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KSB LCV, Installation & Operating Manual

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KSB LCV Installation & Operating Manual Download Page 18

LCV [en-US] 

18 

 

  

6 

Commissioning / Operation 

 

CAUTION 

Compliance with the following requirements is of paramount importance. Damage resulting from non-compliance 
shall  not  be  covered  by  the  scope  of  warranty.  This  manual  applies  to  single  stage  pumps.  Procedures  for 
multistage pumps should be obtained from the GIW/KSB sales office. 

 

6.1 

Commissioning / Return to Service 

 

 WARNING 

Before starting up the pump make sure that the following requirements are checked and fulfilled: 
 
1)  If the pump has been in long term storage (more than 3 months), ensure proper storage procedures were 

followed,  including  instructions  for  removing  the  pumps  from  storage  (see  contract  documents  and/or 
contact your GIW / KSB representative). Failure to follow proper storage procedures will void your warranty.
See Section 3.2 "Storage Requirements". 

2)  For elastomer lined pumps ensure that the piping has been installed and the torqueing of the piping bolts 

has been completed. For all metal pumps this step may be completed during Step 5. 

3)  The impeller nose clearance has been properly set. 

See Section 10.4 "Setting Impeller Nose Gap" for details. 

4)  Pump drive train final alignment is complete. 

See Section 5.3.1 "Alignment" for details. 

5)  Final torquing of all bolts has been completed. 

See Section 11.1 "General Torque" for details. 

6)  All electrical and power supply connections are in order, including fuses and overload protection devices. 

See Section 5.1 "Safety Regulations" for details. 

7)  All required auxiliary connections, such as shaft seal water, oil coolers, etc. are made, tested and ready to 

function. 
See Section 5.4.1 "Auxillary Connection" for details. 

8)  All safety guards and equipment are in place. 

See Section 5.5 "Safety Guards" for details. 

9)  Any required instrumentation has been properly installed. 

See Section 5.6 "Oil Temperature Monitoring" for details on RTD installation. 

10)  Bearing assembly lubrication is completed. 

See Section 6.1.1 "Bearing Lubrication" for details. 

11)  Shaft seal is ready for operation. 

See Section 6.1.2 "Shaft Seal Commissioning" for details. 

12)  Drive train direction of rotation at the pump is correct. 

See Section 6.1.3 "Checking the Direction of Rotation" for details. 

13)  The pump set is primed. 

See Section 6.2.1. "Priming the Pump" 

14)  The desired operating conditions do not exceed those allowed by the pump. 

See Section 6.4 "Operating Limits" for details. 

 

Summary of Contents for LCV

Page 1: ...ering replacement parts This is a standard maintenance manual provided for your convenience This manual may include additional documentation not applicable to your specific pump GIW INDUSTRIES INC 5000 Wrightsboro Road Grovetown GA 30813 USA 1 888 832 4449 FAX 1 706 855 5151 www giwindustries com KSB AG Johann Klein Str 9 D 67227 Frankenthal Germany 49 6233 86 0 FAX 49 6233 86 3289 www ksb com ...

Page 2: ...inal operating manual the original operating manual prevails All rights reserved 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 GIW Industries Inc ...

Page 3: ...cation 19 6 1 2 Shaft Seal Commissioning 19 6 1 3 Checking the Direction of Rotation 19 6 1 4 Cleaning the Plant Piping 19 6 1 5 Suction Strainer 19 6 2 Start up 20 6 2 1 Priming the Pump 20 6 3 Shutdown 21 6 3 1 Measures to be taken for Prolonged Shutdown 21 6 4 Operating Limits 21 6 4 1 Temperature Limits 21 6 4 2 Switching Frequency 22 6 4 3 Density of the Medium Handled 22 6 4 4 ZW Pump Additi...

Page 4: ...ap Adjustment 34 Oil Temperature Monitoring 17 Operating Conditions of Flow and Head 25 Operating Limits 21 Operating Limits ZW Pumps 22 Operation 18 Operation Unauthorized Modes 7 Operational Problems and Solutions 24 Parts Life 24 Personnel 6 Piping System Design 24 Piping Allowable Forces and Moments 14 Piping Cleaning 19 Piping Connecting 16 Power Supply 17 Priming the Pump 20 Pump Casing Part...

Page 5: ...the medium handled capacity speed density pressure temperature and motor rating Make sure that operation is in accordance with the instructions given in this manual or in the contract documentation The nameplate indicates the type series size main operating data and serial number Please quote this information in all queries repeat orders and particularly when ordering spare parts This manual may c...

Page 6: ...cordance with EC Directive 94 9 EC ATEX General hazard In conjunction with one of the signal words this symbol indicates a hazard which will or could result in death or serious injury Electrical hazard In conjunction with one of the signal words this symbol indicates a hazard involving electrical voltage and identifies information about protection against electrical voltage Machine damage In conju...

Page 7: ...ered to without fail Pumps or pump units handling media injurious to health must be decontaminated Immediately following completion of the work all safety protective devices must be re installed and or re activated Please observe all instructions set out in the Section 6 Commissioning before returning the machine to service 2 7 Unauthorized Modification and Manufacture of Spare Parts Modifications...

Page 8: ... in personal injury and damage to equipment Work on the unit must only be carried out with the electrical connections disconnected and locked out Make sure that the pump set cannot be switched on accidentally Pumps handling liquids posing health hazards must be decontaminated When draining the medium ensure there is no risk to persons or the environment All relevant laws must be adhered to Before ...

Page 9: ...st the lifting method for stability before moving pump Ensure that the pump is firmly strapped down during shipment Pump should be protected from direct contact with the elements Motors and gear reducers may require Immediate cover consult manufacturer After arrival on site consult GIW Pump Storage recommendations for further storage instructions In corrosive environments be sure to remove all lif...

Page 10: ... the rotor and stator Units equipped with a vent kit must have the vents either removed and plugged or blocked to prevent air exchange Vertical pumps should be stored horizontally and the blocking on the shaft should be left in place until the pump is ready to be installed Storage Exceeding 12 Months Long Term Storage The following information on long term storage pertains to GIW pump assemblies o...

Page 11: ...from machined surfaces using a wire brush Remove rust inhibitor from all machined surfaces prior to installation assembly Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch up as needed It is recommended that the bearing assembly be drained before shipment and refilled after relocation or installation For grease lubricated units a fresh application of grease ...

Page 12: ...LCV en US 12 3 3 Recommended Lifting WARNING Actual safe lifting method will vary with pump configuration and type of lifting equipment Vertical Lifting Horizontal Lifting ...

Page 13: ...ial operations 4 2 Designation Example Designation LCV M80 300 3T 1OB M1 Pump Type Hydraulic Type Discharge Nozzle mm Nominal Impeller Diameter mm Mechanical Size Seal Type Cantilever Length Options Motor Mount Material Code Hydraulic Type M Metal Mechanical Frame Size 1 35 mm 2 50 mm 3 70 mm 4 100 mm 5 125 mm Seal Type S Seal Plate T Throttle Seal Cantilever Length 1 900 mm 2 1200 mm 3 1500 mm 4 ...

Page 14: ...driven units add an additional 2 dB 4 5 Accessories Couplings pulleys belts motor mounts and or base plates may be provided Refer to the bill of materials data sheets and or drawings for further information 4 6 Dimensions and Weights Dimensions and weights are listed on the pump installation plan 4 7 Forces and Moments at Nozzles Suction piping is normally not used in vertical pump applications Ho...

Page 15: ...g the bolts in place 5 3 Installing the Baseplate and Pump WARNING Do not install the baseplate and pump on unpaved or unsupported foundations Injury can result from vibration or shifting equipment After placing the baseplate on the foundation it must be leveled by shimming Shims should be fitted between the baseplate and the foundation itself they should always be inserted to the left and right o...

Page 16: ...nd pulleys as specified in the installation plan must be observed For V belt installations the pulleys are correctly aligned if a straightedge placed vertically shows a deviation of no more than 1 0 mm 0 04 inch Both pulleys must be parallel V belt Pulley Alignment 1 Align 2 Maximum 1mm 5 3 2 Place of Installation WARNING The volute casing and shaft seal take on roughly the same temperature as the...

Page 17: ...ke care not to drop or damage the RTD unit during installation After the entire assembly is complete the bearing assembly can be put back into service The assembly should be inspected for leaks 5 7 Final Check Verify the alignment as described in Section 5 3 1 It must be easy to rotate the shaft 360 by hand at the coupling For elastomer lined pump assemblies this step should be completed after fin...

Page 18: ... 4 Setting Impeller Nose Gap for details 4 Pump drive train final alignment is complete See Section 5 3 1 Alignment for details 5 Final torquing of all bolts has been completed See Section 11 1 General Torque for details 6 All electrical and power supply connections are in order including fuses and overload protection devices See Section 5 1 Safety Regulations for details 7 All required auxiliary ...

Page 19: ...5 405 3000 80 2 7 80 2 7 ZW 150 480 2000 90 3 0 140 4 7 Monitor commission temperature if exceeded 6 1 2 Shaft Seal Commissioning Ensure that the seal plate is aligned correctly with the shaft Adjust if necessary 6 1 3 Checking the Direction of Rotation CAUTION If motive power is applied to the pump and it is run in the wrong direction of rotation even momentarily the impeller may unscrew causing ...

Page 20: ...damage to the pressure containing components of the pump the mechanical end and or the mechanical seal CAUTION During the initial commissioning once the pump and bearing assembly stabilize at normal operating temperature or in the event of system leaks stop the unit and re tighten all bolts Check the coupling alignment and re align if necessary The pump may be started up against a closed discharge...

Page 21: ...k run In order to make sure that the pump is always ready for instant start up and to prevent the formation of deposits within the pump and the pump intake area start up the pump set regularly once a month for a short time approx 5 minutes during prolonged shutdown periods Prior to an operation check run ensure that there is sufficient liquid available for operating the pump 2 The pump is dismantl...

Page 22: ...oading of the motor pump and coupling the density of the medium must comply with the data specified on the purchase order 6 4 4 ZW Pump Additional Limits Slurry S G should not exceed 1 3 Operating temperature should not exceed 80 C 176 F Operating pH should be kept above 6 0 pH Chlorides in the slurry should not exceed 1000 ppm Size Motor Mount Power Limit kW Speed Limits RPM Motor Limit Applicati...

Page 23: ...ndling liquids posing health hazards see to it that there is no risk to persons or the environment when draining the medium All relevant laws local codes and safety procedures must be heeded If required wear safety clothing and a protective mask If the media handled by the pumps leaves residues which might lead to corrosion when coming into contact with atmospheric humidity or which might ignite w...

Page 24: ... should prevent the formation of a vortex or other means of introducing air into the pump Where a submerged suction is available the depth of water level above the pump suction is more important than the cross sectional area of the sump Frothing of the sump should be eliminated by the installation of baffles a submerged inlet pipe or other methods to prevent air becoming entrained in the slurry If...

Page 25: ...urages localized wear In the event problems are encountered contact your GIW KSB representative The pump serial number in addition to the following should be furnished to assist in evaluation of the problem o Pump serial number from the nameplate on the pedestal or bearing housing customer location and the approximate startup date o Pumped fluid SG specific gravity slurry information including SG ...

Page 26: ...and quantity Mechanical Frame Size Bearings Installed Spherical Roller Double Row Taper Roller Back to Back Double Row Taper Roller Face to Face Part number TIMKEN Bench End Play Part number SKF Bench End Play E Type Cone Cup Spacer mm inch mm inch 1 22216E 31312 J2 QDF 0 12 0 005 2 22220E 31316 J1 QLC7CDF 0 14 0 006 3 23028E HM926740 HM926710CD HM92674XA 0 25 0 010 4 23036E HH932145 HH932110 H932...

Page 27: ...t 45 4 oil lubricated that will come out on the shaft between the two bearings Remove the drive end bearing assembly to expose the thrust bearings The locknut and lock washer that clamp the drive side bearing should also be removed One tab of the lock washer will be bent into a recess on the lock ring and must be bent back to allow the lock nut to be unscrewed The bearings are hot when installed o...

Page 28: ...s are seated fully against the abutting shaft shoulder Taper Bearing Locknut Assembly Torque Mechanical Frame Size Locknut Assembly Torque N m ft lbs 1 135 40 2 200 80 3 270 200 4 680 500 8 3 2 Back to Back Thrust Bearing Installation Heat inboard cone to 120 C 250 F and install Ensure that the larger OD of the bearing is towards the center of the shaft Install spacer and bearing cup A clip may be...

Page 29: ...zontally using a sling at the approximate center of gravity Insert into the housing until a second sling can be secured around the opposite end Level both the housing and shaft at the precise elevation needed Ensure the radial bearing outer diameter and housing bore are thoroughly clean then insert the shaft with the radial bearing from the non drive drive end The radial bearing outer race must go...

Page 30: ...d Use O Ring lubricant Parker O Lube or Parker Super O Lube to lubricate the inner diameter o rings against the shaft Take special care when running the seal over the shaft keyway to avoid cutting the o ring If necessary lightly file the keyway edges to avoid this problem After bolting the end covers in place rotate the shaft by hand There should be no frictional contact between the rotating and s...

Page 31: ...necessary shaft wear and loss of efficiency To adjust the running clearance Loosen the bolts that attach the casing Center the clearance between the throttle bushing inner diameter and the shaft by adjusting the throttle bushing using the set screws in the support assembly The clearance can be determined by inserting a clearance gauge through the access holes The gauge should move freely around th...

Page 32: ...running torque A steady torque or mild yet sudden torsional jolt is usually required to disengage the impeller Several methods of achieving this end are possible One of the easiest methods is outlined below To order the devices described here contact your GIW KSB representative Please provide your pump assembly number with the order to ensure a good fit 10 2 2 Impeller Break Loose Device WARNING 1...

Page 33: ...t Sleeve WARNING Lubrication at any of shaft sleeve release ring if present or shaft shoulder faces may result in overloading and breakage of the shaft A light coat of anti seize can be applied inside the shaft sleeve Do not allow anti seize compound to come in contact with any of the axial faces of the shaft sleeve including the impeller contacting face and the face in contact with the shaft shou...

Page 34: ... away from the impeller end as described above This ensures that the threads of the adjusting screw will contain no backlash against the forward directed thrust loading that the pump will generate during operation It is especially important that this convention be followed when a mechanical seal is being used Before adjustment may proceed the pump wetted end must be completely assembled After supp...

Page 35: ...t Tighten the locking plates in the backed off position Turn the adjusting nut counter clockwise until contact of the impeller is made with the suction liner It is helpful to slowly rotate the impeller during this procedure Turn the adjusting nut clockwise while rotating the shaft until no rubbing of the impeller with the suction liner is apparent Impeller clearance can now be set Three turns of t...

Page 36: ...55 45 60 60 85 5 8 60 80 85 115 90 120 125 170 3 4 105 145 150 200 160 215 220 300 7 8 175 230 240 325 250 350 360 485 1 260 350 360 490 385 520 540 730 1 1 8 320 430 445 600 470 645 660 900 1 1 4 450 610 620 850 670 910 940 1 275 1 3 8 590 800 825 1 115 880 1 195 1 225 1 670 1 1 2 780 1 060 1 090 1 480 1 170 1 585 1 635 2 220 1 3 4 915 1 240 1 280 1 735 1 370 1 850 1 920 2 600 2 1 375 1 864 1 925...

Page 37: ...ction The quantities of parts kept in store will depend upon the severity of the slurry duty and the number of units operating Maintenance practices may also favor keeping fully built sub assemblies or complete pumps on hand in some cases Previous experience in similar duties often provides the best experience If in doubt contact your GIW KSB representative for specific recommendations Commissioni...

Page 38: ...apsed line or partially closed valve Check system calculations Adjustment may be needed to system design and or pump operating conditions Low flow operation Increase flowrate In general operation below 30 of best efficiency flowrate is not recommended System head is lower than expected leading to excessive flowrate Adjustment may be needed to system design and or pump operating conditions Contact ...

Page 39: ...ystem design and or pump operating conditions Speed is too high Reduce the speed Worn parts Loose bolts seals or gaskets Check for worn parts Replace as needed Tighten the bolts and or fit new seals and gaskets if needed Incorrect packing material or adjustment Incorrect seal water pressure too high or low Correct adjustment Replace parts as needed See GIW Tech Article on this subject The unit is ...

Page 40: ...LCV en US 40 14 Notes ...

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