KSB KWP-Bloc Installation & Operating Manual Download Page 1

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Dry-installed Close-Coupled Pump

KWP-Bloc

Installation/Operating Manual

Summary of Contents for KWP-Bloc

Page 1: ...Dry installed Close Coupled Pump KWP Bloc Installation Operating Manual ...

Page 2: ...ents 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 manufacturer s express written consent Subject to technical modification without prior notice KSB SE Co KGaA Frankenthal 03 09 2018 ...

Page 3: ...quipment 11 2 9 4 Operating limits 12 3 Transport Temporary Storage Disposal 13 3 1 Checking the condition upon delivery 13 3 2 Transport 13 3 3 Storage preservation 13 3 4 Return to supplier 14 3 5 Disposal 14 4 Description of the Pump Set 15 4 1 General description 15 4 2 Designation 15 4 3 Name plate 16 4 4 Design details 16 4 5 Materials 18 4 6 Configuration and function 19 4 7 Noise character...

Page 4: ...42 7 4 2 Preparing the pump set 43 7 4 3 Dismantling the motor 43 7 4 4 Removing the impeller 43 7 4 5 Removing mechanical seal MG1 G6 43 7 4 6 Removing the shaft and rolling element bearings 44 7 5 Reassembling the pump set 44 7 5 1 General information Safety regulations 44 7 5 2 Installing the shaft and rolling element bearing 45 7 5 3 Fitting the mechanical seal 45 7 5 4 Fitting the impeller 46...

Page 5: ...irectly fitted to the pump via a flange or a drive lantern Oil reservoir The oil reservoir prevents the mechanical seal from running dry for example in the event of a short period of negative pressure on the suction side Pool of pumps Customers operators pumps which are purchased and stored regardless of their later use Pump Machine without drive additional components or accessories Pump set Compl...

Page 6: ...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 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 i...

Page 7: ...ord 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 potentially explosive atmospheres in accordance with EU Directive 2014 34 EU ATEX General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or seri...

Page 8: ...ot taken into account in this operating manual 2 2 Intended use The pump set must only be operated in the fields of application and within the use limits specified in the other applicable documents ð Section 1 4 Page 6 Only operate pumps pump sets which are in perfect technical condition Do not operate the pump set in partially assembled condition Only use the pump to handle the fluids described i...

Page 9: ...al specialist personnel 2 4 Consequences and risks caused by non compliance with this manual Non compliance with these operating instructions will lead to forfeiture of warranty cover and of any and all rights to claims for damages Non compliance can for example have the following consequences Hazards to persons due to electrical thermal mechanical and chemical effects and explosions Failure of im...

Page 10: ...ervice always adhere to the procedure described in the manual ð Section 6 3 Page 35 Decontaminate pumps which handle fluids posing a health hazard ð Section 7 3 Page 42 As soon as the work has been completed re install and re activate any safety relevant devices and protective devices Before returning the product to service observe all instructions on commissioning ð Section 6 1 Page 28 2 8 Unauth...

Page 11: ...on For the permissible operating temperature of the pump in question refer to the data sheet Table 4 Temperature limits Temperature class to EN 13463 1 or ISO 80079 36 Maximum permissible fluid temperature T1 100 C2 T2 100 C2 T3 100 C2 T4 100 C T5 Only after consultation with the manufacturer Temperature class T4 Based on an ambient temperature of 40 C and proper maintenance and operation complian...

Page 12: ...an additional 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 ð Section 6 2 3 1 Page 34 can be used to check whether additional heat build up may lead to a danger...

Page 13: ...nd fastening points Observe the applicable local accident prevention regulations Use suitable permitted lifting accessories e g self tightening lifting tongs CAUTION Incorrect transport of the pump Damage to the shaft seal For transport lock the pump shaft with a suitable transport lock to prevent any movement of the shaft When transporting the pump without motor shaft 210 must be locked To transp...

Page 14: ...s could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen also neutralise the pump and blow through with anhydrous inert gas to ensure drying 4 Always complete and enclose a certificate of decontamination when returning the pump Indicate any safety measures and decontamination measures taken ð Section 11 Page 61 NOTE If required a blank certi...

Page 15: ...iption 1 3 Pump type KWP KWP 4 Impeller F Free flow impeller K Channel impeller O Open impeller3 5 17 Size e g 125 Nominal suction nozzle diameter mm 100 Nominal discharge nozzle diameter mm 0250 Nominal impeller diameter mm 18 Pump casing material D NORIDUR 1 4593 G Grey cast iron GJL 250 19 Impeller material D NORIDUR 1 4593 N ERN 20 Wear plate material wear ring material D NORIDUR 1 4593 N ERN ...

Page 16: ...G10 2018 0520 5 P 10000 31 997125086300550001 21 0 m h 1420 1 min 13 0 m 1 2 3 4 5 6 7 8 9 Fig 1 Name plate example 1 Type series size material and design version 2 Customer specific information optional 3 KSB order number and KSB order item number 4 Flow rate 5 Speed 6 Year of construction 7 Head 8 Pump input power optional 9 Further required information optional 4 4 Design details Design Volute ...

Page 17: ...tted with an oil reservoir For horizontal installation an oil reservoir can be fitted as an option Only single mechanical seals are fitted in the conical discharge chamber Table 7 Mechanical seal makes Material variant of pump Design Supplier Type Material combination to EN 12756 GNNG GDNG DDDD Single unbalanced Burgmann6 MG1 G6 Q1Q1VGG Q1Q1EGG John Crane 2100 Q5Q5VGG Q5Q5EGG Single balanced KSB 4...

Page 18: ...of 1 25 d for hexagon head bolts Discharge flange with clearance holes to EN 1092 2 PN 16 21 B 4 5 Materials Table 9 Materials depending on material variant Part No Description Material variant DDDD GDNG GNNG 101 Pump casing Noridur 1 4593 EN GJL 250 EN GJL 250 135 01 Wear plate suction side Noridur 1 4593 ERN ERN 146 Intermediate lantern EN GJL 250 EN GJL 250 EN GJL 250 163 Discharge cover Noridu...

Page 19: ...luid passing through The fluid enters the pump axially via a suction nozzle 6 and is accelerated outward in a cylindrical flow by the rotating impeller 7 The flow profile of the pump casing converts the kinetic energy of the fluid into pressure energy The fluid leaves the pump via the discharge nozzle 2 The casing is fitted with a replaceable wear plate 1 The diagonal clearance gap prevents freque...

Page 20: ...pe of supply Pump Surface cooled IEC three phase current squirrel cage motor Cover plates at drive lantern to EN 294 4 9 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing outline drawing of the pump pump set 7 Spatial average as per ISO 3744 and EN 12639 valid for pump operation in the Q Qopt 0 80 1 1 range and for non cavitating operation If noise l...

Page 21: ...ion No special foundation is required for installation An even slab of concrete is sufficient as an installation surface On pumps supplied with a mounting plate the mounting plate can be used as a template for drilling The mounting plate and the foundation rails must not be set in concrete ü The installation surface has the required strength and characteristics 1 Position the pump set on the ancho...

Page 22: ...line can carry the weight of the pump Install suitable supports if necessary 2 Install the pump in the pipeline in a vertical position with the motor on top 5 3 Piping 5 3 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 the pump as an anchorage point for the piping Anchor the pipes in clos...

Page 23: ...ly clean flush and blow through all vessels pipelines and connections especially of new installations 2 Before installing the pump in the piping remove the flange covers on the suction and discharge nozzles of the pump CAUTION Welding beads scale and other impurities in the piping Damage to the pump Remove any impurities from the piping If necessary install a filter Observe the information in ð Se...

Page 24: ...rrection coefficients depending on material and temperature see diagram below DDDD GNNG GDNG 0 4 0 5 0 6 0 7 0 8 0 9 1 0 20 40 60 80 100 k f T T C Fig 6 Temperature correction diagram Calculation of forces and moments for T 20 C Reduction formula Permissible force moment k T x force moment from table Example Material DDDD T 100 C k 0 98 Table 11 Permissible forces F and moments M at the pump nozzl...

Page 25: ... 1345 125 100 0250 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 125 100 0251 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 125 100 0253 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 125 100 0315 6645 4310 5300 6825 4940 3770 2515 3860 2425 4850 3145 5030 3595 2695 1795 5 4 Enclosure insulation WARNING The volut...

Page 26: ...r s direction of rotation to that of the pump 2 Observe the manufacturer s product literature supplied with the motor 5 5 3 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 6 Checking the direction of rotation DANGER Temperature increases...

Page 27: ...e 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 direction of rotation 2 Check the direction of rotation The motor s direction of rotation must match the arrow indicating the direction of rotation on the pump 3 If the motor runs in the wrong direction of rota...

Page 28: ...tdown of the pump set the activities required for returning the equipment to service have been carried out ð Section 6 4 Page 35 6 1 2 Filling in the lubricant Grease lubricated bearings Grease lubricated bearings have been packed with grease at the factory Lubricant reservoir for mechanical seals The oil reservoir is not filled at the factory For horizontal installation of the pump an oil reservo...

Page 29: ...nd maximum markings 3 Tighten vent plug 913 Vertical installation 13 20 21 30 A B Fig 8 Filling topping up the oil reservoir vertical installation A Maximum fill level B Minimum fill level 1 Unscrew vent plug 913 2 Fill in lubricant until the lubricant level indicator lies between the minimum and maximum markings 3 Tighten vent plug 913 6 1 3 Shaft seal Shaft seals are fitted prior to delivery Obs...

Page 30: ...up the pump set vent the pump and suction line and prime both 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 Connection 6D can be used ...

Page 31: ... Page 30 Always operate the pump within the permissible operating range WARNING Unprotected rotating shaft Risk of injury by rotating shaft Always operate the pump set with a shaft guard in accordance with the accident prevention regulations CAUTION Abnormal noises vibrations temperatures or leakage Damage to the pump Switch off the pump set immediately Eliminate the causes before returning the pu...

Page 32: ... 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 may remain open provided that the system conditions and system regulations are considered and observed NOTE If shut off is not possible the pump will run in reverse direction The reverse runaway speed must be lower than the rated speed For prolonged shutdown...

Page 33: ...Operation outside the permissible ambient temperature Damage to the pump set Observe the specified limits for permissible ambient temperatures Observe the following parameters and values during operation Table 13 Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 C if the ambient temperature is any higher contact the manufacturer Minimum See data sheet 6 2 2 Frequenc...

Page 34: ...ted will not cause an additional increase in the temperatures on the pump surface However if the physical properties of the fluids handled differ from those of water the calculation formula below must be used to check if an additional heat build up may lead to a dangerous temperature increase at the pump surface If necessary the minimum flow must be increased Table 15 Key Symbol Description Unit c...

Page 35: ...pump have been observed ð Section 7 4 1 Page 42 1 Spray coat the inside wall of the pump casing and in particular the impeller clearance areas with a preservative 2 Spray the preservative through the suction nozzle and discharge nozzle It is advisable to then close the pump nozzles e g with plastic caps 3 Oil or grease all exposed machined parts and surfaces of the pump with silicone free oil or g...

Page 36: ...6 Commissioning Start up Shutdown 36 of 64 KWP Bloc NOTE If the pump has been out of service for more than one year replace all elastomer seals ...

Page 37: ...ed specialist personnel who are thoroughly familiar with the manual WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents Ensure that the pump set cannot be started unintentionally Always make sure the electrical connections are disconnected before carrying out work on the pump set DANGER Improper cleaning of coated pump surfaces Explosion hazard by ...

Page 38: ...on the Internet Never 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 pump internals in contact with the fluid to be handled including the seal chamber and auxiliary systems must be filled with the fluid to be handled at all times Provide sufficient ...

Page 39: ...ents for leakage Check the rolling element bearings for running noises Vibrations noise and an increase in current input occurring during unchanged operating conditions indicate wear Monitor the correct functioning of any auxiliary connections Monitor the stand by pump To make sure that stand by pumps are ready for operation start them up once a week Monitor the bearing temperature The bearing tem...

Page 40: ...d filter in the suction line Damage to the pump Monitor contamination of filter with suitable means e g differential pressure gauge Clean filter at appropriate intervals 7 2 2 2 Checking the bearing seals DANGER Excessive temperatures caused by mechanical contact Risk of explosion Damage to the pump set Check correct seating of axial seal rings mounted on the shaft Only gentle contact of the seali...

Page 41: ...Oil quality Type Specification Motor oil SAE 10 W 20 W Lubricating oil CL 32 68 DN 51 517 7 2 3 2 3 Oil quantity Table 17 Oil quantity for oil reservoir Size Oil quantity l Horizontal Vertical 125 100 0250 Approx 0 3 Approx 1 080 040 0315 Approx 0 3 Approx 1 080 065 0315 Approx 0 3 Approx 1 065 040 0250 Approx 0 5 Approx 1 100 080 0250 Approx 0 5 Approx 1 100 080 0315 Approx 0 5 Approx 1 125 100 0...

Page 42: ...ion Safety regulations DANGER Insufficient preparation of work on the pump set Risk of injury Properly shut down the pump set Close the shut off elements in the suction line and discharge line Drain the pump and release the pump pressure ð Section 7 3 Page 42 Shut off any auxiliary feed lines Allow the pump set to cool down to ambient temperature WARNING Unqualified personnel performing work on th...

Page 43: ... Risk of squashing hands and feet Suspend or support the motor to prevent it from tipping over ü The pump set is disconnected from the power supply 1 Fasten a rope to motor 800 and intermediate lantern 146 and suspend it from a suitable hoisting tackle 2 Undo hexagon nuts 920 01 3 Pull motor 800 with intermediate lantern 146 and discharge cover 163 out of pump casing 101 in axial direction If the ...

Page 44: ...7 5 Reassembling the pump set 7 5 1 General information Safety regulations WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage to property Use suitable transport devices lifting equipment and lifting tackle to move heavy assemblies or components CAUTION Improper reassembly Damage to the pump Reassemble the pump set in accordance with the general rules of so...

Page 45: ...ave been cleaned 1 Slide rolling element bearing 321 01 onto shaft 210 2 Slide on circlip 932 20 3 Insert O ring 412 11 4 Fit insert ring 513 11 5 Half fill the space between insert ring 513 11 and rolling element bearing 321 01 with a multi purpose high temperature resistant grease of NLGI grade 2 KP 2 P 20 6 Apply a thin coat of oil to the outside diameter of rolling element bearing 321 01 7 Ins...

Page 46: ...worn parts have been replaced by original spare parts ü The sealing surfaces have been cleaned 1 Insert O ring 412 08 2 Fit the mating ring 3 Fit the oil ring if any 4 Fit discharge cover 163 on intermediate lantern 146 5 Fasten hexagon nuts 920 15 on pump sizes 50 200 and 65 200 socket head cap screws 914 22 6 Slide the rotating assembly onto shaft protecting sleeve 524 01 and fasten it 7 Slide O...

Page 47: ...01 6 Tighten hexagon nuts 920 01 7 6 Tightening torques 7 6 1 Tightening torques for the pump Casing bolts Table 18 Tightening torques for bolted screwed connections Materials of bolt hexagon nut C35E QT A4 70 Stamp on bolt hexagon nut YK Y13 A4 70 Thread Torque Nm M 6 5 7 M 10 25 35 M 12 40 60 M 16 100 150 Impeller nut Tightening torques for the impeller nut of all pump sizes 50 Nm 7 7 Spare part...

Page 48: ...6 Table 19 Quantity of spare parts for recommended spare parts stock Part No Description Number of pumps including stand by pumps 1 2 3 4 5 6 and 7 8 and 9 10 and more 135 01 Wear plate 1 2 2 2 3 3 4 50 210 Shaft with hardware 1 1 1 1 2 2 2 20 230 Impeller 1 1 1 1 2 2 2 20 321 01 Deep groove ball bearing 1 1 1 2 2 2 3 25 411 77 Joint ring 1 2 2 2 3 3 4 50 433 02 Complete mechanical seal14 1 1 1 2 ...

Page 49: ...2 1 1 1 1 080 040 0315 5 1 2 4 10 11 12 13 14 5 1 2 2 1 3 1 080 065 0315 6 1 2 4 10 11 12 13 14 6 1 2 2 1 3 1 100 080 0250 7 1 2 1 1 2 3 4 5 7 1 2 1 1 1 1 100 080 0315 8 1 2 4 10 11 12 13 14 8 1 2 2 1 3 1 125 100 0250 9 1 2 5 10 11 12 13 14 9 1 2 2 1 3 1 125 100 0315 10 1 2 4 10 11 12 13 14 10 1 2 2 1 3 1 Table 20 Shaft 210 combination of motor size and shaft number Motor size Shaft number 90 1 6 ...

Page 50: ... 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 vent valve Pump is warped or sympathetic vibrations in the piping Check the piping connections and secure fixing of pump if required reduce distances between the pipe clamps Fix the pipelines using anti vibration...

Page 51: ... casing and discharge cover Re tighten the bolts Worn shaft seal Fit new shaft seal Score marks or roughness on shaft protecting sleeve shaft sleeve Replace shaft protecting sleeve shaft sleeve Replace shaft seal Check balancing line Check throttling bush throttling sleeve clearances Lack of cooling liquid or dirty cooling chamber Increase cooling liquid quantity Clean out cooling chamber Purify c...

Page 52: ... 513 11 950 10 146 904 30 932 20 230 411 10 412 08 902 01 920 01 550 44 903 25 411 25 412 75 135 914 05 411 13 412 05 412 03 940 01 906 210 412 06 901 01 524 01 903 01 411 01 903 03 411 03 101 163 903 02 411 02 902 15 920 15 550 45 901 30 639 N1 720 N1 731 N2 731 N3 731 N1 411 27 731 N4 731 N5 710 N1 710 N2 913 903 17 644 901 30 550 22 163 914 22 Fig 9 General assembly drawing of variants GNNG GDN...

Page 53: ...14 05 411 13 412 05 412 03 940 01 906 210 412 06 901 01 524 01 903 01 411 01 903 03 411 03 101 163 903 02 411 02 902 15 920 15 550 45 901 30 639 N1 720 N1 731 N2 731 N3 731 N1 411 27 731 N4 731 N5 710 N1 710 N2 913 903 17 644 412 08 902 01 920 01 550 44 903 25 411 25 680 01 500 14 163 901 30 509 914 03 550 22 914 02 Fig 10 General assembly drawing of variant DDDD ...

Page 54: ...680 01 901 57 920 04 550 57 932 01 321 01 411 77 412 11 513 11 903 03 411 03 101 163 903 02 411 02 902 15 920 15 550 45 901 30 913 N1 731 N3 731 N4 731 N5 720 N1 950 10 146 904 30 932 20 230 411 10 412 08 902 01 920 01 550 44 903 01 411 01 639 N1 731 N1 731 N2 731 N6 901 30 550 22 163 914 22 Fig 11 General assembly drawing of variants GNNG GDNG ...

Page 55: ...02 15 920 15 550 45 901 30 913 N1 731 N3 731 N4 731 N5 720 N1 412 75 135 914 05 411 13 412 05 412 03 940 01 210 412 06 901 01 524 01 903 01 411 01 906 950 10 146 904 30 932 20 230 411 10 412 08 902 01 920 01 550 44 639 N1 731 N1 731 N2 731 N6 509 412 12 914 03 163 901 30 509 914 03 550 22 914 02 Fig 12 General assembly drawing of variant DDDD ...

Page 56: ...ical seal Mechanical seal KSB 4KBL 412 06 412 53 412 52 523 487 477 473 472 53 472 52 Fig 13 Mechanical seal KSB 4KBL Mechanical seal Burgmann MG1 G6 500 54 412 06 477 54 481 54 500 55 472 54 475 55 412 55 504 54 Fig 14 Mechanical seal Burgmann MG1 G6 ...

Page 57: ...gon head bolt 902 01 Stud 903 0120 0220 0320 Screw plug 920 01 Hexagon nut 135 135 Wear plate 411 13 Joint ring 412 05 75 O ring 914 05 Hexagon socket head cap screw 146 146 Intermediate lantern 550 57 Disc 913 Vent plug 901 57 Hexagon head bolt 903 17 25 26 Screw plug 920 04 Hexagon nut 932 01 Circlip 163 163 Discharge cover 412 08 O ring 550 45 22 Disc 901 30 Hexagon head bolt 902 15 Stud 920 15...

Page 58: ... nipple 731 N6 Pipe union 731 N2 N3 N4 N5 Angle 903 25 Screw plug 680 01 680 01 Guard 800 800 Motor complete 906 906 Impeller screw 412 03 O ring 99 9 99 9 Set of sealing elements 411 01 02 03 10 12 13 16 17 77 Joint ring 412 03 05 06 08 11 75 O ring Table 23 List of components for mechanical seal 4KBL Part No Comprising Scope of supply 433 412 52 53 O ring 472 53 Primary ring 472 52 Primary ring ...

Page 59: ...9 Related Documents 59 of 64 KWP Bloc Part No Comprising Scope of supply 433 475 55 Mating ring 477 54 Spring 481 54 Bellows 500 54 Ring 500 55 Ring ...

Page 60: ...ives 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 Person authorised to compile the technical file Name Function Address company Address Street No Address post or ZIP code city country The EU Declaration of Conformity was issued in on Place date 24 Name Fun...

Page 61: ...r 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 bracket or adapter have also been cleaned For canned motor pumps the rotor and plain bearing have been removed from the pump for cleaning In cases of leakage at the stator can the stator space has been examined for fluid l...

Page 62: ...stallation types 17 Intended use 8 Interchangeability of pump components 49 K Key to safety symbols markings 7 L List of components 57 M Maintenance 38 Materials 18 Monitoring equipment 11 N Name plate 16 Noise characteristics 20 O Oil lubrication Oil quality 41 Oil reservoir 28 Operating limits 33 Order number 6 Other applicable documents 6 P Partly completed machinery 6 Permissible forces and mo...

Page 63: ...Index 63 of 64 KWP Bloc V Vertical installation 29 W Warnings 7 Warranty claims 6 ...

Page 64: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2362 8 05 EN 01317103 ...

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