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Cust. Doc. No.:GDSTP-24090-MAN-0005-P

KSB Doc. No.:KSB-88980-060

KSB REF No: 88980/ 02

Client

: Thiess

Pty

Ltd

Project

Goodna Sewerage Treatment Plant Upgrage [Stage 4A]

P.O. No.

GDSTP-24090-CON-0000

Equipment / Tag No. :

WAS PUMP 1 & 2 PU-0530-010

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: 19/12/2011

Goodnal STP ST041 Biological Treatment (KSB WAS PUMP 1 & 2 PU-0530-010 OM Instructions) Vendor Manual

Q-Pulse Id VM381

Active 29/10/2013

Page 1 of 76

Содержание 88980/02

Страница 1: ...TENANCE 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 Fa...

Страница 2: ...Instructions 2 Additional Data Data Sheet 3 Drawing Certified G A Drawing No UX02010 4 I T P s I T P s Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manua...

Страница 3: ...s DN 50 to DN 100 Motor sizes 2 pole 002 to 042 4 pole 004 to 044 Installation Operating Manual Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Puls...

Страница 4: ...stributed copied reproduced processed for any other purpose nor otherwise transmitted to a third party without KSB s express written consent Subject to technical modification without prior notice KSB...

Страница 5: ...es of operation 11 2 10 Explosion protection 11 3 Transport Temporary Storage Disposal 12 3 1 Transport 12 3 2 Storage and preservation 12 3 3 Return to supplier 13 3 4 Disposal 13 4 Description of th...

Страница 6: ...ues 48 7 7 Spare parts stock 48 8 Trouble shooting 50 9 Related Documents 51 9 1 General assembly drawing with list of components 51 9 2 Wiring diagrams 57 9 3 Wiring diagrams overload protection 59 9...

Страница 7: ...components in contact with the fluid handled Hydraulic system The part of the pump in which the kinetic energy is converted into pressure energy Monobloc pump set Motor housing and pump casing form a...

Страница 8: ...d machinery To install partly completed machinery supplied by KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This manual is aimed at the target group of trained and qualifi...

Страница 9: ...structions Safety instructions Result of an action Cross references 1 2 Step by step instructions Note Recommendations and important information on how to handle the product 1 General Amarex N 7 of 66...

Страница 10: ...symbol indicates 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 oper...

Страница 11: ...nly use impeller types designed for the fluid handled as described below Impeller with cutter impeller type S Suitable for the following fluids Faeces domestic sewage and waste water containing long f...

Страница 12: ...nce and servicing practices Hazard to the environment due to leakage of hazardous substances 2 6 Safety awareness In addition to the safety information contained in this manual and the intended use th...

Страница 13: ...th its intended use 2 10 Explosion protection Always observe the information on explosion protection given in this section when operating an explosion proof pump set Sections of the manual marked by t...

Страница 14: ...time after delivery we recommend that the following measures be taken for pump storage CAUTION Improper storage Damage to the power cables Support the power cables at the cable entry to prevent perma...

Страница 15: ...so be neutralised and anhydrous inert gas must be blown through the pump for drying purposes 4 Always complete and enclose a certificate of decontamination when returning the pump set Section 11 Page...

Страница 16: ...00049 0 3 10 8 0 3 10 8 1 9 1 9 2835 2835 400 400 4 5 4 5 4 4 4 4 42 42 0 83 0 83 50 50 55 15 6 4 99 15 6 4 99 70165000 DKN 82 2 2U DKN 82 2 2U Amarex N F 50 170 012 YLG 120 Nicht unter Spannung ffnen...

Страница 17: ...number of poles 50 172 002 012 022 50 222 032 042 Drive Three phase asynchronous squirrel cage motor Explosion proof pump sets comply with type of protection Ex d IIB 4 5 Types of installation Two des...

Страница 18: ...shaft runs in rolling element bearings 9 and 10 which are supported by a bearing bracket 2 linked with the pump casing and or discharge cover The pump is sealed by two bi rotational mechanical seals...

Страница 19: ...of installation e g at the control panel pipeline or mounting bracket 4 8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing outline drawing or data she...

Страница 20: ...rotational frequency rotational noise must be prevented both in the foundation and in the connected piping as such frequencies may cause extreme vibrations 1 Check the structural requirements All str...

Страница 21: ...903 with joint ring 411 Observe the tightening torques Section 7 6 Page 48 5 2 3 Checking the direction of rotation DANGER Pump set running dry Explosion hazard The direction of rotation of explosion...

Страница 22: ...observe the general arrangement drawing outline drawing when installing the pump set 5 3 1 Stationary wet installation 5 3 1 1 Fastening the duckfoot bend Depending on the pump size the duckfoot bend...

Страница 23: ...NOTE When the pump set is used for draining low level building areas install a swing check valve in the discharge line to avoid backwash from the sewer system CAUTION Critical speed Increased vibratio...

Страница 24: ...t bend 72 1 and back again to suspension bracket 572 and insert it into clamping piece 571 3 Manually tension wire 59 24 01 and secure it by means of hexagon nuts 920 37 4 Pull the wire taut by tighte...

Страница 25: ...ng brackets also serve as spacers between the two guide rails 1 Position adapter 82 5 on duckfoot bend 72 1 and fasten it with screws 914 2 discs 550 02 and nuts 920 02 2 Place rails 710 onto the coni...

Страница 26: ...f guide hoop 571 into the grooves of duckfoot bend 72 1 2 Fasten the flanged duckfoot bend to the tank sump floor with 2 anchor bolts 90 3 38 Section 5 3 1 1 Page 20 5 3 1 6 Preparing the pump set Fas...

Страница 27: ...4785 Attaching the lifting chain rope transportable wet installation Transportable wet installation 1 Attach the lifting chain or rope to the lug eyebolt bail at the pump set on the side of the discha...

Страница 28: ...e installing the pump set fit the 3 pump feet and foot plate if applicable Fitting the pump feet 1 Undo screws 914 03 2 Push pump feet 182 into the opening in the suction cover 3 Tighten screws 914 03...

Страница 29: ...n the name plate 5 4 1 2 Level control DANGER Pump set running dry Explosion hazard Never allow an explosion proof pump set to run dry CAUTION Fluid level below the specified minimum Damage to the pum...

Страница 30: ...of the pump set itself Suitable analysing devices must be selected In this case we recommend to monitor the leakage sensor fitted inside the motor by means of a special relay available from KSB 5 4 1...

Страница 31: ...20 and 21 max 250 V 2 A serve as temperature control devices which open when the winding temperature is too high Opening of the switch contacts must result in the pump set cutting out Automatic re sta...

Страница 32: ...r bend or crush the power cables Never use the power cables to lift up the pump set CAUTION Motor overload Damage to the motor Protect the motor against overloading by a thermal time lag overload prot...

Страница 33: ...read for a M8 x 20 socket head cap screw DANGER Touching the pump set during operation Electric shock Make sure that the pump set cannot be touched during operation DANGER Chemically corrosive fluids...

Страница 34: ...with the fluid to be handled The direction of rotation has been checked The lubricant has been checked only for variants YL and WL After prolonged shutdown of the pump set the required activities have...

Страница 35: ...y of starts CAUTION Excessive frequency of starts Damage to the motor Never exceed the specified frequency of starts To prevent high temperature increases in the motor do not exceed the following numb...

Страница 36: ...he information on fluid density indicated in the data sheet Make sure the power reserve of the motor is sufficient 6 2 5 Supply voltage DANGER Non compliance with permissible supply voltage tolerances...

Страница 37: ...zing remove the pump set from the fluid handled and clean preserve and store it Make sure sufficient fluid is available for the operation check run of the pump set 1 For prolonged shutdown periods sta...

Страница 38: ...re install and or re activate any safety relevant and protective devices NOTE On pumps pump sets older than 5 years we recommend replacing all elastomer seals 6 Commissioning Start up Shutdown 36 of 6...

Страница 39: ...d the environment Decontaminate pumps handling fluids posing a health hazard WARNING Hot surface Risk of personal injury Allow the pump set to cool down to ambient temperature NOTE Special regulations...

Страница 40: ...d must be less than 1 2 Replace any damaged components by original spare parts DANGER Defective earth conductor Electric shock Never switch on a pump set with a defective earth conductor 7 2 1 3 Measu...

Страница 41: ...leakage sensor in the motor Measurement between terminals Resistance 9 and earth conductor PE 1 Lower resistance values suggest water ingress into the motor In this case the motor must be opened and...

Страница 42: ...nd 65 220 B Variant YL WL 2 Place a suitable container under the screwed plug WARNING Excess pressure in the lubricant reservoir Liquid spurting out when the lubricant reservoir is opened at operating...

Страница 43: ...nical seal 433 02 along the shaft 3 Drain the oil 1 Fill 0 25 litres of oil through the opening between the stationary part of mechanical seal 433 02 and rotor 818 2 Thoroughly clean rotor 818 and the...

Страница 44: ...e Risk of personal injury Allow the pump set to cool down to ambient temperature Observe the general safety instructions and information For dismantling and reassembly observe the general assembly dra...

Страница 45: ...n which may affect explosion protection such as re winding and machining repairs must be inspected and approved by an approved expert or performed by the motor manufacturers No modifications must be m...

Страница 46: ...mation Safety regulations CAUTION Improper reassembly Damage to the pump Reassemble the pump set in accordance with the general rules of sound engineering practice Use original spare parts only NOTE B...

Страница 47: ...412 11 into discharge cover 163 and press them into bearing bracket 330 as far as they will go 3 Push pump end mechanical seal 433 02 onto shaft 210 For special mechanical seals with covered spring ti...

Страница 48: ...x is the distance between the upper side of the suction cover and the mounting holes of the suction cover 8 Measure dimension y between pump casing and impeller vanes Dimension y is the distance betw...

Страница 49: ...s scope of supply 13 Insert and tighten the impeller screw 7 5 3 Reassembling the motor section NOTE Before reassembling the motor section check that all joints relevant to explosion protection flamep...

Страница 50: ...ing torques Table 21 Tightening torques Thread Torque Nm M 8 17 Impeller screw M8 40 Screwed plug 903 23 7 7 Spare parts stock NOTE For explosion proof pump sets only original spare parts or parts aut...

Страница 51: ...3 02 Mechanical seal pump end 2 3 4 5 6 7 90 99 9 Set of seal elements 4 6 8 8 9 10 100 7 7 3 Sets of spare parts Table 23 Overview of spare parts sets Description Part No Rolling element bearing moto...

Страница 52: ...pipes Replace seal elements X X X Impermissible air or gas content in the fluid handled Contact KSB X System induced vibrations Contact KSB X X X X Wrong direction of rotation Check the connection of...

Страница 53: ...ooved pin 162 Suction cover 81 2 Connector 210 Shaft 81 59 Stator 230 Impeller 818 Rotor 321 01 02 Radial ball bearing 821 Rotor core pack 330 Bearing bracket 834 Cable gland 410 Profile joint 914 01...

Страница 54: ...tion cover 81 2 Connector 210 Shaft 81 59 Stator 230 Impeller 818 Rotor 321 01 02 Radial ball bearing 821 Rotor core pack 330 Bearing bracket 834 Cable gland 355 Bearing bracket housing 903 Screwed pl...

Страница 55: ...433 01 932 03 412 03 113 914 02 113 321 01 932 02 321 02 932 01 321 476 433 01 433 01 932 03 412 03 330 330 230 914 02 433 02 561 230 914 04 23 7 561 500 914 06 914 04 23 7 162 162 914 03 500 904 914...

Страница 56: ...01 932 02 321 02 932 01 321 412 02 476 476 433 01 433 01 932 03 412 03 330 330 914 02 433 02 230 230 914 04 412 05 162 914 03 903 411 412 04 914 01 834 834 412 04 914 01 162 550 550 ULG Fig 31 Explode...

Страница 57: ...476 476 433 01 932 03 433 01 412 03 330 914 02 330 433 02 230 914 04 550 230 162 914 03 904 162 914 04 904 410 932 04 411 903 834 834 914 01 412 04 412 04 914 01 100 100 410 411 903 ULG Fig 32 Explod...

Страница 58: ...tor 330 Bearing bracket 821 Rotor core pack 355 Bearing bracket housing 834 Cable gland 410 Profile joint 99 9 Set of seal elements 411 Joint ring 903 Screwed plug 412 01 02 03 04 05 O ring 904 Grub s...

Страница 59: ...WLG YLG Fig 33 Wiring diagram for variant WLG YLG 9 Related Documents Amarex N 57 of 66 Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM3...

Страница 60: ...g 34 Wiring diagram for variant ULG 9 Related Documents 58 of 66 Amarex N Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM381 Active 29 1...

Страница 61: ...LC1 D0910 RH Earth leakage protection relay with separate toroid e g Vigirex RH 328 A Merlin Gu rin Tore F Remote control H Auxiliary supply 12 43 44 A1 14 13 RH 230 240 V PE L3 L2 L1 KM KM Q Q M M R...

Страница 62: ...nce ISO inside diameter F7 H8 H8 Tolerance ISO outside diameter g6 Tolerance in m inside diameter to DIN ISO 286 2 Maximum 41 63 39 Minimum 20 0 0 Tolerance in m outside diameter to DIN ISO 286 2 Maxi...

Страница 63: ...meter F7 H8 H8 Tolerance ISO outside diameter g6 Tolerance in m inside diameter to DIN ISO 286 2 Maximum 41 63 39 Minimum 20 0 0 Tolerance in m outside diameter to DIN ISO 286 2 Maximum 14 Minimum 39...

Страница 64: ...hanical seal bellows type mechanical seal 932 01 Circlip 433 01 Mechanical seal bellows type mechanical seal 433 Mechanical seal mechanical seal with covered springs HJ 9 Related Documents 62 of 66 Am...

Страница 65: ...t the following harmonised international standards were applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 EN 60034 1 EN 60034 5 A1 Sequedin Lille 29 12 2009 Martial Smis Head of Product Deve...

Страница 66: ...rotor has been removed from the pump for cleaning No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residues and d...

Страница 67: ...el control 27 Lubricant Intervals 38 Quality 39 M Maintenance work 38 Mechanical seal 62 Minimum fluid level 34 Misuse 9 O Operating voltage 34 Order number 6 Other applicable documents 6 Overload pro...

Страница 68: ...T C 9241 71 1793 4 4 4 B P 95 h 59482 Haubourdin Cedex 128 rue Carnot h 59320 Sequedin Lille H9 I a T 3 20227000 h 9 T 3 20227099 h 333 563 81 11 10 Goodnal STP ST041 Biological Treatment KSB WAS PUM...

Страница 69: ...ntry of manufacture REV IW GDSTP 4A ELE SPEC 6003 Technical Specification for Electrical Instrumentation IW IPSTP 0 MEC SPEC 0062 Technical Specification for Pumps Fluid temperature min 10 max 30 Oper...

Страница 70: ...Maximum starts per hour Vendor to nominate 30 France Enclosure type Submersible kg 1 P2 2 3 The system duty flowrate per pump and operation configuration nominated are for the purpose of sizing the p...

Страница 71: ...5 0 mm Free passage size 76 0 mm Direction of rotation from drive Clockwise Driver accessories Driver type Electric motor Model make KSB Motor const type KSB Sub motor Frequency invertor Yes Frequency...

Страница 72: ...r Hydro primer water based Final coating 2 component epoxy resin Color Ultramarine blue RAL 5002 KSB blue Total film thickness approx 80 m Installation parts Scope of supply Pump with installation par...

Страница 73: ...er Input Flow Curve data Speed of rotation 1406 rpm Fluid density 1011 kg m Viscosity 2 86 mm s Flow rate 15 094 l s Requested flow rate 15 100 l s Total developed head 9 92 m Requested developed head...

Страница 74: ...not a guarantee point within the meaning of IEC 60034 Load 0 0 25 0 50 0 75 0 100 0 P2 0 00 kW 0 93 kW 1 85 kW 2 77 kW 3 70 kW n 1500 rpm 1465 rpm 1430 rpm 1395 rpm 1360 rpm P1 0 61 kW 1 51 kW 2 55 k...

Страница 75: ...Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM381 Active 29 10 2013 Page 75 of 76...

Страница 76: ...Goodnal STP ST041 Biological Treatment KSB WAS PUMP 1 2 PU 0530 010 OM Instructions Vendor Manual Q Pulse Id VM381 Active 29 10 2013 Page 76 of 76...

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