KSB WK 100 Manual Download Page 39

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Works Order No.

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Pump Type & Size :

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Operating Instructions

0011.81 / 00 - 18 G3

High Pressure Centrifugal Pumps

These operating instructions contain fundamental

information and precautionary notes. Please read the

manual thoroughly prior to installation of unit, electrical

connection and commissioning.

It is imperative to comply with all other operating instructions

referring to components of individuals units.

Summary of Contents for WK 100

Page 1: ...Point Description Page No No 10 4 Shutting the pump down 14 10 5 Preserving the pump 15 10 6 Sending the pump back to our Works 15 11 Dismantling the pump 15 11 1 Preparations prior to dismantling 15 11 2 Dismantling the bearing 15 11 2 1 Dismantling the drive end bearing 15 11 2 2 Dismantling the end side bearing 16 11 2 2 1 Standard bearing construction 16 11 2 2 2 Heavy duty bearing constructio...

Page 2: ...x housings 451 are sealed off from the suction and discharge casings respectively 106 and 107 by a flat gasket 400 3 On pumps fitted with special hot water stuffing boxes or with mechanical seals the shaft seal is surrounded by a cooling Fig 1 water compartment which is sealed off against atmosphere by the stuffing box housing cover 165 with flat gasket 400 3 and O ring 412 4 See Fig 2 Fig 2 Stuff...

Page 3: ...ment shall be provided Fig 6 Individual bearing components drive end Part 1 Outer race with cage and rollers Part 2 Adaptor Sleeve Part 3 Inner bearing race Part 4 Locking Washer Part 5 Withdrawal Nut Standard Bearing Construction Drive end 1 Cylindrical roller bearing in accordance with DIN 5412 see Fig 6 with adaptor sleeve in accordance with DIN 5412 and standard bearing bracket No adaptor slee...

Page 4: ... 410 designation in accordance C 3 C 3 C 3 C 3 C 3 C 3 C 3 with DIN 5412 Adaptor sleeve in accordance with DIN 5412 H 206 H 207 H 207 H 208 H 208 H 210 Discharge side Deep groove ball bearing designation in accordance 6305 C 3 6306 C 3 6306 C 3 6307 C 3 6307 C 3 6308 C 3 6410 C 3 with DIN 625 Oil fill in litres 0 16 0 18 0 18 0 25 0 25 0 28 0 45 Fig 10 Bearing end oil requirement table In case of ...

Page 5: ...tuffing boxes mechanical seals can be fitted in lieu of soft packing or vice versa at any time during the service life of the pump with a minimum of machining of the cooling compartment covers On the other hand the fitting of mechanical seals to pumps equipped with standard or hot water type soft packed stuffing boxes necesitates the fitting of new pump components Particulars can be obtained from ...

Page 6: ...ked at any time in respect of rate of flow and temperature The temperature differential between cooling water inlet and outlet should not exceed 100 C The max permissible cooling water outlet temperature should not exceed 500 C The cooling water pressure should be situated between 1 bar min and 10 bar max An isolating valve should be incorporated in the cooling water supply line to enable the rate...

Page 7: ...ightening the stuffing box gland The inserted packing rings should then be compressed moderately with the aid of the stuffing box gland 452 and the nuts see Fig 23 Then the nuts should be slackened again by one to two complete turns and thereafter tightened lightly by hand The correct and even seating of the stuffing box gland 452 should be checked when the pump is subjected to suction pressure by...

Page 8: ...ntly used Fig 29 Flexible coupling Spacer type couplings see Figs 30 and 31 enable inspections and minor repairs e g the fitting of new bearings or shaft protecting sleeves to be carried out without removing the driver Fig 30 Spacer type flexible coupling Fig 31 Mounted spacer type flexible coupling 2 Mode of Operation of Pump The fluid flows through the suction casing towards the impeller at a gi...

Page 9: ...vers to allow them to be described in detail here and we would therefore refer you to the operating instructions for the driver published by the driver manufacturer which are attached 4 Transport If the pump is supplied as a unit bolted onto a baseplate the ropes for handling and transport should be slung under the pump and driver as illustrated in Fig 36 Fig 36 Slinging the ropes under the pump a...

Page 10: ... should be laid in position and levelled up with a spirit level The packing plates should lie flush on the foundation and be levelled up as truly horizontal as possible to facilitate the subsequent alignment and levelling up of the complete pumping set as accurately as possible The exact height is of less importance at this stage because any difference in heights can be compensated by the insertio...

Page 11: ...illed with the cement mortar and that no cavities remain The foundation bolts should be tightened evenly and firmly after the grout has set firmly Then check with the aid of a dial micrometer that the alignment is still correct 8 5 Final Alignment After all the pipelines have been connected and the direction of rotation check has been carried out with the pump disconnected from the driver the fina...

Page 12: ...ightly rising slope towards the suction vessel If it is not feasible to avoid apexes in the suction head line each apex should be equipped with a vent cock It is also advisable to avoid any appreciable length of horizontal suction head line laid close beneath the suction vessel because of the danger of evaporation see Fig 44 9 1 1 Strainers in Suction Head Line Suction Lift Line Before a new pumpi...

Page 13: ...utomatic Recirculation Valve The schroeder system automatic recirculation valve minimum flow device is a safety device the purpose of which has already been explained in section 2 Mode of Operation of Pump It should always be installed immediately downstream of the pump always upstream of the isolating valve and always vertical with the direction of flow from bottom to top see Fig 48 Each automati...

Page 14: ... 4 Fill in oil or check grease fill respectively 5 Pack the stuffing boxes see section 1 5 1 Stuffing Boxes 10 2 Start up 1 Check oil level in pump bearings if necessary top up the oil fill until oil starts pouring out of the over flow hole 2 Check condition of stuffing boxes 451 1 451 2 The stuffing box gland should penetrate deep enough in the stuffing box to ensure positive guidance and must no...

Page 15: ...t be exceeded i e the discharge valve should be partially closed to ensure that the pressure does not fall below the minimum discharge pressure corresponding to the particular speed or capacity at which the pump is operated at the time If the rate of flow drops below the minimum flow the minimum flow device starts operating Any prolonged operation within the response range of the minimum flow devi...

Page 16: ... stuffing box packing 461 1 4 Disconnect coupling see section 1 6 Couplings Check pump alignment at the coupling and make a note of the measurements see section 8 3 Alignment 5 If the pump is to be dismantled completely unscrew the fixing bolts on the suction and discharge lines and on the pump feet and remove the pump from the baseplate 6 Drain off the oil fill in the bearing housing by unscrewin...

Page 17: ...pump size 150 which is fitted with a cylindrical roller bearing without adaptor sleeve the bearing housing 350 including the outer race of the bearing and the other distance ring 543 are removed after unscrewing the hex nuts 920 4 then the inner race of the bearing and the inner distance ring 525 4 are pulled off the shaft and the circlip 932 removed 11 2 2 Dismantling the End side Bearing 11 2 2 ...

Page 18: ...cked Stuffing Box Construction 1 Pull stuffing box gland 452 off the shaft 2 Force off and remove stuffing box housing 451 On pumps equipped with cooled stuffing boxes force off and remove the stuffing box housing 451 including cooling cover 165 see Fig 63 3 Slacken shaft protection sleeve 524 2 and remove it from shaft 210 see Fig 64 Fig 63 Removing the stuffing box housing 451 11 4 Dismantling t...

Page 19: ... 525 1 and shaft protection sleeve 524 1 out of the suction casing see Fig 73 Fig 72 Slackening and removing the stage casing 7 Pull impeller 230 spacer sleeve 525 1 and shaft protection sleeve 524 1 off the shaft see Fig 74 Fig 73 Removing the shaft together with first stage impeller 8 Stack the stage casings on top of one another in correct order The contact faces should be protected by wooden s...

Page 20: ...new clearance Max permissible clearance for material alternative value for material alternative Chrome steel Chrome steel C I Bz throughout C I Bz throughout and bronze and bronze mm on dia mm on dia mm on dia mm on dia Casing Wearing ring Impeller neck 0 30 0 40 1 0 1 0 Diffuser stage sleeve 0 30 0 35 1 0 1 0 Discharge casing spacer sleeves 0 30 0 35 1 0 1 0 Suction head Shaft Suction casing 1 0 ...

Page 21: ...tor If certain rotor components are replaced by new ones or are touched up or if a new shaft is fitted the pump rotor of pump sizes 40 to 100 must be subjected to an out of round check and in addition the pump rotor of pump sizes 125 and 150 must be dynamically balanced if possible at max operatings speed but in any event at 1000 1 min The max permissible residual eccentricity should not exceed 5 ...

Page 22: ... following stages in similar fashion each stage consists of stage casing 9108 diffuser 171 1 casing wearing ring 502 flat gasket 400 2 impeller 230 key and stage sleeve 521 Underpin the stage casings 108 in turn after assembly see Fig 84 Fig 84 Mounting the stage casings 6 After assembly of each individual stage check the total axial clearance Sa 1 Sa 2 of the pump rotor approx 6 mm see Fig 85 7 M...

Page 23: ...tened until abbutment is achieved If the pump should become slightly distorted by uneven tightening the hex nuts 920 1 at the suction end should be slackened slightly 10 At the discharge end the screw threads of the tie rods and the washers should be coated with molybdenum disulphide The hex nuts 920 1 should bbe tightened by hand with a standard short spanner to ensure intimate contact of the sta...

Page 24: ... bearing cover 360 2 onto the shaft and studs 902 3 on the discharge casing and fasten it with the nuts 920 2 3 Slip spacer sleeve 525 5 onto the shaft until it abuts against circlip 932 4 Slip inner guide bush 508 and lubricating 644 onto the shaft Caution The angular contact ball bearings must be mounted in X arrangement To facilitate mounting it is advisabble to pre heat the angular contact bal...

Page 25: ...ghtened see Figs 112 and 113 Fig 112 Mounting the inner race of the cylindrical roller bearing with adaptor sleeve Fig 113 Tightening the withdrawal nut 5 Bend down the tabs on the locking washer see Fig 114 6 Mount bearing cover 360 and flat gasket 400 4 see Fig 115 7 On pump size 150 assembly should proceed as follows see Fig 116 Mount splash ring 507 and circlip 932 on the shaft Insert outer ra...

Page 26: ...with fluid 3 Insufficient pressure differential between suction pressure and vapour pressure NPSH required is not attained observe rate of pressure decrease 4 Mouth of suction line too close to surface of liquid level in the suction vessel or liquid level in vessel too low General Faults in the Installation 5 Rotational speed to low or rate or minimum flow through by pass excessive 6 Rotational sp...

Page 27: ...ause 9 Adjust pressure conditions by means of discharge valve Alter rotation speed alter impeller diameter Refer to manufacturer Cause 10 Check temperature of fluid pumped take steps outlined in 9 above Cause 11 Check operation of minimum flow device Refer to manufacturer Cause 12 Check condition of individual machines Refer to manufacturer Cause 13 Clean out pump check condition of suction system...

Page 28: ...roove roller bearing 1 1 1 322 Cylindrical roller bearing 1 1 1 400 1 Flat gasket 1 1 1 400 2 Flat gasket S S S 400 3 Flat gasket 2 4 4 400 4 Flat gasket 2 2 2 400 5 Flat gasket 1 1 1 Only on heavy duty bearing bracket 400 6 Flat gasket 2 412 2 O ring 1 1 1 412 3 O ring 2 2 2 412 4 O ring 2 2 412 7 O ring 2 2 2 Only on heavy duty bearing bracket 422 1 Felt ring 3 3 3 Only on heavy duty bearing bra...

Page 29: ...e pressures If the pump is turbine driven run up turbine to full operating speed as rapidly as possible and make sure the pump runs quietly during this time 15 3 Priming the Boiler Crack the isolating valve in the discharge line open slowly remember lag of servo actuated valves Run the pump within the confines of the limitation curve of the operating diagram see section 10 3 Pump Operation and Sup...

Page 30: ...1 550 Washer 2 52 1 Adaptor sleeve 16 636 Grease nipple 1 638 Constant level oiler 2 2 2 644 Lubricating ring 5 1 680 Cover sheet Qty Part Designation per No pump 2 720 3 Double nipple 2 731 2 Plug 8 901 2 Hex bolt 4 901 3 Hex bolt 5 4 901 4 Hex bolt 16 902 1 Stud 4 902 2 Stud 8 902 3 Stud 2 903 1 Plug 2 903 2 Plug 2 903 4 Plug 1 903 5 Plug 1 903 12 Plug 8 905 Tie rod 2 913 Vent plug 16 920 1 Hex ...

Page 31: ... 2 524 1 458 VSH 412 3 412 4 461 1 452 165 350 400 3 4003 11E 451 524 2 524 1 458 Grease lubricated construcion 638 731 2 Constant level oiler viewed from X 638 Construction with constant level oiler and bearing housing seal 913 X 500 1 422 1 Construction with bearing housing seal 422 2 500 2 932 WK 150 bearing construction 903 12 361 543 920 4 321 525 4 350 350 322 360 Front end Drive end Bearing...

Page 32: ...the flow of balancing liquid into the balancing chamber which again has to be drawn off In case of WL pumps this piping is either connected back to the suction casing fig A or to the feed water tank fig B depending upon the temperature and differential head of the pumping liquid 3 Size The tapping size provided on the balancing chamber of discharge casing and the recommended pipe line sizes are gi...

Page 33: ...the balancing liquid line is fed back to feed water tank and if more than one pumps are operating in parallel the individual balancing liquid lines should be independently connected to the feed water tank without joining them together or even putting them into a common header iv The globe valve in the balancing liquid line back to feed water tank should always remain in fully open condition and on...

Page 34: ...WK NOTES ...

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Page 36: ...WK NOTES ...

Page 37: ...WK ...

Page 38: ...854237 42 022 2873299 Calcutta 30 Circus Avenue 2nd Floor 700 017 033 2470473 2400117 8 033 2470588 NOIDA KSB House A 96 Sector IV NOIDA 0118 54091 93 0118 525627 550567 Dist Gautam Budh Nagar 201 301 Chennai Guindy House 2nd Floor 95 Anna Salai 600 032 044 2352571 2 2300629 044 2352749 Branch Offices Ahmedabad 079 7540428 7543427 Aurangabad 0240 351440 Bangalore 080 3491806 3493925 Baroda 0265 33...

Page 39: ... 0011 81 00 18 G3 WK High Pressure Centrifugal Pumps These operating instructions contain fundamental information and precautionary notes Please read the manual thoroughly prior to installation of unit electrical connection and commissioning It is imperative to comply with all other operating instructions referring to components of individuals units ...

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