KSB UPA, BSX, UPZ, UPA series, UPA 300 Operating Manual

...
Submersible Borehole Pumps
UPA, UPZ, BSX
with motors of 1000 V operating voltage and above 50 Hz, 60 Hz
Installation/Operating Manual
Mat.No.: 01463374
Legal information/Copyright
Installation/Operating Manual UPA, UPZ, BSX
Original operating manual
KSB Aktiengesellschaft
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 KSB's express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 16.11.2012
Contents
Glossary .................................................................................................5
1 General ..................................................................................................6
1.1 Principles ...........................................................................................................6
1.2 Target group ..................................................................................................... 6
1.3 Other applicable documents ............................................................................ 6
1.4 Symbols .............................................................................................................7
2 Safety .....................................................................................................8
2.1 Key to safety symbols/markings ....................................................................... 8
2.2 General .............................................................................................................. 8
2.3 Intended use .....................................................................................................8
2.4 Personnel qualification and training ............................................................... 9
2.5 Consequences and risks caused by non-compliance with these operating instructions
........................................................................................................ 9
2.6 Safety awareness ..............................................................................................9
2.7 Safety information for the operator/user ..................................................... 10
2.8 Safety information for maintenance, inspection and installation work ..... 10
2.9 Unauthorised modes of operation ................................................................10
3 Transport/Temporary Storage/Disposal .............................................11
3.1 Checking the condition upon delivery .......................................................... 11
3.2 Transport ......................................................................................................... 11
3.3 Storage and preservation ............................................................................... 13
3.4 Return to supplier ........................................................................................... 14
3.5 Disposal ...........................................................................................................15
4 Description of the Pump (Set) ............................................................16
4.1 General description ........................................................................................ 16
4.2 Designation ..................................................................................................... 16
4.3 Name plate ...................................................................................................... 17
4.4 Design details .................................................................................................. 17
4.5 Configuration and function ........................................................................... 18
4.6 Scope of supply ............................................................................................... 18
4.7 Dimensions and weights ................................................................................19
5 Installation at Site ...............................................................................20
5.1 General information/Safety regulations .......................................................20
5.2 Preparing the installation .............................................................................. 21
5.3 Installing the pump set in vertical position ..................................................27
5.4 Installing the pump set in a horizontal position ..........................................30
5.5 Installing the pump set in an angled position .............................................. 32
5.6 Notes on electrical connection ...................................................................... 32
5.7 Electrical connection ...................................................................................... 34
Contents
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6 Commissioning/Start-up/Shutdown ...................................................39
6.1 Commissioning/start-up ................................................................................. 39
6.2 Operating limits .............................................................................................. 41
6.3 Shutdown ........................................................................................................ 44
7 Servicing/Maintenance .......................................................................45
7.1 Servicing/inspection ........................................................................................ 45
7.2 Removing the pump set ................................................................................. 45
7.3 Separating pump and motor ......................................................................... 46
7.4 Motor fill ......................................................................................................... 47
7.5 Storage and preservation ............................................................................... 49
7.6 Reassembling the pump set ........................................................................... 50
8 Trouble-shooting ................................................................................53
9 Related Documents ............................................................................54
9.1 General assembly drawing with list of components .................................... 54
9.2 Mating dimensions for motors V, X, Z, E ......................................................58
9.3 Mating dimensions for motor T ..................................................................... 59
10 EC Declaration of Conformity ............................................................60
11 Certificate of Decontamination .........................................................61
Index ....................................................................................................62
Contents
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Glossary
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.
Pump set
Complete pump set consisting of pump, drive, additional components and accessories
Glossary
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1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated on the front cover (see details listed below).
UPA 250C
UPA 300
UPA 350
UPZ
BSX
BRY
BRZS
BRE
BSF
T
V
X
Z
E
The 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.
1.2 Target group
This manual is aimed at the target group of trained and qualified specialist technical personnel.(⇨ Section 2.4 Page 9)
1.3 Other applicable documents
Table 1: 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
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing
1)
Sectional drawing of the pump Sectional drawing of the motor
Sub-supplier product literature
1)
Operating manuals and other product literature describing accessories and integrated machinery components
Spare parts lists
1)
Description of spare parts Operating manual for accessories
1)
Description of accessories, e.g. cable connector
Pump sizes
Motor sizes
1)
If agreed to be included in the scope of supply
1 General
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For accessories and/or integrated machinery components observe the relevant manufacturer's product literature.
1.4 Symbols
Table 2: 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 Cross-references
1.
2.
Step-by-step instructions
Note Recommendations and important information on how to handle the product
1 General
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2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: 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 EC Directive 94/9/EC (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 manual contains general installation, operating and maintenance instructions that must be observed to ensure safe pump operation and prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/ operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site at all times.
Information attached directly to the pump/motor must always be complied with and be 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 manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits described in the other applicable documents.
Only operate pumps/pump sets which are in perfect technical condition.
Do not operate the pump (set) in partially assembled condition.
Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model.
!
DANGER
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Never operate the pump without the fluid handled.
Never operate the motor without fill liquid.
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).
Do not let the motor run in the wrong direction of rotation for more than two
minutes.
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 discharge-side shut-off elements further than permitted.
The maximum flow rate specified in the data sheet or product literature
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 these operating instructions
Non-compliance with these operating instructions 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
2 Safety
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Applicable standards and laws
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 work
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 all maintenance, inspection and installation work 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.
Prior to any dismantling work, disconnect the motor from the mains.
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.
Decontaminate pumps which handle fluids posing a health hazard.
As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all instructions on commissioning.
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.
2 Safety
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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.
NOTE
The pump set is supplied by the manufacturer/supplier in packaging which largely prevents sagging or other damage during transport and/or storage.
3.2 Transport
WARNING
Improper transport Risk of squashing hands and feet! Damage to the pump set!
Always transport the pump set in horizontal position.
Do not use electrical cables for transport.
Gently set down the pump set.
Observe the centre of gravity of the pump set and the weights indicated.
WARNING
Pump set tipping over or rolling off Risk of personal injury!
Always secure vertically positioned pump sets against tipping over.
Always secure horizontally positioned pump sets against rolling off.
WARNING
Ambient temperature below the specified minimum Danger of frost!
Never subject the pump set to ambient temperatures which are lower than
those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation).
NOTE
Take into account the unequal weight distribution between pump and motor.
Transporting the transport boxes
Submersible borehole pumps are supplied in appropriate packaging, e.g. transport boxes, containing either the pump set or the pump and/or motor as individual components (depending on the design). Use suitable lifting equipment to transport the transport box to the place of installation or storage. Observe the marking on the long side of the transport box! This marking indicates the centre of gravity.
Transport boxes
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Unpacking the pump set/pump/motor
WARNING
Unsecured cable drum Risk of personal injury!
Always secure the cable drum against tipping over.
Always secure the cable drum against rolling off.
WARNING
Laying cables at temperatures below zero degrees Damage to the cables!
Observe the minimum permissible temperature at the cable surface of -25 °C for
moving cables.
Observe the minimum permissible temperature at the cable surface of -40 °C for
stationary cables.
CAUTION
Excessive bending stress on the pump set Damage to the pump set!
Choose sling points which prevent excessive bending stress on the pump set.
Use suitable lifting equipment for lifting the pump set out of the packaging and transporting it(⇨ Section 4.7 Page 19
) Use suitable lifting tackle for lifting the pump
set out of the packaging and transporting it, e. g. lifting straps. Sling points: in the middle of the motor and at the upper end of the pump.
Fig. 1: Transporting the pump set by crane
Suitable lifting equipment and lifting tackle are available.
The surface on which the pump set is to be positioned is solid and level.
Securing means, e.g. timber wedges are on hand.
1.
Gently set down the transport box.
2. Open the transport box.
3. Take out the power cable and put it down.
4. Position the lifting tackle allowing for balanced lifting. Normally, the centre of gravity of the pump set will be in the motor area. Watch any add-on parts, such as piping and cables!
5. Use the lifting equipment to lift the pump set out and position it on a solid and level surface.
6. Use appropriate means to secure the pump set against rolling off.
Unpacking
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3.2.1 Pulling the pump/motor/pump set upright
WARNING
Incorrect positioning Personal injury and damage to property!
Position the pump set vertically with the motor below.
Use appropriate means to secure the pump set against overturning and tipping
over.
Refer to the weights given in the data sheet.
WARNING
Improper handling when setting the pump set down in a vertical/horizontal position Personal injury and damage to property!
Use appropriate means to secure the pump set against overturning, tipping
over and rolling off.
Maintain adequate safety distance during lifting operations (load may swing
when being lifted).
Use additional supports for the transport holder to secure the pump set against
overturning.
WARNING
Improper handling of the power cable when placing the pump set in vertical position or transporting it Personal injury and damage to property!
Secure power cables against falling down.
CAUTION
Improper storage Damage to the power cables!
Support the power cables at the cable entries to prevent permanent
deformation. Observe the minimum bending radius2) of the cables.
Only remove the protective caps from the power cables at the time of
installation.
CAUTION
Excessive bending stress on the pump set Damage to the pump set!
Choose sling points which prevent excessive bending stress on the pump set.
Suitable lifting equipment for the total weight has been selected and is on hand.
1.
Fasten to a suitable lifting accessory, e.g. mounting plate.
2. Attach the lifting equipment, pull the pump/motor/pump set upright, and secure it against tipping over.
3.3 Storage and preservation
If commissioning is to take place some time after delivery, we recommend that the following measures be taken:
2)
See cable manufacturer's documentation or DIN VDE 0298-3.
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WARNING
Pump set tipping over or rolling off Risk of personal injury!
Always secure vertically positioned pump sets against tipping over.
Always secure horizontally positioned pump sets against rolling off.
WARNING
Ambient temperature below the specified minimum Danger of frost!
Never subject the pump set to ambient temperatures which are lower than
those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation).
WARNING
Laying cables at temperatures below zero degrees Damage to the cables!
Observe the minimum permissible temperature at the cable surface of -25 °C for
moving cables.
Observe the minimum permissible temperature at the cable surface of -40 °C for
stationary cables.
CAUTION
Improper storage Damage to the power cables!
Support the power cables at the cable entries to prevent permanent
deformation. Observe the minimum bending radius3) of the cables.
Only remove the protective caps from the power cables at the time of
installation.
Store the submersible borehole pumps as follows:
1.
In its original packaging: horizontally
2. Without packaging: vertically (with the motor below)
3. In a dry environment
4. Protected against direct sunlight and heat
5. Protected against dirt and dust
6. Protected against freezing
7. Protected against vermin
Further information on storing the pump set after use (⇨ Section 7.5 Page 49).
3.4 Return to supplier
WARNING
Ambient temperature below the specified minimum Danger of frost!
Never subject the pump set to ambient temperatures which are lower than
those permitted for the drinking water/antifreeze mixture provided (see section on drinking water/antifreeze mixture / order documentation).
1. Clean the pump set properly from the outside.
3)
See cable manufacturer's documentation or DIN VDE 0298-3.
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2. Always flush and clean the pump, particularly if it has been used for handling noxious, explosive or other hazardous fluids.
3.
If the fluids handled by the pump set leave residues which might lead to corrosion damage when coming into contact with atmospheric humidity, or which might ignite when coming into contact with oxygen, the pump set must also be neutralised, and anhydrous inert gas must be blown through the pump for drying purposes.
4. Always complete and enclose a certificate of decontamination when returning the pump (set). Always indicate any safety and decontamination measures taken.
NOTE
If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination
3.5 Disposal
WARNING
Fluids handled posing a health hazard Hazard to persons and the environment!
Collect and properly dispose of flushing liquid and any liquid residues.
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)
4.1 General description
Pump for handling clean or slightly contaminated water.
Verify the fluid composition against the data sheet.
Not approved for handling explosive fluids or for forming part of an explosion-proof system!
4.2 Designation
Submersible borehole pump Example: UPA 250C - 150 / 5b
Table 4: Key to the designation
Code Description
UPA Pump type 250 Nominal size [mm] C Design status 150 Flow rate at best efficiency point [m³/h] 5 Number of stages b Reduced impeller diameters
Submersible borehole pump Example: BRZS 535 / 5
Table 5: Key to the designation
Code Description
B R Pump type Z Nominal size S Design with suction impeller 535 Hydraulic code 5 Number of stages
Submersible motor Example: VBD FV 31 - 30 5
Table 6: Key to the designation
Code Description
V Motor size, e.g. V = 14 inch B Number of poles, e.g. B = 2 poles D Design status FV Length of core pack 31 Maximum rated power 30 Voltage, e.g. 30 = 3 kV 5 Frequency, e.g. 5 = 50 Hz
4 Description of the Pump (Set)
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4.3 Name plate
Serial No. 9971276748-000100
1
2
3
4
5 6
13
14
15
Pump RE 555/3 Qmin Qmax
Q Motor
340 KW 3300 V
Temp. Min. flow velocity past the motor = 0.2 m/s
EN 60034-1
IP 68
Mat. No.: 01 000 854 ZN 3823 - D 88
300 L/MIN
1170 L/MIN
879.6 L/MIN
Hmax Hmin H
108 M
69 M
92.7 M
3~ XMD HQ 37-335
50 Hz
86 A 0.77 COS
20 °C max. 1467 rpm
7 8
11 12
9
10
16
17 18
19
Fig. 2: Name plate (example)
1 Order number 2 Pump designation 3 Minimum flow rate 4 Maximum flow rate 5 Flow rate at duty point 6 Motor designation 7 Rated power 8 Voltage 9 Frequency 10 Amperage 11 Maximum fluid temperature 12 Minimum available flow along the
motor 13 Maximum head 14 Minimum head 15 Head at duty point 16 Power factor 17 Speed 18 VDE Standard 19 Motor enclosure
4.4 Design details
Pump design
Centrifugal pump
Single-stage or multi-stage
Radial or mixed flow versions
Single-entry or double-entry
Shroud or ring-section design
With non-return valve or connection branch
Pump connection with threaded or flanged end
Rigid connection between pump and motor
Motor design
Submersible motor in squirrel-cage design
Motor shaft4) protected by sealed sleeve coupling
Rubber expansion diaphragm for pressure equalisation
Thrust bearing with tilting pads to absorb the pump's hydraulic thrust
Single mechanical seal
4)
For motor sizes V, X, Z and E
4 Description of the Pump (Set)
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4.5 Configuration and function
6/7
4
5
3
2
1
Fig. 3: Sectional drawing, example of a UPA
Pump and motor are connected by a rigid coupling. The stage casings are supported by straps or stud bolts. A suction strainer at the suction casing protects the pump from coarse particles in the fluid. The pump set is connected to the piping via a non­return valve or connection branch with either internal thread or flanged end (optional).
The fluid flows along the motor and enters the suction casing (2) through the suction strainer (1). It is accelerated outward by the suction impeller (3). In the flow passage of the stage casing (4) the kinetic energy of the fluid is converted into pressure energy, and the fluid is routed to the next impeller (5). This process is repeated in all stages until the fluid has passed the last impeller (5). It is then guided through the integrated non-return valve to the connection branch (7), where it leaves the pump. The integrated non-return valve prevents uncontrolled backflow of the fluid.
4.6 Scope of supply
Depending on the model, the following items are included in the scope of supply:
Pump set with motor lead
Optional: pump and/or motor as individual units
Design
Function
4 Description of the Pump (Set)
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Electric cable
Optional: connected or supplied loosely
Tools for filling the motor
Separate name plate
5)
Accessories, such as:
Cable connector
– Cable ties
– Cooling, suction or pressure shroud
– Bearing pedestals
– Electrical protection devices
– Automatic control units
4.7 Dimensions and weights
For dimensions and weights please refer to the data sheet of the pump (set).
5)
To be attached outside the place of installation, e.g. control panel, pipeline or mounting bracket.
4 Description of the Pump (Set)
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5 Installation at Site
5.1 General information/Safety regulations
DANGER
Using damaged cables in a well Electric shock!
Do not kink cables (observe the minimum bending radius 6) of the cable) or drag the cables over sharp edges.
Use cable ties or other suitable fasteners to fasten the power cables as well as
any measuring and control cables to the riser or piping every three meters.
Do not use any tools, equipment or accessories with sharp edges (e.g. sharp-
edged pipe sockets) during installation.
WARNING
Pump set falling into the well Personal injury or persons being dragged down by uncontrolled cable movements! Damage to the pump set and the well!
Securely store the cable with extension lead. Keep at a safe distance during
installation.
Secure the pump set during the entire installation procedure.
Dimension any securing devices (supporting clamps, supports, etc.) so that they
can carry all weights during the installation.
WARNING
Persons could fall into unsecured wells/reservoirs/tanks Risk of personal injury!
During installation work, take suitable precautions to protect anyone from
falling into an open well/reservoir/tank.
Suitably fence off the work area.
WARNING
Improper handling when setting the pump set down in a vertical/horizontal position Personal injury and damage to property!
Use appropriate means to secure the pump set against overturning, tipping
over and rolling off.
Maintain adequate safety distance during lifting operations (load may swing
when being lifted).
Use additional supports for the transport holder to secure the pump set against
overturning.
WARNING
Improper handling of the power cable when placing the pump set in vertical position or transporting it Personal injury and damage to property!
Secure power cables against falling down.
6)
See cable manufacturer's documentation or DIN VDE 0298-3.
5 Installation at Site
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