Related Manuals for KRAL DL3 Series
Summary of Contents for KRAL DL3 Series
- Page 1 Operating instructions KRAL pump stations. Series DL3 / DL4 / DS1 / DS3 / DS4 Mechanical seal/Radial shaft seal OID 06en-GB Edition 2019-11 Original instructions www.kral.at...
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Page 2: Table Of Contents
Table of contents 1 About this document ............. 4 10 Operation................ 20 General information ............ 4 10.1 Dangers during operation .......... 20 Associated documents .......... 4 10.2 Commissioning ............ 20 10.2.1 Cleaning the pipe system ........ 20 Target groups .............. 4 10.2.2 Filling and venting the pump station .... 20 Symbols................. 4 10.2.3 Checking the direction of rotation .... 21 1.4.1... - Page 3 Table of contents 12.9.2 Replacing seals (DS1) ........ 41 13 Disposal ................ 43 13.1 Dismantling and disposing of the pump station ... 43 14 Troubleshooting............ 43 14.1 Possible faults ............. 43 14.2 Troubleshooting............ 44 15 Accessories .............. 46 15.1 Pump station accessories.......... 46 15.2 Heating ................ 46 15.2.1 Possible types of heating ........ 46 15.2.2 Electrical heating system/fluid heating system ................ 47...
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Page 4: About This Document
1 About this document 1.1 General information 1 About this document 1.1 General information These instructions form part of the product and must be kept for future reference. Furthermore please observe the associated documents. 1.2 Associated documents o Declaration of conformity according to EU Directive 2006/42/EC o Manufacturer's declaration according to EU Directive 2014/68/EU o Corresponding operating instructions of the pump o Technical documentation of the supplied components... -
Page 5: Symbols In This Document
1 About this document 1.4 Symbols Meaning Source and possible consequences of non-observance Raised load Falling objects can result in serious physical injury or death. Heavy load Heavy loads can result in serious back problems. Risk of slipping Discharging pumped liquid and oils on the foundation or tread surfaces can cause falls with serious physical injury or death. -
Page 6: Safety
2 Safety 2.1 Proper use 2 Safety 2.1 Proper use o Use the pump station solely for transporting lubricating liquids that are chemically neutral and that do not contain gas or solid components. o Use the pump station only within the operating limits specified on the rating plate and in the chapter "Technical data". -
Page 7: Identification
ºC ¹ Serial number max. / p max. mm²/s Type Jahr | Year Gewicht | Weight KRAL GmbH, 6890 Lustenau, Austria KRAL GmbH, 6890 Lustenau, Austria Article number www.kral.at www.kral.at Fig. 2: Rating plate Differential pressure Nominal delivery rate Rated speed... -
Page 8: Technical Data
4 Technical data 4.1 Operating limits 4 Technical data 4.1 Operating limits Parameter Unit Light oil Heavy fuel oil Max. operating pressure [bar] Max. inlet pressure o Radial shaft seal [bar] o Mechanical seal [bar] Min. – max. temperature of [°C] 10 – 80 50 – 180 pumped liquid Viscosity min. – max. -
Page 9: Mesh Width Strainer/Filter
4 Technical data 4.5 Mesh width strainer/filter Size DS1 1000 1300 Max. sound pressure level ±3 [dB(A)] Pump 45.0 46.2 47.7 47.9 49.1 50.4 51.8 53.6 Motor 45.0 44.0 45.0 44.0 44.0 54.0 54.0 54.0 1 pump unit 48.0 48.3 49.6 49.3 50.3 55.6 56.1... -
Page 10: Function Description
Pump stations of the DL3 and DL4 series are suitable for pumping light oil. Pump stations of the DS1, DS3 and DS4 series are suitable for pumping heavy fuel oil. The pump stations are equipped with two KRAL screw pumps of the NE series. Screw pumps are rotating pumps. Their displacement effect results from three rotating screws 12 and 14 and the enclosing cartridge housing 15. -
Page 11: Assignment Pump Station - Pump
5 Function description 5.3 Assignment pump station - pump 5.3 Assignment pump station - pump 1800 3200 1600 2300 4000 1100 2000 2900 6000 1500 3200 1800 4000 2300 6000 2900 1000 1300 Tab. 9: Assignment pump station DL/ DS - pump NE 5.4 Reversing valve If the lever of the reversing valve 6 is in one of the two side positions, the respectively other line of the station is separated from the fluid circuit so that the strainer of this line can be opened and cleaned. -
Page 12: Pressure Measurement
6 Transportation, storage 5.6 Pressure measurement Notice o A function test of the overflow valve at least every 5 years is essential for the safe operation Ä Dur- ing operation, Page 22. o Scope and if necessary shorter test intervals must be specified by the operator-owner in accord- ance with the requirements and national provisions (for example Austrian Ordinance of Safety and Health (BetrSichV)). -
Page 13: Dangers During Storage
6 Transportation, storage 6.2 Dangers during storage 6.2 Dangers during storage The following safety instructions must be observed: o Observe the storage conditions. 6.3 Unpacking and checking the state of delivery Upon delivery unpack the pump station and check it for damage during transportation. Report damage during transportation immediately to the manufacturer. -
Page 14: Storing The Pump Station
7 Preservation 6.5 Storing the pump station 6.5 Storing the pump station During the test run, the internal components of the pump station are wetted with test oil, which has a preservative effect. The pipe connections are fitted with protective covers. Unless otherwise specified, the outer parts of the pump station are preserved with a single-coat PU-based two-component paint. -
Page 15: Preserving The Outer Surfaces
7 Preservation 7.3 Preserving the outer surfaces 7.3 Preserving the outer surfaces o Trained personnel Personnel qualification: o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots Aids: o Calcium complex grease (for example TEVI- ®... -
Page 16: Installation, Removal
8 Installation, removal 8.1 Dangers during installation 8 Installation, removal 8.1 Dangers during installation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before installation ensure that the operating limits, NPSH values and ambient conditions are ob- served. -
Page 17: Removing The Pump Station
8 Installation, removal 8.4 Removing the pump station Suction-side connection Pressure-side connection Fastening element Fig. 8: Mounting the pump station Requirement: ü Pump station connections protected against soiling, for example by using the protective cover mounted in the factory Bring the pump station into the installation position. Take the flow direction into consideration. Fasten the pump station with fastening elements 3 securely on the underground. -
Page 18: Connection
9 Connection 9.1 Dangers during connection work Requirement: ü Pump station and pumped liquid cooled down to the ambient temperature Ensure that the pump station is deenergized and is secured against being switched back on. Ensure that the pump station is depressurized. Close the pressure-side and suction-side shut-off devices. -
Page 19: Connecting The Pump Station To The Power Supply
9 Connection 9.3 Connecting the pump station to the power supply ATTENTION Damage to device through impurity in the pipe system. ► During welding work attach protective covers in front of the connecting flanges. ► Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump station. -
Page 20: Operation
10 Operation 10.1 Dangers during operation 10 Operation 10.1 Dangers during operation The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before commissioning ensure that a safety valve has been installed in the pressure-side pipe sys- tem to protect the pump station. -
Page 21: Checking The Direction Of Rotation
10 Operation 10.2 Commissioning WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ► Wear personal protective clothing during all the work. Ensure face protection. ► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 22: Commissioning The Pump Station
10 Operation 10.3 During operation 10.2.4 Commissioning the pump station Personnel qualification: o Fitter o Electrician o Work clothing Personal protective equipment: o Protective helmet o Protective gloves o Safety boots o Face protection o Collection tank Aids: WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. -
Page 23: Activating The Reversing Valve
10 Operation 10.3 During operation ATTENTION Leak in the pressure gauge through permanently opened pressure gauge shut-off valve. ► Close the pressure gauge shut-off valve immediately after completing reading. Open the pressure gauge shut-off valve. Read the operating pressure and close the pressure gauge shut-off valve. 10.3.2 Activating the reversing valve o Trained personnel Personnel qualification:... -
Page 24: Switching Off The Pump Station
10 Operation 10.4 Decommissioning WARNING Risk of injury through emitted pumped liquid. Pumped liquids can be hot, poisonous, combustible and caustic. ► Wear personal protective clothing during all the work. Ensure face protection. ► Collect any discharging pumped liquid safely and dispose of it in an environmentally compatible manner in accordance with the applicable local regulations. -
Page 25: Recommissioning
11 Maintenance 10.5 Recommissioning Carry out the following measures during operation interruptions. Scope of the operation interruption Measure o Pump station shut down for longer period Depending on the pumped liquid o Pump station drained Close the pressure- and suction-side shut-off devices. -
Page 26: Required Maintenance
11 Maintenance 11.2 Required maintenance 11.2 Required maintenance The service life depends on the observance of the operating conditions of the pump station and the re- quirements from the operating instructions of the components. Component Required maintenance Cycle o Visual inspection Pump station 4 weeks o Acoustic inspection... -
Page 27: Servicing
12 Servicing 12.1 Dangers during servicing 12 Servicing 12.1 Dangers during servicing The following safety instructions must be observed strictly: o Have all work carried out only by authorized qualified personnel. o Before beginning work on the pump station ensure that the electrical power supply is deenergized and is secured against being switched back on. -
Page 28: Cleaning The Strainer
12 Servicing 12.3 Cleaning the strainer 12.3 Cleaning the strainer The frequency of cleaning the filter depends on the degree of soiling of the pumped liquid. In case of strongly soiled strainers cavitation and strong noise generation arise. The suction-side pressure gauge is used to indicate the degree of soiling. -
Page 29: Replacing The Coupling
12 Servicing 12.4 Replacing the coupling 12.4 Replacing the coupling 12.4.1 Removing the coupling (inner bearing) As of size 320 couplings are installed in the pump stations of the series DL2. o Fitter Personnel qualification: Personal protective equipment: o Work clothing o Protective gloves o Safety boots Aids:... -
Page 30: Installing The Coupling (Inner Bearing)
12 Servicing 12.4 Replacing the coupling 12.4.2 Installing the coupling (inner bearing) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Measuring stick Aids: o Silicone oil Notice The coupling halves can be mounted more easily if they are heated to 80 °C – 100 °C. Oil the shaft of the pump with silicone oil. -
Page 31: Removing The Coupling (Outer Bearing)
12 Servicing 12.4 Replacing the coupling 12.4.3 Removing the coupling (outer bearing) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Extractor Aids: Requirement: ü Pump unit disconnected from the electrical power supply, deenergized and secured against being switched back on Switch over the lever of the reversing valve 1 in order to shut off the respective side Ä... -
Page 32: Installing The Coupling (Outer Bearing)
12 Servicing 12.4 Replacing the coupling 12.4.4 Installing the coupling (outer bearing) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Measuring stick Aids: o Silicone oil Notice The coupling halves can be mounted more easily if they are heated to 80 °C – 100 °C. Oil the shaft of the pump with silicone oil. -
Page 33: Replacing The Pump
12 Servicing 12.5 Replacing the pump 12.5 Replacing the pump o Fitter Personnel qualification: o Electrician o Work clothing Personal protective equipment: o Face protection o Protective gloves Aids: o Hoisting equipment DANGER Risk of death resulting from electric shock. ►... -
Page 34: Replacing The Mechanical Seal
12 Servicing 12.6 Replacing the mechanical seal 12.6 Replacing the mechanical seal 12.6.1 Removing the mechanical seal (DL2 from 320/DS1) o Fitter Personnel qualification: Personal protective equipment: o Work clothing o Protective gloves o Safety boots o Extractor Aids: Requirement: ü Cartridge pump removed Remove the feather key 1 from the main screw 6. -
Page 35: Removing The Mechanical Seal (Dl3/Dl4/Ds3/Ds4)
12 Servicing 12.6 Replacing the mechanical seal 12.6.3 Removing the mechanical seal (DL3/DL4/DS3/DS4) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Extractor Aids: Requirement: ü Cartridge pump removed Remove the feather key 1 from the main screw 7. Remove the circlip 2 and mounting ring 3 from the pump housing 8. -
Page 36: Replacing The Radial Shaft Seal
12 Servicing 12.7 Replacing the radial shaft seal 12.7 Replacing the radial shaft seal 12.7.1 Removing the radial shaft seal (DL2 as of 320/DS1) o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Aids: o Extractor Requirement: ü... -
Page 37: Removing The Radial Shaft Seal (Dl3/Dl4/Ds3/Ds4)
12 Servicing 12.7 Replacing the radial shaft seal 12.7.3 Removing the radial shaft seal (DL3/DL4/DS3/DS4) Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Protective gloves o Safety boots o Extractor Aids: Requirement: ü Cartridge pump removed Remove the feather key 1 from the main screw 9. Remove the circlip 2 and mounting ring 3 from the pump housing 10 and remove the O-ring 4. -
Page 38: Replacing The Mechanical Seal And Ball Bearing (Outer Bearing)
12 Servicing 12.8 Replacing the mechanical seal and ball bearing (outer bearing) 12.8 Replacing the mechanical seal and ball bearing (outer bearing) o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Aids: o Plastic hammer o Extractor Requirement: ü... -
Page 39: Replacing Seals
12 Servicing 12.9 Replacing seals 12.9 Replacing seals 12.9.1 Replacing seals (DL3/DL4/DS3/DS4) Notice The maintenance kit contains only the parts marked with * and is only supplied complete. o Fitter Personnel qualification: Personal protective equipment: o Work clothing o Protective gloves o Safety boots Aids: o Solvent... - Page 40 12 Servicing 12.9 Replacing seals Control block: Replace the flat gasket 27* Take off the hexagon screws 25, welding neck flange 26 and flat gasket 27*. Clean the sealing surface and place on the new flat gasket. Mount the welding neck flange with hexagon screws with torque. Housing: Replacing the screw plug 10* Replace the screw plug 10*.
- Page 41 12 Servicing 12.9 Replacing seals 12.9.2 Replacing seals (DS1) Notice The maintenance kit contains only the parts marked with * and is only supplied complete. o Fitter Personnel qualification: o Work clothing Personal protective equipment: o Protective gloves o Safety boots Aids: o Solvent o Silicone grease...
- Page 42 12 Servicing 12.9 Replacing seals Housing: Replacing the screw plug 10* Replace the screw plug 10*. Overflow valve: Replacing the screw plug 28* Replace the screw plug 28*. Control block: Replace the screw plug 36* Replace the screw plug 36*. Control block: Remove the O-ring 27* Take off the hexagon screws 25, welding neck flange 26 and O-ring 27*. Lightly grease the new O-ring and insert it.
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Page 43: Disposal
13 Disposal 13.1 Dismantling and disposing of the pump station 13 Disposal 13.1 Dismantling and disposing of the pump station Personnel qualification: o Fitter o Work clothing Personal protective equipment: o Face protection o Protective gloves o Safety boots o Solvents or industrial cleaners suitable for the pumped liquid Aids: o Collection tank WARNING... -
Page 44: Troubleshooting
14 Troubleshooting 14.2 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy 1 – – – – – – Pump suction line closed Check the shut-off devices. If required, open. 1 2 3 – 5 – – Parts soiled (filter, suction line, suction valve, strainer) Clean parts. - Page 45 14 Troubleshooting 14.2 Troubleshooting Fault identification Cause Remedy – – 3 – – – – Pump subject to mechanical stress Support the weight of the pipe system. Connect the pump station correctly to the pipe system Ä Connection, Page 18. – – 3 – – – – Vibrations/pulsations in the system Bear the pump station elastically.
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Page 46: Accessories
15 Accessories 15.1 Pump station accessories 15 Accessories 15.1 Pump station accessories Detailed information is provided in the respectively associated technical documentation. Accessories/function Accessories/function Leak oil monitoring Temperature monitoring Betrie b Entriegel n o Monitoring of the leak oil o Monitoring of the Alar m Prüfen quantity in the oil pan... -
Page 47: Electrical Heating System/Fluid Heating System
15 Accessories 15.2 Heating 15.2.2 Electrical heating system/fluid heating system 915.4 915.4 493 070.1 493 070.1 914.1 908.2 730.2 R 3/8" 908.2 R 1/2" Fig. 13: Electrical heating system/fluid heating system (figure left DS1, figure right DS3, DS4) Control block Terminal strip Heating duct (fluid heating system) Screwed gland 070.1... -
Page 48: Storing Heating Elements
15 Accessories 15.2 Heating Fluid heating system Required heating-up period for temperature differences of 20 °C or 50 °C at liquid temperature of 180 °C and a pressure of the water of 15 bar: Series Steam amount Heating-up period [min] at a temperature difference of [kg/h] 20 °C 50 °C... -
Page 49: Spare Parts
16 Spare parts 16.1 Overview 16 Spare parts 16.1 Overview Model/Size Type Variant Internal Maintenance kit Pump station sealing kit UED162 DL3/DL4/DS3/DS4 Maintenance kit Pump station sealing kit UED163 DL2- 320 – 1300/DS1 Maintenance kit Radial shaft seal sealing kit UED 48 DL2- 320 – 1300/DS1 Maintenance kit Mechanical seal sealing kit... -
Page 50: Maintenance Kits
16 Spare parts 16.2 Maintenance kits 16.2 Maintenance kits 16.2.1 Maintenance kit sealing kit pump station (DL3/DL4/DS3/DS4) Notice The maintenance kit contains only the numbered parts and is only supplied complete. 739.1 055.2 739.2 908.1 739.5 739.2 729.1 735.1 739.3 739.4 739.1 908.1... -
Page 51: Maintenance Kit Sealing Kit Pump Station (Ds1)
16 Spare parts 16.2 Maintenance kits 16.2.2 Maintenance kit sealing kit pump station (DS1) Notice The maintenance kit contains only the numbered parts and is only supplied complete. 055.1 739.1 165.1 739.2 908.1 739.1 165.3 739.5 739.8 739.2 739.3 735.1 739.4 908.1 055.1... -
Page 52: Maintenance Kit Sealing Kit Mechanical Seal (Dl3/Dl4/Ds3/Ds4)
16 Spare parts 16.2 Maintenance kits 16.2.3 Maintenance kit sealing kit mechanical seal (DL3/DL4/DS3/DS4) Notice The maintenance kit contains only the numbered parts and is only supplied complete. 739.3 739.1 739.2 Qty. Item No. Part Mechanical seal 739.1 O-ring 739.2 O-ring 739.3 O-ring... -
Page 53: Maintenance Kit Sealing Kit Radial Shaft Seal (Dl3/Dl4/Ds3/Ds4)
16 Spare parts 16.2 Maintenance kits 16.2.5 Maintenance kit sealing kit radial shaft seal (DL3/DL4/DS3/DS4) Notice The maintenance kit contains only the numbered parts and is only supplied complete. 739.3 739.1 739.2 Qty. Item No. Part Support ring 739.1 O-ring 739.2 O-ring 739.3... -
Page 54: Repair Kits
16 Spare parts 16.3 Repair kits 16.3 Repair kits 16.3.1 Repair kit, overflow valve Notice The repair kit contains only the numbered parts and is only supplied complete. 908.2 055.2 751.1 809.1 Qty. Item No. Part 055.2 Seal ring Adjusting screw 751.1 Pressure spring 809.1... -
Page 55: Repair Kit Non-Return Valve
16 Spare parts 16.3 Repair kits 16.3.2 Repair kit non-return valve Notice The repair kit contains only the numbered parts and is only supplied complete. 751.2 304.1 739.3 739.4 739.3 304.2 751.3 Qty. Item No. Part Flat gasket Valve insert 304.1 Valve cone 304.2... -
Page 56: Other Spare Parts
16 Spare parts 16.4 Other spare parts 16.4 Other spare parts 16.4.1 Outer bearing overview (DS3/DS4) 915.1 Qty. Item No. Part Bearing housing Housing Mechanical seal Ball bearing Circlip 915.1 Socket screw Tab. 29: Spare parts (DS3/DS4) Operating instructions OID 06en-GB Edition 2019-11... -
Page 57: Appendix
17 Appendix 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers 17 Appendix 17.1 Tightening torques for screws with metric screw threads with and without wedge lock washers Notice In the case of galvanised screw plugs and screw plugs made of stainless steel the inner thread and outer thread have to be greased thorough before mounting in order to prevent threads from seizing. -
Page 58: Contents Of The Declaration Of Conformity
17 Appendix 17.3 Contents of the Declaration of Conformity 17.3 Contents of the Declaration of Conformity The products described in these instructions are machinery in the sense of the Directive 2006/42/EC. The original of the EC Declaration of Conformity is enclosed with the machinery at delivery. The machinery fulfils all the relevant provisions of the following directives: Number Name... - Page 59 Notes Operating instructions OID 06en-GB Edition 2019-11...
- Page 60 KRAL GmbH, 6890 Lustenau, Austria, Tel.: +43/5577/86644-0, E-Mail: kral@kral.at www.kral.at...
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