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KSB LCV Installation & Operating Manual

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Installation/Operating Manual
2017.01
Pump Type:
Pump Serial Number:
Date:
Purchaser:
Purchaser's Order Number:
GIW / KSB Work Order Number:
Shipped To:
Include the pump's serial number when ordering replacement parts
This is a standard maintenance manual provided for your convenience
This manual may include additional documentation not applicable to your specific pump
GIW INDUSTRIES, INC.
5000 Wrightsboro Road
Grovetown, GA 30813 USA
FAX
www.giwindustries.com
+1 (888) 832-4449
+1 (706) 855-5151
KSB AG
Johann-Klein-Str. 9
D-67227 Frankenthal, Germany
+49 6233 86-0
FAX
+49 6233 86-3289
www.ksb.com
LCV
[en-US]
.

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Summary of Contents for KSB LCV

  • Page 1 Pump Serial Number: Date: Purchaser: Purchaser’s Order Number: GIW / KSB Work Order Number: Shipped To: Include the pump’s serial number when ordering replacement parts This is a standard maintenance manual provided for your convenience This manual may include additional documentation not applicable to your specific pump GIW INDUSTRIES, INC.
  • Page 2 All rights reserved. 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 KSB´s express written consent. Subject to technical modification without prior notice.

  • Page 3: Table Of Contents

            3.2.2 Pump Storage Seal Plate         3.2.3 Pump Parts Storage 9.1.1 Seal Plate Assembly (LCV Only)     3.2.4 Removal from Storage     Recommended Lifting     Wet End     10.1 Wet End Overview  ...
  • Page 4 Disassembly, Mechanical End Disassembly, Wet End Safety, Regulations Safety, Transport & Handling Drainage / Disposal End Covers and Seals, Installation Seal Plate Seal Plate Assembly (LCV Only) Foundation Impeller Shaft Seal Impeller Installation Shaft Seal, Commissioning Impeller Removal Shaft Sleeve, Mounting...

  • Page 5: General

    Consult your pump/unit drawings and Bill of Materials for details. If you need any additional information or instructions exceeding the scope of this manual or in case of damage, please contact your GIW / KSB representative.

  • Page 6: Safety

    LCV [en-US] Safety These operating instructions contain fundamental information that must be complied with during installation, operation and maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible trained personnel / operators prior to installation and commissioning, and it must always be kept close to the operating location of the machine / unit for easy access.

  • Page 7: Non-Compliance With Safety Instructions

    For sectional drawings and bills of material relating to your specific pump and equipment, locate an official copy of the documentation provided by GIW / KSB. This may be shipped separately from the pump and will include drawings and bills of material as attachments to this basic manual.
  • Page 8 LCV [en-US]  Avoid the use of mounting aids as much as possible. Should a mounting aid be required, use a commercially available contact adhesive. The adhesive should only be applied at selected points (three to four spots) and in thin layers. Do not use cyanoacryiate adhesives (quick-setting adhesives).

  • Page 9: Transport And Storage

    Storage Requirements 3.2.1 Storage of New Pumps - Pumps under Warranty Consult your sales contract documents and/or your GIW / KSB representative for detailed instructions. Note that failure to follow proper storage procedures will void your warranty. 3.2.2 Pump Storage CAUTION ...

  • Page 10: Pump Parts Storage

    LCV [en-US] Storage Upon Receipt and up to 3 Months:  Pump should stored indoors and out of the weather until ready for installation.  In construction environments where indoor storage is not available, store the pump on blocks or pallets, build a frame around it and cover with tarpaulin.

  • Page 11: Removal From Storage

    LCV [en-US] Pump Part Pump Part Pedestal Casing Casing Half  Outdoor storage with monthly inspection permitted for these parts only Liner  Lay sub-bases flat and do not stack Plate Impeller Sub-base  Coat complete part with rust protector and wrap with 6mil/0.15mm VCI (Vapor...

  • Page 12: Recommended Lifting

    LCV [en-US] Recommended Lifting WARNING Actual safe lifting method will vary with pump configuration and type of lifting equipment Vertical Lifting Horizontal Lifting...

  • Page 13: Description

    LCV 150 - 500 LCV 200 - 610 LCV 250 - 660 LCV 300 - 710 For additional information please contact your GIW / KSB representative. Design Features Vertical, end suction, modified volute casing pump with three-vane impeller for large solids passage.

  • Page 14: Noise Characteristics

    Discharge flange loads are limited to the weight of the discharge pipe section supplied with the pump by GIW. Any additional pipe loads or moments must be compensated for by the system pipe supports. For additional information please contact your GIW / KSB representative.

  • Page 15: Installation At Site

    LCV [en-US] Installation at Site Safety Regulations WARNING Electrical equipment operated in hazardous locations must comply with the applicable explosion protection regulations. This is indicated on the motor rating plate. If the equipment is installed in hazardous locations, the applicable local explosion protection regulations and the regulations of the test certificate supplied with the equipment and issued by the responsible approval authorities must be observed and complied with.

  • Page 16: Place Of Installation

    LCV [en-US] CAUTION  All components must be level during system operation unless special provisions for bearing lubrication and oil sealing have been made. After attaching the unit to the foundation and connecting the piping, the pump and drive train must be thoroughly checked and, if necessary, realigned.

  • Page 17: Safety Guards

    LCV [en-US] Safety Guards WARNING In compliance with the accident prevention regulations the pump must not be operated without coupling and drive guards. If the customer specifically requests not to include guards in our delivery, then the operator must supply them.

  • Page 18: Commissioning / Operation

    If the pump has been in long term storage (more than 3 months), ensure proper storage procedures were followed, including instructions for removing the pumps from storage (see contract documents and/or contact your GIW / KSB representative). Failure to follow proper storage procedures will void your warranty. See Section 3.2 "Storage Requirements".

  • Page 19: Bearing Lubrication

    Use high-quality lithium-soap grease, free of resin and acid, not liable to crumble and with good rust-preventive characteristics. Approximate Grease Capacity Grease Size Shaft Speed (RPM) Replenishment Drive Side Pump Side Interval (hours) LCV Frame 1 *1800 LCV Frame 2 *1400 1000 LCV Frame 3 *1000 1500 LCV Frame 4 *750...

  • Page 20: Start-Up

    LCV [en-US] Start-up WARNING Start-up, shutdown, filling and draining procedures must be designed to prevent any possibility of negative torque being experienced on the pump shaft. Negative torque can cause the impeller to unscrew, leading to severe damage throughout the rotating assembly and drive train. In particular, the following practices must be...

  • Page 21: Shutdown

    Failure to do so may result in power overload, excessive vibration, overheating, and/or excessive corrosion or wear. If a data sheet is not available, contact your GIW / KSB representative. CAUTION Any make up water or outside water supply for the system must be installed so that the GIW pump will never be exposed to a pressure in excess of its maximum allowable operating pressure.

  • Page 22: Switching Frequency

    LCV [en-US] 6.4.2 Switching Frequency To prevent high temperature increases in the motor and excessive loads on the pump, coupling, motor, seals and bearings, the switching frequency should not exceed the following number of start-ups per hour. Motor rating Maximum Motor Switchings / Hour <...

  • Page 23: Maintenance

    LCV [en-US] Maintenance WARNING Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump. Supervision of Operation WARNING  Operational procedures which may cause system water hammer must be avoided. Sudden and catastrophic failure of pump casing and plates may result.

  • Page 24: Procedures For Maximum Parts Life

    The wear of slurry pump parts is influenced by many factors and the following procedures are designed to help you get the most out of your wet end wear parts. If problems occur, contact your GIW / KSB representative for a review of your application.
  • Page 25  In the event problems are encountered, contact your GIW / KSB representative. The pump serial number, in addition to the following, should be furnished to assist in evaluation of the problem: Pump serial number (from the nameplate on the pedestal or bearing housing), customer location, and the approximate startup date.

  • Page 26: Mechanical End

    LCV [en-US] Mechanical End Mechanical End Overview  The bearing assembly is a cartridge design mounted on a concentric pedestal with an adjustment mechanism for setting the impeller axial clearance.  Standard lubrication is grease. See Section 6.1.1 "Bearing Lubrication" for lubrication quality and quantity.

  • Page 27: Mechanical End Disassembly

    GIW REGEN Service Centers remanufacture bearing assemblies and refurbish pumps. GIW will rebuild your assembly and return it to its original specifications using genuine OEM replacement parts. Contact your GIW / KSB Sales Representative for details. WARNING Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump.

  • Page 28: Mounting The Bearings

    LCV [en-US] 8.3.1 Mounting the Bearings WARNING Care must be taken when handling heated components. CAUTION Use the bearing assembly drawing to determine if the bearing assembly uses the face to face or back to back taper bearing arrangement. Verify no gap here. Grind if necessary.

  • Page 29: Face To Face Thrust Bearing Installation

    LCV [en-US] CAUTION  Over-tightening can damage the lock washer and allow the locknut to back off during operation.  Do not back off the locknut any amount after tightening in an attempt to set the bearing clearances. The taper bearing has an internal spacer, which automatically sets the internal bearing clearances.

  • Page 30: Bearing Assembly Mounting

    LCV [en-US]  Ensure that the bearing outer diameters and housing bores are clean. Coat shaft between the bearings with GIW Blue Synthetic Bearing Lubricant then insert the shaft with bearings into the housing from the drive end until thrust bearing is located against the housing.

  • Page 31: Shaft Seal

    Standard wet end sealing is accomplished by a seal plate. An optional hard metal throttle seal is available for severe duty. Both seals are non-contacting with the shaft. 9.1.1 Seal Plate Assembly (LCV Only) The seal plate is self aligning but radial adjustment of the optional throttle bushing is required. Failure to correctly center the seal will lead to unnecessary shaft wear and loss of efficiency.

  • Page 32: Wet End

    Several methods of achieving this end are possible. One of the easiest methods is outlined below. To order the devices described here, contact your GIW / KSB representative. Please provide your pump assembly number with the order to ensure a good fit.

  • Page 33: Impeller Removal With Impeller Lifting Device

    LCV [en-US] 10.2.3 Impeller Removal with Impeller Lifting Device WARNING Do not remove, lift, move or reinstall Impeller without properly using a recommended Impeller lifting jig.  For impeller removal or installation, grasp the impeller at the suction eye. The impeller can be leveled by turning the adjusting bolt which bears against the impeller nose.

  • Page 34: Impeller Installation

    10.4 Setting the Nose Gap In order to maximize the performance of your LCV pump, the clearance between the suction face of the impeller and the suction liner must be adjusted to a minimum clearance of 1.00 mm (0.040 inch).

  • Page 35: Nose Gap Adjustment (Frame Size 3 & 4)

    LCV [en-US] 10.4.2 Nose Gap Adjustment (Frame Size 3 & 4) CAUTION Proper locking of the bearing housing end cover is essential to prevent movement of the rotating assembly during operation. Failure to do so can result in severe vibration and damage to all pump components.

  • Page 36: Tooling

    LCV [en-US] Tooling 11.1 Torque Requirements Torque requirements listed below and in previous sections are for lubricated bolting. All bolts must be lubricated to ease in pump assembly and disassembly. Anti seize compound is preferred, but well oiled is also acceptable.

  • Page 37: Spare Parts Stock

    The quantities of parts kept in store will depend upon the severity of the slurry duty and the number of units operating. Maintenance practices may also favor keeping fully built sub-assemblies or complete pumps on hand in some cases. Previous experience in similar duties often provides the best experience. If in doubt, contact your GIW / KSB representative for specific recommendations.

  • Page 38: Troubleshooting

    Adjustment may be needed to system design and/or excessive flowrate. pump operating conditions. ■ ■ Contact your GIW / KSB representative for further advice. Pump and piping are not completely vented or Vent and / or prime. ■ ■ ■...
  • Page 39 Check suction line friction loss calculations. Alter ■ ■ ■ ■ design if necessary. Contact your GIW / KSB representative for further advice. Density or viscosity of the fluid pumped is higher Adjustment may be needed to system design and/or ■...

  • Page 40: Notes

    LCV [en-US] Notes...

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