ksb know-how: supplementary planning information for amacan … · amacan p amacan k amacan s g 1/2...
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Our technology. Your success.Pumps n Valves n Service
KSB Know-how: Supplementary Planning Information for Amacan Pumps
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The know-how volumes can easily be downloaded or
ordered here: www.ksb.de/know-how
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Page
Contents
04 Supplementary Planning Information for Amacan Pumps
04 Calculation of support rope length
06 Cable assembly variants
07 Fitting of cable assembly
07 Venting of discharge tube
11 Cable entry at discharge tube
12 Cable holder in discharge tube
13 Detailed views of cable assembly variants
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04
Supplementary Planning Information for Amacan Pumps
Calculation of support rope length
The support rope length is determined by the installation
conditions and the size of the Amacan pump.
Dimension “L” is always required to determine the correct
length of the support rope.
“L” is the dimension from the lower edge of the discharge tube
to the attachment point on the discharge tube cover, discharge
tube wall or cross bar in the case of an open discharge tube.
Dimension h2 or h4 is determined by the pump size.
The total cable length Lstotal results from the difference
between dimension “L” and h2 or h4 respectively.
The on-site lifting height of the lifting equipment or hoist must
be taken into account when designing the cable assembly.
NOTE:
The lifting height of the hoist must be higher than the total
pump height. If the lifting height is restricted by the building or
the lifting height of the hoist, additional lifting lugs can be
integrated in the support rope to allow the pump to be attached
to a second hoist.
If additional lifting lugs are fitted, two hoists are required.
Fig. 1: Amacan K
Supplementary Planning Information for Amacan Pumps
Lstotal
h4
L
Lower edge of discharge tube
Fig. 2: Amacan P / S
h2
L
Lower edge of discharge tube = lower edge of pump
Lstotal
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Additional lifting lugs allow the support rope including cables
and pump to be attached to a second hoist after the pump has
been partially lifted by the first hoist.
The hoist can continue lifting until the next maximum lifting
height is reached.
This process is repeated until the lifting or installation procedure
is completed.
Fig. 2a = Lifting and positioning the pump set
1 = Lifting rope
2 = Hoist (1)
3 = Lifting accessories (crane hook)
4 = Lifting equipment trolley or hoist 2
5 = Support rope
6 = Free lifting lug
Fig. 2b / 2c = Securing control and power cables
Fig. 2d / 2e = Lowering the pump set
Fig. 2a
Fig. 2b | 2c
Fig. 2d | 2e
1
2 34
56
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06
Minimum lengths must be observed for individual rope sections.
Specifications regarding rope lengths and technical feasibility
depending on rope diameter are made by the rope manufacturer.
The rope diameter is determined by the weight of the pump set.
The optimum number of lifting lugs should be selected based on
technical considerations. As the lifting height of the lifting
equipment must be at least as high as pump length h1, individual
rope sections only need to be this length.
Each additional lifting lug requires additional work and time for
installation on site.
If dimension Lstotal is > 5 m, we recommend using rope spacers
(supports). This is necessary to rule out any possibility of the
support rope incl. cables hitting the discharge tube, and causing
damage.
Cable assembly variants
a = Basic design
b = Design with lifting lug (59-47)
c = Design with lifting lug and support (59-47 and 59-7)
a b c
Supplementary Planning Information for Amacan Pumps
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07
Fitting the cable assembly
When fitting the cable assembly (support rope and control/
power cables), always start at the pump and continue in the
direction of the upper end of the discharge tube. Ensure that the
cables are fitted with a sufficient degree of flexibility to prevent
damage to the cable entries during inspections or repairs.
The installation steps must be carried out carefully (see operating
manual) and only using original KSB parts, otherwise there is a
risk of cable damage.
During this work it is also important to observe the permissible
bending radii in relation to the respective cable diameter.
Bending radii for free movement:
Up to a cable diameter of 12 mm: 4 times the outside cable
diameter
For cable diameters larger than 12 mm: 5 times the outside
cable diameter
Components that come into mechanical contact with the cables
or cable insulation must be checked for sharp corners and edges
and, if necessary, deburred or reworked (filing or grinding).
Venting of discharge tube
Venting the discharge tube is vital for various hydraulic reasons.
It is possible to calculate the size of the air volume and then
determine the size of the cross-sections for the required venting
devices.
The above depends on the discharge tube’s geometry and the
pipe connected to the discharge tube. The system is completely
filled with air to begin with. When the pump starts pumping, the
discharge tube and the connected pipe fill with water. Depending
on the flow velocity in the individual system sections, the air is
entrained or trapped in certain areas and compressed.
The compressed air volume (air cushion) leads to transient or
unsteady pump operating behaviour and influences the H/Q
characteristic curve. As a result, the pump does not operate at
the calculated design point under steady-state operating
conditions. This operating behaviour also places additional loads
on mechanical components and shaft seals.
If air cushions form, i.e. air is trapped, and block e.g. flow
cross-sections, this will also change the operating point. The
friction losses in the piping will increase, causing the pump to be
pushed towards the part load range.
This will significantly increase the input power required by the
hydraulic system and might lead to motor overload. The further
away the operating point from the best efficiency point, the
more likely it is that mechanical vibrations and hydraulic
fluctuations will occur. Noise emissions and recirculation can
occur on the left-hand side of the smallest permissible
continuous operating range.
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08
Discharge tubes and the connected piping should therefore be
assessed with regard to potential air cushions and fitted with
appropriate venting devices.
The uncompressed air volume can be roughly determined based
on the following information: the pump size and thus the
discharge tube diameter, the overall discharge tube length and
the position of the discharge nozzle branching off into the
horizontal pipe. Two options are available for venting: either a
continuous process using a vent pipe/vent hose or a temporary
process using an air valve. If a vent pipe/vent hose is used, it
should end above the max. water level in the pump sump. The
venting devices (vent pipe/vent hose and air valve) must be
attached in the pump sump in such a way that they can also
serve to remove fluid from both the pump and the piping after
pump start-up (fluid via the pipes, a water/air mixture or spray
via the air valve). Contamination is thus avoided, ensuring
compliance with occupational health and safety regulations.
If the installation depth of the discharge tube is more than 10 m,
the conditions in the system should be examined. This is done
using modelling, i.e. a process for analysing transient conditions
(also applied for pressure surge calculation). On the basis of this
analysis, it is possible to determine the starting and stopping
behaviour including the resultant conditions in the system and, if
necessary, the behaviour of the check valve in order to avoid
extreme valve closures.
In addition to this information, backflow into the pump sump
can also be assessed.
In particular, pumps with high specific speeds (ns > 120 rpm)
tend to exceed the speed in reverse operation (turbine mode).
Vent line
Pump size
Amacan P Amacan K Amacan S
G 1/2 500
G 1/2 600
G 1/2 650
G 3/4 700 700
G 1 800 800 800
G 1 850
G 1 900 900
G 1 1/4 1000 1000 1000
G 1 1/2 1200 1200
G 1 1/2 1300
G 2 1500
G 2 1600
Table 1: Recommended cross-sections for vent lines
Supplementary Planning Information for Amacan Pumps
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09
This reverse operating mode can lead to mechanical damage to
the impeller and also to the bearings. A further aspect to be
considered is pump re-start. In the worst case scenario, the
pump and motor would still be rotating in turbine mode while
the machine receives the signal to re-start the pump.
Vent line
Fig. 3: Discharge tube with vent line
Fig. 4: Discharge tube with air valve
Air valve
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10 Supplementary Planning Information for Amacan Pumps
Fig. 5: Throttled-operation curve (pump characteristic curve) with positive speeds | Torque with positive speeds | Throttled-operation curve (turbine characteristic curve) with negative speeds
Fig. 6: Complete characteristic curve of a pump with mixed flow impeller; ηα = 145
+H
/H*
n/n*=+125%
200%
%-100
100
-200 % -100 100 % 200
+100
+75
+50+25
AB
G
H
+Q/Q*
M=0
a
+Q/Q*
G
A
H
B
%-100
200%
+M
/M*
C
D
E
% -100 100 % 200
+100
+75
+50
+25
+125
-M/M
*
-100-75-50
-25F
H=0
100
H=0
b c
M=
0
+H
/H*
200%
D
CE
F
+Q/Q*
%-100
-200 % -100 100 % 200
100
0
-125-100-75-50-250
G
A
B
C
D
F
E
+n
/n*
M=0
M=+
100
H=+100
%
+Q/Q*
%-100
+75+50
+30
+10
+200
+150
+250
H=-
100%
+75+5
0
+30 +1
0
+200
+150+2
50
H=+1
00
+75 +
50 +30
+10
-100%
+100
+75+50
+30
+10
+200+150
+250
M=-10
0-75
-50
-30
-10
-200
-150
-250
H=0
-200
-75-50-30-10
-200-150
-250
Q=
0
H=0
M=0
H=0
M=0
n=0G
A
B
C
DF
E
H
-Q+H+M-η
-Q+H-M-η
-Q-H-M-η
+Q-H-M-η
+Q-H-M+η
+Q-H+M+η
+Q+H+M+η
-Q+H+M+η
-Q
-Q+H+M-η
-Q-H-M-η
+Q-H-M-η
+Q-H-M+η
+Q+H+M+η
-Q+H+M+η
-Q
+Q
-η+η
+n
/n*
+Q/Q*
G
A
B
C
F
E
-100% 100%
-200%
-100
100
H=+100
%
+75+50+30
+10
+200
+150
+250
M=+10
0
M=0
H=0
M=0
H=0
+75
+50+30+10
+200
+150
+250
M=-10
0-75-50
-30
-10
-200-15
0
-250
H=-10
0%-75-50
-30-10
-200-15
0
-250
+Q
H=0
M=0
H=0M
=0
G
A
B
C
D FE
H
n=0
-η+η
Fig. 7: Complete characteristic curve of an axial flow pump; ηα = 260
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11
Cable entry into discharge tube
Split cover variants are only recommended to a limited extent as
leakages can occur at the joint between the two cover parts.
Variants using gland packings as sealing elements make
installation more complicated. If gland packings are used, they
should preferably be installed in a horizontal position as
recommended by the gland packing manufacturer.
Fig. 8: The design with welding sleeves is the variant recommended by KSB.
Fig. 9: Design variant with transit frame (up to 1 bar) (split cover)
A
A
A-A
1
5
6
2
36
A-A
4
7
6
5
4
Key:
1 = Discharge tube cover2 = Manhole cover3 = Welding sleeve4 = Threaded bush with cable entry to DIN 224195 = Eye plate for fastening the cable support (support rope)6 = Gasket
Key:
1 = Discharge tube cover2 = Transit frame3 = Packing and insert blocks4 = Cover segment with cable gland5 = Closed-cell profile seal in groove between the two cover parts6 = Sealing arrangement of groove between the two cover parts7 = Support brackets for cover segment with cable glands8 = Gasket (e.g. rubber with fabric reinforcement)
1
23
8
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12
Fig. 10: Cross bar on the open discharge tube or in the building
Fig. 11: Cable support sleeve for additional strain relief
2 1
3
Key:
1 = Holder2 = Rail / support3 = Lifting lug for holder (rope)
Key:
1 = Cable entry to DIN 224192 = Threaded bush3 = Welding sleeve4 = Shackle5 = Cable support sleeve
1
2
3
4
5
Supplementary Planning Information for Amacan Pumps
Cable holder in discharge tube
Cable support sleeve for additional strain relief if long cable
sections with large cable cross-sections are used or if dimension
Lstotal is very small and an appropriate rope cannot be
manufactured for technical reasons.
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Lsto
tal
L S
l 1
5050
59-8
59-1
7.02
59-4
772
059
-24
733.
05
719.
0559
-17.
01
Detailed view
l 1l 1
= 3
00 ..
. 400
Legende:
A = Basic design 59-8 = Turnbuckle59-17 = Shackle59-24 = Rope720 = Fitting 733.05 = Hose clip 719.05 = Hose
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14 Detailed view
l 1 =
300
... 4
0050
50l 1
5050
AB
59-8
59-1
7.02
59-4
759
-47
59-1
7.01
720
59-2
473
3.05
719.
05
L to
tal
L S
Key:
B = Design with lifting lug (59-47) 59-8 = Turnbuckle59-17 = Shackle59-24 = Rope720 = Fitting733.05 = Hose clip 719.05 = Hose On ropes with additional lifting lugs, the individual ropes (L1=L2) are always the same length
L 1L 2
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15
A
59-8
59-1
7.02
59-4
772
073
3.05
719.
0559
-47
59-1
7.01
A
50
Key:
C = Ausführung mit Tragöse und Stützkörper (59-47 und 59-7) 59-8 = Turnbuckle59-17 = Shackle59-24 = Rope720 = Fitting733.05 = Hose clip 719.05 = HoseOn ropes with additional lifting lugs, the individual ropes (L1=L2) are always the same length
5050
50l 1
l 1 =
300
... 4
00l 1
LSto
tal
L S
59-2
4
L 2L 1
59-7
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1578
.026
/01-
EN /
11.1
9 / ©
KSB
SE
& C
o. K
GaA
201
9 · S
ub
ject
to
tec
hn
ical
mo
dif
icat
ion
wit
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ut
pri
or
no
tice
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