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6 Commissioning/Start-up/Shutdown

50 of 116

CHTRa

CAUTION

Incorrect commissioning/start-up

Damage to the bearings!

▷

Do not perform oil flushing until immediately before commissioning/start-up.

▷

If commissioning/start-up is delayed by more than one month, repeat the oil
flushing.

1. Dismantle the pump-end coupling hub.

2. Dismantle the bearings.

3. For oil flushing mount the bearing housings including the existing labyrinth

rings and throwers without internal parts (bearing shells, bearing segment
carrier, thrust bearing plate, etc.).

4. Check whether all connections on the bearing housings and covers are closed

with plugs.

5. Re-install the pump bearings and lift the pump rotor.

6. Re-mount the pump-end coupling hub.

7. Mount the coupling cover if applicable.

8. Check all the connection points of the oil circuit. Connect and seal if required.

9. Close the oil supply ports of the coupling cover if applicable.

10. Fully open all throttle valves in the oil supply lines.

11. Switch on the oil supply unit or auxiliary oil pump and check for leakage.

12. Check the oil flow at the oil sight gauge in the oil return lines.

13. Check the oil level of the oil reservoir and top up if required.

When the coolers and pipes are filled and vented, the oil level shall be in the
middle between the minimum and maximum mark of the oil sight gauges.

14. Change over and clean the filters of the oil circuits frequently, see the

manufacturer’s catalogue.

15. Switch off the oil supply unit or auxiliary oil pump when the oil filters are free

from dirt for at least eight hours.

16. Check the oil quality. If required, clean or replace the oil.

6.2.5 Filling in lubricants (if applicable)

DANGER

Ignition of lubricant leakage on hot pump surfaces

Explosion hazard!

▷

The ignition temperature of the lubricant should exceed the maximum surface
temperature of the pump by at least 50 K.

CAUTION

Incorrect oil level in bearing housing

Damage to the pump!

▷

Check the oil level only during standstill of the pump!

Содержание CHTRa

Страница 1: ...Process Pump CHTRa Installation Operating Manual...

Страница 2: ...s 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 manufacture...

Страница 3: ...ition upon delivery 14 3 2 Transporting the packaged components of the pump set 14 3 3 Transport 15 3 3 1 Transporting the pump rotor 17 3 3 2 Transporting the accessories 18 3 4 Storage preservation...

Страница 4: ...tem 42 5 16 6 Connecting the piping 42 5 16 7 Bypass and balancing lines 44 5 17 Electrical connection 44 5 17 1 Earthing 45 5 17 2 Connecting the motor 45 5 18 Final installation of the pump set 45 5...

Страница 5: ...3 3 Dismantling guards 81 7 3 4 Dismantling the coupling 82 7 3 5 Removing the pump from the system if necessary 84 7 3 6 Preparing the mechanical seal for dismantling 85 7 3 7 Dismantling the bearin...

Страница 6: ...ify that the product has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Discharge line The pipeline which is connecte...

Страница 7: ...im under warranty 1 2 Installation of partly completed machinery To install partly completed machinery supplied by KSB refer to the sub sections under Servicing Maintenance 1 3 Target group This opera...

Страница 8: ...Symbol Description Conditions which need to be fulfilled before proceeding with the step by step instructions Safety instructions Result of an action Cross references 1 2 Step by step instructions Not...

Страница 9: ...us 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 volta...

Страница 10: ...o sealing elements damage to bearings etc Observe the information on maximum flow rates specified in the data sheet to prevent overheating damage to sealing elements cavitation damage damage to bearin...

Страница 11: ...it an emergency stop control device in the immediate vicinity of the pump set during pump set installation Minimise exposure in the pump set s danger area 2 8 Safety information for maintenance inspec...

Страница 12: ...pump part only Example of such marking II 2 G c TX EN 13463 1 or II 2G Ex h IIC T5 T1 Gb ISO 80079 36 Refer to the individual Temperature Limits table for the temperatures permitted for the individual...

Страница 13: ...e limits specified in the data sheet and on the name plate If the system operator cannot warrant compliance with these operating limits appropriate monitoring devices must be used Check whether monito...

Страница 14: ...ting the packaged components of the pump set The weights of the individual components to be transported have been identified in the packing list Suitable lifting equipment has been selected 1 Attach t...

Страница 15: ...Serious injuries due to parts tipping over Place the pump only on an area designed for this purpose Comply with the requirements to be met by the load bearing capacity of the floor Check the load bea...

Страница 16: ...s on the lifting tackle however it must never be wider than 120 Transporting the pump set Fig 2 Centreline pump feet Fig 3 Transport using a transportation beam Transporting the pump on the baseplate...

Страница 17: ...without transport frame Fig 7 Pump without transport frame 3 3 1 Transporting the pump rotor DANGER Pump rotor could slip out of the suspension arrangement Danger to life from falling parts Never use...

Страница 18: ...pump rotor against overturning or rolling 3 3 2 Transporting the accessories CAUTION Improper transport of strainers filters Damage to the strainer filter through lifting tackle Do not exert pressure...

Страница 19: ...er 120 120 Transporting the Y strainer Transporting the cylindrical strainer 3 4 Storage preservation If commissioning is to take place some time after delivery we recommend that the following measure...

Страница 20: ...months The pump is supplied preserved for storage of up to 12 months Standard preservation Table 5 Measures taken for preservation Type of preservation Preservative To be preserved External preservati...

Страница 21: ...rough with anhydrous inert gas to ensure drying 4 Always complete and enclose a certificate of decontamination when returning the pump Indicate any safety measures and decontamination measures taken S...

Страница 22: ...single entry 3 Nominal discharge nozzle diameter 6 Nominal suction nozzle diameter 9 Nominal impeller diameter 5 Hydraulic system size 8 Number of stages 4 3 Name plate Ord No Ser No Item No Q n Beari...

Страница 23: ...ambers are integrated into the pump casing and compliant with API 610 ISO 13709 and API 682 ISO 21049 dimensions The pressure is balanced in the mechanical seal chambers via throttling bush and integr...

Страница 24: ...5 Impeller 9th stage 6 Balance bush 7 Balance drum 8 Upper half of pump casing 9 Mechanical seal 10 Shaft 11 Lower half of pump casing 12 Bearings 4 6 Order specifications Project KSB order number Ty...

Страница 25: ...rformed at site this should be done at 80 of the critical speed without fluid by means of a balancing machine Table 10 Bearings End of pump Size Drive end Non drive end Table 11 Relevant drawings Desc...

Страница 26: ...requirements of exposure class XC1 to EN 206 1 The mounting surface must be set flat and level Observe the weights indicated DANGER Insufficient stability of pump set as a result of incorrect dimensio...

Страница 27: ...e openings and connections must be open or closed Do not unpack the pump set components until immediately before the installation work starts Take care not to damage the cable The consignee of the com...

Страница 28: ...cover DANGER Improper transport Danger to life from falling parts Observe the safety regulations for transport work Section 2 Page 9 Section 3 Page 14 Observe the applicable local occupational safety...

Страница 29: ...upling cover 5 Remove the internal injection lines 6 Disconnect the lower half of the coupling cover from the flange and remove this half 5 6 3 Dismantling the coupling spacer Dismantle and store the...

Страница 30: ...e marking between coupling hub and shaft Section 7 3 4 Page 82 1 Permissible tolerance at the pump shaft 0 03 mm 0 0012 inch If this value is exceeded inform KSB 2 After every 90 turn read measured va...

Страница 31: ...oved before heating Elastomeric parts which have been heated must not be used any more Fig 13 Fit coupling hub example Pump size Thread size X 2 M12 3 M12 4 M16 5 M16 or M20 5 Fit the coupling hubs un...

Страница 32: ...t the baseplate 2 Place the foundation bolts into the baseplate holes and screw on the nuts until the bolt thread projects by about 10 mm 3 Place the baseplate onto the levelling screws and align the...

Страница 33: ...e baseplate 2 Place the special foundation bolts into the baseplate holes and screw on the nuts until the bolt thread projects by about 10 mm If the crane hook height is not sufficient insert the spec...

Страница 34: ...reased wear due to dry running Damage to the pump set Never operate the pump set without liquid fill Align the pump set components in accordance with the manufacturer s product literature Coupling ali...

Страница 35: ...gnment Damage to the pump set Never turn the coupling by means of the alignment device 5 11 1 1 Coupling hubs with outside step Fig 16 Run out check with outside step example Check each coupling hub f...

Страница 36: ...ignment of pump and drive The high temperature of the fluid handled and the fact that the pump set components heat up during operation cause displacements of the coupling hub in different directions S...

Страница 37: ...ver a period of time Shims must extend at least 5 mm beyond the outer edges of the drive s foot Shims must extend at least 0 25 inches beyond the outer edges of the drive s foot Do not use multiple th...

Страница 38: ...Prepare the concrete shuttering for the baseplate and foundation pedestals up to the planned grouting height as shown in the general arrangement drawing Make provisions for the grouting compound to b...

Страница 39: ...foundation pedestals up to the planned grouting height as shown in the general arrangement drawing Fill at least 1 3 of each field of the baseplate with non shrinking grouting compound e g Pagel conc...

Страница 40: ...de the pump or in the pipelines Increased wear or blockages When flushing the piping the pump must as a rule be protected against welding beads scale and other impurities Use pipe bypasses or filters...

Страница 41: ...per transport Danger to life from falling parts Observe the safety regulations for transport work Section 2 Page 9 Section 3 Page 14 Observe the applicable local occupational safety and accident preve...

Страница 42: ...literature 5 16 6 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from escaping hot toxic corrosive or flammable fluids Do not use the pump as an anchorage p...

Страница 43: ...becoming bolt bound off set holes It must be possible to bring the pipes into their mounting position with one hand It must be possible to prise apart the pump nozzle flanges by approx 300 mm Fitting...

Страница 44: ...lancing line the minimum flow diagram and or P I diagram must be observed Install an orifice immediately ahead of the inlet vessel to avoid vaporisation 5 17 Electrical connection DANGER Electrical co...

Страница 45: ...18 Final installation of the pump set Check coupling alignment and re align if necessary Consider height and lateral displacements in accordance with the assembly sketch If the connection of the pipe...

Страница 46: ...DIN 16258 and tighten the clamping nut Thermometer bearing Insert the seal element Screw in the thermometer Oil sight gauge or constant level oiler if applicable Screw in the oil sight gauge or const...

Страница 47: ...p pump set s and accessories for completeness and in transit damage Section 3 Page 14 2 Check the condition and dimensions of the foundation for compliance with the installation plan 3 Pre align the f...

Страница 48: ...th from electric shock Always have the electrical connections installed by a trained electrician Observe regulations IEC 30364 DIN VDE 0100 and for explosion proof models EN 60079 The pump set s elect...

Страница 49: ...1 Dismantle the pump end coupling hub 2 Dismantle the bearings 3 Remove the mechanical seal and check it in accordance with the manufacturer s product literature If the mechanical seal is clean and u...

Страница 50: ...er if applicable 10 Fully open all throttle valves in the oil supply lines 11 Switch on the oil supply unit or auxiliary oil pump and check for leakage 12 Check the oil flow at the oil sight gauge in...

Страница 51: ...ce the oil if necessary Fill the pump set components with lubricant in accordance with the manufacturer s product literature Observe the permissible ambient temperatures Section 6 6 2 Page 65 For reco...

Страница 52: ...be checked prior to commissioning start up Prerequisites Check the direction of rotation prior to the final assembly of the coupling motor alone is running Observe the manufacturer s documentation The...

Страница 53: ...at the pump set cannot be started unintentionally Always make sure the electrical connections are disconnected before carrying out work on the pump set 4 Secure the drive against unintentional startin...

Страница 54: ...n KSB s delivery then the operator must supply one Observe all relevant regulations for selecting a coupling guard At the end of all preparatory work to be carried out for start up mount all protectiv...

Страница 55: ...d sealing surfaces 2 Fit the gasket and O ring 3 Mount the lower coupling cover half and fasten it to the adapter Fig 30 Adjusting the injection nozzles 4 Adjust the injection nozzles see figure Adjus...

Страница 56: ...emove the assembly fixtures if required Check all the required connections are correctly fitted see general assembly drawing or seal manufacturer s product literature Mechanical seal The mechanical se...

Страница 57: ...nted condition Never close the shut off element in the suction line and or supply line during pump operation All preparatory measures have been completed 1 Close all drains and drain lines 2 Completel...

Страница 58: ...uits have been primed and vented Monitor the bearing oil temperature Make sure that the limits are not exceeded Section 6 6 2 Page 65 6 3 2 Checks prior to commissioning start up WARNING Leakage cause...

Страница 59: ...res exceeding those specified in the data sheet or on the name plate unless the written consent of the manufacturer has been obtained WARNING Sound pressure level above 85 dB A when starting up the pu...

Страница 60: ...Check the pump pressures and differential pressures 5 Monitor the minimum flow valve to make sure it works hydrodynamic noise 6 Check the mechanical seal Mechanical seals must not drip 7 Slowly open t...

Страница 61: ...s and differential pressures 7 Monitor the minimum flow valve to make sure it works hydrodynamic noise 8 Check the mechanical seal Mechanical seals must not drip 9 Increase the pump speed until the op...

Страница 62: ...repare the pump s set s for operation ensure quantity of oil fills check shaft seals start up auxiliary circuits 10 Check all instruments for proper functioning 11 Set the oil flow to the correct flow...

Страница 63: ...the temperature and smooth running of the bearings WARNING Unprotected rotating parts Risk of injury from parts flying off Risk of injury by rotating shafts Operate the pump set only after all protec...

Страница 64: ...ned for Avoid prolonged operation against a closed shut off element Never operate the pump at temperatures pressures or rotational speeds exceeding those specified in the data sheet or on the name pla...

Страница 65: ...bution of the pump operating hours pump changeover 6 6 2 Ambient temperature CAUTION Operation outside the permissible ambient temperature Damage to the pump set Observe the specified limits for permi...

Страница 66: ...e 17 Key Symbol Description Unit c Specific heat capacity J kg K g Gravitational constant m s2 H Head m Tf Temperature of the fluid handled C To Temperature at the casing surface C Pump efficiency at...

Страница 67: ...e 2 Make sure the minimum flow valve works if applicable 3 In the case of a pump sets with variable speed coupling Reduce the speed until the minimum head or minimum speed is reached 4 Switch off the...

Страница 68: ...ine is equipped with a check valve the shut off element in the discharge line may remain open as long as there is some back pressure Monitor the minimum flow valve to make sure it works NOTE The cooli...

Страница 69: ...ning ready for operation General Information If the period of standstill during readiness for instant start up is longer than 2 weeks the pump set components such as gear or motor must be protected ag...

Страница 70: ...d lines Allow the pump set to cool down to ambient temperature WARNING Unintentional starting of the pump set Risk of injury by moving components and shock currents Ensure that the pump set cannot be...

Страница 71: ...container for collecting the fluid is on hand Sufficient preservative is available 1 Secure all shut off elements against opening 2 Place suitable containers under the drain holes 3 Open all drains a...

Страница 72: ...g Start up Shutdown 72 of 116 CHTRa For returning the pump to service observe the items on commissioning start up In addition carry out all servicing maintenance operations before returning the pump s...

Страница 73: ...ial emphasis on lubricants shaft seal and coupling NOTE During the warranty term pumps pump sets must only be dismantled or reassembled by KSB personnel The operator ensures that maintenance inspectio...

Страница 74: ...with oil ring lubrication Middle between the minimum and maximum marks Weekly Check smooth running The pump must run quietly and free from vibrations Weekly Mechanical seal Check for leakage 5 Or see...

Страница 75: ...roduct literature See manufacturer s product literature Static seals general Check tightness The static seal shall be dry Weekly Static seals pressure body Check tightness The static seal shall be dry...

Страница 76: ...be handled at all times Provide sufficient inlet pressure Provide an appropriate monitoring system CAUTION Increased wear due to dry running Damage to the pump set Never operate the pump set without...

Страница 77: ...rvicing plan What where How Work Time intervals Bearings Oil ring lubrication if applicable Oil level oil quality Section 10 2 7 Page 110 First oil change after 500 operating hours Further oil changes...

Страница 78: ...ctioning local measured value indication available Check the switching points Vibration measurement if applicable Perfect condition no mechanical damage on sensor If applicable electrical connections...

Страница 79: ...g position 4 Re insert breather diaphragm 823 with gasket 400 5 After a short time check whether the oil level in the reservoir has dropped It is important to keep at least one third of the reservoir...

Страница 80: ...injury and damage to property Use suitable transport devices lifting equipment and lifting tackle to move heavy assemblies or components WARNING Unintentional starting of the pump set Risk of injury b...

Страница 81: ...d workshops For contact details please refer to the enclosed Addresses booklet or visit www ksb com contact on the Internet 7 3 2 Prerequisites for dismantling The pump set has been taken out of servi...

Страница 82: ...the spacer of the coupling as described in the manufacturer s product literature 7 3 4 2 Pulling off the coupling hub WARNING Falling coupling parts Risk of crushing from falling parts Secure couplin...

Страница 83: ...ction If no marking exists mark the position by stamping Maintaining the balancing grade for reassembly 3 Remove the grub screws WARNING Hot surfaces due to heating of components for assembly dismantl...

Страница 84: ...if required place it underneath the connections of the pipes to be dismantled 2 Secure inlet and discharge lines 3 Undo the connections between discharge nozzle and discharge line and between suction...

Страница 85: ...cupational safety and accident prevention regulations 7 3 6 Preparing the mechanical seal for dismantling The seal manufacturer s product literature has been observed Section 10 Page 103 1 Fit locking...

Страница 86: ...901 05 of bearing cover 360 03 10 Dismantle bearing cover 360 03 labyrinth ring 423 04 and O ring 412 03 11 Bend open lock washer 931 02 12 Remove slotted round nut 920 03 13 Remove lock washer 931 02...

Страница 87: ...n the thrust ring until it can be pulled from the shaft Never bend the thrust ring excessively 12 Remove thrust ring 501 03 7 3 8 Removing the mechanical seal 1 Remove the mechanical seal cartridge fr...

Страница 88: ...still fails to come free the impeller and shaft should be allowed to cool completely and the heating process repeated 1 Remove neck bushes 456 01 456 02 and balance bush 605 01 by pulling them over th...

Страница 89: ...cannot be easily pulled off the shaft additional heat may be necessary If the impeller still fails to come free the impeller and shaft should be allowed to cool completely and repeat the heating proc...

Страница 90: ...ecure the parts if possible Wear safety shoes Observe the applicable local accident prevention regulations WARNING Improper lifting moving of heavy assemblies or components Personal injury and damage...

Страница 91: ...reassembly coat the screw bolt connections and pipe unions as well as the fits of the individual components using the respective specified lubricating agent as described in the work instruction UA4 28...

Страница 92: ...llers must be heated for assembly When heating the impellers observe the following A heat source providing constant heat transfer e g oven or induction heat must be used for impeller heating Heat the...

Страница 93: ...into the lower half of the pump casing 2 Attach the rotor to the lifting equipment See section lifting equipment in the manual 3 Place rotor into the lower casing half During this process ensure that...

Страница 94: ...outer edge of the lower casing half cut gasket with downward strokes only 8 Using a sharp knife cut the gasket material along the inner edge of the lower casing half cut gasket with downward strokes o...

Страница 95: ...ach upper casing half to the lifting equipment 3 Place the upper casing half on the lower casing half and secure using washers 550 01 and cap nuts 920 01 4 Tighten cap nuts 920 01 in 3 or more passes...

Страница 96: ...earing cover 360 02 with O ring 412 02 onto shaft 210 from the non drive end 20 Tighten hexagon head screws 901 03 21 Slide labyrinth ring 423 03 into bearing housing 350 02 Ensure the labyrinth ring...

Страница 97: ...ed hole in another position 13 Tighten hexagon head screws 901 01 14 Slide bearing cover 360 01 towards the bearing housing until it abuts the bearing housing 15 Tighten hexagon head screws 901 02 16...

Страница 98: ...Storing spare parts Spares should be stored in a clean dry area away from vibration Inspection and re treatment of metallic surfaces if necessary with preservative is recommended at 6 monthly interval...

Страница 99: ...ipes Pump or suction line not completely filled with fluid Suction lift too high or fluid level too low NPSHa NPSHr Check for sufficient submergence Check installed strainers and valves remove any dir...

Страница 100: ...new worn wear rings wear ring surfaces Impeller damaged or eroded Replace Contact KSB Leakage under sleeve due to sealing element failure Renew sealing element and check for damage Shaft sleeve worn o...

Страница 101: ...missing parts or damage Remedy or contact KSB Cavitation Check whether the pump has been primed Check for clogging obstructions in the suction line and remove if necessary Table 23 Trouble shooting fo...

Страница 102: ...t 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...

Страница 103: ...10 Related Documents 103 of 116 CHTRa 10 Related Documents Related documents 2 General drawing Resources pdf 9007218461646731 pdf 10 1 List of documents...

Страница 104: ...building plant and or an inappropriate piping layout may increase noise emission and or the vibration level Table 24 Sound pressure level dB depending on octave band Size Number of stages Octave band...

Страница 105: ...544 Between balance drum and balance bush S2 0 28 0 325 Between impeller eye wear ring and interstage bush S3 0 43 0 475 Between impeller hub wear ring and interstage bush S4 0 38 0 435 Between bearin...

Страница 106: ...elated Documents 106 of 116 CHTRa Clearance position Maximum permissible clearance Between impeller hub wear ring and interstage bush S4 0 0169 0 0187 Between bearing sleeve and bearing bush S5 0 01 0...

Страница 107: ...studs Thread Non drive end Drive end M20 47 224 M24 68 346 M27 108 529 M30 163 630 M36 217 1071 M42 318 1891 Flange connection The tightening torques specified here apply to flange connection bolts w...

Страница 108: ...gs The vibration values specified are valid for pump variants with plain bearing or rolling element bearings and grouted baseplates They are based on the proper installation of the pump set in accorda...

Страница 109: ...te N mm Exposure class Minimum compressive strength class Cylinder compressive strength Cube compressive strength XC4 C25 30 25 30 Table 34 Strength classes for concrete lb sq in Exposure class Minimu...

Страница 110: ...cription kg 105 01 Casing half bottom 655 105 02 Casing half top 540 210 Shaft 60 231 Suction stage impeller 8 230 Impeller each stage 8 350 01 Bearing housing drive end 40 350 02 Bearing housing pump...

Страница 111: ...t impeller casing cover bearing ring carrier 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...

Страница 112: ...10 Related Documents 112 of 116 CHTRa 10 5 Order specific documents...

Страница 113: ...ing the impeller wear ring 92 Intended use 10 K Key to safety symbols markings 9 L Lateral 37 Lubrication Oil quality 110 Oil quantity 110 000 000 M Maintenance 74 Mechanical seal 56 Minimum Cement Co...

Страница 114: ...Index 114 of 116 CHTRa W Warnings 9 Warranty claims 7 Weight 110...

Страница 115: ......

Страница 116: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 2700 81 03 EN...

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