KSB HPK Installation & Operating Manual
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KSB HPK Installation & Operating Manual

Thermal oil / hot water pump complementary sizes bearing assemblies p08s, p10as, p12s
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Thermal Oil / Hot Water Pump
HPK
Complementary Sizes
Bearing Assemblies P08s, P10as, P12s
Installation/Operating Manual

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  • Page 1 Thermal Oil / Hot Water Pump Complementary Sizes Bearing Assemblies P08s, P10as, P12s Installation/Operating Manual...
  • Page 2 All rights reserved. The contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise transmitted, published or made available to a third party without the manufacturer's express written consent. Subject to technical modification without prior notice. © KSB Aktiengesellschaft, Frankenthal 16/01/2017...
  • Page 3 Contents Contents Glossary .............................. 6 General.............................. 7 Principles ................................ 7 Installation of partly completed machinery.................... 7 Target group.............................. 7 Other applicable documents.......................... 7 Symbols ................................ 7 Safety .............................. 9 Key to safety symbols/markings........................ 9 General................................ 9 Intended use .............................. 9 Personnel qualification and training...................... 10 Consequences and risks caused by non-compliance with this manual ............ 10 Safety awareness ............................ 10 Safety information for the operator/user ..................... 11 Safety information for maintenance, inspection and installation .............. 11...
  • Page 4 Contents Checking the direction of rotation........................ 33 Commissioning/Start-up/Shutdown.................... 34 Shutdown/storage/preservation ........................ 34 6.1.1 Measures to be taken for shutdown .................... 34 Operating limits.............................. 34 6.2.1 Ambient temperature........................ 34 6.2.2 Frequency of starts.......................... 35 6.2.3 Fluid handled ............................. 35 Commissioning/start-up .......................... 36 6.3.1 Prerequisites for commissioning/start-up .................. 36 6.3.2 Filling in lubricants.......................... 36 6.3.3 Shaft seal ............................ 38 6.3.4...
  • Page 5 Contents EU Declaration of Conformity ...................... 67 Certificate of Decontamination...................... 68 Index .............................. 69 5 of 72...

  • Page 6: Glossary

    Glossary Glossary Back pull-out design The complete back pull-out unit can be pulled out without having to remove the pump casing from the piping. Back pull-out unit Pump without pump casing; partly completed machinery Certificate of decontamination A certificate of decontamination is enclosed by the customer when returning the product to the manufacturer to certify that the product has been properly drained to eliminate any environmental...

  • Page 7: General

    The order number and order item number uniquely identify the pump (set) and serve as identification for all further business processes. In the event of damage, immediately contact your nearest KSB service centre to maintain the right to claim under warranty. Noise characteristics see (ð Section 4.6, Page 21) 1.2 Installation of partly completed machinery...
  • Page 8 1 General Symbol Description Cross-references ⇨ Step-by-step instructions Note Recommendations and important information on how to handle the product 8 of 72...

  • Page 9: Safety

    2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER 2.1 Key to safety symbols/markings Table 3: Definition of safety symbols/markings Symbol Description DANGER DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or serious injury.

  • Page 10: Personnel Qualification And Training

    2 Safety ▪ Only use the pump to handle the fluids described in the data sheet or product literature of the pump model or variant. ▪ Never operate the pump without the fluid to be handled. ▪ Observe the minimum flow rates indicated in the data sheet or product literature (to prevent overheating, bearing damage, etc.).

  • Page 11: Safety Information For The Operator/User

    2 Safety 2.7 Safety information for the operator/user ▪ The operator shall fit contact guards for hot, cold and moving parts and check that the guards function properly. ▪ Do not remove any contact guards during operation. ▪ Provide the personnel with protective equipment and make sure it is used. ▪...

  • Page 12: Marking

    If the pump is to be operated at a higher temperature, if there is no data sheet or if the pump is part of a pool of pumps, contact KSB for the maximum permissible operating temperature. 2.10.3 Monitoring equipment The pump (set) must only be operated within the limits specified in the data sheet and on the name plate.

  • Page 13: Operating Limits

    Check whether monitoring equipment is required to ensure that the pump set functions properly. Contact KSB for further information on monitoring equipment. 2.10.4 Operating limits The minimum flows indicated in (ð Section 6.2.3.1, Page 35) refer to water and water-like fluids handled.

  • Page 14: Transport/Temporary Storage/Disposal

    1. On transfer of goods, check each packaging unit for damage. 2. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the supplying dealer (as applicable) and the insurer about the damage in writing immediately.

  • Page 15: Storage/Preservation

    4. Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken. (ð Section 11, Page 68) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 15 of 72...

  • Page 16: Disposal

    3 Transport/Temporary Storage/Disposal 3.5 Disposal WARNING Fluids, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷ Collect and properly dispose of flushing fluid and any residues of the fluid handled. ▷ Wear safety clothing and a protective mask, if required. ▷...

  • Page 17: Description Of The Pump (Set)

    ▪ Heat transfer fluid pump with shaft seal Pump for handling hot water or organic heat transfer fluids in piping or tank systems. 4.2 Designation Example: HPK S F 250 - 630 Table 5: Key to the designation Code Description Type series...
  • Page 18 Shaft seal Due to the complex conditions in hot water systems, the use of mechanical seals not approved by KSB shall not be covered by KSB's scope of warranty. The following seal designs are used for hot water applications: ▪ Mechanical seal, uncooled ▪...
  • Page 19 Size code (based on dimensions of seal chamber and shaft end) Reinforced bearing bracket (next bearing size up) Paired angular contact ball bearings (drive end) Bearings used Table 8: Bearing design KSB designation FAG designation SKF designation B-TVP-UA BECBP Table 9: Bearing design...

  • Page 20: Configuration And Function

    4 Description of the Pump (Set) 4.5 Configuration and function Fig. 6: Sectional drawing Clearance gap Discharge nozzle Casing cover Shaft Bearing bracket Suction nozzle Impeller Shaft seal Rolling element bearing, pump end Rolling element bearing, motor end Design The pump is designed with an axial fluid inlet and a radial or tangential outlet. The hydraulic system runs in its own bearings and is connected to the motor by a shaft coupling.

  • Page 21: Noise Characteristics

    4 Description of the Pump (Set) 4.6 Noise characteristics 3)4) Table 10: Surface sound pressure level L Pump Pump set 960 rpm, 1450 rpm 2900 rpm 960 rpm, 1450 rpm 2900 rpm 760 rpm 760 rpm [kW] [dB] [dB] [dB] [dB] [dB] [dB] 18,5 4.7 Scope of supply Depending on the model, the following items are included in the scope of supply: ▪...

  • Page 22: Dimensions And Weights

    4 Description of the Pump (Set) 4.8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set. 22 of 72...

  • Page 23: Installation At Site

    5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! ▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information in the data sheet and on the name plates of pump and motor.

  • Page 24: Installation On The Foundation

    5 Installation at Site 5.3.1 Installation on the foundation Fig. 7: Fitting the shims Bolt-to-bolt distance Shim Shim if (L) > 800 mm Foundation bolt ü The foundation has the required strength and characteristics. ü The foundation has been prepared in accordance with the dimensions given in the outline drawing/general arrangement drawing.

  • Page 25: Installation Without Foundation

    5 Installation at Site 5.3.2 Installation without foundation Fig. 8: Adjusting the levelling elements 1, 3 Locknut Adjusting nut Machine mount ü The installation surface has the required strength and characteristics. 1. Position the pump set on the machine mounts (4) and align it with the help of a spirit level (on the shaft/discharge nozzle).
  • Page 26 5 Installation at Site NOTE Installing check and shut-off elements in the system is recommended, depending on the type of plant and pump. However, such elements must not obstruct proper drainage or hinder disassembly of the pump. ü Suction lift lines have been laid with a rising slope, suction head lines with a downward slope towards the pump.

  • Page 27: Permissible Forces And Moments At The Pump Nozzles

    0,60 1.4408 0,55 0,50 °C Fig. 10: Temperature correction diagram HPK-S/E The resulting permissible forces have been determined according to the following formulas: Forces and moments at the pump nozzles Pump feet below Table 11: Forces and moments at the pump nozzles...

  • Page 28: Auxiliary Connections

    400-630 15350 10000 12700 16200 12700 8000 15350 10000 16200 11000 8150 5500 11000 8150 5500 400-710 15350 10000 12700 16200 12700 8000 15350 10000 16200 11000 8150 5500 11000 8150 5500 HPK-SY/EY The resulting permissible forces have been determined according to the...

  • Page 29: Enclosure/Insulation

    5 Installation at Site WARNING Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing liquid, etc.) Risk of injury from escaping fluid! Risk of burns! Malfunction of the pump! ▷ Refer to the general arrangement drawing, the piping layout and pump markings (if any) for the quantity, dimensions and locations of auxiliary connections.

  • Page 30: Aligning The Pump And Motor

    5 Installation at Site CAUTION Misalignment of pump and motor shafts Damage to pump, motor and coupling! ▷ Always check the coupling after the pump has been installed and connected to the piping. ▷ Also check the coupling of pump sets supplied with pump and motor mounted on the same baseplate.

  • Page 31: Electrical Connection

    Risk of injury by rotating shafts! ▷ Always operate the pump set with a coupling guard. If the customer specifically requests not to include a coupling guard in KSB's delivery, then the operator must supply one! ▷ Observe all relevant regulations for selecting a coupling guard.

  • Page 32: Setting The Time Relay

    5 Installation at Site DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! ▷ Always have the electrical connections installed by a trained and qualified electrician. ▷ Observe regulations IEC 60364 and, for explosion-proof models, EN 60079. WARNING Incorrect connection to the mains Damage to the mains network, short circuit!

  • Page 33: Checking The Direction Of Rotation

    5 Installation at Site 5.9 Checking the direction of rotation DANGER Temperature increase resulting from contact between rotating and stationary components Explosion hazard! Damage to the pump set! ▷ Never check the direction of rotation by starting up the unfilled pump set. ▷...

  • Page 34: Commissioning/Start-Up/Shutdown

    6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Shutdown/storage/preservation 6.1.1 Measures to be taken for shutdown The pump (set) remains installed ü Sufficient fluid is supplied for the operation check run of the pump. 1. Start up the pump (set) regularly between once a month and once every three months for approximately five minutes during prolonged shutdown periods.

  • Page 35: Frequency Of Starts

    6 Commissioning/Start-up/Shutdown Table 14: Permissible ambient temperatures Permissible ambient temperature Value Maximum 40 °C Minimum See data sheet. 6.2.2 Frequency of starts DANGER Excessive surface temperature of the motor Explosion hazard! Damage to the motor! ▷ In case of explosion-proof motors, observe the frequency of starts specified in the manufacturer's product literature.

  • Page 36: Commissioning/Start-Up

    6 Commissioning/Start-up/Shutdown × × × Table 16: Key Symbol Description Unit Specific heat capacity J/kg K Gravitational constant m/s² Pump discharge head Fluid temperature °C Temperature at the casing surface °C Pump efficiency at duty point Temperature difference 6.2.3.2 Density of the fluid handled The pump input power changes in proportion to the density of the fluid handled.
  • Page 37 6 Commissioning/Start-up/Shutdown Filling the constant level oiler with lubricating oil (oil-lubricated bearings only) ü The constant level oiler has been fitted. NOTE If no constant level oiler is provided on the bearing bracket, the oil level can be read in the middle of the oil level sight glass arranged at the side of the bearing bracket.

  • Page 38: Shaft Seal

    6.3.3.1 Mechanical seal for hot water Due to the complex conditions in hot water systems, the use of mechanical seals not approved by KSB shall not be covered by KSB's scope of warranty. The following seal designs are used for hot water applications: ▪...

  • Page 39: Priming And Venting The Pump

    6 Commissioning/Start-up/Shutdown – Required pressure: 0.1 bar max. (observe any additional information given in the general arrangement drawing!) ▪ Mechanical seal in tandem arrangement with quench liquid In mechanical seal systems in tandem arrangement the outboard mechanical seal serves as safety back-up seal designed to provide temporary sealing if the inboard seal fails.

  • Page 40: Cooling Of The Shaft Seal ("K" Design)

    6 Commissioning/Start-up/Shutdown Observe the following quality data of the cooling water: ▪ Not deposit forming ▪ Not aggressive ▪ Free from suspended solids ▪ Hardness on average 5 °dH (~1 mmol/l) ▪ pH > 8 ▪ Conditioned and neutral with regard to mechanical corrosion ▪...

  • Page 41: Heating Up/Keeping Warm The Pump (Set)

    6 Commissioning/Start-up/Shutdown Table 18: Cooling of the heat exchanger Bearing bracket Cooling liquid quantity [l/min] n = 1450 rpm P08s P10as P12s 6.3.9 Heating up/keeping warm the pump (set) CAUTION Pump blockage Damage to the pump! ▷ Prior to pump start-up, heat up the pump as described in the manual. Observe the following when heating up the pump (set) and keeping it warm: ▪...

  • Page 42: Checking The Shaft Seal

    6 Commissioning/Start-up/Shutdown DANGER Excessive temperatures due to dry running or excessive gas content in the fluid handled Explosion hazard! Damage to the pump set! ▷ Never operate the pump set without liquid fill. ▷ Prime the pump as per operating instructions. (ð Section 6.3.4, Page 39) ▷...

  • Page 43: Shutdown

    6 Commissioning/Start-up/Shutdown Gland packing The gland packing must drip slightly during operation. DANGER Impermissibly high temperatures at gland packings Explosion hazard! ▷ Always use suitable temperature monitoring for gland packings. ▷ Gland packing must be tightened correctly. Pure graphite packing If a pure graphite packing is used, there must always be some leakage. Table 19: Leakage rate of the pure graphite packing Quantity Values...

  • Page 44: Returning To Service

    6 Commissioning/Start-up/Shutdown NOTE If the discharge line is equipped with a check valve, the shut-off element in the discharge line may remain open, provided the site's requirements and regulations are taken into account and observed. NOTE If shut-off is not possible, the pump will run in reverse direction. The reverse runaway speed must be lower than the rated speed.

  • Page 45: Servicing/Maintenance

    7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations DANGER Sparks produced during servicing work Explosion hazard! ▷ Observe the safety regulations in force at the place of installation! ▷ Always perform maintenance work at an explosion-proof pump (set) outside of potentially explosive atmospheres. DANGER Improperly serviced pump set Explosion hazard!

  • Page 46: Servicing/Inspection

    NOTE All maintenance, service and installation work can be carried out by KSB Service or authorised workshops. For contact details please refer to the enclosed "Addresses" booklet or visit "www.ksb.com/contact" on the Internet.

  • Page 47: Inspection Work

    7 Servicing/Maintenance CAUTION Impermissibly high temperature of fluid handled Damage to the pump! ▷ Prolonged operation against a closed shut-off element is not permitted (heating up of the fluid). ▷ Observe the temperature limits in the data sheet and in the section on operating limits.

  • Page 48: Lubrication And Lubricant Change Of Rolling Element Bearings

    0.85 + 0.1 mm 400-506 400-630 400-710 For temperatures exceeding 250 °C, contact KSB. NOTE If the clearances given are exceeded by more than 1 mm (referring to the diameter) replace the affected components or restore the original clearance by means of a casing wear ring.
  • Page 49 ▷ Collect and dispose of any lubricants. ▷ Observe all legal regulations on the disposal of fluids posing a health hazard. At least once a year For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB. 49 of 72...

  • Page 50: Drainage/Cleaning

    7 Servicing/Maintenance Fig. 14: Bearing bracket with constant level oiler Constant level oiler Screw plug Bearing bracket ü A suitable container for the used oil is on hand. 1. Place the container underneath the screw plug. 2. Undo the screw plug (2) at the bearing bracket (3) and drain the oil. 3.

  • Page 51: Preparing The Pump Set

    7 Servicing/Maintenance WARNING Improper lifting/moving of heavy assemblies or components Personal injury and damage to property! ▷ Use suitable transport devices, lifting equipment and lifting tackle to move heavy assemblies or components. Observe the general safety instructions and information. (ð Section 7, Page 45) For any work on the motor, observe the instructions of the relevant motor manufacturer.

  • Page 52: Removing The Impeller

    7 Servicing/Maintenance WARNING Back pull-out unit tilting Risk of crushing hands and feet! ▷ Suspend or support the bearing bracket at the pump end. 1. If required, suspend or support bearing bracket 330 to prevent it from tipping over. 2. Unbolt support foot 183 from the baseplate. 3.

  • Page 53: Dismantling The Bearings

    7 Servicing/Maintenance 5. Pull the complete mechanical seal assembly with shaft protecting sleeve 524.01, seal cover 471.01 and thrower 507.01 off the shaft. 6. If required, unscrew socket head cap screws 914.09 and use forcing screws to pull out angular casing wear ring 502.02. 7.

  • Page 54: Reassembling The Pump Set

    7 Servicing/Maintenance 12. Unscrew slotted round nut 920.21 (right-hand thread) and remove lock washer 931.01. WARNING Hot surfaces due to heating of components for assembly/dismantling Risk of burns! ▷ Wear heat-resistant protective gloves. ▷ Remove flammable substances from the danger zone. 13.

  • Page 55: Installing The Bearings

    7 Servicing/Maintenance – If assembly adhesives are required, use a commercially available contact adhesive (e.g. "Pattex"). – Only apply adhesive at selected points and in thin layers. – Never use quick-setting adhesives (cyanoacrylate adhesives). – Coat the locating surfaces of the individual components and screwed connections with graphite or similar before reassembly.

  • Page 56: Fitting The Shaft Seal

    7 Servicing/Maintenance 18. Fit keys 940.02. 19. Slide the coupling hub onto the shaft end. 20. Secure the coupling hub with an adjusting screw. 21. Fit thrower 507.01, if any. 7.5.3 Fitting the shaft seal 7.5.3.1 Installing the mechanical seal The following rules must be observed when installing the mechanical seal: ▪...
  • Page 57 7 Servicing/Maintenance 7.5.3.2 Packing the gland UG1269690 UG1269740 Fig. 15: Gland packing chamber a) uncooled and b) cooled, hot water Stuffing box housing, uncooled Table 24: Gland packing chamber - uncooled variant Bearing Gland packing chamber Packing Packing rings bracket cross-section Ø d Ø...

  • Page 58: Fitting The Impeller

    7 Servicing/Maintenance 8. Fit guard 680. 9. Slide pre-assembled stuffing box housing 451.01 and shaft protecting sleeve 524.01 on the shaft and screw them to casing cover 161; take care not to damage gasket 411.09. 7.5.4 Fitting the impeller Bearing assembly P08s: ü...

  • Page 59: Fitting The Back Pull-Out Unit

    7 Servicing/Maintenance 7.5.5 Fitting the back pull-out unit WARNING Back pull-out unit tilting Risk of crushing hands and feet! ▷ Suspend or support the bearing bracket at the pump end. ü The notes and steps stated in (ð Section 7.5.1, Page 54) to (ð Section 7.5.4, Page 58) have been observed/carried out. ü...

  • Page 60: Tightening Torques Impeller Nut/Screw

    7 Servicing/Maintenance Table 26: Tightening torques for screwed connections Material 1.7709+QT / 1.7258+QT Monix3k / Monix3k A4-70 / A4-70 stud/ hexagon Stamp on GA / G MM / MM (M3k) A4-70 / A4-70 stud/ hexagon Tightening torques [Nm] Brand-new -15 % -20 % Brand-new -15 %...

  • Page 61: Recommended Spare Parts Stock For 2 Years' Operation To Din 24296

    7 Servicing/Maintenance 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 27: Quantity of spare parts for recommended spare parts stock Part No. Part description Number of pumps (including stand-by pumps) 6 and 7 8 and 9 10 and more Shaft 20 %...
  • Page 62 7 Servicing/Maintenance Description Part No. 300-710 P12s 350-630 400-630 350-710 400-710 62 of 72...

  • Page 63: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump delivers insufficient flow rate B Motor is overloaded C Excessive discharge pressure...
  • Page 64 8 Trouble-shooting A B C D E F G H Possible cause Remedy - Density or viscosity of fluid handled Contact KSB. ✘ higher than stated in purchase order - Gland follower over-tightened or cocked Correct. ✘ ✘ ✘ ✘...

  • Page 65: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing with list of components Fig. 16: General assembly drawing Fig. 17: a) Impeller fastening on bearing bracket P08s and b) Intensively cooled shaft seal chamber Table 30: List of components Part No. Description Scope of supply Volute casing with joint ring 411.01/.10, casing wear ring 502.01, stud 902.01,...
  • Page 66 9 Related Documents Part No. Description Scope of supply 322.01 Cylindrical roller bearing Bearing bracket Bearing bracket lantern with stud 902.04, hexagon head bolt 920.04 360.01/02 Bearing cover 451.01 Stuffing box housing with stud 902.03, screwed plug 903.16/.17, hexagon nut 920.03 502.01/.02 Casing wear ring 507.01/.02...

  • Page 67: Eu Declaration Of Conformity

    Johann-Klein-Straße 9 67227 Frankenthal (Germany) The manufacturer herewith declares that the product: KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: – Pump (set): Machinery Directive 2006/42/EC The manufacturer also declares that ▪...

  • Page 68: Certificate Of Decontamination

    11 Certificate of Decontamination 11 Certificate of Decontamination Type: ..........................Order number/ Order item number ..........................Delivery date: ..........................Field of application: ..........................Fluid handled ..........................Please tick where applicable ⃞ ⃞ ⃞ ⃞ Radioactive Explosive Corrosive Toxic ⃞ ⃞ ⃞...

  • Page 69: Index

    Index Index Abrasive fluids 36 Impeller type 18 Installation Applications 9 Installation on a foundation 24 Auxiliary connections 29 without foundation 25 Installation at site 23 Intended use 9 Bearing temperature 47 Interchangeability of pump components 61 Bearings 19 Keeping warm 41 Certificate of decontamination 68 Clearance gaps 48 Commissioning 36 Leakage rate 43 Configuration 20 Constant level oiler 37 Contact guard 21 Maintenance 46 Coupling 21, 47...
  • Page 70 Index Safety 9 Safety awareness 10 Scope of supply 21 Shaft seal 18 Shutdown 34, 43 Spare part Ordering spare parts 60 Spare parts stock 61 Start-up 42 Storage 15, 34 Temperature difference 41 Temperature limits 12 Tightening torques 60 Tightening torques  59 Transport 14 Water cooling 40 70 of 72...
  • Page 72 KSB Aktiengesellschaft Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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