 2 Key 330 Bearing bracket 81 92 Cover plate 6B Fluid drai...

Page 58: ...owing Directives as amended from time to time Pump set Machinery Directive 2006 42 EC The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 EN 809 A1 Person authorised to compile the technical file Name Function Address company Address Street No Address post or ZIP code city country The EC Declaration of Conformity was issued in on Place d...

Page 59: ...e hereby declare that this product is free from hazardous chemicals biological or radioactive substances On seal less pumps the rotor has been removed from the pump for cleaning No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residues and disposal We confirm that the above data and information are correct and c...

Page 60: ...ion 21 Installation at site 20 Intended use 8 Interchangeability of pump components 52 M Mechanical seal 33 Misuse 9 Monitoring equipment 11 N Name plate 17 Noise characteristics 18 O Operating limits 8 34 Order number 6 Ordering spare parts 50 Other applicable documents 6 P Partly completed machinery 6 Permissible forces at the pump nozzles 23 Piping 22 Preservation 14 36 Priming and venting 31 P...

Page 61: ......

Page 62: ...1212 8 14 EN 01039397 KSB Aktiengesellschaft 67225 Frankenthal Johann Klein Str 9 67227 Frankenthal Germany Tel 49 6233 86 0 Fax 49 6233 86 3401 www ksb com ...

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