KSB 9972073510/200 Operating And Maintenance Instructions Manual Download

Page: 1 / 41

KSB REF No: 9972073510/200

Client

: Thiess

Pty

Ltd

Project

Goodna Sewerage Treatment Plant Upgrage [Stage 4A]

P.O. No.

GDSTP-24090-CON-0000

Equipment / Tag No. :

ATF Feed Pump Skid PU-0700-110, 120

OPERATING AND

MAINTENANCE
INSTRUCTIONS

K S B A u s t r a l i a P t y L t d

A B N 2 9 0 0 6 4 1 4 6 4 2
A Q u a l i t y E n d o r s e d C o m p a n y A S / N Z I S O 9 0 0 1 : 2 0 0 8

Sales and Service
Phone

: (07)

3436

8600

Fax

: (07)

3436

8699

Email

: [email protected]

Spares

1300 KSB SPARES ( 1300 572 772 )

Issue Date: 7/03/2012

Goodnal STP ST041 Disinfection & Outfall (KSB ATF Feed Pump Skid PU-0700-110

Q-Pulse Id VM405

Active 29/10/2013

Page 1 of 41

Summary of Contents for 9972073510/200

Page 1: ...NSTRUCTIONS K S B A u s t r a l i a P t y L t d A B N 2 9 0 0 6 4 1 4 6 4 2 A Q u a l i t y E n d o r s e d C o m p a n y A S N Z I S O 9 0 0 1 2 0 0 8 Sales and Service Phone 07 3436 8600 Fax 07 3436 8699 Email ksbqldsales ksb com au Spares 1300 KSB SPARES 1300 572 772 Issue Date 7 03 2012 Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013...

Page 2: ...ugged Butterfly Valve Data Sheet Pressure Tank Data Sheet Pressure Gauge Data Sheet Wafer Check Valve Dual Disc Plate Data Sheet FSF Rubber Expansion Joint Data Sheet 4 Drawings Certified G A Drawing No 01376742 Rev 2 Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 2 of 41 ...

Page 3: ...d operating instructions 1798 82 4 10 Movitec V 2 4 6 Movitec V 10 15 Movitec VF 90 Vertical High pressure in line pumps Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 3 of 41 ...

Page 4: ... the product 10 5 3 Modular selection 10 5 4 Operation 11 5 5 Measuring draining and venting 11 5 6 Working range 11 5 7 Explosion safety 12 6 Transport 6 1 Transport 14 6 2 Storage 14 7 Installation instructions 7 1 Setting up the pump 15 7 2 Mounting a motor on the pump 16 7 3 Electrical install 17 7 4 Commissioning 18 8 Operation 8 1 Operation 19 9 Maintenance 9 1 Introduction 20 9 2 Lubricatio...

Page 5: ...3 Movitec V 2 4 6 10 15 90 11 Annexes 11 1 CE declaration of conformity 24 Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 5 of 41 ...

Page 6: ...ructions Never change the sequence of the operations to be carried out Keep this manual or a copy of it together with the logbook in a fixed place near the product which can be accessed by all personnel 1 2 Icons and symbols In this manual and in all accompanying documentation the following icons and symbols are used WARNING Danger of electric Voltage Safety sign according to IEC 417 5036 WARNING ...

Page 7: ...ype design version B 15 kW 12 2 kW Nominal motor power1 required power 1 Frame size in case without motor 50 Hz Nominal frequency Ca Sic Mechanical Seal Surface Code See 2 2 Seal codes EPDM Pump Elastomers Q 23 6 l s Optimum capacity running at fixed speed see fig Duty point H 38 1 Optimum heads running at fixed speed see fig Duty point n fix 2900 rpm Rotation speed indication at which Q H are giv...

Page 8: ...on 2 4 Supplementary documentation Apart from this manual the documentation given below is also available Table 3 Supplementary documentation Code acc to EN 12756 Description Material Note B Q1 U3 Spring loaded ring Carbon graphite Silicon carbide Tungsten carbide Ca SiC TuC Resin impregnated Sintered pressureless CrNiMo binder A B Q1 U3 Seat ring Carbon graphite Carbon graphite Silicon carbide Tu...

Page 9: ...described in the following sections of this manual The limits stated in the data sheet must not be exceeded under any circumstances The warranty becomes invalid if one or more of the points below occur The buyer makes modifications himself The buyer carries out repairs himself or has these carried out by a third party The product has been handled or maintained improperly The product has non origin...

Page 10: ...laid down in this chapter on Safety be complied with but also the safety instructions outlined under specific headings 4 2 Users All personnel involved in the operation maintenance inspection and installation of the product must be fully qualified to carry out the work involved Personal responsibilities competence and supervision must be clearly defined by the operator If the personnel in question...

Page 11: ...h the utmost care Avoid danger for persons or the environment when repairing leakages draining liquids and venting It is strongly recommended to place a relief barge under the pump WARNING Immediately following completion of the work all safety relevant and protective devices must be re installed and or re activated WARNING Please observe all instructions set out in the chapter Commissioning Start...

Page 12: ...ection as well as the base plate Sealings which define the elastomers the mechanical seal and the shaft seal type Electric motor which defines all requirements of the motor such as motor size power voltage frequency and all possible motor accessories Movitec VS F 90 3 1 B Label Movitec Product Label Material Con struction VC Cast Iron pump foot and top bracket hydr 1 4301 AISI 304 V All wetted par...

Page 13: ... to measure the discharge pressure of the pump using a G 3 8 connection 5 6 Working range The working range depends on the application and a combination of pressure and temperature For specific and detailed limits advice the working ranges are described in the chapter 5 3 Modular selection The overall working range of the pumps can be summarised as follows Table 5 Specification of the working rang...

Page 14: ...motor cooling fan must be at least 1 4 of the diameter of the inlet of the cooling fan in order to have a sufficient flow of cooling air 4 Pumps that are intended for 50 Hz operation may not be connected to 60 Hz power supply size Qmin m3 h 50 Hz 60 Hz 2 pole 4 pole 2 pole 4 pole 2 0 2 0 2 4 0 4 0 5 6 0 6 0 8 10 1 1 0 5 1 3 0 6 15 1 6 0 8 2 0 1 0 90 8 5 4 3 10 2 5 1 3675 Figure 5 Minimum capacity ...

Page 15: ... liquid temperature never exceeds the temperature mentioned in the explosion safety code T3 or T4 See table 7 Explosion safety Avoid overheating of the pump to ensure a minimum flow in the pump according with the description in chapter 5 6 Working range The pumps has to be de airated again when the pump is taken out of operation some air is gathered in the pump Make sure that the pump and the moto...

Page 16: ...uency converter if placed electrical parts or the motor cover Be sure that the pump is always in balance WARNING Pumps could tilt while lifting Do not remove the lifting devices from the pump before the pump is placed and mounted correctly Table 9 Transport positions 6 2 Storage Fill the pump with glycol in order to protect it against the risk of frost Table 10 Storage 6 2 1 Inspection during stor...

Page 17: ...e Type DN mm Force N Fx Fy Fz Σ F V S F 2 B 25 3300 2400 1700 4400 V S F 4 B 25 3300 2400 1700 4400 V S F 6 B 32 3300 2400 1700 4400 V S F 10 B 40 4000 3100 3100 5900 V S F 15 B 50 4000 3100 3100 5900 V S F 90 B 100 3500 2500 1000 4400 20090283 C Type DN mm Moment Nm Mx My Mz Σ M V S F 2 B 25 280 95 210 400 V S F 4 B 25 280 95 210 400 V S F 6 B 32 280 95 210 400 V S F 10 B 40 440 180 200 500 V S F...

Page 18: ... an other brand standard IEC norm motor KSB has to be consulted to verify the applicability The motor has to conform to the following conditions Reinforced bearing at driven end to withstand the axial force Axially fixed rotor to minimize the axial play of the pumps hydraulic Smooth shaft no key lock to improve the coupling grip and to improve the motor balance The advised bearings per motor type ...

Page 19: ...Electrical diagrams in the annexes for the correct connection diagram Connect the motor using a motor safety switch PTC connection STM 140 EK Standard motors 3 kW and up are equipped with a PTC thermistor Consult Table 16 Technical specifications PTC STM 140 EK Connect the PTC on a thermistor relay Table 16 Technical specifications PTC STM 140 EK ID2482 Figure 8 Motor connections 20100169 Value tn...

Page 20: ... then pump 1 Remove the fill plug B from the top bracket 2 Close the outlet shut off valve 3 Fill the pump housing to the maximum through the fill plug with the liquid that is to be pumped 4 Insert the fill plug in the top bracket 5 Check the rotational direction of the pump 6 Open the outlet shut off valve 7 4 3 After an extended period of non operation or storage During first start up check the ...

Page 21: ...Operation 8 1 Operation The pump is controlled externally and therefore does not need any operation guidance Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 21 of 41 ...

Page 22: ...d 30 C 160 C bearing lubricant about 15 grams When the pump is delivered without a motor and fitted with an other brand or the standard motor is replaced by an other brand than KSB please consult the maintenance instructions of the motor supplier ATTENTION Also follow the instructions in 7 2 Mounting a motor on the pump 9 3 Maintaining the pump for an extended period of non operation Turn the shaf...

Page 23: ...er and soap as a lubricant Elastomers affected by medium Use the right rubber com pound for the mechanical seal Pressure too high Use the right type of mechanical seal Shaft worn Replace shaft and mechanical seal Pump has been operating without water Replace the mechanical seal Leakage along the shroud at the top bracket or at the pump foot O ring worn Replace the O ring O ring not resistant to th...

Page 24: ...rface Malfunction Internal blockage in the pump Have the pump inspected by a certified company Pump does not start No voltage on the termi nal clamps Check the power supply Circuit Main switch Fuses Check the motor safety relay Earth leakage switch Protective relay Thermal motor safety switch triggered Reset the thermal motor safety Contact the sup plier if this problem occurs more often Check if ...

Page 25: ...eakage Too little water consump tion so air bubbles clog up in the pump Make sure the consump tion increases or use a smaller pump The diameter of the suc tion line is too small Increase the diameter of the suction line Capacity of water meter in the supply line is too small Increase the capacity of the water meter Foot valve blocked Clean the foot valve The impeller or the diffuser is blocked Cle...

Page 26: ...for pumps and which implies the regulations of Machine directive 2006 42 EC in the most recent form In case the pump is delivered with an electromotor IIA to which this declaration refers is in accordance with the following standard EN 809 1998 A1 1998 according to the provisions of the harmonized norm for pumps and which implies the regulations of Machine directive 2006 42 EC EMC 2004 108 EC and ...

Page 27: ...25 Movitec V 2 4 6 10 15 90 Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 27 of 41 ...

Page 28: ...26 Movitec V 2 4 6 10 15 90 Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 28 of 41 ...

Page 29: ...27 Movitec V 2 4 6 10 15 90 Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 29 of 41 ...

Page 30: ...iginal instructions BE00000379 1798 82 4 10 KSB Aktiengesellschaft 67225 Frankenthal Johann Klein Straße 9 67227 Frankenthal Germany Tel 49 6233 86 0 Fax 49 6233 86 34 01 www ksb com Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 30 of 41 ...

Page 31: ...trip setting All circuit breakers HRC fuses or protective devices associated with the motor must be rated to suit motor running current and starting characteristics Initial start up Prior to initial start up the following steps must be taken Insulation resistance test On machines up to 600 volt the minimum value should be 1MΩ Thermistors if fitted should be checked for continuity with a multimeter...

Page 32: ...e required replacement interval for sealed bearings is generally determined by the grease life which is dependant on operating temperature operating speed the limiting speed of the bearing and the type of grease Under normal operating conditions the following relationship applies n n log t 6 54 2 6 N 0 025 0 012 N T Where t Average grease life hours n Speed RPM N Bearing limiting speed with grease...

Page 33: ...O5211 STEM DIAGONAL SQUARE HEAD AS2129 TABLE E DN 50 DN65 DN80 DN100 DN125 DN150 DN200 DN250 DN300 F F07 F07 F07 F07 F07 F07 F10 F10 F10 E 70 70 70 70 70 70 102 102 102 4 d1 10 10 10 10 10 10 12 12 12 M 90 90 90 90 90 90 125 125 125 f 14 1 14 1 14 4 18 1 22 1 22 1 22 1 28 2 28 2 K 11 11 11 14 17 17 17 22 22 H3 31 8 31 8 31 8 31 8 31 8 31 8 35 5 35 5 35 5 D 114 127 146 178 21 235 292 356 406 n M 4 ...

Page 34: ... water air seal ensuring a complete leak free and maintenance free pressure vessel On the exterior the almond colored two part polyurethane paint finish over an epoxy undercoating provides hundreds of hours of UV and salt spray protection PressureWave tanks are quality tested at several stages on the production line to insure the structural integrity of every tank PressureWave tanks represent the ...

Page 35: ...PWB35H PWN35H 48 1 18 9 35 4 13 9 17 8 7 0 1 BSP NPT SS Inline 35 9 2 0 071 2 50 7 9 17 6 PWB60H PWN60H 52 8 21 1 41 4 16 6 21 3 8 5 1 BSP NPT SS Inline 60 14 0 102 3 60 12 5 27 6 PWB80H PWN80H 72 4 29 41 4 16 6 21 3 8 5 1 BSP NPT SS Inline 80 20 0 133 4 70 17 5 38 5 PWB100H PWN100H 72 4 29 48 2 19 24 4 9 6 1 BSP NPT SS Inline 100 26 4 0 171 6 04 19 2 42 3 Vertical Models w base PWB35V PWN35V 55 5...

Page 36: ... The glycerin filled version is damped for wear protection should pulsating pressures and mechanical vibrations occur The measuring system is of accuracy class 1 0 has overrange protection amounting to 1 3 times the max rating and can be loaded up to the full scale value A series of installation possibilities enables adaption to special requirements and installation conditions Features o Stainless...

Page 37: ...ite scale and imprint black Dual scale Pointer Aluminium black microadjustable pointer red Al marker pointer on dial marker pointer on plexiglass with key adjustment or fixed knob Movement Stainless steel plastic gearing and bearing oil damped pointer spindle Manocont Measuring element Stainless steel 316 L Bourdon tube up to 60 bar helical tube from 100 bar Monel Connection position Stainless ste...

Page 38: ...d Model P2324 P2325 Hole pattern for front rear flange Model P2328 P2329 front flange Model P2328 P2329 with triangular bezel Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 38 of 41 ...

Page 39: ...WC65 65MM 127 80 60 2 60 48 36 1 20 2 4KG VWC80 80MM 142 94 66 4 70 64 43 4 28 3 6KG VWC94 100MM 162 117 90 8 88 64 52 8 27 5 7KG VWC95 125MM 192 145 116 9 115 70 65 7 30 7 3KG VWC96 150MM 218 170 144 6 134 76 78 6 31 9 0KG VWC98 200MM 273 224 198 2 184 89 104 4 33 17KG VWCX25 250MM 328 265 233 7 220 114 127 50 26KG VWCX30 300MM 378 310 283 9 280 114 148 3 43 42KG Goodnal STP ST041 Disinfection Ou...

Page 40: ...Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 40 of 41 ...

Page 41: ...Goodnal STP ST041 Disinfection Outfall KSB ATF Feed Pump Skid PU 0700 110 Q Pulse Id VM405 Active 29 10 2013 Page 41 of 41 ...

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