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Thermal Oil / Hot Water Pump
HPK
Complementary Sizes
Bearing Assemblies P08s, P10as, P12s
Installation/Operating Manual
Page 2
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
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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
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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
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10 EU Declaration of Conformity............................................................................................................. 67
11 Certificate of Decontamination........................................................................................................... 68
Index ..................................................................................................................................................... 69
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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
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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
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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
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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
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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.
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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.
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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
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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
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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.
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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
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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
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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
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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).
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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
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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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5 Installation at Site
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5 Installation at Site
5.1 Safety regulations
DANGER
Improper installation in potentially explosive atmospheres
Explosion hazard!
Damage to the pump set!
▷ Comply with the applicable local explosion protection regulations.
▷ Observe the information in the data sheet and on the name plates of pump and
motor.
5.2 Checks to be carried out prior to installation
Place of installation
WARNING
Installation on mounting surface which is unsecured and cannot support the load
Personal injury and damage to property!
▷ Use a concrete of compressive strength class C12/15 which meets the
requirements of exposure class XC1 to EN206-1.
▷ The mounting surface must have set and must be completely horizontal and
even.
▷ Observe the weights indicated.
1. Check the structural requirements.
All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing.
5.3 Installing the pump set
Always install the pump set in a horizontal position.
DANGER
Excessive temperatures due to improper installation
Explosion hazard!
▷ Install the pump in a horizontal position to ensure self-venting of the pump.
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5.3.1 Installation on the foundation
L
1
32
Fig.7: Fitting the shims
L Bolt-to-bolt distance 1 Shim
2 Shim if (L) > 800mm 3 Foundation bolt
ü The foundation has the required strength and characteristics.
ü The foundation has been prepared in accordance with the dimensions given in
the outline drawing/general arrangement drawing.
1. Position the pump set on the foundation and level it with the help of a spirit
level placed on the shaft and discharge nozzle.
Permissible deviation: 0.2mm/m
2. Use shims (1) for height compensation if necessary.
Always fit shims, if any, immediately to the left and right of the foundation
bolts (3) between the baseplate/foundation frame and the foundation.
For a bolt-to-bolt distance (L) > 800mm fit additional shims (2) halfway between
the bolt holes.
All shims must lie perfectly flush.
3. Insert the foundation bolts (3) into the holes provided.
4. Use concrete to set the foundation bolts (3) into the foundation.
5. Wait until the concrete has set firmly, then level the baseplate.
6. Tighten the foundation bolts (3) evenly and firmly.
7. Grout the baseplate using low-shrinkage concrete with a standard particle size
and a water/cement ratio of ≤0.5.
Produce flowability with the help of a solvent.
Perform secondary treatment of the concrete to EN206.
NOTE
For low-noise operation contact the manufacturer to check whether the pump set
can be installed on anti-vibration mounts.
NOTE
Expansion joints can be fitted between the pump and the suction/discharge line.
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5.3.2 Installation without foundation
4
1
2
3
Fig.8: Adjusting the levelling elements
1, 3 Locknut 2 Adjusting nut
4 Machine mount
ü The installation surface has the required strength and characteristics.
1. Position the pump set on the machine mounts (4) and align it with the help of a
spirit level (on the shaft/discharge nozzle).
2. To adjust any differences in height, loosen the locknuts (1, 3) of the machine
mounts (4).
3. Turn the adjusting nut (2) until any differences in height have been
compensated.
4. Re-tighten the locknuts (1, 3) at the machine mounts (4).
5.4 Piping
5.4.1 Connecting the piping
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from escaping hot, toxic, corrosive or flammable fluids!
▷ Do not use the pump as an anchorage point for the piping.
▷ Anchor the pipes in close proximity to the pump and connect them properly
without transmitting any stresses or strains.
▷ Observe the permissible forces and moments at the pump nozzles.
▷ Take appropriate measures to compensate for thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
▷ Never earth the electric welding equipment on the pump or baseplate.
▷ Prevent current flowing through the rolling element bearings.
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NOTE
Installing check and shut-off elements in the system is recommended, depending on
the type of plant and pump. However, such elements must not obstruct proper
drainage or hinder disassembly of the pump.
ü Suction lift lines have been laid with a rising slope, suction head lines with a
downward slope towards the pump.
ü A flow stabilisation section having a length equivalent to at least twice the
diameter of the suction flange has been provided upstream of the suction flange.
ü The nominal diameters of the pipelines are at least equal to the nominal
diameters of the pump nozzles.
ü Adapters to larger diameters have a diffuser angle of approximately 8° to
prevent excessive pressure losses.
ü The pipelines have been anchored in close proximity to the pump and connected
without transmitting any stresses or strains.
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
▷ Free the piping from any impurities.
▷ If necessary, install a filter.
▷ Comply with the instructions set out in (ðSection7.2.2.3,Page48) .
1. Thoroughly clean, flush and blow through all vessels, pipelines and connections
(especially of new installations).
2. Before installing the pump in the piping, remove the flange covers on the
suction and discharge nozzles of the pump.
3. Check that the inside of the pump is free from any foreign objects. Remove any
foreign objects.
4. If required, install a filter in the piping (see figure: Filter in the piping).
1
2
Fig.9: Filter in the piping
1 Differential pressure gauge 2 Filter
NOTE
Use a filter with laid-in wire mesh of 0.5 mm x 0.25 mm (mesh size x wire diameter)
made of corrosion-resistant material.
Use a filter with a filter area three times the cross-section of the piping.
Conical filters have proved suitable.
5. Connect the pump nozzles to the piping.
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CAUTION
Aggressive flushing and pickling agents
Damage to the pump!
▷ Match the cleaning operation mode and duration for flushing and pickling
service to the casing and seal materials used.
5.4.2 Permissible forces and moments at the pump nozzles
The data on forces and moments apply to static piping loads only. If the limits are
exceeded, they must be checked and verified.
If a computerised strength analysis is required, values are available on request only.
The values are only applicable if the pump is installed on a completely grouted
baseplate and bolted to a rigid and level foundation.
For fluid temperatures > 120 °C reduce the values in tables 11 and 12 as per the
temperature correction diagram (see below).
1,00
0,75
0,80
0,85
0,90
0,95
0,50
0,55
0,60
0,65
0,70
400350300250200150120
JL1040
GP240GH+N
JS1025
1.4408
°C
Correction coefficient
Fig.10: Temperature correction diagram
HPK-S/E
[+]
F
y
F
z
F
x
F
x
F
z
F
y
F
x
F
z
F
y
M
y
M
z
M
x
Forces and moments at the pump nozzles
Pump feet below
The resulting permissible forces have
been determined according to the
following formulas:
Table11: Forces and moments at the pump nozzles
Size
Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle
[N] [N] [Nm] [Nm]
F
x
F
y
F
z
F
res
FxF
yTens
+
F
yCompr
- F
z
F
res
MxMyMzMxMyM
z
150-630 7350 4700 5700 7400 3750 2350 4700 3100 4850 5300 3850 2650 3450 2650 1750
200-670 10000 6700 8000 10450 5700 3550 7350 4700 7400 7500 5700 3650 5300 3850 2650
250-630 12000 8000 10000 12800 8000 5000 10000 6700 10450 9150 6900 4500 7500 5700 3650
250-710 12000 8000 10000 12800 8000 5000 10000 6700 10450 9150 6900 4500 7500 5700 3650
300-630 13350 8700 10700 13800 10000 6150 12000 8000 12800 9550 7150 4700 9150 6900 4500
300-710 13350 8700 10700 13800 10000 6150 12000 8000 12800 9550 7150 4700 9150 6900 4500
350-630 15350 10000 12700 16200 10700 6700 13350 8700 13800 11000 8150 5500 9550 7150 4700
350-710 15350 10000 12700 16200 10700 6700 13350 8700 13800 11000 8150 5500 9550 7150 4700
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5 Installation at Site
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Size
Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle
[N] [N] [Nm] [Nm]
F
x
F
y
F
z
F
res
FxF
yTens
+
F
yCompr
- F
z
F
res
MxMyMzMxMyM
z
400-504 15350 10000 12700 16200 12700 8000 15350 10000 16200 11000 8150 5500 11000 8150 5500
400-506 15350 10000 12700 16200 12700 8000 15350 10000 16200 11000 8150 5500 11000 8150 5500
400-630 15350 10000 12700 16200 12700 8000 15350 10000 16200 11000 8150 5500 11000 8150 5500
400-710 15350 10000 12700 16200 12700 8000 15350 10000 16200 11000 8150 5500 11000 8150 5500
HPK-SY/EY
Forces and moments at the pump nozzles
Centreline pump feet
The resulting permissible forces have
been determined according to the
following formulas:
Table12: Forces and moments at the pump nozzles
Size
Suction nozzle Discharge nozzle Suction nozzle Discharge nozzle
[N] [N] [Nm] [Nm]
F
x
F
y
F
z
F
res
FxF
yTens
+ F
yCompr
-
F
z
F
res
M
x
M
y
MzM
x
M
y
M
z
150-630 9800 6200 7600 9800 5000 3100 6200 4100 6450 7050 5150 3550 4600 3550 2350
200-670 13350 8900 10700 13900 7600 4700 9800 6200 9800 10050 7600 4900 70500 5150 3550
250-630 16000 10700 13350 17100 10700 6700 13350 8900 13900 12200 9200 6000 10050 7600 4900
250-710 16000 10700 13350 17100 10700 6700 13350 8900 13900 12200 9200 6000 10050 7600 4900
300-630 17800 11600 14250 18350 13350 8200 16000 10700 17100 12750 9500 6250 12200 9200 6000
300-710 17800 11600 14250 18350 13350 8200 16000 10700 17100 12750 9500 6250 12200 9200 6000
350-630 20500 13350 16900 21550 14250 8900 17800 11600 18350 14650 10850 7350 12750 9500 6250
350-710 20500 13350 16900 21550 14250 8900 17800 11600 18350 14650 10850 7350 12750 9500 6250
400-504 20500 13350 16900 21550 16900 10070 20500 13350 21550 14650 10850 7350 14650 10850 7350
400-506 20500 13350 16900 21550 16900 10070 20500 13350 21550 14650 10850 7350 14650 10850 7350
400-630 20500 13350 16900 21550 16900 10070 20500 13350 21550 14650 10850 7350 14650 10850 7350
400-710 20500 13350 16900 21550 16900 10070 20500 13350 21550 14650 10850 7350 14650 10850 7350
5.4.3 Auxiliary connections
DANGER
Risk of potentially explosive atmosphere by mixing of incompatible fluids in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid
handled.
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WARNING
Failure to use or incorrect use of auxiliary connections (e.g. barrier fluid, flushing
liquid, etc.)
Risk of injury from escaping fluid!
Risk of burns!
Malfunction of the pump!
▷ Refer to the general arrangement drawing, the piping layout and pump
markings (if any) for the quantity, dimensions and locations of auxiliary
connections.
▷ Use the auxiliary connections provided.
5.5 Enclosure/insulation
DANGER
Risk of potentially explosive atmosphere due to insufficient venting
Explosion hazard!
▷ Make sure the space between the casing cover/discharge cover and the bearing
cover is sufficiently vented.
▷ Never close or cover the perforation of the bearing bracket guards (e.g. by
insulation).
WARNING
The volute casing and casing/discharge cover take on the same temperature as
the fluid handled
Risk of burns!
▷ Insulate the volute casing.
▷ Fit protective equipment.
CAUTION
Heat build-up in the bearing bracket
Damage to the bearing!
▷ Never insulate the bearing bracket, bearing bracket lantern and casing cover.
5.6 Checking the coupling alignment
DANGER
Inadmissible temperatures at the coupling or bearings due to misalignment of the
coupling
Explosion hazard!
Risk of burns!
▷ Make sure that the coupling is correctly aligned at all times.
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CAUTION
Misalignment of pump and motor shafts
Damage to pump, motor and coupling!
▷ Always check the coupling after the pump has been installed and connected to
the piping.
▷ Also check the coupling of pump sets supplied with pump and motor mounted
on the same baseplate.
B
A
A
B
a) b)
B
B
A
A
1
1
2
21
1
Fig.11: Checking the coupling alignment: Coupling without spacer sleeve (a) or Coupling with spacer sleeve (b)
1 Straight-edge 2 Gauge
ü The coupling guard and its footboard, if any, have been removed.
1. Loosen the support foot and re-tighten it without transmitting any stresses and
strains.
2. Place the straight-edge axially on both coupling halves.
3. Leave the straight-edge in this position and turn the coupling by hand.
The coupling is aligned correctly if the distances A and B to the respective shafts
are the same at all points around the circumference.
The radial and axial deviation between the two coupling halves must not exceed
0.1 mm, during standstill as well as at operating temperature and under inlet
pressure.
4. Check the distance (dimension see general arrangement drawing) between the
two coupling halves around the circumference.
The coupling is correctly aligned if the distance between the two coupling
halves is the same at all points around the circumference.
The radial and axial deviation between the two coupling halves must not exceed
0.1 mm, during standstill as well as at operating temperature and under inlet
pressure.
5. If alignment is correct, re-install the coupling guard and its footboard, if any.
Checking the coupling alignment with a laser tool
Coupling alignment may also be checked with a laser tool. Observe the
documentation provided by the manufacturer of the measuring instrument.
5.7 Aligning the pump and motor
After having installed the pump set and connected the piping, check the coupling
alignment and, if required, re-align the pump set (with the motor).
Any differences in shaft centre height between the pump and the motor are
compensated by means of shims.
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1
Fig.12: Pump set with shim
1 Shim
ü The coupling guard and its footboard, if any, have been removed.
1. Check the coupling alignment.
2. Loosen the hexagon head bolts at the motor.
3. Insert shims underneath the motor feet until the difference in shaft centreline
height has been compensated.
4. Re-tighten the hexagon head bolts.
5. Check proper functioning of coupling/shaft.
Check that coupling/shaft can easily be rotated by hand.
WARNING
Unprotected rotating coupling
Risk of injury by rotating shafts!
▷ Always operate the pump set with a coupling guard.
If the customer specifically requests not to include a coupling guard in KSB's
delivery, then the operator must supply one!
▷ Observe all relevant regulations for selecting a coupling guard.
6. Fit the coupling guard and its footboard, if any.
7. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
DANGER
Risk of ignition by frictional sparks
Explosion hazard!
▷ Choose a coupling guard material that is non-sparking in the event of
mechanical contact (see DIN EN 13463-1).
5.8 Electrical connection
DANGER
Incorrect electrical installation
Explosion hazard!
▷ For electrical installation, also observe the requirements of IEC 60079-14.
▷ Always use a motor protection switch for explosion-proof motors.
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DANGER
Electrical connection work by unqualified personnel
Danger of death from electric shock!
▷ Always have the electrical connections installed by a trained and qualified
electrician.
▷ Observe regulations IEC 60364 and, for explosion-proof models, EN60079.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷ Observe the technical specifications of the local energy supply companies.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method.
NOTE
A motor protection device is recommended.
5.8.1 Setting the time relay
CAUTION
Switchover between star and delta on three-phase motors with star-delta starting
takes too long.
Damage to the pump (set)!
▷ Keep switch-over intervals between star and delta as short as possible.
Table13: Time relay settings for star-delta starting:
Motor rating Y time to be set
[kW] [s]
≤ 30 < 3
> 30 < 5
5.8.2 Connecting the motor
NOTE
In compliance with IEC 60034-8, three-phase motors are always wired for clockwise
rotation (looking at the motor shaft stub).
The pump's direction of rotation is indicated by an arrow on the pump.
1. Match the motor's direction of rotation to that of the pump.
2. Observe the manufacturer's product literature supplied with the motor.
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5.9 Checking the direction of rotation
DANGER
Temperature increase resulting from contact between rotating and stationary
components
Explosion hazard!
Damage to the pump set!
▷ Never check the direction of rotation by starting up the unfilled pump set.
▷ Separate the pump from the motor to check the direction of rotation.
WARNING
Hands inside the pump casing
Risk of injuries, damage to the pump!
▷ Always disconnect the pump set from the power supply and secure it against
unintentional start-up before inserting your hands or other objects into the
pump.
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
▷ Separate the pump from the motor to check the direction of rotation.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
▷ Refer to the arrow indicating the direction of rotation on the pump.
▷ Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
The correct direction of rotation of the motor and pump is clockwise (seen from the
drive end).
1. Start the motor and stop it again immediately to determine the motor's
direction of rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction
of rotation on the pump.
3. If the motor is running in the wrong direction of rotation, check the electrical
connection of the motor and switchgear, if any.
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6 Commissioning/Start-up/Shutdown
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HPK
6 Commissioning/Start-up/Shutdown
6.1 Shutdown/storage/preservation
6.1.1 Measures to be taken for shutdown
The pump (set) remains installed
ü Sufficient fluid is supplied for the operation check run of the pump.
1. Start up the pump (set) regularly between once a month and once every three
months for approximately five minutes during prolonged shutdown periods.
This will prevent the formation of deposits within the pump and the pump
intake area.
The pump (set) is removed from the pipe and stored
ü The pump has been properly drained (ðSection7.3,Page50) and the safety
instructions for dismantling the pump have been observed.
(ðSection7.4.1,Page50)
1. Spray-coat the inside wall of the pump casing and, in particular, the impeller
clearance areas with a preservative.
2. Spray the preservative through the suction and discharge nozzles.
It is advisable to then close the pump nozzles (e.g. with plastic caps or similar).
3. Oil or grease all exposed machined parts and surfaces of the pump (with
silicone-free oil and grease, food-approved if required) to protect them against
corrosion.
Observe the additional instructions (ðSection3.3,Page15) .
If the pump set is to be stored temporarily, only preserve the wetted components
made of low-alloy materials. Commercially available preservatives can be used for
this purpose. Observe the manufacturer's instructions for application/removal.
Observe any additional instructions and information provided. (ðSection3,Page14)
6.2 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature, fluid handled and
speed
Explosion hazard!
Hot or toxic fluid could escape!
▷ Comply with the operating data indicated in the data sheet.
▷ Never use the pump for handling fluids it is not designed for.
▷ Avoid prolonged operation against a closed shut-off element.
▷ Never operate the pump at temperatures, pressures or rotational speeds
exceeding those specified in the data sheet or on the name plate unless the
written consent of the manufacturer has been obtained.
6.2.1 Ambient temperature
CAUTION
Operation outside the permissible ambient temperature
Damage to the pump (set)!
▷ Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
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HPK
Table14: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum 40 °C
Minimum See data sheet.
6.2.2 Frequency of starts
DANGER
Excessive surface temperature of the motor
Explosion hazard!
Damage to the motor!
▷ In case of explosion-proof motors, observe the frequency of starts specified in
the manufacturer's product literature.
The frequency of starts is usually determined by the maximum temperature increase
of the motor. This largely depends on the power reserves of the motor in steadystate operation and on the starting conditions (DOL, star-delta, moments of inertia,
etc). If the starts are evenly spaced over the period indicated, the following limits
serve as orientation for start-up with the discharge-side gate valve slightly open:
Table15: Frequency of starts
Motor rating Maximum frequency of starts
[kW] [Starts/hour]
≤ 12 15
≤ 100 10
> 100 5
CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
▷ Do not re-start the pump set before the pump rotor has come to a standstill.
6.2.3 Fluid handled
6.2.3.1 Flow rate
Unless specified otherwise in the characteristic curves or in the data sheets, the
following applies:
▪ Short-time operation: Q
min
5)
=0.1×Q
opt
6)
▪ Continuous operation: Q
min
5)
=0.3×Q
opt
6)
▪ 4-pole operation: Q
max
7)
=1.25×Q
opt
6)
The data refer to water and water-like fluids. Longer operating periods with these
fluids and at the flow rates indicated will not cause an additional increase in the
temperatures on the pump surface. However, if the physical properties of the fluids
handled differ from those of water, the calculation formula below must be used to
check if an additional heat build-up may lead to a dangerous temperature increase at
the pump surface. If necessary, the minimum flow must be increased.
5) Minimum permissible flow rate
6) Flow rate at best efficiency point
7) Maximum permissible flow rate
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×
×
×
Table16: Key
Symbol Description Unit
c Specific heat capacity J/kg K
g Gravitational constant m/s²
H Pump discharge head m
T
f
Fluid temperature °C
T
O
Temperature at the casing surface °C
Pump efficiency at duty point -
Temperature difference K
6.2.3.2 Density of the fluid handled
The pump input power changes in proportion to the density of the fluid handled.
CAUTION
Impermissibly high density of the fluid handled
Motor overload!
▷ Observe the information on fluid density in the data sheet.
▷ Make sure the motor has sufficient power reserves.
6.2.3.3 Abrasive fluids
Do not exceed the maximum permissible solids content specified in the data sheet.
When the pump handles fluids containing abrasive substances, increased wear of the
hydraulic system and shaft seal are to be expected. In this case, reduce the commonly
recommended inspection intervals.
6.3 Commissioning/start-up
6.3.1 Prerequisites for commissioning/start-up
Before commissioning/starting up the pump set, make sure that the following
conditions are met:
▪ The pump set has been mechanically connected as specified.
▪ The pump set has been properly connected to the power supply and is equipped
with all protection devices. (ðSection5.8,Page31)
▪ The pump has been primed with the fluid to be handled. The pump has been
vented. (ðSection6.3.4,Page39)
▪ The direction of rotation has been checked. (ðSection5.9,Page33)
▪ All auxiliary connections required are connected and operational.
▪ The lubricants have been checked.
▪ After prolonged shutdown of the pump (set), the activities required for returning
the pump (set) to service have been carried out. (ðSection6.4,Page44)
6.3.2 Filling in lubricants
Fill the bearing bracket with lubricating oil.
Oil quality see (ðSection7.2.3.1.2,Page49)
Oil quantity see (ðSection7.2.3.1.3,Page49)
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Filling the constant level oiler with lubricating oil (oil-lubricated bearings only)
ü The constant level oiler has been fitted.
NOTE
If no constant level oiler is provided on the bearing bracket, the oil level can be
read in the middle of the oil level sight glass arranged at the side of the bearing
bracket.
CAUTION
Insufficient quantity of lubricating oil in the reservoir of the constant level oiler
Damage to the bearings!
▷ Regularly check the oil level.
▷ Always fill the oil reservoir completely.
▷ Keep the oil reservoir properly filled at all times.
1
2
3 4 5
Fig.13: Bearing bracket with constant level oiler
1 Constant level oiler 2 Vent plug
3 Connection elbow of the constant level
oiler
4 Screw plug
5 Bearing bracket
1. Pull out the vent plug (2).
2. Hinge down the reservoir of the constant level oiler (1) from the bearing
bracket (5) and hold it in this position.
3. Fill in oil through the hole for the vent plug until the oil reaches the connection
elbow of the constant level oiler (3).
4. Completely fill the reservoir of the constant level oiler (1).
5. Snap the constant level oiler (1) back into its operating position.
6. Fit the vent plug (2) again.
7. After approximately 5 minutes, check the oil level in the glass reservoir of the
constant level oiler (1).
The oil reservoir must be properly filled at all times to ensure that the correct oil
level is maintained. Repeat steps 1 - 6, if necessary.
8. To check the function of the constant level oiler (1), slowly drain some oil via the
screw plug (4) until air bubbles can be seen in the oil reservoir.
NOTE
An excessively high oil level can lead to a temperature rise and to leakage of the
fluid handled or oil.
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6.3.3 Shaft seal
Shaft seals are fitted prior to delivery.
Observe the instructions on dismantling (ðSection7.4.6,Page52) or assembly
(ðSection7.5.3,Page56) .
Reservoir of non-pressurised
external fluid
If applicable, fill the reservoir of non-pressurised external fluid in accordance with
the general arrangement drawing.
Double mechanical seal
Prior to starting up the pump, apply barrier pressure as specified in the general
arrangement drawing.
External liquid feed
Apply the quantities and pressures specified in the data sheet and the general
arrangement drawing.
Mechanical seal designs and types other than specified herein shall only be used in
exceptional cases and only after prior consultation with the manufacturer.
6.3.3.1 Mechanical seal for hot water
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 with external circulation
▪ Mechanical seal with air-cooled heat exchanger
6.3.3.2 Mechanical seal for thermal oil
DANGER
Improper sealing!
Severe burns! Damage to the environment!
▷ Use only mechanical seals for sealing off thermal oil > 100 °C.
DANGER
Quench supply
Serious injury!
▷ Only operate quench supply systems outdoors, far away from persons and
potential sources of ignition.
CAUTION
Contamination, deposits of cracked products and carbon residues on the seal
faces
Damage to the mechanical seal!
▷ Mechanical seal must only be operated with quench supply.
To prevent deposits of cracked products and carbon residues (from carbonised oil) on
the seal faces, use only mechanical seal systems designed to prevent contact between
oxygen and the mechanical seal faces.
The following seal designs are used for thermal oil applications:
▪ Single-acting mechanical seal with steam/nitrogen quench
If steam quench is used, the steam quench feed rate must be adjusted so that
only a small plume of steam escapes between the shaft protecting sleeve and the
throttling bush.
– Quench medium: steam (max. 160 °C) or nitrogen
– Required feed rate: approx. 1 kg/hour
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– Required pressure: 0.1 bar max. (observe any additional information given in
the general arrangement drawing!)
▪ Mechanical seal in tandem arrangement with quench liquid
In mechanical seal systems in tandem arrangement the outboard mechanical seal
serves as safety back-up seal designed to provide temporary sealing if the
inboard seal fails.
The mechanical seal system must be supplied with a quench liquid (typically cold
thermal oil) in order to dissipate the friction heat generated at the seal faces of
the outboard mechanical seal and to prevent the seal faces of the inboard
mechanical seal from coming into contact with atmospheric oxygen. This is
usually assured by means of a quench pot.
Quench pot installation and operating mode see supplementary sheet.
6.3.4 Priming and venting the pump
DANGER
Risk of potentially explosive atmosphere by mixing of incompatible fluids in the
auxiliary piping
Risk of burns!
Explosion hazard!
▷ Make sure that the barrier fluid or quench liquid are compatible with the fluid
handled.
DANGER
Risk of potentially explosive atmosphere inside the pump
Explosion hazard!
▷ The pump internals in contact with the fluid to be handled, including the seal
chamber and auxiliary systems must be filled with the fluid to be handled at all
times.
▷ Provide sufficient inlet pressure.
▷ Provide an appropriate monitoring system.
DANGER
Shaft seal failure caused by insufficient lubrication
Hot or toxic fluid could escape!
Damage to the pump!
▷ Before starting up the pump set, vent the pump and suction line and prime
both with the fluid to be handled.
1. Vent the pump and suction line and prime both with the fluid to be handled.
2. Fully open the shut-off element in the suction line.
3. Fully open all auxiliary connections (barrier fluid, flushing liquid, etc).
6.3.5 Water cooling
CAUTION
Deposit-forming, aggressive cooling water
Damage to the pump!
▷ Observe the cooling water quality.
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Observe the following quality data of the cooling water:
▪ Not deposit forming
▪ Not aggressive
▪ Free from suspended solids
▪ Hardness on average 5 °dH (~1 mmol/l)
▪ pH > 8
▪ Conditioned and neutral with regard to mechanical corrosion
▪ Inlet temperature tE = 10 to 30 °C
8)
Outlet temperature tA= maximum 45 °C
8)
The cooling liquid quantities indicated are based on Δt = 15 °C (max.).
In the case of deviations, the cooling liquid requirement changes in direct proportion
to the change in the temperature difference.
Q
cooling water
for Δtx = Q
cooling water
x (15 : Δtx)
6.3.6 Cooling of the shaft seal ("K" design)
CAUTION
Vaporisation pressure of fluid handled higher than atmospheric pressure
Damage to the shaft seal/pump!
▷ Cool the shaft seal.
▷ Provide sufficient quantities of cooling liquid (see table).
NOTE
The vaporisation pressure varies depending on the fluid handled, the system
pressure and the material of the shaft seal (e.g. hot water).
Observe the following data for the cooling liquid:
▪ Max. permissible cooling liquid pressure: 10 bar
▪ Cooling liquid quantities: (see table below)
Table17: Cooling liquid quantity depending on the bearing bracket
Bearing bracket Temperature of the fluid handled
up to 250
℃
up to 400
℃
P08s 8 10
P10as 8 10
P12s 8 10
6.3.7 Bearing bracket cooling
When installing the cooled bearing bracket, make sure the following values are met:
▪ Cooling liquid quantity: approx. 3.3 l/min
▪ Cooling liquid pressure: 10 bar
6.3.8 Cooling of the heat exchanger
In "BR" operating mode the heat exchanger must be cooled.
8) Higher temperatures may be permitted for systems using treated cooling water
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Table18: Cooling of the heat exchanger
Bearing bracket Cooling liquid quantity [l/min]
n = 1450 rpm
P08s 10
P10as 10
P12s 10
6.3.9 Heating up/keeping warm the pump (set)
CAUTION
Pump blockage
Damage to the pump!
▷ Prior to pump start-up, heat up the pump as described in the manual.
Observe the following when heating up the pump (set) and keeping it warm:
▪ Make sure that the temperature is increased continuously.
▪ Max. heating speed: 10 °C/min (10 K/min)
Fluid temperatures above
150°C
When the pump is used for handling fluids at temperatures above 150°C make sure
that the pump has been heated throughout before starting it up.
Temperature difference
The temperature difference between the pump's surface and the fluid handled must
not exceed 100 °C (100 K) when the pump is started up.
6.3.10 Final check
1. Remove the coupling guard and its footboard, if any.
2. Check the coupling alignment; re-align the coupling, if required.
(ðSection5.6,Page29)
3. Check proper functioning of coupling/shaft.
Check that coupling/shaft can be easily rotated by hand.
4. Fit the coupling guard and its footboard, if any.
5. Check the distance between coupling and coupling guard.
The coupling guard must not touch the coupling.
6.3.11 Start-up
DANGER
Non-compliance with the permissible pressure and temperature limits if the pump
is operated with the suction and/or discharge line closed.
Explosion hazard!
Hot or toxic fluids escaping!
▷ Never operate the pump with the shut-off elements in the suction line and/or
discharge line closed.
▷ Only start up the pump set with the discharge-side shut-off element slightly or
fully open.
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DANGER
Excessive temperatures due to dry running or excessive gas content in the fluid
handled
Explosion hazard!
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Prime the pump as per operating instructions. (ðSection6.3.4,Page39)
▷ Always operate the pump within the permissible operating range.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
▷ Switch off the pump (set) immediately.
▷ Eliminate the causes before returning the pump set to service.
ü The system piping has been cleaned.
ü The pump, suction line and, if applicable, inlet tank have been vented and
primed with the fluid to be handled.
ü The lines for priming and venting have been closed.
CAUTION
Start-up against open discharge line
Motor overload!
▷ Make sure the motor has sufficient power reserves.
▷ Use a soft starter.
▷ Use speed control.
1. Fully open the shut-off element in the suction head/suction lift line.
2. Close or slightly open the shut-off element in the discharge line.
3. Start up the motor.
4. Immediately after the pump has reached full rotational speed, slowly open the
shut-off element in the discharge line and adjust it to comply with the duty
point.
CAUTION
Misalignment of pump and coupling
Damage to pump, motor and coupling!
▷ When the operating temperature has been reached, switch off the pump set
and check the coupling alignment.
5. Check the coupling alignment and re-align the coupling, if required.
6.3.12 Checking the shaft seal
Mechanical seal
The mechanical seal only leaks slightly or invisibly (as vapour) during operation.
Mechanical seals are maintenance-free.
NOTE
When new plants are commissioned and a large amount of foreign matter is in the
system, short service lives of the mechanical seals are to be expected during the
initial phase of plant operation.
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Gland packing
The gland packing must drip slightly during operation.
DANGER
Impermissibly high temperatures at gland packings
Explosion hazard!
▷ Always use suitable temperature monitoring for gland packings.
▷ Gland packing must be tightened correctly.
Pure graphite packing
If a pure graphite packing is used, there must always be some leakage.
Table19: Leakage rate of the pure graphite packing
Quantity Values
Minimum 10 cm³/min
Maximum 20 cm³/min
Adjusting the leakage
Prior to commissioning
1. Only lightly tighten the nuts of the gland follower by hand.
2. Use a feeler gauge to verify that the gland follower is mounted centred and at a
right angle to the shaft.
ð The gland must leak after the pump has been primed.
After five minutes of operation
WARNING
Unprotected rotating parts
Risk of personal injury!
▷ Do not touch rotating parts.
▷ When the pump is running, perform any work with utmost caution.
The leakage can be reduced.
1. Tighten the nuts on the gland follower by 1/6 turn.
2. Monitor the leakage for another five minutes.
Excessive leakage:
Repeat steps 1 and 2 until the minimum value has been reached.
Not enough leakage:
Slightly loosen the nuts at the gland follower.
No leakage:
Immediately switch off pump set!
Loosen the gland follower and repeat commissioning.
Checking the leakage
After the leakage has been adjusted, monitor the leakage for about two hours at
maximum fluid temperature.
Check that enough leakage occurs at the gland packing at minimum fluid pressure.
6.3.13 Shutdown
ü The shut-off element in the suction line is and remains open.
ü On pump sets with double mechanical seal, apply the required pressure specified
in the general arrangement drawing to the mechanical seal chamber also during
standstill.
ü Also ensure quench liquid supply is ON during pump standstill.
1. Close the shut-off element in the discharge line.
2. Switch off the motor and make sure the pump set runs down smoothly to a
standstill.
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NOTE
If the discharge line is equipped with a check valve, the shut-off element in the
discharge line may remain open, provided the site's requirements and regulations
are taken into account and observed.
NOTE
If shut-off is not possible, the pump will run in reverse direction.
The reverse runaway speed must be lower than the rated speed.
For prolonged shutdown periods:
1. Close the shut-off element in the suction line.
2. Close the auxiliary connections.
If the fluid to be handled is fed in under vacuum, also supply the shaft seal with
barrier fluid during standstill.
Only turn off the cooling liquid supply after the pump has cooled down.
CAUTION
Risk of freezing during prolonged pump shutdown periods
Damage to the pump!
▷ Drain the pump and the cooling/heating chambers (if any) or otherwise protect
them against freezing.
6.4 Returning to service
For returning the equipment to service, observe the sections on commissioning/startup (ðSection6.3,Page36) and the operating limits. (ðSection6.2,Page34)
In addition, carry out all servicing/maintenance operations before returning the
pump (set) to service. (ðSection7,Page45)
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
▷ As soon as the work is complete, re-install and/or re-activate any safety-relevant
and protective devices.
NOTE
If the pump has been out of service for more than one year, replace all elastomer
seals.
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7 Servicing/Maintenance
7.1 Safety regulations
DANGER
Sparks produced during servicing work
Explosion hazard!
▷ Observe the safety regulations in force at the place of installation!
▷ Always perform maintenance work at an explosion-proof pump (set) outside of
potentially explosive atmospheres.
DANGER
Improperly serviced pump set
Explosion hazard!
Damage to the pump set!
▷ Service the pump set regularly.
▷ Prepare a maintenance schedule with special emphasis on lubricants, shaft seal
and coupling.
The operator ensures that maintenance, inspection and installation is performed by
authorised, qualified specialist personnel who are thoroughly familiar with the
manual.
DANGER
Improper cleaning of coated pump surfaces
Explosion hazard by electrostatic discharge!
▷ When cleaning coated pump surfaces in atmospheres of Explosion groupIIC,
use suitable anti-static equipment.
WARNING
Unintentional starting of the pump set
Risk of injury by moving components and shock currents!
▷ Ensure that the pump set cannot be switched on unintentionally.
▷ Always make sure the electrical connections are disconnected before carrying
out work on the pump set.
WARNING
Fluids, consumables and supplies which are hot and/or pose a health hazard
Risk of injury!
▷ Observe all relevant laws.
▷ When draining the fluid take appropriate measures to protect persons and the
environment.
▷ Decontaminate pumps which handle fluids posing a health hazard.
WARNING
Insufficient stability
Risk of crushing hands and feet!
▷ During assembly/dismantling, secure the pump (set)/pump parts to prevent
tilting or tipping over.
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A regular maintenance schedule will help avoid expensive repairs and contribute to
trouble-free, reliable operation of the pump, pump set and pump parts with a
minimum of servicing/maintenance expenditure and work.
NOTE
All maintenance, service and installation work can be carried out by KSB Service or
authorised workshops. For contact details please refer to the enclosed "Addresses"
booklet or visit "www.ksb.com/contact" on the Internet.
Never use force when dismantling and reassembling the pump set.
7.2 Servicing/inspection
7.2.1 Supervision of operation
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing
seals
Explosion hazard!
Fire hazard!
Damage to the pump set!
Risk of burns!
▷ Regularly check the lubricant level.
▷ Regularly check the rolling element bearings for running noises.
DANGER
Incorrectly serviced shaft seal
Explosion hazard!
Hot, toxic fluid escaping!
Damage to the pump set!
Risk of burns!
Fire hazard!
▷ Regularly service the shaft seal.
DANGER
Incorrectly serviced barrier fluid system
Explosion hazard!
Fire hazard!
Damage to the pump set!
Hot and/or toxic fluids escaping!
▷ Regularly service the barrier fluid system.
▷ Monitor the barrier fluid pressure.
CAUTION
Increased wear due to dry running
Damage to the pump set!
▷ Never operate the pump set without liquid fill.
▷ Never close the shut-off element in the suction line and/or supply line during
pump operation.
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CAUTION
Impermissibly high temperature of fluid handled
Damage to the pump!
▷ Prolonged operation against a closed shut-off element is not permitted
(heating up of the fluid).
▷ Observe the temperature limits in the data sheet and in the section on
operating limits. (ðSection6.2,Page34)
While the pump is in operation, observe and check the following:
▪ The pump must run quietly and free from vibrations at all times.
▪ In case of oil lubrication, ensure the oil level is correct.
▪ Check the shaft seal. (ðSection6.3.12,Page42)
▪ Check the static sealing elements for leakage.
▪ Check the rolling element bearings for running noises.
Vibrations, noise and an increase in current input occurring during unchanged
operating conditions indicate wear.
▪ Monitor the correct functioning of any auxiliary connections.
▪ Cooling system
Take the pump out of service at least once a year to thoroughly clean the cooling
system.
▪ Monitor the stand-by pump.
To make sure that stand-by pumps are ready for operation, start them up once a
week.
▪ Monitor the bearing temperature.
The bearing temperature must not exceed 90 °C (measured on the outside of the
bearing bracket).
CAUTION
Operation outside the permissible bearing temperature
Damage to the pump!
▷ The bearing temperature of the pump (set) must never exceed 90 °C (measured
on the outside of the bearing bracket).
7.2.2 Inspection work
DANGER
Excessive temperatures caused by friction, impact or frictional sparks
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Regularly check the coupling guard, plastic components and other guards of
rotating parts for deformation and sufficient distance from rotating parts.
7.2.2.1 Checking the coupling
Check the flexible elements of the coupling. Replace the relevant parts in due time if
there is any sign of wear and check the alignment.
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7.2.2.2 Checking the clearances
To check the clearance gaps, remove the back pull-out unit.
(ðSection7.4.4,Page51)
If the clearance gap is larger than permitted (see the following table), replace casing
wear ring 502.1/502.2 with a new one.
The clearance gaps given refer to the diameter.
Table20: Clearance gaps between impeller and casing/between impeller and casing
wear ring
Sizes
150-630 0.7 + 0.1 mm
200-670 0.7 + 0.1 mm
250-630
250-710
0.85 + 0.1 mm
0.7 + 0.1 mm
300-630
300-710
0.85 + 0.1 mm
350-630
350-710
0.85 + 0.1 mm
400-504
400-506
400-630
400-710
0.85 + 0.1 mm
For temperatures exceeding 250 °C, contact KSB.
NOTE
If the clearances given are exceeded by more than 1 mm (referring to the diameter)
replace the affected components or restore the original clearance by means of a
casing wear ring.
Contact KSB.
7.2.2.3 Cleaning filters
CAUTION
Insufficient inlet pressure due to clogged filter in the suction line
Damage to the pump!
▷ Monitor contamination of filter with suitable means (e.g. differential pressure
gauge).
▷ Clean filter at appropriate intervals.
7.2.3 Lubrication and lubricant change of rolling element bearings
DANGER
Excessive temperatures as a result of bearings running hot or defective bearing
seals
Explosion hazard!
Fire hazard!
Damage to the pump set!
▷ Regularly check the condition of the lubricant.
7.2.3.1 Oil lubrication
The rolling element bearings are usually lubricated with mineral oil.
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7.2.3.1.1 Intervals
Table21: Oil change intervals
Temperature at the
bearing
First oil change All subsequent oil
changes
9)
up to 70 ℃ After 300 operating hours Every 8500 operating hours
70 °C - 80 °C After 300 operating hours Every 4200 operating hours
80 °C - 90 °C After 300 operating hours Every 2000 operating hours
7.2.3.1.2 Oil quality
Table22: Oil quality
Designation Symbol to DIN
51502
Features
CLP46 lubricating oil
to DIN 51517-3
or
HD 20W/20 SAE
□ Kinematic viscosity
at40 °C
46±4 mm²/s
Flash point
(to Cleveland)
+175 °C
Solidification point
(pour point)
-15 °C
Application
temperature
10)
Higher than
permissible bearing
temperature
7.2.3.1.3 Oil quantity
Table23: Oil quantity
Bearing bracket Oil quantity in l
P08s 4.5
P10as 4.0
P12s 4.0
7.2.3.1.4 Changing the oil
WARNING
Lubricants posing a health hazard and/or hot lubricants
Hazard to persons and the environment!
▷ When draining the lubricant take appropriate measures to protect persons and
the environment.
▷ Wear safety clothing and a protective mask, if required.
▷ Collect and dispose of any lubricants.
▷ Observe all legal regulations on the disposal of fluids posing a health hazard.
9) At least once a year
10) For ambient temperatures below -10 °C use a different suitable type of lubricating oil. Contact KSB.
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1 2 3
Fig.14: Bearing bracket with constant level oiler
1 Constant level oiler 2 Screw plug
3 Bearing bracket
ü A suitable container for the used oil is on hand.
1. Place the container underneath the screw plug.
2. Undo the screw plug (2) at the bearing bracket (3) and drain the oil.
3. Once the bearing bracket (3) has been drained, re-insert and re-tighten the
screw plug (2).
4. Re-fill with oil.
7.3 Drainage/cleaning
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.
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 be neutralised, and anhydrous inert gas must be blown through the
pump to ensure drying.
Use connection 6B to drain the fluid handled (see drawing of auxiliary connections).
7.4 Dismantling the pump set
7.4.1 General information/Safety regulations
WARNING
Unqualified personnel performing work on the pump (set)
Risk of injury!
▷ Always have repair and maintenance work performed by specially trained,
qualified personnel.
WARNING
Hot surface
Risk of injury!
▷ Allow the pump set to cool down to ambient temperature.
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WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
Observe the general safety instructions and information. (ðSection7,Page45)
For any work on the motor, observe the instructions of the relevant motor
manufacturer.
For dismantling and reassembly refer to the general assembly drawing.
(ðSection9.1,Page65)
In the event of damage you can always contact our service staff.
DANGER
Insufficient preparation of work on the pump (set)
Risk of injury!
▷ Properly shut down the pump set. (ðSection6.3.13,Page43)
▷ Close the shut-off elements in suction and discharge line.
▷ Drain the pump and release the pump pressure. (ðSection7.3,Page50)
▷ Close any auxiliary connections.
▷ Allow the pump set to cool down to ambient temperature.
7.4.2 Preparing the pump set
1. De-energise the pump set and secure it against unintentional start-up.
2. Disconnect and remove all auxiliary pipework.
3. Remove the coupling guard.
4. Remove the coupling spacer, if any.
5. Drain the oil. (ðSection7.2.3.1.4,Page49)
7.4.3 Removing the motor
NOTE
On pump sets with spacer-type couplings, the back pull-out unit can be removed
while the motor remains bolted to the baseplate.
WARNING
Motor tilting
Risk of crushing hands and feet!
▷ Suspend or support the motor to prevent it from tipping over.
1. Disconnect the motor from the power supply.
2. Unbolt the motor from the baseplate.
3. Shift the motor to separate it from the pump.
7.4.4 Removing the back pull-out unit
ü Pumps without spacer-type coupling: the motor has been removed.
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WARNING
Back pull-out unit tilting
Risk of crushing hands and feet!
▷ Suspend or support the bearing bracket at the pump end.
1. If required, suspend or support bearing bracket 330 to prevent it from tipping
over.
2. Unbolt support foot 183 from the baseplate.
3. Undo hexagon nut 920.01 at the volute casing.
4. Pull the back pull-out unit out of the volute casing.
5. Remove and dispose of joint ring 411.10.
6. Place the back pull-out unit on a clean and level surface.
7.4.5 Removing the impeller
Bearing assembly P08s
ü The notes and steps stated in (ðSection7.4.1,Page50) to
(ðSection7.4.4,Page51) have been observed/carried out.
ü The back pull-out unit is kept in a clean and level assembly area.
1. Undo impeller nut 922 (right-hand thread).
2. Remove impeller 230 with an impeller removal device.
3. Place impeller 230 on a clean and level surface.
4. Remove keys 940.1 from shaft 210.
5. Remove and dispose of joint rings 411.31/411.32.
Bearing assemblies P10as/P12s
ü The notes and steps stated in (ðSection7.4.1,Page50) to
(ðSection7.4.4,Page51) have been observed/carried out.
ü The back pull-out unit is kept in a clean and level assembly area.
1. Unscrew impeller hub cap 260.01 (right-hand thread).
2. Bend open lockwasher 931.02, remove hexagon head bolt 901.87 with
lockwasher 931.02 and disc 550.87.
3. Remove impeller 230 with an impeller removal device.
4. Place impeller 230 on a clean and level surface.
5. Remove keys 940.1 from shaft 210.
6. Remove and dispose of joint rings 411.31/411.32.
7.4.6 Removing the shaft seal
7.4.6.1 Removing the mechanical seal
ü The notes and steps stated in (ðSection7.4.1,Page50) to
(ðSection7.4.5,Page52) have been observed/carried out.
ü The back pull-out unit is kept in a clean and level assembly area.
1. Undo hexagon nuts 920.02 and push back seal cover 471 (if fitted) until it rests
against thrower 507.01.
2. Remove hexagon nut 920.03.
3. Use forcing screws 901.34 to remove stuffing box housing 451.01 from casing
cover 161.
4. Undo socket head cap screws 914.04, if any, and remove neck bush 456.01.
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5. Pull the complete mechanical seal assembly with shaft protecting sleeve 524.01,
seal cover 471.01 and thrower 507.01 off the shaft.
6. If required, unscrew socket head cap screws 914.09 and use forcing screws to
pull out angular casing wear ring 502.02.
7. Remove hexagon nuts 920.15.
8. Use forcing screws 901.31 to separate casing cover 161 from bearing bracket
lantern 344.
Lifting lugs can be screwed into the casing cover for transport.
7.4.6.2 Dismantling the packed gland
ü The notes and steps stated in (ðSection7.4.1,Page50) to
(ðSection7.4.5,Page52) have been observed/carried out.
ü The back pull-out unit is kept in a clean and level assembly area.
1. Unscrew hexagon nuts 920.02 at gland follower 452 and remove the gland
follower.
2. Remove stuffing box ring 454.01 and drip plate 463.01.
3. Remove hexagon nut 920.03.
4. Use forcing screws to remove stuffing box housing 451.01 with the packed
gland from casing cover 161.
5. Remove packed gland 461.01 and lantern ring 458.01 from the packing
chamber.
6. Undo socket head cap screws 914.04, if any, and remove neck bush 456.01.
7. If required, unscrew socket head cap screws 914.09 and use forcing screws to
pull out angular casing wear ring 502.02.
8. Remove hexagon nuts 920.15.
9. Use forcing screws 901.31 to separate casing cover 161 from bearing bracket
lantern 344.
Lifting lugs can be screwed into the casing cover for transport.
10. Pull off guard 680.
11. Pull shaft protecting sleeve 524.01 and thrower 507.01 off shaft 210.
7.4.7 Dismantling the bearings
ü The notes and steps stated in (ðSection7.4.1,Page50) to
(ðSection7.4.6,Page52) have been observed/carried out.
ü The bearing bracket has been placed in a clean and level assembly area.
1. Unscrew hexagon nuts 920.04 at the flange of bearing bracket lantern 344.
2. Remove bearing bracket lantern 344.
3. Unscrew the hexagon socket head cap screw in the coupling hub.
4. Pull the coupling half off the pump shaft with a puller.
5. Remove key 940.02 and thrower 507.02.
6. Undo screws 914.02 and remove drive-end bearing cover 360.02 and joint ring
400.02.
7. Undo screws 914.01 and remove pump-end bearing cover 360.01 and joint ring
400.01.
8. Carefully drive shaft 210 together with angular contact ball bearing 320.02 and
the inner race of cylindrical roller bearing 322.01 out of the bearing bracket
towards the drive end.
9. Remove support disc 550.23 of angular contact ball bearing 320.02 from bearing
bracket 330.
10. Remove cylindrical roller bearing 322.01 (roller cage) from bearing bracket 330.
11. Bend open lock washer 931.01 behind slotted round nut 920.21 on shaft 210.
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7 Servicing/Maintenance
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HPK
12. Unscrew slotted round nut 920.21 (right-hand thread) and remove lock washer
931.01.
WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
13. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
roller bearing 322.01 to80°C, and pull them off shaft 210.
14. Dispose of joint rings 400.01/.02.
7.5 Reassembling the pump set
7.5.1 General information/Safety regulations
WARNING
Improper lifting/moving of heavy assemblies or components
Personal injury and damage to property!
▷ Use suitable transport devices, lifting equipment and lifting tackle to move
heavy assemblies or components.
CAUTION
Improper reassembly
Damage to the pump!
▷ Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
▷ Use original spare parts only.
Sequence
Always reassemble the pump in accordance with the corresponding general assembly
drawing.
Sealing elements
▪ Gaskets
– Always use new gaskets, making sure that they have the same thickness as
the old ones.
– Always fit gaskets of asbestos-free materials or graphite without using
lubricants (e.g. copper grease, graphite paste).
▪ O-rings
– Never use O-rings that have been made by cutting an O-ring cord to size and
gluing the ends together.
▪ Packing rings
– Always use pre-compressed packing rings.
CAUTION
Contact of O-ring with graphite or similar material
Fluid could escape!
▷ Do not coat O-ring with graphite or similar material.
▷ Use animal fats or lubricants based on silicone or PTFE.
▪ Assembly adhesives
– For gaskets, avoid the use of assembly adhesives if possible.
Page 55
7 Servicing/Maintenance
55 of 72
HPK
– If assembly adhesives are required, use a commercially available contact
adhesive (e.g. "Pattex").
– Only apply adhesive at selected points and in thin layers.
– Never use quick-setting adhesives (cyanoacrylate adhesives).
– Coat the locating surfaces of the individual components and screwed
connections with graphite or similar before reassembly.
– Prior to reassembly, screw back any forcing screws and adjusting screws.
Tightening torques
For reassembly, tighten all screws and bolts as specified in this manual.
7.5.2 Installing the bearings
ü The individual parts have been placed in a clean and level assembly area.
ü All dismantled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
WARNING
Hot surfaces due to heating of components for assembly/dismantling
Risk of burns!
▷ Wear heat-resistant protective gloves.
▷ Remove flammable substances from the danger zone.
1. Heat up angular contact ball bearing 320.02 and the inner ring of cylindrical
roller bearing 322.01 to approx. 80°C in an oil bath.
2. Slide angular contact ball bearing 320.02 and the inner ring of cylindrical roller
bearing 322.01 onto shaft 210 until they will not go any further.
NOTE
Angular contact ball bearings must be installed in back-to-back arrangement.
Angular contact ball bearings installed in pairs must always be from the same
manufacturer.
3. Use a C-spanner to tighten slotted round nut 920.21 without lock washer
931.01.
4. Let angular contact ball bearing 320.01 cool down to approximately 5 °C above
ambient temperature.
5. Re-tighten slotted round nut 920.21, then unscrew it again.
6. Apply a few spots of a suitable lubricant (e.g. Molykote) to the contact faces of
lock washer 931.01 and slotted round nut 920.21.
7. Fit lock washer 931.01.
8. Tighten slotted round nut 920.21.
9. Bend back lock washer 931.01.
10. Insert circlip 932.01/932.02 into the bearing bracket.
11. Fit cylindrical roller bearing 322.01 (roller cage) in the bearing bracket.
12. Insert support disc 550.23 of angular contact ball bearing 320.02 into bearing
bracket 330.
13. Carefully insert pre-assembled shaft 210 with angular contact ball bearing
320.02 and the inner ring of cylindrical roller bearing 322.01 into bearing
bracket 330 from the drive end.
14. Fit pump-end bearing cover 360.01 with joint ring 400.01.
15. Fit drive-end bearing cover 360.02 with joint ring 400.02.
16. Fit bearing bracket lantern 344.
17. Tighten hexagon nut 920.04 at the flange of bearing bracket 330.
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7 Servicing/Maintenance
56 of 72
HPK
18. Fit keys 940.02.
19. Slide the coupling hub onto the shaft end.
20. Secure the coupling hub with an adjusting screw.
21. Fit thrower 507.01, if any.
7.5.3 Fitting the shaft seal
7.5.3.1 Installing the mechanical seal
The following rules must be observed when installing the mechanical seal:
▪ For installing the mechanical seal, proceed as shown in the seal installation
drawing.
▪ Work cleanly and accurately.
▪ Only remove the protective wrapping of the contact faces immediately before
installation takes place.
▪ Prevent any damage to the sealing surfaces or O-rings.
▪ After inserting the stationary ring of the mechanical seal, check that it is plane-
parallel in relation to the casing part.
▪ The surface of the shaft protecting sleeve must be absolutely clean and smooth,
and the sleeve's mounting edge must be chamfered.
▪ When sliding the rotating assembly onto the shaft protecting sleeve, take
appropriate steps to protect the surface of the shaft protecting sleeve from
damage.
ü The notes and steps stated in (ðSection7.5.1,Page54) to
(ðSection7.5.2,Page55) have been observed/carried out.
ü The bearing assembly and the individual parts of mechanical seal 433 are kept in
a clean and level assembly area.
ü All dismantled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
1. Slide thrower 507.01 (if any) onto shaft 210 from the pump end.
2. Fit stuffing box housing 451.01 with studs 902.03, hexagon nut 920.03 and
gasket 411.09 in casing cover 161.
3. Fasten seal cover 471 with inserted O-ring and the stationary ring of the
mechanical seal to stuffing box housing 451.01 with studs 902.02 and hexagon
nuts 920.02.
4. Fasten pre-assembled casing cover 161 with stud 902.15 and hexagon nut 920.15
to bearing bracket lantern 344.
5. Fit the rotating assembly of mechanical seal 433 on shaft protecting sleeve
524.01 (observe distance B - see Supplementary Sheet of the mechanical seal).
6. Slide pre-assembled mechanical seal 433 and shaft protecting sleeve 524.01 onto
shaft 210.
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7 Servicing/Maintenance
57 of 72
HPK
7.5.3.2 Packing the gland
a)
b)
l
d
a
UG1269690
d
i
d
a
UG1269740
d
i
l
Fig.15: Gland packing chamber a) uncooled and b) cooled, hot water
Stuffing box housing, uncooled
Table24: Gland packing chamber - uncooled variant
Bearing
bracket
Gland packing chamber Packing
cross-section
Packing rings
Ø d
i
Ø d
a
l
P08s 105 130 98 12,5 x 12,5 6 rings and
1 lantern
ring
P10as 120 152 130 16 x 16
P12s 140 172 130 16 x 16
Stuffing box housing, cooled,
hot water variant
Table25: Gland packing chamber - cooled variant, hot water
Bearing
bracket
Gland packing chamber Packing
cross-section
Packing rings
Ø d
i
Ø d
a
l
P08s 105 130 78 12,5 x 12,5 5 1/2 rings
P10as 120 152 105 16 x 16
P12s 140 172 105 16 x 16
Pure graphite packings see supplementary operating instructions.
Always use pre-compressed packing rings.
ü The notes and steps stated in (ðSection7.5.1,Page54) to
(ðSection7.5.2,Page55) have been observed/carried out.
ü The assembled bearing as well as the individual parts are kept in a clean and
level assembly area.
ü All disassembled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
1. Fasten pre-assembled casing cover 161 with stud 902.15 and hexagon nut 920.15
to bearing bracket lantern 344.
2. Clamp stuffing box housing 451.01 into a vice.
Fit neck bush 456.01, if any, with socket head cap screw 914.04.
3. Insert the first packing ring, ensuring that its cut edge is in horizontal position.
4. Hold the packing ring in place and slide shaft protecting sleeve 524 (chamfered
side first) into the gland packing chamber from the pump end.
5. Slightly expand the inside diameter of the packing ring by moving the shaft
protecting sleeve back and forth. Then pull out shaft protecting sleeve 524.
Insert lantern ring 458, if any (see drawing above).
Insert each subsequent packing ring separately with its joint offset by approx.
90° in relation to the previous one. Repeat the expansion procedure.
After inserting the last packing ring, shaft protecting sleeve 524 remains in the
packing chamber.
6. Insert stuffing box ring 454.01 with the drilled hole down.
7. Fit gland follower 452 and lightly fasten it by hand with the two hexagon nuts
920.02; watch discs 550.01.
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7 Servicing/Maintenance
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HPK
8. Fit guard 680.
9. Slide pre-assembled stuffing box housing 451.01 and shaft protecting sleeve
524.01 on the shaft and screw them to casing cover 161; take care not to
damage gasket 411.09.
7.5.4 Fitting the impeller
Bearing assembly P08s:
ü The notes and steps stated in (ðSection7.5.1,Page54) to
(ðSection7.5.3,Page56) have been observed/carried out.
ü The assembled bearing/mechanical seal as well as the individual parts are kept in
a clean and level assembly area.
ü All disassembled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
ü Impeller bore, shaft and keyways are clean and free from burrs.
1. Insert keys 940.01 into the shaft keyway.
2. Insert joint ring 411.32.
3. Coat the impeller seat with a suitable lubricant.
4. Slip impeller 230 onto shaft 210.
5. Insert joint ring 411.31.
6. Screw impeller nut 922 to shaft 210.
Observe the tightening torques (ðSection7.6.1,Page59)
Bearing assemblies P10as/P12s:
ü The notes and steps stated in (ðSection7.5.1,Page54) to
(ðSection7.5.3,Page56) have been observed/carried out.
ü The assembled bearing/mechanical seal as well as the individual parts are kept in
a clean and level assembly area.
ü All disassembled parts have been cleaned and checked for wear.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
ü Impeller bore, shaft and keyways are clean and free from burrs.
1. Insert keys 940.01 into the shaft keyway.
2. Insert joint ring 411.32.
3. Coat the impeller seat with a suitable lubricant.
4. Slip impeller 230 onto shaft 210.
5. Insert disc 550.87 into the impeller.
6. Fit hexagon head bolt 901.87 with lockwasher 931.02.
Observe the tightening torques (ðSection7.6.1,Page59)
7. Bend back lockwasher 931.02.
8. Fit impeller hub cap 260.01 with joint ring 412.03 on impeller 230.
Page 59
7 Servicing/Maintenance
59 of 72
HPK
7.5.5 Fitting the back pull-out unit
WARNING
Back pull-out unit tilting
Risk of crushing hands and feet!
▷ Suspend or support the bearing bracket at the pump end.
ü The notes and steps stated in (ðSection7.5.1,Page54) to
(ðSection7.5.4,Page58) have been observed/carried out.
ü Any damaged or worn parts have been replaced by original spare parts.
ü The sealing surfaces have been cleaned.
ü For back pull-out units supplied without coupling: Fit the coupling in accordance
with the manufacturer's instructions.
1. If required, suspend or support the back pull-out unit to prevent it from tipping
over. Then slide it into volute casing 102 with a new gasket 411.10.
2. Tighten nut 920.01 at the volute casing.
3. Bolt support foot 183 to the baseplate.
7.5.6 Mounting the motor
NOTE
Steps 1 and 2 do not apply to versions with spacer-type coupling.
1. Shift the motor to connect it to the pump via the coupling.
2. Fasten the motor to the baseplate.
3. Align pump and motor.
4. Connect the motor to the power supply (refer to manufacturer's product
literature).
7.6 Tightening torques
7.6.1 Tightening torques
Use a torque wrench to tighten the screwed connections (902.01/920.01) between the
volute casing and the bearing bracket lantern.
11) Treat unstamped screwed connections like material pair C35/E+QT/C 35.
12) These values are determined on the basis of a friction coefficient of μ = 0.12.
13) After repeated tightening of the threads and in case of good lubrication the values shall be reduced by 15 to 20 %.
Page 60
7 Servicing/Maintenance
60 of 72
HPK
Table26: Tightening torques for screwed connections
Material
stud/
hexagon
nut
1.7709+QT / 1.7258+QT Monix3k / Monix3k A4-70 / A4-70
Stamp on
stud/
hexagon
nut
11)
GA / G MM / MM (M3k) A4-70 / A4-70
Tightening torques [Nm]
Brand-new
threads
12)
-15 %
13)
-20 %
13)
Brand-new
threads
12)
-15 %
13)
-20 %
13)
Brand-new
threads
12)
-15 %
13)
-20 %
13)
M 16 190 162 152 320 272 256 155 132 124
M 20 330 281 264 620 527 496 200 170 160
M 24 570 485 456 900 765 720 270 230 215
M 30 1000 850 800 1200 1020 960 550 468 440
7.6.2 Tightening torques impeller nut/screw
Bearing bracket P08s
Tighten the impeller nut to the following torques:
Bearing bracket Tightening torque [Nm] Wrench size [mm]
P08as 1000 60
Re-tighten the impeller nut some 20 to 30 minutes after assembly.
Bearing brackets P10as and
P12s
Tighten hexagon head bolt 901.87 to the following torques:
Bearing bracket Tightening torque (Nm) Hexagon head bolt 901.87
P10as 350 M 24
P12s 350 M 24
7.7 Spare parts stock
7.7.1 Ordering spare parts
Always quote the following data when ordering replacement or spare parts:
▪ Order number
▪ Order item number
▪ Type series
▪ Size
▪ Material variant
▪ Year of construction
Refer to the name plate for all data.
Also specify the following data:
▪ Part number and description
▪ Quantity of spare parts
▪ Shipping address
▪ Mode of dispatch (freight, mail, express freight, air freight)
Page 61
7 Servicing/Maintenance
61 of 72
HPK
7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296
Table27: Quantity of spare parts for recommended spare parts stock
Part No. Part description Number of pumps (including stand-by pumps)
2 3 4 5 6 and 7 8 and 9 10 and
more
210 Shaft 1 1 1 2 2 2 20 %
230 Impeller 1 1 1 2 2 2 20 %
320.02 Angular contact ball
bearing (set)
1 1 2 2 2 3 25 %
322.01 Cylindrical roller bearing 1 1 2 2 2 3 25 %
502.01/02 Casing wear ring 4 4 6 6 2 3 30 %
503.01/02 Impeller wear ring
524.01 Shaft protecting sleeve 2 2 2 3 3 4 50 %
- Gaskets for pump casing
(set)
4 6 8 8 9 12 150 %
- Torque-transmitting
coupling elements (set)
1 1 2 2 3 4 30 %
Variants with mechanical seal:
433 Mechanical seal, complete 1 1 2 2 2 3 25 %
Variants with gland packing:
461.01 Gland packing (set) 4 4 6 6 6 8 100 %
456.01 Neck bush 1 1 2 2 2 3 30 %
7.7.3 Interchangeability of pump components
Components featuring the same number in a column are interchangeable.
NOTE
Volute casing 102 and impeller 230 are not interchangeable between different
pump sizes.
Table28: Interchangeability of pump components
Bearing bracket
Size
Description
Casing cover
Support foot
Shaft
Impeller hub cap
Angular contact ball bearing
Cylindrical roller bearing
Bearing bracket
Bearing bracket lantern
Mechanical seal
Stuffing box housing
Seal cover
Casing wear ring
Casing wear ring
Thrower
Shaft protecting sleeve
Guard
Impeller screw
Impeller nut
Part No.
161
183
210
260.01
320.02
322.01
330
344
433
451.01
471.01
502.01
502.02
507.01
524.01
680
901.87
922
P08s 150-630 1 1 1 - 1 1 1 1 1 1 1 1 2 1 1 1 - 1
200-670 2 1 1 - 1 1 1 2 1 1 1 2 2 1 1 1 - 1
P10as 250-630 3 2 2 1 2 2 2 2 2 2 2 3 4 2 2 - 1 -
300-630 3 3 2 1 2 2 2 2 2 2 2 5 5 2 2 - 1 -
400-504 4 4 2 1 2 2 2 1 2 2 2 6 6 2 2 - 1 -
400-506 5 4 2 1 2 2 2 1 2 2 2 7 7 2 2 - 1 -
250-710 6 3 2 1 2 2 2 2 2 2 2 8 9 2 2 - 1 -
Page 62
7 Servicing/Maintenance
62 of 72
HPK
Bearing bracket
Size
Description
Casing cover
Support foot
Shaft
Impeller hub cap
Angular contact ball bearing
Cylindrical roller bearing
Bearing bracket
Bearing bracket lantern
Mechanical seal
Stuffing box housing
Seal cover
Casing wear ring
Casing wear ring
Thrower
Shaft protecting sleeve
Guard
Impeller screw
Impeller nut
Part No.
161
183
210
260.01
320.02
322.01
330
344
433
451.01
471.01
502.01
502.02
507.01
524.01
680
901.87
922
300-710 6 3 2 1 2 2 2 2 2 2 2 10 10 2 2 - 1 -
P12s 350-630 7 5 3 2 2 2 2 2 3 3 3 11 11 3 3 - 1 -
400-630 7 5 3 2 2 2 2 2 3 3 3 12 12 3 3 - 1 -
350-710 8 5 3 2 2 2 2 2 3 3 3 11 11 3 3 - 1 -
400-710 8 4 3 2 2 2 2 2 3 3 3 12 12 3 3 - 1 -
Page 63
8 Trouble-shooting
63 of 72
HPK
8 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work to remedy faults observe the relevant information in this
operating manual and/or in the relevant accessory manufacturer's
documentation.
If problems occur that are not described in the following table, consultation with the
KSB customer service is required.
A
Pump delivers insufficient flow rate
B
Motor is overloaded
C
Excessive discharge pressure
D
Increased bearing temperature
E
Leakage at the pump
F
Excessive leakage at the shaft seal
G
Vibrations during pump operation
H
Impermissible temperature increase in the pump
Table29: Trouble-shooting
A B C D E F G H Possible cause Remedy
14)
✘ - - - - - - - Pump delivers against an excessively
high pressure.
Re-adjust to duty point.
Check system for impurities.
Fit a larger impeller.
15)
Increase the speed (turbine, I.C. engine).
✘ - - - - - ✘ ✘ Pump or piping are not completely
vented or primed.
Vent and/or prime.
✘ - - - - - - - Supply line or impeller clogged Remove deposits in the pump and/or piping.
✘ - - - - - - - Formation of air pockets in the piping Alter piping layout.
Fit vent valve.
✘ - - - - - ✘ ✘ Suction lift is too high/NPSH
available
(positive suction head) is too low.
Check/alter fluid level.
Install pump at a lower level.
Fully open the shut-off element in the suction
line.
Change suction line, if the friction losses in
the suction line are too high.
Check any strainers installed/suction opening.
Observe permissible speed of pressure fall.
✘ - - - - - - - Air intake at the shaft seal Clean barrier fluid duct, supply external
barrier fluid, if necessary, or increase barrier
fluid pressure.
Replace shaft seal.
✘ - - - - - - - Wrong direction of rotation Check the electrical connection of the motor
and the control system, if any.
✘ - - - - - - - Speed is too low.
15)
- Operation with frequency inverter
- Operation without frequency inverter
- Increase voltage/frequency at the frequency
inverter in the permissible range.
- Check voltage.
✘ - - - - - ✘ - Impeller Replace worn components by new ones.
- ✘ - - - - ✘ - Pump back pressure is lower than
specified in the purchase order.
Re-adjust to duty point.
In the case of persistent overloading, turn
down impeller.
15)
14) Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
15) Contact KSB.
Page 64
8 Trouble-shooting
64 of 72
HPK
A B C D E F G H Possible cause Remedy
14)
- ✘ - - - - - - Density or viscosity of fluid handled
higher than stated in purchase order
Contact KSB.
- ✘ - - - ✘ - - Gland follower over-tightened or cocked Correct.
- ✘ ✘ - - - - - Speed is too high. Reduce speed.
15)
- - - - ✘ - - - Defective gasket Fit new gasket between volute casing and
casing cover.
- - - - - ✘ - - Worn shaft seal Fit new shaft seal.
Check flushing liquid/barrier fluid.
✘ - - - - ✘ - - Score marks or roughness on shaft
protecting sleeve / shaft sleeve
Replace shaft protecting sleeve/shaft sleeve.
Fit new shaft seal.
- - - - - ✘ - - Vibrations during pump operation Correct suction conditions.
Re-align the pump.
Re-balance the impeller.
Increase pressure at the pump suction nozzle.
- - - ✘ - ✘ ✘ - The pump set is misaligned. Re-align.
- - - ✘ - ✘ ✘ - Pump is warped or sympathetic
vibrations in the piping.
Check the piping connections and secure
fixing of pump; if required, reduce distances
between the pipe clamps.
Fix the pipelines using anti-vibration material.
- - - ✘ - - ✘ - Insufficient or excessive quantity of
lubricant or unsuitable lubricant.
Top up, reduce or change lubricant.
- - - ✘ - - - - Non-compliance with specified coupling
distance
Correct the distance according to general
arrangement drawing.
✘ ✘ - - - - - - Motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
- - - - - - ✘ - Rotor out of balance Clean the impeller.
Re-balance the impeller.
- - - - - - ✘ - Defective bearing(s) Replace.
- - - - - - ✘ ✘ Flow rate is too low. Increase the minimum flow rate.
- - - - - ✘ - - Incorrect inflow of circulation liquid Increase the free cross-section.
Page 65
9 Related Documents
65 of 72
HPK
9 Related Documents
9.1 General assembly drawing with list of components
Fig.16: General assembly drawing
a)
b)
Fig.17: a) Impeller fastening on bearing bracket P08s and b) Intensively cooled shaft
seal chamber
Table30: List of components
Part No. Description Scope of supply
102 Volute casing with joint ring 411.01/.10, casing wear ring 502.01, stud 902.01,
screwed plug 903.01, socket head cap screw 914.10, hexagon nut
920.01
161 Casing cover with joint ring 411.09, casing wear ring 502.02, stud 902.15, socket
head cap screw 914.09, hexagon nut 920.15
183 Support foot
210 Shaft with keywayed nut 920.21, lockwasher 931.01, key 940.01/.02
230 Impeller with impeller wear ring 503.01/.02 (if any)
260.01 Impeller hub cap (bearing brackets P10as, P12s)
320.02 Angular contact ball bearing
Page 66
9 Related Documents
66 of 72
HPK
Part No. Description Scope of supply
322.01 Cylindrical roller bearing
330 Bearing bracket
344 Bearing bracket lantern with stud 902.04, hexagon head bolt 920.04
360.01/02 Bearing cover
451.01 Stuffing box housing with stud 902.03, screwed plug 903.16/.17, hexagon nut 920.03
502.01/.02 Casing wear ring
507.01/.02 Thrower
524.01 Shaft protecting sleeve
550.23 Support disc
550.87 Disc (bearing brackets P10as, P12s)
638 Constant-level oiler
672 Vent plug
901.04 Hexagon head bolt
901.87 Hexagon head bolt
903.46 Screwed plug
914.01/.02 Socket head cap screw
914.09/.10 Socket head cap screw
922 Impeller nut (bearing bracket P08s)
930.01 Spring washer
931.01 Lockwasher
931.02 Lockwasher (bearing brackets P10as, P12s)
932.01/.02 Circlip
Page 67
10 EU Declaration of Conformity
67 of 72
HPK
10 EU Declaration of Conformity
Manufacturer: KSB Aktiengesellschaft
Johann-Klein-Straße 9
67227 Frankenthal (Germany)
The manufacturer herewith declares that the product:
HPK
KSB order number: ...................................................................................................
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Pump (set): Machinery Directive 2006/42/EC
The manufacturer also declares that
▪ the following harmonised international standards have been applied:
– ISO 12100
– EN 809
Person authorised to compile the technical file:
Name
Function
Address (company)
Address (Street, No.)
Address (post or ZIP code, city) (country)
The EU Declaration of Conformity was issued in/on:
Place, date
Page 68
11 Certificate of Decontamination
68 of 72
HPK
11 Certificate of Decontamination
Type: ................................................................................................................................
Order number/
Order item number
16)
: ................................................................................................................................
Delivery date: ................................................................................................................................
Field of application: ................................................................................................................................
Fluid handled
16)
: ................................................................................................................................
Please tick where applicable
16)
:
Radioactive Explosive Corrosive Toxic
Harmful Bio-hazardous Highly flammable Safe
Reason for return
16)
: ................................................................................................................................
Comments: ................................................................................................................................
................................................................................................................................
The product/accessories have been carefully drained, cleaned and decontaminated inside and outside prior to dispatch/
placing at your disposal.
We herewith declare that this product is free from hazardous chemicals, biological and radioactive substances.
For mag-drive pumps, the inner rotor unit (impeller, casing cover, bearing ring carrier, plain bearing, inner rotor) has been
removed from the pump and cleaned. In cases of containment shroud leakage, the outer rotor, bearing bracket lantern,
leakage barrier and bearing bracket or intermediate piece have also been cleaned.
For canned motor pumps, the rotor and plain bearing have been removed from the pump for cleaning. In cases of leakage at
the stator can, the stator space has been examined for fluid leakage; if fluid handled has penetrated the stator space, it has
been removed.
No special safety precautions are required for further handling.
The following safety precautions are required for flushing fluids, fluid residues and disposal:
...............................................................................................................................................................
...............................................................................................................................................................
We confirm that the above data and information are correct and complete and that dispatch is effected in accordance with the
relevant legal provisions.
.................................................................... ....................................................... .......................................................
Place, date and signature Address Company stamp
16) Required fields
Page 69
Index
69 of 72
HPK
Index
A
Abrasive fluids36
Applications9
Auxiliary connections29
B
Bearing temperature47
Bearings19
C
Certificate of decontamination68
Clearance gaps48
Commissioning36
Configuration20
Constant level oiler37
Contact guard21
Coupling21, 47
Coupling alignment30
D
Design17
Designation17
Direction of rotation33
Disassembly51
Disposal16
Drive21
E
Event of damage
Ordering spare parts60
Explosion protection11, 23, 29, 31, 33, 34, 35, 39, 41,
42, 43, 45, 46, 47, 48
F
Faults
Causes and remedies63
Filter26, 48
Final check41
Flow rate35
Fluid handled
Density36
Frequency of starts35
Function20
G
General assembly drawing65
Gland packing43
H
Heating speed41
Heating up41
I
Impeller type18
Installation
Installation on a foundation24
without foundation25
Installation at site23
Intended use9
Interchangeability of pump components61
K
Keeping warm41
L
Leakage rate43
M
Maintenance46
Mechanical seal42
Misuse10
Monitoring equipment13
N
Noise characteristics21
O
Oil lubrication
Intervals49
Oil quality49
Oil quantity49
Operating limits34
Order number7
Other applicable documents7
P
Partly completed machinery7
Permissible forces and moments at the pump
nozzles27
Piping26
Preservation15, 34
Priming and venting39
Product description17
Pure graphite packing43
R
Return to supplier15
Returning to service44
Running noises46, 47
Page 70
Index
70 of 72
HPK
S
Safety9
Safety awareness10
Scope of supply21
Shaft seal18
Shutdown34, 43
Spare part
Ordering spare parts60
Spare parts stock61
Start-up42
Storage15, 34
T
Temperature difference41
Temperature limits12
Tightening torques60
Tightening torques 59
Transport14
W
Water cooling40
Page 71
Page 72
KSB Aktiengesellschaft
Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com
1121.8017/04-EN
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