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Process Pump

RPH-V

Installation/Operating Manual

Legal information/Copyright

Installation/Operating Manual RPH-V

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,edited or processed for any other purpose, nor otherwise transmitted, published or made available to athird party without the manufacturer's express written consent.

Subject to technical modification without prior notice.

© KSB Bombas Hidráulicas SA, Várzea Paulista 23/01/2018

Contents

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Contents

Glossary .................................................................................................................................................. 5

1 General.................................................................................................................................................... 61.1 Principles ........................................................................................................................................................... 61.2 Installation of partly completed machinery.................................................................................................... 61.3 Target group..................................................................................................................................................... 61.4 Other applicable documents............................................................................................................................ 61.5 Symbols ............................................................................................................................................................. 6

2 Safety...................................................................................................................................................... 82.1 Key to safety symbols/markings....................................................................................................................... 82.2 General.............................................................................................................................................................. 82.3 Intended use ..................................................................................................................................................... 92.4 Personnel qualification and training............................................................................................................... 92.5 Consequences and risks caused by non-compliance with this manual ......................................................... 92.6 Safety awareness ............................................................................................................................................ 102.7 Safety information for the operator/user ..................................................................................................... 102.8 Safety information for maintenance, inspection and installation .............................................................. 102.9 Unauthorised modes of operation................................................................................................................ 102.10 Explosion protection ...................................................................................................................................... 10

3 Transport/Temporary Storage/Disposal............................................................................................. 133.1 Checking the condition upon delivery .......................................................................................................... 133.2 Transport......................................................................................................................................................... 133.3 Storage/preservation...................................................................................................................................... 133.4 Return to supplier........................................................................................................................................... 143.5 Disposal ........................................................................................................................................................... 15

4 Description of the Pump (Set) ............................................................................................................. 164.1 General description ........................................................................................................................................ 164.2 Designation..................................................................................................................................................... 164.3 Name plate...................................................................................................................................................... 164.4 Design details.................................................................................................................................................. 174.5 Configuration and function........................................................................................................................... 184.6 Noise characteristics ....................................................................................................................................... 194.7 Scope of supply............................................................................................................................................... 204.8 Dimensions and weights ................................................................................................................................ 20

5 Installation at Site ................................................................................................................................ 215.1 Safety regulations........................................................................................................................................... 215.2 Checks to be carried out prior to installation............................................................................................... 215.3 Installing the pump set .................................................................................................................................. 215.4 Piping .............................................................................................................................................................. 245.5 Enclosure/insulation ....................................................................................................................................... 265.6 Checking the coupling alignment ................................................................................................................. 265.7 Aligning the pump and motor ...................................................................................................................... 275.8 Electrical connection ...................................................................................................................................... 285.9 Checking the direction of rotation................................................................................................................ 29

6 Commissioning/Start-up/Shutdown................................................................................................... 306.1 Commissioning/Start-up................................................................................................................................. 306.2 Operating limits.............................................................................................................................................. 356.3 Shutdown/storage/preservation .................................................................................................................... 376.4 Returning to service ....................................................................................................................................... 37

7 Servicing/Maintenance........................................................................................................................ 397.1 Safety regulations........................................................................................................................................... 397.2 Servicing/inspection........................................................................................................................................ 40

Contents

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7.3 Drainage/cleaning .......................................................................................................................................... 457.4 Dismantling the pump set.............................................................................................................................. 457.5 Reassembling the pump set ........................................................................................................................... 477.6 Tightening torques......................................................................................................................................... 507.7 Spare parts stock............................................................................................................................................. 51

8 Trouble-shooting.................................................................................................................................. 53

9 Related Documents .............................................................................................................................. 559.1 General assembly drawings with list of components................................................................................... 55

10 EU Declaration of Conformity ............................................................................................................. 59

11 Certificate of Decontamination........................................................................................................... 60

Index ..................................................................................................................................................... 61

Glossary

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Glossary

Certificate of decontaminationA certificate of decontamination is enclosed by thecustomer when returning the product to themanufacturer to certify that the product has beenproperly drained to eliminate any environmentaland health hazards arising from components incontact with the fluid handled.

Discharge lineThe pipeline which is connected to the dischargenozzle

Hydraulic systemThe part of the pump in which the kinetic energyis converted into pressure energy

Pool of pumpsCustomers/operators’ pumps which are purchasedand stored regardless of their later use.

PumpMachine without drive, additional components oraccessories

Pump setComplete pump set consisting of pump, drive,additional components and accessories

1 General

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1 General

1.1 PrinciplesThis operating manual is supplied as an integral part of the type series and variantsindicated on the front cover. The operating manual describes the proper and safe useof this equipment in all phases of operation.

The name plate indicates the type series and size, the main operating data, the ordernumber and the order item number. The order number and order item numberuniquely identify the pump (set) and serve as identification for all further businessprocesses.

In the event of damage, immediately contact your nearest KSB service centre tomaintain the right to claim under warranty.

Noise characteristics see (ð Section 4.6, Page 19)

1.2 Installation of partly completed machineryTo install partly completed machinery supplied by KSB refer to the sub-sections underServicing/Maintenance.

1.3 Target groupThis operating manual is aimed at the target group of trained and qualified specialisttechnical personnel. (ð Section 2.4, Page 9)

1.4 Other applicable documents

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 installation dimensionsfor the pump (set), weights

Drawing of auxiliary connections Description of auxiliary connections

Hydraulic characteristic curve Characteristic curves showing head, NPSHrequired, efficiency and power input

General assembly drawing1) Sectional drawing of the pump

Sub-supplier product literature1) Operating manuals and other product literaturedescribing accessories and integrated machinerycomponents

Spare parts lists1) Description of spare parts

Piping layout1) Description of auxiliary piping

List of components1) Description of all pump components

Drawing for assembly1) Sectional drawing of the installed shaft seal

For accessories and/or integrated machinery components observe the relevantmanufacturer's product literature.

1.5 Symbols

Table 2: Symbols used in this manual

Symbol Description

✓ Conditions which need to be fulfilled before proceeding with thestep-by-step instructions

⊳ Safety instructions

⇨ Result of an action

⇨ Cross-references

1) If agreed upon in scope of supply

1 General

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Symbol Description

1.

2.

Step-by-step instructions

NoteRecommendations and important information on how to handlethe product

2 Safety

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2 Safety

! DANGER All the information contained in this section refers to hazardous situations.

2.1 Key to safety symbols/markings

Table 3: Definition of safety symbols/markings

Symbol Description

! DANGER DANGERThis signal word indicates a high-risk hazard which, if not avoided,will result in death or serious injury.

! WARNING WARNINGThis signal word indicates a medium-risk hazard which, if notavoided, could result in death or serious injury.

CAUTION CAUTIONThis signal word indicates a hazard which, if not avoided, couldresult in damage to the machine and its functions.

Explosion protectionThis symbol identifies information about avoiding explosions inpotentially explosive atmospheres in accordance with Directive2014/34/EU (ATEX).

General hazardIn conjunction with one of the signal words this symbol indicates ahazard which will or could result in death or serious injury.

Electrical hazardIn conjunction with one of the signal words this symbol indicates ahazard involving electrical voltage and identifies information aboutprotection against electrical voltage.

Machine damage In conjunction with the signal word CAUTION this symbol indicatesa hazard for the machine and its functions.

2.2 GeneralThis manual contains general installation, operating and maintenance instructionsthat must be observed to ensure safe pump operation and prevent personal injuryand damage to property.

The safety information in all sections of this manual must be complied with.

This manual must be read and completely understood by the specialist personnel/operators responsible prior to installation and commissioning.

The contents of this manual must be available to the specialist personnel at the siteat all times.

Information attached directly to the pump must always be complied with and bekept in a perfectly legible condition at all times. This applies to, for example:

▪ Arrow indicating the direction of rotation

▪ Markings for connections

▪ Name plate

The operator is responsible for ensuring compliance with all local regulations nottaken into account in this manual.

2 Safety

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2.3 Intended use▪ The pump (set) must only be operated within the operating limits described in

the other applicable documents. (ð Section 1.4, Page 6)

▪ Only operate pumps/pump sets which are in perfect technical condition.

▪ Do not operate the pump (set) in partially assembled condition.

▪ Only use the pump to handle the fluids described in the data sheet or productliterature of the pump model or variant.

▪ Never operate the pump without the fluid to be handled.

▪ Observe the minimum flow rates indicated in the data sheet or product literature(to prevent overheating, bearing damage, etc).

▪ Observe the maximum flow rates indicated in the data sheet or productliterature (to prevent overheating, mechanical seal damage, cavitation damage,bearing damage, etc).

▪ Do not throttle the flow rate on the suction side of the pump (to preventcavitation damage).

▪ Consult the manufacturer about any use or mode of operation not described inthe data sheet or product literature.

Prevention of foreseeable misuse

▪ Never open the discharge-side shut-off elements further than permitted.

– The maximum flow rates specified in the product literature or data sheetwould be exceeded.

– Risk of cavitation damage

▪ Never exceed the permissible operating limits specified in the data sheet orproduct literature regarding pressure, temperature, etc.

▪ Observe all safety information and instructions in this manual.

2.4 Personnel qualification and trainingAll personnel involved must be fully qualified to transport, install, operate, maintainand inspect the machinery this manual refers to.

The responsibilities, competence and supervision of all personnel involved intransport, installation, operation, maintenance and inspection must be clearlydefined by the operator.

Deficits in knowledge must be rectified by means of training and instructionprovided by sufficiently trained specialist personnel. If required, the operator cancommission the manufacturer/supplier to train the personnel.

Training on the pump (set) must always be supervised by technical specialistpersonnel.

2.5 Consequences and risks caused by non-compliance with this manual▪ Non-compliance with this operating manual will lead to forfeiture of warranty

cover and of any and all rights to claims for damages.

▪ Non-compliance can, for example, have the following consequences:

– Hazards to persons due to electrical, thermal, mechanical and chemicaleffects and explosions

– Failure of important product functions

– Failure of prescribed maintenance and servicing practices

– Hazard to the environment due to leakage of hazardous substances

2 Safety

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2.6 Safety awarenessIn addition to the safety information contained in this manual and the intended use,the following safety regulations shall be complied with:

▪ Accident prevention, health and safety regulations

▪ Explosion protection regulations

▪ Safety regulations for handling hazardous substances

▪ Applicable standards, directives and laws

2.7 Safety information for the operator/user▪ The operator shall fit contact guards for hot, cold and moving parts and check

that the guards function properly.

▪ Do not remove any contact guards during operation.

▪ Provide 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 the environment.Adhere to all relevant laws.

▪ Eliminate all electrical hazards. (In this respect refer to the applicable nationalsafety regulations and/or regulations issued by the local energy supplycompanies.)

▪ If shutting down the pump does not increase potential risk, fit an emergency-stop control device in the immediate vicinity of the pump (set) during pump setinstallation.

2.8 Safety information for maintenance, inspection and installation▪ Modifications or alterations of the pump are only permitted with the

manufacturer's prior consent.

▪ Use only original spare parts or parts authorised by the manufacturer. The use ofother parts can invalidate any liability of the manufacturer for resulting damage.

▪ The operator ensures that maintenance, inspection and installation is performedby authorised, qualified specialist personnel who are thoroughly familiar withthe manual.

▪ Only carry out work on the pump (set) during standstill of the pump.

▪ The pump casing must have cooled down to ambient temperature.

▪ Pump pressure must have been released and the pump must have been drained.

▪ When taking the pump set out of service always adhere to the proceduredescribed in the manual. (ð Section 6.3, Page 37)

▪ Decontaminate pumps which handle fluids posing a health hazard.

▪ As soon as the work has been completed, re-install and/or re-activate any safety-relevant and protective devices. Before returning the product to service, observeall instructions on commissioning. (ð Section 6.1, Page 30)

2.9 Unauthorised modes of operationNever operate the pump (set) outside the limits stated in the data sheet and in thismanual.

The warranty relating to the operating reliability and safety of the supplied pump(set) is only valid if the equipment is used in accordance with its intended use.(ð Section 2.3, Page 9)

2.10 Explosion protection

! DANGER Always observe the information on explosion protection given in this section whenoperating the product in potentially explosive atmospheres.

2 Safety

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Only pumps/pump sets marked as explosion-proof and identified as such in the datasheet may be used in potentially explosive atmospheres.

Special conditions apply to the operation of explosion-proof pump sets to EUDirective 2014/34/EU (ATEX). Especially adhere to the sections in this manual marked with the symbol opposite andthe following sections (ð Section 2.10.1, ) to (ð Section 2.10.4, Page 12) . The explosion-proof status of the pump set is only assured if the pump set is used inaccordance with its intended use. Never operate the pump set outside the limits stated in the data sheet and on thename plate.Prevent impermissible modes of operation at all times.

2.10.1 Marking

Pump The marking on the pump refers to the pump part only. Example of such marking: II 2 G c TX Refer to the Temperature Limits table for the temperatures permitted for theindividual pump variants.

Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaftcoupling must be marked accordingly.

Motor The motor must be considered separately.

2.10.2 Temperature limits

In normal pump operation, the highest temperatures on accessible components areto be expected on the surface of the soleplate and the discharge piping, at the shaftseal and in the bearing areas.The surface temperature at the discharge piping corresponds to the temperature ofthe fluid handled. If the pump is heated in addition, the operator of the system isresponsible for observing the specified temperature class and fluid temperature(operating temperature).The table below lists the temperature classes and the resulting theoreticaltemperature limits of the fluid handled (a possible temperature rise in the shaft sealarea has already been taken into account).

The temperature class specifies the maximum permissible temperature at the surfaceof the pump set during operation. For the permissible operating temperature of thepump in question refer to the data sheet.

Table 4: Temperature limits

Temperature class to EN 13463-1 Maximum permissiblefluid temperature

T1 Maximum 400 °C2)

T2 280 °C

T3 185 °C

T4 120 °C

Misuse, malfunctions or non-compliance with the instructions may result insubstantially higher temperatures.

If the pump is to be operated at a higher temperature, if there is no data sheet or ifthe pump is part of a pool of pumps, contact KSB for the maximum permissibleoperating temperature.

2.10.3 Monitoring equipment

The pump (set) must only be operated within the limits specified in the data sheetand on the name plate. If the system operator cannot warrant compliance with these operating limits,appropriate monitoring devices must be used. Check whether monitoring equipment is required to ensure that the pump setfunctions properly.

2) Depending on the material variant

2 Safety

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Contact KSB for further information on monitoring equipment.

2.10.4 Operating limits

The minimum flows indicated in (ð Section 6.2.3.1, Page 36) refer to water andwater-like fluids handled. Longer operating periods with these fluids and at the flowrates indicated will not cause an additional increase in the temperatures at the pumpsurface. However, if the physical properties of the fluids handled are different fromwater, it is essential to check whether an additional heat build-up may occur and ifthe minimum flow rate must therefore be increased. The calculation formula in (ð Section 6.2.3.1, Page 36) can be used to check whether additional heat build-upmay lead to a dangerous temperature increase at the pump surface.

3 Transport/Temporary Storage/Disposal

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3.1 Checking the condition upon delivery1. On transfer of goods, check each packaging unit for damage.

2. In the event of in-transit damage, assess the exact damage, document it andnotify KSB or the supplying dealer (as applicable) and the insurer about thedamage in writing immediately.

3.2 Transport

DANGER

The pump (set) could slip out of the suspension arrangementDanger to life from falling parts!

▷ Always transport the pump (set) in the specified position.

▷ Never attach the suspension arrangement to the free shaft end or the motoreyebolt.

▷ Give due attention to the weight data and the centre of gravity.

▷ Observe the applicable local health and safety regulations.

▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.

CAUTION

Incorrect transport of the pumpDamage to the shaft seal!

▷ For transport, lock the pump shaft with a suitable transport lock to prevent anymovement of the shaft.

To transport the pump/pump set or back pull-out unit suspend it from the liftingtackle as shown.

Fig. 1: Transporting the assembled unit

Fig. 2: Transporting the pump casing and part of the support column

3.3 Storage/preservationIf commissioning is to take place some time after delivery, we recommend that thefollowing measures be taken for pump (set) storage.


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CAUTION

Damage during storage due to humidity, dirt, or verminCorrosion/contamination of the pump (set)!

▷ For outdoor storage cover the packed or unpacked pump (set) and accessorieswith waterproof material.

CAUTION

Wet, contaminated or damaged openings and connectionsLeakage or damage to the pump!

▷ Clean and cover pump openings and connections as required prior to puttingthe pump into storage.

Store the pump (set) in a dry, protected room where the atmospheric humidity is asconstant as possible.

Rotate the shaft by hand once a month, e.g. via the motor fan.

If properly stored indoors, the equipment is protected for a maximum of 6 months.New pumps/pump sets are supplied by our factory duly prepared for storage.

For storing a pump (set) which has already been operated, observe the instructions in(ð Section 6.3.1, Page 37) .

3.4 Return to supplier1. Drain the pump as per operating instructions.

2. Always flush and clean the pump, particularly if it has been used for handlingnoxious, explosive, hot or other hazardous fluids.

3. If the pump set has handled fluids whose residues could lead to corrosiondamage in the presence of atmospheric humidity or could ignite upon contactwith oxygen, the pump set must also be neutralised, and anhydrous inert gasmust be blown through the pump to ensure drying.

4. Always complete and enclose a certificate of decontamination when returningthe pump (set).Always indicate any safety and decontamination measures taken.(ð Section 11, Page 60)

NOTE

If required, a blank certificate of decontamination can be downloaded from thefollowing web site: www.ksb.com/certificate_of_decontamination

http://www.ksb.com/GRAS-Cert


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3.5 Disposal

WARNING

Fluids, consumables and supplies which are hot and/or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ 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 and other lubricants during dismantling.

2. Separate and sort the pump materials, e.g. by:- Metals- Plastics- Electronic waste- Greases and other lubricants

3. Dispose of materials in accordance with local regulations or in anothercontrolled manner.

4 Description of the Pump (Set)

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4.1 General description▪ Process pump to API 610

Pump for handling the large variety of petroleum products in refineries as well as inthe chemical and petrochemical industry.

4.2 Designation

Example: RPH-V 50-180

Table 5: Designation key

Code Description

RPH Type series

V Vertical installation

50 Nominal discharge nozzle diameter [mm] of volute casing

180 Nominal impeller diameter [mm]

4.3 Name plate

KSB BOMBAS HIDRAULICS S/AVARZEA PAULISTA-SPPHONE 55-11 4596-8500MADE IN BRAZIL

KSB RPHV 40-361OP R051400055 Q 38 m3/h

mcarpm

kgf/cm2

H 109,04n 2979Bearing 6313C3

Hydrost.Test. MAWP kgf/cm2 50 °CTAG:

Year: 2014Weight: 745 Kg

581 384 BRN 37

1

2

3

4

5

78

6

9

10

Fig. 3: Name plate (example)

1 Type series, size 2 Order number

3 Flow rate 4 Head

5 Speed 6 Bearing design

7 Test pressure 8 Max. permissible operatingpressure

9 Year of construction 10 Weight


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4.4 Design details

Design

▪ Volute casing pump

▪ Vertical installation

▪ Single-stage

▪ Meets the technical requirements to API 610, 11th edition / ISO 13709

▪ Pump shaft, intermediate shaft and drive shaft are connected by a split muffcoupling.

Direction of rotation

▪ Clockwise, viewed from the drive end

Drive

▪ Electric motor

▪ Combustion engine

▪ Turbine

Shaft seal

Standard design:

▪ Mechanical seal

▪ Mechanical seal chamber to API 610, 11th edition

▪ KSB cartridge seal

Pump casing

▪ Single volute

▪ Radially split volute casing

▪ Volute casing with casing wear ring

▪ Casing cover

Impeller type

▪ Closed radial impeller

▪ Impeller with impeller wear ring on the suction side

Balancing device

▪ Sealing gap

Soleplate seal

▪ Flexible graphite stuffing box rings with wire reinforcement for fugitive emissioncontrol (Teadit style 2000lC)

Bearings

▪ Uncooled

▪ Oil-lubricated radial ball bearing

Optional:

▪ Grease-packed radial ball bearing

Shaft guide bearings:

▪ Radial plain bearings made of PEEK

▪ With shaft protecting sleeve

▪ Product-lubricated3)

3) If pumping fluids with lubricating properties, a maximum contamination of 20 ppm and a maximum particle size of 10 µm;the lubricant is supplied through pipes fitted between each shaft guide bearing and the riser.


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Optional:

▪ Lubricated with water from an external source4)

4.5 Configuration and function

1

2

4

5

6

7

3

8

9

10

11

12

13

14

1516

17

18

1920

Fig. 4: Sectional drawing

1 Motor housing 2 Coupling

3 Drive shaft 4 Drive lantern

5 Radial ball bearing 6 Intermediate coupling

7 Bearing bracket lantern 8 Split muff coupling

9 Support column 10 Pump shaft

11 Casing cover 12 Volute casing

13 Impeller 14 Suction nozzle

4) Water is supplied to all shaft guide bearings through an external connection located above the soleplate.


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15 Suction strainer 16 Discharge nozzle, volute casing

17 Riser 18 Soleplate

19 Discharge nozzle, soleplate 20 Packing rings

Design The pump is designed with an axial fluid inlet and a radial outlet. The hydraulicsystem is rigidly connected to the motor via a multiple-disc coupling. It runs inproduct-lubricated plain bearings in the support column, which compensate anylateral movement or shaft deflection. Thanks to the graded lengths of supportcolumn (9) and shaft the pump set can be matched to various immersion depths. Thepump set is mounted on a soleplate (18). A riser (17) connects the discharge nozzle(16) of the volute casing with the discharge nozzle (19) of the soleplate (18).

Function The fluid enters the pump via the suction nozzle (14) and is accelerated outward bythe rotating impeller (13). In the flow passage of the pump casing the kinetic energyof the fluid is converted into pressure energy. The fluid is pumped to the dischargenozzle (16), where it leaves the pump. At the rear side of the impeller, the shaftenters the hydraulic system through the casing cover. The shaft runs in plainbearings, which are supported by bearing spiders in the support column assemblyconnected to the pump casing and/or casing cover.

Sealing The pump is sealed by a standardised mechanical seal.

4.6 Noise characteristics

Table 6: Surface sound pressure level LpA5)6)

PN Pump Pump set

960 rpm,760 rpm

1450 rpm 2900 rpm 960 rpm,760 rpm

1450 rpm 2900 rpm

[kW] [dB] [dB] [dB] [dB] [dB] [dB]

1,5 52 53 54 56 58 63

2,2 53 55 56 58 60 66

3 55 56 57 60 62 68

4 56 58 59 61 63 69

5,5 58 59 61 62 65 71

7,5 59 61 62 64 66 72

11 61 63 64 65 68 74

15 63 65 66 67 69 75

18,5 64 66 67 68 70 76

22 65 67 68 68 71 77

30 66 68 70 70 72 78

37 67 70 71 70 73 79

45 68 71 72 71 74 80

55 69 72 73 72 74 80

75 71 73 75 73 76 81

90 71 74 76 73 76 82

110 72 75 77 74 77 82

132 73 76 78 75 77 83

160 74 77 79 75 78 84

200 75 78 80 76 79 84

250 - 79 81 - 80 85

5) Spatial average; as per ISO 3744 and EN 12639; valid for pump operation in the Q/Qopt = 0.8 - 1.1 range and for non-cavitating operation. If noise levels are to be guaranteed: add +3 dB for measuring and constructional tolerance.

6) Increase for 60 Hz operation: 3500 rpm +3 dB, 1750 rpm +1 dB, 1160 rpm ±0 dB


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4.7 Scope of supplyDepending on the model, the following items are included in the scope of supply:

▪ Pump

Coupling

▪ Torsion-resistant flexible disc coupling

Contact guard

▪ Coupling guard

Soleplate

▪ Rectangular or round

▪ With riser

Accessories

▪ As required

4.8 Dimensions and weightsFor dimensions and weights please refer to the general arrangement drawing/outlinedrawing of the pump/pump set.

5 Installation at Site

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5.1 Safety regulations

DANGER

Improper installation in potentially explosive atmospheresExplosion hazard!

Damage to the pump set!

▷ Comply with the applicable local explosion protection regulations.

▷ Observe the information in the data sheet and on the name plates of pump andmotor.

5.2 Checks to be carried out prior to installation

Place of installation

WARNING

Installation of the foundation rails of the rectangular soleplate on mountingsurfaces which are unsecured and cannot support the loadPersonal injury and damage to property!

▷ Use a concrete of compressive strength class C12/15 which meets therequirements of exposure class XC1 to EN 206-1.

▷ The mounting surface must have set and must be completely horizontal andeven.

▷ Observe the weights indicated.

1. Check the structural requirements.All structural work required must have been prepared in accordance with thedimensions stated in the outline drawing/general arrangement drawing.

5.3 Installing the pump setAlways install the pump set in a vertical position.

DANGER

Excessive temperatures due to improper installationExplosion hazard!

▷ Install the pump in a vertical position to ensure self-venting of the pump.

Foundation

DANGER

Volute casing, support column assembly and soleplate take on the sametemperature as the fluid handled.Risk of burns!

▷ Do not insulate the drive lantern and the bearing bracket lantern.

The sturdy soleplate 893 serves as a foundation on which the pump set is fastened.This soleplate covers the tank opening completely. If the pump set is supplied withsoleplate and riser, the soleplate is supported by a sectional steel frame provided onthe tank.

If pump and motor are delivered as separate units, transport and installation can befacilitated by screwing eyebolts into the threaded holes in the soleplate for attachingsupport ropes.


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Grouting and aligning

1. Insert the foundation rail into the recess provided in the foundation block.Observe the dimensions given in the foundation drawing.

2. Align the foundation rail with a precision alignment tool. Any deviations shouldnot exceed 0.1 mm/m.

NOTE

Soleplate does not seal tightly any more.

▷ Do not insert blocks for alignment, if possible.

3. After the concrete has completely set, remove any concrete residues from thefoundation rail and clean the area appropriately.

4. Place the gasket and soleplate onto the foundation block and fasten thesoleplate. Do not crush, fold or otherwise damage the gasket.

WARNING

Improper installation of gasketFluid or gas could escape!

▷ Never install gasket incorrectly.

NOTE

The tightness of the well can affect the NPSHA value due to the absence ofatmospheric pressure. The operator should make sure that the NPSHA value exceedsthe NPSHR by 1 metre as a minimum.

5. Verify that the soleplate is evenly seated on the foundation rail.

On the nozzle of a pressurevessel

In this case the pump set is supplied mounted on a flange that will cover/close thepressure vessel.

1. Connect the flanges using standard procedures, i.e. parallel flange faces with adeviation of less than 0.5 mm and an alignment deviation of less than 0.1 mm/m.

2. Install the spiral wound gasket properly between the nozzles, making sure notto crush, fold or otherwise damage the spiral wound gasket.


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Installing the pump

Transporting a pump with a roundsoleplate

Transporting a pump with a rectangularsoleplate

1. Carefully align the support for the soleplate or the base of the bracket.

2. Adjust the position of the soleplate in relation to the tank edge, if required.Observe the minimum distance e1 to the tank floor.

a1e1

Fig. 5: Distance to the tank floor

Table 7: Distances to the tank floor

Size e1 a1

[mm] [mm]

25-180, 25-230 65 See type series booklet /outline drawing40-180 to -361 80

50-180, 50-200 100

80-200 120

NOTE

Expansion joints can be fitted at the discharge nozzle.


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5.4 Piping

5.4.1 Connecting the piping

DANGER

Impermissible loads acting on the pump nozzlesDanger to life from escaping hot, toxic, corrosive or flammable fluids!

▷ Do not use the pump as an anchorage point for the piping.

▷ Anchor the pipes in close proximity to the pump and connect them withouttransmitting any stresses or strains.

▷ Observe the permissible forces and moments at the pump nozzles.(ð Section 5.4.2, Page 25)

▷ Take appropriate measures to compensate for thermal expansion of the piping.

WARNING

Incorrect installation of packing ringsFluid or gas could escape!

▷ Check that packing rings are correctly installed and sealing properly.

CAUTION

Welding beads, scale and other impurities in the pipingDamage to the pump!

▷ Remove any impurities from the piping.

▷ If necessary, install a filter.

▷ Observe the information in .

CAUTION

Incorrect earthing during welding work on the pipingDestruction of rolling element bearings (pitting effect)!

▷ Never earth the electric welding equipment on the pump or soleplate.

▷ Prevent current flowing through the rolling element bearings.

CAUTION

Aggressive flushing and pickling agentsDamage to the pump!

▷ Match the cleaning operation mode and duration for flushing and picklingservice to the casing and seal materials used.


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NOTE

Installing check and shut-off elements in the system is recommended, depending onthe type of plant and pump. However, such elements must not obstruct properdrainage or hinder disassembly of the pump.

ü The nominal diameters of the pipes are equal to or greater than the nominaldiameters of the pump nozzles.

ü Adapters to larger nominal diameters are designed with a diffuser angle ofapprox. 8° to avoid excessive pressure losses.

ü The pipelines have been anchored in close proximity to the discharge nozzle andconnected without transmitting any stresses or strains. Their weight must not becarried by the discharge nozzle.

1. Thoroughly clean, flush and blow through all vessels, pipelines and connections(especially of new installations).

2. Before installing the pump in the piping, remove the flange cover on the pumpdischarge nozzle.

3. Check that the inside of the pump is free from any foreign objects. Remove anyforeign objects.

4. Check that packing rings are correctly installed and sealing properly.

5. Connect the discharge nozzle to the piping.

5.4.2 Permissible forces and moments at the discharge nozzle

Mx

My

Mz

Fz

Fy

Fx

Table 8: Forces and moments at the discharge nozzle

Size Forces Moments

Fx Fy Fz Fres Mx My Mz Mres

[N] [Nm]

25-180 710 580 890 1280 460 230 350 620

25-230 710 580 890 1280 460 230 350 620

40-180 1070 890 1330 1930 950 470 720 1280

40-230 1070 890 1330 1930 950 470 720 1280

40-280 1070 890 1330 1930 950 470 720 1280

40-181 1070 890 1330 1930 950 470 720 1280

40-231 1070 890 1330 1930 950 470 720 1280

40-281 1070 890 1330 1930 950 470 720 1280

40-361 1070 890 1330 1930 950 470 720 1280

50-180 1070 890 1330 1930 950 470 720 1280

50-200 1070 890 1330 1930 950 470 720 1280

80-200 2490 2050 3110 4480 2300 1180 1760 3130


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5.4.3 Auxiliary connections

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in theauxiliary pipingRisk of burns!

Explosion hazard!

▷ Make sure that the barrier fluid and quench liquid are compatible with thefluid pumped.

WARNING

Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushingliquid, etc.)Risk of injury from escaping fluid!

Risk of burns!

Malfunction of the pump!

▷ Refer to the general arrangement drawing, the piping layout and pumpmarkings (if any) for the quantity, dimensions and locations of auxiliaryconnections.

▷ Use the auxiliary connections provided.

5.5 Enclosure/insulation

DANGER

Risk of potentially explosive atmosphere due to insufficient ventilationExplosion hazard!

▷ Never close or cover the perforation of the bearing bracket guards (e.g. byinsulation).

WARNING

The soleplate and discharge nozzle take on the same temperature as the fluidhandled.Risk of burns!

▷ Fit protective equipment.

▷ Do not insulate the drive lantern and the bearing bracket lantern.

CAUTION

Heat build-up in the bearing bracketDamage to the bearings!

▷ The bearing bracket must not be insulated.

5.6 Checking the coupling alignment

DANGER

Inadmissible temperatures at the coupling or bearings due to misalignment of thecouplingExplosion hazard!

Risk of burns!

▷ Make sure that the coupling is correctly aligned at all times.


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CAUTION

Misalignment of pump and motor shaftsDamage to pump, motor and coupling!

▷ Always check the coupling after the pump has been installed and connected tothe piping.

▷ Also check the coupling of pump sets supplied with pump and motor mountedon the same soleplate.

Checking the coupling alignment with a dial gauge

Fig. 6: Checking the spacer-type coupling with a dial gauge

1. Mark the installation position of the coupling by dotting marks (balancecondition).

2. Remove the coupling spacer.

NOTE

While the pump's coupling is disengaged, also check the direction of rotation. (ð Section 5.9, Page 29)

3. Check the alignment of the coupling halves with a dial gauge (see drawing"Checking the spacer-type coupling with a dial gauge").The maximum admissible run-out of the coupling face (axial) equals 0.1 mm.The maximum admissible radial deviation, measured over the completecircumference, equals 0.2 mm.

5.7 Aligning the pump and motorAfter having installed the pump set and connected the piping, check the couplingalignment and, if required, re-align the pump set (with the motor).

ü The coupling guard and its footboard, if any, have been removed.

1. Check the coupling alignment.

2. Loosen the hexagon head bolts at the motor.

3. Align the motor shaft with the pump shaft.

4. Re-tighten the hexagon head bolts.

5. Check proper functioning of coupling/shaft. Check that coupling/shaft can easily be rotated by hand.

WARNING

Unprotected rotating couplingRisk of injury by rotating shafts!

▷ Always operate the pump set with a coupling guard.If the customer specifically requests not to include a coupling guard in KSB'sdelivery, then the operator must supply one!

▷ Observe all relevant regulations for selecting a coupling guard.


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6. Fit the coupling guard and its footboard, if any.

7. Check the distance between coupling and coupling guard.The coupling guard must not touch the coupling.

DANGER

Risk of ignition by frictional sparksExplosion hazard!

▷ Choose a coupling guard material that is non-sparking in the event ofmechanical contact (see DIN EN 13463-1).

5.8 Electrical connection

DANGER

Incorrect electrical installationExplosion hazard!

▷ For electrical installation, also observe the requirements of IEC 60079-14.

▷ Always use a motor protection switch for explosion-proof motors.

DANGER

Electrical connection work by unqualified personnelRisk of fatal injury due to electric shock!

▷ Always have the electrical connections installed by a trained and qualifiedelectrician.

▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079.

WARNING

Incorrect connection to the mainsDamage to the mains network, short circuit!

▷ Observe the technical specifications of the local energy supply companies.

1. Check the available mains voltage against the data on the motor name plate.

2. Select an appropriate start-up method.

NOTE

A motor protection device is recommended.

5.8.1 Earthing

DANGER

Electrostatic chargingExplosion hazard!


▷ Connect the PE conductor to the earthing terminal provided.

▷ Provide for potential equalisation between the pump set and foundation.


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5.8.2 Connecting the motor

NOTE

In compliance with IEC 60034-8, three-phase motors are always wired for clockwiserotation (looking at the motor shaft stub).

The pump's direction of rotation is indicated by an arrow on the pump.

1. Match the motor's direction of rotation to that of the pump.

2. Observe the manufacturer's product literature supplied with the motor.

5.9 Checking the direction of rotation

DANGER

Temperature increase resulting from contact between rotating and stationarycomponentsExplosion hazard!


▷ Never check the direction of rotation by starting up the unfilled pump set.

▷ Separate the pump from the motor to check the direction of rotation.

WARNING

Reaching into a tank whose soleplate has been removedRisk of injuries!

▷ When the soleplate is removed, never reach into the uncovered tank opening.

CAUTION

Drive and pump running in the wrong direction of rotationDamage to the pump!

▷ Refer to the arrow indicating the direction of rotation on the pump.

▷ Check the direction of rotation. If required, check the electrical connection andcorrect the direction of rotation.

The correct direction of rotation of the motor and pump is clockwise (seen from themotor end).

1. Start the motor and stop it again immediately to determine the motor'sdirection of rotation.

2. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the directionof rotation on the pump.

3. If the motor is running in the wrong direction of rotation, check the electricalconnection of the motor and the control system, if applicable.

6 Commissioning/Start-up/Shutdown

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6.1 Commissioning/Start-up

6.1.1 Prerequisites for commissioning/start-up

Before commissioning/starting up the pump set, make sure that the followingconditions are met:

▪ The pump set has been mechanically connected as specified.

▪ The pump set has been properly connected to the power supply and is equippedwith all protection devices. (ð Section 5.8, Page 28)

▪ The pump has been primed with the fluid to be handled. The pump has beenvented. (ð Section 6.1.4, Page 32)

▪ The direction of rotation has been checked. (ð Section 5.9, Page 29)

▪ All auxiliary connections required are connected and operational.

▪ The lubricants have been checked.

▪ After prolonged shutdown of the pump (set), the activities required for returningthe pump (set) to service have been carried out. (ð Section 6.4, Page 37)

6.1.2 Filling in the lubricant

Oil-lubricated bearings Fill the bearing bracket with lubricating oil.

▪ Oil quality (ð Section 7.2.3.1.2, Page 43)

▪ Oil quantity (ð Section 7.2.3.1.3, Page 43)

Filling the constant level oiler with lubricating oil (oil-bath-lubricated bearings only)

ü The constant level oiler has been screwed into the upper tapping hole of thebearing bracket.

CAUTION

Insufficient quantity of lubricating oil in the reservoir of the constant level oilerDamage to the bearings!

▷ Regularly check the oil level.

▷ Always fill the oil reservoir completely.

▷ Keep the oil reservoir properly filled at all times.

1

2

3

Fig. 7: Bearing bracket with constant level oiler

1 Constant level oiler 2 Screw plug

3 Bearing bracket 4 Vent plug

1. Remove the protective cage.

2. Unscrew the vent plug (4).

3. Hinge down the reservoir of the constant level oiler (1) from the bearingbracket (3) and hold it in this position.


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4. Fill oil through the hole for the vent plug until the oil reaches the connectionelbow of the constant level oiler (1).

5. Completely fill the reservoir of the constant level oiler (1).

6. Snap the constant level oiler (1) back into its operating position.

7. Screw the vent plug (4) back in.

8. Fit the protective cage.

9. After approximately 5 minutes, check the oil level in the glass reservoir of theconstant level oiler (1). The oil reservoir must be properly filled at all times to provide a constant oillevel. Repeat steps 1 - 8, if necessary.

10. To check the function of the constant level oiler (1), slowly drain some oil via thescrew plug (2) until air bubbles can be seen in the oil reservoir.

NOTE

An excessively high oil level can lead to a temperature rise and to leakage of thefluid handled or oil.

Connecting the oil mist lubrication system (for oil mist lubrication only)

Bearings with oil mistlubrication 916.N3

916.46

Fig. 8: Oil mist lubrication

ü Always observe the instructions of the lubricating system manufacturer(especially on dosing and oil quantity).

1. Remove plug 916.N3.

2. Connect the line of the oil mist lubrication system.

3. Remove drain plug 916.46.

4. Connect the drain line (returning the oil back into the oil mist system).

6.1.3 Shaft seal

Shaft seals are fitted prior to delivery. Observe the instructions on dismantling or assembly .

Reservoir of non-pressurised external fluid

If applicable, fill the reservoir of non-pressurised external fluid in accordance withthe general arrangement drawing.

Double mechanical seal Prior to starting up the pump, apply barrier pressure as specified in the generalarrangement drawing.

External liquid feed Apply the quantities and pressures specified in the data sheet and the generalarrangement drawing.


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6.1.4 Priming and venting the pump

CAUTION

Increased wear due to dry runningDamage to the pump/plain bearing!

▷ Never operate the pump set without liquid fill.

▷ Never supply the pump with cold fluid after dry running.

During pump start-up and operation, the fluid level must be above the minimumlevel. The minimum fluid level is indicated in the type series booklet or the generalarrangement drawing.

DANGER

Risk of potentially explosive atmosphere by mixing of incompatible fluids in theauxiliary pipingRisk of burns!

Explosion hazard!

▷ Make sure that the barrier fluid and quench liquid are compatible with thefluid pumped.

DANGER

Formation of a potentially explosive atmosphere inside the pumpExplosion hazard!

▷ The pump internals in contact with the fluid handled, including the sealchamber and auxiliary systems, must be filled with the fluid handled at alltimes.

▷ Make sure the required fill level is met.

▷ Provide an appropriate monitoring system.

DANGER

Shaft seal failure caused by insufficient lubricationLeakage of hot or toxic fluid handled!

Damage to the pump!

▷ Before starting up the pump set, vent the pump and fill it with the fluid to behandled.

1. Vent the pump and prime it with the fluid to be handled.

2. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc.).

6.1.5 Final check

1. Remove the coupling guard and its footboard, if any.

2. Check the coupling alignment; re-align the coupling, if required.

3. Check proper functioning of coupling/shaft.Check that coupling/shaft can be easily rotated by hand.

4. Fit the coupling guard and its footboard, if any.

5. Check the distance between coupling and coupling guard.The coupling guard must not touch the coupling.


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6.1.6 Water cooling

CAUTION

Deposit-forming, aggressive cooling waterDamage to the pump!

▷ Observe the cooling water quality.

Observe the following quality data of the cooling water:

▪ Not deposit-forming

▪ Not aggressive

▪ Free from suspended solids

▪ Hardness on average 5 °dH (~1 mmol/l)

▪ pH > 8

▪ Conditioned and neutral with regard to mechanical corrosion

▪ Inlet temperature tinl=10 to 30 °COutlet temperature toutl= 45 °C max.

6.1.7 Cooling of the shaft seal

CAUTION

Vaporisation pressure of fluid handled higher than atmospheric pressureDamage to the shaft seal/pump!

▷ Cool the shaft seal.

▷ Provide sufficient quantities of cooling liquid (see table).

NOTE

The vaporisation pressure varies depending on the fluid handled, the systempressure and the material of the shaft seal (e.g. hot water).

6.1.8 Heating

DANGER

Excessive surface temperatureExplosion hazard!

Risk of burns!

▷ Observe the permissible temperature classes.

6.1.9 Start-up

DANGER

Non-compliance with the permissible pressure and temperature limits if the pumpis operated with the suction and/or discharge line closed.Explosion hazard!

Hot or toxic fluids escaping!

▷ Never operate the pump with the shut-off elements in the suction line and/ordischarge line closed.

▷ Only start up the pump set with the discharge-side shut-off element slightly orfully open.


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DANGER

Excessive temperatures due to dry running or excessive gas content in the fluidhandledExplosion hazard!



▷ Prime the pump as per operating instructions.

▷ Always operate the pump within the permissible operating range.

CAUTION

Abnormal noises, vibrations, temperatures or leakageDamage to the pump!

▷ Switch off the pump (set) immediately.

▷ Eliminate the causes before returning the pump set to service.

ü The system piping has been cleaned.

ü The pump, suction line and inlet tank, if fitted, have been vented and primedwith the fluid to be pumped.

ü The fill level of the fluid to be pumped has been checked.

CAUTION

Start-up against open discharge lineMotor overload!

▷ Make sure the motor has sufficient power reserves.

▷ Use a soft starter.

▷ Use speed control.

1. Close or slightly open the shut-off element in the discharge line.

2. Start up the motor.

3. Immediately after the pump has reached rated speed, slowly open the shut-offelement in the discharge line and adjust it to comply with the duty point.

CAUTION

Misalignment of pump and couplingDamage to pump, motor and coupling!

▷ When the operating temperature has been reached, switch off the pump setand check the coupling alignment.

4. Check the coupling alignment and re-align the coupling, if required.

6.1.10 Checking the shaft seal

Mechanical seal The mechanical seal only leaks slightly or invisibly (as vapour) during operation.Mechanical seals are maintenance-free.

6.1.11 Shutdown

ü On pump sets with double mechanical seal, apply the required pressure specifiedin the general arrangement drawing to the mechanical seal chamber also duringstandstill.

ü Quench liquid supply must also be ensured during pump standstill.

1. Close the shut-off element in the discharge line.

2. Stop the motor and make sure the pump set runs down smoothly to a standstill.


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NOTE

If the discharge line is equipped with a check valve, the shut-off element in thedischarge line may remain open, provided the site's requirements and regulationsare taken into account and observed.

NOTE

If shut-off is not possible, the pump will run in reverse direction.The reverse runaway speed must be lower than the rated speed.

For prolonged shutdown periods:

1. Close any auxiliary lines. If the fluid to be handled is fed in under vacuum, also supply the shaft seal withbarrier fluid during standstill.Only turn off the cooling liquid supply after the pump has cooled down.

CAUTION

Risk of freezing during prolonged pump shutdown periodsDamage to the pump!

▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protectthem against freezing.

6.2 Operating limits

DANGER

Non-compliance with operating limits for pressure, temperature, fluid handled andspeedExplosion hazard!

Hot or toxic fluid could escape!

▷ Comply with the operating data indicated in the data sheet.

▷ Never use the pump for handling fluids it is not designed for.

▷ Avoid prolonged operation against a closed shut-off element.

▷ Never operate the pump at temperatures, pressures or rotational speedsexceeding those specified in the data sheet or on the name plate unless thewritten consent of the manufacturer has been obtained.

6.2.1 Ambient temperature

CAUTION

Operation outside the permissible ambient temperatureDamage to the pump (set)!

▷ Observe the specified limits for permissible ambient temperatures.

Observe the following parameters and values during operation:

Table 9: Permissible ambient temperatures

Permissible ambient temperature Value

Maximum 50 °C

40 °C7)

Minimum See data sheet

7) For compliance with 2014/34/EU (ATEX Equipment Directive). Higher ambient temperature possible in individual cases, seedata sheet and name plate.


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6.2.2 Frequency of starts

DANGER

Excessive surface temperature of the motorExplosion hazard!

Damage to the motor!

▷ In case of explosion-proof motors, observe the frequency of starts specified inthe manufacturer's product literature.

The frequency of starts is usually determined by the maximum temperature increaseof the motor. This largely depends on the power reserves of the motor in steady-state operation and on the starting conditions (DOL, star-delta, moments of inertia,etc). If the starts are evenly spaced over the period indicated, the following limitsserve as orientation for start-up with the discharge-side gate valve slightly open:

Table 10: Frequency of starts

Motor rating Maximum frequency of starts

[kW] [Starts/hour]

≤ 12 15

≤ 100 10

> 100 5

CAUTION

Re-starting while motor is still running downDamage to the pump (set)!

▷ Do not re-start the pump set before the pump rotor has come to a standstill.

6.2.3 Fluid handled

6.2.3.1 Flow rate

Unless specified otherwise in the characteristic curves or in the data sheets, thefollowing applies:

Qmax8) See characteristic curves.

Qmin9)= 0.3 × Qopt

10)

The data refer to water and water-like fluids. Longer operating periods with thesefluids and at the flow rates indicated will not cause an additional increase in thetemperatures on the pump surface. However, if the physical properties of the fluidshandled differ from those of water, the calculation formula below must be used tocheck if an additional heat build-up may lead to a dangerous temperature increase atthe pump surface. If necessary, the minimum flow must be increased.

××

×

Table 11: Key

Symbol Description Unit

c Specific heat capacity J/kg K

g Gravitational constant m/s²

8) Maximum permissible flow rate9) Minimum permissible flow rate10) Best efficiency point


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Symbol Description Unit

H Pump discharge head m

Tf Fluid temperature °C

TO Temperature at the casing surface °C

Pump efficiency at duty point -

Temperature difference K

6.2.3.2 Density of the fluid handled

The pump input power changes in proportion to the density of the fluid handled.

CAUTION

Impermissibly high density of the fluid handledMotor overload!

▷ Observe the information on fluid density in the data sheet.

▷ Make sure the motor has sufficient power reserves.

6.2.3.3 Abrasive fluids

Do not exceed the maximum permissible solids content specified in the data sheet.When the pump handles fluids containing abrasive substances, increased wear of thehydraulic system and shaft seal are to be expected. In this case, reduce the commonlyrecommended inspection intervals.

6.3 Shutdown/storage/preservation

6.3.1 Measures to be taken for shutdown

The pump (set) remains installed

ü Sufficient fluid is supplied for the operation check run of the pump.

1. Start up the pump (set) regularly between once a month and once every threemonths for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pumpintake area.

The pump (set) is removed from the pipe and stored

ü The pump has been properly drained and the safety instructions for dismantlingthe pump have been observed.

1. Spray-coat the inside wall of the pump casing and, in particular, the impellerclearance areas with a preservative.

2. Spray the preservative through the suction and discharge nozzles.It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).

3. Oil or grease all exposed machined parts and surfaces of the pump (withsilicone-free oil and grease, food-approved if required) to protect them againstcorrosion.Observe the additional instructions (ð Section 3.3, Page 13) .

If the pump set is to be stored temporarily, only preserve the wetted componentsmade of low-alloy materials. Commercially available preservatives can be used forthis purpose. Observe the manufacturer's instructions for application/removal.

Observe any additional instructions and information provided. (ð Section 3, Page 13)

6.4 Returning to serviceFor returning the pump to service, observe the items on commissioning/start-up (ð Section 6.1, Page 30) and the operating limits (ð Section 6.2, Page 35) .


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In addition, carry out all servicing/maintenance operations before returning thepump (set) to service. (ð Section 7, Page 39)

WARNING

Failure to re-install or re-activate protective devicesRisk of personal injury from moving parts or escaping fluid!

▷ As soon as the work is complete, re-install and/or re-activate any safety-relevantand protective devices.

NOTE

If the pump has been out of service for more than one year, replace all elastomerseals.

NOTE

The pump is protected against splashing water as the covers of the thrust bearingsare water-tight.

NOTE

Observe the relevant manufacturer's product literature for the motor.

7 Servicing/Maintenance

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7.1 Safety regulations

DANGER

Sparks produced during servicing workExplosion hazard!

▷ Observe the safety regulations in force at the place of installation!

▷ Always perform maintenance work at an explosion-proof pump (set) outside ofpotentially explosive atmospheres.

DANGER

Improperly serviced pump setExplosion hazard!


▷ Service the pump set regularly.

▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft sealand coupling.

The operator ensures that maintenance, inspection and installation is performed byauthorised, qualified specialist personnel who are thoroughly familiar with themanual.

WARNING

Unintentional starting of pump setRisk of injury by moving parts!

▷ Ensure that the pump set cannot be started up unintentionally.

▷ Always make sure the electrical connections are disconnected before carryingout work on the pump set.

WARNING

Fluids handled and supplies posing a health hazard and/or hot fluids handled andsuppliesRisk of injury!

▷ Observe all relevant laws.

▷ When draining the fluid take appropriate measures to protect persons and theenvironment.

▷ Decontaminate pumps which handle fluids posing a health hazard.

WARNING

Insufficient stabilityRisk of crushing hands and feet!

▷ During assembly/dismantling, secure the pump (set)/pump parts to preventtilting or tipping over.

A regular maintenance schedule will help avoid expensive repairs and contribute totrouble-free, reliable operation of the pump, pump set and pump parts with aminimum of servicing/maintenance expenditure and work.


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NOTE

All maintenance, service and installation work can be carried out by KSB Service orauthorised workshops. For contact details please refer to the enclosed "Addresses"booklet 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 a result of bearings running hot or defective bearingsealsExplosion hazard!

Fire hazard!


Risk of burns!

▷ Regularly check the lubricant level.

▷ Regularly check the rolling element bearings for running noises.

DANGER

Incorrectly serviced shaft sealExplosion hazard!

Hot, toxic fluid escaping!


Risk of burns!

Fire hazard!

▷ Regularly service the shaft seal.

DANGER

Incorrectly serviced barrier fluid systemExplosion hazard!

Fire hazard!


Hot and/or toxic fluids escaping!

▷ Regularly service the barrier fluid system.

▷ Monitor the barrier fluid pressure.

CAUTION

Increased wear due to dry runningDamage to the pump set!



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CAUTION

Impermissibly high temperature of fluid handledDamage to the pump!

▷ Prolonged operation against a closed shut-off element is not permitted(heating up of the fluid).

▷ Observe the temperature limits in the data sheet and in the section onoperating limits. (ð Section 6.2, Page 35)

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.

▪ Check the shaft seal.

▪ Check the static sealing elements for leakage.

▪ Check the rolling element bearings for running noises.Vibrations, noise and an increase in current input occurring during unchangedoperating conditions indicate wear.

▪ Monitor the correct functioning of any auxiliary connections.

▪ Cooling systemTake the pump out of service at least once a year to thoroughly clean the coolingsystem.

▪ Monitor the stand-by pump.To make sure that the stand-by pumps are ready for operation, start them uponce a week.

▪ Monitor the bearing temperature.The bearing temperature must not exceed 90 °C (measured on the outside of thebearing bracket).

CAUTION

Operation outside the permissible bearing temperatureDamage to the pump!

▷ The bearing temperature of the pump (set) must never exceed 90 °C (measuredon the outside of the bearing bracket).

7.2.2 Inspection work

DANGER

Excessive temperatures caused by friction, impact or frictional sparksExplosion hazard!

Fire hazard!


▷ Regularly check the coupling guard, plastic components and other guards ofrotating parts for deformation and sufficient distance from rotating parts.

7.2.2.1 Checking the coupling

Check the flexible elements of the coupling. Replace the relevant parts in due time ifthere is any sign of wear and check the alignment.


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7.2.2.2 Checking the clearances

Impeller

For checking the clearances remove impeller 230, if required .If the clearance is larger than permitted (see the following table), fit a new casingwear ring 502.01 and/or impeller wear ring 503.01.The clearances given refer to the diameter.

Table 12: Clearances between impeller and casing

Size Suction-side casing wear ring

Inner nominaldiameter (rounded)

Minimum clearanceto API 610

Clearance toAN 1501 Gr. 2

(standard)

[mm] [mm] [mm]

25-180 70 0,3 0,5

25-230 70 0,3 0,5

40-180 80 0,33 0,5

40-181 95 0,35 0,6

40-230 80 0,33 0,5

40-231 95 0,35 0,6

40-280 85 0,33 0,6

40-281 95 0,35 0,6

40-361 95 0,35 0,6

50-180 120 0,4 0,6

50-200 110 0,38 0,6

80-200 125 0,43 0,6

Plain bearing

The clearances between the bearing sleeve (529), the shaft protecting sleeve (524)and the bearing bush (545) must measure between 0.3 mm and 0.7 mm. If thesevalues are not met the components should be replaced. Observe the fasteningmethod for the bushes given in the sectional drawing/general assembly drawing. Theshrinking properties of specific bush materials require bonding agents and grubscrew to be used.

The sleeves can be machined to eliminate any superficial defects provided that thepermissible clearance is maintained.

7.2.2.3 Cleaning the strainer

CAUTION

Insufficient inlet pressure due to clogged strainer in the suction lineDamage to the pump!

▷ Monitor contamination of strainer with suitable means (e.g. differentialpressure gauge).

▷ Clean the strainer at appropriate intervals.


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7.2.3 Lubrication and lubricant change of rolling element bearings

DANGER

Excessive temperatures as a result of bearings running hot or defective bearingsealsExplosion hazard!

Fire hazard!


▷ Regularly check the condition of the lubricant.

7.2.3.1 Oil lubrication

The rolling element bearings are usually lubricated with mineral oil.

7.2.3.1.1 Intervals

Table 13: Oil change intervals

Temperature at thebearing

First oil change All subsequent oilchanges11)

up to 70 ℃ After 300 operating hours Every 8500 operating hours

70 °C - 80 °C After 300 operating hours Every 4200 operating hours

80 °C - 90 °C After 300 operating hours Every 2000 operating hours

7.2.3.1.2 Oil quality

Table 14: Oil quality

Designation Symbol to DIN51502

Properties

CLP46 lubricating oilto DIN 51517

orHD 20W/20 SAE

□ Kinematic viscosityat 40 °C

46±4 mm²/s

Flash point (toCleveland)

+175 ℃

Solidification point(pour point)

-15 ℃

Applicationtemperature12)

Higher thanpermissible bearing

temperature

7.2.3.1.3 Oil quantity

Bearing bracket Oil quantity bearing bracket

[l]

B02 0,75

11) At least once a year12) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.


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7.2.3.1.4 Changing the oil

WARNING

Lubricants posing a health hazard and/or hot lubricantsHazard to persons and the environment!

▷ When draining the lubricant take appropriate measures to protect persons andthe environment.

▷ Wear safety clothing and a protective mask, if required.

▷ Collect and dispose of any lubricants.


1

2

3

Fig. 9: Bearing bracket with constant level oiler

1 Constant level oiler 2 Screw plug

3 Bearing bracket

ü A suitable container for the used oil is on hand.

1. Place the container underneath the screw plug.

2. Undo the screw plug (2) at the bearing bracket (3) and drain the oil.

3. Once the bearing bracket (3) has been drained, re-insert and re-tighten thescrew plug (2).

4. Re-fill with oil.

7.2.4 Radial bearings

In the volute casing and the support column assembly the shaft is guided in plainbearings lubricated by the fluid handled. If the fluid handled is contaminated, thebearings can be lubricated by an external liquid supplied via a lubrication line (specialdesign).

DANGER

Clogged holes in the lubrication line

▷ Regularly check and clean the small holes in the lubrication lines.


45 of 64RPH-V

7.3 Drainage/cleaning

WARNING

Fluids, consumables and supplies which are hot and/or pose a health hazardHazard to persons and the environment!

▷ Collect and properly dispose of flushing fluid and any residues of the fluidhandled.

▷ Wear safety clothing and a protective mask if required.


If the pump set has handled fluids whose residues could lead to corrosion damage inthe presence of atmospheric humidity or could ignite upon contact with oxygen, thepump set must be neutralised, and anhydrous inert gas must be blown through thepump to ensure drying.

7.4 Dismantling the pump set

7.4.1 General information/Safety regulations

WARNING

Unqualified personnel performing work on the pump (set)Risk of injury!

▷ Always have repair and maintenance work performed by specially trained,qualified personnel.

WARNING

Hot surfaceRisk of injury!

▷ Allow the pump set to cool down to ambient temperature.

WARNING

Improper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to moveheavy assemblies or components.

Always observe the safety instructions and information. (ð Section 7, Page 39)

For any work on the motor, observe the instructions of the relevant motormanufacturer.

For dismantling and reassembly refer to the general assembly drawing. (ð Section 9.1, Page 55)

In case of damage you can always contact our service staff.


46 of 64 RPH-V

DANGER

Insufficient preparation of work on the pump (set)Risk of personal injury!

▷ Properly shut down the pump set.

▷ Close the shut-off elements in the discharge line.

▷ Drain the pump and release the pump pressure.

▷ Close any auxiliary connections.

▷ Allow the pump set to cool down to ambient temperature.

7.4.2 Preparing the pump set

1. Interrupt the power supply and secure the pump against unintentional start-up.

2. Disconnect and remove all auxiliary pipework.

3. Remove the coupling guard.

4. Remove the coupling spacer, if any.

5. Drain the oil fill of oil-lubricated bearings.

7.4.3 Removing the complete pump set from the piping

WARNING

Leakage of residual liquid from the pumpHazard to persons and the environment!

▷ Take suitable precautions when draining, collecting and disposing of fluidshandled.

▷ Observe the information on draining and cleaning.

1. Disconnect any auxiliary lines.

2. Separate soleplate 893 from foundation rail 89-8 or from the pressure vesselnozzle.

3. Remove the pump set and soleplate/flange from the sump or tank.

4. Place it down in a horizontal position.

5. Remove the coupling guard.

6. Disconnect the coupling and remove the motor.

7. Undo the screw for fastening the coupling hub.

8. Remove the coupling half of the pump shaft.

9. Remove key 940.1.

10. Undo the connection between the motor and drive lantern 341. Remove themotor.

11. Remove constant level oiler 638 and pipe 710.7, if any.

12. Undo bolts 901.9.

13. Remove drive lantern 341 from bearing bracket lantern 344.

14. Remove adjusting nut 923.2.

15. Loosen and remove bolts 901.3 for fastening bearing cover 360.

16. Use a puller to remove centring sleeve 526 with bearing 321.

17. Remove key 940.2. Undo bolts 901.11. Separate drive shaft 213 and intermediatecoupling 848.

18. Loosen bolts 901.5 and remove bearing housing 350.

19. Undo nuts 920.13.

20. Remove mechanical seal 433.


47 of 64RPH-V

21. Undo nuts 920.17 and studs 902.17.

22. Remove bearing bracket lantern 344 from soleplate 893 or the flange,depending on the seal plan and piping layout. First of all, check if the pipescould be hit in this step. If this is the case, remove the pipes first.

23. Separate pipes 710 at their connections 720.

24. Remove nuts 920.19 and bolts 901.33 from riser spool 711.1/.2 and dischargeelbow 144.

25. Remove packing rings 461.

26. Remove the riser and the discharge elbow.

27. Position the pump on a wooden block.

28. Separate support column assembly 712 from soleplate 893 or the flange.

29. Remove nuts 920.18.

30. Lift the soleplate with a crane.

31. Disconnect support column assembly 712 with bearing spiders 383.

32. Continue dismantling support column assembly 712.

33. Remove intermediate shaft 212 and pump shaft 211, which are connected bysplit muff coupling 853.

34. Remove bearing sleeves 529, which are radially fastened by grub screws 904,from the shaft.

35. Separate volute casing 102 from discharge cover 161.

36. Remove pump shaft 211 together with impeller 230.

37. Remove spiral wound gasket 411.31.

38. Undo impeller nut 922.

39. Pull off impeller 230 together with gaskets 411.

40. Remove key 940.5, gasket 400.33 and shaft protecting sleeve 524.

41. If bearing bush 545.27 needs to be removed from discharge cover 161, use apuller.

42. Bearing bush 545 of bearing spider 383 can be removed by means of a press.

7.5 Reassembling the pump set

7.5.1 General information/Safety regulations

WARNING

Improper lifting/moving of heavy assemblies or componentsPersonal injury and damage to property!

▷ Use suitable transport devices, lifting equipment and lifting tackle to moveheavy assemblies or components.

CAUTION

Improper reassemblyDamage to the pump!

▷ Reassemble the pump (set) in accordance with the general rules of soundengineering practice.

▷ Use original spare parts only.

Sequence Always reassemble the pump in accordance with the corresponding general assemblydrawing.

Sealing elements ▪ Gaskets

– Always use new gaskets, making sure that they have the same thickness asthe old ones.


48 of 64 RPH-V

– Always fit gaskets of asbestos-free materials or graphite without usinglubricants (e.g. copper grease, graphite paste).

▪ O-rings

– Never use O-rings that have been made by cutting an O-ring cord to size andgluing the ends together.

▪ Packing rings

– Always use pre-compressed packing rings

CAUTION

Contact of O-ring with graphite or similar materialFluid could escape!

▷ Do not coat O-ring with graphite or similar material.

▷ Use animal fats or lubricants based on silicone or PTFE.

▪ Assembly adhesives

– For gaskets, avoid the use of assembly adhesives, if possible.

– If assembly adhesives are required, use a commercially available contactadhesive (e.g. "Pattex").

– Only apply adhesive at selected points and in thin layers.

– Never use quick-setting adhesives (cyanoacrylate adhesives).

– Coat the locating surfaces of the individual components and screwedconnections with graphite or similar before reassembly.

Tightening torques For reassembly, tighten all screws and bolts as specified in this manual.

7.5.2 Underfloor installation / Installing the bearing bracket lantern

1. Fit shaft protecting sleeve 524, gasket 400.33, key 940.5, impeller 230, joint rings411 and impeller nut 922 on pump shaft 211.

NOTE

Always replace gaskets 400 and O-rings 412 with new ones for reassembly.

NOTE

Impeller nut 922 is fastened with a “helicoil” thread insert. For safety reasons KSBrecommends replacing the nut after every 3rd or 4th disassembly.

2. Insert the assembly of pump shaft set 211 into volute casing 102.

3. Insert spiral wound gasket 411.31 into discharge cover 161.

4. In the following order fit support column 712, bearing sleeve 529.21 andbearing spider 383.21.

5. Slide intermediate shaft 212 with inserted segmental rings 501 towards pumpshaft 211 until the two shafts abut each other.

6. Fasten them with split muff coupling 853 and studs 902.22.

7. Mount bearing bracket lantern 344 on soleplate 893 or flange.

8. Position support column 712 and bearing spider 383.15.

9. Fasten them to bearing bracket lantern 344 or support column assembly 712.

10. Connect riser spool 711.2 to the soleplate or flange.

11. Connect pipes 710 to fittings 720.


49 of 64RPH-V

7.5.3 Installing the mechanical seal

ü Utmost caution and cleanliness during installation are decisive for trouble-freeoperation of the mechanical seal.

ü The protective wrapping of the contact faces shall only be removed immediatelybefore assembly takes place.

1. After inserting the mating ring, check that it is plane-parallel in relation to thecasing part. The maximum deviation equals 0.02 mm.

2. The surface of the shaft protecting sleeve must be absolutely clean and smooth,and the sleeve's mounting edge must be chamfered.

3. When sliding the rotating assembly onto the shaft protecting sleeve, takeappropriate steps to protect the surface of the shaft protecting sleeve fromdamage.

4. On pumps with double mechanical seal the mechanical seal chamber must beproperly vented and the required pressure specified in the general arrangementdrawing must be applied (also during standstill). Quench liquid supply must alsobe ensured during pump standstill.

7.5.4 Fitting the packing rings

ü Always use pre-compressed packing rings.

1. Mount shaft protecting sleeve 524.02 (if applicable) on the shaft using grubscrews 904.2.

2. Insert the first packing ring into the stuffing box housing.

3. Insert subsequent packing rings one at a time, with their joints staggered atapproximately 90°. Insert the packing rings along the machined surface of theriser and into the gland packing chamber.

4. Place and adjust riser spool 711.1 position when tightening studs 902.02 and therespective washers and nuts.

7.5.5 Above-floor installation

1. Pull the half of intermediate coupling 848 onto the end of the last intermediateshaft 213.

2. Fit key 940.3, washer 550.11 and bolt 901.11.

3. Heat the bearing and inner spacer ring 504.2 up to 80 °C by means of aninduction heater or in an oil bath.

4. Pull inner spacer ring 504.2 onto centring sleeve 526.

5. Insert lock washer 931.

6. Fit and tighten bearing nut 923. Secure it with the lock washer.

7. Fit oil thrower 508.

8. Fasten the lower bearing cover 360.1 or bearing housing 350 and gasket 400.5to bearing bracket lantern 344.

9. Insert inner spacer ring 504.1 into bearing housing 350.

10. Insert the assembly consisting of spacer sleeve and bearing.

11. Insert drive shaft 213 and key 940.2 into the spacer sleeve.

12. Fasten thrower 507, if applicable, and the bearing guard to the lower bearingcover.

13. Align it with intermediate coupling 848.

14. Secure ring 500.

15. Fit the upper part of the spacer sleeve of the intermediate coupling. Fasten itwith bolts 901.12.

16. Fit gasket 400.3, thrower 507 (if applicable) and bearing guard 423.1.

17. Close the thrust bearing with upper bearing cover 360.

18. Prior to connecting the motor via the coupling, adjust the axial clearance.


50 of 64 RPH-V

19. Adjust the axial clearance between impeller 230 and discharge cover 161 withadjusting nut 923.2.

20. Tighten adjusting nut 923.2 until the impeller abuts the discharge cover.

21. Use a depth gauge to lower the rotor by 2.5 mm with the surfaces of the shaftend and the adjusting nut serving as reference dimensions.

22. Fasten drive lantern 341 in bearing bracket 344 with bolts 901.9.

23. Fit key 940.1 and the lower half of coupling 840 on the shaft. Fasten them witha grub screw.

24. Suspend the pump set by eyebolts 900.2. Place it down on foundation rail 89-8or the pressure vessel nozzle. Fasten it with nuts 920.18.

25. Connect motor 801 via the coupling. Fasten it to drive lantern 341.

NOTE

Pumps with support columns of more than 3 metres length should be assembled inthe well. Observe the sequence described.

7.6 Tightening torques

7.6.1 Tightening torques for the pump

Table 15: Tightening torques [Nm]13)14)

Size Stud (casing) Stud (cover) Hexagon head bolt(bearing bracket)

Stud (seal cover) Impeller nut

Part No.

902.31 901.29 901.3 902.13 922

Material

Steel A193 Gr. B7 SAE 1045 8.8 Steel A193 Gr. B7 AISI 316 AISI 316

25-180 190 120 40 50 80

25-230 190 120 40 50 80

40-180 190 120 40 50 80

40-230 190 120 40 50 80

50-200 385 120 40 50 130

80-200 385 120 40 50 130

40-280 385 120 40 50 130

40-181 385 120 40 50 130

40-231 385 120 40 50 130

40-281 385 120 40 50 130

40-361 385 120 40 50 130

50-180 385 120 40 50 130

13) These values are determined on the basis of a friction coefficient of μ = 0.12.14) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.


51 of 64RPH-V

7.7 Spare parts stock

7.7.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:

▪ Order number

▪ Order item number

▪ Type series

▪ Size

▪ Material variant

▪ Year of construction

Refer to the name plate for all data. (ð Section 4.3, Page 16)

Also specify the following data:

▪ Part number and description (ð Section 9.1, Page 55)

▪ Quantity of spare parts

▪ Shipping address

▪ Mode of dispatch (freight, mail, express freight, air freight)

7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296

Table 16: Recommended spare parts stock for 2 years' operation to DIN 24296

Part No. Description Number of pumps15)

2 3 4 5 6 8 10 or more

211 Pump shaft 1 1 2 2 2 3 30%

212 Intermediate shaft 1 1 2 2 2 3 30%

213 Drive shaft 1 1 2 2 2 3 30%

230 Impeller 1 1 2 2 2 3 30%

321 Radial ball bearing 1 1 2 2 3 4 50%

330 Bearing bracket - - - - - 1 2 pcs.

383 Bearing spider 1 1 2 2 2 3 30%

411.31 Spiral wound gasket 4 6 8 8 9 12 150%

423 Bearing guard 1 1 2 2 3 4 50%

433 Mechanical seal 1 1 1 2 2 2 20%

461 Packing rings 1 1 1 2 2 2 20%

502 Casing wear ring 2 2 2 3 3 4 50%

503 Impeller wear ring 2 2 2 3 3 4 50%

524 Shaft protecting sleeve 1 1 1 2 2 2 20%

529 Bearing sleeve 1 1 2 2 3 4 50%

545 Bearing bush 1 1 2 2 3 4 50%

840 Coupling 1 1 2 2 2 3 30%

- Gaskets and O-rings 4 6 8 8 9 12 150%

15) Including stand-by pumps


52 of 64 RPH-V

7.7.3 Interchangeability of pump components

Components featuring the same number in a column are interchangeable.

Size

Vo

lute

cas

ing

Suct

ion

str

ain

er

Cas

ing

co

ver

Pum

p s

haf

t

Inte

rmed

iate

sh

aft

Dri

ve s

haf

t

Imp

elle

r

Rad

ial b

all b

eari

ng

Bea

rin

g b

rack

et la

nte

rn

Bea

rin

g h

ou

sin

g

Bea

rin

g c

ove

r

Bea

rin

g s

pid

er

Bea

rin

g s

pid

er

Spir

al w

ou

nd

gas

ket

Bea

rin

g g

uar

d

Bea

rin

g g

uar

d

Mec

han

ical

sea

l

Pack

ing

rin

gs

Cas

ing

wea

r ri

ng

, su

ctio

n s

ide

Cas

ing

wea

r ri

ng

, dis

char

ge

sid

e

Imp

elle

r w

ear

rin

g, s

uct

ion

sid

e

Imp

elle

r w

ear

rin

g, d

isch

arg

e si

de

Shaf

t p

rote

ctin

g s

leev

e

Inte

rmed

iate

co

up

ling

Split

mu

ff c

ou

plin

g

Imp

elle

r n

ut

Key

Key

Part No.

102

143

161

211

212

213

230

321

344

350

360

383.

15

383.

21

411.

31

423.

1

423.

2

433

461

502.

1

502.

2

503.

1

503.

2

524

848

853

922

940.

5

940.

1

25-180 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1

25-230 2 1 2 1 1 1 2 1 1 1 1 1 1 2 1 2 1 2 1 1 1 1 1 1 1 1 1 1

40-180 3 2 1 1 1 1 3 1 1 1 1 1 1 1 1 2 1 1 2 2 2 2 1 1 1 1 1 1

40-230 4 2 2 1 1 1 4 1 1 1 1 1 1 2 1 2 1 1 2 2 2 2 1 1 1 1 1 1

50-200 5 3 3 1 1 1 5 1 1 1 1 1 1 3 1 2 1 1 3 8 3 8 1 1 1 1 1 1

80-200 6 4 4 1 1 1 6 1 1 1 1 1 1 3 1 2 1 3 4 6 4 6 1 1 1 1 1 1

40-280 7 2 5 2 1 1 7 1 1 1 1 1 1 4 1 2 1 1 5 7 5 7 2 1 1 2 2 1

40-181 8 2 1 2 1 1 8 1 1 1 1 1 1 1 1 2 1 1 6 6 6 6 2 1 1 2 2 1

40-231 9 2 2 2 1 1 9 1 1 1 1 1 1 2 1 2 1 1 6 6 6 6 2 1 1 2 2 1

40-281 10 2 5 2 1 1 10 1 1 1 1 1 1 4 1 2 1 1 6 7 6 7 2 1 1 2 2 1

40-361 11 2 6 2 1 1 11 1 1 1 1 1 1 5 1 2 1 1 6 9 6 9 2 1 1 2 2 1

50-180 12 3 1 2 1 1 12 1 1 1 1 1 1 1 1 2 1 1 7 7 7 7 2 1 1 2 2 1

8 Trouble-shooting

53 of 64RPH-V

8 Trouble-shooting

WARNING

Improper work to remedy faultsRisk of injury!

▷ For any work to remedy faults observe the relevant information in this manualor in the relevant accessory manufacturer's product literature.

If problems occur that are not described in the following table, consultation with theKSB customer service is required.

A Pump delivers insufficient flow rate

B Motor is overloaded

C Excessive discharge pressure

D Increased bearing temperature

E Leakage at the pump

F Excessive leakage at the shaft seal

G Vibrations during pump operation

H Impermissible temperature increase in the pump

Table 17: Trouble-shooting

A B C D E F G H Possible cause Remedy16)

✘ - - - - - - - Pump delivers against an excessivelyhigh pressure.

Re-adjust to duty point.

✘ - - - - - - - Excessively high back pressure Check system for impurities.Increase the speed (turbine, I.C. engine)

✘ - - - - - ✘ ✘ Pump or piping are not completelyvented 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.

- - - ✘ - ✘ ✘ - Pump is warped or sympatheticvibrations in the piping.

Check pipeline connection and secure fixing ofpump.If required, reduce the distance between thepipe clamps.Fix the pipelines using anti-vibration material.

✘ - - - - - ✘ ✘ Suction lift is too high/NPSHavailable

(positive suction head) is too low.Check/alter fluid level.Fully open the shut-off element in the suctionline.Change suction line, if the friction losses in thesuction line are too high.Check any strainers installed/suction opening.Observe permissible speed of pressure fall.

- - - ✘ - - - - Increased axial thrust Correct the rotor adjustment.

✘ - - - - - - - Air intake at the shaft seal Fit new shaft seal.

✘ - - - - - - - Wrong direction of rotation Check the electrical connection of the motorand the control system, if any.

✘ ✘ - - - - - - Motor is running on 2 phases only. Replace the defective fuse.Check the electric cable connections.

✘ - - - - - - - Speed is too low. Increase speed.

- - - - - - ✘ - Defective bearings Replace bearing(s).

- - - ✘ - - ✘ ✘ Flow rate is too low. Increase the minimum flow rate.

✘ - - - - - ✘ - Wear of internal components Replace worn components by new ones.

16) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.

8 Trouble-shooting

54 of 64 RPH-V

A B C D E F G H Possible cause Remedy16)

- ✘ - - - - ✘ - Pump back pressure is lower thanspecified in the purchase order.

Re-adjust to duty point.

- ✘ - - - - - - Density or viscosity of fluid handledhigher than stated in purchase order

Contact the manufacturer.

- ✘ - - - ✘ - - Use of unsuitable materials Change the material combination.

- ✘ ✘ - - - - - Speed is too high. Reduce speed.

- - - - ✘ - - - Tie bolts worked loose / sealingelements worn

Re-tighten bolts. Fit new sealing elements.

- - - - - ✘ - - Worn shaft seal Fit new shaft seal.Check flushing liquid/barrier fluid.

✘ - - - - ✘ - - Score marks or roughness on shaftprotecting sleeve.

Replace the shaft protecting sleeve.Replace the shaft seal.Check the balancing line.Check the throttling bush and its clearances.

- - - - - ✘ - - Lack of cooling liquid or dirty coolingchamber

Increase cooling liquid quantity.Clean out cooling chamber.Purify/clean cooling liquid.

- - - - - ✘ - - Vibrations during pump operation Improve the suction conditions.Re-align the pump set.Re-balance the impeller.Increase pressure at the pump suction nozzle.

- - - ✘ - ✘ ✘ - The pump set is misaligned. Check the coupling and re-align it, if required.

- - - ✘ - - ✘ - Insufficient or excessive quantity oflubricant or unsuitable lubricant.

Top up, reduce or change lubricant.

- - - ✘ - - - - Non-compliance with specifiedcoupling distance

Correct the distance according to generalarrangement drawing.

- ✘ - - - - - - Operating voltage is too low. Increase the voltage.

- - - - - - ✘ - Rotor out of balance Clean the impeller.Re-balance the impeller.

9 Related Documents

55 of 64RPH-V

9 Related Documents

9.1 General assembly drawings with list of components

9.1.1 General assembly drawing, discharge side

720.19720.15

710.20720.20

920.17902.17

461

902.19550.19920.20

893

900.2

900.1681.2

940.3

720.18711.1

720.16550.16920.16901.16411.16720.17

344901.11

550.11

914.11500

550.9920.9901.9

642720.5710.5638

901.5350

360

901.3

904.3508

914.3924

341

900.1681.1

840

529.15904.15

545.15

901.15

383.15

89-8920.18902.18

916.15

400.17

433

902.13920.13

848901.12

901.7

423.2

641

400.5

504.1

504.2526

321

940.2

400.3

916.3423.1

213

940.01

801

902.1920.1550.1

923.1931.1

710.7916.7720.7

400.18

9 Related Documents

56 of 64 RPH-V

Table 18: List of components

Part No. Description Part No. Description

213 Drive shaft 681.1/.2 Coupling guard

321 Radial ball bearing 710.5/.7/.20 Pipe

341 Drive lantern 711.1 Riser spool

344 Bearing bracket lantern 720.5/.7/.15/.16/.17/.18/.19/.20

Fitting

350 Bearing housing 801 Flanged motor

360 Bearing cover 840 Coupling

383.15 Bearing spider 848 Intermediate coupling

400.3/.5/.16/.17/.18 Gasket 893 Soleplate

423.1/.2 Labyrinth ring 89-8 Foundation rail

433 Mechanical seal 900.1/.2 Screw

461 Packing rings 901.3/.5/.7/.9/.11/.12/.15/.16 Hexagon head bolt

500 Ring 902.1/.13/.17/.18/.19 Stud

504.1/.2 Spacer ring 904.3/.15 Grub screw

508 Oil thrower 914.3/.11 Hexagon socket head capscrew

526 Centring sleeve 916.3/.7/.15 Plug

529.15 Bearing sleeve 920.1/.9/.13/.16/.17/.18/.20 Nut

545.15 Bearing bush 923.1 Bearing nut

550.1/.9/.11/.16/.19 Disc 924 Adjusting nut

638 Constant level oiler 931.1 Lock washer

641 Oil level pipe 940.1/.2/.3 Key

642 Oil level sight glass

9 Related Documents

57 of 64RPH-V

9.1.2 General assembly drawing, suction side

550.33920.33901.33

400.33

901.31

524

211

529.21

710.22720.22

720.21

545.21

940.4

914.21

853

212

711.2

550.21920.21901.21

940.5

102

400.33

411.31

916.27

902.31920.31

161

901.29

904.27

712.2

916.21

383.21

904.21

501

902.22920.22

712.1

230400.35931.2

400.37922915

545.27

502

503143

901.35920.35



102 Volute casing 710.22 Pipe

143 Suction strainer 711.2 Riser

161 Casing cover 712.1/.2 Support column

211 Pump shaft 720.21/.22 Fitting

212 Intermediate shaft 853 Split muff coupling

230 Impeller 901.21/.29/.31/.33/.35 Hexagon head bolt

383.21 Bearing spider 902.22/.31 Stud

400.33/.35/.37 Gasket 904.21/.27 Grub screw

9 Related Documents

58 of 64 RPH-V


411.31 Spiral wound gasket 914.21 Hexagon socket head capscrew

501 Segmental ring 915 Threaded insert

502 Casing wear ring 916.21/.27 Plug

503 Impeller wear ring 920.21/.22/.31/.33/.35 Nut

524 Shaft protecting sleeve 922 Impeller nut

529.21 Bearing sleeve 931.2 Lock washer

545.21/.27 Bearing bush 940.4/.5 Key

550.21/.33 Disc

9.1.3 Detailed view of the bearing housing

507.2

904.22

423.2

423.1

904.21

507.1

Fig. 10: Detailed view: bearing housing with grease-lubricated bearing and throwers /labyrinth rings


Part No. Description

423.1/.2 Labyrinth ring

507.1/.2 Thrower

904.21/.22 Grub screw

10 EU Declaration of Conformity

59 of 64RPH-V

10 EU Declaration of Conformity

Manufacturer: KSB Bombas Hidráulicas S.ARua José Rabello Portella, 638

CEP: 13.220-540 - Jardim Maria de FátimaVárzea Paulista (Brazil)

The manufacturer herewith declares that the product:

RPH-V

KSB order number: ...................................................................................................

▪ is in conformity with the provisions of the following Directives as amended from time to time:

– Pump (set): 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:

Dr. Norbert KastrupHead of Product DevelopmentCorporate Unit Pumps KSB SE & Co. KGaABahnhofplatz 1 91257 Pegnitz (Germany)

The EU Declaration of Conformity was issued in/on:

Place, date

..............................17).............................

Name

Function

CompanyAddress

17) A signed, legally binding EU Declaration of Conformity is supplied with the product.

11 Certificate of Decontamination

60 of 64 RPH-V

11 Certificate of Decontamination

Type: ................................................................................................................................

Order number/

Order item number18): ................................................................................................................................

Delivery date: ................................................................................................................................

Field of application: ................................................................................................................................

Fluid handled18): ................................................................................................................................

Please tick where applicable18):

⃞ ⃞ ⃞ ⃞Radioactive Explosive Corrosive Toxic

⃞ ⃞ ⃞ ⃞Harmful Bio-hazardous Highly flammable Safe

Reason for return18): ................................................................................................................................

Comments: ................................................................................................................................

................................................................................................................................

The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/placing at your disposal.

We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.

For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has beenremoved from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern,leakage barrier and bearing bracket or intermediate piece have also been cleaned.

For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage atthe stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it hasbeen removed.

⃞ No special safety precautions are required for further handling.

⃞ The following safety precautions are required for flushing fluids, fluid residues and disposal:

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We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with therelevant legal provisions.

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Place, date and signature Address Company stamp

18) Required fields

Index

61 of 64RPH-V

Index

AAbrasive fluids 37

Applications 9

Auxiliary connections 26

BBearing temperature 41

Bearings 17

CCertificate of decontamination 60

Clearances 42

Commissioning 30

Configuration 18

Constant level oiler 30

Contact guard 20

Coupling 20, 41

DDesign 17

Designation 16

Direction of rotation 17, 29

Dismantling 45

Disposal 15

Drive 17

EEvent of damage

Ordering spare parts 51

Explosion protection 11, 21, 26, 28, 29, 32, 33, 34, 35,36, 39, 40, 41, 43

FFaults

Causes and remedies 53

Final check 32

Flow rate 36Fluid handled

Density 37

Frequency of starts 36

Function 18

IImpeller type 17

Installation at site 21

Intended use 9

Interchangeability of pump components 52

MMaintenance 40

Mechanical seal 34

Misuse 9

Monitoring equipment 11

NName plate 16

Noise characteristics 19

OOil lubrication

Intervals 43Oil quality 43

Operating limits 35

Order number 6

Other applicable documents 6

PPartly completed machinery 6

Preservation 14, 37

Priming and venting 32

Product description 16

Pump casing 17

RReturn to supplier 14

Returning to service 38

Running noises 40, 41

SSafety 8

Safety awareness 10

Scope of supply 20

Shaft guide bearings 17

Shaft seal 17

Shutdown 34, 37

Soleplate 20Spare part

Ordering spare parts 51

Start-up 34

Storage 14, 37

TTemperature limits 11

Transport 13

WWater cooling 33

KSB Bombas Hidráulicas S/A

Rua José Rabello Portella, 638

CEP: 13.220-540 - Jardim Maria de Fátima

Várzea Paulista (Brasil)

Tel.: +55 11 4596 8500 • Fax Fax: +55 11 4596 8580

www.ksb.com

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