Table of Contents
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Operating Instructions
Nº A1766.8E/2
Works Nº: ________________________________
Type series: ______________________________
These
operating
fundamental
precautionary
notes.
Please
thoroughly prior to installation of unit, connection to
the
power
supply
and
imperative to comply with all other operating
instructions referring to components of this unit.
This manual shall always be kept close to
the unit´s location of operation or directly
on the pump set.
instructions
contain
information
and
read
the
manual
commissioning.
It
is
KSB WKT
Vertical Process Pump
according to API 610
as per Directive 94/9/EC
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Summary of Contents for KSB WKT
- Page 1 Operating Instructions KSB WKT Nº A1766.8E/2 Vertical Process Pump according to API 610 as per Directive 94/9/EC Works Nº: ________________________________ Type series: ______________________________ These operating instructions contain fundamental information precautionary notes. Please read manual thoroughly prior to installation of unit, connection to...
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Page 2: Table Of Contents
Contents Page Page General Commissioning, start-up / shutdown Safety Preparations Marking of Instructions in the manual 6.1.1 Recommended safety instrumentation for Personnel qualification and training pump Non-compliance with safety instructions 6.1.2 Lubrication Safety awareness 6.1.3 Pre-comissioning checks Safety instructions for the operator / user 6.1.4 Lubrication Safety instructions... - Page 3 Introduction KSB has supplied you an equipment that has been designed and manufactured with the latest technology. Due to its simple and tough construction, it will need few maintenance. With the aim to provide our clients with a satisfactory, trouble free operation, we recommend to install and care our equipment according to the instructions contained in this service manual.
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Page 4: General
/ supplier to take care of such training. In please contact KSB´s nearest customer service centre. addition, the operator is responsible for ensuring that the For noise characteristics please refer to section 4.3.6. -
Page 5: Safety Instructions For The Operator / User
2.9.5. the manual for taking the unit out of service must be Pumps WKT are designed to meet the requirements of adhered to without fail. Zone 1 and Category 2 as per EN1127-1 when sealed Pumps or pump units handling fluids injurious to health by mechanical seal. -
Page 6: Temperature Limits
Interim storage (indoors) / Preservation Temperature class to Temperature limit of EN 13463-1: fluid handled KSB standard storage and preservation procedures 85ºC maintain the pump protected for a maximum period of 6 120ºC months in an indoor installation. The unit / pump should 185ºC... -
Page 7: Devolution / Discard
Should always be sent with the pump / motor pump made of ductile material with a maximum magnesium set a certificate of decontamination completely content of 7.5% (see EN 13463-1). This is a standard fulfilled. (Annex 1). feature in all KSB supplies. Please always indicate adopted safety 4.3.2... -
Page 8: Bearing Arrangement
Arragement drawing (examples) Intermediate shaft Gland packing (special variant-consult KSB to use in Bearing spider explosive atmospheres) 400.2 Flat gasket 529.3 Bearing sleeve 545.3 Bearing bush 711.1 Riser pipe Fig. 05 Intermediate shaft bearing 4.3.4.2.1 Rigid Couplings for intermediate shafts... -
Page 9: Permissible Forces And Moments At The
Pump size 50/65 80/100 VÖB and VOQJ 1500 1800 2500 3000 3500 1500 1800 2500 3000 3500 1500 1800 2500 3000 3500 1200 1500 2000 2500 3000 1200 1500 2000 2500 3000 1200 1500 2000 2500 3000 1500 2000 2500 3000 1500 2000... -
Page 10: Installation At Site
Fit and align pump set and driver as described in section 5. Installation at site 5.6. Then concrete in the base frame; re-check the alignment Pumps should be installed, leveled and aligned by and secure the barrel flange to the base frame using qualified people. -
Page 11: Connecting The Piping
Danger of life when toxic or hot fluids are handled! are non-sparking in the event of mechanical contact. The flange covers on the pump suction and discharge KSB’s scope of supply meets this requirement. nozzles must be removed prior to installation in the piping. -
Page 12: Commissioning, Start-Up / Shutdown
Filling and topping 6. Commissioning, start-up / shutdown Remove the protective case of the constant level-oiler. Compliance with following Caution Unscrew vent plug. Pour in the oil through the vent plug requirements paramount tapping hole after having removed out the reservoir of the importance. -
Page 13: Shaft Seal
Lubrication by product pumped Packing material The pump bearings and intermediate shaft bearings are When selecting the packing material, remember to lubricated directly by the product pumped (suction side ascertain its compatibility with the product pumped. bearing by inlet pressure and intermediate shaft bearings Always use new packing material, preferably material by liquid at pump discharge pressure). -
Page 14: Checking The Direction Of Rotation
Back to suction (in vapour state) Never run the pump dry! Caution Fig. 16 – Decoupled drive Open or switch on all auxiliary lines (cooling, lubrication, sealing liquid etc) and ensure they are not blocked. 6.2 Start-up For water cooling, use suitable non-aggressive cooling Before starting the pump ensure that the shut-off element water not liable to form deposits and not containing in the suction line (if any) is fully open. -
Page 15: Shutdown
In the case of pumps with discharge nozzles of nominal If a data sheet is not available, contact KSB! sizes between 40 and 150 this minimum rate of flow normally amounts to 0,15 Qopt, taking the heat conditions 6.4.1 Temperature of the fluid handled, ambient... -
Page 16: Shutdown / Storage / Preservation
6.5 Shutdown / storage / preservation with the electrical connections disconnected. Make sure that the pump set cannot be switched on Each KSB pump leaves the factory carefully assembled. accidentally (danger to life!). If commissioning is to take place some time after delivery,... -
Page 17: Lubrication And Lubricant Change
Weekly supervision Dismantling and reassembly must always be carried Check: out in accordance with the relevant sectional drawing. Pump operation point; 7.4.1 Fundamental instructions and recommendations Motor current consumption and net tension value; Vibration and abnormal noises; Repair and maintenance work to the pump must only be carried out by specially trained personnel;... -
Page 18: Examination Of Individual Components
7.4.2.3 Dismantling the pump body 2. Dismantle thrust bearing as described in section 7.4.2.1 After a prolonged period of operation, it Caution happen that individual rotor 3. Dismantle shaft seal as described in section 7.4.2.2. components (impeller and distance bushes) are difficult to pull off the shaft, in such cases, do not use force or 4. - Page 19 Observe the greatest cleanliness when mounting the Single deep grooves can be left untouched. See figs. bearings. Use washing oil to clean the old bearings. After 18 & 18a. washing, the bearings should be dried and immediately sprayed with oil. Plain bearings (pump and intermediate shafts) Examine the bearing bushes for signs of galling (seizure).
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Page 20: Reassembly
7.4.3.6 Rotor and bearing clearances Clearances mm on for material combination Operating Pump sizes temperature ºC “as new” max. perm. “as new” max. perm. Cast iron / Cast iron AISI 316 / AISI 316 40 to 150 0 to +200 12% Cr / 12% Cr Fig. -
Page 21: Preparations
2. Push discharge casing (107) with fitted bearing bush Do no coat o-rings with graphite or (545.2) and diffuser (171.2) onto pump shaft (211) Caution similar products. Use animal fats or from the drive end. silicone-base or PTFE-base lubricants instead. O-rings 3. - Page 22 7.5.2.3 Assembly of thrust bearing 2. Lay internal auxiliary piping in accordance with the installation drawing. Fig. 07 and 08 3. Examine barrel for dirt and clean it if necessary. 1. Thoroughly clean centering sleeve (526) and examine the oil retaining tube for unimpeded flow. 4.
- Page 23 7. Place the distributor casing (10-1) over the drive shaft and fit it on the top flange of the column pipe main or on the intermediate shaft bearing and fasten it. 8. Attach hoisting ropes to the distributor casing, raise the pump, detach and remove the pipe clip, carefully clean the sealing faces on the barrel and distributor casing, insert gasket (412.1 or 400.3) and lower the pump until...
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Page 24: Tightening Torques
WKT150 2500 1000 For other materials consult KSB. 7.6 Spare parts stock When ordering spare parts, please indicate pump type and size, Production Order number, part number and designation. This information can be obtained from the Data Sheet, Sectional Drawings and Parts List. -
Page 25: Troubleshooting
8. Troubleshooting Cause Remedy The pump generates an excessively high Open discharge valve further until the duty differential pressure. point conditions have been attained. Fit larger impeller (s) Excessively high back pressure. Increase speed (applies to turbine driven or I.C Engine driven pumps) The pump or piping are incompletely vented Vent or prime the pump and piping... -
Page 26: Sectional Drawing
9. Sectional drawing (part 1/2) - reference 902.2 920.6... - Page 27 Sectional drawing (part 2/2) - reference 501.1 900.1 940.6 900.3 902.9 920.9 932.2 901.1 711.1 920.5 400.1 545.2 903.1 529.2 411.1 940.3 940.8 521.2 521.3 502.1 904.1 171.2 503.1 521.1 412.1 501.2 940.2 171.1 503.2 502.2 931.1 920.1 920.2 550.1 940.1 529.1 903.2...
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Page 28: Supplementary Sheet
Supplementary sheet Pump with impeller wearing rings and interstage Calculate the average actual diameter of all bushes (see fig.01) smoothed down impeller wearing rings. Adding this Pump sizes 40 to 150, pressure rating 20/40. to the “as new” clearance per figs. 4 and 5 gives the bore diameter for the casing wearing rings, Supplements for sections: tolerance + 0,04mm. -
Page 29: Annex 01
ANNEX 01 Certificate of decontamination Type ............................Order number / ............................Order item number ............................Delivery date ............................Field of application: ............................Fluid handled ............................Please tick where applicable “ X “ radioactive explosive corrosive toxic harmful bio-hazardous highly flammable safe Reason for return ............................ - Page 30 KSB Bombas Hidráulicas SA Rua José Rabello Portella, 400 Várzea Paulista SP 13220-540 Brazil http://www.ksb.com phone.: 55 11 4596 8500 Fax: 55 11 4596 8580 – KSB Customer Service e-mail: gqualidade@ksb.com.br Fax: 55 11 4596 8656...
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Questions and answers
What does keep off device do and how
The KSB WKT "keep off" device (or procedure) ensures safety during pump shutdown and maintenance. It includes steps such as allowing the pump to cool, securing shut-off elements, draining fluids, and filling the pump with preservative to prevent damage from freezing or moisture during long standstill periods. It also prevents accidental start-up and protects system integrity under vacuum conditions.
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