KSB Sewabloc Series Installation & Operating Manual Download Page 27

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6 Commissioning/Start-up/Shutdown

27 of 60

Sewabloc

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the following
conditions are met:

▪

The pump set has been properly connected to the power supply and is equipped
with all protection devices. (

Section 5.7, Page 25)

▪

The pump has been primed with the fluid to be handled. The pump has been
vented.

▪

The direction of rotation has been checked.

▪

All auxiliary connections required are connected and operational.

▪

The lubricant has been checked.

▪

After prolonged shutdown of the pump (set), the activities required for returning
the equipment to service have been carried out.

6.1.2 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pump
is operated with the suction and/or discharge line closed.

Explosion hazard!

Hot or toxic fluids escaping!

▷

Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.

▷

Only start up the pump set with the discharge-side shut-off element slightly or
fully open.

DANGER

Excessive temperatures due to dry running or excessive gas content in the fluid
handled

Explosion hazard!

Damage to the pump set!

▷

Never operate the pump set without liquid fill.

▷

Prime the pump as per operating instructions.

▷

Always operate the pump within the permissible operating range.

▷

If the pump is in slurp mode, stop the pump immediately.

WARNING

Pump sets with high noise levels

Damage to hearing!

▷

Persons must only enter the vicinity of the running pump set if they are
wearing protective clothing/ear protection.

▷

See noise characteristics. (

Section 4.6, Page 17)

Summary of Contents for Sewabloc Series

Page 1: ...Dry installed Volute Casing Pump Sewabloc 50 60 Hz DIN IEC motors Installation Operating Manual Mat No 01104323 ...

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 24 08 2018 ...

Page 3: ... 12 3 2 Transport 12 3 3 Storage preservation 13 3 4 Return to supplier 13 3 5 Disposal 14 4 Description of the Pump Set 15 4 1 General description 15 4 2 Designation 16 4 3 Name plate 16 4 4 Design details 16 4 5 Configuration and function 17 4 6 Noise characteristics 17 4 7 Scope of supply 18 4 8 Dimensions and weights 18 5 Installation at Site 19 5 1 Safety regulations 19 5 2 Checks to be carri...

Page 4: ...moving the motor 40 7 4 6 Removing the impeller 40 7 4 7 Dismantling the mechanical seal 42 7 4 8 Removing shaft and rolling element bearing 43 7 4 9 Removing the wear plate for D type impellers only 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 bearings 45 7 5 3 Installing the mechanical seal 45 7 5 4 Fitting the...

Page 5: ...rds arising from components in contact with the fluid handled Discharge line The pipeline which is connected to the discharge nozzle Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Pump Machine without drive additional components or accessories Pump set Complete pump set consisting of pump drive additional components and accessories Suction lift ...

Page 6: ... 1 Overview 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...

Page 7: ...1 General 7 of 60 Sewabloc Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product ...

Page 8: ...ious 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 conjunction with the signal word CAUTION this symbol indicates a hazard for the machine and its functions 2 2 General This operating manual contains general installation operati...

Page 9: ...cribed below Free flow impeller impeller type F F max Suitable for the following fluids fluids containing solids and stringy material as well as fluids with entrapped air or entrapped gas Open diagonal single channel impeller impeller type D Suitable for the following fluids fluids containing solid substances and long fibres Closed multi channel impeller impeller type K K max Suitable for the foll...

Page 10: ...act guards during operation Provide the personnel with protective equipment and make sure it is used Contain leakages e g at the shaft seal of hazardous fluids handled e g explosive toxic hot so as to avoid any danger to persons and the environment Adhere to all relevant laws Eliminate all electrical hazards In this respect refer to the applicable national safety regulations and or regulations iss...

Page 11: ...erated outside of potentially explosive atmospheres Only pumps pump sets marked as explosion proof and identified as such in the data sheet may be used in potentially explosive atmospheres Special conditions apply to the operation of an explosion proof pump set to EU Directive 2014 34 EU ATEX Especially adhere to the sections in this manual marked with the symbol opposite The explosion proof statu...

Page 12: ...e due attention to the weight data centre of gravity and fastening points Use suitable permitted lifting accessories e g self tightening lifting tongs WARNING Uncontrolled lifting of the pump set or drive Risk of injury Maintain adequate safety distance during lifting operations load may swing when being lifted WARNING Placing the pump set on unsecured and uneven surfaces Personal injury and damag...

Page 13: ...ior to putting the pump into storage Table 5 Ambient conditions for storage Ambient condition Value Relative humidity 5 to 85 non condensing Ambient temperature 20 C to 70 C Store the pump set in dry vibration free conditions and in its original packaging ð Section 6 3 Page 30 1 Spray coat the inside wall of the pump casing and in particular the impeller clearance areas with a preservative 2 Spray...

Page 14: ...ination can be downloaded from the following web site www ksb com certificate_of_decontamination 3 5 Disposal WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Hazard to persons and the environment Collect and properly dispose of flushing fluid and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the ...

Page 15: ...n type Illustration Description Close coupled pump without motor Pump can be supplied without motor horizontal installation Figur Bloc Pump set with directly flanged motor construction type B5 V1 horizontal installation Figur Bloc V Pump set with directly flanged motor construction type B5 V1 vertical installation with soleplate and suction elbow underfloor installation Close coupled pump VF Pump ...

Page 16: ...27 Frankenthal KSB SE Co KGaA Fig 1 Name plate example 1 Series number 2 Identification of the pump set 3 Order number 4 Flow rate 5 Speed 6 Weight of the pump as close coupled pump 7 Year of supply 8 Order item number 9 Head 10 Impeller diameter 4 4 Design details Design Volute casing pump Close coupled pump with shaft seal Various application oriented installation types ð Section 4 1 Page 15 Sha...

Page 17: ...leaves the pump The clearance gap 1 prevents any fluid from flowing back from the casing to the suction nozzle At the rear side of the impeller the shaft 4 enters the casing via the discharge cover 3 The shaft passage through the discharge cover is sealed to the atmosphere with a dynamic shaft seal 8 The shaft runs in a rolling element bearing 9 which is supported by a bearing bracket 5 linked wit...

Page 18: ...tor Suction side flanged spacer or suction elbow with inspection hole Foundation rails 3 Soleplate 4 Suction elbow 4 Suction duckfoot bend 4 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 ...

Page 19: ...g surface must be set flat and level 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 arrangement drawing 5 3 Setting up the pump set DANGER Electrostatic charging Explosion hazard Damage to the pump set Connect the potential equalisation conductor to the ea...

Page 20: ...perfectly flush 3 Drill the holes as specified in the Chemical anchor dimensions table Then clean the holes WARNING Improper handling of mortar cartridge Skin sensitisation and or irritation Wear suitable protective clothing 4 Insert the mortar cartridges into the drilled holes Observe the curing times of the mortar cartridges 5 Insert threaded rods into the corresponding drilled holes with an ele...

Page 21: ...ch elements must not obstruct proper drainage or hinder disassembly of the pump ü Suction lift lines have been laid with a rising slope suction head lines with a downward slope towards the pump ü A flow stabilisation section having a length equivalent to at least twice the diameter of the suction flange has been provided upstream of the suction flange ü The nominal pipe diameters are at least equa...

Page 22: ... 1400 400 450 600 800 600 750 650 1150 400 400 550 750 080 215 F B01 100 80 950 1200 1050 1850 450 500 600 900 700 900 800 1400 400 450 600 800 080 216 F B01 100 80 950 1200 1050 1850 450 500 600 900 700 900 800 1400 400 450 600 800 080 216 E B02 100 80 950 1200 1050 1850 450 500 600 900 700 900 800 1400 400 450 600 800 080 217 F B01 100 80 950 1200 1050 1850 450 500 600 900 700 900 800 1400 400 4...

Page 23: ...700 200 315 D B03 200 200 1900 2350 2100 3650 800 950 1150 1700 1900 2350 2100 3650 800 950 1150 1700 200 316 K B03 200 200 1900 2350 2100 3650 800 950 1150 1700 1900 2350 2100 3650 800 950 1150 1700 200 317 K B03 200 200 1900 2350 2100 3650 800 950 1150 1700 1900 2350 2100 3650 800 950 1150 1700 200 318 K B03 200 200 1900 2350 2100 3650 800 950 1150 1700 1900 2350 2100 3650 800 950 1150 1700 5 4 ...

Page 24: ...ns Connection Description Size 050 215 050 216 050 250 050 251 065 215 065 216 065 217 065 250 065 252 065 253 080 215 080 216 080 217 080 250 080 252 080 253 080 315 080 316 080 317 100 215 F 100 251 F 100 252 F 100 253 100 254 100 255 100 316 100 317 150 251 125 315 125 317 150 315 150 317 200 315 200 316 200 317 200 318 1M 1 Pressure gauge G 1 2 6D Vent G 1 2 G 3 4 G 1 3M Pressure vacuum gauge ...

Page 25: ...icant level is below the tolerance range refill the chamber with lubricant 5 7 Electrical connection DANGER Electrical connection work by unqualified personnel Risk of fatal injury due to electric shock Always have the electrical connections installed by a trained and qualified electrician Observe regulations IEC 60364 and for explosion proof models EN 60079 WARNING Incorrect connection to the mai...

Page 26: ...on and correct the direction of rotation The correct direction of rotation of motor and pump is in clock wise direction seen from the motor end 1 Start the pump set 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 pump runs i...

Page 27: ...GER Non compliance with the permissible pressure and temperature limits if the pump is operated with the suction and or discharge line closed Explosion hazard Hot or toxic fluids escaping Never operate the pump with the shut off elements in the suction line and or discharge line closed Only start up the pump set with the discharge side shut off element slightly or fully open DANGER Excessive tempe...

Page 28: ...ately 3 to 5 minutes Pump start up with long start ramps and low frequency may cause clogging 6 1 3 Shutdown 1 Close the shut off element in the discharge line If the discharge line is equipped with a check valve the shut off element may remain open as long as there is back pressure 2 Switch off the motor making sure that the unit runs down smoothly to a standstill Prolonged shutdown periods For p...

Page 29: ...operating pressure specified in the data sheet Table 13 Maximum operating pressure bar Size Maximum operating pressure Maximum test pressure 050 215 10 15 050 216 10 15 050 250 10 15 050 251 10 15 065 215 6 9 065 216 6 9 065 217 7 10 5 065 250 6 9 065 252 6 9 065 253 6 9 080 215 6 8 5 080 216 7 10 5 080 217 6 9 080 250 6 9 080 252 6 9 080 253 6 9 080 315 10 15 080 316 10 15 080 317 10 15 100 215 6...

Page 30: ... proportion to the density of the fluid handled CAUTION Impermissibly high density of the fluid handled Motor overload Observe the information about fluid density in the data sheet Make sure the motor has sufficient power reserves 6 2 3 3 Abrasive fluids Do not exceed the maximum permissible solids content specified in the data sheet When the pump handles fluids containing abrasive substances incr...

Page 31: ...n 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 grease food approved if required to protect them against corrosion Observe the additional instructions on preservation 6 4 Returning to service For returning the equipment to service observe the sections on ...

Page 32: ...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 33: ...losion 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 inlet pressure Provide an appropriate monitoring system If the pump is in slurp mode stop the pump immediately CAUTION Increased wear due to dry running Damage to the pump set Never operate the pump set...

Page 34: ...n between the pump set and the foundation 7 2 2 1 Visual inspection through the inspection hole If there are problems with clogging the inside of the casing and the impeller can be checked via the inspection hole WARNING Fluids handled consumables and supplies which are hot and or pose a health hazard Hazard to persons and the environment Collect and properly dispose of flushing fluid and any flui...

Page 35: ...n hole Fit new O ring 412 05 Fit inspection cover 164 02 Fit discs 550 04 and nuts 920 17 on screws 900 02 Tighten the nuts Observe the instructions on commissioning start up ð Section 6 1 1 Page 27 7 2 3 Lubrication and lubricant change 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 t...

Page 36: ...ant 903 90 411 90 903 46 411 46 903 22 411 22 Fig 8 Draining the lubricant ü Have a suitable container on hand for the used lubricant 1 Place the container underneath screw plug 903 46 2 Remove screw plug 903 46 and joint ring 411 46 at the bottom side of the bearing bracket and drain off the lubricant 3 Fit screw plug 903 46 with joint ring 411 46 NOTE Paraffin oil is bright and transparent in ap...

Page 37: ...150 317 B03 6 0 200 315 B03 6 0 200 316 B03 6 0 200 317 B03 6 0 200 318 B03 6 0 7 2 3 4 Lubricant quality The lubricant reservoir is filled at the factory with environmentally friendly non toxic lubricant of medical quality The following oils can be used for lubrication Recommended quality of lubricant Merkur white oil Pharma 40 made by DEA Thin bodied paraffin oil made by Merck No 7174 or equival...

Page 38: ...ions WARNING Unqualified personnel performing work on the pump set Risk of injury Always have repair work and maintenance work performed by specially trained qualified personnel 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 Observe th...

Page 39: ... casing can remain installed in the piping for further dismantling 1 Disconnect the power supply e g at the motor 2 Disconnect and remove all auxiliary pipework 3 Remove coupling guard 681 4 Remove the coupling spacer of coupling 848 if any 5 Drain the oil 7 4 3 Separating the pump from the piping ü The pump set has been switched off properly ü The shut off elements in the suction line and dischar...

Page 40: ...otor in axial direction out of bearing bracket 330 and stub shaft 210 7 4 6 Removing the impeller NOTE A forcing screw is required to remove the impeller The forcing screw is not included in the scope of supply It can be ordered separately from KSB ü The notes and steps stated in ð Section 7 4 5 Page 40 have been observed carried out 1 Remove screw plug 903 46 and joint ring 411 46 Then drain off ...

Page 41: ... 080 250 F K M 16 ADS 1 080 252 F M 16 ADS 1 080 253 F E M 20 ADS 2 080 315 F K M 20 ADS 2 080 315 D M 20 ADS 4 080 316 D M 20 ADS 4 080 317 D M 20 ADS 4 100 215 F M 10 ADS 6 100 251 F M 20 ADS 2 100 252 F M 16 ADS 1 100 253 E F K M 20 ADS 2 100 253 D M 16 ADS 3 100 254 F K M 16 ADS 1 100 255 E K M 20 ADS 2 100 316 D M 20 ADS 4 100 317 E M 20 ADS 2 125 315 F K M 20 ADS 2 150 253 D M 16 ADS 3 150 3...

Page 42: ... as described above 1 Pull the rotating assembly of mechanical seal 433 01 off shaft 210 2 Remove discharge cover 163 from bearing bracket 330 3 Press the stationary seat of mechanical seal 433 02 out of discharge cover 163 7 4 7 2 Dismantling the motor end mechanical seal ü The back pull out unit and the impeller have been removed as described above 1 Remove locking ring 515 or circlip 932 03 2 P...

Page 43: ...ress forcing screw 914 52 against shaft 210 and pull mechanical seal 433 out of discharge cover 163 7 4 8 Removing shaft and rolling element bearing ü Motor impeller and mechanical seal have been removed as described 1 Remove circlip 932 02 from bearing bracket 330 2 Drive shaft 210 with deep groove ball bearing 321 01 out of the bearing bracket towards the drive end 3 Remove circlip 932 20 4 Pull...

Page 44: ...eassemble the pump set in accordance with the general rules of sound engineering practice Use original spare parts only Sequence Always re assemble the pump in accordance with the corresponding general assembly drawing or exploded view Sealing elements Check O rings for any damage and replace by new O rings if required Never use O rings that have been made by cutting an O ring cord to size and glu...

Page 45: ...als wet the inside diameter of the bellows with soapy water not oil To prevent any damage to the rubber bellows place a thin foil of approximately 0 1 to 0 3 mm thickness around the free shaft stub Slide the rotating assembly over the foil into its installation position Then remove the foil 7 5 3 1 Installing the bellows type mechanical seal ü The shaft and rolling element bearings have been prope...

Page 46: ...080 217 F 29 0 080 250 F K 29 0 080 252 F 29 0 080 253 E F 38 5 080 315 F K 38 5 080 315 D 38 5 080 316 D 38 5 080 317 D 38 5 100 215 F 29 0 100 251 F 38 5 100 252 F 29 0 100 253 D E F K 38 5 100 254 F K 29 0 100 255 K 38 5 100 316 D 38 5 125 315 F K 38 5 150 253 D 38 5 150 315 D F K 38 5 150 317 K 38 5 200 315 D K 38 5 200 316 K 38 5 200 317 K 38 5 200 318 K 38 5 7 5 3 2 Installing the KSB double...

Page 47: ...ase or other permanent lubricants for fitting the torque transmitting elements of a mechanical seal Use soft soap to reduce any friction caused during assembly Never coat the mechanical seal faces with grease or oil 2 Prior to assembly wet the external elastomers O rings and gasket and the seats of the mechanical seal at the shaft discharge cover 163 and seal housing with a suitable lubricant e g ...

Page 48: ...alled 1 Slide impeller 230 onto the shaft end 2 Screw in impeller screw 914 10 with disc 550 23 Tighten with a torque wrench Table 20 Tightening torque for impeller screw Nm Size Impeller type Thread Tightening torque Nm 050 215 F M 8 26 050 216 F M 8 26 050 250 F K M 10 35 050 251 F K M 16 150 065 215 F M 8 26 065 216 E M 10 35 065 217 F M 8 26 065 250 F K M 10 35 065 252 B01 K M 10 35 065 252 B0...

Page 49: ...operly 502 904 01 101 230 0 5 mm Fig 18 Fitting the casing wear ring 1 Insert casing wear ring 502 into pump casing 101 2 Glue 3 pieces of cardboard7 of approximately 2 mm in thickness and 15 mm in length to the front face of the impeller ð In assembled condition this will result in a clearance of 0 5 mm between impeller and casing wear ring 3 Insert the complete back pull out unit into the pump c...

Page 50: ...o the wear plate 5 Insert the complete back pull out unit into the pump casing 6 Evenly tighten screwed connection 920 01 between pump casing and bearing bracket 7 5 6 Leak test After reassembly of the pump subject the mechanical seal area lubricant reservoir to a leak test 1 Tightly screw the testing device into the filler opening auxiliary connection 13D 2 Test medium Compressed air Test pressur...

Page 51: ...stock for 2 years operation to DIN 24296 Table 22 Quantity of spare parts for recommended spare parts stock Part No Description Number of pumps including stand by pumps Type 1 2 3 4 5 6 8 10 and more 163 Discharge cover 1 2 2 2 3 3 4 50 S 210 Shaft 1 1 1 2 2 2 3 30 S 230 Impeller 1 1 1 2 2 2 3 30 R 321 01 02 Rolling element bearing set 1 1 1 2 2 3 4 50 W 330 Bearing bracket complete 1 2 S 433 01 0...

Page 52: ...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 material Suction lift is too high NPSHavailable positive suction head is too low Check al...

Page 53: ...ndled is higher than stated in the purchase order Speed is too high Reduce speed 9 Assembly bolts sealing elements Re tighten bolts Fit new sealing elements Worn shaft seal Fit new shaft seal Vibrations during pump operation Correct the suction conditions Re align the pump Re balance the impeller Increase pressure at the pump suction nozzle Operating voltage too low Increase the voltage 9 Contact ...

Page 54: ...awing Sewabloc If applicable Sizes 100 250 100 251 125 315 150 315 only Table 24 List of components Part No Description Part No Description 101 Pump casing 550 23 57 Disc 135 Wear plate 800 Motor 163 Discharge cover 901 57 99 Hexagon head bolt 164 Inspection cover 902 01 Stud 210 Shaft 903 01 02 03 22 46 90 Screw plug 230 Impeller 904 01 Grub screw 321 01 Radial ball bearing 906 Impeller screw 330...

Page 55: ...iew of a Sewabloc Table 25 List of components Part No Description Part No Description 101 Pump casing 515 02 Locking ring 163 Discharge cover 550 23 57 Disc 210 Shaft 800 Motor 230 Impeller 85210 Threaded coupling 321 01 Radial ball bearing 901 57 Hexagon head bolt 330 Bearing bracket 902 01 Stud 411 01 02 03 22 46 90 Joint ring 903 01 02 03 22 46 90 Screw plug 412 04 15 O ring 914 10 73 Hexagon s...

Page 56: ...ves 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 11 Name Func...

Page 57: ...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 58: ...dation 20 Installation at site 19 Intended use 9 K Key to safety symbols markings 8 L Lubricant Quantity 36 M Maintenance 33 Misuse 9 O Operating limits 28 33 Order number 6 Other applicable documents 6 P Partly completed machinery 6 Permissible forces and moments at the pump nozzles 22 Piping 21 Preservation 13 Priming and venting 26 Product description 15 R Reassembly 38 Return to supplier 13 Re...

Page 59: ......

Page 60: ...KSB SE Co KGaA Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2580 817 10 EN 01104323 ...

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