Contents Contents Glossary .............................. 6 General.............................. 7 Principles ................................ 7 Installation of partly completed machinery.................... 7 Target group.............................. 7 Other applicable documents.......................... 7 Symbols ................................ 7 Key to safety symbols/markings........................ 8 Safety .............................. 9 General................................ 9 Intended use .............................. 9 Personnel qualification and training....................... 9 Consequences and risks caused by non-compliance with this manual ............ 10 Safety awareness ............................ 10 Safety information for the operator/user ..................... 10 Safety information for maintenance, inspection and installation .............. 10...
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Contents Checking the direction of rotation........................ 29 Commissioning/Start-up/Shutdown.................... 31 Commissioning/Start-up .......................... 31 6.1.1 Prerequisites for commissioning/start-up .................. 31 6.1.2 Filling in the lubricant ........................ 31 6.1.3 Shaft seal ............................ 33 6.1.4 Priming and venting the pump...................... 33 6.1.5 Final check ............................ 34 6.1.6 Water cooling............................. 34 6.1.7 Cooling the pump .......................... 34 6.1.8 Cooling the shaft seal ........................ 35 6.1.9...
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Contents 9.1.3 Design variants........................... 70 EU Declaration of Conformity ...................... 73 Certificate of Decontamination...................... 74 Index .............................. 75 5 of 80...
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...
In the event of damage, immediately contact your nearest KSB service facility 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.
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.
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.
2 Safety 2.4 Consequences and risks caused by non-compliance with this manual ▪ Non-compliance with these operating instructions will lead to forfeiture of warranty cover and of any and all rights to claims for damages. ▪ Non-compliance can, for example, have the following consequences: –...
2 Safety ▪ When taking the pump set out of service always adhere to the procedure described in the manual. (ð Section 6.1.13, Page 38) (ð Section 6.3, Page 40) ▪ Decontaminate pumps which handle fluids posing a health hazard. (ð Section 7.3, Page 49) ▪ As soon as the work has been completed, re-install and re-activate any safety- relevant devices and protective devices.
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. 2.9.3 Monitoring equipment The pump (set) must only be operated within the limits specified in the data sheet and on the name plate.
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.
4. Always complete and enclose a certificate of decontamination when returning the pump. Indicate any safety measures and decontamination measures taken. (ð Section 11, Page 74) NOTE If required, a blank certificate of decontamination can be downloaded from the following web site: www.ksb.com/certificate_of_decontamination 14 of 80...
3 Transport/Temporary Storage/Disposal 3.5 Disposal WARNING Fluids handled, 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 fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷...
Version with auxiliary impeller (inducer) Material variant to API 610 Nominal discharge nozzle diameter [mm] Nominal impeller diameter [mm] Special hydraulic system (type B) 4.3 Name plate KSB SE & Co. KGaA Johann-Klein-Straße 9 67227 Frankenthal Order No. Year 2019 Serial No.
4 Description of the Pump (Set) Impeller Shaft seal Rolling element bearing, pump end 10 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.
4 Description of the Pump (Set) Coupling ▪ Spacer-type multiple-disc coupling ▪ Coupling guard Baseplate ▪ Welded baseplate for pump and motor, in torsion-resistant design Special accessories ▪ As required 4.8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing/outline drawing of the pump/pump set.
5 Installation at Site 5 Installation at Site 5.1 Safety regulations DANGER Excessive temperatures in the shaft seal area Explosion hazard! ▷ Never operate a pump (set) with gland packing in potentially explosive atmospheres. 5.2 Checks to be carried out prior to installation Place of installation WARNING Installation on mounting surface which is unsecured and cannot support the load...
5 Installation at Site 5.3.1 Installation on a foundation Fig. 6: Fitting the shims Bolt-to-bolt distance Shim Shim if (L) > 31.5 inches 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.
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 escaping hot, toxic, corrosive or flammable fluids! ▷ Do not use the pump as an anchorage point for the piping. ▷...
5 Installation at Site 4. If required, install a filter in the piping (see drawing: Filter in the piping). Fig. 7: Filter in the piping Differential pressure gauge Filter NOTE Use a filter with laid-in wire mesh of 0.05 inches x 0.01 inches (mesh width x wire diameter) of corrosion-resistant material.
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5 Installation at Site Table 11: Forces and moments at the pump nozzles Suction nozzle Discharge nozzle Forces Moments Forces Moments [lbf] [ft×lbf] [lbf] [ft×lbf] 25-180 25-230 40-180 40-230 40-280 40-181 40-231 40-281 40-361 50-180 1400 1060 1900 50-230 1400 1060 1900 50-280 1400...
5 Installation at Site 5.4.3 Auxiliary connections DANGER Risk of potentially explosive atmosphere by incompatible fluids mixing in the auxiliary piping Risk of burns! Explosion hazard! ▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid handled.
5 Installation at Site 5.6 Checking the coupling alignment DANGER Inadmissible temperatures at the coupling or bearings due to misalignment of the coupling Explosion hazard! Risk of burns! ▷ Make sure that the coupling is correctly aligned at all times. CAUTION Misalignment of pump and motor shafts Damage to pump, motor and coupling!
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.
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.
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5 Installation at Site CAUTION Incorrect direction of rotation of model with auxiliary impeller (inducer) Damage to the pump! ▷ Separate the pump from the motor to check the direction of rotation. CAUTION Drive and pump running in the wrong direction of rotation Damage to the pump! ▷...
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 mechanically connected as specified. ▪ The pump set has been properly connected to the power supply and is equipped with all protection devices.
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6 Commissioning/Start-up/Shutdown Fig. 11: Bearing bracket with constant level oiler Constant level oiler Vent plug Connection elbow of the constant Screw plug level oiler Bearing bracket Oil level sight glass 1. Remove the protective cage. 2. Unscrew the vent plug (2). 3.
6 Commissioning/Start-up/Shutdown Connecting the oil mist lubrication system (for oil mist lubrication only) Bearings with oil mist lubrication Fig. 12: Oil mist lubrication ü Always observe the instructions of the lubricating system manufacturer (especially on dosing and oil quantity). 1. Remove plugs 916.N3. 2.
6 Commissioning/Start-up/Shutdown 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.
6 Commissioning/Start-up/Shutdown Observe the following quality data of the cooling water: ▪ Maximum permissible cooling liquid pressure p = 145 psi ▪ Maximum permissible cooling liquid test pressure p = 215 psi ▪ Observe the specified cooling liquid quantity. 6.1.8 Cooling the shaft seal CAUTION Vaporisation pressure of fluid handled higher than atmospheric pressure Damage to the shaft seal/pump!
6 Commissioning/Start-up/Shutdown CAUTION Time for warming up the pump too short Damage to the pump! ▷ Check that the pump is sufficiently warmed up throughout. The casing cover can be heated with hot water or steam. Observe the following data for the heating medium: ▪...
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 6.1.4, Page 33) ▷...
6 Commissioning/Start-up/Shutdown 6.1.13 Shutdown ü The shut-off element in the suction line is and remains open. ü On pump sets with double mechanical seal, apply the required pressure specified in the general arrangement drawing to the mechanical seal chamber also during standstill.
6 Commissioning/Start-up/Shutdown 6.2.1 Ambient temperature CAUTION Operation outside the permissible ambient temperature Damage to the pump (set)! ▷ Observe the specified limits for permissible ambient temperatures. Observe the following parameters and values during operation: Table 14: Permissible ambient temperatures Permissible ambient temperature Value Maximum 122 °F...
6 Commissioning/Start-up/Shutdown = 0.3 × Q The data refer to water and water-like fluids. Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the temperatures on the pump surface. However, if the physical properties of the fluids handled differ from those of water, the calculation formula below must be used to check if an additional heat build-up may lead to a dangerous temperature increase at the pump surface.
6 Commissioning/Start-up/Shutdown The pump (set) is removed from the pipe and stored ü The pump has been properly drained. (ð Section 7.3, Page 49) ü The safety instructions for dismantling the pump have been observed. (ð Section 7.4.1, Page 49) 1. Spray-coat the inside wall of the pump casing and, in particular, the impeller clearance areas with a preservative.
7 Servicing/Maintenance 7 Servicing/Maintenance 7.1 Safety regulations DANGER Improper cleaning of coated pump surfaces Explosion hazard by electrostatic discharge! ▷ When cleaning coated pump surfaces in atmospheres of Explosion group IIC, use suitable anti-static equipment. DANGER Sparks produced during servicing work Explosion hazard! ▷...
NOTE All maintenance work, service work 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.
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7 Servicing/Maintenance DANGER Incorrectly serviced barrier fluid system Explosion hazard! Fire hazard! Damage to the pump set! Hot and/or toxic fluids escaping! ▷ Regularly service the barrier fluid system. ▷ Monitor the barrier fluid pressure. CAUTION Increased wear due to dry running Damage to the pump set! ▷...
7 Servicing/Maintenance CAUTION Operation outside the permissible bearing temperature Damage to the pump! ▷ The bearing temperature of the pump (set) must never exceed 194 °F (measured on the outside of the bearing bracket). 7.2.2 Inspection work DANGER Excessive temperatures caused by friction, impact or frictional sparks Explosion hazard! Fire hazard! Damage to the pump set!
+347 °F HD 20W/20 SAE Cleveland) Solidification point 59 °F (pour point) Application Higher than temperature permissible bearing temperature At least once a year For ambient temperatures below 15 °F use a different suitable type of lubricating oil. Contact KSB. 47 of 80...
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7 Servicing/Maintenance 7.2.3.1.3 Oil quantity Bearing bracket Oil quantity bearing bracket [gal] 0.23 0.47 0.66 1.50 1.24 7.2.3.1.4 Changing the oil 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.
7 Servicing/Maintenance 7.3 Drainage/cleaning WARNING Fluids handled, 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 fluid residues. ▷ Wear safety clothing and a protective mask if required. ▷...
7 Servicing/Maintenance DANGER Insufficient preparation of work on the pump (set) Risk of injury! ▷ Properly shut down the pump set. (ð Section 6.1.13, Page 38) ▷ Close the shut-off elements in the suction line and discharge line. ▷ Drain the pump and release the pump pressure. (ð Section 7.3, Page 49) ▷...
7 Servicing/Maintenance 7.4.5 Removing the impeller 7.4.5.1 Loosening the impeller — for bearing brackets B02 to B05 ü The notes and steps stated in (ð Section 7.4.1, Page 49) to (ð Section 7.4.4, Page 50) have been observed/carried out. ü The back pull-out unit has been placed in a clean and level assembly area. 1.
7 Servicing/Maintenance 7.4.7 Dismantling the bearing assembly ü The notes and steps stated in (ð Section 7.4.1, Page 49) to (ð Section 7.4.6, Page 51) been observed/carried out. ü The bearing bracket has been placed in a clean and level assembly area. 1. Unscrew the hexagon socket head cap screw in the coupling hub. 2.
7 Servicing/Maintenance Sequence Always reassemble the pump in accordance with the corresponding general assembly drawing. Sealing elements ▪ Gaskets – Always use new gaskets, making sure that they have the same thickness as the old ones. – Always fit gaskets of asbestos-free materials or graphite without using lubricants (e.g.
7 Servicing/Maintenance 5. Use a C-spanner to tighten slotted round nut 920.21 (right-hand thread) without lock washer 931.01. 6. Let angular contact ball bearing 320.01 cool down to approximately 9 °R above ambient temperature. 7. Re-tighten slotted round nut 920.21, then unscrew it again. 8.
7 Servicing/Maintenance 7.5.5 Installing 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 52) to (ð Section 7.5.4, Page 55) have been observed and carried out. ü...
7 Servicing/Maintenance 7.6 Tightening torques 7.6.1 Tightening torques for the pump Use a torque wrench to tighten the screwed connections (902.01/920.01) between the volute casing and the casing cover. Table 20: Tightening torques for bolted/screwed connections Material A 193 Grade B7/ A 193 Grade B7/ 10.9 A276 Type 316 Ti /...
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7 Servicing/Maintenance Material A 193 Grade B7/ A 193 Grade B7/ 10.9 A276 Type 316 Ti / B16 / Type 420 (Asia and Americas) A 540 Grade B24 Material 1.7709/1.6772 C35E+QT A4-70 1.4571/1.4021 (Monix 3K) (Europe) Stud Stud 902.15 Hexagon head bolt Stud 902.02 Impeller nut 922.01 901.37 and impeller screw...
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7 Servicing/Maintenance Material A 193 Grade B7/ A 193 Grade B7/ 10.9 A276 Type 316 Ti / B16 / Type 420 (Asia and Americas) A 540 Grade B24 Material 1.7709/1.6772 C35E+QT A4-70 1.4571/1.4021 (Monix 3K) (Europe) Stud Stud 902.15 Hexagon head bolt Stud 902.02 Impeller nut 922.01 901.37 and impeller screw...
7 Servicing/Maintenance 7.7.2 Recommended spare parts stock for 2 years' operation to DIN 24296 Table 22: Quantity of spare parts for recommended spare parts stock Part No. Description Number of pumps (including stand-by pumps) 6 and 7 8 and 9 10 and more Shaft 20 %...
If problems occur that are not described in the following table, consultation with the KSB service is required. A Pump delivers insufficient flow rate B Motor is overloaded...
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In the case of persistent overloading, turn down impeller. ✘ - Density or viscosity of fluid handled Contact KSB. higher than stated in purchase order - Speed is too high. Reduce speed. ✘ ✘ ✘...
9 Related Documents 9 Related Documents 9.1 General assembly drawings with list of components 9.1.1 Bearing brackets B02 to B05 Fig. 15: Bearing brackets B02 to B05, a) uncooled and b) cooled Table 25: List of components, bearing brackets B02 to B05 Part No.
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9 Related Documents Part No. Comprising Description 920.15 Hexagon nut Shaft 920.21 Slotted round nut 931.01 Lock washer 940.01/.02 Impeller 931.02 Lock washer 503.01/.02 Impeller wear ring 904.06/.07 Grub screw 411.31/.32/.67 Joint ring 320.02/550 Angular contact ball bearing with disc 550 (adjusting washer) 322.01 322.01 Cylindrical roller bearing...
9 Related Documents Part No. Comprising Description 70-3 70-3 Drain line 411.01 Joint ring 902.42 Stud 920.42 Hexagon nut 550.42 Disc 723.23 Flange 744.07 Gate valve 710.21 Pipe 723.21 Flange 411.41 Joint ring 24.01 Blind flange 901.20 Hexagon head bolt 920.20 Hexagon nut 550.20...
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9 Related Documents Design Detailed view Design with plug 916.01 D01044 Design with welded drain Design with bearings in tandem arrangement D01043 320.02 71 of 80...
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9 Related Documents Design Detailed view Design with heatable casing D01126 Design with auxiliary impeller 23-2 72 of 80...
10 EU Declaration of Conformity 10 EU Declaration of Conformity Manufacturer: KSB SE & Co. KGaA 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: –...
Index Index Installation Installation on a foundation 22 Abrasive fluids 40 Installation at site 21 Auxiliary connections 26 Intended use 9 Interchangeability of pump components 62 Back pull-out unit 50 Bearing temperature 44 Keeping warm 36 Bearings 17 Key to safety symbols/markings 8 Certificate of Decontamination 74 List of components 66, 68 Clearances 45 Commissioning 31 Constant level oiler 31 Maintenance 43...
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Index Spare part Ordering spare parts 60 Special accessories 20 Start-up 37 Storage 14, 41 Temperature difference 36 Temperature limits 11, 12 Tightening torques 57 Shaft nut 60 Transport 13 Warnings 8 Warranty claims 7 Water cooling 34, 35 76 of 80...
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