KSB HPK, HPKS, HPKE, HPK-EY, HPK-SY Operating Manual
Thermal Oil / Hot Water Pump
HPK
Complementary Sizes
Bearing Assemblies P08s, P10as, P12s
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual HPK
Original operating manual
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 Aktiengesellschaft, Frankenthal 16/01/2017
Contents
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Contents
Glossary .................................................................................................................................................. 6
1 General.................................................................................................................................................... 7
1.1 Principles ...........................................................................................................................................................7
1.2 Installation of partly completed machinery....................................................................................................7
1.3 Target group.....................................................................................................................................................7
1.4 Other applicable documents............................................................................................................................7
1.5 Symbols .............................................................................................................................................................7
2 Safety...................................................................................................................................................... 9
2.1 Key to safety symbols/markings.......................................................................................................................9
2.2 General..............................................................................................................................................................9
2.3 Intended use .....................................................................................................................................................9
2.4 Personnel qualification and training.............................................................................................................10
2.5 Consequences and risks caused by non-compliance with this manual .......................................................10
2.6 Safety awareness ............................................................................................................................................10
2.7 Safety information for the operator/user.....................................................................................................11
2.8 Safety information for maintenance, inspection and installation ..............................................................11
2.9 Unauthorised modes of operation................................................................................................................11
2.10 Explosion protection ......................................................................................................................................11
2.10.1 Marking ..............................................................................................................................................12
2.10.2 Temperature limits.............................................................................................................................12
2.10.3 Monitoring equipment......................................................................................................................12
2.10.4 Operating limits .................................................................................................................................13
3 Transport/Temporary Storage/Disposal............................................................................................. 14
3.1 Checking the condition upon delivery..........................................................................................................14
3.2 Transport.........................................................................................................................................................14
3.3 Storage/preservation......................................................................................................................................15
3.4 Return to supplier...........................................................................................................................................15
3.5 Disposal ...........................................................................................................................................................16
4 Description of the Pump (Set)............................................................................................................. 17
4.1 General description ........................................................................................................................................17
4.2 Designation.....................................................................................................................................................17
4.3 Name plate......................................................................................................................................................17
4.4 Design details..................................................................................................................................................17
4.5 Configuration and function...........................................................................................................................20
4.6 Noise characteristics .......................................................................................................................................21
4.7 Scope of supply...............................................................................................................................................21
4.8 Dimensions and weights ................................................................................................................................22
5 Installation at Site................................................................................................................................ 23
5.1 Safety regulations...........................................................................................................................................23
5.2 Checks to be carried out prior to installation...............................................................................................23
5.3 Installing the pump set ..................................................................................................................................23
5.3.1 Installation on the foundation..........................................................................................................24
5.3.2 Installation without foundation .......................................................................................................25
5.4 Piping ..............................................................................................................................................................25
5.4.1 Connecting the piping.......................................................................................................................25
5.4.2 Permissible forces and moments at the pump nozzles....................................................................27
5.4.3 Auxiliary connections.........................................................................................................................28
5.5 Enclosure/insulation .......................................................................................................................................29
5.6 Checking the coupling alignment .................................................................................................................29
5.7 Aligning the pump and motor ......................................................................................................................30
5.8 Electrical connection ......................................................................................................................................31
5.8.1 Setting the time relay ........................................................................................................................32
5.8.2 Connecting the motor .......................................................................................................................32
Contents
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5.9 Checking the direction of rotation................................................................................................................33
6 Commissioning/Start-up/Shutdown................................................................................................... 34
6.1 Shutdown/storage/preservation ....................................................................................................................34
6.1.1 Measures to be taken for shutdown ................................................................................................34
6.2 Operating limits..............................................................................................................................................34
6.2.1 Ambient temperature........................................................................................................................34
6.2.2 Frequency of starts.............................................................................................................................35
6.2.3 Fluid handled .....................................................................................................................................35
6.3 Commissioning/start-up .................................................................................................................................36
6.3.1 Prerequisites for commissioning/start-up ......................................................................................... 36
6.3.2 Filling in lubricants.............................................................................................................................36
6.3.3 Shaft seal ............................................................................................................................................38
6.3.4 Priming and venting the pump.........................................................................................................39
6.3.5 Water cooling.....................................................................................................................................39
6.3.6 Cooling of the shaft seal ("K" design)..............................................................................................40
6.3.7 Bearing bracket cooling ....................................................................................................................40
6.3.8 Cooling of the heat exchanger .........................................................................................................40
6.3.9 Heating up/keeping warm the pump (set).......................................................................................41
6.3.10 Final check ..........................................................................................................................................41
6.3.11 Start-up............................................................................................................................................... 41
6.3.12 Checking the shaft seal......................................................................................................................42
6.3.13 Shutdown ...........................................................................................................................................43
6.4 Returning to service .......................................................................................................................................44
7 Servicing/Maintenance........................................................................................................................ 45
7.1 Safety regulations...........................................................................................................................................45
7.2 Servicing/inspection........................................................................................................................................46
7.2.1 Supervision of operation ................................................................................................................... 46
7.2.2 Inspection work..................................................................................................................................47
7.2.3 Lubrication and lubricant change of rolling element bearings ...................................................... 48
7.3 Drainage/cleaning ..........................................................................................................................................50
7.4 Dismantling the pump set..............................................................................................................................50
7.4.1 General information/Safety regulations...........................................................................................50
7.4.2 Preparing the pump set..................................................................................................................... 51
7.4.3 Removing the motor..........................................................................................................................51
7.4.4 Removing the back pull-out unit ...................................................................................................... 51
7.4.5 Removing the impeller ......................................................................................................................52
7.4.6 Removing the shaft seal ....................................................................................................................52
7.4.7 Dismantling the bearings ..................................................................................................................53
7.5 Reassembling the pump set...........................................................................................................................54
7.5.1 General information/Safety regulations...........................................................................................54
7.5.2 Installing the bearings .......................................................................................................................55
7.5.3 Fitting the shaft seal ..........................................................................................................................56
7.5.4 Fitting the impeller ............................................................................................................................58
7.5.5 Fitting the back pull-out unit............................................................................................................59
7.5.6 Mounting the motor .........................................................................................................................59
7.6 Tightening torques.........................................................................................................................................59
7.6.1 Tightening torques ............................................................................................................................59
7.6.2 Tightening torques impeller nut/screw ............................................................................................60
7.7 Spare parts stock.............................................................................................................................................60
7.7.1 Ordering spare parts.......................................................................................................................... 60
7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296...........................................61
7.7.3 Interchangeability of pump components.........................................................................................61
8 Trouble-shooting.................................................................................................................................. 63
9 Related Documents.............................................................................................................................. 65
9.1 General assembly drawing with list of components ....................................................................................65
Contents
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10 EU Declaration of Conformity............................................................................................................. 67
11 Certificate of Decontamination........................................................................................................... 68
Index ..................................................................................................................................................... 69
Glossary
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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
and health hazards arising from components in
contact with the fluid handled.
Discharge line
The pipeline which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic energy
is converted into pressure energy
Pool of pumps
Customers/operators’ pumps which are purchased
and stored regardless of their later use.
Pump
Machine without drive, additional components or
accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line
The pipeline which is connected to the suction
nozzle
1 General
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1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The operating manual describes the proper and safe use
of this equipment in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
Noise characteristics see (ðSection4.6,Page21)
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance. (ðSection7.5.5,Page59)
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.4,Page10)
1.4 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump (set)
General arrangement drawing/
outline drawing
Description of mating and installation dimensions
for the pump (set), weights
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing
1)
Sectional drawing of the pump
Sub-supplier product literature1)Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists
1)
Description of spare parts
Piping layout
1)
Description of auxiliary piping
List of components
1)
Description of all pump components
Drawing for assembly
1)
Sectional drawing of the installed shaft seal
For accessories and/or integrated machinery components observe the relevant
manufacturer's product literature.
1.5 Symbols
Table2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
1) If agreed upon in scope of supply
1 General
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Symbol Description
⇨ Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
2 Safety
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2 Safety
!
DANGER
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table3: 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.
!
WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with Directive
2014/34/EU (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 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.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪ Arrow indicating the direction of rotation
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
2.3 Intended use
▪ The pump (set) must only be operated within the operating limits described in
the other applicable documents. (ðSection1.4,Page7)
▪ Only operate pumps/pump sets which are in perfect technical condition.
▪ Do not operate the pump (set) in partially assembled condition.
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▪ Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model or variant.
▪ Never operate the pump without the fluid to be handled.
▪ Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc.).
▪ Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc.)
▪ Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪ Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪ Never open the discharge-side shut-off elements further than permitted.
– The maximum flow rates specified in the product literature or data sheet
would be exceeded.
– Risk of cavitation damage
▪ Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪ Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with this manual
▪ Non-compliance with this operating manual 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:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪ Accident prevention, health and safety regulations
▪ Explosion protection regulations
▪ Safety regulations for handling hazardous substances
▪ Applicable standards, directives and laws
2 Safety
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2.7 Safety information for the operator/user
▪ The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪ Do not remove any contact guards during operation.
▪ Provide the personnel with protective equipment and make sure it is used.
▪ Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪ Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪ If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
2.8 Safety information for maintenance, inspection and installation
▪ Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪ Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
▪ The operator ensures that maintenance, inspection and installation is performed
by authorised, qualified specialist personnel who are thoroughly familiar with
the manual.
▪ Only carry out work on the pump (set) during standstill of the pump.
▪ Any work on the pump set shall only be performed when it has been
disconnected from the power supply (de-energised).
▪ The pump casing must have cooled down to ambient temperature.
▪ Pump pressure must have been released and the pump must have been drained.
▪ When taking the pump set out of service always adhere to the procedure
described in the manual. (ðSection6.3.13,Page43) (ðSection6.1,Page34)
▪ Decontaminate pumps which handle fluids posing a health hazard.
(ðSection7.3,Page50)
▪ As soon as the work has been completed, re-install and/or re-activate any safety-
relevant and protective devices. Before returning the product to service, observe
all instructions on commissioning. (ðSection6.3,Page36)
2.9 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
manual.
The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
(ðSection2.3,Page9)
2.10 Explosion protection
!
DANGER
Always observe the information on explosion protection given in this section when
operating the product in potentially explosive atmospheres.
Only pumps/pump sets marked as explosion-proof and identified as such in the data
sheet may be used in potentially explosive atmospheres.
Special conditions apply to the operation of explosion-proof pump sets to EU
Directive 2014/34/EU (ATEX).
Especially adhere to the sections in this manual marked with the Ex symbol and the
following sections, (ðSection2.10.1,Page12) to (ðSection2.10.4,Page13)
The explosion-proof status of the pump set is only assured if the pump set is used in
accordance with its intended use.
2 Safety
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Never operate the pump set outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
2.10.1 Marking
Pump
The marking on the pump refers to the pump part only.
Example of such marking: II 2 G c TX
Refer to the Temperature Limits table for the temperatures permitted for the
individual pump variants. (ðSection2.10.2,Page12)
Shaft coupling
An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor
The motor must be considered separately.
2.10.2 Temperature limits
In normal pump operation, the highest temperatures are to be expected on the
surface of the pump casing, at the shaft seal and in the bearing areas.
The surface temperature at the pump casing corresponds to the temperature of the
fluid handled. If the pump is heated in addition, the operator of the system is
responsible for observing the specified temperature class and fluid temperature
(operating temperature).
The table below lists the temperature classes and the resulting theoretical
temperature limits of the fluid handled (a possible temperature rise in the shaft seal
area has already been taken into account).
The temperature class specifies the maximum permissible temperature at the surface
of the pump set during operation.
For the permissible operating temperature of the pump in question refer to the data
sheet.
Table4: Temperature limits
Temperature class to EN 13463-1 Maximum permissible fluid
temperature
T1 Maximum 400 °C
2)
T2 280 °C
T3 185 °C
T4 120 °C
T5 85 °C
T6 Only after consultation
with the manufacturer
Temperature class T4
In the area of the rolling element bearings, based on an ambient temperature of
40°C and assuming proper service and operation, compliance with the requirements
of temperature class T4 is warranted. If the ambient temperature exceeds 40 °C,
contact the manufacturer.
Temperature class T6
A special design is required to comply with the requirements of temperature class T6
in the bearing area.
Misuse, malfunctions or non-compliance with the instructions may result in
substantially higher temperatures.
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.
2.10.3 Monitoring equipment
The pump (set) must only be operated within the limits specified in the data sheet
and on the name plate.
If the system operator cannot warrant compliance with these operating limits,
2) Depending on the material variant
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appropriate monitoring devices must be used.
Check whether monitoring equipment is required to ensure that the pump set
functions properly.
Contact KSB for further information on monitoring equipment.
2.10.4 Operating limits
The minimum flows indicated in (ðSection6.2.3.1,Page35) refer to water and
water-like fluids handled. Longer operating periods with these fluids and at the flow
rates indicated will not cause an additional increase in the temperatures at the pump
surface. However, if the physical properties of the fluids handled are different from
water, it is essential to check whether an additional heat build-up may occur and if
the minimum flow rate must therefore be increased. The calculation formula in
(ðSection6.2.3.1,Page35) can be used to check whether additional heat build-up
may lead to a dangerous temperature increase at the pump surface.
3 Transport/Temporary Storage/Disposal
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3 Transport/Temporary Storage/Disposal
3.1 Checking the condition upon delivery
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 (as applicable) and the insurer about the
damage in writing immediately.
3.2 Transport
DANGER
The pump (set) could slip out of the suspension arrangement
Danger to life from falling parts!
▷ Always transport the pump (set) in the specified position.
▷ Never attach the suspension arrangement to the free shaft end or the motor
eyebolt.
▷ Give due attention to the weight data and the centre of gravity.
▷ Observe the applicable local health and safety regulations.
▷ Use suitable, permitted lifting accessories, e.g. self-tightening lifting tongs.
To transport the pump/pump set or back pull-out unit suspend it from the lifting tackle
as shown.
Fig.1: Transporting the back pull-out unit
Fig.2: Transporting the pump
≤ 90 °
Fig.3: Transporting the pump set
3 Transport/Temporary Storage/Disposal
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≤ 90 °
Fig.4: Transporting the pump on the baseplate
3.3 Storage/preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷ For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump!
▷ Clean and cover pump openings and connections as required prior to putting
the pump into storage.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, the shutdown measures
must be adhered to. (ðSection6.1.1,Page34)
3.4 Return to supplier
1. Drain the pump as per operating instructions. (ðSection7.3,Page50)
2. Always flush and clean the pump, particularly if it has been used for handling
noxious, explosive, hot or other hazardous fluids.
3. If the pump set has handled fluids whose residues could lead to corrosion
damage in the presence of atmospheric humidity or could ignite upon contact
with oxygen, the pump set must also be neutralised, and anhydrous inert gas
must be blown through the pump to ensure drying.
4. Always complete and enclose a certificate of decontamination when returning
the pump (set).
Always indicate any safety and decontamination measures taken.
(ðSection11,Page68)
NOTE
If required, a blank certificate of decontamination can be downloaded from the
following web site: www.ksb.com/certificate_of_decontamination
3 Transport/Temporary Storage/Disposal
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3.5 Disposal
WARNING
Fluids, 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 residues of the fluid
handled.
▷ Wear safety clothing and a protective mask, if required.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set).
Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metals
- Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another
controlled manner.
4 Description of the Pump (Set)
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4 Description of the Pump (Set)
4.1 General description
▪ Heat transfer fluid pump with shaft seal
Pump for handling hot water or organic heat transfer fluids in piping or tank
systems.
4.2 Designation
Example: HPK S F 250 - 630
Table5: Key to the designation
Code Description
HPK Type series
S Material of wetted components
F Additional code
250 Nominal discharge nozzle diameter [mm]
630 Nominal impeller diameter [mm]
Materials see data sheet
Additional codes:
F = off-standard flange design
Y = centreline pump feet
M = mechanical seal with internal or external circulation
K = intensively cooled shaft seal chamber
4.3 Name plate
HPK S F 300-500
P-No. 997125086300550001
Q 1660 m
3
/h H 73 m
n 1488 1/min
KSB Aktiengesellschaft
67227 Frankenthal
Mat-No. 01 109 223 ZN 3804 - D 52 x 74
2009
0520-5-P-10000-31
1
2
5
4
3
6
7
Fig.5: Name plate (example)
1 Type series, size 2 Customer-specific information
(optional)
3 KSB order and order item number 4 Flow rate
5 Speed 6 Year of construction
7 Head
4.4 Design details
Design
▪ Volute casing pump
▪ Horizontal installation
▪ Back pull-out design
▪ Single-stage
▪ Meets the technical requirements to ISO 5199
▪ Dimensions and ratings to ISO2858
complemented by pumps of nominal diameters DN150 to DN400
4 Description of the Pump (Set)
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Pump casing
▪ Single or double volute, depending on the pump size
▪ Volute casing (depending on the design and size with casing wear ring)
and casing cover
▪ Radially split volute casing
▪ Volute casing with integrally cast pump feet
Table6: Pump feet
HPKS/E HPK-EY/SY
Pump feet below Centreline pump feet
Impeller type
▪ Closed radial impeller with multiply curved vanes
▪ Back vanes reduce axial thrust.
Shaft seal
Due to the complex conditions in hot water systems, the use of mechanical seals not
approved by KSB shall not be covered by KSB's scope of warranty.
The following seal designs are used for hot water applications:
▪ Mechanical seal, uncooled
▪ Mechanical seal with jacket cooling
Mechanical seal, uncooled
(operating mode "E")
Uncooled, single-acting, balanced
mechanical seal
y = circulation starting from the discharge
nozzle
y
Mechanical seal with jacket cooling
(operating mode "BM")
Cooled shaft seal with single-acting,
balanced mechanical seal
▪ Cooling of seal chamber via seal
housing
▪ Venting via clearance gap
Cooled shaft seal with single-acting,
balanced mechanical seal
▪ Cooling of seal chamber via seal
housing and coolable seat ring
▪ Venting via clearance gap
x = cooling liquid ON/OFF
x
4 Description of the Pump (Set)
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Bearings
Design specifications
Motor-end bearing:
▪ Fixed bearing
▪ Paired angular contact ball bearing
▪ Axial movement of the rotor limited to 0.5 mm maximum
▪ Oil lubrication
Pump-end bearing:
▪ Radial bearing
▪ Cylindrical roller bearing
▪ Absorbs radial loads only
▪ Oil lubrication
Bearing bracket designation
Example: P10as
Table7: Bearing bracket designation
Code Description
P Bearing bracket
10 Size code (based on dimensions of seal chamber and shaft
end)
a Reinforced bearing bracket (next bearing size up)
s Paired angular contact ball bearings (drive end)
Bearings used
Table8: Bearing design
KSB designation FAG designation SKF designation
B.G B-TVP-UA BECBP
Table9: Bearing design
Bearing bracket Cylindrical roller bearing
(DIN 5412)
Angular contact ball
bearing (DIN 628)
P08s NU 416 7319 B. G
P10as NU 324 7324 B. G
P12s NU 324 7324 B. G
4 Description of the Pump (Set)
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4.5 Configuration and function
1
2
3
4
5
6 7 8 9 10
Fig.6: Sectional drawing
1 Clearance gap 2 Discharge nozzle
3 Casing cover 4 Shaft
5 Bearing bracket 6 Suction nozzle
7 Impeller 8 Shaft seal
9 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.
Function
The fluid enters the pump axially via the suction nozzle (6) and is accelerated
outward by the rotating impeller (7). In the flow passage of the pump casing the
kinetic energy of the fluid is converted into pressure energy. The fluid is pumped to
the discharge nozzle (2), where it leaves the pump. The clearance gap (1) prevents
any fluid from flowing back from the casing to the suction nozzle. At the rear side of
the impeller, the shaft (4) enters the casing via the casing cover (3). The shaft passage
through the cover is sealed to atmosphere with a shaft seal (8). The shaft runs in
rolling element bearings (9 and 10), which are supported by a bearing bracket (5)
linked with the pump casing and/or casing cover.
Sealing
The pump is sealed by a shaft seal (standardised mechanical seal or gland packing).
4 Description of the Pump (Set)
21 of 72
HPK
4.6 Noise characteristics
Table10: Surface sound pressure level L
pA
3)4)
P
N
Pump Pump set
960rpm,
760rpm
1450rpm 2900rpm 960rpm,
760rpm
1450rpm 2900rpm
[kW] [dB] [dB] [dB] [dB] [dB] [dB]
1,5 52 53 54 56 58 63
2,2 53 55 56 58 60 66
3 55 56 57 60 62 68
4 56 58 59 61 63 69
5,5 58 59 61 62 65 71
7,5 59 61 62 64 66 72
11 61 63 64 65 68 74
15 63 65 66 67 69 75
18,5 64 66 67 68 70 76
22 65 67 68 68 71 77
30 66 68 70 70 72 78
37 67 70 71 70 73 79
45 68 71 72 71 74 80
55 69 72 73 72 74 80
75 71 73 75 73 76 81
90 71 74 76 73 76 82
110 72 75 77 74 77 82
132 73 76 78 75 77 83
160 74 77 79 75 78 84
200 75 78 80 76 79 84
250 - 79 81 - 80 85
4.7 Scope of supply
Depending on the model, the following items are included in the scope of supply:
▪ Pump
Drive
▪ Surface-cooled IEC frame three-phase squirrel-cage motor
Coupling
▪ Flexible coupling with or without spacer
Contact guard
▪ Coupling guard
Baseplate
▪ Cast or welded baseplate for the complete unit (pump and motor), in torsion-
resistant design
Accessories
▪ As ordered
3) Spatial average; as per ISO3744 and EN12639; valid for pump operation in the Q/Qopt = 0.8-1.1 range and for non-
cavitating operation. If noise levels are to be guaranteed: add +3dB for measuring and constructional tolerance.
4) Increase for 60Hz operation: 3500rpm +3dB, 1750rpm +1dB, 1160rpm ±0dB
4 Description of the Pump (Set)
22 of 72
HPK
4.8 Dimensions and weights
For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump/pump set.
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