KSB WKT Operating Instructions Manual

Operating Instructions Nº A1766.8E/2
Works Nº: ________________________________
Type series: ______________________________
precautionary notes. Please read the manual thoroughly prior to installation of unit, connection to the power supply and commissioning. It is imperative to comply with all other operating instructions referring to components of this unit.
KSB WKT
Vertical Process Pump
according to API 610
as per Directive 94/9/EC
This manual shall always be kept close to the unit´s location of operation or directly
on the pump set.
Contents
Page
1 General 4 2 Safety 4
2.1 Marking of Instructions in the manual 4
2.2 Personnel qualification and training 4
2.3 Non-compliance with safety instructions 4
2.4 Safety awareness 4
2.5 Safety instructions for the operator / user 5
2.6 Safety instructions for maintenance, inspection and installation work
2.7 Unauthorized modification and manufacture of spare parts
2.8 Unauthorized modes of operation 5
2.9 Explosion protection 5
2.9.1 Unit fill 5
2.9.2 Marking 5
2.9.3 Checking the direction of rotation 5
2.9.4 Pump operating mode 5
2.9.5 Temperature limits 6
2.9.6 Maintenance 6
3 Transport an d interim storage 6
3.1 Transport 6
3.2 Interim storage (indoors) / preservation 6
3.3 Devolution / discard 7
3.3.1 Devolution 7
3.3.2 Discard 7
4 Description of the product an
accessories
4.1 Technical specification 7
4.2 Designation 7
4.3 Design details 7
4.3.1 Pump casing 7
4.3.2 Impeller 7
4.3.3 Shaft seal 7
4.3.4 Bearing arrangement 8
4.3.5 Permissible forces and moments at the discharge nozzle
4.3.6 Noise characteristics
4.4 Accessories
4.5 Dimensions and weights
5 Installation at site 10
5.1 Safety regulations
5.2 Checks to be carried out prior to installation 10
5.2.1 Place of installation 10
5.3 Foundation 10
5.4 Barrel cleaning
5.5 Mounting 10
5.6 Aligning the pump / drive
5.7 Connecting the piping
5.7.1 Auxiliary connections 11
5.7.2 Coupling guard 11
5.8 Final check 11
5.9 Connection to power supply 11
5
5
7
9
9 9 9
10
10 10
11
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Page
6 Commissioning, start-up / shutdown 12
6.1 Preparations 12
6.1.1 Recommended safety instrumentation for pump
6.1.2 Lubrication 12
6.1.3 Pre-comissioning checks 12
6.1.4 Lubrication 12
6.1.5 Shaft seal 13
6.1.6 Priming the pump and checks to be carried out
6.1.7 Checking the direction of rotation 14
6.2 Start-up 14
6.2.1 Minimum flow 14
6.3 Shutdown
6.4 Operating limits 15 Temperature of the fluid handled, ambient
6.4.1 temperature, bearing temperature
6.4.2 Switching frequency 15
6.4.3 Density or fluid pumped 15
6.4.4 Abrasive fluids
6.4.5 Minimum / Maximum flow
6.5 Shutdown / storage / preservation
6.5.1 Storage of new pumps Measures to be taken for prolonged
6.5.2 shutdown
6.6 Returning to service after storage
7 Servicing / Maintenance
7.1 General instructions
7.2 Servicing / inspection
7.2.1 Supervision of operation 16
7.2.2 Lubrication and lubricant change 17
7.3 Drainage / disposal 17
7.4 Dismantling 17
7.4.1 Fundamental instructions and recommendations
7.4.2 Dismantling the pump 17
7.4.3 Examination of individual components 18
7.5 Reassembly 20
7.5.1 General instructions 20
7.5.2 Preparations 21
7.5.3 Tightening torques 24
7.6 Spare parts stock 24
7.6.1 Recommended spare parts stock for 2 years’ operation to DIN 24296
8 Troubleshooting 25 9 Sectional drawing 26 Supplementary sheet 28
Annex 01 29
12
13
15
15
15 15 16 16 16
16
16
16 16
17
24
Introduction
KSB has supplied you an equipment that has been designed and manufactured with the latest technology. Due to its simple and tough construction, it will need few maintenance. With the aim to provide our clients with a satisfactory, trouble free operation, we recommend to install and care our equipment according to the instructions contained in this service manual.
This manual has been prepared to inform the end user about construction and operati on of our pumps, describing the proper procedures for handling and maintenance. We recommend that this manual should be handled by the maintenance supervision.
This equipment must be used at operation conditions for which it has been selected, suc h as: flow rate, total head, speed, voltage, frequency and temperature of pumped liquid.
Place for description of type and size of the pump
WKT
Place for order number
Fig. 01 - Nameplate
For requests about the equipment, or when ordering spare parts, please mention the t ype of the pump and the Production Order number (serial nº). This information can be obtained from the nameplate of each pump. If the nameplate is not available, the OP number is engraved in low relief o n the suction flange and on the discharge flange you may find the impeller diameter.
Attention: This manual contains very important recommendations and instructions. Must be carefully read before
installation, electrical connection, first start up and maintenance.
3
1. General Caution
technology; it is manufactured with utmost care and subject to continuous quality control. These operating instructions are intended to facilitate familiarization with the unit and its designated use. The manual contains important information for reliable, proper and efficient operation. Compliance with the operating instructions is of vital importance to ensure reliability and a long service life of the unit and to avoid any risks. These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly observed by all, including the personnel called in for installation.
This pump / unit must not be operated beyond
the limit values for the fluid handled, capacity, speed, density, pressure, temperature and motor rating specified in the technical documentation. Make sure that operation is in accordance with the instructions laid down in this manual or in the contract documentation. Contact the manufacturer, if required. The nameplate indicates the type series / size, main operating data and works number; please quote this information in all queries, repeat orders and particularly when ordering spare parts. If you need any additional information or instructions exceeding the scope of this manual or in c ase of damage please contact KSB´s nearest customer service centre. For noise characteristics please refer to section 4.3.6.
This KSB product has been developed in accordance with state-of-the-art
2. Safety
These operating instructions contain fundamental information which must be complied with during installation, operation, monitoring and maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible trained personnel / operators prior to installation and commissioning, and it must always be kept close to the location of operation of the machine / unit for easy access. Not only must the general safety instructions laid down in this chapter on “Safety” be complied with, but also the safety instructions outlined under specific headings, particularly if the pump / unit is operated in hazardous areas (see section 2.9).
2.1 Marking of instructions in the manual
The safety instructions contained in this manual whose non-observance might cause hazards to persons are specially marked with the symbol
general hazard sign to ISO 7000-0434 the electrical danger warning sign is
safety sign to IEC 417-5036
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and special instructions concerning explosion protection are marked
The word
is used to introduce safety instructions whose non­observance may lead to damage to the machine and its functions.
Instructions attached directly to the machine, e.g.
- arrow indicating the direction of rotation
- markings for fluid connections
must always be complied with and be kept in a perfectly legible condition at all times.
2.2 Personnel qualification and training
All personnel involved in the operation, maintenance, inspection and installation of the unit must be fully qualified to carry out the work involved. Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question is not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the operator may commission the manufacturer / supplier to take care of such training. In addition, the operator is responsible for ensuring that the contents of the operating instructions are fully un derstood by the responsible personnel.
2.3 Non-compliance with safety instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine / unit itself. Non-compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
- failure of important machine / system functions;
- failure of prescribed maintenance and servicing
practices;
- hazard to persons by electrical, mechanical and chemical effects as well as explosion;
- hazard to the environment due to leakage of hazardous substances.
2.4 Safety awareness
It is imperative to comply with the safety instructions contained in this manual, the relevant national and international explosion protection regulations, and the operator´s own internal work, operation and safety regulations.
Ex symbol relates to additional requirements which must be adhered to when the pump is
operated in hazardous areas.
Caution
4
2.5 Safety instructions for the operator / user
- Any hot or cold components that could pose a hazard must be equipped with a guard by the operator.
- Guards which are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed whilst the unit is operating.
- Leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g. explosive, toxic, hot) must be contained so as to avoid any danger to persons or the environment. All relevant laws must be heeded.
- Electrical hazards must be eliminated. (In this respect refer to the relevant safety regulations applicable to different countries and / or the local energy supply companies.)
- Any components in contact with the fluid pumped, especially in the case of abrasive fluids, shall be inspected for wear at regular intervals and replaced by original spare parts (see section 2.7) in due time.
If the pumps / units are located in hazardous
areas, it is imperative to make sure that unauthorized modes of operation are prevented. Non– compliance may result in the specified t emperature limits being exceeded.
2.6 Safety instructions for maintenance, inspection and installation work
The operator is responsible for ensuring that all maintenance, inspection and installation work be performed by authorized, qualified specialist personnel who are thoroughly familiar with the manual. The pump must have cooled down to ambient temperature, pump pressure must have been released and the pump must have been drained. Work on the machine / unit must be carried out only during standstill. The shutdown procedure described in the manual for taking the unit out of service must be adhered to without fail. Pumps or pump units handling fluids injurious to health must be decontaminated. Immediately following completion of the work, all safety­relevant and protective devices must be re-installed and / or re-activated. Please observe all instructions set out in the chapter on “Commissioning” before returning the unit to service.
2.7 Unauthorized modification and manufacture of spare parts
Modifications or alterations of the equipment supplied are only permitted after consultation with the manufacturer and to the extent permitted by the manufacturer. Original spare parts and accessories authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer for consequential damage.
2.8 Unauthorized modes of operation
The warranty relating to the operating reliability and safety of the unit supplied is only valid if the equipment is used in accordance with its designated use as described in the following sections. The limits stated in the data sheet must not be exceeded under any circumstances.
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2.9 Explosion protection
If the pumps / units are installed in hazardous
areas, the measures and instructions given in the following sections 2.9.1 to 2.9.6 must be adhered to without fail, to ensure explosion protection.
2.9.1 Unit fill
It is assumed that the system of suction and
discharge lines and thus the wetted pump internals are completely filled with the product to be handled at all times during pump operation, so that an explosive atmosphere is prevented.
If the operator cannot warrant this condition,
appropriate monitoring devices must be used.
Caution
systems of the shaft seal and the heating and cooling systems are properly filled.
2.9.2 Marking
The marking on the pump only refers to the pump part, i.e. the coupling and motor must be regarded separately. The coupling must have an EC manufacturer’s declaration. The driver must be regarded separately.
Example of marking on the pump part:
The marking indicates the theoretically available temperature range as stipulated by the respective temperature classes. The temperatures permitted for the individual pump variants are outlined in section 2.9.5. Pumps WKT are designed to meet the requirements of Zone 1 and Category 2 as per EN1127-1 when sealed
by mechanical seal.
2.9.3 Checking the direction of rotation (see also
6.1.7)
If the explosion hazard also exists during the
installation phase, the direction of rotation must never be checked by starting up the unfille d pump unit, even for a short period, to prevent temperature increases resulting from contact between rotating and stationary components.
2.9.4 Pump operating mode
Make sure that the pump is always started up with the suction-side shut-off valve fully open and the discharge­side shut-off valve slightly open. However, the pump can also be started up against a closed swing check valve. The discharge-side shut-off valve shall be adjusted to comply with the duty point immediately following the ru n­up process (see 6.2).
Pump operation with the shut-off valves in the suction and / or discharge pipes closed is not permitted.
Caution
temperatures after a very short time, due to a rapid temperature rise in the pumped fluid inside the pump.
In addition, it is imperative to make sure that the seal chambers, auxiliary
Ex II 2 G T1 - T5
In this condition, there is a risk of the pump casing taking on high surface
5
Additionally, the resulting rapid pressure build-up inside the pump may cause excessive stresses on the pump materials or even bursting. The minimum flows indicated in section 6.4.5 refer to water and water-like liquids. Longer operating periods with these liquids and at the flow rates indicated will not cause an additional increase in the temperatures on th e pump surface. However, if the physical properties of the fluids handled are different from water, it is essential to check if an additional heat build-up may occur and if the minimum flow rate must therefore be increased. To check, proceed as described in section 6.4.5. In addition, the instructions given in section 6 of this operating manual must be observed.
Both gland packings and mechanical s eals may
exceed the specified temperature limits if run dry. Dry running may not only result from an inadequately filled seal chamber, but also from excessive gas content in the fluid handled. Pump operation outside its specified operating range may also result in dry running. In hazardous areas, gland packings shall only be used if combined with a suitable temperature monitoring device.
2.9.5 Temperature limits
In normal pump operation, the highest
temperatures are to be expected on the surface of the pump and distributor 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, it must be ensured that the temperature classes stipulated for the plant are observed. In the bearing bracket area, the unit surfaces must be freely exposed to the atmosphere.
In any case, responsibility for compliance with the specified fluid temperature (operating temperature) lies with the plant operator. The maximum permissible fluid temperature depends on the temperature class to be complied with.
The table below lists the temperature classes to EN 13463-1 and the resulting theoretical temperature limits of the fluid handled. In stipulating these temperatures, any temperature rise in the shaft seal area has already been taken into account.
Temperature class to
EN 13463-1:
T5 T4 T3 T2 T1
*) depending on material variant Safety note:
Caution
data sheet. If the pump is to be operated at a higher temperature, the data sheet is missing or if the pump is part of a pool of pumps, the maximum permissible operating temperature must be inquired from the pump manufacturer. Based on an ambient temperature of 40ºC and proper maintenance and operation, compliance with temperatur e class T4 is warranted in the area of the rolling element bearings. A special design is required to comply with
The permissible operating temperature of the pump in question is indicated on the
Temperature limit of
fluid handled
85ºC 120ºC 185ºC 280ºC
Max. 400ºC *)
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temperature class T6 in the bearing area. In such cases, and if ambient temperature exceeds 40ºC, contact the manufacturer.
2.9.6 Maintenance
Only a pump unit which is properly serviced and
maintained in perfect technical condition will give safe and reliable operation. This also applies to the reliable function of the rolling element bearings whose actual lifetime largely depends on the operating mode and operating conditions. Regular checks of the lubricant and the running noises will prevent the risk of excessive temperatures as a result of bearings running hot or defective bearing seals (also see section 6.1.4). The correct function of the shaft seal must be checked regularly. Any auxiliary systems installed must be monitored, if necessary, to make sure they function correctly. Gland packings must be tightened correctly, to prevent excessive temperatures due to packings running hot.
3. Transport and interim storage
3.1 Transport
The transport of motor-pump set or only pump should be made with ability and sound sense, according to safety standards. By the motor eyebolt should only lift it, never the motor-pump set.
If the pump / unit slips out of the suspension
arrangement, it may cause personal injury and damage to property!
Vertical pumps up to about 4 m shipping length are dispatched completely assembled. Larger pumps are dispatched in sub-assemblies and must be assembled at site under KSB´s supervision only. The stuffing box is not packed and the packing is supplied loose. The barrel is normally supplied loose with the pump. To avoid damage in transit, the motor is usually not mounted before dispatch. Please refer packing list received with the pump for more details.
3.2 Interim storage (indoors) / Preservation
KSB standard storage and preservation procedures maintain the pump protected for a maximum period of 6 months in an indoor installation. The unit / pump should be stored in a dry room where the atmospheric humidity is as constant as possible. When this period is exceeded, additional storage procedure should be taken. For that, please use the following conservation liquids:
- Internal parts of ferrous material in contact with
pumped liquid (except mechanical seal contact surfaces): water repellent of mineral oil basis.
- Bearings: mineral oil for internal conservation.
- Polished parts: mineral oil for internal and external
conservation.
- Mechanical seals: should be cleaned by dry air. Do
not apply any liquid or other conservation material i n
6
order to not damage secondary sealings (O´rings and flat gaskets).
All existing connections, like plugs for external source liquid, priming, drainage, etc, should be properly covered. Pump suction and discharge flanges are properly covered with adhesive, in order to avoid strange contents in its interior. Assembled pumps waiting for startup or installation should have their rotor manually rotated each 15 days. In case of difficulty, use some adjustable spanner, protecting the motor shaft surface. Before conservation liquids application, areas should be washed with gas or kerosene until they are completely cleaned. The conservative liquids can be removed from the areas in contact with pumped liquid, polished parts and surfaces like: shaft, salient faces and couplings, by means of solvents derived from petroleum or clean industrial liquids. Drain the conservative oil from bearing bracket before fulfill it with lubricant oil.
3.3 Devolution / discard
3.3.1 Devolution
- Drain the pump correctly.
- Carefully wash and clean the pump, especially in
case of harmful, explosive, hot fluids or other hazardous fluids.
- In the case fluids are pumped, and they are with residues which can cause corrosion damage when in contact with atmospheric humidity or that can ignite in contact with oxygen, the pump aggregate must be additionally neutralized and its dry process must be executed through blowing inert gas without water through the aggregate.
- Should always be sent with the pump / motor pump set a certificate of decontamination completely fulfilled. (Annex 1).
- Please always indicate adopted safety and decontamination measurements.
3.3.2 Discard
CAUTION
Medium handled is harmful to health. Hazardous for people and environment!
Collect and dispose of the liquid from
the washing as well as any residual liquids.
If necessary, use protective clothing and
mask.
Observe the legal disposals related to
the discard of harmful liquids to health.
- Disassemble the pump / moto-pump set. Collect the masses and lubricants during dismantling.
- Separate materials part of the pump, example:
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Metal Plastic Eletronic scrap Masses and lubricants
4. Description of the product and accessories
4.1 Technical specification
Fields of application: Used in the chemical and petrochemical industry as well as in refineries for handling chemically aggressive media with low solids content. As well used in industry in general as for process pump process gas and condensate.
4.2 Designation
KSB WKT 80 / 3 Trade mark Type series Discharge nozzle (mm) Number of stages
For materials refer to the data sheet.
4.3 Design details
Vertical, radially split shaft-driven sump pump with multiple stages, in wet installation.
4.3.1 Pump casing
Radially split, multiple stages. For handling combustible media, the pump casing,
the pipe assembly and the flanged elbow must be made of ductile material with a maximum magnesium content of 7.5% (see EN 13463-1). This is a standard feature in all KSB supplies.
4.3.2 Impeller
Closed radial impeller with multiply curved vanes. Axial thrust is balanced by means of suction and discharge­side casing wear rings and balancing holes.
4.3.3 Shaft seal
Shaft sealing is effected by gland packing or single or double acting mechanical seals. The relevant seal version is shown in the mecha nical seal drawing.
7
Arragement drawing (examples) Gland packing (special variant-consult KSB to use in
explosive atmospheres)
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212 Intermediate shaft 383 Bearing spider
400.2 Flat gasket
529.3 Bearing sleeve
545.3 Bearing bush
711.1 Riser pipe
Fig. 02
Mechanical seal
Mechanical seal
Single-acting
Fig. 03
Mechanical seal
Double-acting
Fig. 04
4.3.4 Bearing arrangement
4.3.4.1 Pump bearings
The pump shaft runs in two plain bearings. The bearing at the suction end is arranged in the suction
casing (106) and the bearing at the discharge end is arranged in the discharge casing (107). Both these bearings are lubricated by the product pumped.
4.3.4.2 Intermediate shaft bearings
(See fig. 05) The intermediate shafts are guided by bearing spiders
(383) with built-in bearing bushes (545.3) between the lengths of column pipe. Their construction and lubrication corresponds to that of the pump bearings.
Fig. 05 Intermediate shaft bearing
4.3.4.2.1 Rigid Couplings for intermediate shafts
Depending on the shaft diameter, rotational speed, switching frequency and type of driver, either rigid screwed couplings, or split (muff) couplings are used to connect the intermediate shafts to one another and to transmit the driving torque. In order to prevent the unscrewing (slackening) of screwed couplings during reverse rotation pumping sets fitted with such couplings must be provided with a revers e rotation stop device. Hollow shaft motors and hollow shaft bevel gears are equipped with such a reverse rotation stop device. Electric motors of V1 type series are however not so equipped, and the direction of rotation of such motors should therefore be checked before connection to the shafting. It is therefore preferable to use split (muff) couplings in conjunction with V1 type series electric motors. The type of coupling applying to your installatio n can be ascertained from the data sheet attached to the Order confirmation. See figures below for construction and arrangement.
Screwed coupling Split (muff) coupling
4.3.4.3 Thrust bearing
(See fig. 07 and 08 for construction). The thrust bearing arranged in the motor lantern absorbs
the weight of the complete pump rotor, including the weight of the intermediate shafts (212) and drive shaft (213), and the radial forces which arise, it also absorbs the residual axial thrust generated, and transmits all these weights and forces to the motor lantern. Depending on the values 3 different configurations are available. See fig. 06. The bearing is oil lubricated, in the normal execution. Oil mist lubrication is possible, however it is special and made up on consult.
Pump sizes
Thrust bearing constructions
VÖR 6311 6312 6315 6317
VÖQJ 311 312 315 317
VÖB 25 (7311) 35 (7312) 45 (7315) 60 (7318)
40 50 and 65
80 and
100
125 and
150
Fig. 06
8
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p
VÖB and VOQJ
Pump size 40 50/65 80/100 125 150
Fx N 1500 1800 2500 3000 3500 Fy N 1500 1800 2500 3000 3500 Fz N 1500 1800 2500 3000 3500
Mx N.m 1200 1500 2000 2500 3000
Suction
My N.m 1200 1500 2000 2500 3000 Mz N.m 1200 1500 2000 2500 3000
Fx N 800 1500 2000 2500 3000 Fy N 800 1500 2000 2500 3000
Fz N 800 1500 2000 2500 3000 Mx N.m 500 1200 1500 2000 2500 My N.m 500 1200 1500 2000 2500
Discharge
Mz N.m 500 1200 1500 2000 2500
4.3.6 Noise characteristics
Fig. 07 Construction of support bearing VÖB (deep groove ball bearing and VÖQJ (four point contact bearing).
VÖB
Fig. 08 Construction of support bearing VÖB
4.3.5 Permissible forces and moments at the nozzles
For max. permissible forces & moments refer table below.
Fig. 09
Rated power input
P
110,0 79,0 77,0 76,0 132,0 79,5 77,5 76,5 160,0 80,0 78,0 77,0 200,0 81,0 79,0 77,5 250,0 81,5 79,5 78,5 400,0 83,0 81,0 80,0 500,0 84,0 82,0 80,5 750,0 85,0 83,0 81,5
1000,0 86,0 84,0 82,5
Sound pressure level
(kW)
N
2,2 60,0 60,0 -
5,5 65,5 65,0 64,5 11,0 70,0 68,5 67,5 15,0 71,5 70,0 69,0 22,0 73,5 72,0 71,0 30,0 74,5 73,0 72,0 37,0 75,5 74,0 73,0 45,0 76,0 74,5 73,0 55,0 76,5 75,0 73,5 75,0 77,5 76,0 74,5 90,0 78,0 76,5 75,0
2900
1/min
Pump only
1450
1/min
L
(db)  
A
980
1/min
Measured at a distance of 1m from the pump outline (as per DIN 45635 Part 1 and 24). Room and foundation influences have not been included. The tolerance for these factors is 1 to 2 dB.
Increase for 60 Hz operation Pump without motor: --­ Pump with motor: 3500min-1:+3dB, 1750min-1: + 1dB, 1160min-1: ---dB
4.4 Accessories
As a general rule, the following items are supplied with the pump:
- Motor lantern,
- Special tools and tackles for assembly / disassembly
of conical coupling, On request the following items can be supplied amongst others:
- Coupling: flexible coupling with spacer,
- Coupling guard,
- Coupling extractor device,
- Motor,
- Base plate: welded construction,
- Pressure gauges for suction and discharge,
- ARC valve,
- Suction strainer.
4.5 Dimensions and weights
For dimensions and weights please refer to the general arrangement drawing of the pump.
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