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KSB Etanorm-R, Installation & Operating Manual

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KSB Etanorm-R Installation & Operating Manual Download Page 72

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Etanorm-R

1222.8/13-EN

Part No.

Part No.

Description

452.01

30)

452.01

Gland follower

454.01

30)

454.01

Stuffing box ring

456.01

30)

456.01

Neck bush

458.01

30)

458.01

Lantern ring, split

461

461

Gland packing

502.01/.02/.03

28)

/.04

28)

502.01/.02/.03/.04

Casing wear ring

507

507

Thrower

524

524

Shaft protecting sleeve

400.04

Joint ring

525.01

28)

525.01

Spacer sleeve

731.04

29)

731.04

Pipe union

81-92

81-92

Cover plate

550.74

Disc

901.14

Hexagon head bolt

901.01/.02/.04/.14/.30/.31

901.01/.02/.04/.14/.30/.31

Hexagon head bolt

902.01/.04

902.01/.04

Stud

903.01/.03/.04/.08/.62

903.01/.03/.04/.08/.62

Screw plug

920.01/.04

920.01/.04

Hexagon nut

922

922

Impeller nut

940.01/.02

940.01/.02

Key

30

Not shown

Summary of Contents for Etanorm-R

Page 1: ...Standardised Pump Etanorm R Installation Operating Manual...

Page 2: ...nts 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 the manufactu...

Page 3: ...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...

Page 4: ...1 Supervision of operation 45 7 2 2 Inspection work 47 7 2 3 Lubrication and lubricant change of rolling element bearings 48 7 3 Drainage cleaning 51 7 4 Dismantling the pump set 51 7 4 1 General info...

Page 5: ...Contents 5 of 78 Etanorm R 10 EU Declaration of Conformity 73 11 Certificate of Decontamination 74 Index 75...

Page 6: ...drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Discharge line The pipeline which is connected to the discharge nozzle Hydraulic sy...

Page 7: ...rview of other 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 di...

Page 8: ...gnal word indicates a hazard which if not avoided could result in damage to the machine and its functions Explosion protection This symbol identifies information about avoiding explosions in potential...

Page 9: ...s specified in the other applicable documents Section 1 4 Page 7 Only operate pumps pump sets which are in perfect technical condition Do not operate the pump set in partially assembled condition Only...

Page 10: ...rovide the personnel with protective equipment and make sure it is used Contain leakages e g at the shaft seal of hazardous fluids handled e g explosive toxic hot so as to avoid any danger to persons...

Page 11: ...only assured if the product is used in accordance with its intended use Never operate the product outside the limits stated in the data sheet and on the name plate Prevent impermissible modes of opera...

Page 12: ...nstructions may result in substantially higher temperatures If the pump is to be operated at a higher temperature the data sheet is missing or if the pump is part of a pool of pumps contact KSB for th...

Page 13: ...suspension arrangement Danger 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 Obs...

Page 14: ...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 set which has already been operated th...

Page 15: ...fluid and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Dismantle the pump set Collect grea...

Page 16: ...stics see documented 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...

Page 17: ...2 Customer reference 3 KSB order number ten digits 4 Flow rate 5 Speed 6 Minimum efficiency index 7 Customer reference 8 Year of construction 9 Order item number six digits 10 Consecutive number two...

Page 18: ...adial impeller with multiply curved vanes Sizes 200 250 250 300 300 340 Mixed flow impeller Bearings Grease packed deep groove ball bearing Oil lubricated deep groove ball bearing Direction of rotatio...

Page 19: ...axially via the suction nozzle 6 and is accelerated outward by the rotating impeller 7 In the flow passage of the pump casing the kinetic energy of the fluid is converted into pressure energy The flui...

Page 20: ...2 4 8 Scope of supply Depending on the model the following items are included in the scope of supply Pump Drive Baseplate Coupling Coupling guard 4 9 Dimensions and weights For dimensions and weights...

Page 21: ...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 be set flat and level Observe the weights indicated 1 Check...

Page 22: ...olts 3 between the baseplate foundation frame and the foundation For a bolt to bolt distance L 800 mm fit additional shims 2 halfway between the bolt holes All shims must lie perfectly flush 3 Insert...

Page 23: ...1 3 at the machine mounts 4 5 4 Piping 5 4 1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from escaping hot toxic corrosive or flammable fluids Do not use...

Page 24: ...p and connected without transmitting any stresses or strains CAUTION Welding beads scale and other impurities in the piping Damage to the pump Remove any impurities from the piping If necessary instal...

Page 25: ...nor the load distribution among the nozzles are taken into account in these sums The values indicated also apply to pumps on non grouted baseplates Table 7 Forces and moments at the pump nozzles DN M...

Page 26: ...y connections DANGER Risk of potentially explosive atmosphere by incompatible fluids mixing in the auxiliary piping Risk of burns Explosion hazard Make sure that the barrier fluid or quench liquid are...

Page 27: ...ket Damage to the bearing Never insulate the bearing bracket bearing bracket lantern and casing cover NOTE Pump casings handling fluids at temperatures below freezing point may be insulated at the sit...

Page 28: ...type coupling checking the coupling alignment 1 Straight edge 2 Gauge B B A A 2 1 1 Fig 13 Spacer type coupling checking the coupling alignment 1 Straight edge 2 Gauge B A A B 1 1 2 2 1 2 2 Fig 14 Dou...

Page 29: ...is correctly aligned if the distance between the two coupling halves is the same at all points around the circumference Observe the permissible axial offset in coupling half alignment Table 8 both dur...

Page 30: ...ard Choose a coupling guard material that is non sparking in the event of mechanical contact 6 Fit the coupling guard and its footboard if any 7 Check the distance between coupling and coupling guard...

Page 31: ...oupling 5 8 Electrical connection DANGER Electrical connection work by unqualified personnel Risk of fatal injury due to electric shock Always have the electrical connections installed by a trained an...

Page 32: ...tation to that of the pump 2 Observe the manufacturer s product literature supplied with the motor 5 9 Checking the direction of rotation DANGER Temperature increase resulting from contact between rot...

Page 33: ...correct the direction of rotation The correct direction of rotation of the motor and pump is clockwise seen from the drive end 1 Start the motor and stop it again immediately to determine the motor s...

Page 34: ...prolonged shutdown of the pump set the activities required for returning the equipment to service have been carried out Section 6 4 Page 42 6 1 2 Filling in the lubricants Grease lubricated bearings...

Page 35: ...n 7 After approximately 5 minutes check the oil level in the glass reservoir of the constant level oiler 1 The oil reservoir must be properly filled at all times to ensure that the correct oil level i...

Page 36: ...n be used for venting see drawing of auxiliary connections 2 Fully open the shut off element in the suction line 3 Fully open all auxiliary feed lines barrier fluid flushing liquid etc if any 4 Open t...

Page 37: ...t without liquid fill Prime the pump as per operating instructions Section 6 1 3 Page 35 Always operate the pump within the permissible operating range CAUTION Abnormal noises vibrations temperatures...

Page 38: ...th double mechanical seal make sure that the barrier fluid s temperature does not exceed 60 C Gland packing The gland packing must drip slightly during operation CAUTION Excessive leakage or no leakag...

Page 39: ...sure 6 1 7 Shutdown CAUTION Heat build up inside the pump Damage to the shaft seal Depending on the type of installation the pump set requires sufficient after run time with the heat source switched o...

Page 40: ...s been obtained DANGER Formation of a potentially explosive atmosphere inside the pump Explosion hazard When draining tanks take suitable measures to prevent dry running of the pump e g fill level mon...

Page 41: ...6 2 3 Fluid handled 6 2 3 1 Flow rate Table 13 Flow rate Minimum flow rate Maximum flow rate For a short period approximately 2 minutes 25 of QOpt 7 See hydraulic characteristic curves Continuous dut...

Page 42: ...7 4 1 Page 51 The permissible ambient temperature for storing the pump is observed 1 Spray coat the inside wall of the pump casing and in particular the impeller clearance areas with a preservative 2...

Page 43: ...6 Commissioning Start up Shutdown 43 of 78 Etanorm R 1222 8 13 EN NOTE If the equipment has been out of service for more than one year replace all elastomer seals...

Page 44: ...he pump set regularly Prepare a maintenance schedule with special emphasis on lubricants shaft seal and coupling The operator ensures that maintenance inspection and installation are performed by auth...

Page 45: ...er use force when dismantling and reassembling the pump set 7 2 Servicing Inspection 7 2 1 Supervision of operation DANGER Risk of potentially explosive atmosphere inside the pump Explosion hazard The...

Page 46: ...6 2 Page 40 While the pump is in operation observe and check the following The pump must run quietly and free from vibrations at all times In case of oil lubrication ensure the oil level is correct S...

Page 47: ...ure that the connection between pump and baseplate is electrically conductive 7 2 2 1 Checking the coupling Check the flexible elements of the coupling Replace the relevant parts in due time if there...

Page 48: ...on 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 Reg...

Page 49: ...pose of any lubricants Observe all legal regulations on the disposal of fluids posing a health hazard 1 2 3 Fig 18 Bearing bracket with constant level oiler 1 Constant level oiler 2 Screw plug 3 Beari...

Page 50: ...Free of resin and acid Not liable to crumble Rust preventive characteristics If required the bearings may be lubricated with greases of other soap bases Make sure to remove any old grease and rinse th...

Page 51: ...afety regulations DANGER Insufficient preparation of work on the pump set Risk of injury Properly shut down the pump set Section 6 1 7 Page 39 Close the shut off elements in the suction line and disch...

Page 52: ...ork 3 Remove the coupling guard 4 Remove the coupling spacer if fitted 5 Drain the oil fill of oil lubricated bearings Section 7 2 3 1 4 Page 49 7 4 3 Removing the motor NOTE On pump sets with spacer...

Page 53: ...rmediate ring 509 95 Sizes 200 500 250 300 300 340 and KSB cartridge seal 4EB Remove intermediate ring 509 7 4 5 2 Double stage variant The notes and steps stated in Section 7 4 1 Page 51 to Section 7...

Page 54: ...ring 500 97 Insert screws 900 97 into the second bore of the assembly fixture and fasten the assembly fixture to seal cover 471 01 again 2 Undo grub screws 904 97 in ring 500 97 3 Undo nuts 920 05 4 R...

Page 55: ...ng cover 161 with gland packing 461 01 4 Remove packing rings 461 01 and lantern ring 458 01 if any from the packing chamber 5 Pull shaft protecting sleeve 524 and thrower 507 off shaft 210 7 4 7 Dism...

Page 56: ...ractice Use original spare parts only Sequence Always reassemble the pump in accordance with the corresponding general assembly drawing or exploded view Sealing elements Check O rings for any damage a...

Page 57: ...0 01 02 5 Fasten bearing covers 360 01 02 with hexagon head bolts 901 01 02 take care not to damage lip seals 421 01 02 6 Fit thrower 507 7 Insert keys 940 02 8 Fit the coupling half on the drive end...

Page 58: ...e seal 4ES The notes and steps stated in Section 7 5 1 Page 56 to Section 7 5 2 Page 57 have been observed carried out The installation area has been cleaned A suitable lubricant has been applied to t...

Page 59: ...been applied to the mechanical seal s O rings B to reduce the friction when sliding on the cartridge seal The KSB cartridge seal is kept in a clean and level assembly area All dismantled parts have b...

Page 60: ...ing the mechanical seal Work cleanly and accurately Only remove the protective wrapping of the contact faces immediately before installation takes place Prevent any damage to the sealing surfaces or O...

Page 61: ...t sleeve 523 NOTE To reduce friction forces when assembling the seal wet the shaft sleeve and the location of the stationary ring with water 8 Position the rotating part of the mechanical seal primary...

Page 62: ...tly and evenly with hexagon nuts 920 02 so that packing rings 461 01 are not compressed yet 5 Use a feeler gauge to verify that gland follower 452 01 is fitted centred and at a right angle to the shaf...

Page 63: ...cleaned and checked for wear Any damaged or worn parts have been replaced by original spare parts The sealing surfaces have been cleaned 1 Insert key 940 31 into shaft 210 2 If equipped with KSB cartr...

Page 64: ...tor to the power supply refer to manufacturer s product literature 7 6 Tightening torques 7 6 1 Tightening torques for the pump 920 01 922 901 04 920 04 920 02 901 01 901 02 Fig 29 Tightening points a...

Page 65: ...ghtening torques for bolted screwed connections at the pump set Position Thread Tightening torques20 Comments Nm 1 M20 140 Pump on baseplate M24 140 M 30 140 2 M16 75 3 M24 1 5 140 4 M8 10 Motor on ba...

Page 66: ...stock Part No Description Number of pumps including stand by pumps 2 3 4 5 6 and 7 8 and 9 10 and more 171 Diffuser22 1 1 1 2 2 2 20 210 Shaft 1 1 1 2 2 2 20 230 Impeller 1 1 1 2 2 2 20 230 01 02 Impe...

Page 67: ...ve Part No 210 321 421 433 161 461 500 1 500 3 502 1 502 2 507 523 524 525 125 500 2 65 1 1 1 1 1 1 1 150 500 1 65 1 1 1 1 1 1 1 1 1 1 1 1 1 200 250 65 2 1 1 1 1 1 1 3 1 2 2 200 260 65 1 1 1 1 1 1 1 1...

Page 68: ...ed 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 vent valve Suction lift is too h...

Page 69: ...seal if required Vibrations during pump operation Correct the suction conditions Re align the pump set Re balance the impeller Increase pressure at the pump suction nozzle Pump set is misaligned Re a...

Page 70: ...77 901 31 330 903 03 411 03 411 04 903 04 411 04 102 502 01 940 01 922 230 524 502 02 903 01 411 01 81 92 901 14 550 74 400 02 360 02 901 02 a 903 08 411 08 161 400 19 400 01 902 01 920 01 500 18 412...

Page 71: ...0 01 02 Key 230 230 Impeller 230 01 02 230 01 02 Impeller 321 01 02 321 01 02 Deep groove ball bearing 330 330 Bearing bracket 330 330 Bearing bracket 210 Shaft 312 01 02 Deep groove ball bearing 360...

Page 72: ...28 502 01 02 03 04 Casing wear ring 507 507 Thrower 524 524 Shaft protecting sleeve 400 04 Joint ring 525 0128 525 01 Spacer sleeve 731 0429 731 04 Pipe union 81 92 81 92 Cover plate 550 74 Disc 901 1...

Page 73: ...llowing harmonised international standards31 have been applied ISO 12100 EN 809 Person authorised to compile the technical file Name Function Address company Address street No Address post or ZIP code...

Page 74: ...ver bearing ring carrier plain bearing inner rotor has been removed from the pump and cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing...

Page 75: ...G General assembly drawing 71 Gland packing 38 Grease lubrication Grease quality 50 Intervals 50 I Impeller type 18 Installation 17 Installation on a foundation 22 without foundation 23 Installation a...

Page 76: ...ty 9 Safety awareness 10 Scope of supply 20 Shaft seal 18 Shutdown 42 Spare part Ordering spare parts 66 Spare parts stock 66 Start up 37 Storage 14 42 T Temperature limits 11 Tightening torques 64 65...

Page 77: ......

Page 78: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1222 8 13 EN 01316918...

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