KSB MEGAFLOW 50-160 Operating Instructions Manual
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KSB MEGAFLOW 50-160 Operating Instructions Manual

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Operating Instructions Manual
NºA2370.8E/2

1. Application

The
KSB
MEGAFLOW
recommended for industrial and municipal waste water,
as well as all kinds of pulps not liable to plait, sewage
water, chemical effluents.
Municipal and industrial waste-water treatment
-
Drainage
-
Pulp and paper
-
Food processing
-
Sugar and alcohol
-
Mining and manufacturing
-
Civil construction
-
2. Design
Horizontal, single-stage, simple horizontal suction and
vertical upwards discharge. The "back-pull-out" design
allows maintenance and repair services through the back
side, without dismantling piping and alignment.
The available hydraulics and impeller types allow proper
selection for the handled liquid and required application.
Pumps for Sewage, Effluents and Mixtures
centrifugal
pump
is
KSB MEGAFLOW

3. Designation

KSB
Trade Mark
Model / Type
Discharge Nozzle Diameter (mm)
Nominal Impeller Diameter (mm)
Rotor

4. Operating Data

Sizes
Flow
Head
Temperature
Max. Suction pressure
Speed
LINE:
Mega
Megaflow
50 - 160
- DN 50 up to 350
(2 ½" to 14" )
- to 11,000 gpm
3
(2,500 m
/h)
- to 328 ft (100m)
º
º
- to 221
F (105
- to 43 psi (3 bar)
- to 3,500 rpm
K
C)

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Summary of Contents for KSB MEGAFLOW 50-160

  • Page 1: Application

    KSB MEGAFLOW Operating Instructions Manual NºA2370.8E/2 Pumps for Sewage, Effluents and Mixtures LINE: Mega 1. Application 3. Designation MEGAFLOW centrifugal pump Megaflow 50 - 160 recommended for industrial and municipal waste water, as well as all kinds of pulps not liable to plait, sewage water, chemical effluents.
  • 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 Brasil Ltda., Várzea Paulista 04/04/2022...

  • Page 3: Table Of Contents

    KSB Megaflow Content 1. Application ............................... 1 2. Description ............................... 1 3. Designation ..............................1 4. Operating Data ..............................1 5. Introduction ..............................5 6. Technical Data ..............................6 6.1 Bearings ..............................7 6.2 Maximum speed ............................8 7. Constructive Details ............................10 7.1 Casing ................................
  • Page 4 KSB Megaflow 15.2 Lubrication intervals and oil specifications ....................23 15.3 Oil quantity ............................... 24 15.4 Shaft Sealing Maintenance ........................23 15.5 Wear Parts Maintenance ......................... 25 15.6 Dismantling instructions ........................... 26 15.7 Assembly instructions ..........................27 16. Operational problems, Probable Causes e Solutions................29 17.

  • Page 5: Introduction

    5. Introduction KSB has supplied you with an equipment that has been designed and manufactured with a must advanced technology. Due to its simple and tough construction it will not need much maintenance. With the aim of providing our clients with a satisfactory, trouble free operation, we recommend to install and care our equipment according to the instructions contained in this operating instructions.

  • Page 6: Technical Data

    KSB Megaflow 6. Technical Data Sizes Technical Data Bearing Bracket Impeller Max. allowed solid diameter Rotating element with water Hydrostatic test pressure Max. suction pressure Max. discharge pressure Minimum Abrasive without washing Not abrasive Abrasive with washing Axial Thrust Balancing - Back vanes Min./Max.

  • Page 7: Bearings

    350-500 350-630 Table 2 (1) For size 100-400 “K” at 1450 and 1750 rpm – bearing bracket P55/140s. Please consult KSB. Notes: For size 100-400 “O” at 1450 and 1750 rpm – bearing bracket P65/160ax. Please consult KSB. Note: Consult KSB for pump sizes 350-400, 350-500 and 350-630.

  • Page 8: Maximum Speed

    KSB Megaflow Maximum speed γ = 1,0 kgf/dm γ = 1,2 kgf/dm γ = 1,4 kgf/dm Impeller Speed Pump size type (rpm) Maximum Impeller Diameter (mm) 1750 50-160 2900 3500 1750 2900 50-200 3500 1750 2900 65-200 3500 1450 65-315...
  • Page 9 KSB Megaflow Maximum speed γ = 1,0 kgf/dm γ = 1,2 kgf/dm γ = 1,4 kgf/dm Impeller Speed Pump size type (rpm) Maximum Impeller Diameter (mm) 1160 150-500 1450 1160 1450 200-315 1750 1160 1450 200-400 1750 200-500 250-500 1160...

  • Page 10: Constructive Details

    KSB Megaflow 7. Constructive Details 7.1 Casing Ample clearance volute, one piece casting including support feet. Radially split with discharge cover. Replaceable wear plate on suction side. 7.2. Nozzle Layout Axial, horizontal suction and radial vertical discharge. Optionally an intermediate suction piece with clean out and inspection manhole can be offered.

  • Page 11: Shaft

    KSB Megaflow Impeller type E: Single vane closed impeller, recommended for liquids containing solids in suspension, as for example, sewage, long fibers, sludge with air concentration, fruits, vegetables, fish, sugar cane, residues in the food industry, rags, wood pieces, bones, etc.

  • Page 12: Shaft Seal Selection

    8.2 Sealing Flow / Wash 8.2.1 Pumps with Impellers type K e O Fig.5 Legend 50-160 50-200 65-315 80-400 125-500 250-500 65-200 100-250 100-400 150-500 300-500 80-250 100-315 150-315 200-400 200-315 Table 6 Notes: For pump size 350, please consult KSB.

  • Page 13: Pumps With Impeller E

    KSB Megaflow 8.2.2. Pump with Impeller type E Fig.6 Notes: To calculate pressure PW, please consult the Type series booklet. 9. Mechanical Seal If the pumped liquid is inflammable, explosive, toxic, of high cost, or when after an accurate cost analyze the result is benefic, we recommend the use of Mechanical Seal.

  • Page 14: Transportation

    Service / Storage The following procedures of service and storage are performed by KSB and by DEALER NETWORK up to effective delivery of the pump. It is the responsibility of the client to continue with this procedure after receiving the pump. When the pump is not subjected to a performance test after is sale, the areas in contact with the pumped liquid which are not painted as: stuffing box housing, wear rings, flange sealing areas, etc, receive an application of RUSTILO DW-301 by brush.

  • Page 15: Additional Procedures Of Service And Storage

    KSB Megaflow 11.1 Additional procedures of Service and Storage Pumps stored for periods exceeding one year should be serviced every 12 months. They should be disassembled, cleaned and the whole process described in the item 11 should be repeated. Pumps equipped with PACKING should have their packing removed before storage.

  • Page 16: Base Leveling

    KSB Megaflow 12.2 Base Leveling Check if the base plate is equally resting on its chock blocks. If it is OK, place and tighten uniformly the nuts on the foundation bolts. With the help of a precision level, check the leveling of the base longitudinally and transversally.

  • Page 17: Suction Pipe Line - Recommendations

    KSB Megaflow Fig. 12 – Radial Control Fig.13 – Axial Control To correct the alignment, loosen the driver bolts and replace driver over the side face or insert shim to adjust height as required. Axial and radial alignments should remain with a tolerance of 0.1 mm with the pump and driver set screws tighten securely.
  • Page 18 KSB Megaflow When the liquid being pumped has large temperature variations, expansion joints should be installed preventing the effects of contractions and expansions of the suction pipeline on the pump. With positive suction, it is advisable to install an inlet valve to close the flow to the pump when necessary. During the pump operation it should stay totally opened.

  • Page 19: Discharge Pipeline - Recommendations

    KSB Megaflow 12.6 Discharge Pipeline - recommendations To install the discharge pipeline follow these instructions: if the overpressures originated in liquid returning on long lines exceed the limits specified for the line and the pump, water hammer control devices should be installed on the discharge pipe line.

  • Page 20: Auxiliary Pipings And Connections

    For pumps with Mechanical Seals it is possible to have another connections installed in the gland. In case of supply with Mechanical seals, additional instructions will follow. Accessories (Optionals) 13.1 Coupling KSB standard or from other manufacturers with or without spacer. 13.2 Electrical Motor, Turbine, Diesel Motor, etc. 13.3 KSB standard of structural welded steel with under drain channel.

  • Page 21: Operation

    KSB Megaflow 13.4 Coupling Guard KSB Standard, belts and pulley in accordance to its manufacturers. Intermediate part KSB standard. See Technical manual. Operation 14.1 First start-up procedure The following items must be provided for pump first starting: Pump and its driver must be securely fastened to the base.

  • Page 22: Operation Supervision

    KSB Megaflow 14.3 Operation supervision Depending on the disposability of personnel and on the importance of the pump, we recommend the following supervision. In case of any irregularity, the maintenance supervisor should be called immediately. 14.3.1 Weekly supervision Check: Operating point of the pump...

  • Page 23: Maintenance

    KSB Megaflow 15. Maintenance 15.1 Bearing Maintenance Remove vent plug. Tilt the reservoir down. Pour oil through the hole left by the vent plug until oil appears in the vertical section of the elbow connecting bearing bracket and reservoir. Fill up the reservoir Snap the reservoir back into position.

  • Page 24: Oil Quantity

    KSB Megaflow 15.3 Oil Quantity Oil quantity for KSB Megaflow bearing brackets. Bearing bracket Oil volume (ml) CS40 CS50 A30K A40K A50K A60K P55/140s 1500 P65/160X 1800 P65/160ax 1500 P80/200S 4500 Table 10 15.4 Shaft Sealing Maintenance 15.3.1. Mechanical Seal Maintenance In case of pump supply with mechanical seal, additional instructions of the seal manufacturer will follow attached to this manual.

  • Page 25: Wear Parts Maintenance

    KSB and Dealer Network supply wear plate for repair or as spare parts, to be applied in the KSB Megaflow pumps, K/O/E types.

  • Page 26: Dismantling Instructions

    KSB Megaflow Fig.24 – Clearance Impeller type E Clearance (mm) Pump Size 80-200 0,25 + 0,05 100-250 125-315 150-400 0,45 + 0,05 200-500 Table 12 – Clearances for Impeller type E 15.4.2 Replace of the Volute Casing Wear Plate Center the impeller through the inner passage hole of the shaft (use cutter block), machining the wear region of the impeller (hub suction side) until it becomes uniform (machining limit 2 mm of diameter).

  • Page 27: Assembly Instructions

    KSB Megaflow Carefully, remove the shaft (210) from the casing pump side to drive end side. The shaft with the bearing (321) and the inner ring of the other bearing (322) will be released from the bearing bracket (330). Then, remove the parts located in the sealing chamber as packing rings (461), lantern ring (458), neck bush (456).
  • Page 28 KSB Megaflow Mount the bearing (320) and the bearing inner ring (322) in the shaft. With a piece of lead, mount the shaft in the support, from the suction side, making the external side of the bearing slide into the support until they reach the same measures in both sides of the support for setting the bearing covers.

  • Page 29: Operational Problems, Probable Causes E Solutions

    KSB Megaflow 16. Operational Problems, Probable Causes and Solutions Operational Problems Probable Causes and Solutions Insufficient Flow 1, 2, 3, 4, 5, 6, 8, 9, 10, 11 Drive Overload 12, 13, 14, 15, 28 Pump final pressure excessively high Bearings Overheating...
  • Page 30 KSB Megaflow 13- Density or viscosity of the pumped liquid is higher than the specified in the order. 14- The gland cover is incorrect tighten. correct it. 15- Too high rotation. reduce it. 16- The flat gasket between the volute casing and discharge cover is defective.

  • Page 31: Cross Sectional Drawing/ Parts List / Materials

    KSB Megaflow 17. Cross Sectional Drawing / Parts List / Materials 17.1 Execution with K Impeller – Bearing Brackets CS40 and CS50 Figure 25...

  • Page 32: Parts List - Execution With K Impeller - Bearing Brackets Cs40 And Cs50

    KSB Megaflow 17.2 Parts List – K Impeller – Bearing Brackets CS40 and CS50 Part Nº Description Qty. Volute casing Wear plate Discharge cover Support foot Shaft Impeller Bearing Bearing bracket Bearing cover 360.1 Bearing cover 360.2 Flat gasket 400.1 Flat gasket 400.2...

  • Page 33: Execution With K Impeller - Bearing Bracket Ak

    KSB Megaflow 17.3 Execution with K Impeller – AK Bearing Bracket Figure 26...

  • Page 34: Execution With Impeller O - Bearing Bracket Ak

    KSB Megaflow 17.4 Execution with O Impeller – AK Bearing Bracket Figure 27...

  • Page 35: Parts List - Execution With K/O Impeller - Bearing Bracket Ak

    KSB Megaflow 17.5 Parts List – K/O Impeller – AK Bearing Bracket Denomination Part nº Qtty Volute casing Note: Wear plate Discharge cover Support foot Shaft (2) For bearing bracket A30 K part 321 bearing motor side = 6306 C3...

  • Page 36: Execution With K/O Impeller - Bearing Bracket P65/160

    KSB Megaflow 17.6 Execution with Impeller K/O Bearing Bracket P65/160 Figure 27...

  • Page 37: Parts List - Execution With K/O Impeller - Bearing Bracket P65/160

    KSB Megaflow 17.7 Parts List – K/O Impellers – Bearing Bracket P 65/160 X Denomination Part Nº Qtty Volute casing Wear plate Discharge cover Support foot Shaft Impeller Bearing (1) Notes: Bearing (1) Bearing bracket (1) For bearing bracket P65/160X part 322 bearing pump side = NU 413...

  • Page 38: Execution With K/O Impeller - Bearing Bracket P80/200S

    KSB Megaflow 17.8. Execution with Impeller K and Bearing Bracket P80/200S Figure 28...

  • Page 39: Parts List - Execution With K/O Impeller - Bearing Bracket P80/200S

    KSB Megaflow 17.9 Parts List - K Impeller – Bearing bracket P 80/200S Denomination Part Nº Qtty Volute casing Wear plate Discharge cover Support foot Shaft Impeller Notes: Bearing (1) Bearing (1) (1) For bearing bracket P80/200S part 322 bearing motor side = 7319 BUA...

  • Page 40: Execution With E Impeller - Bearing Bracket Ak

    KSB Megaflow 17.10 Execution with Impeller E – Bearing Bracket AK Figure 29...

  • Page 41: Parts List - Execution With E Impeller - Bearing Bracket Ak

    KSB Megaflow 17.11 Parts List - E Impeller – Bearing Bracket AK Denomination Part Nº Qtty Volute casing Wear plate Notes: Discharge cover Support foot (1) A48 CL30 for size 125-315 Shaft Impeller (2) For bearing bracket A40k, part 321 bearing motor side = 6308 C3...

  • Page 42: Execution With E Impeller - Bearing Bracket P65/160X

    KSB Megaflow 17.12 Execution with Impeller E and Bearing Bracket P65/160X Figure 30...

  • Page 43: Parts List - Execution With E Impeller - Bearing Bracket P65/160X

    KSB Megaflow 17.13 Parts List – Impeller E – Bearing Bracket P65/160X Denomination Part Nº Qtty Volute casing Wear plate Discharge cover Inspection cover Support foot Shaft Impeller Notes: Bearing (1) Bearing (1) (1) For bearing bracket P65/160X. Part 320 bearing motor side = 7313 BG Bearing bracket For bearing bracket P65/160X.

  • Page 44: Parts Interchangeability

    KSB Megaflow 18. Parts Interchangeability Impeller type Part Denomination number Volute casing 10 11 12 13 14 15 16 17 18 19 20 21 Wear plate 10 11 12 13 14 15 16 17 18 19 20 Discharge cover 10 11 12 13...

  • Page 45: Recommended Spare Parts

    KSB Megaflow 19. Recommended Spare Parts Recommended spare parts for a continuous work of 2 years, according to the standard VDMA 24296. Pumps quantity ( included spare pumps) 6 and 8 and 10 or more Spare parts quantity Part Denomination...
  • Page 46 KSB Megaflow KSB Brasil Ltda Rua José Rabello Portella, 638 Várzea Paulista SP 13220-540 Brasil http://www.ksb.com.br Tel.: 11 4596 8500 – KSB Customer Service e-mail: sak@ksb.com...

This manual is also suitable for:

Megaflow 50-200Megaflow 65-200Megaflow 80-200Megaflow 80-250Megaflow 65-315Megaflow 100-250 ... Show all

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