KSB B Series Installation And Operating Manual
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KSB B Series Installation And Operating Manual

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Deep-well Turbine Pump
B-Pump
Installation/Operating Manual

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  • Page 1 Deep-well Turbine Pump B-Pump 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 SE & Co. KGaA, Frankenthal 23/01/2018...

  • Page 3: Table Of Contents

    Contents Contents General.............................. 6 Principles ................................ 6 Installation of partly completed machinery.................... 6 Target group.............................. 6 Other applicable documents.......................... 6 Symbols ................................ 6 Key to safety symbols/markings........................ 7 Safety .............................. 8 General................................ 8 Intended use .............................. 8 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 9 Safety awareness .............................. 9 Safety information for the operator/user ....................... 9 Safety information for maintenance, inspection and installation .............. 10...
  • Page 4 Contents 6.1.5 Checking the shaft seal........................ 29 6.1.6 Shutdown ............................ 30 Operating limits.............................. 31 6.2.1 Maximum operating pressure ...................... 31 6.2.2 Temperature of the fluid handled.................... 31 6.2.3 Abrasive fluids/solids.......................... 31 6.2.4 Hydraulic operating range ........................ 32 6.2.5 Frequency of starts.......................... 33 6.2.6 Fluid handled ............................. 33 Shutdown/storage/preservation ........................ 34 6.3.1 Measures to be taken for shutdown .................... 34 Returning to service ............................ 34...
  • Page 5 Glossary Glossary 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 and health hazards arising from components in contact with the fluid handled.

  • Page 6: General

    In the event of damage, immediately contact your nearest KSB Service centre to maintain the right to claim under warranty. 1.2 Installation of partly completed machinery To install partly completed machinery supplied by KSB refer to the sub-sections under Servicing/Maintenance.

  • Page 7: Key To Safety Symbols/Markings

    1 General Symbol Description Step-by-step instructions Note Recommendations and important information on how to handle the product 1.6 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 8: Safety

    2 Safety 2 Safety All the information contained in this section refers to hazardous situations. DANGER In addition to the present general safety information the action-related safety information given in the other sections must be observed. 2.1 General This operating manual contains general installation, operating and maintenance instructions that must be observed to ensure safe operation of the system and prevent personal injury and damage to property.

  • Page 9: Personnel Qualification And Training

    2 Safety 2.3 Personnel qualification and training All personnel involved must be fully qualified to transport, install, operate, maintain and inspect the machinery this manual refers to. The responsibilities, competence and supervision of all personnel involved in transport, installation, operation, maintenance and inspection must be clearly defined by the operator.

  • Page 10: Safety Information For Maintenance, Inspection And Installation

    2 Safety 2.7 Safety information for maintenance, inspection and installation ▪ Modifications or alterations of the pump are only permitted with the manufacturer's prior consent. ▪ Use only original spare parts or parts authorised by the manufacturer. The use of other parts can invalidate any liability of the manufacturer for resulting damage.

  • Page 11: 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 and the insurer about the damage in writing immediately.

  • Page 12: Storage/Preservation

    3 Transport/Temporary Storage/Disposal DANGER Risk of falling when working at a great height Danger to life by falling from a great height! ▷ Use a sturdy scaffold. ▷ Observe the applicable local occupational safety and accident prevention regulations. 1. Refer to the weights of the individual components stated in the general arrangement drawing and/or the manufacturer's product literature.

  • Page 13: Return To Supplier

    Indicate any safety measures and decontamination measures taken. (ð Section 11, Page 56) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 3.5 Disposal WARNING Fluids handled, consumables and supplies which are hot and/or pose a health hazard Hazard to persons and the environment! ▷...

  • Page 14: Description Of The Pump (Set)

    Number of stages of the hydraulic system Type of installation (VN = discharge nozzle above floor) Type of drive (V1 = direct drive by vertical electric motor 4.3 Name plate KSB Pumps Co. Ltd., 16/2 Sir Agha Khan Road, Lahore - PAKISTAN B-pump...

  • Page 15: Design Details

    4 Description of the Pump (Set) 4.4 Design details Design ▪ Centrifugal pump ▪ Vertical installation ▪ Single-stage or multistage ▪ Nominal diameter of the discharge nozzles: 80 mm to 500 mm ▪ Borehole diameter: 6 inches to 24 inches Pump casing ▪ Radially split relative to the shaft ▪...

  • Page 16: Scope Of Supply

    4 Description of the Pump (Set) 4.6 Scope of supply Depending on the model, the following items are included in the scope of supply: ▪ Pump ▪ Drive ▪ Base frame, supporting frame, foundation blocks, foundation rails, foundation ring ▪ Coupling and coupling guard ▪...

  • Page 17: Installation At Site

    5 Installation at Site 5 Installation at Site 5.1 Safety regulations For all work involving assembly, reassembly and installation, observe the following safety information: DANGER Improper installation in potentially explosive atmospheres Explosion hazard! Damage to the pump set! ▷ Comply with the applicable local explosion protection regulations. ▷...

  • Page 18: Installing The Pump Set

    5 Installation at Site Suction head/suction lift line WARNING Foreign objects in the intake/suction line Personal injury and damage to property! ▷ Make sure that the intake area (e.g.: intake chamber/intake channel) is clean and free from foreign objects. ▷ Make sure that the suction line is clean and free from foreign objects. ▷...

  • Page 19: Checking And Adjusting The Pump Rotor Clearance

    5 Installation at Site Installation on existing elements DANGER The pump or individual components could slip out of the suspension arrangement Danger to life from falling parts! ▷ Always transport the pump or components in the specified position. ▷ Never attach the suspension arrangement to free shaft areas on the pump. ▷...
  • Page 20 5 Installation at Site Fig. 2: Axial clearance Axial clearance A Axial clearance B Height of casing wear ring Table 5: Axial clearance Size Axial clearance [mm] Casing wear ring C ü Suitably dimensioned lifting equipment and lifting accessories are available. ü The pump has been completely assembled. ü...

  • Page 21: Connecting The Piping

    5 Installation at Site 3. After establishing the correct axial clearance, turn the adjusting nut further until the holes of the locking screws align with the next threaded holes. This slightly increases the permissible clearance. 4. Fit the locking screws of the adjusting nut. 5.

  • Page 22: Enclosure/Insulation

    5 Installation at Site CAUTION Welding beads, scale and other impurities in the piping Damage to the pump! ▷ Remove any impurities from the piping. ▷ If necessary, install a filter/strainer. 4. If required, install a filter/strainer in the piping. 5.

  • Page 23: Permissible Forces And Moments At The Pump Nozzles

    See the general arrangement drawing for forces and moments at the pump nozzles. The values indicated do not apply to reaction forces from unbraced expansion joints! (See the general arrangement drawing for permissible values, or contact KSB) Determine the resulting permissible forces according to...

  • Page 24: Auxiliary Connections

    5 Installation at Site The data on forces and moments apply to static piping loads only. If the limits are exceeded, they must be checked and verified. The values are only applicable if the pump is installed on completely grouted elements and bolted to a rigid and level foundation.

  • Page 25: Earthing

    5 Installation at Site WARNING Incorrect connection to the mains Damage to the mains network, short circuit! ▷ Observe the technical specifications of the local energy supply companies. 1. Check the available mains voltage against the data on the motor name plate. 2.

  • Page 26: Removing The Transport Lock

    5 Installation at Site CAUTION Drive and pump running in the wrong direction of rotation Damage to the pump! ▷ Refer to the arrow indicating the direction of rotation on the pump. ▷ Check the direction of rotation. If required, check the electrical connection and correct the direction of rotation.

  • Page 27: 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. (ð Section 5.9, Page 24) ▪...

  • Page 28: Start-Up

    6 Commissioning/Start-up/Shutdown 6.1.4 Start-up DANGER Non-compliance with the permissible pressure and temperature limits if the pump is operated with the suction and/or discharge line closed. Explosion hazard! Hot or toxic fluids escaping! ▷ Never operate the pump with the shut-off elements in the suction line and/or discharge line closed.

  • Page 29: Checking The Shaft Seal

    6 Commissioning/Start-up/Shutdown DANGER Seal leakages at operating temperature Hot or toxic fluid could escape! ▷ After the operating temperature has been reached and/or in the event of leakage, switch off the pump set and tighten the bolts on the casing to the specified torques.

  • Page 30: Shutdown

    6 Commissioning/Start-up/Shutdown Not enough leakage: Slightly loosen the nuts at the gland follower. No leakage: Switch off the pump set immediately! Loosen the gland follower and repeat start-up. Checking for leakage After the leakage has been adjusted, monitor the leakage for about two hours at maximum fluid temperature.

  • Page 31: Operating Limits

    6 Commissioning/Start-up/Shutdown 6.2 Operating limits DANGER Non-compliance with operating limits for pressure, temperature, fluid handled and speed Explosion hazard! Hot or toxic fluid could escape! ▷ Comply with the operating data indicated in the data sheet. ▷ Never use the pump for handling fluids it is not designed for. ▷...

  • Page 32: Hydraulic Operating Range

    6 Commissioning/Start-up/Shutdown 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 shaft seal are to be expected. In this case, reduce the commonly recommended inspection intervals.

  • Page 33: Frequency Of Starts

    6 Commissioning/Start-up/Shutdown If the pump set is operated outside its operating limits or system-related changes occur, check the NPSH values. If necessary, consult your nearest customer service centre. 6.2.5 Frequency of starts DANGER Excessive surface temperature of the motor Explosion hazard! Damage to the motor! ▷...

  • Page 34: Shutdown/Storage/Preservation

    If the intake area (e.g. intake elbow) and the pump have been drained, special measures must be taken for the functional check run. See section on routine maintenance and inspection intervals or contact KSB. B-Pump 34 of 60...
  • Page 35 6 Commissioning/Start-up/Shutdown NOTE On pumps/pump sets older than 5 years we recommend replacing all elastomer seals. B-Pump 35 of 60...

  • Page 36: Servicing/Maintenance

    NOTE All maintenance, service and installation work can be carried out by KSB Service. See data sheet for contact addresses Never use force when dismantling and reassembling the pump set.

  • Page 37: Servicing/Inspection

    7 Servicing/Maintenance 7.2 Servicing/inspection 7.2.1 Supervision of operation DANGER Risk of 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 38: Inspection Work

    7 Servicing/Maintenance ▪ Monitor the correct functioning of any auxiliary connections. ▪ Monitor the stand-by pump. To make sure that the stand-by pumps are ready for operation, start them up once a month. ▪ Monitor the bearing temperature. The bearing temperature must not exceed the value specified in the data sheet (measured on the outside of the bearing housing).
  • Page 39 7 Servicing/Maintenance Interval Number of Time Maintenance job persons Daily 6 min. ▪ Check the oil level and top up the oil, if required (only for oil- lubricated bearings) Weekly 15 min. ▪ Check pump operation (inlet pressure, head, bearing temperature, noise and vibrations).
  • Page 40 7 Servicing/Maintenance 7.2.2.5 Lubrication and lubricant change of the thrust and radial bearings DANGER Excessive temperatures as a result of bearings running hot or defective bearing seals Explosion hazard! Fire hazard! Damage to the pump set! ▷ Regularly check the bearing seals. ▷...
  • Page 41 7 Servicing/Maintenance 7.2.2.5.1.2 Changing the grease ü The bearing assembly must be dismantled to change the grease. 1. Thoroughly clean bearing, bearing housing and bearing cover with petrol, benzene or a similar cleaning agent. Carefully remove the cleaning agent from the components again.

  • Page 42: Drainage/Cleaning

    7 Servicing/Maintenance 3. Once the bearing housing has run empty, close the lubricant drain. 4. Remove the venting element. 5. Fill the lubricant up to the mark using the opening provided for the venting element. 6. After a short time, check whether the oil level has dropped at the marking. If the oil level is too low, top it up with oil.

  • Page 43: Preparing The Pump Set

    7 Servicing/Maintenance WARNING Unqualified personnel performing work on the pump (set) Risk of injury! ▷ Always have repair work and maintenance work performed by specially trained, qualified personnel. WARNING Improper lifting/moving of heavy assemblies or components Personal injury and damage to property! ▷...

  • Page 44: Dismantling The Supplied Design/Installation

    7 Servicing/Maintenance DANGER Pump (set) tipping over Danger to life from pump or components tipping over! ▷ Never undo screwed connections without suspending and securing the components to be dismantled in a hoisting tackle. ▷ Only dismantle the pump (set) in the specified order. ▷...
  • Page 45 7 Servicing/Maintenance DANGER Pump (set) tipping over Danger to life from pump or components tipping over! ▷ Never undo screwed connections without suspending and securing the components to be dismantled in a hoisting tackle. ▷ Only dismantle the pump (set) in the specified order. ▷...

  • Page 46: Assembling The Supplied Design/Installation

    See other applicable documents for installing and assembling the delivered design/ installation. 7.6 Spare parts stock 7.6.1 Ordering spare parts Please order any replacement or spare parts required from: KSB Pumps Company Limited 16/2, Sir Aga Khan Road Lahore, Pakistan Telefax: +92 42 3636 8878-4 Telephone: +92 42 3630 4173-4 Always quote the following data when ordering replacement or spare parts: ▪...

  • Page 47: Recommended Spare Parts Stock For 2 Years' Operation To Din 24296

    7 Servicing/Maintenance 7.6.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 9: Quantity of spare parts for recommended spare parts stock Part No. Description Number of pumps (including stand-by pumps) 6 / 7 8 / 9 10 and more Quantity of spare parts 8)9)

  • Page 48: Trouble-Shooting

    If problems occur that are not described in the following table, consultation with the KSB customer service is required. A Pump discharge pressure is too low B Excessive discharge pressure...
  • Page 49 8 Trouble-shooting A B C D E F G J K L M Possible cause Remedy - NSPH available/water level too low ▪ Check operating mode. ✘ ✘ ✘ ✘ ✘ ▪ Increase back pressure by throttling. ▪ Correct the suction conditions. ▪...
  • Page 50 8 Trouble-shooting A B C D E F G J K L M Possible cause Remedy - Pump is warped. ▪ Check piping connections and ✘ ✘ ✘ ✘ ✘ fixing of pump. - Increased axial thrust ▪ Clean balancing holes in the ✘...
  • Page 51 8 Trouble-shooting A B C D E F G J K L M Possible cause Remedy - Non-compliance with specified ▪ Correct the distance according ✘ coupling distance to general arrangement drawing. ✘ ✘ ✘ ✘ - Motor is running on 2 phases only. ▪...
  • Page 52 8 Trouble-shooting A B C D E F G J K L M Possible cause Remedy - Operating voltage too low ▪ Increase the operating voltage. ✘ ✘ - Excessive surface pressure in the ▪ Check installation mechanical seal's sealing clearance, dimensions.

  • Page 53: Explanation Of Faults

    Q. The operating point B is given by the intersection between the system curve H and the pump's characteristic curve H. If the cause of a fault or malfunction is unclear, consult your nearest KSB service centre. NPSH NPSH Fig. 6: Adjusting to the duty point...

  • Page 54: Related Documents

    9 Related Documents 9 Related Documents B-Pump 54 of 60...

  • Page 55: Eu Declaration Of Conformity

    10 EU Declaration of Conformity 10 EU Declaration of Conformity KSB Pumps Company Limited Manufacturer: 16/2, Sir Aga Khan Road Lahore (Pakistan) The manufacturer herewith declares that the product: P-Pump KSB order number: ....................▪ is in conformity with the provisions of the following Directives as amended from time to time: –...

  • Page 56: 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 57: Index

    Index Index Abrasive fluids 32, 34 Operating limits 31 Auxiliary connections 24 Order number 6 Other applicable documents 6 Bearing temperature 38 Bearings 12 Partly completed machinery 6 Permissible forces and moments at the pump nozzles 24 Piping 21 Certificate of decontamination 56 Preservation 12, 34 Commissioning/start-up 27 Pump casing 15 Design 15 Reassembly 46 Designation 14 Return to supplier 13 Dismantling 43 Returning to service 34...
  • Page 60 KSB SE & Co. KGaA Johann-Klein-Straße 9 • 67227 Frankenthal (Germany) Tel. +49 6233 86-0 www.ksb.com...

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