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KSB HPK Series, Инструкция по установке и эксплуатации, Страница: 3 / 80

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Contents

3 of 80

HPK

Contents

Glossary ..................................................................................................................................................  6

1

General....................................................................................................................................................  7

1.1

Principles ........................................................................................................................................................... 7

1.2

Installation of partly completed machinery.................................................................................................... 7

1.3

Target group..................................................................................................................................................... 7

1.4

Other applicable documents............................................................................................................................ 7

1.5

Symbols ............................................................................................................................................................. 7

1.6

Key to safety symbols/markings....................................................................................................................... 8

2

Safety ......................................................................................................................................................  9

2.1

General.............................................................................................................................................................. 9

2.2

Intended use ..................................................................................................................................................... 9

2.3

Personnel qualification and training............................................................................................................... 9

2.4

Consequences and risks caused by non-compliance with this manual ....................................................... 10

2.5

Safety awareness ............................................................................................................................................ 10

2.6

Safety information for the operator/user ..................................................................................................... 10

2.7

Safety information for maintenance, inspection and installation .............................................................. 10

2.8

Unauthorised modes of operation ................................................................................................................ 11

2.9

Explosion protection ...................................................................................................................................... 11
2.9.1

Marking .............................................................................................................................................. 11

2.9.2

Temperature limits............................................................................................................................. 11

2.9.3

Monitoring equipment...................................................................................................................... 12

2.9.4

Operating limits ................................................................................................................................. 12

3

Transport/Storage/Disposal ................................................................................................................  13

3.1

Transport......................................................................................................................................................... 13

3.2

Storage/preservation ...................................................................................................................................... 14

3.3

Return to supplier........................................................................................................................................... 14

3.4

Disposal ........................................................................................................................................................... 15

4

Description of the Pump (Set) .............................................................................................................  16

4.1

General description ........................................................................................................................................ 16

4.2

Product information as per Regulation No. 1907/2006 (REACH)................................................................. 16

4.3

Designation..................................................................................................................................................... 16

4.4

Name plate...................................................................................................................................................... 16

4.5

Design details.................................................................................................................................................. 17

4.6

Configuration and function........................................................................................................................... 20

4.7

Noise characteristics ....................................................................................................................................... 21

4.8

Scope of supply............................................................................................................................................... 21

4.9

Dimensions and weights ................................................................................................................................ 22

5

Installation at Site ................................................................................................................................  23

5.1

Safety regulations........................................................................................................................................... 23

5.2

Checks to be carried out prior to installation............................................................................................... 23

5.3

Installing the pump set .................................................................................................................................. 23
5.3.1

Installation on the foundation.......................................................................................................... 24

5.3.2

Installation without foundation ....................................................................................................... 25

5.4

Piping .............................................................................................................................................................. 25
5.4.1

Connecting the piping....................................................................................................................... 25

5.4.2

Permissible forces and moments at the pump nozzles.................................................................... 27

5.4.3

Auxiliary connections......................................................................................................................... 29

5.5

Enclosure/insulation ....................................................................................................................................... 30

5.6

Checking the coupling alignment ................................................................................................................. 30

5.7

Aligning the pump and motor ...................................................................................................................... 32
5.7.1

Motors with adjusting screw............................................................................................................. 33

5.7.2

Motors without adjusting screw ....................................................................................................... 33

Содержание HPK Series

Страница 1: ...Thermal Oil Hot Water Pump HPK Bearing Assemblies P02as to P08s Installation Operating Manual...

Страница 2: ...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...

Страница 3: ...3 3 1 Transport 13 3 2 Storage preservation 14 3 3 Return to supplier 14 3 4 Disposal 15 4 Description of the Pump Set 16 4 1 General description 16 4 2 Product information as per Regulation No 1907 2...

Страница 4: ...vicing Maintenance 50 7 1 Safety regulations 50 7 2 Servicing Inspection 51 7 2 1 Supervision of operation 51 7 2 2 Inspection work 53 7 2 3 Lubrication and lubricant change of rolling element bearing...

Страница 5: ...PK 8 Trouble shooting 68 9 Related Documents 70 9 1 General assembly drawing with list of components 70 9 2 Version with gland packing 73 10 EU Declaration of Conformity 74 11 Certificate of Decontami...

Страница 6: ...ained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Discharge line The pipeline which is connected to the discharge nozzle Hydraulic syste...

Страница 7: ...s Table 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 in...

Страница 8: ...CAUTION This signal word indicates a hazard which if not avoided could result in damage to the machine and its functions Explosion protection This symbol identifies information about avoiding explosi...

Страница 9: ...pecified in the other applicable documents Section 1 4 Page 7 Only operate pumps pump sets which are in perfect technical condition Do not operate the pump set in partially assembled condition Only us...

Страница 10: ...ide 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...

Страница 11: ...y assured if the product is used in accordance with its intended use Never operate the product outside the limits stated in the data sheet and on the name plate Prevent impermissible modes of operatio...

Страница 12: ...to be operated at a higher temperature the data sheet is missing or if the pump is part of a pool of pumps contact KSB for the maximum permissible operating temperature 2 9 3 Monitoring equipment The...

Страница 13: ...sion arrangement to the free shaft end or the motor eyebolt Observe the information about weights centre of gravity and fastening points Observe the applicable local accident prevention regulations Us...

Страница 14: ...ored indoors the pump set is protected for a maximum of 12 months New pumps pump sets are supplied by our factory duly prepared for storage For storing a pump set which has already been operated the s...

Страница 15: ...id and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazard 1 Dismantle the pump set Collect greases...

Страница 16: ...n About KSB Corporate responsibility reach 4 3 Designation Example HPK SY F 80 160 Table 5 Key to the designation Code Description HPK Type series S Material of wetted components e g nodular cast iron...

Страница 17: ...casing wear ring if applicable and casing cover Table 6 Pump feet HPK E EX E4 S SX HPK EY SY Pump feet bottom Centreline pump feet Impeller type Closed radial impeller with multiply curved vanes Back...

Страница 18: ...ion line in the discharge nozzle Circulation from discharge nozzle Mechanical seal with air cooled heat exchanger operating mode BL Uncooled single balanced mechanical seal Circulation via air cooled...

Страница 19: ...BR Cooled shaft seal with single balanced mechanical seal Cooling of seal chamber via seal housing and product circulation through external heat exchanger pumping ring Cooling liquid IN OUT Circulatio...

Страница 20: ...x 7307 BG P03s NU307 2 x 7307 BG P03as NU311 2 x 7311 BG8 P04s NU311 2 x 7311 BG8 P04as NU313 2 x 7313 BG8 P05s NU313 2 x 7313 BG8 P05as NU413 2 x 7315 BG8 P06s NU413 2 x 7315 BG8 P06as NU416 2 x 731...

Страница 21: ...ng cover Sealing The pump is sealed by a shaft seal standardised mechanical seal or gland packing 4 7 Noise characteristics Table 10 Surface sound pressure level LpA 4 5 PN Pump Pump set 960 rpm 760 r...

Страница 22: ...th or without spacer Contact guard Coupling guard Baseplate to ISO 3661 cast or welded for pump and motor in torsion resistant design Channel section steel or folded steel plate Special accessories As...

Страница 23: ...a concrete of compressive strength class C12 15 which meets the requirements of exposure class XC1 to EN 206 1 The mounting surface must be set flat and level Observe the weights indicated 1 Check th...

Страница 24: ...lts 3 between the baseplate foundation frame and the foundation For a bolt to bolt distance L 800 mm fit additional shims 2 halfway between the bolt holes All shims must lie perfectly flush 3 Insert t...

Страница 25: ...ocknuts 1 3 at the machine mounts 4 5 4 Piping 5 4 1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from escaping hot toxic corrosive or flammable fluids Do...

Страница 26: ...nd connected without transmitting any stresses or strains CAUTION Welding beads scale and other impurities in the piping Damage to the pump Remove any impurities from the piping If necessary install a...

Страница 27: ...ely grouted baseplate and bolted to a rigid and level foundation No reduction is necessary for material 1 7706 1 00 0 75 0 80 0 85 0 90 0 95 0 50 0 55 0 60 0 65 0 70 400 350 300 250 200 150 120 JL1040...

Страница 28: ...2700 1750 2800 2750 2100 1400 2000 1500 1000 100 315 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000 1500 1000 100 400 3700 2400 2950 3800 2150 1350 2700 1750 2800 2750 2100 1400 2000...

Страница 29: ...400 250 500 16000 10700 13300 17100 10700 6700 13300 8900 13900 12200 9200 6000 10000 7600 4900 300 400 300 500 17800 11600 14200 18300 13300 8200 16000 10700 17100 12700 9500 6200 12200 9200 6000 350...

Страница 30: ...the bearing bracket Damage to the bearing Never insulate the bearing bracket bearing bracket lantern and casing cover NOTE Pump casings handling fluids at temperatures below freezing point may be insu...

Страница 31: ...e coupling checking the coupling alignment 1 Straight edge 2 Gauge B B A A 2 1 1 Fig 12 Spacer type coupling checking the coupling alignment 1 Straight edge 2 Gauge B A A B 1 1 2 2 1 2 2 Fig 13 Double...

Страница 32: ...t Table 13 both during standstill and at operating temperature as well as under inlet pressure 4 Check the distance dimension see general arrangement drawing between the two coupling halves around the...

Страница 33: ...coupling shaft Check that coupling shaft can easily be rotated by hand WARNING Unprotected rotating coupling Risk of injury by rotating shafts Always operate the pump set with a coupling guard If the...

Страница 34: ...guard If the customer specifically requests not to include a coupling guard in KSB s delivery then the operator must supply one Observe all relevant regulations for selecting a coupling guard DANGER...

Страница 35: ...eep switch over intervals between star and delta as short as possible Table 14 Time relay settings for star delta starting Motor rating Y time to be set kW s 30 3 30 5 5 8 2 Earthing DANGER Electrosta...

Страница 36: ...ble mechanical seal Damage to the mechanical seal and leakage Separate the pump from the motor to check the direction of rotation CAUTION Drive and pump running in the wrong direction of rotation Dama...

Страница 37: ...e have been carried out Section 6 4 Page 48 6 1 2 Filling in lubricants DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Fire hazard Damage to the pump set...

Страница 38: ...the constant level oiler 1 slowly drain some oil via the screw plug 4 until air bubbles can be seen in the oil reservoir NOTE An excessively high oil level can lead to a temperature rise and to leaka...

Страница 39: ...l designs are used for thermal oil applications Section 4 5 Page 17 Single acting mechanical seal with steam nitrogen quench If steam quench is used the steam quench feed rate must be adjusted so that...

Страница 40: ...nsufficient lubrication Hot or toxic fluid could escape Damage to the pump Before starting up the pump set vent the pump and suction line and prime both with the fluid to be handled 1 Vent the pump an...

Страница 41: ...quantity l min Fluid temperature Bearing bracket 250 C 400 C P02as 3 4 P03s P03as 4 5 P04s P04as 4 5 P05s P05as 5 6 P06s P06as 5 6 P08s 6 7 Cooling liquid pressure 10 bar max 6 1 7 Bearing bracket co...

Страница 42: ...rface and the fluid handled must not exceed 100 C 100 K when the pump is started up 6 1 10 Final check 1 Remove the coupling guard and its footboard if any 2 Check the coupling alignment re align the...

Страница 43: ...have been closed CAUTION Start up against open discharge line Motor overload Make sure the motor has sufficient power reserves Use a soft starter Use speed control 1 Fully open the shut off element in...

Страница 44: ...o leakage Switch off the pump set immediately It is not recommended to operate pump sets with gland packings in combination with a frequency inverter variable speed system Table 17 Leakage rate in con...

Страница 45: ...e the shut off element in the discharge line 2 Switch off the motor and make sure the pump set runs down smoothly to a standstill NOTE If the discharge line is equipped with a non return or check valv...

Страница 46: ...t temperature CAUTION Operation outside the permissible ambient temperature Damage to the pump set Observe the specified limits for permissible ambient temperatures Observe the following parameters an...

Страница 47: ...periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface However if the physical properties of the fluids handled differ...

Страница 48: ...1 Page 56 The permissible ambient temperature for storing the pump is observed 1 Spray coat the inside wall of the pump casing and in particular the impeller clearance areas with a preservative 2 Spr...

Страница 49: ...6 Commissioning Start up Shutdown 49 of 80 HPK 1121 8 06 EN NOTE If the equipment has been out of service for more than one year replace all elastomer seals...

Страница 50: ...pump set regularly Prepare a maintenance schedule with special emphasis on lubricants shaft seal and coupling The operator ensures that maintenance inspection and installation are performed by authori...

Страница 51: ...let or visit www ksb com contact on the Internet Never use force when dismantling and reassembling the pump set 7 2 Servicing Inspection 7 2 1 Supervision of operation DANGER Excessive temperatures as...

Страница 52: ...6 2 Page 46 While the pump is in operation observe and check the following The pump must run quietly and free from vibrations at all times In case of oil lubrication ensure the oil level is correct S...

Страница 53: ...ing Replace the relevant parts in due time if there is any sign of wear and check the alignment 7 2 2 2 Checking the clearances To check the clearance gaps remove the back pull out unit Section 7 4 4...

Страница 54: ...re usually lubricated with mineral oil 7 2 3 1 1 Intervals Table 22 Oil change intervals Temperature at the bearing First oil change All subsequent oil changes 10 Up to 70 C After 300 operating hours...

Страница 55: ...ect persons and the environment Wear safety clothing and a protective mask if required Collect and dispose of any lubricants Observe all legal regulations on the disposal of fluids posing a health haz...

Страница 56: ...e fluid handled see drawing of auxiliary connections 7 4 Dismantling the pump set 7 4 1 General information Safety regulations WARNING Unqualified personnel performing work on the pump set Risk of inj...

Страница 57: ...out unit can be removed while the motor remains bolted to the baseplate WARNING Motor tipping over Risk of crushing hands and feet Suspend or support the motor to prevent it from tipping over 1 Discon...

Страница 58: ...Dismantling the gland packing The notes and steps stated in Section 7 4 1 Page 56 to Section 7 4 5 Page 58 have been observed carried out The back pull out unit is kept in a clean and level assembly a...

Страница 59: ...r bearing 322 01 to 80 C and pull them off shaft 210 14 Dispose of joint rings 400 01 02 7 5 Reassembling the pump set 7 5 1 General information Safety regulations WARNING Improper lifting moving of h...

Страница 60: ...g surfaces have been cleaned WARNING Hot surfaces due to heating of components for assembly dismantling Risk of burns Wear heat resistant protective gloves Remove flammable substances from the danger...

Страница 61: ...he stationary ring of the mechanical seal check that it is plane parallel in relation to the casing part The surface of the shaft protecting sleeve must be absolutely clean and smooth and the sleeve s...

Страница 62: ...iginal spare parts The sealing surfaces have been cleaned 1 Clamp casing cover 161 into a vice 2 Push in neck bush 456 01 3 Insert the first packing ring ensuring that its cut edge is in horizontal po...

Страница 63: ...ght onto each other 3 Fit the gland follower at a right angle to the shaft and make sure it is properly centered 4 Gently tighten the hexagon nuts at the gland follower by hand 7 5 4 Fitting the impel...

Страница 64: ...ump via the coupling 2 Fasten the motor to the baseplate 3 Align pump and motor Section 5 7 Page 32 4 Connect the motor to the power supply refer to manufacturer s product literature 7 6 Tightening to...

Страница 65: ...mm P02as 55 22 P03s P03as 125 27 P04s P04as 200 32 P05s P05as 300 41 P06s P06as 520 55 P08s 1000 60 Re tighten the impeller nut some 20 to 30 minutes after assembly 7 7 Spare parts stock 7 7 1 Orderin...

Страница 66: ...between different pump sizes Table 30 Interchangeability of pump components Size Bearing bracket Description Casing cover Support foot Shaft 16 Angular contact ball bearing 17 Deep groove ball bearin...

Страница 67: ...0 315 7 7 2 1 1 1 2 7 2 2 2 2 2 7 2 2 2 2 100 250 P04s P04as 8 8 3 2 2 2 3 6 3 3 3 3 3 13 3 3 3 3 125 250 8 9 3 2 2 2 3 6 3 3 3 3 3 15 3 3 3 3 150 250 8 10 3 2 2 2 3 6 3 3 3 3 3 16 3 3 3 3 65 315 9 8...

Страница 68: ...ely vented or primed Vent and or prime Supply line or impeller clogged Remove deposits in the pump and or piping Formation of air pockets in the piping Alter piping layout Fit vent valve Suction lift...

Страница 69: ...eration Correct suction conditions Re align the pump Re balance the impeller Increase pressure at the pump suction nozzle The pump set is misaligned Re align Pump is warped or sympathetic vibrations i...

Страница 70: ...2 932 02 550 23 320 02 400 02 914 02 360 02 421 02 940 02 210 903 18 411 18 902 02 920 02 902 04 920 04 903 02 411 02 903 03 411 03 230 940 01 411 32 902 01 920 01 903 19 411 19 344 524 01 507 01 360...

Страница 71: ...1 01 330 903 46 411 46 638 183 901 04 930 01 914 04 931 01 920 21 Fig 21 General assembly drawing of HPK EX SX 411 10 901 31 161 903 18 411 18 902 02 920 02 914 01 902 04 920 04 400 01 322 01 932 01 6...

Страница 72: ...931 01 Lock washer 940 01 02 Key 230 230 Impeller 411 32 Joint ring 320 02 320 02 Angular contact ball bearing 322 01 322 01 Cylindrical roller bearing 330 330 Bearing bracket 360 01 02 Bearing cover...

Страница 73: ...Hexagon head bolt 902 902 Stud 903 903 Screw plug 914 914 Hexagon socket head cap screw 920 920 Nut 922 922 Impeller nut 411 31 Joint ring 930 930 Safety device 931 931 Lock washer 932 932 Circlip 940...

Страница 74: ...harmonised international standards 23 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...

Страница 75: ...r 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 barrier and bearing b...

Страница 76: ...nction 20 G General assembly drawing 70 Gland packing 44 H Heating speed 42 Heating up 42 I Impeller type 17 Installation Installation on a foundation 24 without foundation 25 Installation at site 23...

Страница 77: ...e part Ordering spare parts 65 Spare parts stock 65 Special accessories 22 Start up 43 Storage 14 48 T Temperature difference 42 Temperature limits 11 Tightening torques 64 65 Transport 13 W Warnings...

Страница 78: ......

Страница 79: ......

Страница 80: ...KSB SE Co KGaA Johann Klein Stra e 9 67227 Frankenthal Germany Tel 49 6233 86 0 www ksb com 1121 8 06 EN 01316813...

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