KSB MEGAFLOW 100-250 Operating Instructions Manual Download Page 1

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Operating Instructions Manual

NºA2370.8E/2

KSB MEGAFLOW

Pumps for Sewage, Effluents and Mixtures

1. Application

The

KSB

MEGAFLOW

centrifugal

pump

recommended for industrial and municipal waste water,

as well as all kinds of pulps not liable to plait, sewage

water, chemical effluents.

Municipal and industrial waste-water treatment

Drainage

Pulp and paper

Food processing

Sugar and alcohol

Mining and manufacturing

Civil construction

2. Design

Horizontal, single-stage, simple horizontal suction and

vertical upwards discharge. The “back-pull-out” design

allows maintenance and repair services through the back

side, without dismantling piping and alignment.

The available hydraulics and impeller types allow proper

selection for the handled liquid and required application.

3. Designation

KSB

Megaflow

160

Trade Mark

Model / Type

Discharge Nozzle Diameter (mm)

Nominal Impeller Diameter (mm)

Rotor

4. Operating Data

Sizes

- DN 50 up to 350

(2 ½” to 14” )

Flow

- to 11,000 gpm

(2,500 m

/h)

Head

- to 328 ft (100m)

Temperature

- to 221

F (105

Max. Suction pressure

- to 43 psi (3 bar)

Speed

- to 3,500 rpm

LINE:

Mega

Summary of Contents for MEGAFLOW 100-250

Page 1: ...gn Horizontal single stage simple horizontal suction and vertical upwards discharge The back pull out design allows maintenance and repair services through the back side without dismantling piping and alignment The available hydraulics and impeller types allow proper selection for the handled liquid and required application 3 Designation KSB Megaflow 50 160 K Trade Mark Model Type Discharge Nozzle...

Page 2: ...ided 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 Brasil Ltda Várzea Paulista 04 04 2022 ...

Page 3: ...echanical Seal 13 10 Transportation 14 11 Service Storage 14 11 1 Additional procedures of Service and Storage 15 12 Installation 15 12 1 Base Grouting 15 12 2 Base Leveling 16 12 3 Grouting 16 12 4 Coupling alignment 16 12 5 Suction Pipe Line Recommendations 17 12 6 Discharge Pipe Line Recommendations 19 12 7 Auxiliary pipings and connections 20 13 Accessories Optionals 20 14 Operation 21 14 1 Fi...

Page 4: ...racket AK 33 17 4 Execution with Impeller O Bearing bracket AK 34 17 5 Parts List Execution with K O Impeller Bearing bracket AK 35 17 6 Execution with K O Impeller Bearing bracket P65 160 36 17 7 Parts List Execution with K O Impeller Bearing bracket P65 160 37 17 8 Execution with K O Impeller Bearing bracket P80 200S 38 17 9 Parts List Execution with K O Impeller Bearing bracket P80 200S 39 17 1...

Page 5: ...ase indicate the type of pump and manufacturing order nº serial nº This information can be obtained from the nameplate on the actual pump If the nameplate is not available the OP nº 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 important instructions and advice Its careful reading it is an obligati...

Page 6: ...ive without washing 90 Not abrasive 105 Abrasive with washing 105 Axial Thrust Balancing Back vanes Min Max Flow 0 1 Qopt see characteristic curve Rotation side Clockwise seen from the drive side Maximum rotation See table 2 Lubricating Oil though the automatic resupply glass Flanges Cast iron ANSI B16 1 125lb FF Stainless steel ANSI B16 5 150lb RF Sealing Chamber Sleeve mm 35 45 60 70 80 100 Cham...

Page 7: ...0 O 18 100 250 K 54 O 44 E 70 100 315 K 47 80 400 K 40 A60K 1 NU312 6312C3 0 158 O 22 100 400 K 45 A60K 1 2 O 30 125 315 E 90 A60K 150 315 K 85 O 60 200 315 K 80 125 500 K 50 P65 160X NU413 2x 7313BUA 0 310 150 400 E 3 150 500 K 60 O 85 200 400 K 80 O 80 200 500 E 150 250 500 K 75 P80 200S NU419 2x 7319BUA 0 422 O 3 300 500 K 95 350 400 K 2 3 3 350 500 K 2 350 630 K 2 Table 2 Notes 1 For size 100 ...

Page 8: ...50 K O 1450 260 260 260 1750 260 260 260 2900 230 220 210 80 400 K O 1450 404 404 404 1750 404 380 370 100 250 K O 1450 260 260 260 1750 260 260 260 2900 230 215 205 100 250 E up to 1450 255 255 255 1750 255 255 235 2000 255 235 215 100 315 K O 1450 320 320 320 1750 320 320 310 100 400 K O 1450 404 404 404 1750 404 380 360 125 315 E up to 1160 315 315 315 1450 315 300 270 1750 270 240 240 125 500 ...

Page 9: ...0 315 K O 1160 320 320 320 1450 320 305 295 1750 300 280 270 200 400 K O 1160 404 404 404 1450 404 404 380 1750 360 330 200 500 E 480 500 500 500 580 500 500 500 725 500 480 420 875 500 450 420 960 500 450 420 250 500 K O 725 504 504 504 960 475 450 430 1160 430 400 300 500 K O 725 504 500 475 960 460 430 410 1160 405 350 400 K 1160 408 408 408 350 500 K 1160 350 630 K 875 630 630 630 Table 3 ...

Page 10: ...of impellers are available K O e E a Impeller type K Closed with two or three channels they are specially recommended for pumping dirty or muddy liquids with no gases and without the tendency to form long fiber plaits Also adequate for paper and cellulose pulp with a mass concentration up to 3 Pumps with 3 channels impellers K 200 315 150 500 125 500 200 400 e 250 500 Fig 2 b Impeller Type O Multi...

Page 11: ...y the bearings 7 6 Shaft seal Gland packing standard or optionally by means of a single or double mechanical seal The shaft seal selection depends on the handled liquid and required application When the shaft seal is made with gland packing the position of the neck ring 457 neck bush 456 lantern ring 458 and of the gasket rings are represented in the sectional drawing The dimensions of chamber and...

Page 12: ...series booklet 3 For liquids free of solids in suspension and positive suction Seal though the pumped liquid 9 Single or double Mechanical Seals Table 4 Notes The codes indicated in the Table 3 comply with the seal executions indicated in the Cross Sectional Drawing according to chapter 17 8 1 Pressure of seal liquid Wash for pumps with impellers type K O E Seal code Pressure bar P Seal bar P Wash...

Page 13: ...ing over the fixed one of which polished surface remains jointed by means of pressure by spring The sealing of the rotative ring over the shaft and the sealing of the fixed ring in the gland are of appropriate material to the pumped liquid For a safe and of long duration operation it is important that the liquid film between the slide surfaces is formed and the consequent heat is properly absorbed...

Page 14: ...ery of the pump It is the responsibility of the client to continue with this procedure after receiving the pump When the pump is not subjected to a performance test after is sale the areas in contact with the pumped liquid which are not painted as stuffing box housing wear rings flange sealing areas etc receive an application of RUSTILO DW 301 by brush When the pump is equipped with packing and is...

Page 15: ...sene before applying the protecting liquids Characteristics of the protecting liquids Protecting Liquid Thickness of the applied Layer µm Drying time Removal Manufacturer TECTYL 506 From 80 to 100 1 2 up to 1 hour Gasoline benzene diesel oil BRASCOLA RUSTILO DW301 From 6 to 10 1 up to 2 hours Gasoline benzene CASTROL MOBILARMA 524 6 Does not dry Not necessary MOBIL OIL Table 7 Protecting Liquids 1...

Page 16: ...ng alignment The useful lift of the turning assembly and its operation free of irregular vibrations will rely on the perfect alignment between the pump and the driver The alignment performed at the factory must be remade because during transportation and handling the motor pump assembly is subjected to deformations which affect the initial alignment After the complete set of the grout perform the ...

Page 17: ...e the horizontal section of the pipeline should be installed with a gradual rise slope to the suction tank d The nominal diameter of the pump suction flange does not determine the suction pipe nominal diameter To calculate the ideal diameter as a reference the liquid velocity can be defined between 1 and 2 m s e If it were necessary to use a reduction it should be eccentric mounted with its taper ...

Page 18: ... be made with line angle changes less than 45 degrees In all these applications of gate valves the valve stems should be directed either horizontally or vertically downwards k To prevent turbulence leakage of air sand or mud at the pump suction all recommendations of the HYDRAULIC INSTITUTE referred to these types of installation should be strictly observed l Even if the coupling alignment has bee...

Page 19: ...ves should be installed d Install a valve if possible immediately after the discharge nozzle of the pump so as to control adequately the flow rate and pressure or prevent driver overloads e When a non return valve is installed it should be mounted between the pump and the valve prevailing this condition over item d f Tie band mounting joints should be installed to absorb the system reaction forces...

Page 20: ...nections Note 1 Inlet and outlet piping of external source liquid should be provided with register and visor in order to control the flow and observe the priming 2 For pumps with Mechanical Seals it is possible to have another connections installed in the gland In case of supply with Mechanical seals additional instructions will follow 13 Accessories Optionals 13 1 Coupling KSB standard or from ot...

Page 21: ...on valve if any and close discharge valve 14 2 Immediate steps after first start up Once started up and with the pump running follow these instructions a Adjust pump to its operation point pressure and flow by opening slowly the discharge valve shortly after pump drive has reached its nominal speed b Motor current consumption amperage must be controlled as well as network voltage value c Assure th...

Page 22: ... 2 14 3 3 Semestral supervision Check a Fixing bolts on pump driver and base b Alignment of the motor pump assembly c Coupling lubrication if any 14 3 4 Annual supervision a Disassemble the pump for maintenance After cleaning inspect condition of ball and roller bearings very carefully radial seal rings gaskets o rings impellers internal areas of the volute casing check also thickness wear areas a...

Page 23: ... in this item Attention A defective lubrication or an excessive one may cause damage Fig 18 Constant Level Oiler 15 2 Lubrication intervals and oil specifications The first oil change should be made after the first 200 or 300 working hours The next oil change should be made after 1500 or 2000 service hours This will avoid dirt particles which have not been eliminated by cleaning to contaminate oil...

Page 24: ...remove it To remove it as it is split push it in the direction of the bearing cover and then pull half of the gland cover to the right and the other half to the left Remove with the help of a flexible rod all the packing rings and the lantern ring Clean the stuffing box chamber Check the condition of the shaft protecting sleeve If it is rough air has grove that could damage the packing the sleeve ...

Page 25: ... supply wear plate for repair or as spare parts to be applied in the KSB Megaflow pumps K O E types They are supplied with the groove outlet diameter in the appropriate tolerance and the inlet diameter with 2 mm 0 079 overmetal 15 4 1 When replacement is necessary The replace of the wear plate must be done when the clearance between the plate and the impeller presents wear value 3 times over the m...

Page 26: ...CS40 CS50 A30K A40K A50K and A60K Close suction and discharge valves if any Drain the pump by removing the threaded plug 903 2 Disconnect and remove any auxiliary connections if any Remove coupling guard if fitted Remove the venting 672 Remove the threaded plug 903 4 and drain oil from support Remove the constant level oiler 638 from the support If the coupling sleeve has spacer remove it In case ...

Page 27: ...er as packing rings 461 lantern ring 458 neck ring 457 neck bush 456 After this procedure all parts will be available for analysis and maintenance Bearing Bracket P65 160X Since it has bearing casing 382 loosen the bolts 901 6 and remove the shaft 210 from the pump side to the motor side making the bearing casing 382 to slip out of the bearing bracket 330 Extract the circlip 932 2 and the washer 5...

Page 28: ...th up to a maximum temperature of 80 to 90ºC above the shaft temperature observing the maximum limit of 125ºC Mount the bearing 320 and the bearing inner ring 322 in the shaft With a piece of lead mount the shaft in the support from the motor side making the external side of the bearing slide into the support until it reaches the ring 932 2 Mount the radial seal ring 421 in the bearing covers 360 ...

Page 29: ...iping with the liquid to be pumped and or seal both 4 Suction piping and or impeller are obstructed remove the obstructions from the piping and or impeller 5 Air pocket formation in the piping Change the piping layout if necessary install venting valve 6 Available NPSH too low installation with negative suction check and if necessary correct the level of pumped liquid install the pump in a level l...

Page 30: ...22 Pump set misaligned align the set 23 Pump parts are out of specified radial and axial run out Suction and discharge pipings carry mechanical tension out correct radial and axial run out of the parts or change them eliminate the existing tension fixing the piping appropriately or if necessary install compensation gaskets 25 Too much too little or unsuitable bearing lubricant reduce complete or u...

Page 31: ...KSB Megaflow 31 17 Cross Sectional Drawing Parts List Materials 17 1 Execution with K Impeller Bearing Brackets CS40 and CS50 Figure 25 ...

Page 32: ... cover 452 1 Neck ring 457 1 Lantern ring 458 1 Packing 2 461 3 Thrower 507 1 Shaft protection sleeve 524 1 Washer 550 1 8 Washer 550 4 1 Washer 550 5 8 Constant level oiler 638 1 Oil dipstick 643 1 Hexagonal head bolt 901 2 4 Hexagonal head bolt 901 3 1 Hexagonal head bolt 901 4 1 Hexagonal head bolt 901 5 8 Hexagonal head bolt 901 31 2 Stud 902 1 8 Threaded plug 903 1 2 Hexagonal head bolt 914 1...

Page 33: ...KSB Megaflow 33 17 3 Execution with K Impeller AK Bearing Bracket Figure 26 ...

Page 34: ...KSB Megaflow 34 17 4 Execution with O Impeller AK Bearing Bracket Figure 27 ...

Page 35: ...Gland packing 4 461 5 Quantity 16 for pumps 80 400 100 400 Thrower 507 1 Shaft protecting sleeve 524 1 7 Quantity 4 for pumps 50 160 50 200 65 200 80 250 100 250 Washer 551 1 1 Washer 551 2 1 Locking disc 552 1 Quantity 8 for pumps 65 315 100 315 150 315 200 315 Washer 554 1 6 80 400 100 400 Washer 554 2 1 Rivet 565 8 8 Quantity 6 for sealing 9 Constant level oiler 638 1 Quantity 8 for sealing 0 a...

Page 36: ...KSB Megaflow 36 17 6 Execution with Impeller K O Bearing Bracket P65 160 Figure 27 ...

Page 37: ...ntity 3 for pumps with impellers 250 Washer 550 3 11 Quantity 4 for pumps with impellers 315 400 500 Spacer disc 551 1 Locking disc 552 1 Rivet 565 14 Constant level oiler 638 1 10 Quantity 4 for pumps with suction 100 125 150 200 Venting 672 1 Quantity 8 for pumps with suction 100 125 150 200 Hexagonal head bolt 901 1 9 Quantity 12 for pumps with suction 200 250 Hexagonal head bolt 901 2 4 Hexago...

Page 38: ...KSB Megaflow 38 17 8 Execution with Impeller K and Bearing Bracket P80 200S Figure 28 ...

Page 39: ...ealings 0 and 2 Washer 550 2 1 Quantity 2 for sealing 1 Washer 550 3 12 Not used in sealing 9 Spacer disc 551 1 Locking disc 552 1 Rivet 565 7 Constant level oiler 638 1 10 Quantity 2 for pumps with impellers 160 200 Venting 672 1 Quantity 3 for pumps with impellers 250 Hexagonal head bolt 901 1 10 Quantity 4 for pumps with impellers 315 400 500 Hexagonal head bolt 901 2 12 Hexagonal head bolt 901...

Page 40: ...KSB Megaflow 40 17 10 Execution with Impeller E Bearing Bracket AK Figure 29 ...

Page 41: ...Gland packing 461 4 Quantity 12 for size 100 250 Thrower 507 1 Shaft protecting sleeve 524 1 6 Quantity 6 for sealing 9 Washer 551 1 1 Quantity 8 for sealing 0 and 2 Washer 551 2 1 Quantity 10 for sealing 1 Locking disc 552 1 Washer 554 1 5 Washer 554 2 1 7 Quantity 6 for size 80 200 Rivet 565 6 Quantity 8 for size 100 250 Constant level oiler 638 1 Quantity 12 for size 125 315 Venting 672 1 Hexag...

Page 42: ...KSB Megaflow 42 17 12 Execution with Impeller E and Bearing Bracket P65 160X Figure 30 ...

Page 43: ...or Impeller O 500 Radial seal ring 421 2 1 Quantity 2 parts for Pumps with Gasket Gland cover 452 1 Quantity 4 parts for Pumps with Mechanical Seal Gland cover ring 454 1 Neck bush 456 1 7 Quantity 1 part for execution 0 and 9 Lantern ring 458 1 Quantity 2 parts for execution 1 Gland packing 4 461 3 Spacer ring 9 504 1 8 Quantity 6 parts for execution 9 Thrower 507 1 Shaft protecting sleeve 524 1 ...

Page 44: ... x x x x x x 1 1 1 1 1 1 1 412 1 O Ring 1 2 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 412 3 O Ring x x x x x x x x x x x x x x 1 1 1 1 1 x X 421 Radial seal ring 1 2 2 2 2 3 3 3 3 4 4 4 4 4 x x x x x x X 421 1 2 Radial seal ring x x x x x x x x x x x x x x 1 1 1 1 1 2 2 452 Gland cover 1 2 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5 5 5 6 6 454 Gland cover ring x x x x x x x x x x x x x x 1 1 1 1 1 2 2 456 Neck bus...

Page 45: ... 2 3 30 230 Impeller 1 1 1 2 2 2 3 30 320 Bearing 1 1 1 2 2 3 4 50 321 Bearing 1 1 1 2 2 3 4 50 322 Bearing 1 1 1 2 2 3 4 50 330 Bearing bracket 1 2 unit 421 Radial seal ring pair 1 2 3 4 5 6 8 50 461 Gland Packing load 1 4 4 6 6 6 8 40 524 Shaft protective sleeve 1 1 1 1 2 2 2 20 Gasket set 4 4 6 8 8 9 12 150 O ring set 4 4 6 8 8 9 12 150 Execution with mechanical seal Gasket set 4 4 6 8 8 9 12 1...

Page 46: ...KSB Megaflow 46 04 04 2022 A2370 8E 2 KSB Brasil Ltda Rua José Rabello Portella 638 Várzea Paulista SP 13220 540 Brasil http www ksb com br Tel 11 4596 8500 SAK KSB Customer Service e mail sak ksb com ...

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