KSB Sewabloc series Installation & Operating Manual
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KSB Sewabloc series Installation & Operating Manual

KSB Sewabloc series Installation & Operating Manual

60 hz dry-installed volute casing pump
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Dry-installed Volute Casing Pump
Sewabloc (60 Hz)
Installation/Operating Manual

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Summary of Contents for KSB Sewabloc series

  • Page 1 Dry-installed Volute Casing Pump Sewabloc (60 Hz) 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 06.10.2016...
  • Page 3 Contents Contents Glossary ............................5 General ............................6 Principles .................................6 Installation of partly completed machinery ....................6 Target group ..............................6 Other applicable documents ..........................6 Symbols ................................6 Safety ............................. 8 Key to safety symbols/markings ........................8 General ................................8 Intended use ..............................8 Personnel qualification and personnel training ...................9 Consequences and risks caused by non-compliance with these operating instructions ......10 Safety awareness ............................10 Safety information for the operator/user ....................10...
  • Page 4 Contents Auxiliary connections ...........................24 Checking the lubricants ..........................25 Electrical connection ............................26 Checking the direction of rotation ......................26 Priming and venting the pump ........................27 Commissioning/Start-up/Shutdown ................... 28 Commissioning/start-up ..........................28 Operating limits ............................29 Shutdown/storage/preservation ........................31 Returning to service after storage .......................31 Servicing/Maintenance ....................... 32 Safety regulations ............................32 Maintenance/inspection ..........................33 Drainage/disposal ............................36...

  • Page 5: Glossary

    Glossary Glossary Certificate of decontamination Pump If a product is to be returned to the Machine without drive, additional components manufacturer, the customer declares in a or accessories certificate of decontamination that the product has been properly drained to eliminate any Pump set environmental and health hazards arising from Complete pump set consisting of pump, drive,...

  • Page 6: General

    (set) and serve as identification for all further business processes. In the event of damage, contact your nearest KSB service center immediately to maintain the right to claim warranty. Noise characteristics see (⇨ Section 4.6 Page 18) 1.2 Installation of partly completed machinery...
  • Page 7 1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product Sewabloc (60 Hz) 7 of 56...

  • Page 8: 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 9: Personnel Qualification And Personnel Training

    2 Safety ▪ Observe the limits for continuous operation specified in the data sheet or product literature (Q and Q ) (to prevent damage such as shaft fracture, bearing failure, mechanical seal damage, etc). ▪ When untreated waste water is handled, the duty points in continuous operation lie within 0.7 to 1.2 x Q to minimize the risk of clogging/hardening.

  • Page 10: Consequences And Risks Caused By Non-Compliance With These Operating Instructions

    2 Safety Deficits in knowledge must be rectified by sufficiently trained specialist personnel training and instructing the personnel who will carry out the respective tasks. If required, the operator can commission the manufacturer/supplier to train the personnel. Training on the pump (set) must always be supervised by technical specialist personnel.

  • Page 11: Unauthorized Modes Of Operation

    2 Safety ▪ Pump pressure must have been released and the pump must have been drained. ▪ When taking the pump set out of service always adhere to the procedure described in the manual. ▪ Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3 Page 36) ▪...

  • Page 12: Transport/Temporary Storage/Disposal

    On transfer of goods, check each packaging unit for damage. In the event of in-transit damage, assess the exact damage, document it and notify KSB or the distributor and the insurance company about the damage in writing immediately. 3.2 Transport...

  • Page 13: Storage/Preservation

    3 Transport/Temporary Storage/Disposal Horizontal transport Horizontal transport Close-coupled pump Close-coupled pump without motor 3.3 Storage/Preservation If commissioning is to take place some time after delivery, we recommend that the following measures be taken: CAUTION Improper storage Damage to the power cables! ▷...

  • Page 14: Return To Supplier

    Always indicate any safety and decontamination measures taken. (⇨ Section 11 Page 54) NOTE If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids handled, consumables and operating supplies which are hot or pose a health...

  • Page 15: Description Of The Pump (Set)

    4 Description of the Pump (Set) 4 Description of the Pump (Set) 4.1 General description Pump for handling untreated sewage and all types of waste water. ▪ Close-coupled pump with shaft seal ▪ Directly flanged standardized motor ▪ Direct drive electric motor Table 7: Types of installation Type of Illustration...

  • Page 16: Name Plate

    4 Description of the Pump (Set) 4.3 Name plate Aktiengesellschaft D-67227 Frankenthal SNr. 24 17 41 2008 SEWABLOC F 100 - 250 P-No. 9971402925 / 000200 Q 110,32 GPM H 4,87 ft 949 rpm LD = 260 Gew. 140 lbs Mat.-No.
  • Page 17 4 Description of the Pump (Set) Open, diagonal single- For use with the following fluids: vane impeller Fluids containing solid substances and (D impeller) long fibers E impeller: Closed single-channel For use with the following fluids: impeller Fluids containing solid substances and (impeller type E) stringy material F impeller/F-max impeller:...

  • Page 18: Configuration And Function

    4 Description of the Pump (Set) 4.5 Configuration and function Fig. 2: Sectional drawing Sewabloc with K impeller Clearance gap Discharge nozzle Discharge cover Shaft Bearing bracket Suction nozzle Impeller Shaft seal Rolling element bearing Motor Design The hydraulic system and the motor are firmly connected and form a close-coupled unit.

  • Page 19: Scope Of Supply

    4 Description of the Pump (Set) Rated power input 1750 rpm 1160 / 875 rpm [dB] [dB] 7.5 hp (5.5 kW) 63.5 63.0 10.0 hp (7.5 kW) 65.0 63.5 15.0 hp (11.0 kW) 67.0 65.5 20.0 hp (15.0 kW) 68.0 66.5 25.0 hp (18.5 kW) 68.5...

  • Page 20: Installation At Site

    5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Improper installation in potentially explosive atmospheres Damage to the pump set! ▷ Comply with the applicable local explosion protection regulations. ▷ Observe the information given in the data sheet and on the pump/motor name plates.
  • Page 21 5 Installation at Site ✓ The foundation has been prepared in accordance with the dimensions given in the outline drawing/general arrangement drawing. Position the pump set on the foundation and align it with the help of a spirit level placed on the shaft and discharge nozzle. Permissible deviation: 0.0079 inch/m (0.2 mm/m).

  • Page 22: Piping

    5 Installation at Site 5.4 Piping 5.4.1 Connecting the piping DANGER Impermissible loads acting on the pump nozzles Danger to life from leakage of hot, toxic, corrosive or flammable fluids! ▷ Do not use the pump as an anchorage point for the piping. ▷...
  • Page 23 The data on forces and moments apply to static piping loads only. If the limits are exceeded, they must be checked and verified. If a computerized strength analysis is required, please contact KSB. The values are only applicable if the pump is installed on a completely grouted baseplate and bolted to a rigid and level foundation.

  • Page 24: Auxiliary Connections

    5 Installation at Site ▪ The line extends above the highest permissible fluid level in the tank. Fig. 5: Vacuum balance line Vessel under vacuum Vacuum balance line Shut-off element Swing check valve Main shut-off element Vacuum-tight shut-off element NOTE An additional line fitted with a shut-off valve (from the pump discharge nozzle to the balance line) facilitates venting of the pump before start-up.

  • Page 25: Checking The Lubricants

    5 Installation at Site Table 14: Sizes of auxiliary connections Connection Description Size 50 - 215 65 - 216 80 - 216 125 - 315 50 - 216 65 - 250 80 - 250 125 - 317 50 - 250 K 65 - 252 80 - 315 150 - 315...

  • Page 26: Electrical Connection

    5 Installation at Site 5.7 Electrical connection DANGER Incorrect electrical installation Danger of death from electric shock! ▷ For electrical installation also observe the requirements of IEC 60079-14. ▷ Always connect explosion-proof motors via a motor protection switch. DANGER Electrical connection work by unqualified personnel Danger of death from electric shock! ▷...

  • Page 27: Priming And Venting The Pump

    5 Installation at Site Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. If the impeller rotates in the wrong direction of rotation, check and correct the electrical connection of the motor and the control system, if applicable.

  • Page 28: Commissioning/Start-Up/Shutdown

    6 Commissioning/Start-up/Shutdown 6 Commissioning/Start-up/Shutdown 6.1 Commissioning/start-up 6.1.1 Prerequisites for commissioning/start-up Before commissioning/starting up the pump set, make sure that the following conditions are met: ▪ The pump set has been properly connected to the electric power supply and is equipped with all protection devices. ▪...

  • Page 29: Operating Limits

    6 Commissioning/Start-up/Shutdown ✓ The pump, suction line and discharge line have been vented and primed with the fluid to be handled. Fully open the shut-off element in the suction head/suction lift line. Close/slightly open the shut-off element in the discharge line; fully open the shut-off element if a check valve is installed.
  • Page 30 6 Commissioning/Start-up/Shutdown Size Maximum operating pressure [psi] [bar] 50 - 251 F 65 - 215 65 - 250 F 80 - 216 80 - 250 80 - 315 80 - 316 F 100 - 215 100 - 250 100 - 251 F 100 - 252 F 100 - 253 100 - 316...

  • Page 31: Shutdown/Storage/Preservation

    6 Commissioning/Start-up/Shutdown 6.2.3.3 Abrasive fluids Do not exceed the maximum permissible solids content specified in the data sheet. When the pump handles fluids containing abrasive substances, increased wear of the hydraulic system and the shaft seal is to be expected. In this case, halve the intervals commonly recommended for servicing and maintenance.

  • Page 32: Servicing/Maintenance

    (set) with a minimum of maintenance expenditure and work. NOTE All maintenance, service and installation work can be carried out by KSB Service or an authorized workshop. Find your contact in the attached "Addresses" booklet or on the Internet under "www.ksb.com/contact".

  • Page 33: Maintenance/Inspection

    7 Servicing/Maintenance Never use force when dismantling and reassembling the pump set. 7.2 Maintenance/inspection 7.2.1 Supervision of operation DANGER Formation of a potentially explosive atmosphere inside the pump Explosion hazard! ▷ The pump internals in contact with the fluid to be handled, including the seal chamber and auxiliary systems must be filled with the fluid to be handled at all times.
  • Page 34 7 Servicing/Maintenance WARNING Hands or objects inside the pump casing Risk of injuries, damage to the pump! ▷ Check that the inside of the pump is free from any foreign objects. Remove any foreign objects. ▷ Never insert your hands or any other objects into the pump if the pump has not been de-energized and secured against unintentional start-up.
  • Page 35 7 Servicing/Maintenance 7.2.3.2 Changing the lubricant WARNING Lubricants posing a health hazard and/or hot lubricants Hazard to persons and the environment! ▷ When draining the lubricant take appropriate measures to protect persons and the environment. ▷ Wear safety clothing and a protective mask, if required. ▷...

  • Page 36: Drainage/Disposal

    7 Servicing/Maintenance Size Lubricant quantity [quart] F 80 - 216 80-250 80-315 80-316 F 100 - 215 100-250 100-251 100-252 100-253 100-316 125-315 125-317 150-251 150-315 200-315 200-316 7.2.3.4 Lubricant quality The lubricant reservoir is filled with an environmentally friendly, non-toxic lubricant of medical quality.

  • Page 37: Dismantling The Pump Set

    7 Servicing/Maintenance 7.4 Dismantling the pump set 7.4.1 General information/Safety regulations WARNING Unqualified personnel performing work on the pump (set) Risk of personal injury! ▷ Always have repair and servicing work performed by specially trained, qualified personnel. WARNING Improper lifting/moving of heavy assemblies or components Personal injury and damage to property! ▷...
  • Page 38 7 Servicing/Maintenance NOTE For further dismantling the pump casing may remain installed in the piping. Disconnect the power supply (e.g. at the motor). Disconnect and remove all auxiliary pipework. Remove coupling guard 681. Remove the coupling spacer of coupling 848, if any. Drain the oil (⇨...
  • Page 39 A forcing screw is required to remove the impeller. The forcing screw is not included in the scope of supply. It can be ordered separately from KSB. ✓ The notes and steps stated in (⇨ Section 7.4.5 Page 38) have been observed/ carried out.
  • Page 40 7 Servicing/Maintenance 7.4.7 Removing the mechanical seal 433.02 433.01 515 / 932.03 Fig. 11: Removing the mechanical seal 7.4.7.1 Removing the pump-end mechanical seal ✓ The back pull-out unit and the impeller have been removed as described above. Pull the rotating assembly of mechanical seal 433.02 off shaft 210. Remove discharge cover 163 from bearing bracket 330.

  • Page 41: Reassembling The Pump Set

    7 Servicing/Maintenance Drive shaft 210 with deep groove ball bearing 321.01 out of the bearing bracket towards the drive end. Remove circlip 932.20. Pull deep groove ball bearing 321.01 off the shaft. Remove the stationary seat of drive-end mechanical seal 433.01 from bearing bracket 330.
  • Page 42 7 Servicing/Maintenance Table 19: Bearings Size Grease-packed Size: deep groove ball bearings, Bearing bracket / motor sealed for life F 50 - 215 6307 - 2 Z - C3 B01 / 112; B01 / 132; B01 / 160 F 50 - 216 6307 - 2 Z - C3 B01 / 100;...
  • Page 43 7 Servicing/Maintenance Insert O-rings 412.04 and 412.15 into discharge cover 163. Press the discharge cover into bearing bracket 330 until it will not go any further. Slide pump-end mechanical seal 433.02 onto shaft 210. For special mechanical seals with covered spring, tighten the socket head cap screw at the rotating assembly before fitting the impeller.
  • Page 44 7 Servicing/Maintenance Size Thread Tightening torque [ft lbs] [Nm] F 100 - 252 M 10 25,82 F 100 - 253 M 16 110,64 100 - 316 M 16 110,64 125 - 315 M 16 110,64 125 - 317 M 16 110,64 150 - 251 M 10...
  • Page 45 7 Servicing/Maintenance 914.12 412.34 914.24 412.33 Fig. 15: Fitting the wear plate Equip wear plate 135 with two new O-rings 412.33/34. Insert wear plate 135 into pump casing 101. Fasten wear plate 135 to pump casing 101 with hexagon socket head cap screws 914.12.

  • Page 46: Tightening Torques

    7 Servicing/Maintenance 7.6 Tightening torques Table 22: Tightening torques Thread Tightening torque Thread Tightening torque 316 SS / Duplex A4-70 / 1.4462 [ft lbs] [Nm] 5.16 12.54 25.82 M 10 44.25 M 12 110.64 M 16 213.90 M 20 205.05 / 368.8 M 24 278 / 500 301.67 / 542.8...
  • Page 47 7 Servicing/Maintenance S = spare part R = replacement part W = wear part NOTE Keeping a stock of wear and replacement parts is recommended also during the warranty period. Sewabloc (60 Hz) 47 of 56...

  • Page 48: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with KSB’s customer service is required. Pump delivers insufficient flow rate Motor overload...
  • Page 49 Increase pressure at the pump suction nozzle. ✘ - Insufficient operating voltage Increase the voltage. Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. Contact KSB. Sewabloc (60 Hz) 49 of 56...

  • Page 50: Related Documents

    9 Related Documents 9 Related Documents 9.1 General assembly drawing 411.02 903.02 902.01 920.01 903.90 932.02 903.03 411.90 321.01 411.03 433.01 433.02 914.10 / 550.23* 515 / 904.01** 932.03 932.20 901.57 920.57 903.01 411.01 412.15 412.04 903.46 411.46 903.22 411.22 550.57 901.99 Fig.
  • Page 51 9 Related Documents Table 26: List of components Part No. Description Part No. Description Pump casing Taper lock ring Wear plate 550.23/.57 Disc Discharge cover Motor Inspection cover Bolt/screw Shaft 901.57/.99 Hexagon head bolt Impeller 902.01 Stud Impeller hub cap 903.01/.02/.03/.22/.46/.90 Screw plug 321.01...

  • Page 52: Exploded View

    9 Related Documents 9.2 Exploded view Fig. 17: Exploded view: Sewabloc Part No. Description Part No. Description Part No. Description Pump casing O-ring Hexagon head bolt Discharge cover Mechanical seal Stud Shaft Casing wear ring Screw plug Impeller Taper lock ring Hexagon socket head cap screw Deep groove ball bearing 550...

  • Page 53: Ec Declaration Of Conformity

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

  • Page 54: 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 check where applicable ⃞ ⃞ ⃞ ⃞ Radioactive Explosive Corrosive Toxic ⃞ ⃞ ⃞...

  • Page 55: Index

    Index Index Bearings 17 Maintenance 33 Misuse 9 Certificate of decontamination 54 Commissioning/start-up 28 Operating limits 8, 29 Order number 6 Other applicable documents 6 Design 16 Direction of rotation 26 Dismantling 37 Partly completed machinery 6 Disposal 14 Permissible forces and moments at the pump nozzles Piping 22 Preservation 13 Priming and venting 27...
  • Page 56 KSB Aktiengesellschaft 67225 Frankenthal • Johann-Klein-Str. 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 • Fax +49 6233 86-3401 www.ksb.com...

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