KSB Omega Installation & Operating Manual Download Page 47

Page: 47 / 94

7 Servicing/Maintenance

7.1 Safety regulations

DANGER

Sparks produced during servicing work

Explosion hazard!

▷

Observe the safety regulations in force at the place of installation!

▷

Always perform maintenance work on explosion-proof pump sets outside
potentially explosive atmospheres.

DANGER

Improperly serviced pump set
Explosion hazard!
Damage to the pump set!

▷

Service the pump set regularly.

▷

Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.

DANGER

Excessive temperatures due to dry running
Explosion hazard!
Fire hazard!
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.

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 rolling element bearings for running noises.

The operator ensures that maintenance, inspection and installation is performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.

WARNING

Unintentional starting of pump set
Risk of injury by moving parts!

▷

Ensure that the pump set cannot be started up unintentionally.

▷

Always make sure the electrical connections are disconnected before carrying
out work on the pump set.

7 Servicing/Maintenance

Omega / Omega V

47 of 94

Summary of Contents for Omega

Page 1: ...Axially Split Volute Casing Pump Omega Omega V Horizontal installation type 3E Vertical installation types DB DK DP DJ Installation Operating Manual Mat No 01059616 ...

Page 2: ...ts 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 Aktiengesellschaft Frankenthal 20 06 2016 ...

Page 3: ...nstallation 10 2 9 Unauthorised modes of operation 10 2 10 Explosion protection 10 3 Transport Temporary Storage Disposal 12 3 1 Checking the condition upon delivery 12 3 2 Transport 12 3 3 Storage preservation 14 3 4 Return to supplier 15 3 5 Disposal 15 4 Description of the Pump Set 17 4 1 General description 17 4 2 Designation 18 4 3 Name plate 19 4 4 Design details 19 4 5 Configuration and fun...

Page 4: ...utdown storage preservation 46 6 4 Returning to service 46 7 Servicing Maintenance 47 7 1 Safety regulations 47 7 2 Servicing inspection 48 7 3 Drainage cleaning 53 7 4 Dismantling the pump set 53 7 5 Reassembling the pump set 60 7 6 Tightening torques 66 7 7 Spare parts stock 67 8 Trouble shooting 69 8 1 Explanation of faults 73 9 Related Documents 74 9 1 Weights of individual components 74 9 2 G...

Page 5: ... which is connected to the discharge nozzle Drive end The side of the pump which faces the motor Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Non drive end The side of the pump which faces away from the motor Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump drive additional component...

Page 6: ...r 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 Ge...

Page 7: ...Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product 1 General Omega Omega V 7 of 94 ...

Page 8: ...ates 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 personnel o...

Page 9: ...ities competence 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 pu...

Page 10: ...ndstill of the pump The pump casing must 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 3 Page 46 Decontaminate pumps which handle fluids posing a health hazard Section 7 3 Page 53 As soon as the work has been completed re insta...

Page 11: ...and the resulting theoretical temperature limits of the fluid handled a possible temperature rise in the shaft seal area has already been taken into account The temperature class specifies the maximum permissible temperature at the surface of the pump set during operation For the permissible operating temperature of the pump in question refer to the data sheet Table 4 Temperature limits Temperatur...

Page 12: ...he individual components stated in the manufacturer s product literature DANGER The pump set could slip out of the 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 Give due attention to the weight data and the centre of gravity Observe the applicable lo...

Page 13: ...mp vertically figure 0 or installation type DJ Transporting the pump with base frame figure 0 Motor size 315 and larger Total weight of the pump set more than 1500 kg Transporting the pump vertically installation types DB and DK 3 Transport Temporary Storage Disposal Omega Omega V 13 of 94 ...

Page 14: ...P 3 3 Storage preservation If commissioning is to take place some time after delivery we recommend that the following measures be taken CAUTION Damage during storage by humidity dirt or vermin Corrosion contamination of the pump set For outdoor storage cover the packed or unpacked pump set and accessories with waterproof material CAUTION Wet contaminated or damaged openings and connections Leakage...

Page 15: ...instructions Section 7 3 Page 53 2 Always flush and clean the pump particularly if it has been used for handling noxious explosive hot or other hazardous fluids 3 If the pump set has handled fluids whose residues could lead to corrosion damage in the presence of atmospheric humidity or could ignite upon contact with oxygen the pump set must also be neutralised and anhydrous inert gas must be blown...

Page 16: ...ismantling 2 Separate and sort the pump materials e g by Metals Plastics Electronic waste Greases and other lubricants 3 Dispose of materials in accordance with local regulations or in another controlled manner 3 Transport Temporary Storage Disposal 16 of 94 Omega Omega V ...

Page 17: ...stations and industrial water supply Table 6 Installation types Installation type Illustration Description Figure 0 Bare shaft pump Figure 3E Pump and drive on a common base frame Horizontal installation direct coupling Figure DJ Pump on its own base frame drive on a different construction level Vertical installation Figure DB Pump on base frame and drive on drive lantern Vertical installation 4 D...

Page 18: ...s V Design 2 Horizontal installation V Vertical installation 150 Nominal discharge nozzle diameter mm 460 Nominal impeller diameter mm A Impeller type GB Material variant GB Grey cast iron bronze GC Grey cast iron chrome steel SB Nodular cast iron bronze SC Nodular cast iron chrome steel DD35 Duplex stainless steel duplex stainless steel P Shaft seal P Gland packing G Mechanical seal M Bearing lub...

Page 19: ...ge Nominal diameter of the discharge nozzles 80 mm to 350 mm Pump casing Axially split volute casing Volute casing with integrally cast pump feet Replaceable casing wear rings Mating dimensions to EN or ASME Impeller type Double entry radial impeller Optionally with impeller wear rings Pump shaft Completely dry shaft for design with rolling element bearings Shaft protecting sleeves in the seal are...

Page 20: ...tem through the volute casing 4 The shaft passage through the sealing housing is sealed to atmosphere with a shaft seal 9 The shaft runs in rolling element bearings 3 and 8 located in a bearing housing 2 which is connected to the volute casing 4 The pump is sealed by a shaft seal standardised mechanical seal or gland packing 4 6 Noise characteristics Table 8 Surface sound pressure level LpA 3 depe...

Page 21: ...mp set 3500 rpm 2900 rpm 1750 rpm 1450 rpm 1160 870 rpm 960 750 rpm dB A dB A dB A dB A dB A dB A 10 74 5 74 0 70 0 69 0 66 4 64 6 15 75 7 75 2 71 4 70 5 67 9 66 2 20 76 6 76 1 72 4 71 5 69 0 67 4 30 77 8 77 3 73 8 72 9 70 6 69 0 40 78 7 78 2 74 8 74 0 71 7 70 1 50 79 4 78 9 75 6 74 8 72 6 71 0 60 79 9 79 4 76 3 75 4 73 3 71 8 70 80 4 79 9 76 8 76 0 73 8 72 4 80 80 8 80 3 77 3 76 5 74 4 72 9 90 81...

Page 22: ...nitoring Pt100 temperature sensor Pressure gauge Measuring nipple for shock pulse measurement Cyclone 4 8 Dimensions and weights For dimensions and weights please refer to the data sheet of the pump set Pump weight See name plate of the pump Motor weight See motor product literature Weight of the shipping unit base frame with pump See weight indicated on the base frame Weight of the shipping unit ...

Page 23: ...ge 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 1 Check the structural requirements All structural work required must have been prepared in accordance with the dimensions stated in the outline drawing general a...

Page 24: ... suitable permitted lifting accessories Fig 4 3E installation pump and motor on a common base frame The relevant general arrangement drawing is available The foundation has the required strength and characteristics The foundation has been prepared in accordance with the dimensions given in the outline drawing 1 2 3 4 Fig 5 Installation drawing 1 Base frame part No 891 2 Adjusting screw part No 901...

Page 25: ...5 4 Page 30 12 Align the coupling as described in the coupling manufacturer s operating manual 5 3 2 Type of installation DJ DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts Always transport the pump or components in the specified position Never attach the suspension arrangement to the free shaft end of the pump Refer to the we...

Page 26: ...ng low shrinkage concrete mixture 6 7 When the concrete has set tighten the foundation bolts 2 evenly 8 Connect the piping to the pump without transmitting any stresses or strains Section 5 4 Page 30 5 3 3 Installation type DJ with cardan shaft WARNING Exposed rotating coupling or universal joint shaft Risk of injury by rotating shafts Always operate the pump set with a coupling guard If the custo...

Page 27: ...ssories Fig 8 DB and DK installation The relevant general arrangement drawing is available The foundation has the required strength and characteristics The foundation has been prepared in accordance with the dimensions given in the general arrangement drawing 1 2 3 4 5 6 Fig 9 Installation drawing 1 Foot part No 182 2 Hexagon head bolt part No 901 11 3 Disc part No 550 05 4 Foundation block part N...

Page 28: ...urer s operating instructions 10 Align the coupling as described in the coupling manufacturer s operating instructions 5 3 5 Type of installation DP DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts Always transport the pump or components in the specified position Never attach the suspension arrangement to the free shaft end of ...

Page 29: ...cks 4 in accordance with the general arrangement drawing 4 Align the pump with the piping 5 Place the foot 4 including the foundation blocks 1 with the adjusting screws 5 on the shims 6 Use the adjusting screws to align the foot Installing the motor support frame 1 2 3 4 Fig 12 Installation drawing 1 Screw adjusting screws 2 into the foundation rails 1 in accordance with the general arrangement dr...

Page 30: ...operating instructions Final assembly 1 Align the pump on the foot base plate with the motor on the support frame Align and connect the pump with the piping Section 5 4 Page 30 2 Grout the recesses for the foundation blocks with a quick setting low shrinkage concrete mixture8 3 When the concrete has set tighten the foundation bolts 2 evenly 4 Connect the piping to the pump without transmitting any...

Page 31: ... nominal diameters of the pipes are equal to or greater than the nominal diameters of the pump nozzles To prevent excessive pressure losses adapters to larger diameters have a diffuser angle of approx 8 The pipelines have been anchored in close proximity to the pump and connected without transmitting any stresses or strains 1 Thoroughly clean flush and blow through all vessels pipelines and connec...

Page 32: ...om moving parts or escaping fluid As soon as the work is completed re install and or re activate any safety relevant and protective devices CAUTION Heat build up in the bearing housing Damage to the bearing Never insulate the bearing housing and bearing cover 5 6 Aligning the pump and motor DANGER Inadmissible temperatures at the coupling or bearings due to misalignment of the coupling Explosion h...

Page 33: ...nch until the coupling alignment is correct and all motor feet rest squarely on the baseplate 5 Re tighten the hexagon head bolts 1 at the motor and the locknuts 3 at the baseplate 6 Check that coupling 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 n...

Page 34: ...nsated 5 Re tighten the hexagon head bolts 6 Check that coupling 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 coupli...

Page 35: ...ts at the pump nozzles depending on the material N Nm Size Grey cast iron GB GC Nodular cast iron SB SC Cast steel DD35 Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz Fx Fy Fz Mx My Mz N Nm N Nm N Nm 80 210 800 500 1120 700 1520 950 80 270 800 500 1120 700 1520 950 80 370 800 500 1120 700 1520 950 100 250 1000 700 1400 980 1900 1330 100 310 1000 700 1400 980 1900 1330 100 375 1000 700 1400 980 1900 1330 125 ...

Page 36: ...re to use or incorrect use of auxiliary connections e g barrier fluid flushing liquid etc Risk of injury from escaping fluid Risk of burns Malfunction of the pump Refer to the general arrangement drawing the piping layout and pump markings if any for the quantity dimensions and locations of auxiliary connections Use the auxiliary connections provided WARNING Open pipelines Risk of injuries by esca...

Page 37: ...leakage drain G 3 4 26M 1 Connection for vibration measurement at the drive end M8 26M 2 Connection for vibration measurement at the non drive end M8 5 9 Connection to power supply DANGER Incorrect electrical installation Explosion hazard For electrical installation also observe the requirements of IEC 60079 14 Always use a motor protection switch for explosion proof motors DANGER Electrical conne...

Page 38: ... Connect the PE conductor to the earthing terminal provided 5 10 Checking the direction of rotation DANGER Temperature increase resulting from contact between rotating and stationary components Explosion hazard Damage to the pump set Never check the direction of rotation by starting up the unfilled pump set Separate the pump from the motor to check the direction of rotation DANGER Rotating shaft d...

Page 39: ...t match the arrow indicating the direction of rotation on the pump 3 If the motor runs in the wrong direction of rotation check the electrical connection of the motor and the control system if applicable 5 11 Removing the transport lock This type of transport lock is only used for vertical pumps with a product lubricated plain bearing 160 901 17 Fig 20 Transport lock 1 Undo bolt 901 17 at cover 16...

Page 40: ...nd venting the pump DANGER Risk of potentially explosive atmosphere inside the pump Explosion hazard Before starting up the pump vent the suction line and the pump and prime them with the fluid to be handled DANGER Shaft seal failure caused by insufficient lubrication Hot fluid may escape Before starting up the pump set vent the pump and suction line and prime both with the fluid to be handled 1 C...

Page 41: ...ng pump set if they are wearing protective equipment ear protection See noise characteristics Section 4 6 Page 20 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 Pump suction line and inlet tank if any have been vented and primed with th...

Page 42: ...1 Only lightly tighten the nuts of the gland follower by hand 2 Use a feeler gauge to verify that the gland follower is mounted centred and at a right angle to the shaft The gland must leak after the pump has been primed WARNING Unprotected rotating parts Risk of personal injury Do not touch rotating parts When the pump is running perform any work with utmost caution The leakage can be reduced 1 T...

Page 43: ...e auxiliary connections CAUTION Risk of freezing during prolonged pump shutdown periods Damage to the pump Drain the pump and the cooling heating chambers if any or otherwise protect them against freezing 6 2 Operating limits DANGER Non compliance with operating limits for pressure temperature fluid handled and speed Explosion hazard Hot or toxic fluid could escape Comply with the operating data i...

Page 44: ... C Operating range without NPSH margin The flow rate Q will develop automatically as a function of the discharge head H in line with the pump s characteristic curve The pump s permissible operating range has limits that are independent of each other in terms of their cause Low flow operating limit This limit is indicated in the H Q characteristic by Qmin or by discontinuation of the characteristic...

Page 45: ...against a closed shut off element Never operate the pump at temperatures above or below those specified in the data sheet or on the name plate unless the written consent of the manufacturer has been obtained If the values are not indicated in the data sheet the following temperature limits apply The temperatures must neither be below nor above these limits Table 13 Temperature limits of the fluid ...

Page 46: ...he inside wall of the pump casing and in particular the impeller clearance areas with a preservative 2 Spray the preservative through the suction and discharge nozzles It is advisable to close the pump nozzles e g with plastic caps or similar 3 Oil or grease all exposed machined parts and surfaces of the pump with silicone free oil and grease food approved if required to protect them against corro...

Page 47: ...ate the pump set without liquid fill Never close the shut off element in the suction line and or supply line during pump operation 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 rolling element bearings for running noises The operator ensures that maintenance inspection and install...

Page 48: ...rried out by KSB Service or authorised workshops For contact details please refer to the enclosed Addresses booklet or visit www ksb com contact 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 ...

Page 49: ... 42 Check the static sealing elements 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 be...

Page 50: ...al information Check and service all components of the pump set as described in the corresponding operating manuals provided by the manufacturers For the manufacturers product literature see other applicable documents 7 2 2 2 Routine maintenance and inspection intervals Table 15 Routine maintenance and inspection intervals Interval Number of persons Time Maintenance task Daily 1 6 min Check the le...

Page 51: ... check the clearances remove the rotor If the clearance is larger than permitted replace the casing wear ring and impeller wear ring Table 16 Clearances mm Pump size Maximum permissible nominal clearance wear limit Minimum clearance Maximum clearance D2 D1 2 S min S max 80 210 0 3 0 15 0 2 80 270 0 3 0 15 0 2 80 370 0 3 0 15 0 2 100 250 0 35 0 17 0 2 100 310 0 35 0 17 0 2 100 375 0 35 0 17 0 2 125...

Page 52: ...iate intervals 7 2 2 5 Lubricating the 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 bearing seals CAUTION Temporary storage of the pump set too long Formation of deposits or condensate resinification or leakage of grease Replace the complete rolling eleme...

Page 53: ...ANGER Insufficient preparation of work on the pump set Risk of injury Properly shut down the pump set Close the shut off elements in suction and discharge line Drain the pump and release the pump pressure Section 7 3 Page 53 Close any auxiliary connections Allow the pump set to cool down to ambient temperature WARNING Unqualified personnel performing work on the pump set Risk of injury Always have...

Page 54: ...he 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 NOTE Horizontal installation The pumps have been designed in such a way that the complete rotor can be removed and dismantled without the need to remove the suction and discharge line and without disturbing the alignment of...

Page 55: ...The pump has been separated from the motor 1 Undo the connecting elements between the pump flanges and the pipes 2 Suspend volute casing 102 from the lifting equipment and secure it 3 Undo screwed connection 901 13 920 08 between the pump and rail 593 01 Remove the rail 4 Remove stud 904 02 5 Undo screwed connection 901 12 between the pump and foot 182 Lift up the pump and place it down in a horiz...

Page 56: ...341 and place it down on a suitable surface 5 Undo the connecting elements between the pump flanges and the pipes 6 Remove stud 904 02 7 Suspend volute casing 102 from the lifting equipment and secure it 8 Undo screwed connection 901 12 between the pump and foot 182 Lift up the pump and place it down in a horizontal position on a suitable surface Removing vertically installed pumps in DK installat...

Page 57: ...t and secure it 9 Undo screwed connection 901 12 between the pump and foot 182 Lift up the pump and place it down in a horizontal position on a suitable surface Removing vertically installed pumps in DP installation 901 13 920 08 593 01 904 02 901 12 182 102 550 04 901 14 920 14 550 14 901 15 89 12 901 17 550 17 Fig 26 DP installation Lifting equipment of suitable dimensions for the indicated comp...

Page 58: ...casing The pump has been placed in horizontal position on a solid and level surface Suitably dimensioned lifting equipment is available 1 Suspend volute casing 102 from the lifting equipment and secure it 2 Undo screwed connections 901 16 at seal cover 47116 and slide back the seal cover 3 Remove bolts 901 1 901 02 from the casing split flange Separate upper casing half 105 02 from lower casing ha...

Page 59: ...ousing 441 10 Impeller 234 sits on the shaft with a sliding fit Normally it can be removed easily If the impeller is hard to remove it can be loosened by gently tapping the hub with a wooden mallet 11 If applicable remove the complete second shaft protecting sleeve 524 01 with shaft seal housing 441 and shaft seal ring 12 Pull off bearing housing 350 01 13 Remove circlip 932 and pull off deep groo...

Page 60: ...ays have repair and maintenance work performed by specially trained qualified personnel WARNING Unintentional starting of pump set Risk of injury by moving parts Ensure that the pump set cannot be started up unintentionally Always make sure the electrical connections are disconnected before carrying out work on the pump set WARNING Components heated up for installation Risk of burns to hands Wear ...

Page 61: ...of the individual components and screwed connections with graphite or similar before reassembly For reassembly tighten all screws and bolts as specified in this manual 7 5 2 Installing the rotor Suitably dimensioned lifting equipment is available The pump shaft has been placed down in a horizontal position on a level and clean assembly surface and secured against rolling off The corresponding gene...

Page 62: ...chanical seal torque transmitting element springs primary ring secondary seal etc onto shaft protecting sleeve 524 01 as far as it will go 3 Tighten grub screws with cup point evenly alternately and gradually to the torques specified depending on the nominal thread diameter Grub screws with cup point may be used without applying a thread locking agent Grub screws with cup point must not be re used...

Page 63: ... and tighten it lightly to allow the packing rings in the gland packing chamber to adjust 4 Loosen the gland follower to relieve the load on the packing 7 5 2 3 Installing the bearings WARNING Components heated up for installation Risk of burns to hands Wear protective gloves suitable for installation work Let components cool down after installation Installing the drive end bearings The impeller h...

Page 64: ...tecting sleeve 524 01 2 Pull on shaft protecting sleeve 524 02 and mount bearing housing 350 02 with fitted bearing bush 545 and O ring 412 1 3 Fasten shaft protecting sleeve 524 02 to the shaft with disc 550 03 disc spring 950 and nut 920 01 4 Load the rotor parts elastically by means of slotted round nut 920 and disc spring 950 For this purpose compress disc spring 950 to blocking point Then und...

Page 65: ...ing wear ring and the seal housing 2 Insert the rotor Observe the direction of rotation 3 Align the rotor Make sure that the fastening studs are correctly inserted into the pump casing 4 Observe the position of pins 561 01 561 01 a Fig 33 Position of pins 561 01 a Casing wear rings 5 Slide bearing housing 350 01 with inserted discs 550 02 0319 over deep groove ball bearings 321 6 Screw bearing hou...

Page 66: ...ot 183 to drive lantern 341 with screwed connection 901 60 and to foot 182 with screwed connection 901 61 5 Proceed with the installation as described in the corresponding sections Section 5 3 2 Page 25 Section 5 3 4 Page 27 7 6 Tightening torques With the exception of the following screwed bolted connections all screws bolts must be tightened as per the table Tightening torques Part No Descriptio...

Page 67: ...66 1888 2098 1563 1737 1327 1475 M36 2445 2717 3591 3990 802 891 1719 1910 2292 2547 2445 2717 2025 2250 1719 1910 M42 3904 4338 5734 6371 1281 1423 2745 3050 3660 4067 3904 4338 3233 3592 2745 3050 M48 5880 6534 8637 9596 1929 2144 4135 4594 5513 6125 5880 6534 4870 5411 4135 4594 7 7 Spare parts stock 7 7 1 Ordering spare parts Always quote the following data when ordering replacement or spare p...

Page 68: ...412 1 O ring21 4 8 12 16 16 18 18 24 24 150 412 2 O ring 4 8 12 16 16 18 18 24 24 150 412 3 O ring 4 8 12 16 16 18 18 24 24 150 412 4 O ring 2 4 6 8 8 9 9 12 12 150 412 5 O ring 2 4 6 8 8 9 9 12 12 150 412 6 O ring 2 4 6 8 8 9 9 12 12 150 421 1 Shaft seal 2 4 6 8 8 9 9 12 12 150 421 2 Shaft seal21 4 8 12 16 16 18 18 24 24 150 Shaft protecting sleeve 524 1 Shaft protecting sleeve21 2 2 2 4 4 4 4 6 ...

Page 69: ...he pump Table 20 Trouble shooting A B C D E F G H I J K L M Possible causes Remedy22 Operating point B does not match the Q and H performance data calculated in advance Re adjust to duty point Pump and or piping are not completely vented or primed Vent Supply line or impeller clogged Clean the impeller Check system for impurities Remove deposits in pump and or piping Check any strainers installed ...

Page 70: ...led for contamination by chemicals check solids content Replace worn components by new ones Pump pressure lower than specified in the purchase order Re adjust to duty point Increase back pressure by throttling Density or viscosity of fluid handled higher than stated in purchase order Reduce speed In the case of persistent overloading turn down impeller if possible Speed is too high Reduce speed In...

Page 71: ...g liquid or dirty cooling chamber Check flushing liquid barrier fluid pressure Clean barrier fluid line supply external barrier fluid if necessary or increase barrier fluid pressure Increase cooling liquid quantity Purify clean cooling liquid Pump is warped or sympathetic vibrations in the piping Re align pump drive Check pipeline connections and secure fixing of pump improve fixing of pipelines i...

Page 72: ...ction line for leakage seal if necessary Air intake at pump inlet Correct suction conditions Reduce flow velocity at suction line inlet Increase suction head Check suction line for leakage seal if necessary Replace defective pipes Cavitation rattling noise Correct suction conditions Check operating mode Increase suction head Install pump at a lower level Foundation not rigid enough Check Adjust Im...

Page 73: ... system characteristic curves HA and NPSHA as a function of flow rate Q The operating point B is given by the intersection between the system curve HA and the pump s characteristic curve H If the cause of a fault or malfunction is unclear consult your nearest KSB service centre P HA H NPSH NPSHA HV B Q H geo Eta Fig 34 Adjusting to the duty point P Pump power output HA System curve B Operating poi...

Page 74: ...5 100 375 170 61 35 25 25 25 25 125 230 226 66 30 25 25 25 25 125 290 231 70 30 25 25 25 25 125 365 234 79 55 25 25 25 25 125 500 285 110 55 25 25 25 25 150 290 253 88 53 25 25 25 25 150 360 255 92 53 25 25 25 25 150 460 307 109 95 25 25 25 25 150 605 458 168 98 25 25 25 25 200 320 365 128 67 25 25 25 25 200 420 389 122 67 25 25 25 25 200 520 580 200 109 30 27 31 25 200 670 667 276 109 30 27 31 25...

Page 75: ...903 04 932 102 502 524 01 550 01 550 01 920 05 550 11 904 421 01 211 940 03 321 901 07 920 03 580 940 01 520 360 350 01 901 04 903 08 Fig 35 General assembly drawing for horizontal installation For ATEX version labyrinth ring 423 02 For ATEX version labyrinth ring 423 01 Does not apply to ATEX version Does not apply to version with KSB mechanical seal 4OM 9 Related Documents Omega Omega V 75 of 94...

Page 76: ...01 01 L 5203 Table 22 List of components Part No Description Part No Description 102 Volute casing 471 Seal cover 211 Pump shaft 502 Casing wear ring 234 Impeller 503 Impeller wear ring 321 Radial ball bearing 520 Sleeve 350 01 Bearing housing 524 01 Shaft protecting sleeve 360 Bearing cover 525 02 Spacer sleeve 411 01 Joint ring 550 01 02 11 Disc 412 01 02 03 O ring 561 01 02 Grooved pin 421 01 0...

Page 77: ...gon head bolt 441 Shaft seal housing 902 01 Stud 452 Gland follower 903 01 02 03 04 08 Screw plug 455 Stuffing box insert 904 Grub screw 457 02 Neck ring 920 02 03 05 Nut 458 Lantern ring 932 Circlip 461 Gland packing 940 01 02 03 Key 950 Spring 9 Related Documents Omega Omega V 77 of 94 ...

Page 78: ...950 914 01 930 01 412 04 920 02 902 02 350 02 412 05 550 04 182 550 05 898 01 901 10 901 11 89 4 04 421 01 350 01 901 04 360 901 16 471 904 02 920 08 593 433 525 02 457 02 Fig 36 General assembly drawing for installation type DJ For ATEX version labyrinth ring 423 02 For ATEX version labyrinth ring 423 01 Does not apply to ATEX version Does not apply to version with KSB mechanical seal 4OM 9 Relat...

Page 79: ...asing split flange 503 502 901 03 901 02 901 01 901 13 901 12 L 5203 Table 23 List of components Part No Description Part No Description 102 Volute casing 503 Impeller wear ring 160 Cover 524 01 02 Shaft protecting sleeve 182 Foot 525 01 02 Spacer sleeve 211 Pump shaft 545 Bearing bush 234 Impeller 550 01 02 03 04 05 Disc 321 Radial ball bearing 561 01 02 04 Grooved pin 350 01 02 Bearing housing 5...

Page 80: ...2 Lip seal 902 01 02 Stud 433 Mechanical seal 903 01 02 03 04 Screw plug 441 Shaft seal housing 904 02 Grub screw 452 Gland follower 914 01 Hexagon socket head cap screw 455 Stuffing box insert 920 01 02 05 08 Nut 457 02 Neck ring 930 01 Safety device 458 Lantern ring 932 Circlip 461 Gland packing 940 02 03 Key 471 Seal cover 950 Spring 502 Casing wear ring 9 Related Documents 80 of 94 Omega Omega...

Page 81: ...920 08 433 525 02 457 02 502 412 06 525 01 412 01 524 02 545 550 03 950 914 01 930 01 920 01 160 412 04 920 02 902 02 350 02 412 05 550 04 182 550 05 898 01 901 10 901 11 89 4 04 903 08 Fig 37 General assembly drawing for installation type DB For ATEX version labyrinth ring 423 02 For ATEX version labyrinth ring 423 01 Does not apply to ATEX version Does not apply to version with KSB mechanical se...

Page 82: ...01 531 01 901 13 901 12 L 5203 Table 24 List of components Part No Description Part No Description 102 Volute casing 502 Casing wear ring 160 Cover 503 Impeller wear ring 182 Foot 524 01 02 Shaft protecting sleeve 211 Pump shaft 525 01 02 Spacer sleeve 234 Impeller 531 01 Locking sleeve 321 Radial ball bearing 545 Bearing bush 341 Drive lantern 550 01 02 03 04 05 Disc 350 01 02 Bearing housing 561...

Page 83: ... seal 902 01 02 Stud 433 Mechanical seal 903 01 02 03 04 08 Screw plug 441 Shaft seal housing 904 02 Grub screw 452 Gland follower 914 01 Hexagon socket head cap screw 455 Stuffing box insert 920 01 02 05 08 12 Nut 457 02 Neck ring 930 01 Safety device 458 Lantern ring 932 Circlip 461 Gland packing 940 02 03 Key 471 Seal cover 950 Spring 9 Related Documents Omega Omega V 83 of 94 ...

Page 84: ... 950 920 01 914 01 930 01 160 412 04 920 02 902 02 350 02 412 05 550 04 182 550 05 898 01 901 10 901 11 89 4 04 901 14 920 12 341 421 01 350 01 901 04 360 901 16 471 904 02 920 08 433 525 02 457 02 Fig 38 General assembly drawing for installation type DK For ATEX version labyrinth ring 423 02 For ATEX version labyrinth ring 423 01 Does not apply to ATEX version Does not apply to version with KSB m...

Page 85: ...1 531 01 901 13 901 12 L 5203 Table 25 List of components Part No Description Part No Description 102 Volute casing 502 Casing wear ring 160 Cover 503 Impeller wear ring 182 Foot 524 01 02 Shaft protecting sleeve 183 Support foot 525 01 02 Spacer sleeve 211 Pump shaft 531 01 Locking sleeve 234 Impeller 545 Bearing bush 321 Radial ball bearing 550 01 02 03 04 05 60 Disc 341 Drive lantern 561 01 02 ...

Page 86: ...902 01 02 Stud 421 01 02 Lip seal 903 01 02 03 04 Screw plug 433 Mechanical seal 904 02 Grub screw 441 Shaft seal housing 914 01 Hexagon socket head cap screw 452 Gland follower 920 01 02 05 08 12 Nut 455 Stuffing box insert 930 01 Safety device 457 02 Neck ring 932 Circlip 458 Lantern ring 940 02 03 Key 461 Gland packing 950 Spring 471 Seal cover 9 Related Documents 86 of 94 Omega Omega V ...

Page 87: ...50 920 01 914 01 930 01 160 412 04 902 02 920 02 350 02 412 05 182 898 01 901 10 901 11 89 4 04 550 04 903 03 903 04 550 02 321 421 02 411 01 903 02 903 08 412 03 903 01 441 524 01 412 02 234 102 940 02 502 412 06 Fig 39 General assembly drawing for installation type DP For ATEX version labyrinth ring 423 02 For ATEX version labyrinth ring 423 01 Does not apply to ATEX version Does not apply to ve...

Page 88: ...sing split flange 503 502 901 03 901 02 901 01 901 13 901 12 L 5203 Table 26 List of components Part No Description Part No Description 102 Volute casing 503 Impeller wear ring 160 Cover 524 01 02 Shaft protecting sleeve 182 Foot 525 01 02 Spacer sleeve 211 Pump shaft 545 Bearing bush 234 Impeller 550 01 02 03 04 05 17 Disc 321 Radial ball bearing 561 01 02 04 Grooved pin 350 01 02 Bearing housing...

Page 89: ...2 Lip seal 902 01 02 Stud 433 Mechanical seal 903 01 02 03 04 Screw plug 441 Shaft seal housing 904 02 Grub screw 452 Gland follower 914 01 Hexagon socket head cap screw 455 Stuffing box insert 920 01 02 05 08 Nut 457 02 Neck ring 930 01 Safety device 458 Lantern ring 932 Circlip 461 Gland packing 940 02 03 Key 471 Seal cover 950 Spring 502 Casing wear ring 9 Related Documents Omega Omega V 89 of ...

Page 90: ...y 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 Function Company Address 24 A signed legally binding E...

Page 91: ...nd cleaned In cases of containment shroud leakage the outer rotor bearing bracket lantern leakage barrier and bearing bracket or intermediate piece 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 leakage if fluid handled has penetrated the stator...

Page 92: ... Gland packing 42 I Impeller type 19 Installation at site 23 Intended use 8 M Maintenance 48 Mechanical seal 42 Misuse 9 N Noise characteristics 20 21 O Operating limits 43 Order number 6 Other applicable documents 6 P Partly completed machinery 6 Piping 31 Preservation 14 Priming and venting 40 Pump casing 19 R Reassembly 61 Return to supplier 15 Returning to service 46 Running noises 48 S Safety...

Page 93: ......

Page 94: ...1384 8 10 EN 01059616 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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KSB Omega, Installation & Operating Manual

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