KSB CPK Operating Instructions Manual

CPK

Contents

Point no. Description Page no.

1 General 1

1.1 Handling 1

2 Installation (on site) 1

2.1 Foundation 1

2.2 Base frame and Pump 1

2.3 Alignment of pump and driver 1

2.4 Connecting the piping 1

2.4.1 Auxiliary connections 2

2.4.2 Vacuum balance line 2

2.5 Coupling guard 2

2.6 Measuring Instruments 2

2.7 Final check 2

3 Commissioning, Start-up/Shutdown 2

3.1 Preliminary remarks regarding
commissioning 2

3.1.1 Lubricants 2

3.1.2 Shaft seal 2

3.1.2.1 Stuffing box 3

3.1.2.2 Shaft seal 3

3.1.2.3 Cooling to casing cover 3

3.1.2.4 Packing the stuffing box 3

3.1.2.5 Packing material 4

3.1.2.6 Sealing liquid 4

3.1.3 Alternate packing arrangement available 4

3.1.4 Checking the direction of rotation 4

3.2 Start-up 4

3.3 Shut down 4

4 Maintenance and lubrication 4

4.1 Supervision of operation 4

4.2 Bearings and lubrication 5

4.2.1 Lubricant quantities 5

4.2.2 Oil changes 5

4.2.3 Procedure 5

4.3 Preservation 5

5 Special instructions 5

5.1 General precautions 5

5.2 Dismantling 5

5.2.1 Soft-packed stuffing box 5

5.2.2 Mechanical seal stuffing box 6

5.3 Reassembly 6

5.3.1 Reassembly of stuffing box packing 6

5.3.2 Reassembly of mechanical seal 7

5.4 Cooling / heating 7

5.5 Spares 8

5.5.1 Ordering spare parts 8

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6 Interchangeability of pump components 9

7 Recommended stock of spare parts

for 2 years of operation 10

8 Faults 10

8.1 Faults, causes and suggested remedies 10

8.2 Cause-Remedy 10

9 Sectional drawing & part list 12

9.1 Sectional drawing of CPK Y pumps 13

Annexure I 14
Annexure II 16
Annexure III 16
Annexure IV 17

CPK

1. General

Your centrifugal pumps will give you completely trouble free
and satisfactory service on condition that it is installed with
due care and properly maintained. It is absolutely essential
that the instructions contained in this manual be scrupulously
observed and that the pumps are not operated under conditions
which differ from those specified under our ‘Operating
Conditions’. This operating instruction manual does not take
any account of any safety regulation which may apply to the
installation site, and the Site Engineer or Site Operator is
responsible for notifying our erection staff of any such
regulations and seeing that they are complied with.

The pump type size, main operating data and works order
number are stamped on the name plate affixed to the pump.
Please make sure to quote this information every time you
write to us in respect of queries, repeat orders and particularly
when ordering spare parts.

1.1 Handling

The Pump set should be properly handled and slung for
transport. Do not thread the ropes through the eye bolt on the
motor. (See Fig. 1)

During handling do not remove the rubber blankings provided
on the suction and discharge nozzles.

Fig. 1 : Pump and driver mounted on a combined baseplate

6. Grout the foundation bolts and the packer plate (if
applicable) by using quick setting non-shrink cement,
ACC make “Shrinkkomp” or FORSORC make
“Conbextra-GP2” or equivalent.

7. Allow curing time of 24 to 72 hours depending upon the
grout used.

8. Remove bolts which are holding packer plates with the
base frame (if applicable).

9. Carry out final levelling by inserting shims (S.S. Shims
preferred) between packer plates and base frame (if
applicable).

10. Tighten the foundation bolts and recheck the levelling.
Correct it, if necessary.

11. Grout the complete base frame, including hollow portion,
if any, using conventional grouting mix i.e. portland
cement, sand and aggregate in proportion 1:2:4 and
gravel size not exceeding 20 mm.

12. Plaster the foundation and apply suitable oil resistant
paint.

For figures refer Annexure I.

2.3 Alignment of pump and driver

Accurate coupling alignment requires a coupling alignment
jig. This can be manufactured from 20 x 20 mm steel flat. The
jig should be attached to the shafts. See Fig. 2.

The coupling can be considered correctly aligned with the aid
of the jigs illustrated if the difference measured does not
exceed 0.1 mm both in the radial and axial directions,
measurements being taken in 4 planes at 900 intervals.
Alignment should be checked when the pump is hot
(applicable for pump handling hot fluids), In case any deviation
is found, please check the pipe lines and or realign the pump.
The coupling alignment check should be repeated after the
piping has been connected to the pump to ensure stress free
piping. Prior to alignment, individual concentricity of coupling
should be checked. It should be within 0.03 mm. If not,
corrective action should be taken. The coupling should be
dynamically balanced in accordance with VDI 2060 (ISO

1940)/G6.3 for motor driven pumps and G2.5 for turbine driven

pumps.

2. Installation (on site)

2.1 Foundation

Make sure that the concrete foundation has set firmly before
placing the base frame along with the pump set or pump on
it. The surface of the foundation should be truly horizontal and
perfectly flat. The foundation bolts should be suspended in
the baseplate.

2.2 Base Frame and Pump

Procedure

1. Bolt the Pump on the base frame.

2. Bolt the packer plates on the bottom pads of the base
frame, if applicable.

3. Place the unit on the foundation.

4. Suspend the foundation bolts in the pockets provided on
the foundation block.

5. Level the pump on the delivery flanges or feet within 0.2
mm per mtr., using jacking bolts provided on the corners
of the base frame.

Fig. 2 : Alignment of coupling

2.4 Connecting the piping

Never use the pump itself as an anchor point for the piping.
Suction lift lines should be laid with a rising slope towards the
pump and suction head line with a downward slope towards
the pump. The pipelines should be anchored in close proximity
to the pump and should be connected to the latter without
transmitting any stress or strain, nor should the weight of the
piping be loaded on to the pump. The nominal sizes of the

1

pipelines should be at least equal to the nominal sizes of the

V

B

C

E

R

ZA

Pump

pump nozzle. In case the suction pipeline size is bigger, the
connection should be done by means of an eccentric reducer,
in order to avoid air pockets. We recommended the
incorporation of check valves or non return valves and
isolating valves in the system, depending on the type of
installation and pump. Any thermal expansion of the piping
(due to high temperatures) must be compensated by suitable
means, so as not to impose any additional load on the pump.

CPK

A Main isolating valve R Check valve
B Vacuum balance line V Vessel under vacuum
C Isolating valve Z Intermediate flange
E Vacuum-tight isolating valve

Fig. 5 Suction line and vacuum balance line

Fig. 3

Fig. 4

2.4.1 Auxiliary Connections

The auxiliary connections required for your pump (cooling,
heating, sealing liquid, flushing liquid etc. as the case may
be) are indicated in the installation drawing and on the piping
diagram in respect of size and location.

2.4.2 Vacuum Balance Line

If the pump has to pump a liquid out of a vessel under vacuum,
it is advisable to install a vacuum balance line. This line should
have a nominal size of 25 mm at least. It should be arranged
to lead back into the vacuum vessel at a point above the
highest permissible liquid level. An additional line starting at
the pump discharge nozzle facilitates venting of the pump
before start up. The vacuum-tight isolating valve E in this
connecting line should be closed after the venting procedure
& should remain closed while the pump is running. The main
isolating valve C in the vacuum balance line must remain
open at all times when the pump is running and should be
closed when the pump is shutdown. Refer Fig. 5.

2.5 Coupling Guard

In compliance with the accident prevention regulations, the
pump may only be operated if it is fitted with a coupling guard.
If the customer states specifically that coupling guard is not to
be supplied by KSB, it must be provided by the pump operator.

2.6 Measuring Instruments

Each pump should be equipped with two pressure gauges,
one at the suction nozzle and the other at the discharge nozzle.
Their measuring range should be suitable for the prevalent
pressure conditions, and they should be provided with a stop
cock or stop valve. If the suction conditions demand (e.g.
suction lift operation), the gauge on the suction nozzle should
be pressure vacuum gauge.

2.7 Final check

Check the alignment once more as described in section 2.3. It
must be possible to rotate the pump rotor freely without
additional effort by hand at the coupling.

3. Commissioning, Start-up/Shutdown

3.1 Preliminary remarks regarding commissioning

3.1.1 Lubricants

The bearing bracket should be filled with oil of any one of the
following types and specifications :

Indian Oil : Servosystem 46

Hindustan Petroleum : Enklo 46

Bharat Petroleum : Bharat Hydrol 46

If some other make of oil is used the properties of the oil should
be as follows.

Kinematic viscosity : 46 +4mm2/s at 40 0C
Flash point : +175 0C
Solidification point : 15 0C
Applicable temperature : Higher than permissible bearing
temperature
for 10 0C contact KSB

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CPK

Oil level in bearing

bracket and connection elbow

Drain

plug

Vent or filler

plug

cooling (pH =~ 7). The maximum pressure of cooling water is
10 bar. The cooling water quantities are specified in lpm for

∆t = 150C in Table No. 1.

Inlet temp. : 100C to 300C

Outlet temp. : 450C max.

Fig. 6 : Oil fill

Procedure

Unscrew vent plug. Pour in oil through the vent plug aperture
after removing the reservoir of the constant level oiler, until oil
appears in the vertical portion of the connection elbow of the
constant level oiler (see fig. 6).

Then fill the reservoir of the constant level oiler with oil and fit
it back into operating position. Screw vent plug in again. After
a short time has elapsed, check whether the oil level in the
reservoir has sunk. The reservoir should always remain filled.
If the vent plug is inaccessible or difficult to reach e.g. the oil
can be filled into the bearing bracket through the connection
elbow of the constant level oiler.

Bearing
Bracket

P 25/62 5 6 8

P 35/80 6 8 9

P 45/120 9 11 12

P 55/140 12 14 15

P 65/160s 15 17 18

Quantity of cooling water in LPM

Temperature of pumping liquid

Up to 1500C 1500 to 2500C above 2500C

3.1.2.4 Packing the Stuffing Box

Caution :

The pump is despatched from our Works with the stuffing box
packed.

Before repacking, thoroughly clean stuffing box gland (452),
packing compartment and shaft protection sleeve (524).

Cut the packing rings to correct length and ends at 45º. Ensure

that the packing rings ends come into contact with one another
on fitment. (See Fig. 7)

Caution :

The oil level should always be situated below the level of the
vent slot arranged at the top edge of the connection elbow
and this slot should always be perfectly dry. Do not tighten the
elbow by applying force on the reservoir use lock nut for this
purpose.

3.1.2.1. Stuffing Box

The shaft is sealed at its exit through the casing by soft packed
stuffing box or a mechanical seal. Change over from gland
packing execution and vice verca is possible by using
conversion kit. For details refer KSB.

3.1.2.2 Shaft Seal

Soft-packed stuffing box reduce the flow of leakage liquid at
the clearance gap between casing cover and shaft protection
sleeve when the pressure inside the pump is higher than
atmospheric. Conversely, on pumps which operate on suction
lift pressure, the soft-packed stuffing box prevents the ingress
of air into the pump. Sealing is effected by means of soft
packings arranged in a number of rings in the annular space
between the casing cover (161) and the shaft protection sleeve
(524) and lightly compressed by the stuffing box gland (452).
Refer Fig. 8.

3.1.2.3 Cooling of Casing Cover

The casing cover jacket of soft packed stuffing boxes must be
cooled if the temperature of pumped fluid exceeds 900C.

Clean, clear and non aggressive water is recommended for

Fig. 7 : Cutting the packing rings to length.

If the packing rings are either too long or too short, the stuffing
box will not be able to perform its function properly. In the case
of asbestos-graphite packing material, the rubbing faces of
the individual rings should be lightly coated with Molykote
before insertion in the packing compartment. The first packing
ring is then inserted and pushed home into the compartment
with aid of the stuffing box gland (452).

The following packing rings are then inserted into the packing
compartment one by one, making sure that the butt joint of
each ring is offset by 900 approx. in relation to the butt joint of
the preceding ring. The individual rings are pushed home
into the packing compartment with the aid of the stuffing box
gland (452). The packing rings should only be pressed lightly
against one another. They should be inserted in the packing
compartment in such a way that a clear gap of 6 to 8 mm is left
at the outer end of the compartment for the positive guidance
of the stuffing box gland (452).

The inserted packing rings should then be compressed
moderately with the aid of the stuffing box gland (452) and the
nuts (920.03). Then the nuts (920.03) should be slackened

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CPK

again by one to two complete turns, and thereafter tightened
lightly by hand. The correct and even seating of the stuffing
box gland (452) should be checked when the pump is
subjected to suction pressure, by inserting a feeler gauge
between the stuffing box gland (452) and the shaft protection
sleeve (524).

In the case of the special stuffing boxes, a lantern ring is also
inserted in the packing compartment, at the centre of the
compartment (between the packing rings). In these cases,
an information plate is affixed to the casing cover (161),
showing the position of the lantern ring. The lantern ring must
register beneath the drilled hole in the casing cover (161), to
enable the sealing liquid to enter. The pressure of the liquid
should be 1 to 4 bar above the pressure existing in the packing
compartment of the stuffing box.

The packing of the stuffing box should be carried out with
great care, to avoid an excessively high radial pressing force
of the packing rings against the shaft protection sleeve, which
might damage the latter. If the shaft protection sleeve is scored
or grooved, even a new packing cannot be expected to last
very long in service.

A newly packed stuffing box should leak profusely at first. If
this leakage does not cease of its own after a relatively short
period of operation, the nuts on the stuffing box (452) gland
should be tightened slowly and evenly while the pump is
running, until the stuffing box only drips slightly. Make sure
that the stuffing box gland (452) is tightened evenly and not
askew, as otherwise the shaft protection sleeve (524) might
be damaged.

If the newly packed stuffing box starts to emit smoke when the
pump is started up for the first time, the pump should be
switched off. If the smoking persists after the pump has been
started up again and operated several times in succession,
the nuts on the gland should be slackened slightly, or the
stuffing box should be inspected if necessary.

3.1.2.5 Packing Material

When selecting the packing material, make sure it is
compatible with the fluid pumped (consult the manufacturer
in case of doubt).

must be opened fully and the unimpeded flow through these
lines must be verified. Open the isolating valve in the vacuum
balance line (if applicable to your installation) and close the

vacuum tight isolating valve ‘E”. (see Z fig.5).

3.1.4 Checking the direction of rotation

The direction of rotation must correspond to the arrow on the
pump. This can be checked by switching on the driver for a
short instant and switching it off again immediately. Mount the
coupling guard after checking the direction of rotation.

3.2 Start up

Always make sure that the isolating valve in the discharge
line is closed when the pump is switched on. Only after the
pump has attained full operating speed should the discharge
valve be opened gradually and the operating point conditions
adjusted by means of this valve.

Caution :

After the operating temperature has been attained and/or in
the event of leakage, tighten the Bearing bracket lantern to
casing connection bolts after switching off the pumping set. If
the leakage persists, check/change the gasket.

3.3 Shut down

Close isolating valve in the discharge line. If non-return valve
or a check valve has been incorporated in the discharge line,
the isolating valve can remain open so far as there is a back
pressure present in the line. Switch off driver. Observe the
pumping set running down smoothly and quietly to a standstill.

In the event of a prolonged shutdown, the isolating valve in
the suction lift line should be closed.

The shaft seal of pumps which are connected to a supply
vessel under vacuum must be fed with flushing liquid even
when the pump is switched off. In the event of frost and/or of
prolonged shutdowns, the pump and the cooling
compartments (if applicable) must be drained or otherwise
protected against freezing using suitable antifreeze solution.

4. Maintenance and lubrication

Packing material which has been kept in store for a certain
period has a longer service life than standard fresh packing
material from the packing manufacturer. Packing material fitted
in the pump while despatching are :-

CPK G/GC : Style 1003

E/EC : Style 1003
C : Style 1003

CPK EY : Graphoil

3.1.2.6 Sealing liquid

In case of soft packed pumps working under vacuum, handling
impure liquids, sealing liquid is required to be fed through
lantern ring connection. For this the GA drawing of the pump
should be referred to.

3.1.3 Alternate packing arrangements available

The pump suction lift line must be vented and primed with the
fluid pumped before start up. This valve in the suction lift line
must be fully open. All auxiliary connections provided on your
pump (e.g. flushing liquid, sealing liquid, cooling liquid etc.)

4.1 Supervision of operation

The pump should run quietly and free from vibration at all
times. The pump must never be allowed to run dry. Avoid any
prolonged running against a closed discharge valve.

The bearing temperature may be allowed to attain up to 500C
above room temperature but should not exceed 800C.

Make sure the oil level is adequate (see section 3.1.1). The
isolating valves in the auxiliary feed lines must always remain
open when the pump is running.

The soft packed stuffing box (if your pump has one) should
drip slightly during operation. The stuffing box gland should
only be tightened lightly.

Any standby pumps in the pumping installation should be
operated once a week for a short instant, by switching on and
switching off again, so as to maintain them in good condition
for instant start-up in case of emergency. The correct
functioning of the auxiliary connections should be kept under
observation. When signs of wear become apparent on the

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