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7/25/2019 a - Index & OIM

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Contents OIM Pages 3 1 / 7

CONTENTSDESCRIPTION PAGE REFERENCE

Chapter : General OIMPG General 1

1. General Information OIMPG General 2

2. Disposal OIMPG General 3

3. Conformity with EU Regulations (if applicable) OIMPG General 3

Chapter : SafetyMarking of Instructions in the Instruction Manual OIMPG Safety 1

Personnel Qualification and Training OIMPG Safety 1

Non-compliance with Safety Instructions OIMPG Safety 1

Safety Awareness OIMPG Safety 1

Safety Instructions for the Operator/User OIMPG Safety 1Safety Instructions for Work on the Pump Set OIMPG Safety 2

Unauthorized Modification and Manufacture of Spare Parts OIMPG Safety 2

Unauthorized Modes of Operation OIMPG Safety 2

Chapter : Transport / Interim Storage1. General Information OIMPG TRANSPORT 1

1.1 Hoisting Tackle (e.g. ropes, gear) OIMPG TRANSPORT 1

1.2 Signals during Transport OIMPG TRANSPORT 1

1.3 Transport Symbols OIMPG TRANSPORT 2

2. Transport of the Packaged Components of the Pump Set OIMPG TRANSPORT 2

3. Transport of the Partly-packaged or Unpackaged Components OIMPG TRANSPORT 2

of the Pump Set3.1 Transport of Pump Set OIMPG TRANSPORT 3

3.2 Transport of the Pump OIMPG TRANSPORT 4

3.3 Transport of the Other Pump Set Components OIMPG TRANSPORT 5

3.4 Transport of Pump Rotor OIMPG TRANSPORT 5

3.5 Transport of Pump Set Accessories OIMPG TRANSPORT 6

4 Interim Storage OIMPG TRANSPORT 7

4.1 Prerequisites OIMPG TRANSPORT 7

4.2 Place of Storage OIMPG TRANSPORT 7

4.3 Period of Storage up to 12 Months OIMPG TRANSPORT 7

4.4 Period of Storage over 12 Months OIMPG TRANSPORT 7

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DESCRIPTION PAGE REFERENCE

Chapter : Installation on SiteConditions Installation 1

Foundation Installation 1

Site management Installation 1

Place of Installation Installation 1

Drive way to the Place of Installation Installation 1

Adequate means of Transport Installation 1

Preparations Installation 1

Checking the Foundation Installation 1

Correct deviating foundation dimensions Installation 1

Transporting the Pump Set Components to the Place of Installation Installation 1

Removal of Packaging Installation 2

Protecting the Pump Set Components Installation 2

Procedure for leveling and grouting of Base Frame at Site GEN 02.01 I

Making the Piping Installation 3

Cleaning the Piping Installation 3

Connecting the Piping Installation 4

Information about Readiness for connecting of the Piping Installation 4

Checking the Alignment Installation 4

Mounting the Instruments Installation 4

Detailed description of Preservation for Standstill Installation 4

Detailed description of Mounting/dismounting the Connecting Coupling Installation 5

General Information Installation 5

Mounting Installation 5

Dismantling Installation 6

Detailed Description of Connecting Coupling Alignment Installation 8

1. Conditions Installation 8

2. Preparations Installation 8

3. Runout Check of the Coupling Hubs Installation 8

4. Alignment of Coupling Installation 9

5. Alignment Corrections Installation 10

6. Pinning the Feet Installation 12

Cladding (touch guard) for the Shaft Seal Installation 13

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Chapter : Commissioning, Start-up/Shutdown

1. Work to be carried out prior to Commissioning, Start-up OIMPG COMM 31

1.2 General Information OIMPG COMM 31

1.3 Removal of Preservation OIMPG COMM 31

1.4 Additional Work to be carried out Prior to returning to Service after OIMPG COMM 31

Standstill > 12 Months1.5 Topping up the Bearings with Lubricating Oil OIMPG COMM 31

1.5.1 General Information OIMPG COMM 31

1.5.2 Bearing with Oil Sight Gauge OIMPG COMM 31

1.5.3 Lift-off Device (if applicable) OIMPG COMM 32

1.5.4 Bearing wit Constant Level Oiler OIMPG COMM 32

1.5.5 Other Accessories OIMPG COMM 32

1.6 Checking the Direction of Rotation OIMPG COMM 32

1.6.1 Prerequisites OIMPG COMM 33

1.6.2 Direction of Rotation OIMPG COMM 33

1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator OIMPG COMM 33

1.6.4 Checking the Direction of Rotation without a Phase-sequence Indicator OIMPG COMM 33

1.7 Rotatability of the pump Rotor OIMPG COMM 34

1.8 Mounting the Connecting Coupling OIMPG COMM 34

1.9 Mounting Guards Preventing Accidental Contact OIMPG COMM 34

1.10 Functional Test and Adjustment of the Instruments OIMPG COMM 34

2. Commissioning, Start-up OIMPG COMM 35

2.1 Prerequisites OIMPG COMM 35

2.2 Priming OIMPG COMM 35

2.3 Checks Prior to Starting OIMPG COMM 36

2.4 Starting and Trial Run OIMPG COMM 36

3. Shutdown OIMPG COMM 37

3.1 Pump Set remains Ready for Operation OIMPG COMM 37

3.2 For Maintenance of the Pump Set or Prolonged Standstill OIMPG COMM 37

4. Work after Shutdown OIMPG COMM 38

4.1 During Readiness for Instant Start-up OIMPG COMM 38

4.2 For Maintenance of the Pump Set OIMPG COMM 38

4.3 Standstill, Pump not ready for Operation OIMPG COMM 39

5. Detailed description of Preservation for Standstill OIMPG COMM 39

Chapter : Pump Supervision Plan OIMPG SUPERVISION 06

Supervision of Rotor Position (only for the pumps with Balancing Disc) OIMPG SUPERVISION 02

Supervision of Rotor Position (only for the pumps with Balancing Disc) OIMPG SUPERVISION 03

Log Sheet

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Chapter : Servicing OIMPG SERVICING 01

1. General Information OIMPG SERVICING 01

1.2 Requirement of Documentation OIMPG SERVICING 01

1.3 Prerequisites OIMPG SERVICING 01

1.4 Service Intervals OIMPG SERVICING 01

2. Dismantling the Guards Preventing Accidental Contact OIMPG SERVICING 01

3. Pump Servicing Plan OIMPG SERVICING 02

4. Servicing Work OIMPG SERVICING 03

4.1 Oil Changes OIMPG SERVICING 03

4.2 Re-lubrication OIMPG SERVICING 04

Chapter : Maintenance OIMPG MAINTENANCE 01

1. General Information OIMPG MAINTENANCE 01

1.2 Required Documentation OIMPG MAINTENANCE 01

1.3 Prerequisites OIMPG MAINTENANCE 01

2. Dismantling the Guards Preventing Accidental Contact OIMPG MAINTENANCE 01

2.1 Sound Insulation Hood OIMPG MAINTENANCE 01

2.2 Coupling Guard/Cover OIMPG MAINTENANCE 01

2.3 Guard Preventing Accidental Contact for Shaft Seal OIMPG MAINTENANCE 02

3. Dismantling the Connecting Coupling OIMPG MAINTENANCE 02

3.2 Removing the Coupling Hubs OIMPG MAINTENANCE 02

3.3 Run-out Check of the Shaft Ends OIMPG MAINTENANCE 03

4. Removing the Pump from the Installation OIMPG MAINTENANCE 03

4.1 Dismantling the Piping and Instruments OIMPG MAINTENANCE 03

4.2 Removing the Pump from Baseframe OIMPG MAINTENANCE 04

4.3 Transporting the Pump to the Place of Dismantling OIMPG MAINTENANCE 05

5. Dismantling the Bearings OIMPG MAINTENANCE 06

5.1 Preparations OIMPG MAINTENANCE 06

5.2 Dismantling the Add-on Parts OIMPG MAINTENANCE 06

5.3 Dismantling the Lift-off Device, with Antifriction Bearings OIMPG MAINTENANCE 06

5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing OIMPG MAINTENANCE 06

5.5 Dismantling the Thrust Bearing OIMPG MAINTENANCE 06

5.6 Dismantling the Radial Bearings OIMPG MAINTENANCE 07

5.6.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 07

5.6.2 HG Pump Sizes 3 to 6 OIMPG MAINTENANCE 07

5.7 Dismantling the Bearing Housings OIMPG MAINTENANCE 08


5.7.2 HG Pump size 3 OIMPG MAINTENANCE 08


6. Dismantling the Shaft Seal OIMPG MAINTENANCE 13

6.1 Preparations OIMPG MAINTENANCE 13

6.2 Dismantling the Mechanical Seal OIMPG MAINTENANCE 13

6.2.1 Make : Eagle Poonawalla OIMPG MAINTENANCE 13

6.2.2 Make : Flowserve Sanmar OIMPG MAINTENANCE 13

6.2.3 Make : Burgmann OIMPG MAINTENANCE 14

6.3 Dismantling the Casing Parts OIMPG MAINTENANCE 14

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7. Dismantling the Balancing Device OIMPG MAINTENANCE 26

7.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 26

7.2 HG Pump Size 3 OIMPG MAINTENANCE 26



7.4 Measuring the Approximate Radial Clearance OIMPG MAINTENANCE 26

8. General Information on Reassembly OIMPG MAINTENANCE 27

9. Checking the Balancing Device with Contact Fluid OIMPG MAINTENANCE 27

9.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 27OIMPG MAINTENANCE 28


OIMPG MAINTENANCE 30

9.3 HG Pump Sizes 4 OIMPG MAINTENANCE 31



OIMPG MAINTENANCE 34OIMPG MAINTENANCE 35

10. Mounting the Balancing Device OIMPG MAINTENANCE 36






11. Mounting the Shaft Seal OIMPG MAINTENANCE 40

11.1 Mounting the Housing Components OIMPG MAINTENANCE 40



11.2 Assembling the Shaft Seal OIMPG MAINTENANCE 40

11.2.1 Make Eagle Poonawalla OIMPG MAINTENANCE 40

11.2.2 Make : Flowserve Sanmar OIMPG MAINTENANCE 40

11.2.3 Make : Burgmann OIMPG MAINTENANCE 40

12. Mounting the Bearings OIMPG MAINTENANCE 43

12.1 Mounting the Bearing Housings and Lifting the Pump Rotor OIMPG MAINTENANCE 43



12.2 Mounting the Radial Bearings OIMPG MAINTENANCE 44



12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings OIMPG MAINTENANCE 45

12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Bearing OIMPG MAINTENANCE 46

12.5 Mounting the Thrust Bearing (if applicable) OIMPG MAINTENANCE 47OIMPG MAINTENANCE 48

13. Mounting the Piping and Instruments OIMPG MAINTENANCE 49

14. Mounting the Connecting Coupling OIMPG MAINTENANCE 49

14.1 Fitting the Coupling Hubs OIMPG MAINTENANCE 49OIMPG MAINTENANCE 50

14.2 Aligning the Connecting Coupling OIMPG MAINTENANCE 51

14.3 Mounting the Coupling Connections OIMPG MAINTENANCE 51

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15. Mounting the Guards Preventing Accidental Contact OIMPG MAINTENANCE 51

15.1 Coupling Guard OIMPG MAINTENANCE 51

15.2 Coupling Cover OIMPG MAINTENANCE 51

15.3 Guard Preventing Accidental Contact for Shaft seal OIMPG MAINTENANCE 52

15.4 Sound Insulating Hood OIMPG MAINTENANCE 52

16. Maintenance of the Other Pump Set Components OIMPG MAINTENANCE 52

16.1 Maintenance of Connecting coupling OIMPG MAINTENANCE 52

16.2 Maintenance of Drive OIMPG MAINTENANCE 52

16.3 Maintenance of Minimum Flow System OIMPG MAINTENANCE 53

16.4 Maintenance of Instruments and Valves OIMPG MAINTENANCE 53

16.5 Maintenance of Oil Supply Unit, etc. (if applicable) OIMPG MAINTENANCE 53

16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable) OIMPG MAINTENANCE 53

17. Spare Parts OIMPG MAINTENANCE 5317.1 Ordering Spare Parts OIMPG MAINTENANCE 53

17.2 Spare Parts Stock OIMPG MAINTENANCE 53

17.3 Storage OIMPG MAINTENANCE 53

Chapter : Trouble Shooting OIMPG TROUBLE-SHOOTING 1

1. General Information OIMPG TROUBLE-SHOOTING 1

1.2 Requisite Documentation OIMPG TROUBLE-SHOOTING 1

1.3 Prerequisites OIMPG TROUBLE-SHOOTING 1

Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 2

Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 3Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 4



Chapter : Tables of ClearancesAntifriction BearingsDiametrical Clearance : Balancing Device OIMPG CLEAR AF 1

Theoretical Axial Clearance OIMPG CLEAR AF 2

Plane BearingsDiametrical Clearance : Balancing Device OIMPG CLEAR AF 1

Theoretical Axial Clearance OIMPG CLEAR AF 2

Bearing Clearance OIMPG CLEAR PLANE 1Plane Bearings, HeavyTheoretical Axial Clearance OIMPG CLEAR AF 2

Bearing Clearance OIMPG CLEAR PLANE H1

Diametrical Clearance : Balancing Device OIMPG CLEAR PLANE H1

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Chapter : Table of Tightening Torque1. Prerequisites OIMPG TIGHT TRQ 1

2. Pump OIMPG TIGHT TRQ 1

3. Fastening of Pump Feet OIMPG TIGHT TRQ 1

4. Flange Connections OIMPG TIGHT TRQ 1

Bolts for Flange Connection, Discharge Nozzle and Tapping OIMPG TIGHT TRQ 2

Nozzle; Flanges as per DIN Bolts for Flange Connection, Discharge Nozzle and Tapping OIMPG TIGHT TRQ 3

Nozzle; Flanges as per ANSI Bolts for Flange Connection, Suction Nozzle OIMPG TIGHT TRQ 4

Chapter : Table of WeightsHG Pump Size 1 OIMPG WEIGHT 1

HG Pump Size 2 OIMPG WEIGHT 2





Technical Data

Technical Appendix

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OIMPG General 1

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General

Non-compliance with the regulations laid down in the instruction manualleads to forfeiture of any and all rights to claim for damages.

All work on the pump set must only be performed by properly trainedpersonnel who are familiar with the dismantling/reasembly work required.

This instruction manual must always be kept close to the location of

operation of the pump set for easy access.

We recommend to call in KSB’s experienced personnel for installation,commissioning/start-up, maintenance, and in case of problems.

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OIMPG General 2

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1. General InformationThis instruction manual contains fundamental information which must be complied with during work on thepump set.Therefore this instruction manual must be read both by the service engineers and responsible trainedpersonnel, prior to commencement of work. All users must not only comply with the general safety instructions laid down in the chapter on “Safety”, but alsothe specific safety instructions included elsewhere in the instruction manual.

KSB pumps are developed in accordance with state-of-the-art technology, are manufactured with utmost careand are subjected to continuous quality control. If they are properly installed, serviced and maintained, thepumps will give reliable and trouble-free operation.

We recommend to call our specialist personnel for installation and commissioning/start-up. KSB will onlyassume responsibility for faultless execution of the work and for the safety of the personnel involved if dismantling/reassembly and maintenance have been performed by KSB’s specialist personnel.

This pump set must not be operated beyond the limit values specified in the data sheets. Make sure that theoperation in accordance with the instructions laid down in this manual. The operator must take into account theinformation given in Technical Appendix, or in other parts of the instruction manual or in the contractdocumentation.

It is of vital importance to observe the specified electrical connection values as well as thedismantling/reassembly and servicing instructions. In particular, it must be ensured that all necessary measuresare taken and the regulations in accordance with the relevant legislation are complied with. ________________________________________________________________________________________

Caution The temperature of the medium handled must not exceed the values

indicated on the pump name plate. ________________________________________________________________________________________ ________________________________________________________________________________________

Operation of the pump set outside the conditions mentioned above

! may lead to overloads which, in turn, may result in personal injury anddamage to property.

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The descriptions and instructions set forth in this instruction manual refer to KSB’s scope of supply (e.g. pumpor pump set). This instruction manual does not cover all possible eventualities or events which might occur during installation, maintenance, servicing and operation of the machine.

Neither does the instruction manual take into account any safety regulations applicable at the place of installation; the Operator must ensure that such regulations are strictly observed by all, including the personnelcalled in for execution of the work.

Instructions on labels, tags and stickers attached to the pump set must be observed.

The pump name plate indicates the main data; please quote this information in allqueries, repeat orders and particularly when ordering spare parts.

If you need any additional information or instructions exceeding the scope of this instruction manual, pleasecontact KSB’s nearest customer service centre.

In case of problems please contact your nearest customer service centre or the manufacturing works.

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OIMPG General 3

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Prior to returning any pump set components, carefully follow the

! instructions given in the Disposal section and in the chapter on

‘Commissioning, Start-up/Shut-down’ to avoid any risks (e.g. thoseposed by residues of the medium handled in the pump).

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____________________________________________________________________________

Caution All measuring instruments supplied with the pump should be

calibrated before commissioning of the pump set. ____________________________________________________________________________

Set points of the instruments, wherever conveyed through operating instruction manual, are only as guideline, and

final values are to be set on the site as per observations and requirements.

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Caution The pump should never be run below the speed of 1000 rpm (higher

limit in case of mechanical seals with pumping ring), even during thestarting process. The acceleration time from switch on (zero rpm) to1000 rpm should be less than 10 seconds. Specific care is necessaryfor the pumps with variable frequency drive & pumps with hydrauliccoupling.

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2. Disposal According to the local anti-pollution regulations- packaging components must be disposed of by the consignee- lubricants no longer used, cleaning material, media handled, electric equipment, etc. must be disposed

of by the Operator at their own expense.

3. Conformity with EU Regulations (if applicable)The relevant declaration as defined in EU Directive “Machinery” (89/292/EEC) is enclosed separately.

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OIMPG Safety 1

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Safety

Marking of Instructions in the Instruction ManualThe safety instructions contained in this instruction manual which must be observed without fail to avoidhazards to persons are specially marked with the general hazard sign, namely

The electrical danger warning sign is

The word

is used to introduce safety instructions which must be observed to avoid damage to the pump set and itsfunctions.Instructions attached directly to the pump set, e.g.- the arrow indicating the direction of rotation- markings for fluid connections and safety instructionsmust always be complied with and be kept in perfectly legible condition at all times.

Personnel Qualification and Training All personnel involved in the work to be performed on the pump set must be fully qualified to carry out thework involved. Personnel responsibilities, competence and supervision must be clearly defined by theOperator. If the personnel in question is not already in possession of the requisite know-how, appropriatetraining and instruction must be provided. If required, the Operator may commission the manufacturer/supplier to take care of such training. In addition the Operator is responsible for ensuring that the contentsof the instruction manual are fully understood by his personnel.

Non-compliance with Safety InstructionsNon-compliance with safety instructions can jeopardize the safety of the personnel, the environment andthe pump set itself. Moreover non-compliance with these safety instructions may lead to forfeiture of anyand all rights to claims for damages.

In particular, non-compliance can, for example, result in:- failure of important pump set functions- hazard to persons by electrical, mechanical, chemical and thermal effects- hazard to the environment caused by leakage of hazardous substances.

Safety AwarenessIt is imperative to comply with safety instructions contained in this manual, the relevant national health andsafety regulations, and the Operator’s own internal work, operation and safety regulations, if any.

Safety Instructions for the Operator/User Any hot or cold components of the pump set that could pose a hazard must be equipped with a guardpreventing accidental contact by the Operator.Guards which are fitted to prevent accidental contact with moving parts must not be removed whilst thepump set is operating.Leakages (e.g. at the shaft seal) of hazardous media handled must be contained so as to avoid any hazard to personsand the environment caused by hot, toxic or explosive media. Pertinent legal provisions must be

Caution

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OIMPG Safety 2

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adhered to. Any electrical hazard must be eliminated. For details, please refer to the relevant safety regulations of theindividual countries or the local energy supply companies.

The Operator must ensure that the pumps can be cooled down to a temperature below 50 0C anddepressurized prior to any work on the pump set. The drives must have been disconnected from theirenergy supply (e.g. electrical power system, steam or fuel supply system) and secured so as to preventunintentional starting.

Safety Instructions for Work on the Pump SetThe operator is responsible for ensuring that all work on the pump set performed by authorized, qualifiedpersonnel who are thoroughly familiar with the contents of the instruction manual.Work on the pump set must be carried out only during standstill and after the pump or pump set has cooleddown to a temperature below 50

0C. The shut down procedure described in the instruction manual for

taking the pump set out of service must be adhered to without fail. Pump set components in contact with

media injurious to health or harmful to the environment must be decontaminated by the Operator inaccordance with the applicable local regulations. Immediately following completion of the work, all safety-relevant and protective devices must be re-installed or re-activated.Please observe all instructions set out in chapter on ‘Commissioning, Start-up/Shutdown’ before returningthe pump set to service.

Unauthorized Modification and Manufacture of Spare Parts Any modifications or alterations of the pump set are permitted only after consultation with and approval bythe manufacturer. Original spare parts and accessories authorized by the manufacturer ensure safety. Theuse of other parts invalidates any liability of the manufacturer for damage resulting thereof.

Unauthorized Modes of OperationThe warranty relating to the operating reliability and safety of the supplied pump set is only valid if it is usedin accordance with its designated use and if all operating instructions described in chapter ‘General’ of theinstruction manual have been followed.The limits stated in data sheets must neither be exceeded nor underrun under any circumstances.Deviations require prior consultation with KSB.

Markings Lifting links

All lifting links are marked with the chain symbol.

Temperature > 800C/176

0F

It is imperative to observe the information plate on the pump.

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Transport / Interim Storage

1. General Information

Check the load carrying capacity of the floor (consult the building drawing) before

Caution starting with the transport and hoisting work. Above all give due attention to the

position of the centre of gravity.

Observe the applicable local safety regulations.

Loose parts must be fastened so as to prevent them from falling down.

If a crane is used, check the brake of the hoisting gear by trial braking

under load.After fastening the ropes, align the crane hook in such a manner thatthe crane hoisting ropes are suspended vertically.

Loads must be lifted at a right angle to the drum axis of the ropewinch. Loads must not be lifted at an angle.

Keep the period of tome for which the load is in free suspension to a

minimum.

Use a guide rope in addition if long objects are handled.

Transport of persons together with load is not permitted.

Keep out of the danger area. Work under suspended loads is notpermitted.

The permissible lifting capacity of the lifting equipment must not beexceeded.

Lower the loads at the lowest lowering speed of the hoist.

1.1 Hoisting Tackle (e.g. ropes, gear)1.1.1 To determine the lifting capacity, give due consideration to the position of the center of

gravity, the angle of spread and bending radii of the lifting links attached to the load to be

lifted.1.1.2 Do not use chains, if possible.

Hoisting tackle, and any transport device that might be required, must

only be attached in accordance with section 2 and 3 in this chapter.

Damaged or untested hoisting tackle must not be used

1.1.3 For selection and attachment, only follow the instructions given by the person responsible

for this.

1.2 Signals during TransportOnly follow the instructions given by responsible for giving signals during transporting.

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OIMPG TRANSPORT 3

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3.1 Transport of the Pump Set

For transporting the pump set components mounted on the base plate, shackles

must be attached to the lifting lugs of the pump/baseplate. __________________________________________________________________

Caution Do not damage any built-on accessories and pipes.

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Transport of pump sets mounted on baseplates ( examples )

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OIMPG TRANSPORT 4

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3.2 Transport of the Pump

Attach the hoisting tackle as shown in the figure or to the marked lifting links.

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Caution Do not attach the ropes to the shaft ends or bearing housings.

Secure the pump against overturning. _________________________________________________________________

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OIMPG TRANSPORT 5

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3.3 Transport of the Other Pump Set Components3.3.1 Transport the other pump set components in accordance with the relevant manufacturer’s

documentation.

3.3.2 If these components are included in KSB’s scope of supply, the relevant documentsmentioned elsewhere in the manual.

3.4 Transport of the Pump Rotor

3.4.1 Attach hemp or plastic ropes as required by the length of the pump rotor and transport thepump rotor horizontally; see figure. _______________________________________________________________________

Caution Do not use wire ropes or chains in order not to damage the pump

rotor. _______________________________________________________________________

3.4.2 When setting the pump rotor down, it must be supported so that it is not damaged and issecured against overturning/rolling.

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OIMPG TRANSPORT 6

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3.5 Transport of Pump Set Accessories Attach the hoisting tackle as shown in the figure. ______________________________________________________________________

Caution Do not exert pressure on the strainer element and strainer meshes or

damage them.We recommend transport by hand.

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<120°

<120° <1 2 0 °

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OIMPG TRANSPORT 7

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4. Interim Storage4.1 Prerequisites

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Caution The load carrying capacity of the floor of the storage area must beadequately designed.

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4.1.1 Weights with packaging : see packing list.4.1.2 Weights without packaging : See table of weights given in Technical Appendix.4.1.3 Check each package for damage before it is stored. In case of transport damage, asses

the exact damage, document it and notify KSB about the damage, in writing, immediately. ______________________________________________________________________

Caution All openings of the mounted pump set components are closed and

must not be opened before they are needed during installation. _______________________________________________________________________

4.2 Place of Storage _______________________________________________________________________

Caution Protect the stored components from humidity, dirt, vermin and

unauthorized access. _______________________________________________________________________

4.2.1 All components supplied should be stored in a dry room where the atmospheric humidityis as constant as possible.

4.2.2 In case of outdoor storage it is absolutely necessary to cover the pump set and crates toform watertight barrier and to protect them against condensation of water so that anycontact with humidity is avoided. ______________________________________________________________________

Elastomeric parts must not be stored together with chemicals,Caution solvents, fuels, acids, etc. In addition, they should be kept away from

light, in particular sunlight, strong artificial light high in ultravioletrays.

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4.3 Period of Storage up to 12 Months

The pimp is supplied duly preserved for storage up to 12 months (standard preservation).4.4 Period of Storage over 12 Months

If the pump is to be stored more than 12 months, it must be preserved appropriately. If therequisite preservation measures have not been performed by KSB (special preservation),they must be discussed with and approved by KSB prior to putting the pump into storage. _______________________________________________________________________

Caution In case of storage periods of more than 5 years, the pump must be

dismantled before it is installed, and the O-rings must be replaced. _______________________________________________________________________

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Installation 1

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Installation on Site

Conditions

Foundation- has been prepared- the concrete has set- the surface is truly horizontal and even (check with a spirit level, accuracy < 0.3 mm/m in longitudinal

and cross directions.- The area surrounding the foundation holes is truly horizontal and even.

Site management- has checked the dimensional accuracy of the foundation and its correct position as per the reference

points given in the foundation and building drawing.- Has marked the center line of the foundation- Has released the foundation

Place of installation- is cleared- its condition is such that the installation can be performed without interruptions- adequate devices for aligning are available

Drive way to the place of installation- is cleared- is suitable for transport

Adequate means of transport- including personnel are available until completion of the installation work

Preparations

Checking the foundation- for dimensional accuracy in accordance with GA drawing.- Whether the foundation is truly horizontal and even- Whether the area surrounding the foundation holes is truly horizontal and even.

Correct deviating foundation dimensions- by adequate measures after consultation with site management

Transporting the pump set components to the place of installation- using adequate means of transport- For weights, please refer to GA drawing _____________________________________________________________________________________

Caution For transport, the guidelines of the chapters on Safety, and

Transport/Interim Storage must be complied with. _______________________________________________________________________

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Installation 2

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Removal of packaging- not until the installation work actually starts

- Avoid damaging the pump set- All connection points must be closed- The packaging must be disposed off by the consignee (responsible contractor)

_____________________________________________________________________________________

! If parts have to be lifted to remove the packaging, proceed as described in

the chapter on Transport / Interim Storage. ______________________________________________________________________________________________

Protecting the pump set components

_____________________________________________________________________________________

Caution Components remaining on site have to be protected against dirt,

humidity and damage. If components of the pump set are receiveddamaged, wet or dirty, inform KSB.

_______________________________________________________________________

- Completely cover the pump set components to protect them for the full duration of the installation workon site against construction site dirt, spark discharge, grinding dust and other harmful ambientinfluences.Take special care to adequately protect instruments, electrical cables and wiring ducts.

- Spare parts and parts which are not immediately needed must be stored in such a way that they are

protected from dirt accumulation, humidity and damage. _____________________________________________________________________________________

Caution Do not store elastomeric parts together with chemicals, solvents,

fuels, acids etc. In addition, they should be kept away from thelight, particular direct sunlight and strong artificial light high in ultravioletlight.

_______________________________________________________________________

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6

PROCEDURE FOR LEVELLING & GROUTING OF BASE FRAME AT SITE

( FOR HDA / HDB / HG / CHT PUMPS ONLY )

PURPOSE :

High speed rotory equipment needs to be installed with maximum contact area between base frame

and the foundation. To achieve this conventionally, blue matching procedure is adopted between packer plates and foundation. This calls for skilled millwright fitters to work on and consumes lot of time.

Despite this, the contact area achieved is nowhere near 100%.

Therefore, the following procedure is recommended which ensures :

1. Nearly 100% contact area between the foundation, the packer plates and the base frame.

2. Considerable saving in time and manpower.

PREPARATION :

The following preparation is followed, in case the base frame and the packer plates ( equal to the

number of foundation bolts ) are in scope of KSB. Otherwise, the user is requested to follow the

preparation as under :

l The base frame is provided with the pads, which are welded at the bottom, machined in one setting

and drilled to 15 mm. Dia. ( Ref. Fig. 1).

l Machined packer plates, having 0.02 mm. face parallality, and of the dimensions equal to the

welded pads at the bottom of the base frame, are required with tapping of M 10. These packer plates

are to be bolted with pads at the bottom of the base frame, using M10 bolts ( Ref. Fig. 2 & 3 ).

PROCEDURE :

01.Bolt the pump on the base frame.

02.Bolt the packer plates on the bottom pads of the base frame.

03.Place the unit on the foundation.

04.Suspend foundation bolts into the pockets provided on the foundation blocks.05.Level the pump on the delivery flange or feet, within 0.04 mm. per meter, using jacking bolts pro

vided at the corners of the base frame.

06.Grout the foundation bolts and the packer plates by using quick setting non-shrink cement, ACC

make ‘Shrinkkomp’ or Forsoc make ‘Cobextra-GP2’ or equivalent ( Ref. Fig. 4 ).

07.Allow curing time of 24 to 72 hours depending upon the grout used.

08.Remove M 10 bolts, which are holding packer plates with the base frame.

09.Carry out final levelling by inserting shims (SS shims preferred) between packer plates and the base

frame.

10.Tighten the foundation bolts and recheck the levelling. Correct it, if necessary.

11.Grout the complete base frame, including the hollow portion, if any, using conventional grouting mix, i.e.,portland cement, sand and aggregate in proportion 1 : 2 : 2 and gravel size not to exceed 20 mm.

12.Plaster the foundation and apply suitable oil resistant paint.

GEN 02.01 I

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GEN 02.01I 6a

Fig. 4 : Grouting of packer plate

Note : The foundation to be made of concrete on solid ground. Foundation bolts and packer plates to begrouted with non shrink grout only. Balance hollow portion of base frame to be grouted with

portland cement sand and aggreegate in preparation 1:2.2 Gravel size should be < 20 mm. After

final grouting all surface should be finished with fine plaster and apply oil resistent paint.

Fig. 1 : Base frame bottom pad

View from W

Fig. 2 : Packer plates in pairs, machined for Fig. 2A : Packer plates in pairs, machined for

for base frame with channel base frame with double channel / I beam

W

Fig. 3 : Clamping of packer plate and bottom pads with M10 bolts

Base frame Levelling bolts Non shrink cement grout

80 min.15

1.5xd

20

30 ∅ d

Found block

Packer plate

Found

bolt

View from Z

Z

M10Packer plate

Found

boltM10

Base frame for bottom pads

machined with ∅15 plain holes

Base frame

Weld

Base frame

∅15

M20 through

for leveling M10 bolts

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Installation 3

_____________________________________________________________________

Making the pipingGeneral information- The pipes are already mounted within the dimensions of base frame.- Straight length pipes are supplied for further connection of piping, if within the scope of KSB supply. Bends and

flanges are supplied loose.- Offset at flanges and pipe connections is not allowed.

Cleaning the pipingGeneral information- Pipes delivered by KSB are cleaned and closed.- The pipes delivered shall be checked for subsequent impurities in the interior and cleaned, if required. ___________________________________________________________________________________________

Caution Pipes made on the site must be cleaned prior to final mounting.

____________________________________________________________________________

Connecting the pipingGeneral information- Run the pipes as indicated in the G. A. Drawing.- Do not remove the covers on the pump nozzles and the desiccants till the pipes are to be actually connected.

Disposal by the consignee / Operator.- The nominal diameters of the pipes shall be at least equal to the pump connections.- It is recommended to fit check valves and isolating valves.- The thermal expansions of the pipes must be compensated by suitable measures in order not to transfer them

on the pump.- The suction piping must be slanting towards the pump.- The weight of the suction piping must not transfer on the pump.- Under no circumstances the pump should be used as an anchorage point for the piping.

___________________________________________________________________________________________

Caution Connect all the pipes in cold condition and without transmitting any stresses or

strains. The unbalance of the forces and moments created by the suction / discharge

piping must not exceed the permissible values. (Refer G. A. Drawing) ____________________________________________________________________________

Suction piping- Not the part of KSB scope of supply.- Clean the tank and pipe prior to fitting.Balancing liquid piping

- The balancing liquid piping is connected back to the suction nozzle.- If the balancing liquid piping is connected back to the suction vessel (deaerator) the flow velocity in the

balancing liquid piping should on no account exceed 5 m/s. The pressure of the balancing liquid must at least0.5 bar higher than the suction pressure (at the pump suction nozzle), and the permissible damping pressuremust not exceed 2.5 % of the maximum discharge pressure.

Discharge piping- Not the part of KSB scope of supply.Flushing piping- The piping is already installed.Minimum flow system- On the discharge side of the pump, a minimum flow control valve is required. G. A. Drawing indicates whether it

is in KSB’s scope of supply.- Refer separate operating instructions for Minimum flow control valve.

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Installation 4

_____________________________________________________________________

Minimum flow piping- Not the part of KSB’s scope of supply.Return piping- For drain and leakage liquids, the Operator must fit a return piping. Connections and dimensions are specified

in the G. A. drawing.

Information about readiness for connection of the piping- Inform the responsible site management that the piping is ready for connection.- Do not continue the piping unless the required piping by the Operator is completed.

Checking the alignment- Repeat the alignment of the coupling, after the completion of piping by the Operator.- Enter the final measuring results in the coordinate system of the alignment / acceptance record sheet of each

connecting coupling.- Record the shaft displacements due to vertical and lateral misalignment of the pump set components under

“remarks”.- Have the alignment/acceptance record sheet confirmed by the responsible site management and distribute it to

the authorized persons.

- Have the table of tightening torques for all fastening screws and foundation bolts checked and confirmed byresponsible site management.

Mounting the instrumentsGeneral information- Measuring lines with isolation valves have been installed.- Do not remove the plugs of the connection points till the actual mounting.- Just before commissioning / start up perform the functional test.- Laying of electrical cables varies according to the constructional conditions. Cables must be layed in the

conduits up to the points just near the actual measuring point.- Electrical cable connections must be done by authorized personnel.Mounting the pressure gauges- Insert the sealing disc.- Select the pressure gauge with sufficient measuring range.Mounting the oil sight gauge- Remove the plug and screw in the oil sight gauge with seal.- Attach required extension piece.

Detailed description of preservation for standstill- Close the suction, discharge and minimum flow pipe and secure against opening.- Close all openings and inlet pipes.- Introduce and fasten desiccants in the pump or the strainer casing.- For quality, identification and monitoring of the desiccants please refer to DIN 55473 and DIN 55474.

- In case of water ingress, open the pump drain, flush the pump interior, close the pump drain and re-preservethe pump interior.- Remove visible foreign matter which falls in the pump through the pump nozzle. In case of problem in removing

the foreign matter, inform KSB. Additional measures after standstill of 6 months.- Dismantle the spacer sleeve of the coupling, preserve it and the bolts using an appropriate preservative, pack

into foil and store properly.

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Installation 5

_____________________________________________________________________

Detailed description of mounting/dismantling the connecting coupling

General Information ____________________________________________________________________________

Caution Check the shaft ends for runout, prior to mounting the coupling hubs. Permissible

tolerance < 0.04 mm (see figure Runout check of the shaft ends). If the toleranceis exceeded, please inform KSB.Observe the manufacturer’s mounting/dismantling instructions. The pump shaft’scheck values shall be read after a 90

0turn.

____________________________________________________________________________

Runout check of Shaft ends

z Mounting- Fitting the coupling hubs- Thoroughly clean shaft ends and bores of the coupling hubs and check them for dimensional accuracy.- Slightly deburr the hub grooves and insert the key.- Check the protrudent dimension of the key. Tolerance in accordance with the figure Clearance between groove

and key.

- In case of a cylindrical shaft with key, smear the shaft end and coupling hub end with an adequate antiseizeagent.

- To facilitate fitting, the coupling hub may be heated evenly to a temperature of 800 C max.

Elastomeric parts must be removed before heating! ___________________________________________________________________________________________

Caution Do not use elastomers which have already been heated up once. Use new parts!

______________________________________________________________________________________________________

0 . 2 - 0 . 3 m m

Clearance between groove and key

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Installation 6

_____________________________________________________________________

Use safety gloves.Risk of fire in case of open fire.Remove inflammable material

____________________________________________________________________________

- Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft end and the hub facematch.

___________________________________________________________________________________________

Caution Fit the coupling hubs only using the appropriate device to prevent the shaft

bearings from damages by the axial friction force. Impacts on the coupling hubsare not allowed.

____________________________________________________________________________

X = thread size, refer Technical Appendix.

- Securely tighten the grub screws, wherever provided.

Connecting the coupling hubs

- Assemble the connecting coupling as described in manufacturer’s documentation.

DismantlingPreparations

- Make sure that the connecting coupling is marked or mark the connecting coupling in order to avoid

subsequent confusions.

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Installation 8

_____________________________________________________________________

Detailed description of connecting coupling alignment1. Conditions

- Shaft distances as indicated in the G. A. drawing.

- Pump set components are set in place on the base frame.- Coupling hubs are mounted in accordance with the description under Detailed description of

mounting/dismantling the connecting coupling.

2. Preparations- Dismantle the coupling guards mounted to the pump set as described under Detailed description of

mounting/dismantling the connecting coupling guards, and store them appropriately.- Separate the couplings mounted to the pump set as described under Detailed description of

mounting/dismantling the connecting coupling .- Comply with the coupling hub distance shown in the G. A. drawing.

3. Runout check of the coupling hubs- Check the coupling halves using a dial micrometer.- Use spacer plates.

Arrangement of spacer plates ( examples )

! Secure the drive against unintentional starting.

____________________________________________________________________________

- True running tolerance ≤ 0.04 mm.- If true running tolerance > 0.04 mm : inform KSB

Runout check ( example )

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Installation 9

_____________________________________________________________________

4. Alignment of couplingGeneral information- Align the coupling when the pump is cold (< 50

0 C/ 122

0 F).

- In case of motors with axial tolerance, their rotors must be set in the magnetic center. For this purpose,either set the rotor to the center marking made by the manufacturer (if any) or to the center positionbetween right and left side.

- Move the pump shaft towards the suction casing until the rotor abuts.

Order of alignment :pump – drive. Alignment using dial micrometer ___________________________________________________________________________________________

Caution The coupling must not be turned at the alignment device.

Do not damage the shaft and hubs.

___________________________________________________________________________

Device for connecting coupling with spacer sleeve ( example )

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Installation 10

_____________________________________________________________________

Radial misalignment of the coupling hubs

- Permissible value : ∆kr ≤ 0.04 mm, measured at 4 points at a distance of 900.

___________________________________________________________________________________________

Caution ∆kr < 0.04 mm/0.016 inch + vertical/lateral misalignment. (For dimensions,

please refer to the section Alignment corrections) ___________________________________________________________________________________________

Angular misalignment of the coupling hubs in horizontal direction

- Permissible value : ∆kh ≤ 0.04 mmSmax – Smin

∆ kh = _________________

2 Angular misalignment of the coupling hubs in vertical direction

- Permissible value : ∆kv≤ 0.04 mmSmax – Smin

∆ kv = _________________

2

5. Alignment correctionsVertical correctionPump :

K r

Smin.

Smax.

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Installation 12

_____________________________________________________________________

6. Pinning the feet Pump

A = nozzle orientation in accordance with the G. A. drawing.C = drill and mount after final adjustment of the pump at the place installation. ( Drill 10mm diameter x 20mm deep )D = tighten the bolts and lock the nuts with locknuts.Drive :- In accordance with the manufacturer’s documentation.

Detailed description of mounting/dismantling the guardsCoupling guard _______________________________________________________________________

Caution The pump must not be operated without coupling guard.

_______________________________________________________________________ Mounting the coupling guard :- Align the coupling guard over the connecting coupling.- Make sure there is an adequate distance from both shaft ends and the coupling halves.- Fasten the coupling guard adequately with bolts.

Coupling guard ( example )

A

CD

Pinning the pump feet

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Installation 13

_____________________________________________________________________

Dismantling the coupling guard :- Remove the guard and store it appropriately.

Cladding (touch guard) for the shaft seal _____________________________________________________________________________________

Caution The pump must not be operated without cladding (touch guard) _____________________________________________________________________________________

Mounting the cladding (touch guard) :- Fasten the cladding (touch guard) adequately with bolts at the bearing housing.

Dismantling cladding (touch guard) :- Remove the guard and store it appropriately.

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OIMPG COMM 31

_____________________________________________________________________

Commissioning, Start-up/Shutdown

1. Work to be carried out prior to Commissioning, Start-up _________________________________________________________________________

Caution Improper handling of preservatives, oil and grease causes hazardous environmental impact. Handling and disposal only by qualified personnel!

_________________________________________________________________________

1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc.,please refer P & I Diagram.

1.2 General Information1.2.1 In addition to this instruction manual of pump portion, the technical documents (instruction manuals)

of other accessories & instrumentation etc. are also needed for commissioning/start-up and shutdown. If

these are part of scope of supply of KSB, the relevant instruction manuals are separately enclosed.1.2.2 Perform all dismantling and reassembly work in accordance with chapter ‘Maintenance’.

1.3 Removal of Preservation1.3.1 If the pump has been filled with a glycol/water mixture for preservation, this fill must be drained before

further work is started.1.3.1.1 Open the pump drain (6B), collect fill in an appropriate container and dispose of according to the local

anti-pollution regulations.1.3.1.2 Close the pump drain.

1.3.2 Flush sufficiently to remove any residues of the preservative.1.3.3 Remove the grease on the out sides of all pump set components.

1.4 Additional Work to Be Carried out Prior to Returning to Service after Standstill> 12 Months1.4.1 Dismantle the pump-end coupling hub.1.4.2 Dismantle the bearing.1.4.3 Dismantle the mechanical seal and check it in accordance with the manufacturer’s documentation.1.4.4 If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a new seal must be

fitted.1.4.5 Re-mount the bearing and, in case of pump with plain bearings, lift the pump rotor.1.4.6 Re-mount the pump-end coupling hub.

1.5 Topping up the Bearings with Lubricating Oil1.5.1 General Information

1.5.1.1 Oil quality, refer Technical Appendix.1.5.1.2 After standstill > 12 months, check the oil quality. Clean or replace the oil, if required.

1.5.1.3 Filter the oil prior to topping up; filter mesh size 30 µm.

_______________________________________________________________________

Caution During operation, the oil level in the bearing housing falls!

Check the oil level only during standstill of pump! _______________________________________________________________________

1.5.2 Bearing with Oil Sight Gauge

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OIMPG COMM 32

________________________________________________________________________

1.5.2.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between theminimum and maximum markings of the oil sight gauge (639).

1.5.2.2 Fit the vent plug (913.01 or 672) again.

1.5.3 Lift-off Device (if applicable)

1.5.3.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between theminimum and maximum markings of the oil sight glass (642.01).

1.5.3.2 Fit the vent plug (913.01 or 672) again.

1.5.4 Bearing with Constant Level Oiler (if applicable)1.5.4.1 Remove the vent plug (913.01 or 672).1.5.4.2 Hinge down the constant level oiler (638).1.5.4.3 Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant

level oiler until oil appears in the vertical portion of the connecting elbow of the constant level oiler, seefigure Constant level oiler .

1.5.4.4 Fill the reservoir of the constant level oiler with oil and snap it back into operating position.1.5.4.5 Fit the vent plug (913.01 or 913.02 or 672) again.1.5.4.6 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one

third of the reservoir filled at all times. If the oil level is underrun, top up with oil.

_____________________________________________________________________________________

Caution The oil level always be below the level of the vent opening arranged at the top edge of the connecting elbow. Make sure the opening is alwaysperfectly dry.

1.5.5 Other accessoriesFill with oil in accordance with the manufacturer’s documentation.

1.6 Checking the Direction of Rotation If the pump set is driven by an electric motor, the direction of rotation of the motor must be checked prior to Commissioning/start-up.

_____________________________________________________________________________________

! Secure the drive against unintentional starting. _______________________________________________________________________

Oil level

Position of

reservoir for

topping up oil

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OIMPG COMM 33

_____________________________________________________________________

1.6.1 Prerequisites1.6.1.1 Check the direction of rotation prior to the final assembly of the connecting coupling.1.6.1.2 Comply with the manufacturer’s documentation.1.6.1.3 The electric motor is provided with a lubricant.

1.6.2 Direction of Rotation1.6.2.1 The pump’s direction of rotation is indicated by an arrow on the driven-end bearing housing. In order to

ensure the correct direction of rotation, the direction of rotation of the drive must correspond to thedirection indicated in the G. A. drawing.

1.6.2.2 The direction of rotation of the drive is indicated in the G. A. drawing.

1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator The direction of rotation of the electric motor can be checked by means of an electromagnetic phase-

sequence indicator.

1.6.4 Checking the Direction of Rotation without Phase-sequence Indicator 1.6.4.1 In the case of curve tooth coupling, fix the drive-end coupling sleeve on the hub using spacer plate (if

applicable – supplied loose), see figure Arrangement of spacer plates.

1.6.4.2 The electric motor shall be switched on by authorized personnel for a short period of time.1.6.4.3 Switch off the electric motor again immediately before the operating speed is reached.1.6.4.4 Check the direction of rotation. If wrong, have the terminal connections reversed by authorized personnel

and check the direction of rotation once again. _____________________________________________________________________________________

Caution Mark the connections in the terminal box. _______________________________________________________________________

_______________________________________________________________________


____________________________________________________________

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OIMPG COMM 34

_____________________________________________________________________

1.6.4.5 In case of electric motors with axial float, if applicable, the coupling hub of motor shaft must be realigned asrequired by the actual magnetic center. If coupling has a spacer, it must be possible to mount and removeit.

1.7 Rotatibility of the Pump Rotor 1.7.1 In the case of curved tooth coupling, fix the pump-end coupling sleeve on the hub using spacer plate (if

applicable – supplied loose), see figure Arrangement of spacer plates.1.7.2 Prior to start of the work, check the oil level in the bearing housings.1.7.3 It must be easy to rotate the pump rotor by hand, and it may be only rotated in the direction of rotation of

the pump. If necessary, attach an appropriate tool at the coupling hub, see figure Rotatability of the pumprotor .

1.7.4 In case the pump with balancing disc without lift off device, move the pump rotor towards the driven end byapprox. 1 mm before you turn it by hand, see figure Rotatability of the pump rotor .

Rotatability of the pump rotor ( example )

1.8 Mounting the Connecting CouplingMount the spacer of the connecting coupling as described in the manufacturer’s documentation.

1.9 Mounting Guards Preventing Accidental ContactsMount all guards preventing accidental contact.

1.10 Functional Test and Adjustment of The Instruments1.10.1 Check all the instruments in accordance with the individual manufacturer’s documentation for correct

measuring data and adjust the instruments, if required.

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OIMPG COMM 35

_____________________________________________________________________

_____________________________________________________________________________________

Caution All measuring instruments supplied with the pump should be calibrated

before commissioning of the pump set.

_______________________________________________________________________

1.10.2 Set the Alarm & Trip values in accordance with the Logic Diagram, in cooperation with control engineeringspecialists. _____________________________________________________________________________________

Caution The pump should never be run below the speed of 1000 rpm, even during

the starting process. The acceleration time from switch on (zero rpm) to1000 rpm should be less than 10 seconds. Specific care is necessary forthe pumps with variable frequency drive & pumps with hydraulic coupling.

_______________________________________________________________________

2. Commissioning, Start-up2.1 Prerequisites2.1.1 Installation and alignment have been performed in accordance with good engineering practice, recorded

and accepted by the Operator.2.1.2 The pump rotor’s rotatability by hand has been checked.2.1.3 All pump set components have been checked in accordance with the relevant manufacturer’s

documentation.2.1.4 The direction of rotation of the drive has been checked.2.1.5 All guards preventing accidental contact have been mounted.2.1.6 All pipes have been cleaned and connected.2.1.7 All instruments have been fitted and checked for correct functioning.

2.2 Priming2.2.1 Close all drains and drain pipes.2.2.2 Fully open the cooling water main valve and all cooling water throttle valves.2.2.3 Vent the complete cooling water circuit.2.2.4 Vent the complete mechanical seal cooling circuit.2.2.5 Monitor the cooling water flow at the sight glasses or flow indicators.

_____________________________________________________________________________________

Caution Do not cool the cooling chamber and heat exchangers with aggressive

untreated water. _______________________________________________________________________

2.2.6 If applicable, check the filter in the mechanical seal’s cooling circuit and clean, if required.2.2.7 Open the valves in the minimum flow line.2.2.8 Check the oil levels and top up with oil, if required.

_____________________________________________________________________________________

Caution During operation, the oil level in the bearing housing falls!

Check the oil levels only during standstill of the pump! ______________________________________________________________________

2.2.9 If there is no bypass, open the gate valve in the suction piping by 10 to 20 %.2.2.10 Prime the suction piping, pump and discharge piping up to the closed discharge gate valve.2.2.11 Vent all pressure gauge lines until there is no more air to escape.2.2.12 Fully open the valve in the suction piping.

2.2.13 Check whether suction pressure is available.

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OIMPG COMM 36

_____________________________________________________________________

2.3 Checks Prior to Starting2.3.1 The suction tank, suction piping, pump and discharge piping have been primed and vented.2.3.2 The valve in the suction piping is fully open.2.3.3 The valve in the discharge piping is fully closed.2.3.4 The connection for tapping, if applicable, is closed.2.3.5 The shut-off valves in the stand-by heating system, if applicable, are closed.2.3.6 The shut-off valves in the minimum flow line are open.2.3.7 The cooling water system is in operation.2.3.8 The cooling liquid pressure at the inlet must not exceed 6 bar.2.3.9 The cooling liquid temperature at the outlet must not exceed 55

0 C.

2.3.10 All temperatures indicated are below the limit values.2.3.11 In the case of a pump set with variable speed coupling, check the scoop tube position for compliance with

the manufacturer’s documentation and readjust, if required.2.3.12 Check all pipes, flanges, screw/bolt connections and pipe unions for leakage.

2.4 Starting and Trial Run _______________________________________________________________________

Caution Should alarm signals or problems occur during starting or trial run,

proceed as described in chapter Trouble shooting! _______________________________________________________________________

_______________________________________________________________________

Caution The minimum discharge head of 150 m must not be underrun, except the

start-up and shutdown phases.

The pump should never be run below the speed of 1000 rpm, even duringthe starting process. The acceleration time from switch on (zero rpm) to1000 rpm should be less than 10 seconds. Specific care is necessary forthe pumps with variable frequency drive & pumps with hydraulic coupling.

_______________________________________________________________________

2.4.1 Switch on the drive as described in the manufacturer’s documentation.2.4.2 For pump set with variable speed coupling :2.4.2.1 The drive is operating at maximum speed. Due to the scoop tube position, however, the pump is operating

at a minimum speed of 1000 rpm or a minimum head of Hmin = 150 m.2.4.2.2 Adjust the pump to minimum flow by changing the scoop tube position.2.4.3 Monitor the temperature and smooth running of the bearings.

2.4.4 Monitor the pump pressures and differential pressures.2.4.5 Make sure the minimum flow control valve works (hydrodynamic noise).

_____________________________________________________________________________________

! The minimum flow pipe gets hot.

____________________________________________________________

2.4.6 Check the mechanical seals. Mechanical seal must not drip.2.4.7 For pump set with variable speed coupling:2.4.7.1 For minimum speed or minimum head (pump) set the limiting cams of the scoop tube positioning device to

approx. 80% (can be read on the scale).2.4.7.2 Increase the pump speed until the operating speed is reached.

2.4.8 Slowly open the valve of the discharge pipe until it is completely open.

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OIMPG COMM 37

_____________________________________________________________________

2.4.9 Permanently monitor the pump set’s operating behaviour.2.4.10 Open the shut-off valves upstream and downstream of the orifice plate in the stand-by heating system, if

applicable. _____________________________________________________________________________________

Caution Close the shut-off valves of the standby heating system only for

maintenance work of the pump. _______________________________________________________________________

2.4.11 For mechanical seals with circulating cooling :If there is a magnetic separator, check after its commissioning/start-up whether the temperature of thecirculation liquid remains constant.

3. Shutdown3.1 Pump set remains ready for Operation3.1.1 Close the valve in the discharge pipe.3.1.2 Make sure the minimum flow control vale works.

_____________________________________________________________________________________


_______________________________________________________________________ _______________________________________________________________________

Caution The minimum discharge head of 150 m must not be underrun, except in

the start-up and shutdown phases.

The pump should never be run below the speed of 1000 rpm, even duringthe starting process. The acceleration time from switch on (zero rpm) to1000 rpm should be less than 10 seconds. Specific care is necessary forpumps with variable frequency drive & pumps with hydraulic coupling.

_______________________________________________________________________

3.1.3 In the case of a pump set with variable speed coupling reduce the speed until the minimum head or minimum speed is reached.

3.1.4 Switch off the drive, making sure it runs smoothly down to a standstill.3.1.5 Note the run down time.3.1.6 The cooling water remains on!

3.2 For Maintenance of the Pump Set or Prolonged Standstill3.2.1 Close the valve in the discharge pipe.3.2.2 Make sure the minimum flow control valve works.

_____________________________________________________________________________________


____________________________________________________________

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OIMPG COMM 38

_____________________________________________________________________ _______________________________________________________________________

Caution The minimum discharge head of 150 m must not be underrun, except in

the start-up and shutdown phases. The pump should never be run below the speed of 1000 rpm, even during

the starting process. The acceleration time from switch on (zero rpm) to1000 rpm should be less than 10 seconds. Specific care is necessary forpumps with variable frequency drive & pumps with hydraulic coupling.

_______________________________________________________________________ 3.2.3 In the case of a pump set with variable speed coupling reduce the speed until the minimum head or

minimum speed is reached.3.2.4 Switch off the drive, making sure it runs smoothly down to a standstill.3.2.5 Note the run down time.

_____________________________________________________________________________________


_______________________________________________________________________ 3.2.6 Close the shut-off valve in the tapping pipe, if applicable.3.2.7 Close the shut-off valves of the standby heating system, if applicable.3.2.8 Close the shut-off valves in the minimum flow line.3.2.9 Close the shut-off valves in inlet pipe.3.2.10 Turn off the cooling water when the casing temperature, measured the pump nozzles, is lower than 50

0 C.

3.2.11 Close the other pipes.

4. Work after shutdown4.1 During Readiness for Instant Start-up4.1.1 General Information

If the period of standstill during readiness for start-up is longer than 2 weeks, the pump set components

such as gear or variable speed coupling must be protected against water ingress and humidity asdescribed in the manufacturer’s preservation instructions.

4.1.2 Every 4 to 6 weeks4.1.2.1 Put the pump into operation as described in Commissioning, Start-up section of this chapter.4.1.2.2 Switch off the pump after approx. 10 minutes as described in Shutdown section of this chapter.4.1.2.3 Check at the connecting coupling whether pump rotor runs down smoothly to a standstill.

4.1.3 Every two months (in the case of pump set with variable speed coupling)If the scoop tube actuator was used during stand-by operation, re-lubricate the guide bush; see themanufacturer’s documentation.

4.2 For Maintenance of the Pump set

_________________________________________________________________________

! The pump has been depressurized and the casing temperature is < 500 C,

measured at the pump nozzles!

______________________________________________________________

4.2.1 Secure all valves against opening.4.2.2 Open all drains and/or drain pipes.4.2.3 Collect the fill in an appropriate container and dispose off according to local anti-pollution regulations.

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OIMPG COMM 39

_____________________________________________________________________ _____________________________________________________________________________________

! If the medium handled is toxic, inflammable, explosive or hazardous in a

different way, the pump must be flushed thoroughly to avoid that any residues

remain in the pump. ____________________________________________________________

4.2.4 If the period of standstill is longer than 2 weeks, the pump set components such as gear or variable speedcoupling must be protected against water ingress and humidity as described in the manufacturer’spreservation instructions.

4.3 Standstill, Pump not Ready for Operation.4.3.1 General information

_____________________________________________________________________________________

Caution In the case of dander of frost, the pump must be drained and preserved as

described under Detailed Description of Preservation for Standstill in this chapter.

_______________________________________________________________________

4.3.1.1 Secure all valves against opening.4.3.1.2 Close all openings and supply pipes.

4.3.2 Standstill > 2 Weeks4.3.2.1 Preserve the pump as described under Detailed Description of Preservation for Standstill in this chapter.4.3.2.2 Protect the pump set components such as gear or variable speed coupling against water ingress and

humidity as described in the manufacturer’s preservation instructions.

5. Detailed Description of Preservation for Standstill ________________________________________________________________________

! The pump has been depressurized and the casing temperature is < 500 C,

measured at the pump nozzles! _________________________________________________________________________

5.1 Secure all valves against opening.5.2 Open all drain and/or drain pipes.5.3 Collect the fill in an appropriate container and dispose of according to anti-pollution regulations.

________________________________________________________________________________________

! If the medium handled is toxic, inflammable, explosive or hazardous in a

different way, the pump must be flushed thoroughly to avoid that anyresidues remain in the pump.

_________________________________________________________________________

5.4 Close all drains and/or drain pipes.5.5 Fill the pump with glycol/water mixture at a proportion of 1 : 2.

Important : This mixture ensures protection against frost up to approx. – 200C.

A mixture at a proportion of 1 : 1 increases the protection up to –420C.

5.6 Dismantle and store the coupling guards mounted on the pump set.5.7 Dismantle and store the connecting coupling spacer in accordance with the manufacturer’s documentation.5.8 If necessary, fill the bearing housing with oil.

5.9 Rotate the pump rotor once or twice a month to prevent a separation of the preservation fill, check the fill level

and top up, if required.

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OIMPG SUPERVISION 02

_____________________________________________________________________

Supervision of Rotor Position (only for the pumps with Balancing Disc)The Rotor Position Indicator is mounted on the discharge side of the pump. There are two types of Rotor PositionIndicators.

The first and most commonly used by KSB India, consists of the indicator bush (623) screwed on the bearing

end cover, which is the stationary part, and the rotating indicator (624) is screwed in the shaft threading.The bush has two scriber marks, at right angles to shaft axis, which are 1.5 mm apart.1. If the balancing device is new, the position of the indicator (624) must be as shown in the figure “Pump running

normally”.2. In the case of maximum wear of the balancing device the position of the indicator (624) is as shown in the

figure “Time to shut down the pump”.

Pump running normally

623 624

0

Rotor position indicator Rotor position indicator

Time to shut down the pump

623 624

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OIMPG SUPERVISION 06

_____________________________________________________________________

Pump Supervision PlanFor exact description of pump as well as scope of supply of accessories & instrumentation etc.,please refer P & I Diagram.

Point to be supervised Supervisory action Value to be met

Checking the temperature once a week < 900 C

Checking the oil level once a week(only for pumps with ring oil lubrication)

Middle between minimum andmaximum marks

Pump Bearings : Plain

Checking for smooth operationOnce a week

The pump set shall run smoothand free from vibrations.

Checking the temperature once a week < 900 CThrust Bearing – Tilting pads

(if applicable)

Checking for smooth operationOnce a week


Checking the temperature once a week < 900 C

Checking the oil level once a week Middle of oil level sight glass

Lift-off device with antifriction bearings

(if applicable)

Checking for smooth operation

Once a week

The pump set shall run smooth

and free from vibrations.Checking the temperature once a week < 900 CLift-off device with Tilting pads bearings

(if applicable)Checking for smooth operationOnce a week


Indicator (only for pumps with balancing disc)

Checking the rotor position once a week See section Rotor Position inthis chapter

Checking the temperature once a week ≤ 800 CMechanical seal (433)

Checking the leakage once a week 15 drops per minute

Differential pressure gaugeStrainer I suction pipe (if applicable)

Checking the differential pressureOnce a week

< 0.3 bar

Differential pressure gaugeDuplex filter (if applicable)

Checking the differential pressureOnce a week

Measuring instrument, suction side ps

(gauge holder ) (if applicable)Checking the pressure once a week

Measuring instrument, discharge side pd

(gauge holder ) (if applicable)Checking the pressure once a week

Measuring instrument, tapping(gauge holder ) (if applicable)

Checking the pressure once a week

Measuring instrument, balancing water pE

(gauge holder ) (if applicable)Checking the pressure once a week PE ≥ ps + 0.5 bar

Thermometer (Suction nozzle/discharge nozzle) (if applicable)

Checking the temperature once a week

Thermometer (cooling water inlet) (if applicable )

Checking the temperature once a week ≤ 450 C

Cooling water pipe(supply and return flow) (if applicable)

Checking the temperature once a week ∆t ≤ 100 C

Sight glass(cooling water inlet pipe) (if applicable)

Checking the cooling water flow once aweek

Water is flowing

Oil pressure gauge(gauge holder) (if applicable)

Checking the pressure once a week

Level indicator (Oil supply system) (if applicable)

Checking the oil level once a week - 20 mm

Connecting coupling(only for coupling with pressure oil lubr.)

Checking for leakage once a week No leakage permitted

In case of deviations, proceed in accordance with the “Cause – Remedy” specified under the chapter “Trouble – shooting”.

We recommend recording the information tabulated above in a logbook, in the form of enclosed

LOG SHEET.

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LOG SHEETPUMP TYPE

CUSTOMER ITEM NO.

NO. DESCRIPTION UNITPRESSURE AT

1 Suction nozzle kg/cm2

2 Differential across suction strainer kg/cm23 Discharge nozzle kg/cm2

4 Balancing line kg/cm2

5 Oil inlet to bearing (forced oil lubrication)

5.1 Suction side bearing kg/cm2

5.2 Discharge side bearing kg/cm2

5.3 Lift off / Thrust bearing kg/cm2

TEMPERATURE AT

6 Suction nozzle Deg C

7 Discharge nozzle Deg C

8 Balancing line Deg C

9 Bearings

9.1 Suction side Deg C

9.2 Discharge side Deg C

9.3 Lift off / Thrust Deg C

10 Oil inlet to bearing (forced oil lubrication)

10.1 Suction side Deg C

10.2 Discharge side Deg C


11 Flushing liquid

11.1 Shaft seal - Suction Deg C

11.2 Shaft seal - Discharge Deg C

Cooling Water Inlet / outlet11.3 Suction Deg C

11.4 Discharge Deg C


12 ROTOR POSITION

13

VIBRATIONS AT

H V A H V A

13.1 Suction side bearing housing

13.2 Discharge side bearing housing13.3 Lift off / Thrust bearing housing

13.4 Suction flange

13.5 Discharge flange

13.6 Suction side support foot

13.7 Discharge side support foot

13.8 Base Frame

H = Horizontal ; V = Vertical ; A = Axial.

SIGNATURE OF OPERATORDATE / TIME

Amplitude

READING

RMS Velocity

microns (peak to peak)

SERIAL NO.

mm / s

LOG SHEETB1

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OIMPG SERVICING 01

_____________________________________________________________________

Servicing


We recommend that KSB’s specialist personnel be present during the servicing of thepump! ________________________________________________________________________________________

Caution Improper handling of preservatives, oil and grease causes hazardous

environmental impact. Handling and disposal only by qualified personnel!

_________________________________________________________________________


1.2 Required documentation1.2.1 The following documents are necessary for servicing of pump set.

Sectional Drawing, PumpList of Components, PumpDocumentation of the Mechanical Seal (if applicable)

1.2.2 Documentation of Connecting Coupling1.2.3 Documentation of Drive1.2.4 Documentation of the Minimum Flow System (if applicable)1.2.5 Documentation of Valves and Equipment (if applicable)1.2.6 Documentation of the Instrumentation (if applicable)

1.3 Prerequisites1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown

sections of chapter “Commissioning, Start-up/Shutdown) and has been prepared for the servicing work. _____________________________________________________________________________________

! Secure the drive against unintentional starting

____________________________________________________________

1.4 Service Intervals ________________________________________________________________________________________

Caution Perform a visual inspection of the pump set – as far as accessible – about

500 operating hours after commissioning/start-up. _________________________________________________________________________

1.4.1 The periods of the time indicated are recommendations for normal operating conditions at trouble-freeoperation, which have to be adapted to the actual operating conditions, for example the dirt accumulation,switching frequency, load, etc.

1.4.2 In the case of problems and unusual operating conditions that represent electric or mechanical overloads,off-schedule servicing must be performed.

2. Dismantling the Guards Preventing Accidental ContactDismantle / remove the guards preventing accidental contact mounted to the pump set as described in theDismantling the Guards Preventing Accidental Contact section in chapter “Maintenance”.

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OIMPG SERVICING 02

_____________________________________________________________________

3. Pump Servicing Planafter Commissioning/Start-up and Stand-by

Location to be

serviced

Checks Servicing Intervals Servicing Work

First oil change after 300operating hours

Bearing(Ring oil lubricated)

(if applicable)

Oil level, oil quality

Subsequent oil changesafter 8000 operating hours,at least after 1 year

See the Servicing Work section in this chapter

First oil change after 300operating hours

Bearing(Forced oil lubricated)

(if applicable)

Oil level, oil quality

Subsequent oil changesafter 8000 operating hours,at least after 2 years

Grease fill(if applicable)

See manufacturer’sdocumentation


Connecting Coupling

(if applicable)Checking the axialmovability

After approx. 8000operating hours


Drive(if applicable)




Instruments

(if applicable)

Perfect condition andfunctioning


Replace defective equipment;see manufacturer’sdocumentation

Pressure gauge(if applicable)



Differential pressuregauge

(if applicable)Opening and closingpoints


Temperature measuringinstruments

(if applicable) Switching points

Vibration measurement(if applicable)


Shaft positioningmonitoring (if applicable)


Every 3 months;See the manufacturer’sdocumentation


Inspection(axial thrust measurement)

(if applicable)


After approx. 8000operating hours, at leastafter 2 years


In case of deviations, proceed in accordance with the (Cause – Remedy” specified under the chapter (Trouble – shooting”.

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OIMPG SERVICING 03

_____________________________________________________________________

4. Servicing Work

4.1 Oil Change4.1.1 General Information4.1.1.1 Oil quantity and quality, refer Technical Appendix.

4.1.1.2 Filter the oil prior to topping up; filter mesh size 30 µm.

4.1.2 Bearing with Oil Sight Gauge (639)4.1.2.1 Remove the screwed plug (13 B.1 and/or 13 B.2), completely drain off the oil fill and dispose of in

accordance with the local anti-pollution regulations.4.1.2.2 Screw the screwed plug (including sealing element) back again.4.1.2.3 Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the

minimum and maximum markings of the oil sight gauge (639).4.1.2.4 Fit the vent plug (913.01 or 672) back again.

4.1.3 Bearing with Constant Level Oiler (638) (if applicable)4.1.3.1 Remove the screwed plug (13 B.1), completely drain off the oil fill and dispose of in accordance with the

local anti-pollution regulations.4.1.3.2 Screw the screwed plug (including sealing element) back again.4.1.3.3 Remove the vent plug (913.01 or 913.02 or 672).4.1.3.4 Hinge down the constant level oiler (638).4.1.3.5 Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant

level oiler until oil appears ii the vertical portion of the connecting elbow of the constant level oiler, seefigure Constant level oiler .

4.1.3.6 Fill the reservoir of the constant level oiler with oil and snap it back into operating position.4.1.3.7 Fit the vent plug (913.01 or 913.02 or 672) back again.4.1.3.8 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one

third of the reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________

Caution The oil level must always be below the level of the vent opening arranged

at the top edge of the connecting elbow. Make sure the opening is alwaysdry.

_______________________________________________________________________

4.1.4 Other Pump set Components

Fill the oil in accordance with the manufacturer’s documentation.

Oil level

Position of

reservoir for

topping up oil

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OIMPG SERVICING 04

_____________________________________________________________________

4.2 Re-lubrication4.2.1 General Information4.2.1.1 Oil quantity and quality, see Technical Appendix.

4.2.1.2 Filter the oil prior to topping up; filter mesh size 30µm.

_____________________________________________________________________________________

Caution During operation, the oil level in the bearing housing drops! Check the oil

level only during standstill of the pump!In case of extraordinary loss of oil, find and eliminate the cause.

_______________________________________________________________________ 4.2.2 Bearing with Oil Sight Gauge (639)

_____________________________________________________________________________________

Caution The oil level may drop during start-up of the pump. If the minimum mark is

underrun, top up with oil.

_____________________________________________________________________________________ 4.2.1.1 Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between theminimum and maximum markings of the oil sight gauge (639).

4.2.1.2 Fit the vent plug (913.01 or 672) back again.4.2.2 Bearing with Constant Level Oiler 4.2.3.1 Remove the vent plug (913.01 or 913.02 or 672).4.2.3.2 Hinge down the constant level oiler (638).4.2.3.3 Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant

level oiler until oil appears in the vertical portion of connecting elbow of the constant level oiler, see figureConstant level oiler .

4.2.3.4 Fill the reservoir of the constant level oiler with oil and snap it back into operating position.4.2.3.5 Fit the vent plug (913.01 or 913.02 or 672) back again.4.2.3.6 After a short time check whether the oil level in the reservoir has dropped. It is important to keep at

least one third of reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________

Caution The oil level must always be below the level of the vent opening arranged

at the top of the connection elbow. Make sure the opening is always perfectly dry. _______________________________________________________________________

4.2.4 Other Pump Set ComponentsTop up with oil in accordance with the manufacturer’s documentation.

4.3 Connecting Coupling (if applicable)

4.3.1 Perform all dismantling and reassembly work in accordance with the Dismantling of the Connecting Coupling and Mounting the Connecting Coupling in chapter “Maintenance”.

4.3.2 Perform all servicing work in accordance with the manufacturer’s documentation.

Oil level

Position of

reservoir for

topping up oil

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_____________________________________________________________________

Maintenance


________________________________________________________________________________________

Caution During the warranty period, pumps should be dismantled only by KSB

personnel! _________________________________________________________________________


1.2 Required documentation1.2.1 The following documents are necessary for servicing of pump set.

Sectional Drawing, PumpList of Components, Pump

Documentation of the Mechanical Seal (if applicable)1.2.2 Documentation of Connecting Coupling1.2.3 Documentation of Drive1.2.4 Documentation of the Minimum Flow System (if applicable)1.2.5 Documentation of Valves and Equipment (if applicable)1.2.6 Documentation of the Instrumentation (if applicable)

1.3 Prerequisites1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown

sections of chapter “Commissioning, Start-up/Shutdown) and has been prepared for the servicing work.1.3.2 All spare parts required are available.1.3.3 Proper hoisting tackle and means of transport are available and ready for use.1.3.4 Sufficient room space and appropriate tools are available.

1.3.5 The drive has been secured against unintentional starting.

2. Dismantling the Guards Preventing Accidental Contact2.1 Sound Insulating Hood (If applicable)

Dismantle the sound insulating hood as far as necessary as described in manufacturer’s documentation.2.2 Coupling Guard/Coupling Cover

Dismantle and store the coupling guards and/or coupling covers mounted on the pump set.

Coupling guard ( example ) Coupling cover ( example )

Dismantling the coupling cover. ________________________________________________________________________________________

Caution Do not damage the seal elements and sealing surfaces!

_________________________________________________________________________

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_____________________________________________________________________

2.2.1 Remove all pipes on the cover.2.2.2 Remove the taper pins and screw of the cover split joint.2.2.3 Use the eye bolt as transport aid as shown in the figure Coupling cover .2.2.4 Unscrew the screws in the upper part of the flange.2.2.5 Remove the upper half of the coupling cover.

2.2.6 Remove the internal injection lines.2.2.7 Disconnect the lower half of the coupling cover from the flange and store it.

2.3 Guard Preventing Accidental Contact for Shaft Seal.Dismantle the guard preventing accidental contact as far as necessary and store it.

3. Dismantling the Connecting Coupling3.1 Dismantling the Coupling Connection3.1.1 Give due attention to markings on the coupling, if any, or mark the coupling to rule out later mix-ups.

3.1.2 Dismantle the connecting coupling spacer as described in the manufacturer’s documentation. ____________________________________________________________________________________

! Secure the spacer against falling down.

____________________________________________________________ 3.1.3 Store the parts appropriately.

3.2 Removing the Coupling Hubs3.2.1 Dismantle the retaining ring, if applicable, from the coupling hub.3.2.2 Remove the grub screws (if provided).3.2.3 To facilitate removing, the coupling hub may be heated uniformly to a temperature of 80

0 C max.

_____________________________________________________________________________________

Use protective gloves!

! Risk of fire in case of open flames.

Remove flammable substances from the danger area.

_______________________________________________________________________

3.2.4 Elastomeric parts must be removed before heating! _____________________________________________________________________________________

Caution Elastomeric parts which have been heated must not be used any more.

Use new parts for reassembly. _______________________________________________________________________

3.2.5 Remove the coupling hubs as shown in the figure Removing the coupling hubs.

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_____________________________________________________________________

_____________________________________________________________________________________

! Secure the coupling against falling down. _____________________________________________________________________________________ _____________________________________________________________________________________

Caution Remove the coupling hubs using only the appropriate device to prevent

the shaft bearings form damage by axial frictional force. Impacts on thecoupling are not permitted.

_______________________________________________________________________

3.2.6 Mark the keys prior to removing them.3.2.7 Store the coupling hubs and keys appropriately.

3.3 Run-out Check of the Shaft Ends3.3.1 After removing the coupling hubs check the shaft ends for run-out, see figure Run-out check of shaft ends.

3.3.2 Permissible tolerance ≤ 0.03 mm; if this value is exceeded, inform KSB.

Run-out check of the shaft ends (example)

4. Removing the Pump from the InstallationThe work described in sections 4.1 to 4.3 is required only if the pump is to beremoved from the installation for maintenance.

4.1 Dismantling the Piping and Instruments

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_____________________________________________________________________

_____________________________________________________________________________________

! Operating fluids can run out when unscrewing the pipes and instruments.

These are to be collected and properly disposed of by the Operator.

_____________________________________________________________________________________ 4.1.1 Undo the connections between discharge nozzle and discharge pipe & between suction nozzle and suctionpipe.

4.1.2 Fasten the suction and discharge pipes to temporary holders.4.1.3 Dismantle the minimum flow control valve, if necessary.4.1.4 Disconnect the tapping pipe, if applicable.4.1.5 Detach and dismantle any auxiliary lines such as circulation, cooling liquid and oil pipes as well as

measuring lines as far as necessary.4.1.6 Dismantle the measuring devices and instruments as far as necessary, and store them appropriately.4.1.7 If required, dismantle the cooler of the shaft seal including support.

4.2 Removing the Pump from Baseframe

4.2.1 Unscrew the fastening studs at the pump feet; see the figure Fastening of the pump feet .

1 2 3

6 5 4

1-Pump foot, 2-Nut, 3-Disc, 4-Shims, 5-Stud, 6-Base plate

4.2.2 Loosen nuts and adjusting screws at the guide block; see figure Adjusting screw at the guide casing .

Adjusting screws at the guide casing ( example )

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_____________________________________________________________________

4.3 Transporting the Pump to the Place of Dismantling _______________________________________________________________________________________

The pumps have to be lifted and transported in accordance with the Caution guidelines laid down in the chapter “Transport / Interim Storage”.

Do not fasten the ropes to the shaft ends or the bearing housings. _______________________________________________________________________________________

4.3.1 Lift the pump from the baseframe, transport it to the place of dismantling and set it down on assemblysupports. _____________________________________________________________________________________

! Secure the pump against overturning. _____________________________________________________________________________________

_____________________________________________________________________________________

Mark the matching shims between the pump feet and baseframe so that

Caution they can be inserted in the same place on subsequent reassembly, andstore them appropriately.

_______________________________________________________________________

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_____________________________________________________________________

5. Dismantling the Bearings

5.1 Preparations5.1.1 Prior to dismantling, drain the oil fill of the bearing housings and the thrust bearing housing and dispose of

in accordance with the local anti-pollution regulations.5.1.2 If applicable, dismantle the cooling liquid pipes and oil supply pipes as far as necessary.5.1.3 If applicable, dismantle the oil sight gauge (639) and/or constant level oiler (638) as well as the

thermometer (692.01 or 692.02) and/or RTDs.5.1.4 If applicable, remove the splash ring (507.01 and/or 507.02) on the driven end from the shaft (210) after

loosening the grub screws (904.05, if applicable).

5.2 Dismantling the Add-on Parts (for example flanged-on oil pump, shaft positionindicator, etc.) (if applicable)

5.2.1 For applicable add-on parts, refer Sectional Drawing and P&I Diagram.

5.3 Dismantling the Lift-off Device, with Antifriction Bearings (if applicable)

5.3.1 Unscrew the hex nut (920.08) and remove the bearing end cover (361) including O-ring (412.11).5.3.2 Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).5.3.3 Pull the bearing cartridge (381) including the two angular contact ball bearings (320) out of the thrust

bearing housing (354) using the appropriate device as described in the work instruction UA3 13473 01.Dismantle further, if required. _____________________________________________________________________________________

In case of slight discolourations (incl. rust stain) or any damage, the bearings Caution must be replaced.

Clean used bearings with cleaning oil! After cleaning immediately spray thebearings with oil!

_____________________________________________________________________________________ 5.3.4 Take the springs out of the thrust bearing housing (354).

5.3.5 Take away the thrust bearing housing (354) including O-ring (412.10).5.3.6 If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).5.3.7 Remove the spacer ring (504.01) from the shaft (210).

5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing (if applicable)\5.4.1 Unscrew the hex nuts (920.08) and remove the bearing end cover (361) including O-ring (412.11).5.4.2 Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).5.4.3 Pull the bearing cartridge (381) including the thrust bearing, thrust bearing plate (384) and counter thrust

bearing plate (388) out of the thrust bearing housing (354) using the appropriate device as described in thework instruction UA3 13473 01. Dismantle further, if required. _____________________________________________________________________________________

Caution In case of slight discolourations (incl. rust stain) or any damage, the

bearing segments must be replaced! _______________________________________________________________________

5.4.4 Take the springs out of the thrust bearing housing (354).5.4.5 Take away the thrust bearing housing (354) including O-ring (412.10).5.4.6 If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).5.4.7 Take away the key out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).

5.5 Dismantling the Thrust Bearing (if applicable)5.5.1 Unscrew the hex nuts (920.11) and remove the bearing end cover (361) including thrust bearing (314), O-

ring (412.11), circlip (932.03) and shaft seal (420.01, 562.02).5.5.2 Screw nut (920.09) from the shaft (210).5.5.3 Remove the spacer sleeve (525.05) from the shaft (210).

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_____________________________________________________________________

5.5.4 Remove the thrust bearing plate (384) from the shaft (210) using the appropriate device as described in thework instruction UA3 13475 01 or UA3 14758 01.

5.5.5 Take the key (940.05) out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).5.5.6 Unscrew two opposite hex socket head cap screws between the segments of the thrust bearing (314) and

remove them together with the adjoining segments.

5.5.7 Pull the thrust bearing (314) out of the thrust bearing housing (354) using the appropriate device asdescribed in the work instruction UA3 13475 01 or UA3 14758 01.

5.5.8 Unscrew the hex socket head cap screws (614.04) and take the thrust bearing housing (354) includingparallel pin (562.02), shaft seal ring (420.01) circlip (932.03) and O-ring (412.10) out of the bearing housing(350.01). _____________________________________________________________________________________

Caution In the case of slight discolourations (incl. rust stain) or any damage, the

bearing segments must be replaced! ______________________________________________________________________

5.6 Dismantling the Radial Bearings ______________________________________________________________________________________

Caution When the bearing shells are dismantled, the shaft must not rest on the

bearing housing or labyrinth rings! ________________________________________________________________________

_____________________________________________________________________________________

Caution Mark the bearing shells to ensure their correct assignment to the bearing

housings! Protect the bearing shells against damage! _____________________________________________________________________________________

_____________________________________________________________________________________

Caution In the case of slight discolourations (incl. rust stain) or any damage, the

bearing segments must be replaced! _______________________________________________________________________

5.6.1 HG Pump Sizes 1 and 25.6.1.1 Unscrew the hex head bolts (901.01 and 901.03) and remove the bearing cover (360) and bearing end

cover (361) including O-ring (412.09).5.6.1.2 Remove the pins (560.01) including washers (550.07) and nuts (920.07) as well as hex socket head cap

screw (914.05) including circlips (932.05) and take away the upper part of the bearing housing (350.01)

including the upper half of labyrinth ring (423.01).5.6.1.3 Remove the upper bearing shell (370) and lubricating ring (644, if applicable).5.6.1.4 Remove the lower half of labyrinth ring (423.01) and lower bearing shell (370); for that purpose lift the shaft

(210) using a wooden rod.5.6.2 HG pump sizes 3 to 65.6.2.1 Unscrew the hex head bolts (901.01 and 901.06) and remove the bearing cover (360) and bearing end

cover (361) including O-ring (412.09).5.6.2.2 Remove the hex head bolt (901.13) including washers (550.12) and gasket (411.03).5.6.2.3 If applicable, undo the grub screw (904.06) and dismantle the lubricating ring (644).5.6.2.4 Remove the bearing shell (370) and glued-in labyrinth ring (423.01) and O-ring (412.18) from the shaft,

using the appropriate device as described in the work instruction UA7 23062 01.

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_____________________________________________________________________

5.7 Dismantling the Bearing Housings5.7.1 HG Pump Sizes 1 and 25.7.1.1 Remove the hex head bolts (901.05) and nuts (920.14).5.7.1.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing

housing (350.01).

5.7.1.3 Remove the splash ring (507.01 or 507.02) from the shaft (210).5.7.2 HG Pump Size 35.7.2.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts

(921.14).5.7.2.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing

housing (350.01).5.7.2.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws

(904.05, if applicable).5.7.3 HG Pump Sizes 4 to 6.5.7.3.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts

(921.14).5.7.3.2 Unscrew the nuts (920.04) at the studs (902.01) and take away the bearing housing (350.01).5.7.3.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws

(904.05, if applicable).

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_____________________________________________________________________

6 Dismantling the Shaft Seal

6.1 Preparations

Dismantle any cooling, flushing, quenching pipes, wherever applicable. All the openings should be plugged.

6.2 Dismantling the Mechanical Seal.(Part numbers, specified in the following description are only representative) _______________________________________________________________________________________

Caution Refer order specific sectional drawing of mechanical seal for correct part

numbers as well as description! Refer Manufacturer’s documentation!

_______________________________________________________________________________________

6.2.1 Make : Eagle Poonawalla6.2.1.1 Shaft Seal6.2.1.1.1 Loosen the hex bolt (14) and locate the sliding washer (13) into the groove provided on the sleeve (6)

and tighten the hex bolt (14).6.2.1.1.2 Loosen socket screws (12) and dog point screws (17).6.2.1.1.3 Unscrew and remove fixing screws of gland plate (4).6.2.1.1.4 With the help of jacking bolts, provision made on gland plate (4), remove cartridge off the shaft (210).

Follow the same procedure to pull out the mechanical seal cartridge on the discharge side.6.2.1.2 Dismantling of Cartridge (if required).6.2.1.2.1 Remove hex bolt (14) and sliding washer (13). For removing sliding washers, slightly compress the

springs (e) of the mechanical seal.6.2.1.2.2 Remove socket screws (12) and dog point screw (17) from the drive collar (11).6.2.1.2.3 Remove drive collar (11) from the sleeve (6).

6.2.1.2.4 Remove the mechanical seal rotary head assembly consisting of components a,b,c,d,e,f. _____________________________________________________________________________________

Caution Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical

seal components should be replaced by new ones. _______________________________________________________________________ _____________________________________________________________________________________

Caution In the event of slight scoring marks on the rubbing faces of seal ring (b)

and mating ring (2), they can be sent back to the manufacturer fortouching up.

_____________________________________________________________________________________

6.2.2 Make : Flowserve Sanmar 6.2.2.1 Shaft Seal6.2.2.1.1 Loosen the cap screw (K) and locate retaining plate (15) into the groove provided on the sleeve (10)

and tighten the cap screw (K).6.2.2.1.2 Loosen set screws (13) of sleeve collar (9).6.2.2.1.3 Unscrew and remove fixing screws of gland ring (1).6.2.2.1.4 With the help of jacking bolts, provision made on gland ring (1), remove cartridge off the shaft (210).

Follow the same procedure to pull out the mechanical seal cartridge on the discharge side.6.2.2.2 Dismantling of Cartridge (if required).6.2.2.2.1 Remove cap screw (K) and retaining plate (15). For removing retaining plate, slightly compress the

spring’s (c) of the mechanical seal.6.2.2.2.2 Remove socket screws (13) and dog point screw (12) from the sleeve collar (9).

6.2.2.2.3 Remove sleeve collar (9) from the sleeve (10).6.2.2.2.4 Remove the mechanical seal rotary head assembly consisting of components 3,4,45,5,c,d,e,p.

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_____________________________________________________________________

_____________________________________________________________________________________

Caution Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical

seal components should be replaced by new ones.

_______________________________________________________________________ _____________________________________________________________________________________

Caution In the event of slight scoring marks on the rubbing faces of seal ring (b)

and mating ring (2), they can be sent back to the manufacturer fortouching up.

____________________________________________________________________________________________

6.2.3 Make : Burgmann6.2.3.1 Shaft Seal6.2.3.1.1 Loosen the hex bolt (15) and locate the assembly fixture (14) into the groove provided on the sleeve (6)

and tighten the hex bolt (15).6.2.3.1.2 Loosen set screws (13) of clamping ring (11).6.2.3.1.3 Unscrew and remove fixing screws of gland (4).6.2.3.1.4 With the help of jacking bolts, provision made on gland (4), remove cartridge off the shaft (210). Follow

the same procedure to pull out the mechanical seal cartridge on the discharge side.6.2.3.2 Dismantling of Cartridge (if required).

6.2.3.2.1 Remove hex bolt (15) and assembly fixture (14). For removing assembly fixture, slightly compress thesprings (1.4) of the mechanical seal.

6.2.3.2.2 Remove set screws (12) and (13) from the clamping ring (11).6.2.3.2.3 Remove clamping ring (11) from the sleeve (6).6.2.3.2.4 Remove the mechanical seal rotary head assembly consisting of components 1.1,1.2,1.3,1.4,1.5,1.6.

_____________________________________________________________________________________

Caution Damaged sleeve (6), seal face (1.1), seat (2) and other mechanical seal components should be replaced by new ones.

_______________________________________________________________________ _____________________________________________________________________________________

Caution In the event of slight scoring marks on the rubbing faces of seal face (1.1)

and seat (2), they can be sent back to the manufacturer for touching up. ______________________________________________________________________________________________

6.3 Dismantling the Casing Parts6.3.1 HG Pump Sizes 1 and 2

6.3.1.1 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part(130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable).

6.3.2 HG Pump Sizes 3 to 66.3.2.1 If applicable, loosen and remove the hex socket head cap screws (914.08, non-driven end).6.3.2.2 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part

(130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable).6.3.2.3 If applicable, loosen and remove the hex nuts (920.04 or 920.05) on the studs (902.01, on either end or

902.05, on the driven end).6.3.2.4 Fasten the seal casing (441 or 441.01 or 441.02 as per the execution) to the crane by means of eyebolt

and rope, force off with screws and remove it. Unscrew the hex socket head cap screws (914.09, if applicable).

6.3.2.5 On the driven end, loosen and remove hex nuts (920.05) on the studs (902.05) or the hex socket head capscrews (914.15, if applicable), fasten the casing part (130) to the crane by means of eyebolt and rope,

force off with screws and remove it.

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_____________________________________________________________________

7. Dismantling the Balancing Device

7.1 HG Pump Sizes 1 and 27.1.1 Remove the spacer ring (504.02) and if applicable spacer sleeve (525.02) from the shaft (210).7.1.2 Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the

work instruction UA2 13474 017.1.3 Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as

described in the work instruction UA2 13474 017.1.4 Check the balancing disc (601.01) and counter balancing disc (602.01) for signs of damage.

7.2 HG Pump Size 37.2.1 Pull the retainer ring (505.01) from the shaft (210) and remove key (940.07) and split ring (501.01).7.2.2 Remove the spacer ring (504.02) or spacer sleeve (525.02) from the shaft (210).7.2.3 Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the

work instruction UA2 14761 01.7.2.4 Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as

described in the work instruction UA2 14761 01.7.2.5 If applicable, take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from

the shaft (210).7.2.6 Check the balancing disc (601.01), the counter balancing disc (602.02) and throttle sleeve (522.01), if

applicable, for signs of damage.

7.3 HG Pump Size 47.3.1 Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.07) out of the shaft keyway.7.3.2 Unscrew the hex socket head cap screws (914.10) and pull off the retainer ring (505.01).7.3.3 Take the split ring (501.01) out of the shaft groove and pull the spacer ring (504.02) from the shaft (210).7.3.4 Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the

work instruction UA2 14765 01.7.3.5 Unscrew the hex socket head cap screw (914.06) and pull the counter balancing disc (602.01) out of the

discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 01.

7.3.6 Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft.7.3.7 Check the balancing disc (603.02), counter balancing disc (602.01) and throttle sleeve (522.01) for signs of damage.

7.4 HG Pump Sizes 5 and 67.4.1 Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.06) out of the shaft keyway.7.4.2 Unscrew the hex socket head cap screws (914.10) and remove the retainer ring (505.01).7.4.3 Take the split ring (501.01) out of the shaft groove and remove the spacer ring (504.02) from the shaft

(210).7.4.4 Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the

work instruction UA2 14765 027.4.5 Unscrew the hex socket head cap screw (914.06) and pull the counter balancing disc (602.01) out of the

discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 02.

7.4.6 Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft (210).7.4.7 Pull the throttle bush (542.01) out of the discharge casing (107) using the appropriate device as describedin the work instruction UA2 14765 02.

7.4.8 Check the balancing disc (603.02), counter balancing disc (602.01), throttle bush (542.01) and throttlesleeve (522.01) for signs of damage.

7.5 Measuring the Approximate Radial Clearance _______________________________________________________________________________________

Caution Measure the approximate radial clearance if the pump body is not to be

dismantled. Exact checking of the rotor clearance is possible only with the pump

dismantled. _________________________________________________________________________________________________

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_____________________________________________________________________

7.5.1 Place the dial gauge holder on a firm base (for example flange or discharge nozzle) and position the dialgauge on the seat of the balancing piston as shown in the figure Measuring the approximate radial clearance.

7.5.2 Carefully lift the shaft until it abuts on the top. Shaft deflection must not be increased (incorrectmeasurement).

7.5.3 The diametrical clearance determined this way must not exceed 0.8 mm; if it does, the pump must bedismantled and overhauled.

8. General Information on Reassembly8.1 Meticulously clean all dismantled components, in particular the fit and sealing surface areas.

________________________________________________________________________________________

Caution Do not damage the locating and sealing surfaces! ________________________________________________________________________________________

8.2 If required, remove any lime and incrustation from the cooling chambers.8.3 Check all dismantled components for signs of damage.

8.4 If required, use new parts.8.5 As a general rule, always use new O-rings and gaskets for reassembly. ________________________________________________________________________________________

Caution Do not take the O-rings out of their original packing until those are actually

required to be fitted and protect them from mineral oil and grease! _________________________________________________________________________

_________________________________________________________________________ Caution Do not fit the O-rings in dry condition but wet them with silicone grease! In

exceptional cases, soapy water may be used. ________________________________________________________________________ 8.6 Prior to reassembly coat the screw/bolt connections and pipe unions as well as the fits of the individual

components using respective specified lubricating agent as described in the work instruction UA4 28699 01.8.7 Reassembly must be performed in accordance with the rules of good engineering practice.

9. Checking the Balancing Device with the Contact Fluid “Engineers Blue”.The steps 9.1 to 9.3 are required only if balancing piston (603.02) or counter balancing disc (602.02) were remachined or replaced.

9.1 HG Pump Sizes 1 and 29.1.1 Meticulously clean the axial running face of the counter balancing disc (602.02).9.1.2 Insert the grooved pin (561.03) in the discharge casing (107).

HG Pump Sizes 1 - 3

Measuring the approximate radial clearanceHG Pump Sizes 4 - 6

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_____________________________________________________________________

9.1.3 Fit the counter balancing disc (602.02) without O-rings (412.04 and/or 412.05). The grooved pin (561.03)must engage in the groove of the counter balancing disc (602.02).

9.1.4 Adjust the pump rotor position; see figure Adjusting pump rotor position.

5 0 2 . 0 2 2 3 0 . 0 2

1 7 1 . 0 2

A d j u s t i n g t h e p u m p r o t o r p o s i t i o n

S a 2

S a 1

9.1.4.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the non-driven end. _____________________________________________________________________________________

Caution This rotor position must not be changed when measuring the balancing

device! _____________________________________________________________________________________

9.1.5 Adjust the balancing disc (601.01); see figure Adapting the balancing piston.

Adapting the Balancing disc

9.1.5.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of the last stage.

9.1.5.2 Shorten the balancing disc (601.01) to the dimension “b1” as sown in the figure Adapting the balancing disc : b1 = a1 – SL2 (SL2, see table of clearances).

9.1.6 Adapt the spacer ring (504.02); see figure Adapting the spacer ring .

a1

602.01

b1 Sl2

Machine here

601.01504.02

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_____________________________________________________________________

Adjusting the spacer ring

9.1.6.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the shaft collar.9.1.6.2 Determine the dimension “b” between the running face and face of balancing disc (601.01) as well as the

length “y” of the spacer sleeve (525.02, if applicable).9.1.6.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b or a = x - b-y. The maximum permissible

deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.02)!

_______________________________________________________________________

9.1.7 Insert the key (940.04).9.1.8 Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the

balancing piston (601.01) without O-ring (412.02) on the shaft (210).9.1.9 Slide the spacer sleeve (525.02, if applicable) and spacer ring (504.02) over the shaft (210)9.1.10 Mount the casing part (130, if applicable) and seal casing (441) without O-rings.

9.1.11 Mount the shaft sleeve (524.01, pump with gland packings).9.1.12 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section so far

as to make the free rotation of the pump rotor possible.9.1.13 For the check with the contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it

slowly.9.1.14 Move the pump rotor to the non-driven end and dismantle all pump components including the counter

balancing disc (602.01) in reverse order.9.1.15 At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the

contact fluid in the upper zone. If this is not the case, remachining the counter balancing disc (602.01) on alathe and repeat the contact fluid checks.

9.1.16 After completion of the contact fluid check, clean the axial running faces of the balancing piston (601.01)and counter balancing disc (602.01).

9.2 HG Pump Size 39.2.1 Meticulously clean the axial running face of the counter balancing disc (602.02).9.2.2 Insert the grooved pin (561.03) in the discharge casing (107).9.2.3 Fit the counter balancing disc (602.01) without O-rings (412.04 or 412.05). The grooved pin (561.03) must

engage in the groove of the counter balancing disc (602.01).9.2.4 If applicable, slide throttle sleeve (522.01) without O-ring (412.02) over the shaft (210) and hey (940.03)

until abutting against the impeller (230.02).9.2.5 Adjust the pump rotor position; see figure Adjusting the pump rotor position.

b

x

a

504.02 601.01 602.01

Varient without spacer sleeve Varient with spacer sleeve (525.02)

602.01601.01525.02504.02

a

x

by

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_____________________________________________________________________

5 0 2 . 0 2 2 3 0 . 0 2

1 7 1 . 0 2

A d j u s t i n g t h e p u m p r o t o r p o s i t i o n

S a 2

S a 1

9.2.5.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the non-driven end. _____________________________________________________________________________________

Caution The rotor position must not be changed when the measuring the balancing

device! _______________________________________________________________________

9.2.6 Adapt the throttle sleeve (522.01) and/or balancing disc (601.01); see figure Adapting the throttle sleeve or figure Adjusting the balancing disc .

Machine

here

Machine

here

522.01601.01504.02

Adapting the throttle sleeve

602.01

Adapting the balance disc

504.02 601.01602.01

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_____________________________________________________________________

9.2.6.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of the last stage and, if required, the dimension “c1” of the balancing disc (601.01).

9.2.6.2 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting thethrottle sleeve and/or the balancing disc (601.01) in accordance with the figure Adapting the balancing disc : b1 = a1 – c1 – Sl2 or b1 = a1 – Sl2 (Sl2 see tables of clearances).

9.2.7 Adapt the spacer ring (504.2) or spacer sleeve (525.02); see figure Adapting the spacer ring or see figure Adapting the spacer sleeve.

9.2.7.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring(501.01).

9.2.7.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01).9.2.7.3 Shorten the spacer ring (504.02) or spacer sleeve (525.02) to the dimension “a” : a = x – b. The maximum

permissible deviation form plane parallelism is 0.02 mm.

_____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.02)or spacer sleeve

(525.02)! _______________________________________________________________________

9.2.8 Insert the key (940.04).9.2.9 Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the

balancing disc (601.01) without O-ring (412.02) on the shaft (210).9.2.10 Slide the spacer ring (504.02) or spacer sleeve (525.02, if applicable) over the shaft (210).9.2.11 Insert the key (940.07) and split ring (501.01) into the shaft groove, slide the retainer ring (505.01) over

them.

9.2.12 Mount the casing part (130, if applicable) and seal casing (441) without O-rings.9.2.13 Fit the driven-end and non-driven end bearings in accordance with the Mounting the Bearings section, sofar as to make possible the free rotation of the pump rotor.

9.2.14 For the check with contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly.9.2.15 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing

disc (602.01) in reverse order.9.2.16 At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the

contact fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.02) on alathe and repeat the contact fluid check.

9.2.17 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) andcounter balancing disc (602.01).

9.3 HG Pump Size 4

9.3.1 Meticulously clean the axial running face of counter balancing disc (602.01).

504.02 601.01 602.01 522.01

Adapting the spacer ring

525.02 601.01

Adapting the spacer sleeve

602.01 522.01

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_____________________________________________________________________

9.3.6.1 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttlesleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances).


9.3.7.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring(501.01).

9.3.7.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01).9.3.7.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b. The maximum permissible deviation from

plane parallelism is 0.02 mm. _____________________________________________________________________________________


_______________________________________________________________________

9.3.8 Insert the key (940.04).9.3.9 Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing

disc (601.01) without O-ring (412.02) on the shaft (210).9.3.10 Slide the spacer ring (504.02) over the shaft (210).9.3.11 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the

balancing disc (601.01), using hex socket head cap screws (914.10).9.3.12 Mount the casing part (130) and seal casing (441) without O-rings.9.3.13 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so

far as to make possible the free rotation of the pump rotor.9.3.14 For the check with contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly.9.3.15 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing



9.3.17 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) andcounter balancing disc (602.01).

9.4 HG Pump Sizes 5 and 69.4.1 Meticulously clean the axial running face of the counter balancing disc (602.01).9.4.2 Fit the throttle bush (542.01) without O-ring (412.05).9.4.3 Insert the parallel pin (562.03) in the discharge casing (107).

9.4.4 Insert the key (940.03) and slide the throttle sleeve (522.01) without O-ring (412.02) over the shaft (210)and key (940.03) until abutting against the impeller (230.02).

a b

x

504.02 601.01 602.01 522.01


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_____________________________________________________________________

9.4.5 Fit the counter balancing disc (602.01) without O-ring (412.16) and fasten with the hex socket cap screws(914.06). The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01).

9.4.6 Place the pump rotor in the center of the overall axial clearance ( Sa1 + Sa2); see figure Adjusting the pumprotor position.

_____________________________________________________________________________________

Caution This rotor position must not be changed when measuring the balancing

device! _______________________________________________________________________

9.4.7 Adapt the throttle sleeve (522.01); see figure Adapting the throttle sleeve.

502.02

171.02

230.02

Adjusting the pump rotor position

Sa2

Sa1

a1

c1 b1 Sl2

Machine

here

522.01601.01504.02542.01602.01

Adapting the throttle sleeve

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_____________________________________________________________________

9.4.7.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of last stage and the dimension “c1” of the balancing disc (601.01).

9.4.7.2 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttlesleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances).


9.4.8.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring

(501.01).9.4.8.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01).9.4.8.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b. The maximum permissible deviation from

plane parallelism is 0.02 mm. _____________________________________________________________________________________


_______________________________________________________________________

9.4.9 Insert the key (940.04).9.4.10 Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing

disc (601.01) without O-ring (412.02) on the shaft (210).9.4.11 Slide the spacer ring (504.02) over the shaft (210).9.4.12 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the

balancing disc (601.01), using hex socket head cap screws (914.10).9.4.13 Mount the casing part (130) and seal casing (441) without O-rings.9.4.14 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so

far as to make possible the free rotation of the pump rotor.9.4.15 For the check with contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly.9.4.16 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing



9.4.18 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and

counter balancing disc (602.01).

a b

x

504.02 601.01 602.01 522.01 542.01


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_____________________________________________________________________

10. Mounting the Balancing Device ______________________________________________________________________________________

If the throttle sleeve (522.01), balancing disc (601.01) or counter balancing

Caution disc (602.01) were remachined or replaced, the check with the contactfluid “engineer’s blue” as outlined in sections 9.1 to 9.4 must be performed!

_____________________________________________________________________________________

10.1 HG Pump Sizes 1 and 210.1.1 Insert the grooved pin (561.03) in the discharge casing (107).10.1.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03)

must engage in the groove of the counter balancing disc (602.01).10.1.3 Adjust the pump rotor position; see figure Adjusting the pump rotor position.

10.1.3.1 Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to thenon-driven end.

10.1.4 Insert the key (940.04).

10.1.5 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc(601.01) over the shaft (210) until abutting against the counter balancing disc (602.01).

10.2 HG Pump Size 310.2.1 Insert the grooved pin (561.03) in the discharge casing (107).10.2.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03)

must engage in the groove of the counter balancing disc (602.01).10.2.3 If applicable, slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key

(940.03) until abutting against the impeller (230.02).

10.2.4 Adjust the pump rotor position; see figure Adjusting the pump rotor position.

502.02 230.02

171.02

3mm


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_____________________________________________________________________

10.2.4.1 Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to thenon-driven end.

10.2.5 Insert the key (940.04).10.2.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc

(601.01) over the shaft until abutting against the counter balancing disc (602.01).10.2.7 Slide the spacer ring (504.02) or spacer sleeve (525.02) over the shaft (210).10.2.8 Insert the key (940.07) and split ring (501.01) in the shaft keyway and slide the retainer ring (505.01) over

them.

10.3 HG Pump Size 410.3.1 Insert the parallel pin (562.03) in the discharge casing (107).10.3.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex

socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin(562.03) must engage in the groove of the counter balancing disc (602.01).

10.3.3 Insert the key (940.04) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210)and key (940.04) until it abuts against the impeller (230.02).

10.3.4 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pumprotor position.

10.3.5 Insert the key (940.04).

502.02 230.02

171.02

3mm


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_____________________________________________________________________

10.3.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01)over the shaft (210) until it abuts against the counter balancing disc (602.01).

10.3.7 Slide the spacer ring (504.02) over the shaft (210).10.3.8 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the

balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevantwork instruction.

10.3.9 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.

10.4 HG Pump Sizes 5 and 610.4.1 Fit the throttle bush (542.1) including O-ring (412.05).10.4.2 Insert the parallel pin (562.03) in the discharge casing (107).10.4.3 Insert the key (940.03) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210)

and key (940.03) until it abuts against the impeller (230.02).10.4.4 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex

socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin(562.03) must engage in the groove of the counter balancing disc (602.01).

10.4.5 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pumprotor position.

10.4.6 Insert the key (940.04).

Sa2

Sa1

502.02

171.02

230.02


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_____________________________________________________________________

10.4.7 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01)over the shaft (210) until it abuts against the counter balancing disc (602.01).

10.4.8 Slide the spacer ring (504.02) over the shaft (210).

10.4.9 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to thebalancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevantwork instruction.

10.4.10 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.

Sa2

Sa1

502.02

171.02

230.02


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_____________________________________________________________________

11. Mounting the Shaft Seal11.1 Mounting the Housing Components11.1.1 HG Pump Size 1 to 311.1.1.1 In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in

position.11.1.1.2 If applicable, mount on the driven end casing part (130) including O-rings (412.06 or 412.13, if

applicable) and parallel pin (562.11, if applicable). The parallel pin (562.11) must engage in the grooveof the counter balancing disc (602.02).

11.1.1.3 Mount the seal casing (441 or 441.01 and 441.02, depending upon the execution). Fit hex socket headcap screws (914.09, if applicable).

11.1.2 HG Pump Sizes 4 to 611.1.2.1 In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in

position.11.1.2.2 Insert O-ring (412.19) in the groove of the casing part (130, non driven end) and fit the casing part to

the discharge casing (107).11.1.2.3 Depending upon the execution, fit the washers (550.05 or 550.09) and hex nuts (920.05 or 920.04), or

hex socket head cap screws (914.09) and tighten them; tightening torque, see the relevant work

instruction.11.1.2.4 Depending upon the execution, fit again the studs (902.01 or 602.05) on the non driven end, if they

have been removed.11.1.2.5 Fit the seal casing (441 or 441.01 and 441.02, depending upon the execution) including O-rings

(412.07 and 412.08) to the suction casing (106) and/or casing part (13.0). Fit the hex socket head capscrews (914.09, if applicable).

11.2 Assembling the Shaft Seal(Part no.s specified in the following description are only representative)

Caution Refer order specific sectional drawing of mechanical seal for correct part

numbers as well as description. Refer manufacturer’s documentation.

_______________________________________________________________________________________

11.2.1 Make : Eagle Poonawalla11.2.1.1 Slide mechanical seal cartridge [attached to gland plate (4)] on the shaft until the gland plate (4) gets

located on seal casing (441).11.2.1.2 Tighten the nuts of gland plate.11.2.1.3 Tighten set screws (12 and 17) of drive collar (11).11.2.1.4 Loosen the bolt (14) and take aside the sliding washer (13) from the groove of the sleeve (6).11.2.1.5 Slip splash ring (507) onto the shaft.

11.2.2 Make : Flowserve Sanmar

11.2.2.1 Slide mechanical seal cartridge [attached to gland ring (1)] on the shaft until the gland ring (1) getslocated on seal casing (441).11.2.2.2 Tighten the nuts of gland plate.11.2.2.3 Tighten set screws (13) of sleeve collar (9).11.2.2.4 Loosen the cap screw (K) and take aside the retaining plate (15) from the groove of the sleeve (10).11.2.2.5 Slip splash ring (507) onto the shaft.

11.2.3 Make : Burgmann11.2.3.1 Slide mechanical seal cartridge [attached to gland (4)] on the shaft until the gland (4) gets located on

seal casing (441).11.2.3.2 Tighten the nuts of gland.11.2.3.3 Tighten set screws (13) of clamping ring (11).11.2.3.4 Loosen the hex bolt (15) and take aside the assembly fixture (14) from the groove of the sleeve (6).

11.2.3.5 Slip splash ring (507) onto the shaft.

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_____________________________________________________________________

12. Mounting the Bearings

12.1 Mounting the Bearing Housing and Lifting the Pump Rotor 12.1.1 HG Pump Sizes 1 and 212.1.1.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210).

12.1.1.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tightenthe hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing.

12.1.1.3 On the driven end, slide the bearing cover (360) including O-ring (412.09) and if applicable the splashring (507.01 and/or 507.02) over the shaft (210). Do not yet fasten the bearing cover to the bearinghousing.

12.1.1.4 Fit the pump coupling hub as described under Mounting the connecting coupling .12.1.1.5 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work

instruction UA7 28679 01.12.1.1.6 The lifting values (only approximate values) are stamped on the bearing housings and marked with “Lift

up”. They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increased within the permissible limits, half the clearance increase must be added to the liftingvalues.

_____________________________________________________________________________________

Caution When the bearing shells and labyrinth rings are dismantled the shaft must

not rest on the bearing housing! _______________________________________________________________________

12.1.1.7 On the driven and non driven ends insert the lower bearing shells (370) and read the vertical pumprotor displacement at the dial gauges. To facilitate inserting the bearing shells (370), lift the shaft (210)using a wooden rod.

12.1.1.8 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex headbolts (901.05).

_____________________________________________________________________________________

Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________

12.1.1.9 In order to check the measured values, remove the bearing shells (370) and insert them again. Themeasured values must be reached again. Enter the lifting values in the check data sheet.

12.1.1.10 The bearing housings (350.01) are aligned laterally by means of the horizontally fitted hex head bolts(901.05). The exact lateral alignment has been achieved when the lower bearing shells (370) can beplaced easily from either side in their fits between shaft (210) and bearing housing (350.01).

____________________________________________________________________________________

Caution This adjustment may only be effected by trained specialist personnel!

_______________________________________________________________________________

12.1.1.11 After having completed rotor lifting, lock the hex head bolts (901.05) with nuts (920.14) and tighten thehex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction.

12.1.2 HG Pump Sizes 3 to 612.1.2.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210).12.1.2.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten

the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing.12.1.2.3 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work

instruction UA7 23062 01.12.1.2.4 The lifting values (only approximate values) are stamped on the bearing housings and marked with “Lift up”.

They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increasedwithin the permissible limits, half the clearance increase must be added to the lifting values.

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_____________________________________________________________________ _____________________________________________________________________________________

Caution When the bearing shells and labyrinth rings are dismantled the shaft must

not rest on the bearing housing! _______________________________________________________________________

12.1.2.5 On the driven and non driven ends insert the half ring (tool 969.85) in accordance with the work instructionUA7 23.062 01and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting of the half rings (tool 969.85), lift the shaft (210) using wooden rod.

12.1.2.6 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex headbolts (901.05).

_____________________________________________________________________________________


_______________________________________________________________________

12.1.2.7 In order to check the measured values, remove half rings (969.85) and insert them again. The measuredvalues must be reached again. Enter the lifting values in the check data sheet.

12.1.2.8 Check the position of the shaft in relation to the bearing housing by means of the instrument holder (699.71) and fitted measuring instrument (690) and adjust the position, if required, by means of the hexbolts (901.05); see work instruction UA7 23062 01.

____________________________________________________________________________________


_______________________________________________________________________________

12.1.2.9 After having completed rotor lifting, tighten hex nuts (920.04 and/or 920.05) uniformly; tightening torque,see the relevant work instruction; and fix the bearing housing (350.01) with the taper pins (560.02); if necessary, drill out and ream the holes. Position the splash ring (507.01 and/or 507.02) and tighten thegrub screws (904.05, if applicable).

12.2 Mounting the Radial Bearings _____________________________________________________________________________________

Caution When mounting the bearings, the holes for thermometers in the bearing

shells and the associated thermometer connections in the bearinghousings must be aligned!

_____________________________________________________________________________________

12.2.1 HG Pump Sizes 1 and 212.2.1.1 Turn the lower bearing shells (370) and lower labyrinth ring half (423.01) in the bearing housing bottom

part (350.01); for that purpose lift the shaft (210) using a wooden rod.12.2.1.2 Fit the lubricating ring (644, if applicable) and the upper bearing shell (370) including parallel pin (562.01).12.2.1.3 Place the upper labyrinth ring half (423.01) including the parallel pin (562.10) in the bearing housing top

part (350.01).12.2.1.4 Mount the bearing housing top part (350.01) including the upper labyrinth ring half (423.01) and fix with

the taper pins (560.01). The parallel pin (560.01) must engage in the groove of the bearing housing toppart (350.01).

12.2.1.5 Fit the hex socket head cap screws (914.05) including circlips (932.05) and tighten them uniformly;tightening torque, see the relevant work instruction.

12.2.1.6 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tightenthe hex head bolts (901.01 or 901.03) uniformly; tightening torque, see the relevant work instruction.

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_____________________________________________________________________

Additional Work for Pumps with Balancing Disc :12.2.1.7 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the


12.2.1.8 For rotor position indicator the description under “Supervision of Rotor Position” in the section “PumpSupervision Plan”.

12.2.2 HG Pump Sizes 3 to 612.2.2.1 Place the bearing shell (370) with glued-in labyrinth ring (423.01) and O-ring (412.18) in the bearing

housing (350.01). _____________________________________________________________________________________

Caution The labyrinth ring has been glued in the bearing shell with Loctite 75/AVV

or equivalent!

12.2.2.2 Fit and tighten the hex head bolts (901.13) including washer (550.012) and gasket (411.03); the bolt mustengage in the bearing shell groove.

12.2.2.3 If applicable, fit the lubricating ring (644).

12.2.2.4 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tightenthe hex head bolts (901.01 or 901.06) uniformly; tightening torque, see relevant work instruction.

Additional Work for Pumps with Balancing Disc :12.2.2.5 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the


12.2.2.6 For rotor position indicator the description under “Supervision of Rotor Position” in the section “PumpSupervision Plan”.

12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings.12.3.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09).12.3.2 Fit the thrust bearing housing (354) including O-ring (412.10) and springs (950).

12.3.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts againstcounter balancing disc (602.01).

12.3.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with rolling element bearing .

12.3.4.1.1 Measure the dimension “a” from the face of the thrust bearing housing (354) to the bottom faces of thesprings (950), dimension “b” between the contact face of the angular contact ball bearing and the

springs’ contact face of the bearing cartridge (381) as well as the distance “c” from the face of thethrust bearing housing (354) to the shaft collar.

z

y

b

a

c

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_____________________________________________________________________

12.3.4.2 Calculate the auxiliary dimension “x” : x = a – b – 30 mm. (30 mm = installation length of the prestressedsprings).

12.3.4.3 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation fromparallelism is 0.02 mm.

_____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.01)! _____________________________________________________________________________________

12.3.5 Slide the spacer ring (504.01) over the shaft (210).12.3.6 Mount the bearing cartridge (381) including two angular contact ball bearings (320) and the circlip

(932.04).12.3.7 Screw in the hex socket head cap screw (914.03), fit and tighten the shaft nit (920.09).12.3.8 Check the lift-off limitation “z” : when the balancing disc (601.01) abuts against the counter balancing disc

(602.01), the specified value is 1±0.1 mm. If required, remachine the bearing end cover (361); see figure Adjusting the lift-off device with rolling element bearing .

12.3.9 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354).12.3.10 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with tightening torque given in the

relevant work instruction.

12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Thrust Bearing12.4.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09).12.4.2 Fit the thrust bearing housing (354) including O-ring (4121.10) and springs (950).12.4.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the

counter balancing disc (602.01).12.4.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with tilting-pad thrust bearing .

12.4.1.1 Measure the dimension “a” from the face of the thrust bearing housing (354) to the bottom faces of springs (950), dimension “b” from the thrust bearing plate (384) to the springs’ contact faces on thebearing cartridge (381), distance “c” from the face of the thrust bearing housing (354) to shaft collar aswell as the dimension “d” of the thrust bearing plate.

12.4.1.2 Calculate the auxiliary dimension “x” : x = a – b + d – 30 mm. (30 mm = installation length of the pre-stressed springs.

12.4.4.2 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation fromparallelism is 0.02 mm.

_____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.01)! _____________________________________________________________________________________

z

d

y

b

a

f

x

e

c

Slg1

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_____________________________________________________________________

12.4.5 Slide the spacer ring (504.01) over the shaft (210).12.4.6 If parts of the lift-off device have been reworked or replaces , adjust the thrust bearing clearance “S lg1”

as shown in the figure Adjusting the lift-off device with tilting-pad bearing.12.4.6.1 Measure the distance “e” from the contact face of the bearing cartridge (381) to the circlip (932.04).12.4.6.2 Determine the total length “f” of the thrust bearing (314) and thrust bearing plate (384).

12.4.6.3 Shorten the counter thrust bearing plate (388) to the dimension “x” : x = e – f – Slg1 (Slg1, seetable of clearances). The maximum permissible deviation from plane parallelism is 0.02 mm.

_____________________________________________________________________________________

Caution As a general rule, always use a new counter thrust bearing plate (388)!

_______________________________________________________________________

12.4.7 Mounting the bearing cartridge (381) :12.4.7.1 Fit the parallel pin (562.02) and shaft seal (420.01) in the bearing cartridge (381) and fasten them

with the circlip (932.03).12.4.7.2 Fit the thrust bearing (314) including parallel pin; the parallel pin must engage in the groove of the

bearing cartridge (381).

12.4.7.3 Insert the thrust bearing plate (384).12.4.7.4 Fit the parallel pin (562.02) and shaft seal (420.01) to the counter thrust bearing plate (388) andfasten with the circlip (932.03).

12.4.7.5 Mount the counter thrust bearing plate (388) so that the groove in the counter thrust bearing plateis in alignment with the hole in the bearing cartridge (381) and insert the circlip (932.03).

12.4.8 Insert the key (940.05) and slide the completely assembled bearing cartridge (381) on the shaft (210).12.4.9 Screw in the hex socket head cap screw (914.03), and fit and tighten the shaft nut (920.09).12.4.10 Check the lift-off dimension “z” : when the balancing disc (601.01) abuts against the counter balancing

disc (602.01), the specified value is 1±0.1 mm. If required, remachine the bearing end cover (361); seefigure Adjusting the lift-off device with tilting-pad thrust bearing.

12.4.11 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354).12.4.12 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with the tightening torque given in

the relevant work instruction.

12.5 Mounting the Thrust Bearing (if applicable) _____________________________________________________________________________________

Caution When mounting the bearings, the holes for thermometers in the bearing

shells and the associated thermometer connections in the bearinghousings and/or bearing end cover must be aligned!

_______________________________________________________________________

12.5.1 Fit the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01), circlip (932.03)and O-ring (412.10) in the bearing housing (350.01).

12.5.2 Fit the hex socket head cap screws (914.04) including the gaskets (411.02) and tighten the screws with thetightening torque given in the relevant work instruction.

12.5.3 Mount the thrust bearing (314) including all segments and fit it in the thrust bearing housing (354).12.5.4 Move the pump rotor in the direction of the driven end until the balancing piston (603.02) abuts against the

counter balancing disc (602.02).12.5.5 Adjust the axial clearance “Sl3” at the balancing piston and “S lg2” at thrust bearing as shown in the figure

Adjusting the thrust bearing .

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_____________________________________________________________________

12.5.5.1 Measure the distance “a” from the bearing face of the thrust bearing (314) to the shaft collar.12.5.5.2 Shorten the spacer ring (504.01) to the dimension “b” : b = a – Sl3 (Sl3 see table of clearances). Themaximum permissible deviation from the plane parallelism is 0.02 mm.

_____________________________________________________________________________________


______________________________________________________________________

12.5.5.3 Measure the distance “c” from bearing face of the thrust bearing (314, in bearing end cover) to the contactface of the bearing end cover (361), distance “d” from the bearing face of the thrust bearing (314, in thethrust bearing housing) to the contact face of the thrust bearing housing (354), and width “e” of the thrustbearing plate (384).

12.5.5.4 Calculate the bearing clearance : Slg2 = c + d – e.12.5.5.5 If the bearing clearance is within the permissible limits given in the table of clearances, the thrust bearing

may be mounted. If the clearance is too large, the contact face of the bearing end cover (361) must beremachined. If the clearance is too small, the contact face of the thrust bearing (314) in the bearing endcover (361) must be remachined.

12.5.6 Slide the spacer ring (504.01) over the shaft (210) and insert the key (940.05) into the shaft keyway.12.5.7 Slide the thrust bearing plate (384) and spacer sleeve (525.05) on the shaft (210).12.5.8 Screw the nut (920.09) on the shaft (210) and tighten it.12.5.9 Fit the studs (902.11) to the bearing end cover (361).

12.5.10 Fit the bearing end cover (361) including thrust bearing (314), O-rings (412.11 and 412.12), parallel pin(562.02), shaft seal ring (420.01) and circlip (932.03) and tighten the hex nuts (920.11) uniformly;tightening torque, see the relevant work instruction.

c

d

e

bSlg2

a

Adjusting the thrust bearing

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_____________________________________________________________________

13. Mounting the Piping and Instruments All pipes and instruments, which have been dismantled in connection with maintenance work, must be re-installed as described in the chapter Installation on Site.

14. Mounting the Connecting Coupling14.1 Fitting the Coupling Hubs14.1.1 Thoroughly clean the shaft ends and bores of the coupling hubs and check them for dimensional accuracy.

_____________________________________________________________________________________

Caution Check the shaft ends for run-out prior to mounting the coupling hubs.

Permissible tolerance < 0.03 mm (see figure Run-out check of the shaftends). If the tolerance is exceeded, please inform KSB.Observe the manufacturer’s mounting/dismantling instructions.

The pump shaft’s check values shall be read after each 900 turn.

_____________________________________________________________________________________

14.1.2 Slightly deburr the hub keyway and insert the keys.14.1.3 Check the protrudent dimension of the keys. Tolerance in accordance with figure Clearance between

keyway and key .

Run-out check of the shaft ends (example)

0 . 2 - 0 . 3 m m

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_____________________________________________________________________

14.1.4 To facilitate fitting, the coupling hub may be heated uniformly to a temperature of 800 C max.

_____________________________________________________________________________________

Use protective gloves.

! Risk of fire in case of open flames.

Remove flammable substances from the danger area. ______________________________________________________________________

14.1.5 Elastomeric parts must be removed before heating! _____________________________________________________________________________________

Caution Elastomeric parts which have been heated must not be used anymore.

Use new parts for reassembly. _____________________________________________________________________________________

14.1.6 Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft ends and the hub facesare in alignment. _____________________________________________________________________________________

Caution Fit the coupling hubs using only the appropriate device to prevent the

shaft bearings from damage by axial friction force. Impacts on the coupling hubs are not permitted.

14.1.7 Securely tighten the grub screws (wherever applicable).

14.1.8 Fit the retaining ring, if applicable, to the coupling hub.

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_____________________________________________________________________

14.2 Aligning the Connecting Coupling Align the connecting coupling in accordance with the Connecting Coupling Alignment section in the chapter Installation on Site.

14.3 Mounting the Coupling ConnectionMount the connecting coupling spacer as described in the manufacturer’s documentation.

15. Mounting the Guards Preventing Accidental Contact15.1 Coupling Guard

______________________________________________________________________________________

Caution The pump must not be operated without a coupling guard.

________________________________________________________________________

Coupling guard ( example )

15.1.1 Align the coupling guard over the connecting coupling.15.1.2 Make sure the distance between the shaft ends and the coupling components is sufficient.

15.2 Coupling Cover ______________________________________________________________________________________

Caution The pump must not be operated without a coupling cover!

________________________________________________________________________

Couplin cover (example )

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_____________________________________________________________________

15.2.1 Meticulously clean the locating and sealing surfaces. _____________________________________________________________________________________

Caution Do not damage the seal elements and sealing surfaces! _____________________________________________________________________________________

15.2.2 Insert the gasket and O-ring.15.2.3 Mount the lower cover half and fasten it to the backing ring.15.2.4 Adjust the injection nozzles (if applicable) as shown in the figure Installation of the injection nozzles.

15.2.5 Coat the sealing surfaces of the cover flanges with a liquid, oil and temperature resistant sealing agent (upto 120

0 C).

15.2.6 Use eyebolt as a transport aid as shown in the figure Coupling cover .15.2.7 Fix the cover halves with two taper pins.

15.2.8 Fasten the upper and lower halves with screws.15.2.9 Connect the pipes to the cover.

15.3 Guard Preventing Accidental Contact for Shaft Seal _____________________________________________________________________________________

Caution The pump must not be operated without a guard preventing accidentalcontact!

_____________________________________________________________________________________

Fasten the guard preventing accidental contact to bearing housing using screws.

15.4 Sound Insulating Hood (if applicable)Mount the sound insulating hood as described in the manufacturer’s documentation.

16. Maintenance of the Other Pump Set Components16.1 Maintenance of the Connecting Coupling

See the manufacturer’s documentation.

16.2 Maintenance of DriveSee the manufacturer’s documentation.

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_____________________________________________________________________

16.3 Maintenance of the Minimum Flow SystemSee the manufacturer’s documentation.

16.4 Maintenance of the Instruments and ValvesMaintenance actions are not required; in the case of malfunctioning they are replaced.

16.5 Maintenance of Oil Supply Unit, etc. (if applicable)See the manufacturer’s documentation.

16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable)See the manufacturer’s documentation.

17. Spare Parts17.1 Ordering Spare Parts

Please direct your orders to the nearest KSB Customer Service Center or Sales Office.

When ordering spare parts, please quote17.1.1 The KSB work orders number as indicated on the title page of this instruction manual or the pump name

plate.17.1.2 The required pump set component, part no., designation and quantity required in accordance with the

list of components and sectional drawing.

17.2 Spare Parts StockFor quick elimination of possibly occurring problems, we recommend to keep a stock of spare parts .

17.3 StorageThe parts should be stored as described under Interim Storage in the chapter Transport/Interim Storage.

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OIMPG TROUBLE-SHOOTING 1

_____________________________________________________________________

Trouble Shooting

1. General Information ________________________________________________________________________________________

Caution During the warranty period, pumps must be attended only by KSB

personnel! ________________________________________________________________________________________

1.1 For exact description of the pump design as well as the pump set components andaccessories supplied by KSB, please refer to P & I Diagram.

1.2 Requisite DocumentationFor the elimination of problems described in the tables on the subsequent pages, the technical documentation

of the order pump set components is required in addition to this instruction manual. If these components areincluded in kSB’s scope of supply, the relevant documents are appended to this instruction manual.

- Technical Data- Operating Data- General Arrangement Drawing- P & I Diagram- Table of Clearances- Table of Tightening Torques- Cross Sectional Drawing, Pump- List of components, Pump- Cross Sectional Drawing, Mechanical seal (if applicable)- Documentation of Mechanical seal (if applicable)

- Work Instructions- Documentation of the Connecting Coupling- Documentation of the Drive- Documentation of the Minimum Flow System (if applicable)- Documentation of the Valves and Equipment (if applicable)- Documentation of the Sound Insulating Hood, i.e. Acoustic Enclosure (if applicable)- Documentation of Oil Supply Unit, i.e. Lube Oil Plant (if applicable)- Documentation of Gear/Variable Speed Coupling (if applicable)

1.3 Prerequisites1.3.1 All spare parts required are available.1.3.2 Proper hoisting tackle and means of transport are available and ready for use.1.3.3 Sufficient room space and appropriate tools are available.

1.3.4 For the work required as per the tables on the subsequent pages, the pump set has been taken out of service in accordance with the Shutdown and Work after Shutdown sections in chapter Commissioning,Start-up/Shutdown.

1.3.5 The drive has been secured against unintentional starting. _____________________________________________________________________________________

Caution Before rectifying any faults, check all measuring instruments for proper

functioning! _____________________________________________________________________________________

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OIMPG TROUBLESHOOTING 2

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In case of problems not described in the following table, consultation withKSB’s Customer service is required.

Problem (what) Possible causes Measures

Pump delivers against an excessive high Open the valve in the discharge pipe further until theDuty point is adjusted

Mount larger impeller(s)

Contact KSB’s Service CenterIncrease the speed of the turbine or internal combustionengine

Excessive back pressure

Check plant for impurities

Pump or piping are not completely vented or primed

Vent and/or prime

Inlet pipe or impeller(s) clogged Remove deposits in the pump and/or piping

Alter the piping layoutFormation of air pockets in the piping

Fit a new valve

Correct the liquid levelFully open the valve in the inlet pipe

Change the inlet pipe, if the resistances in the inlet pipeare too high

Inlet pipe is too bigCheck the strainers installed

NPSHavailable too low (inlet)

Observe the permissible speed of pressure fall

Clean the strainer element and inlet pipe

Correct the liquid level

Change the inlet pipe

Suction head is too high

Check the strainers installed

Air intake at the gland packing Replace the gland packingSee chapter ‘Commissioning Startup/Shutdown’ &Maintenance

Wrong direction of rotation Interchange 2 phases of the power supply

Increase the speed

Increase the voltage

Speed is too low

Alter the impeller diameter

Contact KSB’s Service CenterWear of internal pump parts (check inaccordance with the Tables of clearances)

Replace defective parts

Contact KSB’s Service CenterReplace defective fuses

Flow rate of pump > specifiedvalue

Motor is running on 2 phases only

Check the power cable connections

Pump discharge pressure >specified value

Speed is too high Alter the impeller diameter

Contact KSB’s Service Center

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Damaged measuring instrument Replace the measuring instrument

Differential pressure in the strainer element istoo high

Dismantle and clean the strainer element

Valve in the inlet pipe is not fully open Open the valve

Pressure ps > specified value

Pressure in the inlet vessel is too low Check the inlet vessel and/or increase the pressure

Damaged measuring instrument Replace the measuring instrument

Speed is too low Check the drive

Inlet pressure is too low Check the inlet pressure and inlet vessel

In case of tapping, quantity tapped is too high Throttle the tapping quantity

Temperature of the medium pumped is too lowor too high

Increase or reduce the temperature

Pressure pd > specified value

Defective minimum flow system Check the minimum flow system

Defective shaft seal Check; replace, if required

Score marks or roughness on shaft protectionsleeve (524) and/or sleeve of mechanical seal

Replace the shaft protection sleeve (524) or sleeve of mechanical seal

Gland (gland plate / gland ring) have beentightened incorrectly

Check

Wrong packing material ReplaceSee chapter ‘Commissioning/Startup/Shutdown’ &Maintenance

Correct the suction conditions

Re-align the pump

Re-balance the pump rotor

Pump runs rough

Increase pressure at the suction nozzle

Pump set alignment Check the coupling; re-align, if required

Pump is warped Check the piping connections and the fastening of thepump

Insufficient quanti ty of cooling liquid Increase the cool ing l iquid quanti ty

Clean the cooling liquid chamber and/or cooler Dirty cooling liquid chamber or cooler Check the cooling liquid; purify/clean, if required

Increase the effective cross sectionFault in the circulation liquid pipe

Check the pipes

Shaft seal leakage

Surface pressure on the sealing clearance istoo high, lack of lubricant or circulation liquid

Check the installation dimensions


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Defective bearing Check; replace, if requiredSee chapter ‘Maintenance’

Oil quantity Check the oil quantity; top up or replace, if requiredSee chapter ‘Servicing’ and Technical Appendix

Oil quality CheckSee chapter ‘Servicing’ and Technical Appendix

Increased axial thrust Replace the casing wearing ringsContact KSB’s Service Center

Wear of internal pump parts (check inaccordance with the Tables of clearances)

Replace the defective parts

Contact KSB’s Service CenterClean the pump rotor Unbalance of the pump rotor

Balance the pump rotor

Pump set not correctly aligned Check the coupling and re-align, if required


Increased bearing temperature

Coupling hub distance Check the coupling hub distance for compliance with theGA Drawing; correct, if required


Vent and/or prime


Fully open the valve in the inlet pipe

Change in the inlet pipe, if resistances in the inlet pipeare too high

Inlet pipe is too long




Temperature of pump >specified value

Flow rate < specified value Increase the minimum flow

Defective O-rings and/or metallic sealingsurfaces

Replace O-rings and/or remachine the metallic sealingsurfaces


Pump leakage

Tie rods have loosened Tighten

In accordance with the relevant work instruction


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Vent and/or prime



Change the inlet pipe, if the resistances in the inlet pipeare too high





Wear of internal pump parts ( check inaccordance with the Tables of clearances)

Replace defective parts


Adjust the duty point accurately by means of the valve inthe discharge pipe

Backpressure of pump is lower than specifiedin the purchase order

In the case of permanently overload, turn down theimpeller(s), if necessary


Pump set alignment Check the coupling and re-align, if required


Oil quantity Check the oil quantity; top or replace, if required


Oil quality CheckSee Technical Appendix

Clean the pump rotor Unbalance of the pump rotor

Balance the pump rotor

Defective bearing Replace

Pump runs rough

Flow rate < specified value Increase the minimum flow

Damaged inlet pipe Check the inlet pipe

Valve in the inlet pipe is not fully open Open the valve

Pressure in the inlet vessel is too low Check the inlet vessel and/or increase the pressure

Check the inlet pipe

Change the inlet pipe

NPSHavailable / NPSHrequired too low

Excessive speed of pressure fall

Air intake at the seal elements/valves/shaft seal Check the piping; check shaft seal for leakage

Cavitation noise in the pumpand/or piping


Vent and/or prime

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Vent and/or prime



Change the inlet pipe, if resistances in the inlet pipe aretoo high








Increased axial thrust Replace the casing wearing ringContact KSB’s Service Center

Pressure and/or quantity of balancing liquid fluctuates

Change in cross section of balancing liquid pipeExcessive resistancesJoining of several pipes near the pumpBalance flow leakage counter balancing disc /final stage diffuser Wear on the balancing device

Check the mode of operationCheck the return pipe

Check the pump pressures

Check the rotor clearances and balancing device




Back pressure of pump is lower than specifiedin the purchase order

Adjust the duty point accurately by means of the valve inthe discharge pipe

In the case of permanently overload, turn down the

impeller(s), if necessary


Higher density or viscosity of the mediumpumped than specified in the purchase order


Gland tightened excessively or askew Alter

Alter the impeller diameter


Speed is too high

Reduce the speed of the turbine or internal combustionengine


Operating voltage is low Check the power cable connections

Replace defective fuses

Drive is overloaded

Motor is running on 2 phases only

Check the power cable connections

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OIMPG CLEAR AF 1

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Tables of Clearances

Diametrical Clearances :

Nominal diametrical clearances [mm]Pump size Hydraulics

S6 S7 S8 S9 Sl2 Sl3

1 1 ; 2 0.90 – 1.40

2 3 ; 4

0.25 – 0.34 0.35 – 0.50 0.27 – 0.36

0.90 – 1.50

5 0.30 – 0.363

6 0.30 – 0.37

0.40 – 0.51 0.35 – 0.45 1.0 – 1.5

0.50 – 1.0

4 7 ; 8 0.32 – 0.39

5 9 ; 10

0.35 – 0.41 0.45 – 0.51

0.35 – 0.47

6 11;12;13 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48

1.0 – 1.60.80 – 1.2

0.25 – 0.40

Max. permissible diamet-rical clearance (mm)

1.0 1.0 1.0 2.0

Sl2

S 8

2

S 7 2

S 6 2

Sl3 Sl2

Clearance between balance disc seat

and throttle sleeve or balance disc

Clearance between double balance

drum and balance disc seat

S 9 2

Clearance between suction

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OIMPG CLEAR AF 2

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Theoretical Total Axial Clearance

Sa1 + Sa2 [mm]Impeller materialPump size Hydraulic

CI Cr Steel

1 8.5 – 8.0 8.5 – 8.012 7.5 – 7.0 7.5 – 7.03 9.0 – 8.5 8.5 – 8.02

4 7.0 – 6.5 6.5 – 6.05 9.0 – 8.5 8.5 – 8.03

6 7.0 – 6.5 6.0 – 5.57 ---4

8 --- 6.5 – 8.0

9 ---510 --- 8.5 – 10.0

11 ---612 --- 10.0

Sa2

Sa1

502.02

171.02

230.02

Total axial clearance of pump rotor

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OIMPG CLEAR PLANE 1

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Tables of ClearancesBearing ClearancesBearing design : Tilting-pad Thrust Bearing

Pump size Bearing Clearance Slg2 [mm](Diametrical clearance)

1 , 2 0.33 – 0.58

3, 4 0.34 – 0.60

5, 6 0.40 – 0.75

Bearing design : Lift-off Device with Tilting-pad Thrust Bearing

Pump size Bearing clearance Slg1 [mm]

1 - 6 0.30 - 0.50

Slg2

Tilting-pad Thrust Bearing

Slg1

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OIMPG CLEAR PLANE H 1

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Tables of Clearances

Bearing Clearances

Bearing design : Tilting-pad Thrust Bearing

Pump sizeBearing clearance Slg2 [mm]

(Diametrical clearance)

3, 4 0.34 - 0.60

5, 6 0.40 - 0.75

Diametrical Clearances :

Nominal diametrical clearances [mm]Pump size Hydraulics

S6 S7 S8 S9 Sl2 Sl3

1 1 ; 2 0.90 – 1.40

2 3 ; 4

0.25 – 0.34 0.35 – 0.50 0.27 – 0.36

0.90 – 1.50

5 0.30 – 0.363

6 0.30 – 0.37

0.40 – 0.51 0.35 – 0.45 1.0 – 1.5

0.50 – 1.0

4 7 ; 8 0.32 – 0.39

5 9 ; 10

0.35 – 0.41 0.45 – 0.51

0.35 – 0.47

6 11;12;13 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48

1.0 – 1.60.80 – 1.2

0.25 – 0.40

Max. permissiblediamet-rical clearance (mm)

1.0 1.0 1.0 2.0

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OIMPG TIGHT TRQ 1

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Table of Tightening Torques

Tightening Torques [Nm]

HG Pump Sizes 1 – 6

1. Prerequisites1.1 The threads of the screws/bolts and nuts are not damaged.1.2 The threads and bearing surfaces of the screws/bolts and nuts are plane, deburred and cleaned thoroughly.1.3 The threads move smoothly.1.4 The washers are plane, deburred and cleaned thoroughly.

2. PumpObserve the tightening torques for the screwed/bolted connections as per relevant work instruction.

3. Fastening of Pump FeetThread Tightening torque MA [Nm]

M 20 190

M 24 330

M 30 660

M 36 1160

4. Flange ConnectionIf the bolting for the flanged connections are in the KSB’s scope of Supply, the tightening torques will be asspecified in the table on the following pages.

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OIMPG TIGHT TRQ 2

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Bolts for Flange Connection, Discharge Nozzle and Tapping NozzleThe tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.

Flanges as per DINNominal diameter DN [mm] Nominal pressure PN [bar] Tightening torque MA [Nm]

160 9025 250 140

64 140

160 16040

250 240

64 160

160 27050

250 240

64 140

160 24065

250 27064

160 25080

250 370

64

160 350

250 530

320

400

100

500

160 500

250 490

320400125

500

160 490

250 650

320

400

150

500

160 660

250 1150

320

400

200

500

160 1260250

320

250

400

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OIMPG TIGHT TRQ 3

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Bolts for Flange Connection, Discharge Nozzle and Tapping NozzleThe tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.

Flanges as per ANSINominal diameter DN [inch] Nominal pressure PN [class] Tightening torque MA

[Nm]

600 801” 1500 240

600 1401 ½” 1500 350

600 902” 1500 240

600 1402 ½” 1500 270

600

900 2403”1500 490

600 490

900

1500 6504” 2500

900 650

1500 11005” 2500

900 490

1500 8306” 2500

900 8301500 13508” 2500

900 840

150010”

2500

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OIMPG TIGHT TRQ 4

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Bolts for Flange Connection, Suction NozzleThe tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.

Flanges as per DINNominal diameter DN [mm] Nominal pressure PN [bar] Tightening torque MA [Nm]

16 5065 40 70

16 5080 40 70

16 70125 40 150

16 130150 40 200

16 130

25 190200

40 24016 210

25 290250 40 380

16 210

25 240300 40 320

Flanges as per ANSINominal diameter DN [inch] Nominal pressure PN [class] Tightening torque MA [Nm]

2 ½” 300 90

3” 300 90

5” 300 210

6” 300 120

8” 300 210

10” 300 260

12” 300 320

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OIMPG WEIGHT 1

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Table of WeightsHG Pump Size 1

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Caution Weights ≥≥ 25 kg _____________________________________________________________________________________

Pump Components

Part No. Designation Weights (reference values in kg)

106 Suction Casing 35.0

107 Discharge Casing 58.0

210 Shaft for 3 stageseach additional stage

17.91.2

350.01 Bearing Housing 25.0

Rotor 3 stages

Each additional stage

31.0

4.0

Pump

Weights (reference values in kg)Number of stages

Without water fill Water fill

3 234 8.0

4 250 809

5 266 9.7

6 282 10.6

7 298 11.58 314 12.4

9 330 13.3

10 346 14.2

11 362 15.1

12 378 16.0

13 394 16.9

14 410 17.8

15 426 18.7

16 442 19.6

17 458 20.5

18 474 21.4

19 490 22.3

20 506 23.2

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OIMPG WEIGHT 2

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Pump Components




108 Stage Casing 25.0


21.11.6


Rotor 3 stagesEach additional stage

52.06.0

Pump



3 410 19.0

4 440 21.6

5 470 24.2

6 500 26.87 530 29.4

8 560 32.0

9 590 34.6

10 620 37.2

11 650 39.8

12 680 42.4

13 710 45.0

14 740 47.6

15 770 50.2

16 800 52.8

17 830 55.4

18 860 58.0

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OIMPG WEIGHT 3

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Pump Components




108.01 Stage Casing 38.00


130 Casing Part, for double piston For mechanical seal

25.030.5


51.43.0


354 Thrust Bearing Housing, thrust bearing/plain bearing 25.0

361 Bearing End Cover, thrust bearing/plain bearing 29.0

441 Seal Casing 39.0


83.09.0

Pump



3 736 27.0

4 774 30.0

5 812 33.0

6 850 36.0

7 888 39.0

8 926 42.0

9 964 45.0

10 1002 48.0

11 1040 51.0

12 1078 54.0

13 1116 57.014 1154 60.0

15 1192 63.0

16 1230 66.0

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OIMPG WEIGHT 4

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Pump Components


106 Suction Casing < 320 bar

≤ 420 bar

210.0250.0

107 Discharge Casing < 320 bar DN 80 < 250 bar DN 100

>320 bar DN 100

≤ 420 bar DN 100

DN 125

255.0285.0315.0530.0

550.0108.01 Stage Casing 31.0


130 Casing Part, for double piston For mechanical seal

25.030.5

131 Inlet Ring 80.0


51.43.0

350.01 Bearing Housing, suction side Heavy bearing housing

57.061.0

350.02 Bearing Housing, discharge side 150.0


361 Bearing End Cover, thrust bearing/plain bearing Heavy bearing housing

29.035.0



83.09.0

Pump



3 736 27.0

4 774 30.05 812 33.0

6 850 36.0

7 888 39.0

8 926 42.0

9 964 45.0

10 1002 48.0

11 1040 51.0

12 1078 54.0

13 1116 57.0

14 1154 60.0

15 1192 63.0

16 1230 66.0

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OIMPG WEIGHT 5

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Pump Components






130 Casing Part 33.0

131 Inlet Ring 110.0210 Shaft for 3 stages

each additional stage74.74.8

350.01 Bearing Housing, suction side Heavy bearing housing

57.061.0

350.02 Bearing Housing, discharge side 150.0


361 Bearing End Cover, thrust bearing/plain bearing Heavy bearing housing

29.035.0


603.02 Balancing Piston 28.0

905 Tie Rods for 3 Stages M 45Each additional stage

10.31.3


130.016.0

Pump



3 1380 41.8

4 1477 47.4

5 1574 53.0

6 1671 58.67 1768 64.2

8 1865 69.8

9 1962 75.4

10 2059 81.0

11 2156 86.6

12 2253 92.2

13 2350 97.8

14 2447 103.4

15 2544 109.0

16 2641 114.6

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OIMPG WEIGHT 6

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Pump Components


106 Suction Casing DN 200

≤ 420 bar DN 200 DN 250

622.0819.0635.0

107 Discharge Casing

≤ 420 bar DN 150

≤ 420 bar DN 200

821.01020.01170.0

108.02 Stage Casing, Hydraulic 9

Hydraulic 10

93.0

84.0108.03 Stage Casing, Hydraulic 9 100.0

13-6 Casing Insert 96.0

130 Casing Part 59.0

131 Inlet Ring 180.0

171.01 Diffuser 25.0

171.02 Diffuser 25.0


109.07.0




360.01 Bearing Cover 36.0

361 Bearing End Cover 44.0441 Seal Casing 29.0

601 Balancing Disc 25.0



905 Tie Rods for 3 Stages M 45Each additional stageTie Rods for 3 Stages M 52Each additional stage

12.91.617.52.1


243.025.0

Pump



3 2775 80

4 2930 90

5 3085 100

6 3240 110

7 3395 120

8 3550 130

9 3705 140

10 3860 150

11 4015 160

12 4170 17013 4325 180

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