Feed Pump Ksb 41e4e

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CONTENTS DESCRIPTION

PAGE REFERENCE

Chapter : General

OIMPG General 1

1. General Information 2. Disposal 3. Conformity with EU Regulations (if applicable)

OIMPG General 2 OIMPG General 3 OIMPG General 3

Chapter : Safety Marking of Instructions in the Instruction Manual Personnel Qualification and Training Non-compliance with Safety Instructions Safety Awareness Safety Instructions for the Operator/ Safety Instructions for Work on the Pump Set Unauthorized Modification and Manufacture of Spare Parts Unauthorized Modes of Operation

OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 2 OIMPG Safety 2 OIMPG Safety 2

Chapter : Transport / Interim Storage 1. General Information 1.1 Hoisting Tackle (e.g. ropes, gear) 1.2 Signals during Transport 1.3 Transport Symbols 2. Transport of the Packaged Components of the Pump Set 3. Transport of the Partly-packaged or Unpackaged Components of the Pump Set 3.1 Transport of Pump Set 3.2 Transport of the Pump 3.3 Transport of the Other Pump Set Components 3.4 Transport of Pump Rotor 3.5 Transport of Pump Set Accessories 4 Interim Storage 4.1 Prerequisites 4.2 Place of Storage 4.3 Period of Storage up to 12 Months 4.4 Period of Storage over 12 Months

Contents OIM Pages 3

OIMPG TRANSPORT 1 OIMPG TRANSPORT 1 OIMPG TRANSPORT 1 OIMPG TRANSPORT 2 OIMPG TRANSPORT 2 OIMPG TRANSPORT 2 OIMPG TRANSPORT 3 OIMPG TRANSPORT 4 OIMPG TRANSPORT 5 OIMPG TRANSPORT 5 OIMPG TRANSPORT 6 OIMPG TRANSPORT 7 OIMPG TRANSPORT 7 OIMPG TRANSPORT 7 OIMPG TRANSPORT 7 OIMPG TRANSPORT 7

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DESCRIPTION

Chapter : Installation on Site

Conditions Foundation Site management Place of Installation Drive way to the Place of Installation Adequate means of Transport Preparations Checking the Foundation Correct deviating foundation dimensions Transporting the Pump set Components to the Place of Installation Removal of Packaging Protecting the Pump Set Components Procedure for levelling and grouting of Base Frame at Site Making the Piping Cleaning the Piping Connecting the Coupling Information about Readiness for connecting of the Piping Checking the Alignment Mounting the Instruments Detailed description of Mounting/dismounting the connecting Coupling General Information Mounting Dismantling Detailed description of Connecting Coupling Alignment 1. Conditions 2. Preparations 3. Runout Check of the Coupling Hubs 4. Alignment of Coupling 5. Alignment Corrections 6. Pinning the Feet Cladding (touch guard) for the Shaft Seal

Contents OIM Pages 3 Rev. 17.07.2007

PAGE REFERENCE

Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 2 Installation 2 GEN 02.01 I Installation 3 Installation 3 Installation 4 Installation 4 Installation 4 Installation 4 Installation 4 Installation 5 Installation 5 Installation 6 Installation 7 Installation 8 Installation 8 Installation 8 Installation 8 Installation 9 Installation 10 Installation 11 Installation 12 Installation 13

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DESCRIPTION

PAGE REFERENCE

Chapter : Commissioning, Start-up/Shutdown 1. Work to be carried out prior to Commissioning, Start-up OIMPG COMM 31 1.2 General Information OIMPG COMM 31 1.3 Removal of Preservation OIMPG COMM 31 1.4 Additional Work to be carried out Prior to returning to Service after OIMPG COMM 31 Standstill > 12 Months 1.5 Topping up the Bearings with Lubricating Oil OIMPG COMM 31 1.5.1 General Information OIMPG COMM 31 1.5.2 Bearing with Oil Sight Gauge OIMPG COMM 31 1.5.3 Lift-off Device (if applicable) OIMPG COMM 32 1.5.4 Bearing wit Constant Level Oiler OIMPG COMM 32 1.5.5 Other Accessories OIMPG COMM 32 1.6 Checking the Direction of Rotation OIMPG COMM 32 1.6.1 Prerequisites OIMPG COMM 33 1.6.2 Direction of Rotation OIMPG COMM 33 1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator OIMPG COMM 33 1.6.4 Checking the Direction of Rotation without a Phase-sequence Indicator OIMPG COMM 33 1.7 Rotatability of the pump Rotor OIMPG COMM 34 1.8 Mounting the Connecting Coupling OIMPG COMM 34 1.9 Mounting Guards Preventing Accidental OIMPG COMM 34 1.10 Functional Test and Adjustment of the Instruments OIMPG COMM 34 2. Commissioning, Start-up OIMPG COMM 35 2.1 Prerequisites OIMPG COMM 35 2.2 Priming OIMPG COMM 35 2.3 Checks Prior to Starting OIMPG COMM 36 2.4 Starting and Trial Run OIMPG COMM 36 3. Shutdown OIMPG COMM 37 3.1 Pump Set remains Ready for Operation OIMPG COMM 37 3.2 For Maintenance of the Pump Set or Prolonged Standstill OIMPG COMM 37 4. Work after Shutdown OIMPG COMM 38 4.1 During Readiness for Instant Start-up OIMPG COMM 38 4.2 For Maintenance of the Pump Set OIMPG COMM 38 4.3 Standstill, Pump not ready for Operation OIMPG COMM 39 5. Detailed description of Preservation for Standstill OIMPG COMM 39

Chapter : Pump Supervision Plan Supervision of Rotor Position (only for the pumps with Balancing Disc) Supervision of Rotor Position (only for the pumps with Balancing Disc) Log Sheet


OIMPG SUPERVISION 06 OIMPG SUPERVISION 02 OIMPG SUPERVISION 03

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DESCRIPTION

PAGE REFERENCE

Chapter : Servicing

OIMPG SERVICING 01

1. General Information 1.2 Requirement of Documentation 1.3 Prerequisites 1.4 Service Intervals 2. Dismantling the Guards Preventing Accidental 3. Pump Servicing Plan 4. Servicing Work 4.1 Oil Changes 4.2 Re-lubrication

OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 02 OIMPG SERVICING 03 OIMPG SERVICING 03 OIMPG SERVICING 04

Chapter : Maintenance

OIMPG MAINTENANCE 01

1. General Information 1.2 Required Documentation 1.3 Prerequisites 2. Dismantling the Guards Preventing Accidental 2.1 Sound Insulation Hood 2.2 Coupling Guard/Cover 2.3 Guard Preventing Accidental for Shaft Seal 3. Dismantling the Connecting Coupling 3.2 Removing the Coupling Hubs 3.3 Run-out Check of the Shaft Ends 4. Removing the Pump from the Installation 4.1 Dismantling the Piping and Instruments 4.2 Removing the Pump from Baseframe 4.3 Transporting the Pump to the Place of Dismantling

OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 02 OIMPG MAINTENANCE 02 OIMPG MAINTENANCE 02 OIMPG MAINTENANCE 03 OIMPG MAINTENANCE 03 OIMPG MAINTENANCE 03 OIMPG MAINTENANCE 04 OIMPG MAINTENANCE 05

5. Dismantling the Bearings 5.1 Preparations 5.2 Dismantling the Add-on Parts 5.3 Dismantling the Lift-off Device, with Antifriction Bearings 5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing 5.5 Dismantling the Thrust Bearing 5.6 Dismantling the Radial Bearings 5.6.1 HG Pump Sizes 1 and 2 5.6.2 HG Pump Sizes 3 to 6 5.7 Dismantling the Bearing Housings 5.7.1 HG Pump Sizes 1 and 2 5.7.2 HG Pump size 3 5.7.3 HG Pump Sizes 4 to 6

OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 07 OIMPG MAINTENANCE 07 OIMPG MAINTENANCE 07 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 08

6. Dismantling the Shaft Seal 6.1 Preparations 6.2 Dismantling the Mechanical Seal 6.2.1 Make : Eagle Poonawalla 6.2.2 Make : Flowserve Sanmar 6.2.3 Make : Burgmann 6.3 Dismantling the Casing Parts

OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 14 OIMPG MAINTENANCE 14


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DESCRIPTION

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7. Dismantling the Balancing Device 7.1 HG Pump Sizes 1 and 2 7.2 HG Pump Size 3 7.3 HG Pump Size 4 7.3 HG Pump Sizes 5 and 6 7.4 Measuring the Approximate Radial Clearance

OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26

8. General Information on Reassembly


9. Checking the Balancing Device with Fluid 9.1 HG Pump Sizes 1 and 2

OIMPG MAINTENANCE 27 OIMPG MAINTENANCE 27 OIMPG MAINTENANCE 28 OIMPG MAINTENANCE 29 OIMPG MAINTENANCE 30 OIMPG MAINTENANCE 31 OIMPG MAINTENANCE 30 OIMPG MAINTENANCE 33 OIMPG MAINTENANCE 34 OIMPG MAINTENANCE 35

9.2 HG Pump Size 3 9.3 HG Pump Sizes 4 9.4 HG Pump Sizes 5 and 6

10. Mounting the Balancing Device 10.1 HG Pump Sizes 1 and 2 10.2 HG Pump Size 3 10.3 HG Pump Size 4 10.4 HG Pump Sizes 5 and 6

OIMPG MAINTENANCE 36 OIMPG MAINTENANCE 36 OIMPG MAINTENANCE 36 OIMPG MAINTENANCE 37 OIMPG MAINTENANCE 38 OIMPG MAINTENANCE 39

11. Mounting the Shaft Seal 11.1 Mounting the Housing Components 11.1.1 HG Pump Sizes 1 to 3 11.1.2 HG Pump Sizes 4 to 6 11.2 Assembling the Shaft Seal 11.2.1 Make Eagle Poonawalla 11.2.2 Make : Flowserve Sanmar 11.2.3 Make : Burgmann

OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40

12. Mounting the Bearings 12.1 Mounting the Bearing Housings and Lifting the Pump Rotor 12.1.1 HG Pump Sizes 1 and 2 12.1.2 HG Pump Sizes 3 to 6 12.2 Mounting the Radial Bearings 12.2.1 HG Pump Sizes 1 and 2 12.2.2 HG Pump Sizes 3 to 6 12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings 12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Bearing 12.5 Mounting the Thrust Bearing (if applicable)

OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 44 OIMPG MAINTENANCE 44 OIMPG MAINTENANCE 45 OIMPG MAINTENANCE 45 OIMPG MAINTENANCE 46 OIMPG MAINTENANCE 47 OIMPG MAINTENANCE 48

13. Mounting the Piping and Instruments


14. Mounting the Connecting Coupling 14.1 Fitting the Coupling Hubs

OIMPG MAINTENANCE 49 OIMPG MAINTENANCE 49 OIMPG MAINTENANCE 50 OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 51

14.2 Aligning the Connecting Coupling 14.3 Mounting the Coupling Connections


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DESCRIPTION

PAGE REFERENCE

15. Mounting the Guards Preventing Accidental 15.1 Coupling Guard 15.2 Coupling Cover 15.3 Guard Preventing Accidental for Shaft seal 15.4 Sound Insulating Hood

OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52

16. Maintenance of the Other Pump Set Components 16.1 Maintenance of Connecting coupling 16.2 Maintenance of Drive 16.3 Maintenance of Minimum Flow System 16.4 Maintenance of Instruments and Valves 16.5 Maintenance of Oil Supply Unit, etc. (if applicable) 16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable)

OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53

17. Spare Parts 17.1 Ordering Spare Parts 17.2 Spare Parts Stock 17.3 Storage

OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53

Chapter : Trouble Shooting

OIMPG TROUBLE-SHOOTING 1

1. General Information 1.2 Requisite Documentation 1.3 Prerequisites Problem / Possible causes / Measures Problem / Possible causes / Measures Problem / Possible causes / Measures Problem / Possible causes / Measures Problem / Possible causes / Measures

OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 2 OIMPG TROUBLE-SHOOTING 3 OIMPG TROUBLE-SHOOTING 4 OIMPG TROUBLE-SHOOTING 5 OIMPG TROUBLE-SHOOTING 6

Chapter : Tables of Clearances Antifriction Bearings Diametrical Clearance : Balancing Device Theoretical Axial Clearance Plane Bearings Diametrical Clearance : Balancing Device Theoretical Axial Clearance Bearing Clearance Plane Bearings, Heavy Theoretical Axial Clearance Bearing Clearance Diametrical Clearance : Balancing Device


OIMPG CLEAR AF 1 OIMPG CLEAR AF 2 OIMPG CLEAR AF 1 OIMPG CLEAR AF 2 OIMPG CLEAR PLANE 1 OIMPG CLEAR AF 2 OIMPG CLEAR PLANE H1 OIMPG CLEAR PLANE H1

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DESCRIPTION

PAGE REFERENCE

Chapter : Table of Tightening Torque 1. Prerequisites 2. Pump 3. Fastening of Pump Feet 4. Flange Connections Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle; Flanges as per DIN Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle; Flanges as per ANSI Bolts for Flange Connection, Suction Nozzle

OIMPG TIGHT TRQ 1 OIMPG TIGHT TRQ 1 OIMPG TIGHT TRQ 1 OIMPG TIGHT TRQ 1 OIMPG TIGHT TRQ 2 OIMPG TIGHT TRQ 3 OIMPG TIGHT TRQ 4

Chapter : Table of Weights HG Pump Size 1 HG Pump Size 2 HG Pump Size 3 HG Pump Size 3 HG Pump Size 4 HG Pump Size 5

OIMPG WEIGHT 1 OIMPG WEIGHT 2 OIMPG WEIGHT 3 OIMPG WEIGHT 4 OIMPG WEIGHT 5 OIMPG WEIGHT 6

Technical Data Technical Appendix


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General

Non-compliance with the regulations laid down in the instruction manual leads to forfeiture of any and all rights to claim for damages.

All work on the pump set must only be performed by properly trained personnel who are familiar with the dismantling/reasembly work required.

This instruction manual must always be kept close to the location of operation of the pump set for easy access.

We recommend to call in KSB’s experienced personnel for installation, commissioning/start-up, maintenance, and in case of problems.

OIMPG General 1

_____________________________________________________________________ 1. General Information This instruction manual contains fundamental information which must be complied with during work on the pump set. Therefore this instruction manual must be read both by the service engineers and responsible trained personnel, prior to commencement of work. All s must not only comply with the general safety instructions laid down in the chapter on “Safety”, but also the specific safety instructions included elsewhere in the instruction manual. KSB pumps are developed in accordance with state-of-the-art technology, are manufactured with utmost care and are subjected to continuous quality control. If they are properly installed, serviced and maintained, the pumps will give reliable and trouble-free operation. We recommend to call our specialist personnel for installation and commissioning/start-up. KSB will only assume responsibility for faultless execution of the work and for the safety of the personnel involved if dismantling/reassembly and maintenance have been performed by KSB’s specialist personnel. This pump set must not be operated beyond the limit values specified in the data sheets. Make sure that the operation in accordance with the instructions laid down in this manual. The operator must take into the information given in Technical Appendix, or in other parts of the instruction manual or in the contract documentation. It is of vital importance to observe the specified electrical connection values as well as the dismantling/reassembly and servicing instructions. In particular, it must be ensured that all necessary measures are taken and the regulations in accordance with the relevant legislation are complied with. ________________________________________________________________________________________

Caution

The temperature of the medium handled must not exceed the values indicated on the pump name plate.

________________________________________________________________________________________ ________________________________________________________________________________________

!

Operation of the pump set outside the conditions mentioned above may lead to overloads which, in turn, may result in personal injury and damage to property.

_______________________________________________________________ The descriptions and instructions set forth in this instruction manual refer to KSB’s scope of supply (e.g. pump or pump set). This instruction manual does not cover all possible eventualities or events which might occur during installation, maintenance, servicing and operation of the machine. Neither does the instruction manual take into any safety regulations applicable at the place of installation; the Operator must ensure that such regulations are strictly observed by all, including the personnel called in for execution of the work. Instructions on labels, tags and stickers attached to the pump set must be observed.

The pump name plate indicates the main data; 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 instruction manual, please KSB’s nearest customer service centre. In case of problems please your nearest customer service centre or the manufacturing works.

OIMPG General 2

_____________________________________________________________________ __________________________________________________________________________________________

Prior to returning any pump set components, carefully follow the ! instructions given in the Disposal section and in the chapter on ‘Commissioning, Start-up/Shut-down’ to avoid any risks (e.g. those posed by residues of the medium handled in the pump). ____________________________________________________________________________ ____________________________________________________________________________ Caution

All measuring instruments supplied with the pump should be calibrated before commissioning of the pump set. ____________________________________________________________________________ Set points of the instruments, wherever conveyed through operating instruction manual, are only as guideline, and final values are to be set on the site as per observations and requirements. ___________________________________________________________________________________________

Caution

The pump should never be run below the speed of 1000 rpm (higher limit in case of mechanical seals with pumping ring), even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for the pumps with variable frequency drive & pumps with hydraulic coupling. ____________________________________________________________________________ 2.

Disposal According to the local anti-pollution regulations - packaging components must be disposed of by the consignee - lubricants no longer used, cleaning material, media handled, electric equipment, etc. must be disposed of by the Operator at their own expense.

3.

Conformity with EU Regulations (if applicable) The relevant declaration as defined in EU Directive “Machinery” (89/292/EEC) is enclosed separately.

OIMPG General 3

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Safety Marking of Instructions in the Instruction Manual The safety instructions contained in this instruction manual which must be observed without fail to avoid hazards to persons are specially marked with the general hazard sign, namely

The electrical danger warning sign is

The word

Caution is used to introduce safety instructions which must be observed to avoid damage to the pump set and its functions. Instructions attached directly to the pump set, e.g. - the arrow indicating the direction of rotation - markings for fluid connections and safety instructions must always be complied with and be kept in perfectly legible condition at all times.

Personnel Qualification and Training All personnel involved in the work to be performed on the pump set 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 instruction manual are fully understood by his personnel.

Non-compliance with Safety Instructions Non-compliance with safety instructions can jeopardize the safety of the personnel, the environment and the pump set itself. Moreover non-compliance with these safety instructions may lead to forfeiture of any and all rights to claims for damages. In particular, non-compliance can, for example, result in: - failure of important pump set functions - hazard to persons by electrical, mechanical, chemical and thermal effects - hazard to the environment caused by leakage of hazardous substances.

Safety Awareness It is imperative to comply with safety instructions contained in this manual, the relevant national health and safety regulations, and the Operator’s own internal work, operation and safety regulations, if any.

Safety Instructions for the Operator/ Any hot or cold components of the pump set that could pose a hazard must be equipped with a guard preventing accidental by the Operator. Guards which are fitted to prevent accidental with moving parts must not be removed whilst the pump set is operating. Leakages (e.g. at the shaft seal) of hazardous media handled must be contained so as to avoid any hazard to persons and the environment caused by hot, toxic or explosive media. Pertinent legal provisions must be

OIMPG Safety 1

_____________________________________________________ adhered to. Any electrical hazard must be eliminated. For details, please refer to the relevant safety regulations of the individual countries or the local energy supply companies. The Operator must ensure that the pumps can be cooled down to a temperature below 50 0C and depressurized prior to any work on the pump set. The drives must have been disconnected from their energy supply (e.g. electrical power system, steam or fuel supply system) and secured so as to prevent unintentional starting.

Safety Instructions for Work on the Pump Set The operator is responsible for ensuring that all work on the pump set performed by authorized, qualified personnel who are thoroughly familiar with the contents of the instruction manual. Work on the pump set must be carried out only during standstill and after the pump or pump set has cooled down to a temperature below 50 0C. The shut down procedure described in the instruction manual for taking the pump set out of service must be adhered to without fail. Pump set components in with media injurious to health or harmful to the environment must be decontaminated by the Operator in accordance with the applicable local regulations. Immediately following completion of the work, all safetyrelevant and protective devices must be re-installed or re-activated. Please observe all instructions set out in chapter on ‘Commissioning, Start-up/Shutdown’ before returning the pump set to service.

Unauthorized Modification and Manufacture of Spare Parts Any modifications or alterations of the pump set are permitted only after consultation with and approval by the manufacturer. Original spare parts and accessories authorized by the manufacturer ensure safety. The use of other parts invalidates any liability of the manufacturer for damage resulting thereof.

Unauthorized Modes of Operation The warranty relating to the operating reliability and safety of the supplied pump set is only valid if it is used in accordance with its designated use and if all operating instructions described in chapter ‘General’ of the instruction manual have been followed. The limits stated in data sheets must neither be exceeded nor underrun under any circumstances. Deviations require prior consultation with KSB.

Markings Lifting links All lifting links are marked with the chain symbol.

0

0

Temperature > 80 C/176 F It is imperative to observe the information plate on the pump.

OIMPG Safety 2

Transport / Interim Storage 1.

General Information

Caution

Check the load carrying capacity of the floor (consult the building drawing) before starting with the transport and hoisting work. Above all give due attention to the position of the centre of gravity.

Observe the applicable local safety regulations. Loose parts must be fastened so as to prevent them from falling down. If a crane is used, check the brake of the hoisting gear by trial braking under load. After fastening the ropes, align the crane hook in such a manner that the crane hoisting ropes are suspended vertically. Loads must be lifted at a right angle to the drum axis of the rope winch. Loads must not be lifted at an angle. Keep the period of tome for which the load is in free suspension to a minimum. Use a guide rope in addition if long objects are handled. Transport of persons together with load is not permitted. Keep out of the danger area. Work under suspended loads is not permitted. The permissible lifting capacity of the lifting equipment must not be exceeded. Lower the loads at the lowest lowering speed of the hoist.

1.1

Hoisting Tackle (e.g. ropes, gear)

1.1.1

To determine the lifting capacity, give due consideration to the position of the center of gravity, the angle of spread and bending radii of the lifting links attached to the load to be lifted. Do not use chains, if possible.

1.1.2

Hoisting tackle, and any transport device that might be required, must only be attached in accordance with section 2 and 3 in this chapter. Damaged or untested hoisting tackle must not be used 1.1.3

For selection and attachment, only follow the instructions given by the person responsible for this.

1.2

Signals during Transport Only follow the instructions given by responsible for giving signals during transporting.

_____________________________________________________________________ 3.1

Transport of the Pump Set For transporting the pump set components mounted on the base plate, shackles must be attached to the lifting lugs of the pump/baseplate. __________________________________________________________________ Caution Do not damage any built-on accessories and pipes. __________________________________________________________________

Transport of pump sets mounted on baseplates ( examples )

OIMPG TRANSPORT 3

_____________________________________________________________________ 3.2

Transport of the Pump Attach the hoisting tackle as shown in the figure or to the marked lifting links. _________________________________________________________________ Caution

Do not attach the ropes to the shaft ends or bearing housings. Secure the pump against overturning. _________________________________________________________________

OIMPG TRANSPORT 4

_____________________________________________________________________ 3.3 Transport of the Other Pump Set Components 3.3.1 Transport the other pump set components in accordance with the relevant manufacturer’s documentation. 3.3.2 If these components are included in KSB’s scope of supply, the relevant documents mentioned elsewhere in the manual. 3.4 Transport of the Pump Rotor 3.4.1 Attach hemp or plastic ropes as required by the length of the pump rotor and transport the pump rotor horizontally; see figure. _______________________________________________________________________ Caution

Do not use wire ropes or chains in order not to damage the pump rotor. _______________________________________________________________________

3.4.2 When setting the pump rotor down, it must be ed so that it is not damaged and is secured against overturning/rolling. OIMPG TRANSPORT 5

_____________________________________________________________________ 3.5

Transport of Pump Set Accessories Attach the hoisting tackle as shown in the figure. ______________________________________________________________________ Caution

Do not exert pressure on the strainer element and strainer meshes or damage them. We recommend transport by hand. ______________________________________________________________________

<120° <120°

OIMPG TRANSPORT 6

<120°

_____________________________________________________________________ 4.

Interim Storage

4.1

Prerequisites ______________________________________________________________________ Caution

The load carrying capacity of the floor of the storage area must be adequately designed. ______________________________________________________________________ 4.1.1 Weights with packaging : see packing list. 4.1.2 Weights without packaging : See table of weights given in Technical Appendix. 4.1.3 Check each package for damage before it is stored. In case of transport damage, asses the exact damage, document it and notify KSB about the damage, in writing, immediately. ______________________________________________________________________ Caution

4.2

All openings of the mounted pump set components are closed and must not be opened before they are needed during installation. _______________________________________________________________________ Place of Storage _______________________________________________________________________ Caution

Protect the stored components from humidity, dirt, vermin and unauthorized access. _______________________________________________________________________ 4.2.1 All components supplied should be stored in a dry room where the atmospheric humidity is as constant as possible. 4.2.2 In case of outdoor storage it is absolutely necessary to cover the pump set and crates to form watertight barrier and to protect them against condensation of water so that any with humidity is avoided. ______________________________________________________________________ Elastomeric parts must not be stored together with chemicals, solvents, fuels, acids, etc. In addition, they should be kept away from Caution light, in particular sunlight, strong artificial light high in ultraviolet rays. _______________________________________________________________________ 4.3 4.4

Period of Storage up to 12 Months The pimp is supplied duly preserved for storage up to 12 months (standard preservation). Period of Storage over 12 Months If the pump is to be stored more than 12 months, it must be preserved appropriately. If the requisite preservation measures have not been performed by KSB (special preservation), they must be discussed with and approved by KSB prior to putting the pump into storage. _______________________________________________________________________ Caution

In case of storage periods of more than 5 years, the pump must be dismantled before it is installed, and the O-rings must be replaced. _______________________________________________________________________

OIMPG TRANSPORT 7

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Installation on Site Conditions Foundation -

has been prepared the concrete has set the surface is truly horizontal and even (check with a spirit level, accuracy < 0.3 mm/m in longitudinal and cross directions. The area surrounding the foundation holes is truly horizontal and even.

Site management -

has checked the dimensional accuracy of the foundation and its correct position as per the reference points given in the foundation and building drawing. Has marked the center line of the foundation Has released the foundation

Place of installation -

is cleared its condition is such that the installation can be performed without interruptions adequate devices for aligning are available

Drive way to the place of installation -

is cleared is suitable for transport

Adequate means of transport -

including personnel are available until completion of the installation work

Preparations Checking the foundation -

for dimensional accuracy in accordance with GA drawing. Whether the foundation is truly horizontal and even Whether the area surrounding the foundation holes is truly horizontal and even.

Correct deviating foundation dimensions -

by adequate measures after consultation with site management

Transporting the pump set components to the place of installation - using adequate means of transport - For weights, please refer to GA drawing _____________________________________________________________________________________

Caution

For transport, the guidelines of the chapters on Safety, and Transport/Interim Storage must be complied with. _______________________________________________________________________

Installation 1

_____________________________________________________________________ Removal of packaging -

not until the installation work actually starts Avoid damaging the pump set All connection points must be closed The packaging must be disposed off by the consignee (responsible contractor)

_____________________________________________________________________________________

!

If parts have to be lifted to remove the packaging, proceed as described in the chapter on Transport / Interim Storage.

______________________________________________________________________________________________

Protecting the pump set components _____________________________________________________________________________________

Caution

Components remaining on site have to be protected against dirt, humidity and damage. If components of the pump set are received damaged, wet or dirty, inform KSB. _______________________________________________________________________ Completely cover the pump set components to protect them for the full duration of the installation work on site against construction site dirt, spark discharge, grinding dust and other harmful ambient influences. Take special care to adequately protect instruments, electrical cables and wiring ducts. - Spare parts and parts which are not immediately needed must be stored in such a way that they are protected from dirt accumulation, humidity and damage. _____________________________________________________________________________________ -

Caution

Do not store elastomeric parts together with chemicals, solvents, fuels, acids etc. In addition, they should be kept away from the light, particular direct sunlight and strong artificial light high in ultraviolet light. _______________________________________________________________________

Installation 2

PROCEDURE FOR LEVELLING & GROUTING OF BASE FRAME AT SITE ( FOR HDA / HDB / HG / CHT PUMPS ONLY ) PURPOSE : High speed rotory equipment needs to be installed with maximum area between base frame and the foundation. To achieve this conventionally, blue matching procedure is adopted between packer plates and foundation. This calls for skilled millwright fitters to work on and consumes lot of time. Despite this, the area achieved is nowhere near 100%. Therefore, the following procedure is recommended which ensures : 1. Nearly 100% area between the foundation, the packer plates and the base frame. 2. Considerable saving in time and manpower. PREPARATION : The following preparation is followed, in case the base frame and the packer plates ( equal to the number of foundation bolts ) are in scope of KSB. Otherwise, the is requested to follow the preparation as under : l l

The base frame is provided with the pads, which are welded at the bottom, machined in one setting and drilled to 15 mm. Dia. ( Ref. Fig. 1). Machined packer plates, having 0.02 mm. face parallality, and of the dimensions equal to the welded pads at the bottom of the base frame, are required with tapping of M 10. These packer plates are to be bolted with pads at the bottom of the base frame, using M10 bolts ( Ref. Fig. 2 & 3 ).

PROCEDURE : 01.Bolt the pump on the base frame. 02.Bolt the packer plates on the bottom pads of the base frame. 03.Place the unit on the foundation. 04.Suspend foundation bolts into the pockets provided on the foundation blocks. 05.Level the pump on the delivery flange or feet, within 0.04 mm. per meter, using jacking bolts pro vided at the corners of the base frame. 06.Grout the foundation bolts and the packer plates by using quick setting non-shrink cement, ACC make ‘Shrinkkomp’ or Forsoc make ‘Cobextra-GP2’ or equivalent ( Ref. Fig. 4 ). 07.Allow curing time of 24 to 72 hours depending upon the grout used. 08.Remove M 10 bolts, which are holding packer plates with the base frame. 09.Carry out final levelling by inserting shims (SS shims preferred) between packer plates and the base frame. 10.Tighten the foundation bolts and recheck the levelling. Correct it, if necessary. 11. Grout the complete base frame, including the hollow portion, if any, using conventional grouting mix, i.e., portland cement, sand and aggregate in proportion 1 : 2 : 2 and gravel size not to exceed 20 mm. 12.Plaster the foundation and apply suitable oil resistant paint.

GEN 02.01 I

6

Base frame

Base frame for bottom pads machined with ∅15 plain holes

Weld

Fig. 1 : Base frame bottom pad

Found bolt M10

M10

Packer plate

Found bolt Packer plate

➮

W

View from W

➮

Fig. 2 : Packer plates in pairs, machined for for base frame with channel

Z

View from Z

Fig. 2A : Packer plates in pairs, machined for base frame with double channel / I beam

M20 through for leveling

M10 bolts Base frame

∅15

Fig. 3 : Clamping of packer plate and bottom pads with M10 bolts 20 Base frame

Non shrink cement grout

Levelling bolts

15 30

Found block

80 min.

∅d

1.5xd

Fig. 4 : Grouting of packer plate Note :

GEN 02.01I

The foundation to be made of concrete on solid ground. Foundation bolts and packer plates to be grouted with non shrink grout only. Balance hollow portion of base frame to be grouted with portland cement sand and aggreegate in preparation 1:2.2 Gravel size should be < 20 mm. After final grouting all surface should be finished with fine plaster and apply oil resistent paint. 6a

_____________________________________________________________________ Making the piping General information - The pipes are already mounted within the dimensions of base frame. - Straight length pipes are supplied for further connection of piping, if within the scope of KSB supply. Bends and flanges are supplied loose. - Offset at flanges and pipe connections is not allowed.

Cleaning the piping General information - Pipes delivered by KSB are cleaned and closed. - The pipes delivered shall be checked for subsequent impurities in the interior and cleaned, if required. ___________________________________________________________________________________________

Caution Pipes made on the site must be cleaned prior to final mounting. ____________________________________________________________________________ Connecting the piping General information - Run the pipes as indicated in the G. A. Drawing. - Do not remove the covers on the pump nozzles and the desiccants till the pipes are to be actually connected. Disposal by the consignee / Operator. - The nominal diameters of the pipes shall be at least equal to the pump connections. - It is recommended to fit check valves and isolating valves. - The thermal expansions of the pipes must be compensated by suitable measures in order not to transfer them on the pump. - The suction piping must be slanting towards the pump. - The weight of the suction piping must not transfer on the pump. - Under no circumstances the pump should be used as an anchorage point for the piping. ___________________________________________________________________________________________

Caution

Connect all the pipes in cold condition and without transmitting any stresses or strains. The unbalance of the forces and moments created by the suction / discharge piping must not exceed the permissible values. (Refer G. A. Drawing) ____________________________________________________________________________ Suction piping - Not the part of KSB scope of supply. - Clean the tank and pipe prior to fitting. Balancing liquid piping - The balancing liquid piping is connected back to the suction nozzle. - If the balancing liquid piping is connected back to the suction vessel (deaerator) the flow velocity in the balancing liquid piping should on no exceed 5 m/s. The pressure of the balancing liquid must at least 0.5 bar higher than the suction pressure (at the pump suction nozzle), and the permissible damping pressure must not exceed 2.5 % of the maximum discharge pressure. Discharge piping - Not the part of KSB scope of supply. Flushing piping - The piping is already installed. Minimum flow system - On the discharge side of the pump, a minimum flow control valve is required. G. A. Drawing indicates whether it is in KSB’s scope of supply. - Refer separate operating instructions for Minimum flow control valve.

Installation 3

_____________________________________________________________________ Minimum flow piping - Not the part of KSB’s scope of supply. Return piping - For drain and leakage liquids, the Operator must fit a return piping. Connections and dimensions are specified in the G. A. drawing. Information about readiness for connection of the piping - Inform the responsible site management that the piping is ready for connection. - Do not continue the piping unless the required piping by the Operator is completed. Checking the alignment - Repeat the alignment of the coupling, after the completion of piping by the Operator. - Enter the final measuring results in the coordinate system of the alignment / acceptance record sheet of each connecting coupling. - Record the shaft displacements due to vertical and lateral misalignment of the pump set components under “remarks”. - Have the alignment/acceptance record sheet confirmed by the responsible site management and distribute it to the authorized persons. - Have the table of tightening torques for all fastening screws and foundation bolts checked and confirmed by responsible site management. Mounting the instruments General information - Measuring lines with isolation valves have been installed. - Do not remove the plugs of the connection points till the actual mounting. - Just before commissioning / start up perform the functional test. - Laying of electrical cables varies according to the constructional conditions. Cables must be layed in the conduits up to the points just near the actual measuring point. - Electrical cable connections must be done by authorized personnel. Mounting the pressure gauges - Insert the sealing disc. - Select the pressure gauge with sufficient measuring range. Mounting the oil sight gauge - Remove the plug and screw in the oil sight gauge with seal. - Attach required extension piece.

Detailed description of preservation for standstill Close the suction, discharge and minimum flow pipe and secure against opening. Close all openings and inlet pipes. Introduce and fasten desiccants in the pump or the strainer casing. For quality, identification and monitoring of the desiccants please refer to DIN 55473 and DIN 55474. In case of water ingress, open the pump drain, flush the pump interior, close the pump drain and re-preserve the pump interior. - Remove visible foreign matter which falls in the pump through the pump nozzle. In case of problem in removing the foreign matter, inform KSB. Additional measures after standstill of 6 months. - Dismantle the spacer sleeve of the coupling, preserve it and the bolts using an appropriate preservative, pack into foil and store properly. -

Installation 4

_____________________________________________________________________ Detailed description of mounting/dismantling the connecting coupling General Information ____________________________________________________________________________ Caution Check the shaft ends for runout, prior to mounting the coupling hubs. Permissible tolerance < 0.04 mm (see figure Runout check of the shaft ends). If the tolerance is exceeded, please inform KSB. Observe the manufacturer’s mounting/dismantling instructions. The pump shaft’s check values shall be read after a 900 turn. ____________________________________________________________________________

Runout check of Shaft ends

z Mounting Fitting the coupling hubs Thoroughly clean shaft ends and bores of the coupling hubs and check them for dimensional accuracy. Slightly deburr the hub grooves and insert the key. Check the protrudent dimension of the key. Tolerance in accordance with the figure Clearance between groove and key.

0.2-0.3mm

-

Clearance between groove and key

In case of a cylindrical shaft with key, smear the shaft end and coupling hub end with an adequate antiseize agent. 0 - To facilitate fitting, the coupling hub may be heated evenly to a temperature of 80 C max. Elastomeric parts must be removed before heating! ___________________________________________________________________________________________ -

Caution

Do not use elastomers which have already been heated up once. Use new parts!

______________________________________________________________________________________________________

Installation 5

_____________________________________________________________________ Use safety gloves. Risk of fire in case of open fire. Remove inflammable material ____________________________________________________________________________ -

Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft end and the hub face match. ___________________________________________________________________________________________

Caution

Fit the coupling hubs only using the appropriate device to prevent the shaft bearings from damages by the axial friction force. Impacts on the coupling hubs are not allowed. ____________________________________________________________________________ X = thread size, refer Technical Appendix.

-

Securely tighten the grub screws, wherever provided.

Connecting the coupling hubs - Assemble the connecting coupling as described in manufacturer’s documentation. Dismantling Preparations - Make sure that the connecting coupling is marked or mark the connecting coupling in order to avoid subsequent confusions.

Installation 6

_____________________________________________________________________ Detailed description of connecting coupling alignment 1. Conditions -

Shaft distances as indicated in the G. A. drawing. Pump set components are set in place on the base frame. Coupling hubs are mounted in accordance with the description under Detailed description of mounting/dismantling the connecting coupling.

2. Preparations -

Dismantle the coupling guards mounted to the pump set as described under Detailed description of mounting/dismantling the connecting coupling guards, and store them appropriately. Separate the couplings mounted to the pump set as described under Detailed description of mounting/dismantling the connecting coupling. Comply with the coupling hub distance shown in the G. A. drawing.

3. Runout check of the coupling hubs -

Check the coupling halves using a dial micrometer. Use spacer plates.

Arrangement of spacer plates ( examples )

!

Secure the drive against unintentional starting. ____________________________________________________________________________ -

True running tolerance ≤ 0.04 mm. If true running tolerance > 0.04 mm : inform KSB

Runout check ( example )

Installation 8

_____________________________________________________________________ 4. Alignment of coupling General information - Align the coupling when the pump is cold (< 500 C/ 1220 F). - In case of motors with axial tolerance, their rotors must be set in the magnetic center. For this purpose, either set the rotor to the center marking made by the manufacturer (if any) or to the center position between right and left side. - Move the pump shaft towards the suction casing until the rotor abuts.

Order of alignment :pump – drive. Alignment using dial micrometer ___________________________________________________________________________________________

Caution

The coupling must not be turned at the alignment device. Do not damage the shaft and hubs. ___________________________________________________________________________

Device for connecting coupling with spacer sleeve ( example )

Installation 9

_____________________________________________________________________ Radial misalignment of the coupling hubs - Permissible value : ∆kr ≤ 0.04 mm, measured at 4 points at a distance of 900. ___________________________________________________________________________________________

Caution

∆kr < 0.04 mm/0.016 inch + vertical/lateral misalignment. (For dimensions, please refer to the section Alignment corrections)

Kr

___________________________________________________________________________________________

Angular misalignment of the coupling hubs in horizontal direction - Permissible value : ∆kh ≤ 0.04 mm ∆ kh =

Smax – Smin _________________ 2

Angular misalignment of the coupling hubs in vertical direction - Permissible value : ∆kv ≤ 0.04 mm ∆ kv =

Smax – Smin _________________ 2

Smax.

Smin.

5. Alignment corrections Vertical correction Pump :

Installation 10

_____________________________________________________________________ 6. Pinning the feet Pump

A

D

C Pinning the pump feet

A = nozzle orientation in accordance with the G. A. drawing. C = drill and mount after final adjustment of the pump at the place installation. ( Drill 10mm diameter x 20mm deep ) D = tighten the bolts and lock the nuts with locknuts. Drive : - In accordance with the manufacturer’s documentation.

Detailed description of mounting/dismantling the guards Coupling guard _______________________________________________________________________ Caution The pump must not be operated without coupling guard. _______________________________________________________________________ Mounting the coupling guard : - Align the coupling guard over the connecting coupling. - Make sure there is an adequate distance from both shaft ends and the coupling halves. - Fasten the coupling guard adequately with bolts.

Coupling guard ( example )

Installation 12

_____________________________________________________________________ Dismantling the coupling guard : - Remove the guard and store it appropriately.

Cladding (touch guard) for the shaft seal _____________________________________________________________________________________

Caution

The pump must not be operated without cladding (touch guard)

_____________________________________________________________________________________ Mounting the cladding (touch guard) : - Fasten the cladding (touch guard) adequately with bolts at the bearing housing. Dismantling cladding (touch guard) : - Remove the guard and store it appropriately.

Installation 13

_____________________________________________________________________

Commissioning, Start-up/Shutdown 1. Work to be carried out prior to Commissioning, Start-up _________________________________________________________________________ Caution

Improper handling of preservatives, oil and grease causes hazardous environmental impact. Handling and disposal only by qualified personnel! _________________________________________________________________________ 1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc., please refer P & I Diagram.

1.2 General Information 1.2.1 In addition to this instruction manual of pump portion, the technical documents (instruction manuals) of other accessories & instrumentation etc. are also needed for commissioning/start-up and shutdown. If these are part of scope of supply of KSB, the relevant instruction manuals are separately enclosed. 1.2.2 Perform all dismantling and reassembly work in accordance with chapter ‘Maintenance’.

1.3 Removal of Preservation 1.3.1 If the pump has been filled with a glycol/water mixture for preservation, this fill must be drained before further work is started. 1.3.1.1 Open the pump drain (6B), collect fill in an appropriate container and dispose of according to the local anti-pollution regulations. 1.3.1.2 Close the pump drain. 1.3.2 Flush sufficiently to remove any residues of the preservative. 1.3.3 Remove the grease on the out sides of all pump set components.

1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6

1.5

Additional Work to Be Carried out Prior to Returning to Service after Standstill > 12 Months Dismantle the pump-end coupling hub. Dismantle the bearing. Dismantle the mechanical seal and check it in accordance with the manufacturer’s documentation. If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a new seal must be fitted. Re-mount the bearing and, in case of pump with plain bearings, lift the pump rotor. Re-mount the pump-end coupling hub.

Topping up the Bearings with Lubricating Oil

1.5.1 General Information 1.5.1.1 Oil quality, refer Technical Appendix. 1.5.1.2 After standstill > 12 months, check the oil quality. Clean or replace the oil, if required. 1.5.1.3 Filter the oil prior to topping up; filter mesh size 30 µm.

_______________________________________________________________________ Caution

During operation, the oil level in the bearing housing falls! Check the oil level only during standstill of pump! _______________________________________________________________________ 1.5.2

Bearing with Oil Sight Gauge

OIMPG COMM 31

________________________________________________________________________ 1.5.2.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the minimum and maximum markings of the oil sight gauge (639). 1.5.2.2 Fit the vent plug (913.01 or 672) again. 1.5.3 Lift-off Device (if applicable) 1.5.3.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the minimum and maximum markings of the oil sight glass (642.01). 1.5.3.2 Fit the vent plug (913.01 or 672) again. 1.5.4 1.5.4.1 1.5.4.2 1.5.4.3

Bearing with Constant Level Oiler (if applicable) Remove the vent plug (913.01 or 672). Hinge down the constant level oiler (638). Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of the connecting elbow of the constant level oiler, see figure Constant level oiler. 1.5.4.4 Fill the reservoir of the constant level oiler with oil and snap it back into operating position. 1.5.4.5 Fit the vent plug (913.01 or 913.02 or 672) again. 1.5.4.6 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one third of the reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________

Caution

The oil level always be below the level of the vent opening arranged at the top edge of the connecting elbow. Make sure the opening is always perfectly dry.

Position of reservoir for topping up oil

Oil level

Constant level oiler 1.5.5 Other accessories Fill with oil in accordance with the manufacturer’s documentation.

1.6 Checking the Direction of Rotation If the pump set is driven by an electric motor, the direction of rotation of the motor must be checked prior to Commissioning/start-up. _____________________________________________________________________________________

! Secure the drive against unintentional starting. _______________________________________________________________________

OIMPG COMM 32

_____________________________________________________________________ 1.6.1 Prerequisites 1.6.1.1 1.6.1.2 1.6.1.3

Check the direction of rotation prior to the final assembly of the connecting coupling. Comply with the manufacturer’s documentation. The electric motor is provided with a lubricant.

1.6.2 Direction of Rotation 1.6.2.1

1.6.2.2

The pump’s direction of rotation is indicated by an arrow on the driven-end bearing housing. In order to ensure the correct direction of rotation, the direction of rotation of the drive must correspond to the direction indicated in the G. A. drawing. The direction of rotation of the drive is indicated in the G. A. drawing.

1.6.3 Checking the Direction of Rotation with a Phase-sequence Indicator The direction of rotation of the electric motor can be checked by means of an electromagnetic phasesequence indicator.

1.6.4 Checking the Direction of Rotation without Phase-sequence Indicator 1.6.4.1 In the case of curve tooth coupling, fix the drive-end coupling sleeve on the hub using spacer plate (if applicable – supplied loose), see figure Arrangement of spacer plates.

Arrangement of spacer plates (example) 1.6.4.2 The electric motor shall be switched on by authorized personnel for a short period of time. 1.6.4.3 Switch off the electric motor again immediately before the operating speed is reached. 1.6.4.4 Check the direction of rotation. If wrong, have the terminal connections reversed by authorized personnel and check the direction of rotation once again. _____________________________________________________________________________________

Caution Mark the connections in the terminal box. _______________________________________________________________________ _______________________________________________________________________

! Secure the drive against unintentional starting. ____________________________________________________________

OIMPG COMM 33

_____________________________________________________________________

1.6.4.5 In case of electric motors with axial float, if applicable, the coupling hub of motor shaft must be realigned as required by the actual magnetic center. If coupling has a spacer, it must be possible to mount and remove it.

1.7

Rotatibility of the Pump Rotor

1.7.1

In the case of curved tooth coupling, fix the pump-end coupling sleeve on the hub using spacer plate (if applicable – supplied loose), see figure Arrangement of spacer plates. Prior to start of the work, check the oil level in the bearing housings. It must be easy to rotate the pump rotor by hand, and it may be only rotated in the direction of rotation of the pump. If necessary, attach an appropriate tool at the coupling hub, see figure Rotatability of the pump rotor. In case the pump with balancing disc without lift off device, move the pump rotor towards the driven end by approx. 1 mm before you turn it by hand, see figure Rotatability of the pump rotor.

1.7.2 1.7.3

1.7.4

Rotatability of the pump rotor ( example )

1.8 Mounting the Connecting Coupling Mount the spacer of the connecting coupling as described in the manufacturer’s documentation.

1.9 Mounting Guards Preventing Accidental s Mount all guards preventing accidental .

1.10 Functional Test and Adjustment of The Instruments 1.10.1 Check all the instruments in accordance with the individual manufacturer’s documentation for correct measuring data and adjust the instruments, if required.

OIMPG COMM 34

_____________________________________________________________________ _____________________________________________________________________________________

Caution

All measuring instruments supplied with the pump should be calibrated before commissioning of the pump set. _______________________________________________________________________ 1.10.2 Set the Alarm & Trip values in accordance with the Logic Diagram, in cooperation with control engineering specialists. _____________________________________________________________________________________

Caution

The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for the pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________

2. Commissioning, Start-up 2.1 Prerequisites 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7

Installation and alignment have been performed in accordance with good engineering practice, recorded and accepted by the Operator. The pump rotor’s rotatability by hand has been checked. All pump set components have been checked in accordance with the relevant manufacturer’s documentation. The direction of rotation of the drive has been checked. All guards preventing accidental have been mounted. All pipes have been cleaned and connected. All instruments have been fitted and checked for correct functioning.

2.2 Priming 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

Close all drains and drain pipes. Fully open the cooling water main valve and all cooling water throttle valves. Vent the complete cooling water circuit. Vent the complete mechanical seal cooling circuit. Monitor the cooling water flow at the sight glasses or flow indicators. _____________________________________________________________________________________

Caution

Do not cool the cooling chamber and heat exchangers with aggressive untreated water. _______________________________________________________________________ 2.2.6 2.2.7 2.2.8

If applicable, check the filter in the mechanical seal’s cooling circuit and clean, if required. Open the valves in the minimum flow line. Check the oil levels and top up with oil, if required. _____________________________________________________________________________________

During operation, the oil level in the bearing housing falls! Check the oil levels only during standstill of the pump! ______________________________________________________________________ Caution

2.2.9 2.2.10 2.2.11 2.2.12 2.2.13

If there is no by, open the gate valve in the suction piping by 10 to 20 %. Prime the suction piping, pump and discharge piping up to the closed discharge gate valve. Vent all pressure gauge lines until there is no more air to escape. Fully open the valve in the suction piping. Check whether suction pressure is available.

OIMPG COMM 35

_____________________________________________________________________ 2.3 Checks Prior to Starting 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9 2.3.10 2.3.11

The suction tank, suction piping, pump and discharge piping have been primed and vented. The valve in the suction piping is fully open. The valve in the discharge piping is fully closed. The connection for tapping, if applicable, is closed. The shut-off valves in the stand-by heating system, if applicable, are closed. The shut-off valves in the minimum flow line are open. The cooling water system is in operation. The cooling liquid pressure at the inlet must not exceed 6 bar. The cooling liquid temperature at the outlet must not exceed 550 C. All temperatures indicated are below the limit values. In the case of a pump set with variable speed coupling, check the scoop tube position for compliance with the manufacturer’s documentation and readjust, if required. 2.3.12 Check all pipes, flanges, screw/bolt connections and pipe unions for leakage.

2.4 Starting and Trial Run _______________________________________________________________________ Caution

Should alarm signals or problems occur during starting or trial run, proceed as described in chapter Trouble shooting! _______________________________________________________________________ _______________________________________________________________________ The minimum discharge head of 150 m must not be underrun, except the start-up and shutdown phases. The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for the pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________ Caution

2.4.1 Switch on the drive as described in the manufacturer’s documentation. 2.4.2 For pump set with variable speed coupling : 2.4.2.1 The drive is operating at maximum speed. Due to the scoop tube position, however, the pump is operating at a minimum speed of 1000 rpm or a minimum head of Hmin = 150 m. 2.4.2.2 Adjust the pump to minimum flow by changing the scoop tube position. 2.4.3 Monitor the temperature and smooth running of the bearings. 2.4.4 Monitor the pump pressures and differential pressures. 2.4.5 Make sure the minimum flow control valve works (hydrodynamic noise). _____________________________________________________________________________________

! The minimum flow pipe gets hot. ____________________________________________________________ 2.4.6 Check the mechanical seals. Mechanical seal must not drip. 2.4.7 For pump set with variable speed coupling: 2.4.7.1 For minimum speed or minimum head (pump) set the limiting cams of the scoop tube positioning device to approx. 80% (can be read on the scale). 2.4.7.2 Increase the pump speed until the operating speed is reached. 2.4.8 Slowly open the valve of the discharge pipe until it is completely open.

OIMPG COMM 36

_____________________________________________________________________ 2.4.9 Permanently monitor the pump set’s operating behaviour. 2.4.10 Open the shut-off valves upstream and downstream of the orifice plate in the stand-by heating system, if applicable. _____________________________________________________________________________________

Caution

Close the shut-off valves of the standby heating system only for maintenance work of the pump. _______________________________________________________________________ 2.4.11 For mechanical seals with circulating cooling : If there is a magnetic separator, check after its commissioning/start-up whether the temperature of the circulation liquid remains constant.

3. Shutdown 3.1 Pump set remains ready for Operation 3.1.1 3.1.2

Close the valve in the discharge pipe. Make sure the minimum flow control vale works. _____________________________________________________________________________________

!

The minimum flow pipe gets hot. _______________________________________________________________________ _______________________________________________________________________ Caution

The minimum discharge head of 150 m must not be underrun, except in the start-up and shutdown phases. The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________ 3.1.3 3.1.4 3.1.5 3.1.6

In the case of a pump set with variable speed coupling reduce the speed until the minimum head or minimum speed is reached. Switch off the drive, making sure it runs smoothly down to a standstill. Note the run down time. The cooling water remains on!

3.2 For Maintenance of the Pump Set or Prolonged Standstill 3.2.1 3.2.2

Close the valve in the discharge pipe. Make sure the minimum flow control valve works. _____________________________________________________________________________________

! The minimum flow pipe gets hot. ____________________________________________________________

OIMPG COMM 37

_____________________________________________________________________ _______________________________________________________________________ Caution

The minimum discharge head of 150 m must not be underrun, except in the start-up and shutdown phases. The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________ 3.2.3

In the case of a pump set with variable speed coupling reduce the speed until the minimum head or minimum speed is reached. Switch off the drive, making sure it runs smoothly down to a standstill. Note the run down time. _____________________________________________________________________________________

3.2.4 3.2.5

! Secure the drive against unintentional starting. _______________________________________________________________________ 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11

Close the shut-off valve in the tapping pipe, if applicable. Close the shut-off valves of the standby heating system, if applicable. Close the shut-off valves in the minimum flow line. Close the shut-off valves in inlet pipe. Turn off the cooling water when the casing temperature, measured the pump nozzles, is lower than 500 C. Close the other pipes.

4. Work after shutdown 4.1 During Readiness for Instant Start-up 4.1.1

General Information If the period of standstill during readiness for start-up is longer than 2 weeks, the pump set components such as gear or variable speed coupling must be protected against water ingress and humidity as described in the manufacturer’s preservation instructions.

4.1.2 Every 4 to 6 weeks 4.1.2.1 Put the pump into operation as described in Commissioning, Start-up section of this chapter. 4.1.2.2 Switch off the pump after approx. 10 minutes as described in Shutdown section of this chapter. 4.1.2.3 Check at the connecting coupling whether pump rotor runs down smoothly to a standstill. 4.1.3

Every two months (in the case of pump set with variable speed coupling) If the scoop tube actuator was used during stand-by operation, re-lubricate the guide bush; see the manufacturer’s documentation.

4.2 For Maintenance of the Pump set _________________________________________________________________________

!

The pump has been depressurized and the casing temperature is < 500 C, measured at the pump nozzles!

______________________________________________________________ 4.2.1 4.2.2 4.2.3

Secure all valves against opening. Open all drains and/or drain pipes. Collect the fill in an appropriate container and dispose off according to local anti-pollution regulations.

OIMPG COMM 38

_____________________________________________________________________ _____________________________________________________________________________________

!

If the medium handled is toxic, inflammable, explosive or hazardous in a different way, the pump must be flushed thoroughly to avoid that any residues remain in the pump.

____________________________________________________________ 4.2.4

If the period of standstill is longer than 2 weeks, the pump set components such as gear or variable speed coupling must be protected against water ingress and humidity as described in the manufacturer’s preservation instructions.

4.3 Standstill, Pump not Ready for Operation. 4.3.1

General information _____________________________________________________________________________________

Caution

In the case of dander of frost, the pump must be drained and preserved as described under Detailed Description of Preservation for Standstill in this chapter. _______________________________________________________________________ 4.3.1.1 Secure all valves against opening. 4.3.1.2 Close all openings and supply pipes. 4.3.2 Standstill > 2 Weeks 4.3.2.1 Preserve the pump as described under Detailed Description of Preservation for Standstill in this chapter. 4.3.2.2 Protect the pump set components such as gear or variable speed coupling against water ingress and humidity as described in the manufacturer’s preservation instructions.

5. Detailed Description of Preservation for Standstill ________________________________________________________________________ The pump has been depressurized and the casing temperature is < 500 C, measured at the pump nozzles! _________________________________________________________________________

!

5.1 Secure all valves against opening. 5.2 Open all drain and/or drain pipes. 5.3 Collect the fill in an appropriate container and dispose of according to anti-pollution regulations. ________________________________________________________________________________________

!

If the medium handled is toxic, inflammable, explosive or hazardous in a different way, the pump must be flushed thoroughly to avoid that any residues remain in the pump. _________________________________________________________________________ 5.4 Close all drains and/or drain pipes. 5.5 Fill the pump with glycol/water mixture at a proportion of 1 : 2. 0 Important : This mixture ensures protection against frost up to approx. – 20 C. A mixture at a proportion of 1 : 1 increases the protection up to –420C. 5.6 Dismantle and store the coupling guards mounted on the pump set. 5.7 Dismantle and store the connecting coupling spacer in accordance with the manufacturer’s documentation. 5.8 If necessary, fill the bearing housing with oil. 5.9 Rotate the pump rotor once or twice a month to prevent a separation of the preservation fill, check the fill level and top up, if required.

OIMPG COMM 39

_____________________________________________________________________ Supervision of Rotor Position (only for the pumps with Balancing Disc) The Rotor Position Indicator is mounted on the discharge side of the pump. There are two types of Rotor Position Indicators. The first and most commonly used by KSB India, consists of the indicator bush (623) screwed on the bearing end cover, which is the stationary part, and the rotating indicator (624) is screwed in the shaft threading. The bush has two scriber marks, at right angles to shaft axis, which are 1.5 mm apart. 1. If the balancing device is new, the position of the indicator (624) must be as shown in the figure “Pump running normally”. 2. In the case of maximum wear of the balancing device the position of the indicator (624) is as shown in the figure “Time to shut down the pump”. Pump running normally 623

624

Time to shut down the pump 623

624

0 Rotor position indicator

OIMPG SUPERVISION 02

Rotor position indicator

_____________________________________________________________________ Pump Supervision Plan For exact description of pump as well as scope of supply of accessories & instrumentation etc., please refer P & I Diagram.

Point to be supervised Pump Bearings : Plain

Thrust Bearing – Tilting pads

(if applicable) Lift-off device with antifriction bearings

(if applicable) Lift-off device with Tilting pads bearings (if applicable) Indicator (only for pumps with balancing disc) Mechanical seal (433) Differential pressure gauge Strainer I suction pipe (if applicable) Differential pressure gauge Duplex filter (if applicable) Measuring instrument, suction side ps (gauge holder ) (if applicable) Measuring instrument, discharge side pd (gauge holder ) (if applicable) Measuring instrument, tapping (gauge holder ) (if applicable) Measuring instrument, balancing water pE (gauge holder ) (if applicable) Thermometer (Suction nozzle/discharge nozzle) (if applicable) Thermometer (cooling water inlet) (if applicable ) Cooling water pipe (supply and return flow) (if applicable) Sight glass (cooling water inlet pipe) (if applicable) Oil pressure gauge (gauge holder) (if applicable) Level indicator (Oil supply system) (if applicable) Connecting coupling (only for coupling with pressure oil lubr.)

Supervisory action

Value to be met 0

Checking the temperature once a week Checking the oil level once a week (only for pumps with ring oil lubrication) Checking for smooth operation Once a week Checking the temperature once a week Checking for smooth operation Once a week

< 90 C Middle between minimum and maximum marks The pump set shall run smooth and free from vibrations. 0 < 90 C The pump set shall run smooth and free from vibrations.

Checking the temperature once a week Checking the oil level once a week Checking for smooth operation Once a week Checking the temperature once a week Checking for smooth operation Once a week Checking the rotor position once a week

< 90 C Middle of oil level sight glass The pump set shall run smooth and free from vibrations. 0 < 90 C The pump set shall run smooth and free from vibrations. See section Rotor Position in this chapter 0 ≤ 80 C 15 drops per minute < 0.3 bar

Checking the temperature once a week Checking the leakage once a week Checking the differential pressure Once a week Checking the differential pressure Once a week Checking the pressure once a week

0

Checking the pressure once a week Checking the pressure once a week Checking the pressure once a week

PE ≥ ps + 0.5 bar

Checking the temperature once a week


≤ 45 C


∆t ≤ 10 C

Checking the cooling water flow once a week Checking the pressure once a week

Water is flowing

Checking the oil level once a week

- 20 mm

Checking for leakage once a week

No leakage permitted

0

0

In case of deviations, proceed in accordance with the “Cause – Remedy” specified under the chapter “Trouble – shooting”. We recommend recording the information tabulated above in a logbook, in the form of enclosed LOG SHEET. OIMPG SUPERVISION 06

LOG SHEET PUMP TYPE CUSTOMER ITEM NO.

NO. 1 2 3 4 5

DESCRIPTION PRESSURE AT Suction nozzle Differential across suction strainer Discharge nozzle Balancing line Oil inlet to bearing (forced oil lubrication) 5.1 Suction side bearing 5.2 Discharge side bearing 5.3 Lift off / Thrust bearing

6 7 8 9 9.1 9.2 9.3 10 10.1 10.2 10.3 11 11.1 11.2 11.3 11.4 11.4 12

TEMPERATURE AT Suction nozzle Discharge nozzle Balancing line Bearings Suction side Discharge side Lift off / Thrust Oil inlet to bearing (forced oil lubrication) Suction side Discharge side Lift off / Thrust Flushing liquid Shaft seal - Suction Shaft seal - Discharge Cooling Water Inlet / outlet Suction Discharge Lift off / Thrust

SERIAL NO.

UNIT

READING

kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2

Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C

ROTOR POSITION

13 VIBRATIONS AT 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8

Amplitude microns (peak to peak) H V A

RMS Velocity mm / s H V A

Suction side bearing housing Discharge side bearing housing Lift off / Thrust bearing housing Suction flange Discharge flange Suction side foot Discharge side foot Base Frame H = Horizontal ; DATE / TIME

V = Vertical ;

A = Axial.

SIGNATURE OF OPERATOR

LOG SHEET B1

_____________________________________________________________________

Servicing 1. General Information We recommend that KSB’s specialist personnel be present during the servicing of the pump! ________________________________________________________________________________________

Caution

Improper handling of preservatives, oil and grease causes hazardous environmental impact. Handling and disposal only by qualified personnel! _________________________________________________________________________ 1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc., please refer P & I Diagram. 1.2 Required documentation 1.2.1 The following documents are necessary for servicing of pump set. Sectional Drawing, Pump List of Components, Pump Documentation of the Mechanical Seal (if applicable) 1.2.2 Documentation of Connecting Coupling 1.2.3 Documentation of Drive 1.2.4 Documentation of the Minimum Flow System (if applicable) 1.2.5 Documentation of Valves and Equipment (if applicable) 1.2.6 Documentation of the Instrumentation (if applicable) 1.3 Prerequisites 1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown sections of chapter “Commissioning, Start-up/Shutdown) and has been prepared for the servicing work. _____________________________________________________________________________________

! Secure the drive against unintentional starting ____________________________________________________________ 1.4 Service Intervals ________________________________________________________________________________________

Caution Perform a visual inspection of the pump set – as far as accessible – about 500 operating hours after commissioning/start-up. _________________________________________________________________________ 1.4.1

1.4.2

The periods of the time indicated are recommendations for normal operating conditions at trouble-free operation, which have to be adapted to the actual operating conditions, for example the dirt accumulation, switching frequency, load, etc. In the case of problems and unusual operating conditions that represent electric or mechanical overloads, off-schedule servicing must be performed.

2. Dismantling the Guards Preventing Accidental Dismantle / remove the guards preventing accidental mounted to the pump set as described in the Dismantling the Guards Preventing Accidental section in chapter “Maintenance”.

OIMPG SERVICING 01

_____________________________________________________________________ 3. Pump Servicing Plan after Commissioning/Start-up and Stand-by Location to be serviced Bearing (Ring oil lubricated)

(if applicable) Bearing (Forced oil lubricated)

(if applicable) Connecting Coupling

(if applicable) Drive (if applicable) Instruments (if applicable) Pressure gauge (if applicable) Differential pressure gauge (if applicable) Temperature measuring instruments (if applicable) Vibration measurement (if applicable) Shaft positioning monitoring (if applicable) Inspection (axial thrust measurement) (if applicable)

Checks

Oil level, oil quality

Oil level, oil quality

Grease fill (if applicable) Checking the axial movability See manufacturer’s documentation Perfect condition and functioning Perfect condition and functioning Perfect condition and functioning Opening and closing points Perfect condition and functioning Switching points Perfect condition and functioning Perfect condition and functioning Perfect condition and functioning

Servicing Intervals

Servicing Work

First oil change after 300 operating hours Subsequent oil changes after 8000 operating hours, at least after 1 year First oil change after 300 operating hours Subsequent oil changes after 8000 operating hours, at least after 2 years See manufacturer’s documentation After approx. 8000 operating hours See manufacturer’s documentation See manufacturer’s documentation

See the Servicing Work section in this chapter

Every 3 months; See the manufacturer’s documentation

Replace defective equipment; see manufacturer’s documentation

After approx. 8000 operating hours, at least after 2 years

Replace defective equipment; see manufacturer’s documentation

See manufacturer’s documentation See manufacturer’s documentation See manufacturer’s documentation Replace defective equipment; see manufacturer’s documentation

In case of deviations, proceed in accordance with the (Cause – Remedy” specified under the chapter (Trouble – shooting”.

OIMPG SERVICING 02

_____________________________________________________________________ 4. Servicing Work 4.1 Oil Change 4.1.1 General Information 4.1.1.1 Oil quantity and quality, refer Technical Appendix. 4.1.1.2 Filter the oil prior to topping up; filter mesh size 30 µm. 4.1.2 Bearing with Oil Sight Gauge (639) 4.1.2.1 Remove the screwed plug (13 B.1 and/or 13 B.2), completely drain off the oil fill and dispose of in accordance with the local anti-pollution regulations. 4.1.2.2 Screw the screwed plug (including sealing element) back again. 4.1.2.3 Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the minimum and maximum markings of the oil sight gauge (639). 4.1.2.4 Fit the vent plug (913.01 or 672) back again. 4.1.3 Bearing with Constant Level Oiler (638) (if applicable) 4.1.3.1 Remove the screwed plug (13 B.1), completely drain off the oil fill and dispose of in accordance with the local anti-pollution regulations. 4.1.3.2 Screw the screwed plug (including sealing element) back again. 4.1.3.3 Remove the vent plug (913.01 or 913.02 or 672). 4.1.3.4 Hinge down the constant level oiler (638). 4.1.3.5 Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant level oiler until oil appears ii the vertical portion of the connecting elbow of the constant level oiler, see figure Constant level oiler. 4.1.3.6 Fill the reservoir of the constant level oiler with oil and snap it back into operating position. 4.1.3.7 Fit the vent plug (913.01 or 913.02 or 672) back again. 4.1.3.8 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one third of the reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________

Caution

The oil level must always be below the level of the vent opening arranged at the top edge of the connecting elbow. Make sure the opening is always dry. _______________________________________________________________________ Position of reservoir for topping up oil

Oil level

Constant level oiler 4.1.4

Other Pump set Components Fill the oil in accordance with the manufacturer’s documentation.

OIMPG SERVICING 03

_____________________________________________________________________ 4.2 Re-lubrication 4.2.1 General Information 4.2.1.1 Oil quantity and quality, see Technical Appendix. 4.2.1.2 Filter the oil prior to topping up; filter mesh size 30µm. _____________________________________________________________________________________

Caution

During operation, the oil level in the bearing housing drops! Check the oil level only during standstill of the pump! In case of extraordinary loss of oil, find and eliminate the cause. _______________________________________________________________________ 4.2.2 Bearing with Oil Sight Gauge (639) _____________________________________________________________________________________

Caution 4.2.1.1 4.2.1.2 4.2.2 4.2.3.1 4.2.3.2 4.2.3.3

4.2.3.4 4.2.3.5 4.2.3.6

The oil level may drop during start-up of the pump. If the minimum mark is underrun, top up with oil.

_____________________________________________________________________________________ Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the minimum and maximum markings of the oil sight gauge (639). Fit the vent plug (913.01 or 672) back again. Bearing with Constant Level Oiler Remove the vent plug (913.01 or 913.02 or 672). Hinge down the constant level oiler (638). Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of connecting elbow of the constant level oiler, see figure Constant level oiler. Fill the reservoir of the constant level oiler with oil and snap it back into operating position. Fit the vent plug (913.01 or 913.02 or 672) back again. After a short time check whether the oil level in the reservoir has dropped. It is important to keep at least one third of reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________

Caution The oil level must always be below the level of the vent opening arranged at the top of the connection elbow. Make sure the opening is always perfectly dry. _______________________________________________________________________ Position of reservoir for topping up oil

Oil level

Constant level oiler 4.2.4 4.3 4.3.1 4.3.2

Other Pump Set Components Top up with oil in accordance with the manufacturer’s documentation. Connecting Coupling (if applicable) Perform all dismantling and reassembly work in accordance with the Dismantling of the Connecting Coupling and Mounting the Connecting Coupling in chapter “Maintenance”. Perform all servicing work in accordance with the manufacturer’s documentation.

OIMPG SERVICING 04

_____________________________________________________________________

Maintenance 1. General Information ________________________________________________________________________________________

Caution

During the warranty period, pumps should be dismantled only by KSB personnel! _________________________________________________________________________ 1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc., please refer P & I Diagram. 1.2 Required documentation 1.2.1 The following documents are necessary for servicing of pump set. Sectional Drawing, Pump List of Components, Pump Documentation of the Mechanical Seal (if applicable) 1.2.2 Documentation of Connecting Coupling 1.2.3 Documentation of Drive 1.2.4 Documentation of the Minimum Flow System (if applicable) 1.2.5 Documentation of Valves and Equipment (if applicable) 1.2.6 Documentation of the Instrumentation (if applicable) 1.3 Prerequisites 1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown sections of chapter “Commissioning, Start-up/Shutdown) and has been prepared for the servicing work. 1.3.2 All spare parts required are available. 1.3.3 Proper hoisting tackle and means of transport are available and ready for use. 1.3.4 Sufficient room space and appropriate tools are available. 1.3.5 The drive has been secured against unintentional starting.

2. Dismantling the Guards Preventing Accidental 2.1 Sound Insulating Hood (If applicable) Dismantle the sound insulating hood as far as necessary as described in manufacturer’s documentation. 2.2 Coupling Guard/Coupling Cover Dismantle and store the coupling guards and/or coupling covers mounted on the pump set.

Coupling guard ( example )

Coupling cover ( example )

Dismantling the coupling cover. ________________________________________________________________________________________

Caution Do not damage the seal elements and sealing surfaces! _________________________________________________________________________


_____________________________________________________________________ 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7

Remove all pipes on the cover. Remove the taper pins and screw of the cover split t. Use the eye bolt as transport aid as shown in the figure Coupling cover. Unscrew the screws in the upper part of the flange. Remove the upper half of the coupling cover. Remove the internal injection lines. Disconnect the lower half of the coupling cover from the flange and store it.

2.3 Guard Preventing Accidental for Shaft Seal. Dismantle the guard preventing accidental as far as necessary and store it.

3. Dismantling the Connecting Coupling 3.1 Dismantling the Coupling Connection 3.1.1

Give due attention to markings on the coupling, if any, or mark the coupling to rule out later mix-ups.

3.1.2

Dismantle the connecting coupling spacer as described in the manufacturer’s documentation. ____________________________________________________________________________________

! Secure the spacer against falling down. ____________________________________________________________ 3.1.3

Store the parts appropriately.

3.2 Removing the Coupling Hubs 3.2.1 3.2.2 3.2.3

Dismantle the retaining ring, if applicable, from the coupling hub. Remove the grub screws (if provided). 0 To facilitate removing, the coupling hub may be heated uniformly to a temperature of 80 C max. _____________________________________________________________________________________

Use protective gloves! ! Risk of fire in case of open flames. Remove flammable substances from the danger area. _______________________________________________________________________ 3.2.4

Elastomeric parts must be removed before heating! _____________________________________________________________________________________

Caution

Elastomeric parts which have been heated must not be used any more. Use new parts for reassembly. _______________________________________________________________________ 3.2.5 Remove the coupling hubs as shown in the figure Removing the coupling hubs.


_____________________________________________________________________ _____________________________________________________________________________________

!

Secure the coupling against falling down.

_____________________________________________________________________________________ _____________________________________________________________________________________

Caution

Remove the coupling hubs using only the appropriate device to prevent the shaft bearings form damage by axial frictional force. Impacts on the coupling are not permitted. _______________________________________________________________________

3.2.6 3.2.7

Mark the keys prior to removing them. Store the coupling hubs and keys appropriately.

3.3 Run-out Check of the Shaft Ends 3.3.1 3.3.2

After removing the coupling hubs check the shaft ends for run-out, see figure Run-out check of shaft ends. Permissible tolerance ≤ 0.03 mm; if this value is exceeded, inform KSB.

Run-out check of the shaft ends (example)

4. Removing the Pump from the Installation The work described in sections 4.1 to 4.3 is required only if the pump is to be removed from the installation for maintenance. 4.1 Dismantling the Piping and Instruments


_____________________________________________________________________ _____________________________________________________________________________________

! 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7

4.2 4.2.1

Operating fluids can run out when unscrewing the pipes and instruments. These are to be collected and properly disposed of by the Operator.

_____________________________________________________________________________________ Undo the connections between discharge nozzle and discharge pipe & between suction nozzle and suction pipe. Fasten the suction and discharge pipes to temporary holders. Dismantle the minimum flow control valve, if necessary. Disconnect the tapping pipe, if applicable. Detach and dismantle any auxiliary lines such as circulation, cooling liquid and oil pipes as well as measuring lines as far as necessary. Dismantle the measuring devices and instruments as far as necessary, and store them appropriately. If required, dismantle the cooler of the shaft seal including .

Removing the Pump from Baseframe Unscrew the fastening studs at the pump feet; see the figure Fastening of the pump feet.

1

6

2

5

3

4

1-Pump foot, 2-Nut, 3-Disc, 4-Shims, 5-Stud, 6-Base plate 4.2.2

Loosen nuts and adjusting screws at the guide block; see figure Adjusting screw at the guide casing.

Adjusting screws at the guide casing ( example )


_____________________________________________________________________ 4.3 Transporting the Pump to the Place of Dismantling _______________________________________________________________________________________

Caution

The pumps have to be lifted and transported in accordance with the guidelines laid down in the chapter “Transport / Interim Storage”. Do not fasten the ropes to the shaft ends or the bearing housings.

_______________________________________________________________________________________ 4.3.1

Lift the pump from the baseframe, transport it to the place of dismantling and set it down on assembly s. _____________________________________________________________________________________

!

Secure the pump against overturning.

_____________________________________________________________________________________ _____________________________________________________________________________________

Mark the matching shims between the pump feet and baseframe so that they can be inserted in the same place on subsequent reassembly, and store them appropriately. _______________________________________________________________________ Caution


_____________________________________________________________________ 5. Dismantling the Bearings 5.1 Preparations 5.1.1 5.1.2 5.1.3 5.1.4

Prior to dismantling, drain the oil fill of the bearing housings and the thrust bearing housing and dispose of in accordance with the local anti-pollution regulations. If applicable, dismantle the cooling liquid pipes and oil supply pipes as far as necessary. If applicable, dismantle the oil sight gauge (639) and/or constant level oiler (638) as well as the thermometer (692.01 or 692.02) and/or RTDs. If applicable, remove the splash ring (507.01 and/or 507.02) on the driven end from the shaft (210) after loosening the grub screws (904.05, if applicable).

5.2 Dismantling the Add-on Parts (for example flanged-on oil pump, shaft position indicator, etc.) (if applicable) 5.2.1

For applicable add-on parts, refer Sectional Drawing and P&I Diagram.

5.3 Dismantling the Lift-off Device, with Antifriction Bearings (if applicable) 5.3.1 5.3.2 5.3.3

Unscrew the hex nut (920.08) and remove the bearing end cover (361) including O-ring (412.11). Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03). Pull the bearing cartridge (381) including the two angular ball bearings (320) out of the thrust bearing housing (354) using the appropriate device as described in the work instruction UA3 13473 01. Dismantle further, if required. _____________________________________________________________________________________

In case of slight discolourations (incl. rust stain) or any damage, the bearings Caution must be replaced. Clean used bearings with cleaning oil! After cleaning immediately spray the bearings with oil! 5.3.4 5.3.5 5.3.6 5.3.7

_____________________________________________________________________________________ Take the springs out of the thrust bearing housing (354). Take away the thrust bearing housing (354) including O-ring (412.10). If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08). Remove the spacer ring (504.01) from the shaft (210).

5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing (if applicable)\ 5.4.1 5.4.2 5.4.3

Unscrew the hex nuts (920.08) and remove the bearing end cover (361) including O-ring (412.11). Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03). Pull the bearing cartridge (381) including the thrust bearing, thrust bearing plate (384) and counter thrust bearing plate (388) out of the thrust bearing housing (354) using the appropriate device as described in the work instruction UA3 13473 01. Dismantle further, if required. _____________________________________________________________________________________

Caution

In case of slight discolourations (incl. rust stain) or any damage, the bearing segments must be replaced! _______________________________________________________________________ 5.4.4 5.4.5 5.4.6 5.4.7

Take the springs out of the thrust bearing housing (354). Take away the thrust bearing housing (354) including O-ring (412.10). If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08). Take away the key out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).

5.5 Dismantling the Thrust Bearing (if applicable) 5.5.1 5.5.2 5.5.3

Unscrew the hex nuts (920.11) and remove the bearing end cover (361) including thrust bearing (314), Oring (412.11), circlip (932.03) and shaft seal (420.01, 562.02). Screw nut (920.09) from the shaft (210). Remove the spacer sleeve (525.05) from the shaft (210).


_____________________________________________________________________ 5.5.4 5.5.5 5.5.6 5.5.7 5.5.8

Remove the thrust bearing plate (384) from the shaft (210) using the appropriate device as described in the work instruction UA3 13475 01 or UA3 14758 01. Take the key (940.05) out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210). Unscrew two opposite hex socket head cap screws between the segments of the thrust bearing (314) and remove them together with the ading segments. Pull the thrust bearing (314) out of the thrust bearing housing (354) using the appropriate device as described in the work instruction UA3 13475 01 or UA3 14758 01. Unscrew the hex socket head cap screws (614.04) and take the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01) circlip (932.03) and O-ring (412.10) out of the bearing housing (350.01). _____________________________________________________________________________________

Caution

In the case of slight discolourations (incl. rust stain) or any damage, the bearing segments must be replaced! ______________________________________________________________________ 5.6 Dismantling the Radial Bearings ______________________________________________________________________________________

Caution

When the bearing shells are dismantled, the shaft must not rest on the bearing housing or labyrinth rings! ________________________________________________________________________ _____________________________________________________________________________________

Caution

Mark the bearing shells to ensure their correct assignment to the bearing housings! Protect the bearing shells against damage!

_____________________________________________________________________________________ _____________________________________________________________________________________

Caution

In the case of slight discolourations (incl. rust stain) or any damage, the bearing segments must be replaced! _______________________________________________________________________ 5.6.1 HG Pump Sizes 1 and 2 5.6.1.1 Unscrew the hex head bolts (901.01 and 901.03) and remove the bearing cover (360) and bearing end cover (361) including O-ring (412.09). 5.6.1.2 Remove the pins (560.01) including washers (550.07) and nuts (920.07) as well as hex socket head cap screw (914.05) including circlips (932.05) and take away the upper part of the bearing housing (350.01) including the upper half of labyrinth ring (423.01). 5.6.1.3 Remove the upper bearing shell (370) and lubricating ring (644, if applicable). 5.6.1.4 Remove the lower half of labyrinth ring (423.01) and lower bearing shell (370); for that purpose lift the shaft (210) using a wooden rod. 5.6.2 HG pump sizes 3 to 6 5.6.2.1 Unscrew the hex head bolts (901.01 and 901.06) and remove the bearing cover (360) and bearing end cover (361) including O-ring (412.09). 5.6.2.2 Remove the hex head bolt (901.13) including washers (550.12) and gasket (411.03). 5.6.2.3 If applicable, undo the grub screw (904.06) and dismantle the lubricating ring (644). 5.6.2.4 Remove the bearing shell (370) and glued-in labyrinth ring (423.01) and O-ring (412.18) from the shaft, using the appropriate device as described in the work instruction UA7 23062 01.


_____________________________________________________________________ 5.7 Dismantling the Bearing Housings 5.7.1 HG Pump Sizes 1 and 2 5.7.1.1 Remove the hex head bolts (901.05) and nuts (920.14). 5.7.1.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing housing (350.01). 5.7.1.3 Remove the splash ring (507.01 or 507.02) from the shaft (210). 5.7.2 HG Pump Size 3 5.7.2.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts (921.14). 5.7.2.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing housing (350.01). 5.7.2.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws (904.05, if applicable). 5.7.3 HG Pump Sizes 4 to 6. 5.7.3.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts (921.14). 5.7.3.2 Unscrew the nuts (920.04) at the studs (902.01) and take away the bearing housing (350.01). 5.7.3.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws (904.05, if applicable).


_____________________________________________________________________ 6 Dismantling the Shaft Seal 6.1 Preparations Dismantle any cooling, flushing, quenching pipes, wherever applicable. All the openings should be plugged.

6.2 Dismantling the Mechanical Seal. (Part numbers, specified in the following description are only representative) _______________________________________________________________________________________

Caution

Refer order specific sectional drawing of mechanical seal for correct part numbers as well as description! Refer Manufacturer’s documentation!

_______________________________________________________________________________________ 6.2.1 Make : Eagle Poonawalla 6.2.1.1 Shaft Seal 6.2.1.1.1 Loosen the hex bolt (14) and locate the sliding washer (13) into the groove provided on the sleeve (6) and tighten the hex bolt (14). 6.2.1.1.2 Loosen socket screws (12) and dog point screws (17). 6.2.1.1.3 Unscrew and remove fixing screws of gland plate (4). 6.2.1.1.4 With the help of jacking bolts, provision made on gland plate (4), remove cartridge off the shaft (210). Follow the same procedure to pull out the mechanical seal cartridge on the discharge side. 6.2.1.2 Dismantling of Cartridge (if required). 6.2.1.2.1 Remove hex bolt (14) and sliding washer (13). For removing sliding washers, slightly compress the springs (e) of the mechanical seal. 6.2.1.2.2 Remove socket screws (12) and dog point screw (17) from the drive collar (11). 6.2.1.2.3 Remove drive collar (11) from the sleeve (6). 6.2.1.2.4 Remove the mechanical seal rotary head assembly consisting of components a,b,c,d,e,f. _____________________________________________________________________________________

Caution

Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical seal components should be replaced by new ones. _______________________________________________________________________ _____________________________________________________________________________________

Caution

In the event of slight scoring marks on the rubbing faces of seal ring (b) and mating ring (2), they can be sent back to the manufacturer for touching up.

_____________________________________________________________________________________ 6.2.2 Make : Flowserve Sanmar 6.2.2.1 Shaft Seal 6.2.2.1.1 Loosen the cap screw (K) and locate retaining plate (15) into the groove provided on the sleeve (10) and tighten the cap screw (K). 6.2.2.1.2 Loosen set screws (13) of sleeve collar (9). 6.2.2.1.3 Unscrew and remove fixing screws of gland ring (1). 6.2.2.1.4 With the help of jacking bolts, provision made on gland ring (1), remove cartridge off the shaft (210). Follow the same procedure to pull out the mechanical seal cartridge on the discharge side. 6.2.2.2 Dismantling of Cartridge (if required). 6.2.2.2.1 Remove cap screw (K) and retaining plate (15). For removing retaining plate, slightly compress the spring’s (c) of the mechanical seal. 6.2.2.2.2 Remove socket screws (13) and dog point screw (12) from the sleeve collar (9). 6.2.2.2.3 Remove sleeve collar (9) from the sleeve (10). 6.2.2.2.4 Remove the mechanical seal rotary head assembly consisting of components 3,4,45,5,c,d,e,p.


_____________________________________________________________________ _____________________________________________________________________________________

Caution

Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical seal components should be replaced by new ones. _______________________________________________________________________ _____________________________________________________________________________________

Caution

In the event of slight scoring marks on the rubbing faces of seal ring (b) and mating ring (2), they can be sent back to the manufacturer for touching up.

____________________________________________________________________________________________ 6.2.3 Make : Burgmann 6.2.3.1 Shaft Seal 6.2.3.1.1 Loosen the hex bolt (15) and locate the assembly fixture (14) into the groove provided on the sleeve (6) and tighten the hex bolt (15). 6.2.3.1.2 Loosen set screws (13) of clamping ring (11). 6.2.3.1.3 Unscrew and remove fixing screws of gland (4). 6.2.3.1.4 With the help of jacking bolts, provision made on gland (4), remove cartridge off the shaft (210). Follow the same procedure to pull out the mechanical seal cartridge on the discharge side. 6.2.3.2 Dismantling of Cartridge (if required). 6.2.3.2.1 Remove hex bolt (15) and assembly fixture (14). For removing assembly fixture, slightly compress the springs (1.4) of the mechanical seal. 6.2.3.2.2 Remove set screws (12) and (13) from the clamping ring (11). 6.2.3.2.3 Remove clamping ring (11) from the sleeve (6). 6.2.3.2.4 Remove the mechanical seal rotary head assembly consisting of components 1.1,1.2,1.3,1.4,1.5,1.6. _____________________________________________________________________________________

Caution

Damaged sleeve (6), seal face (1.1), seat (2) and other mechanical seal components should be replaced by new ones. _______________________________________________________________________ _____________________________________________________________________________________

Caution

In the event of slight scoring marks on the rubbing faces of seal face (1.1) and seat (2), they can be sent back to the manufacturer for touching up.

______________________________________________________________________________________________

6.3 Dismantling the Casing Parts 6.3.1 HG Pump Sizes 1 and 2 6.3.1.1 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part (130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable). 6.3.2 HG Pump Sizes 3 to 6 6.3.2.1 If applicable, loosen and remove the hex socket head cap screws (914.08, non-driven end). 6.3.2.2 Force off and take away the seal casings (441 or 441.01 or 441.02 as per the execution) and casing part (130, if applicable). Unscrew the hex socket head cap screws (914.09, if applicable). 6.3.2.3 If applicable, loosen and remove the hex nuts (920.04 or 920.05) on the studs (902.01, on either end or 902.05, on the driven end). 6.3.2.4 Fasten the seal casing (441 or 441.01 or 441.02 as per the execution) to the crane by means of eyebolt and rope, force off with screws and remove it. Unscrew the hex socket head cap screws (914.09, if applicable). 6.3.2.5 On the driven end, loosen and remove hex nuts (920.05) on the studs (902.05) or the hex socket head cap screws (914.15, if applicable), fasten the casing part (130) to the crane by means of eyebolt and rope, force off with screws and remove it.


_____________________________________________________________________ 7. Dismantling the Balancing Device 7.1 HG Pump Sizes 1 and 2 7.1.1 7.1.2 7.1.3 7.1.4

Remove the spacer ring (504.02) and if applicable spacer sleeve (525.02) from the shaft (210). Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the work instruction UA2 13474 01 Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as described in the work instruction UA2 13474 01 Check the balancing disc (601.01) and counter balancing disc (602.01) for signs of damage.

7.2 HG Pump Size 3 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6

Pull the retainer ring (505.01) from the shaft (210) and remove key (940.07) and split ring (501.01). Remove the spacer ring (504.02) or spacer sleeve (525.02) from the shaft (210). Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the work instruction UA2 14761 01. Pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as described in the work instruction UA2 14761 01. If applicable, take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft (210). Check the balancing disc (601.01), the counter balancing disc (602.02) and throttle sleeve (522.01), if applicable, for signs of damage.

7.3 HG Pump Size 4 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7

Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.07) out of the shaft keyway. Unscrew the hex socket head cap screws (914.10) and pull off the retainer ring (505.01). Take the split ring (501.01) out of the shaft groove and pull the spacer ring (504.02) from the shaft (210). Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the work instruction UA2 14765 01. Unscrew the hex socket head cap screw (914.06) and pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 01. Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft. Check the balancing disc (603.02), counter balancing disc (602.01) and throttle sleeve (522.01) for signs of damage.

7.4 HG Pump Sizes 5 and 6 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5 7.4.6 7.4.7 7.4.8

Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.06) out of the shaft keyway. Unscrew the hex socket head cap screws (914.10) and remove the retainer ring (505.01). Take the split ring (501.01) out of the shaft groove and remove the spacer ring (504.02) from the shaft (210). Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the work instruction UA2 14765 02 Unscrew the hex socket head cap screw (914.06) and pull the counter balancing disc (602.01) out of the discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 02. Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft (210). Pull the throttle bush (542.01) out of the discharge casing (107) using the appropriate device as described in the work instruction UA2 14765 02. Check the balancing disc (603.02), counter balancing disc (602.01), throttle bush (542.01) and throttle sleeve (522.01) for signs of damage.

7.5 Measuring the Approximate Radial Clearance _______________________________________________________________________________________

Caution

Measure the approximate radial clearance if the pump body is not to be dismantled. Exact checking of the rotor clearance is possible only with the pump dismantled.

_________________________________________________________________________________________________


_____________________________________________________________________ 7.5.1

7.5.2 7.5.3

Place the dial gauge holder on a firm base (for example flange or discharge nozzle) and position the dial gauge on the seat of the balancing piston as shown in the figure Measuring the approximate radial clearance. Carefully lift the shaft until it abuts on the top. Shaft deflection must not be increased (incorrect measurement). The diametrical clearance determined this way must not exceed 0.8 mm; if it does, the pump must be dismantled and overhauled.

HG Pump Sizes 1 - 3

HG Pump Sizes 4 - 6

Measuring the approximate radial clearance

8. General Information on Reassembly 8.1 Meticulously clean all dismantled components, in particular the fit and sealing surface areas. ________________________________________________________________________________________

Caution 8.2 8.3 8.4 8.5

Do not damage the locating and sealing surfaces!

________________________________________________________________________________________ If required, remove any lime and incrustation from the cooling chambers. Check all dismantled components for signs of damage. If required, use new parts. As a general rule, always use new O-rings and gaskets for reassembly. ________________________________________________________________________________________

Caution

Do not take the O-rings out of their original packing until those are actually required to be fitted and protect them from mineral oil and grease! _________________________________________________________________________ _________________________________________________________________________ Do not fit the O-rings in dry condition but wet them with silicone grease! In Caution exceptional cases, soapy water may be used. ________________________________________________________________________ 8.6 Prior to reassembly coat the screw/bolt connections and pipe unions as well as the fits of the individual components using respective specified lubricating agent as described in the work instruction UA4 28699 01. 8.7 Reassembly must be performed in accordance with the rules of good engineering practice.

9. Checking the Balancing Device with the Fluid “Engineers Blue”. The steps 9.1 to 9.3 are required only if balancing piston (603.02) or counter balancing disc (602.02) were remachined or replaced. 9.1 HG Pump Sizes 1 and 2 9.1.1 9.1.2

Meticulously clean the axial running face of the counter balancing disc (602.02). Insert the grooved pin (561.03) in the discharge casing (107).


_____________________________________________________________________ 9.1.3 9.1.4

Fit the counter balancing disc (602.02) without O-rings (412.04 and/or 412.05). The grooved pin (561.03) must engage in the groove of the counter balancing disc (602.02). Adjust the pump rotor position; see figure Adjusting pump rotor position.

5 0 2 .0 2

2 3 0 .0 2 1 7 1 .0 2

S a 1 S a 2 A d ju s tin g t h e p u m p r o t o r p o s itio n

9.1.4.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the nondriven end. _____________________________________________________________________________________

Caution

This rotor position must not be changed when measuring the balancing device!

_____________________________________________________________________________________ 9.1.5 Adjust the balancing disc (601.01); see figure Adapting the balancing piston.

b1

Sl2

a1

Machine here

602.01

504.02

601.01

Adapting the Balancing disc

9.1.5.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of the last stage. 9.1.5.2 Shorten the balancing disc (601.01) to the dimension “b1” as sown in the figure Adapting the balancing disc: b1 = a1 – SL2 (SL2, see table of clearances). 9.1.6 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.


_____________________________________________________________________ x a

x

b

504.02

a

601.01 602.01

Varient without spacer sleeve

y

b

504.02 525.02

601.01 602.01

Varient with spacer sleeve (525.02)

Adjusting the spacer ring 9.1.6.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the shaft collar. 9.1.6.2 Determine the dimension “b” between the running face and face of balancing disc (601.01) as well as the length “y” of the spacer sleeve (525.02, if applicable). 9.1.6.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b or a = x - b-y. The maximum permissible deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.02)! _______________________________________________________________________ 9.1.7 9.1.8 9.1.9 9.1.10 9.1.11 9.1.12 9.1.13 9.1.14 9.1.15 9.1.16

Insert the key (940.04). Coat the axial running face of the balancing disc (601.01) thinly with the fluid and slide the balancing piston (601.01) without O-ring (412.02) on the shaft (210). Slide the spacer sleeve (525.02, if applicable) and spacer ring (504.02) over the shaft (210) Mount the casing part (130, if applicable) and seal casing (441) without O-rings. Mount the shaft sleeve (524.01, pump with gland packings). Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section so far as to make the free rotation of the pump rotor possible. For the check with the fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly. Move the pump rotor to the non-driven end and dismantle all pump components including the counter balancing disc (602.01) in reverse order. At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the fluid in the upper zone. If this is not the case, remachining the counter balancing disc (602.01) on a lathe and repeat the fluid checks. After completion of the fluid check, clean the axial running faces of the balancing piston (601.01) and counter balancing disc (602.01).

9.2

HG Pump Size 3

9.2.1 9.2.2 9.2.3

Meticulously clean the axial running face of the counter balancing disc (602.02). Insert the grooved pin (561.03) in the discharge casing (107). Fit the counter balancing disc (602.01) without O-rings (412.04 or 412.05). The grooved pin (561.03) must engage in the groove of the counter balancing disc (602.01). If applicable, slide throttle sleeve (522.01) without O-ring (412.02) over the shaft (210) and hey (940.03) until abutting against the impeller (230.02). Adjust the pump rotor position; see figure Adjusting the pump rotor position.

9.2.4 9.2.5


_____________________________________________________________________

5 0 2 .0 2

2 3 0 .0 2 1 7 1 .0 2

S a 1 S a 2 A d ju s tin g t h e p u m p r o t o r p o s itio n

9.2.5.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the nondriven end. _____________________________________________________________________________________

Caution

The rotor position must not be changed when the measuring the balancing device! _______________________________________________________________________ 9.2.6 Adapt the throttle sleeve (522.01) and/or balancing disc (601.01); see figure Adapting the throttle sleeve or figure Adjusting the balancing disc.

Machine here

602.01

504.02

601.01

522.01

Adapting the throttle sleeve

Machine here

602.01

504.02 Adapting the balance disc


601.01

_____________________________________________________________________ 9.2.6.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of the last stage and, if required, the dimension “c1” of the balancing disc (601.01). 9.2.6.2 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttle sleeve and/or the balancing disc (601.01) in accordance with the figure Adapting the balancing disc : b1 = a1 – c1 – Sl2 or b1 = a1 – Sl 2 (Sl2 see tables of clearances). 9.2.7 Adapt the spacer ring (504.2) or spacer sleeve (525.02); see figure Adapting the spacer ring or see figure Adapting the spacer sleeve.

504.02

601.01 602.01 522.01

Adapting the spacer ring

525.02 601.01 602.01 522.01 Adapting the spacer sleeve

9.2.7.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring (501.01). 9.2.7.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01). 9.2.7.3 Shorten the spacer ring (504.02) or spacer sleeve (525.02) to the dimension “a” : a = x – b. The maximum permissible deviation form plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution

As a general rule, always use a new spacer ring (504.02)or spacer sleeve (525.02)! _______________________________________________________________________ 9.2.8 9.2.9 9.2.10 9.2.11 9.2.12 9.2.13 9.2.14 9.2.15 9.2.16

9.2.17

9.3 9.3.1

Insert the key (940.04). Coat the axial running face of the balancing disc (601.01) thinly with the fluid and slide the balancing disc (601.01) without O-ring (412.02) on the shaft (210). Slide the spacer ring (504.02) or spacer sleeve (525.02, if applicable) over the shaft (210). Insert the key (940.07) and split ring (501.01) into the shaft groove, slide the retainer ring (505.01) over them. Mount the casing part (130, if applicable) and seal casing (441) without O-rings. Fit the driven-end and non-driven end bearings in accordance with the Mounting the Bearings section, so far as to make possible the free rotation of the pump rotor. For the check with fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly. Move the pump rotor to the non-driven end and dismantle all components including the counter balancing disc (602.01) in reverse order. At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.02) on a lathe and repeat the fluid check. After completion of the fluid check clean the axial running faces of balancing disc (601.01) and counter balancing disc (602.01).

HG Pump Size 4 Meticulously clean the axial running face of counter balancing disc (602.01).


_____________________________________________________________________ 9.3.6.1 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttle sleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances). 9.3.7 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.

x b

a

504.02

601.01 602.01

522.01

Adapting the spacer ring

9.3.7.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring (501.01). 9.3.7.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01). 9.3.7.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b. The maximum permissible deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.02)! _______________________________________________________________________ 9.3.8 9.3.9 9.3.10 9.3.11 9.3.12 9.3.13 9.3.14 9.3.15 9.3.16

9.3.17

Insert the key (940.04). Coat the axial running face of balancing disc (601.01) thinly with the fluid and slide the balancing disc (601.01) without O-ring (412.02) on the shaft (210). Slide the spacer ring (504.02) over the shaft (210). Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the balancing disc (601.01), using hex socket head cap screws (914.10). Mount the casing part (130) and seal casing (441) without O-rings. Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so far as to make possible the free rotation of the pump rotor. For the check with fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly. Move the pump rotor to the non-driven end and dismantle all components including the counter balancing disc (602.01) in reverse order. At least ¾ of the axial running face of the counter balancing disc (602.02) must have a uniform print of the fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.01) on a lathe and repeat the fluid check. After completion of the fluid check clean the axial running faces of balancing disc (601.01) and counter balancing disc (602.01).

9.4 HG Pump Sizes 5 and 6 9.4.1 9.4.2 9.4.3

9.4.4

Meticulously clean the axial running face of the counter balancing disc (602.01). Fit the throttle bush (542.01) without O-ring (412.05). Insert the parallel pin (562.03) in the discharge casing (107). Insert the key (940.03) and slide the throttle sleeve (522.01) without O-ring (412.02) over the shaft (210) and key (940.03) until abutting against the impeller (230.02).


_____________________________________________________________________ 9.4.5 9.4.6

Fit the counter balancing disc (602.01) without O-ring (412.16) and fasten with the hex socket cap screws (914.06). The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01). Place the pump rotor in the center of the overall axial clearance ( Sa1 + Sa2); see figure Adjusting the pump rotor position. 502.02 230.02 171.02

Sa1 Sa2 Adjusting the pump rotor position _____________________________________________________________________________________

Caution

This rotor position must not be changed when measuring the balancing device! _______________________________________________________________________ 9.4.7

Adapt the throttle sleeve (522.01); see figure Adapting the throttle sleeve.

c1

b1

Sl2

a1 Machine here

602.01

542.01

504.02

601.01

Adapting the throttle sleeve


522.01

_____________________________________________________________________ 9.4.7.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller of last stage and the dimension “c1” of the balancing disc (601.01). 9.4.7.2 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttle sleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances). 9.4.8 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.

x b

a

504.02

601.01 602.01

522.01 542.01

Adapting the spacer ring 9.4.8.1 Measure the distance “x” from the running face of the counter balancing disc (602.01) to the split ring (501.01). 9.4.8.2 Determine the dimension “b” between the running face and face of the balancing disc (601.01). 9.4.8.3 Shorten the spacer ring (504.02) to the dimension “a” : a = x – b. The maximum permissible deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.02)! _______________________________________________________________________ 9.4.9 Insert the key (940.04). 9.4.10 Coat the axial running face of balancing disc (601.01) thinly with the fluid and slide the balancing disc (601.01) without O-ring (412.02) on the shaft (210). 9.4.11 Slide the spacer ring (504.02) over the shaft (210). 9.4.12 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the balancing disc (601.01), using hex socket head cap screws (914.10). 9.4.13 Mount the casing part (130) and seal casing (441) without O-rings. 9.4.14 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so far as to make possible the free rotation of the pump rotor. 9.4.15 For the check with fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly. 9.4.16 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing disc (602.01) in reverse order. 9.4.17 At least ¾ of the axial running face of the counter balancing disc (602.02) must have a uniform print of the fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.01) on a lathe and repeat the fluid check. 9.4.18 After completion of the fluid check clean the axial running faces of balancing disc (601.01) and counter balancing disc (602.01).


_____________________________________________________________________ 10. Mounting the Balancing Device ______________________________________________________________________________________

Caution

If the throttle sleeve (522.01), balancing disc (601.01) or counter balancing disc (602.01) were remachined or replaced, the check with the fluid “engineer’s blue” as outlined in sections 9.1 to 9.4 must be performed!

_____________________________________________________________________________________

10.1 HG Pump Sizes 1 and 2 10.1.1 Insert the grooved pin (561.03) in the discharge casing (107). 10.1.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03) must engage in the groove of the counter balancing disc (602.01). 10.1.3 Adjust the pump rotor position; see figure Adjusting the pump rotor position.

502.02

230.02 171.02

3mm

Adjusting the pump rotor position 10.1.3.1

Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to the non-driven end. 10.1.4 Insert the key (940.04). 10.1.5 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01) over the shaft (210) until abutting against the counter balancing disc (602.01).

10.2 HG Pump Size 3 10.2.1 Insert the grooved pin (561.03) in the discharge casing (107). 10.2.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05). The grooved pin (561.03) must engage in the groove of the counter balancing disc (602.01). 10.2.3 If applicable, slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key (940.03) until abutting against the impeller (230.02). 10.2.4 Adjust the pump rotor position; see figure Adjusting the pump rotor position.


_____________________________________________________________________ 502.02

230.02 171.02

3mm

Adjusting the pump rotor position 10.2.4.1 Move the pump rotor in the direction of the driven end until abutting and then move it 3 mm back to the non-driven end. 10.2.5 Insert the key (940.04). 10.2.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01) over the shaft until abutting against the counter balancing disc (602.01). 10.2.7 Slide the spacer ring (504.02) or spacer sleeve (525.02) over the shaft (210). 10.2.8 Insert the key (940.07) and split ring (501.01) in the shaft keyway and slide the retainer ring (505.01) over them.

10.3

HG Pump Size 4

10.3.1 Insert the parallel pin (562.03) in the discharge casing (107). 10.3.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01). 10.3.3 Insert the key (940.04) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key (940.04) until it abuts against the impeller (230.02). 10.3.4 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pump rotor position. 10.3.5 Insert the key (940.04).


_____________________________________________________________________ 230.02

502.02 171.02

Sa1 Sa2 Adjusting the pump rotor position 10.3.6 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01) over the shaft (210) until it abuts against the counter balancing disc (602.01). 10.3.7 Slide the spacer ring (504.02) over the shaft (210). 10.3.8 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevant work instruction. 10.3.9 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.

10.4 HG Pump Sizes 5 and 6 10.4.1 Fit the throttle bush (542.1) including O-ring (412.05). 10.4.2 Insert the parallel pin (562.03) in the discharge casing (107). 10.4.3 Insert the key (940.03) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key (940.03) until it abuts against the impeller (230.02). 10.4.4 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01). 10.4.5 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pump rotor position. 10.4.6 Insert the key (940.04).


_____________________________________________________________________ 230.02

502.02 171.02

Sa1 Sa2 Adjusting the pump rotor position

10.4.7 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01) over the shaft (210) until it abuts against the counter balancing disc (602.01). 10.4.8 Slide the spacer ring (504.02) over the shaft (210). 10.4.9 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevant work instruction. 10.4.10 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.


_____________________________________________________________________ 11. Mounting the Shaft Seal 11.1 Mounting the Housing Components 11.1.1 HG Pump Size 1 to 3 11.1.1.1 In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in position. 11.1.1.2 If applicable, mount on the driven end casing part (130) including O-rings (412.06 or 412.13, if applicable) and parallel pin (562.11, if applicable). The parallel pin (562.11) must engage in the groove of the counter balancing disc (602.02). 11.1.1.3 Mount the seal casing (441 or 441.01 and 441.02, depending upon the execution). Fit hex socket head cap screws (914.09, if applicable). 11.1.2 HG Pump Sizes 4 to 6 11.1.2.1 In case the studs (902.01, driven end and 902.05, non-driven end) have been removed, place them in position. 11.1.2.2 Insert O-ring (412.19) in the groove of the casing part (130, non driven end) and fit the casing part to the discharge casing (107). 11.1.2.3 Depending upon the execution, fit the washers (550.05 or 550.09) and hex nuts (920.05 or 920.04), or hex socket head cap screws (914.09) and tighten them; tightening torque, see the relevant work instruction. 11.1.2.4 Depending upon the execution, fit again the studs (902.01 or 602.05) on the non driven end, if they have been removed. 11.1.2.5 Fit the seal casing (441 or 441.01 and 441.02, depending upon the execution) including O-rings (412.07 and 412.08) to the suction casing (106) and/or casing part (13.0). Fit the hex socket head cap screws (914.09, if applicable).

11.2 Assembling the Shaft Seal (Part no.s specified in the following description are only representative)

Caution

Refer order specific sectional drawing of mechanical seal for correct part numbers as well as description. Refer manufacturer’s documentation.

_______________________________________________________________________________________ 11.2.1 Make : Eagle Poonawalla 11.2.1.1 Slide mechanical seal cartridge [attached to gland plate (4)] on the shaft until the gland plate (4) gets located on seal casing (441). 11.2.1.2 Tighten the nuts of gland plate. 11.2.1.3 Tighten set screws (12 and 17) of drive collar (11). 11.2.1.4 Loosen the bolt (14) and take aside the sliding washer (13) from the groove of the sleeve (6). 11.2.1.5 Slip splash ring (507) onto the shaft. 11.2.2 Make : Flowserve Sanmar 11.2.2.1 Slide mechanical seal cartridge [attached to gland ring (1)] on the shaft until the gland ring (1) gets located on seal casing (441). 11.2.2.2 Tighten the nuts of gland plate. 11.2.2.3 Tighten set screws (13) of sleeve collar (9). 11.2.2.4 Loosen the cap screw (K) and take aside the retaining plate (15) from the groove of the sleeve (10). 11.2.2.5 Slip splash ring (507) onto the shaft. 11.2.3 Make : Burgmann 11.2.3.1 Slide mechanical seal cartridge [attached to gland (4)] on the shaft until the gland (4) gets located on seal casing (441). 11.2.3.2 Tighten the nuts of gland. 11.2.3.3 Tighten set screws (13) of clamping ring (11). 11.2.3.4 Loosen the hex bolt (15) and take aside the assembly fixture (14) from the groove of the sleeve (6). 11.2.3.5 Slip splash ring (507) onto the shaft.


_____________________________________________________________________ 12. Mounting the Bearings 12.1 Mounting the Bearing Housing and Lifting the Pump Rotor 12.1.1 HG Pump Sizes 1 and 2 12.1.1.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210). 12.1.1.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing. 12.1.1.3 On the driven end, slide the bearing cover (360) including O-ring (412.09) and if applicable the splash ring (507.01 and/or 507.02) over the shaft (210). Do not yet fasten the bearing cover to the bearing housing. 12.1.1.4 Fit the pump coupling hub as described under Mounting the connecting coupling. 12.1.1.5 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work instruction UA7 28679 01. 12.1.1.6 The lifting values (only approximate values) are stamped on the bearing housings and marked with “Lift up”. They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increased within the permissible limits, half the clearance increase must be added to the lifting values. _____________________________________________________________________________________

Caution When the bearing shells and labyrinth rings are dismantled the shaft must not rest on the bearing housing! _______________________________________________________________________ 12.1.1.7

On the driven and non driven ends insert the lower bearing shells (370) and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting the bearing shells (370), lift the shaft (210) using a wooden rod. 12.1.1.8 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head bolts (901.05). _____________________________________________________________________________________

Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________ 12.1.1.9

In order to check the measured values, remove the bearing shells (370) and insert them again. The measured values must be reached again. Enter the lifting values in the check data sheet. 12.1.1.10 The bearing housings (350.01) are aligned laterally by means of the horizontally fitted hex head bolts (901.05). The exact lateral alignment has been achieved when the lower bearing shells (370) can be placed easily from either side in their fits between shaft (210) and bearing housing (350.01). ____________________________________________________________________________________

Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________________ 12.1.1.11

After having completed rotor lifting, lock the hex head bolts (901.05) with nuts (920.14) and tighten the hex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction.

12.1.2 HG Pump Sizes 3 to 6 12.1.2.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210). 12.1.2.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing. 12.1.2.3 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work instruction UA7 23062 01. 12.1.2.4 The lifting values (only approximate values) are stamped on the bearing housings and marked with “Lift up”. They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increased within the permissible limits, half the clearance increase must be added to the lifting values.


_____________________________________________________________________ _____________________________________________________________________________________

Caution When the bearing shells and labyrinth rings are dismantled the shaft must not rest on the bearing housing! _______________________________________________________________________ 12.1.2.5 On the driven and non driven ends insert the half ring (tool 969.85) in accordance with the work instruction UA7 23.062 01and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting of the half rings (tool 969.85), lift the shaft (210) using wooden rod. 12.1.2.6 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head bolts (901.05). _____________________________________________________________________________________

Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________ 12.1.2.7 In order to check the measured values, remove half rings (969.85) and insert them again. The measured values must be reached again. Enter the lifting values in the check data sheet. 12.1.2.8 Check the position of the shaft in relation to the bearing housing by means of the instrument holder (699.71) and fitted measuring instrument (690) and adjust the position, if required, by means of the hex bolts (901.05); see work instruction UA7 23062 01. ____________________________________________________________________________________

Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________________ 12.1.2.9 After having completed rotor lifting, tighten hex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction; and fix the bearing housing (350.01) with the taper pins (560.02); if necessary, drill out and ream the holes. Position the splash ring (507.01 and/or 507.02) and tighten the grub screws (904.05, if applicable).

12.2

Mounting the Radial Bearings _____________________________________________________________________________________

Caution

When mounting the bearings, the holes for thermometers in the bearing shells and the associated thermometer connections in the bearing housings must be aligned!

_____________________________________________________________________________________ 12.2.1 HG Pump Sizes 1 and 2 12.2.1.1 Turn the lower bearing shells (370) and lower labyrinth ring half (423.01) in the bearing housing bottom part (350.01); for that purpose lift the shaft (210) using a wooden rod. 12.2.1.2 Fit the lubricating ring (644, if applicable) and the upper bearing shell (370) including parallel pin (562.01). 12.2.1.3 Place the upper labyrinth ring half (423.01) including the parallel pin (562.10) in the bearing housing top part (350.01). 12.2.1.4 Mount the bearing housing top part (350.01) including the upper labyrinth ring half (423.01) and fix with the taper pins (560.01). The parallel pin (560.01) must engage in the groove of the bearing housing top part (350.01). 12.2.1.5 Fit the hex socket head cap screws (914.05) including circlips (932.05) and tighten them uniformly; tightening torque, see the relevant work instruction. 12.2.1.6 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten the hex head bolts (901.01 or 901.03) uniformly; tightening torque, see the relevant work instruction.


_____________________________________________________________________ Additional Work for Pumps with Balancing Disc : 12.2.1.7 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the counter balancing disc (602.01). 12.2.1.8 For rotor position indicator the description under “Supervision of Rotor Position” in the section “Pump Supervision Plan”. 12.2.2 HG Pump Sizes 3 to 6 12.2.2.1 Place the bearing shell (370) with glued-in labyrinth ring (423.01) and O-ring (412.18) in the bearing housing (350.01). _____________________________________________________________________________________

Caution

The labyrinth ring has been glued in the bearing shell with Loctite 75/AVV or equivalent!

12.2.2.2 Fit and tighten the hex head bolts (901.13) including washer (550.012) and gasket (411.03); the bolt must engage in the bearing shell groove. 12.2.2.3 If applicable, fit the lubricating ring (644). 12.2.2.4 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten the hex head bolts (901.01 or 901.06) uniformly; tightening torque, see relevant work instruction. Additional Work for Pumps with Balancing Disc : 12.2.2.5 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the counter balancing disc (602.01). 12.2.2.6 For rotor position indicator the description under “Supervision of Rotor Position” in the section “Pump Supervision Plan”.

12.3

Mounting the Lift-off Device (if applicable) with Antifriction Bearings.

12.3.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09). 12.3.2 Fit the thrust bearing housing (354) including O-ring (412.10) and springs (950). 12.3.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against counter balancing disc (602.01). 12.3.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with rolling element bearing.

a c b y z

Adjusting the lift-off device

12.3.4.1.1 Measure the dimension “a” from the face of the thrust bearing housing (354) to the bottom faces of the springs (950), dimension “b” between the face of the angular ball bearing and the springs’ face of the bearing cartridge (381) as well as the distance “c” from the face of the thrust bearing housing (354) to the shaft collar.


_____________________________________________________________________ 12.3.4.2 Calculate the auxiliary dimension “x” : x = a – b – 30 mm. (30 mm = installation length of the prestressed springs). 12.3.4.3 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation from parallelism is 0.02 mm. _____________________________________________________________________________________

Caution

As a general rule, always use a new spacer ring (504.01)!

_____________________________________________________________________________________ 12.3.5 12.3.6

Slide the spacer ring (504.01) over the shaft (210). Mount the bearing cartridge (381) including two angular ball bearings (320) and the circlip (932.04). 12.3.7 Screw in the hex socket head cap screw (914.03), fit and tighten the shaft nit (920.09). 12.3.8 Check the lift-off limitation “z” : when the balancing disc (601.01) abuts against the counter balancing disc (602.01), the specified value is 1±0.1 mm. If required, remachine the bearing end cover (361); see figure Adjusting the lift-off device with rolling element bearing. 12.3.9 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354). 12.3.10 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with tightening torque given in the relevant work instruction.

12.4

Mounting the Lift-off Device (if applicable) with Tilting-pad Thrust Bearing

12.4.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09). 12.4.2 Fit the thrust bearing housing (354) including O-ring (4121.10) and springs (950). 12.4.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the counter balancing disc (602.01). 12.4.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with tilting-pad thrust bearing. a c e

b Slg1

d z

f

y x

Adjusting the lift-off device tilting-pad thrusthousing bearing (354) to the bottom faces of 12.4.1.1 Measure the dimension “a” from the face of with the thrust bearing springs (950), dimension “b” from the thrust bearing plate (384) to the springs’ faces on the bearing cartridge (381), distance “c” from the face of the thrust bearing housing (354) to shaft collar as well as the dimension “d” of the thrust bearing plate. 12.4.1.2 Calculate the auxiliary dimension “x” : x = a – b + d – 30 mm. (30 mm = installation length of the prestressed springs. 12.4.4.2 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation from parallelism is 0.02 mm. _____________________________________________________________________________________

Caution

As a general rule, always use a new spacer ring (504.01)!

_____________________________________________________________________________________


_____________________________________________________________________ 12.4.5 Slide the spacer ring (504.01) over the shaft (210). 12.4.6 If parts of the lift-off device have been reworked or replaces, adjust the thrust bearing clearance “Slg1” as shown in the figure Adjusting the lift-off device with tilting-pad bearing. 12.4.6.1 Measure the distance “e” from the face of the bearing cartridge (381) to the circlip (932.04). 12.4.6.2 Determine the total length “f” of the thrust bearing (314) and thrust bearing plate (384). 12.4.6.3 Shorten the counter thrust bearing plate (388) to the dimension “x” : x = e – f – Slg1 (Slg1, see table of clearances). The maximum permissible deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution As a general rule, always use a new counter thrust bearing plate (388)! _______________________________________________________________________ 12.4.7 Mounting the bearing cartridge (381) : 12.4.7.1 Fit the parallel pin (562.02) and shaft seal (420.01) in the bearing cartridge (381) and fasten them with the circlip (932.03). 12.4.7.2 Fit the thrust bearing (314) including parallel pin; the parallel pin must engage in the groove of the bearing cartridge (381). 12.4.7.3 Insert the thrust bearing plate (384). 12.4.7.4 Fit the parallel pin (562.02) and shaft seal (420.01) to the counter thrust bearing plate (388) and fasten with the circlip (932.03). 12.4.7.5 Mount the counter thrust bearing plate (388) so that the groove in the counter thrust bearing plate is in alignment with the hole in the bearing cartridge (381) and insert the circlip (932.03). 12.4.8 Insert the key (940.05) and slide the completely assembled bearing cartridge (381) on the shaft (210). 12.4.9 Screw in the hex socket head cap screw (914.03), and fit and tighten the shaft nut (920.09). 12.4.10 Check the lift-off dimension “z” : when the balancing disc (601.01) abuts against the counter balancing disc (602.01), the specified value is 1±0.1 mm. If required, remachine the bearing end cover (361); see figure Adjusting the lift-off device with tilting-pad thrust bearing. 12.4.11 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354). 12.4.12 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with the tightening torque given in the relevant work instruction.

12.5 Mounting the Thrust Bearing (if applicable) _____________________________________________________________________________________

Caution

When mounting the bearings, the holes for thermometers in the bearing shells and the associated thermometer connections in the bearing housings and/or bearing end cover must be aligned! _______________________________________________________________________ 12.5.1 Fit the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01), circlip (932.03) and O-ring (412.10) in the bearing housing (350.01). 12.5.2 Fit the hex socket head cap screws (914.04) including the gaskets (411.02) and tighten the screws with the tightening torque given in the relevant work instruction. 12.5.3 Mount the thrust bearing (314) including all segments and fit it in the thrust bearing housing (354). 12.5.4 Move the pump rotor in the direction of the driven end until the balancing piston (603.02) abuts against the counter balancing disc (602.02). 12.5.5 Adjust the axial clearance “Sl3” at the balancing piston and “Slg2” at thrust bearing as shown in the figure Adjusting the thrust bearing.


_____________________________________________________________________

d c

a

b Slg2 e

Adjusting the thrust bearing

12.5.5.1 Measure the distance “a” from the bearing face of the thrust bearing (314) to the shaft collar. 12.5.5.2 Shorten the spacer ring (504.01) to the dimension “b” : b = a – Sl3 (Sl3 see table of clearances). The maximum permissible deviation from the plane parallelism is 0.02 mm. _____________________________________________________________________________________

Caution As a general rule, always use a new spacer ring (504.01)! ______________________________________________________________________ 12.5.5.3 Measure the distance “c” from bearing face of the thrust bearing (314, in bearing end cover) to the face of the bearing end cover (361), distance “d” from the bearing face of the thrust bearing (314, in the thrust bearing housing) to the face of the thrust bearing housing (354), and width “e” of the thrust bearing plate (384). 12.5.5.4 Calculate the bearing clearance : Slg2 = c + d – e. 12.5.5.5 If the bearing clearance is within the permissible limits given in the table of clearances, the thrust bearing may be mounted. If the clearance is too large, the face of the bearing end cover (361) must be remachined. If the clearance is too small, the face of the thrust bearing (314) in the bearing end cover (361) must be remachined. 12.5.6 Slide the spacer ring (504.01) over the shaft (210) and insert the key (940.05) into the shaft keyway. 12.5.7 Slide the thrust bearing plate (384) and spacer sleeve (525.05) on the shaft (210). 12.5.8 Screw the nut (920.09) on the shaft (210) and tighten it. 12.5.9 Fit the studs (902.11) to the bearing end cover (361). 12.5.10 Fit the bearing end cover (361) including thrust bearing (314), O-rings (412.11 and 412.12), parallel pin (562.02), shaft seal ring (420.01) and circlip (932.03) and tighten the hex nuts (920.11) uniformly; tightening torque, see the relevant work instruction.


_____________________________________________________________________ 13. Mounting the Piping and Instruments All pipes and instruments, which have been dismantled in connection with maintenance work, must be reinstalled as described in the chapter Installation on Site.

14. Mounting the Connecting Coupling 14.1 Fitting the Coupling Hubs 14.1.1 Thoroughly clean the shaft ends and bores of the coupling hubs and check them for dimensional accuracy. _____________________________________________________________________________________

Caution

Check the shaft ends for run-out prior to mounting the coupling hubs. Permissible tolerance < 0.03 mm (see figure Run-out check of the shaft ends). If the tolerance is exceeded, please inform KSB. Observe the manufacturer’s mounting/dismantling instructions. The pump shaft’s check values shall be read after each 900 turn.

_____________________________________________________________________________________

Run-out check of the shaft ends (example)

0.2-0.3mm

14.1.2 Slightly deburr the hub keyway and insert the keys. 14.1.3 Check the protrudent dimension of the keys. Tolerance in accordance with figure Clearance between keyway and key.

Clearance between keyway and key


_____________________________________________________________________ 14.1.4 To facilitate fitting, the coupling hub may be heated uniformly to a temperature of 800 C max. _____________________________________________________________________________________

Use protective gloves. ! Risk of fire in case of open flames. Remove flammable substances from the danger area. ______________________________________________________________________ 14.1.5 Elastomeric parts must be removed before heating! _____________________________________________________________________________________

Caution

Elastomeric parts which have been heated must not be used anymore. Use new parts for reassembly.

_____________________________________________________________________________________ 14.1.6 Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft ends and the hub faces are in alignment. _____________________________________________________________________________________

Caution

Fit the coupling hubs using only the appropriate device to prevent the shaft bearings from damage by axial friction force. Impacts on the coupling hubs are not permitted.

14.1.7 Securely tighten the grub screws (wherever applicable).

14.1.8 Fit the retaining ring, if applicable, to the coupling hub.


_____________________________________________________________________ 14.2 Aligning the Connecting Coupling Align the connecting coupling in accordance with the Connecting Coupling Alignment section in the chapter Installation on Site.

14.3 Mounting the Coupling Connection Mount the connecting coupling spacer as described in the manufacturer’s documentation.

15. Mounting the Guards Preventing Accidental 15.1 Coupling Guard ______________________________________________________________________________________

Caution The pump must not be operated without a coupling guard. ________________________________________________________________________

Coupling guard ( example ) 15.1.1 Align the coupling guard over the connecting coupling. 15.1.2 Make sure the distance between the shaft ends and the coupling components is sufficient.

15.2 Coupling Cover ______________________________________________________________________________________

Caution The pump must not be operated without a coupling cover! ________________________________________________________________________

Couplin cover (example )


_____________________________________________________________________ 15.2.1 Meticulously clean the locating and sealing surfaces. _____________________________________________________________________________________

Caution

Do not damage the seal elements and sealing surfaces!

_____________________________________________________________________________________ 15.2.2 Insert the gasket and O-ring. 15.2.3 Mount the lower cover half and fasten it to the backing ring. 15.2.4 Adjust the injection nozzles (if applicable) as shown in the figure Installation of the injection nozzles.

15.2.5 Coat the sealing surfaces of the cover flanges with a liquid, oil and temperature resistant sealing agent (up 0 to 120 C). 15.2.6 Use eyebolt as a transport aid as shown in the figure Coupling cover. 15.2.7 Fix the cover halves with two taper pins. 15.2.8 Fasten the upper and lower halves with screws. 15.2.9 Connect the pipes to the cover.

15.3 Guard Preventing Accidental for Shaft Seal _____________________________________________________________________________________

Caution

The pump must not be operated without a guard preventing accidental !

_____________________________________________________________________________________ Fasten the guard preventing accidental to bearing housing using screws.

15.4 Sound Insulating Hood (if applicable) Mount the sound insulating hood as described in the manufacturer’s documentation.

16. Maintenance of the Other Pump Set Components 16.1 Maintenance of the Connecting Coupling See the manufacturer’s documentation.

16.2 Maintenance of Drive See the manufacturer’s documentation.


_____________________________________________________________________ 16.3 Maintenance of the Minimum Flow System See the manufacturer’s documentation.

16.4 Maintenance of the Instruments and Valves Maintenance actions are not required; in the case of malfunctioning they are replaced.

16.5 Maintenance of Oil Supply Unit, etc. (if applicable) See the manufacturer’s documentation.

16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable) See the manufacturer’s documentation.

17. Spare Parts 17.1 Ordering Spare Parts Please direct your orders to the nearest KSB Customer Service Center or Sales Office. When ordering spare parts, please quote 17.1.1 The KSB work orders number as indicated on the title page of this instruction manual or the pump name plate. 17.1.2 The required pump set component, part no., designation and quantity required in accordance with the list of components and sectional drawing.

17.2 Spare Parts Stock For quick elimination of possibly occurring problems, we recommend to keep a stock of spare parts.

17.3 Storage The parts should be stored as described under Interim Storage in the chapter Transport/Interim Storage.


_____________________________________________________________________

Trouble Shooting 1. General Information ________________________________________________________________________________________

Caution

During the warranty period, pumps must be attended only by KSB personnel!

________________________________________________________________________________________

1.1 For exact description of the pump design as well as the pump set components and accessories supplied by KSB, please refer to P & I Diagram.

1.2 Requisite Documentation For the elimination of problems described in the tables on the subsequent pages, the technical documentation of the order pump set components is required in addition to this instruction manual. If these components are included in kSB’s scope of supply, the relevant documents are appended to this instruction manual. -

Technical Data Operating Data General Arrangement Drawing P & I Diagram Table of Clearances Table of Tightening Torques Cross Sectional Drawing, Pump List of components, Pump Cross Sectional Drawing, Mechanical seal (if applicable) Documentation of Mechanical seal (if applicable) Work Instructions Documentation of the Connecting Coupling Documentation of the Drive Documentation of the Minimum Flow System (if applicable) Documentation of the Valves and Equipment (if applicable) Documentation of the Sound Insulating Hood, i.e. Acoustic Enclosure (if applicable) Documentation of Oil Supply Unit, i.e. Lube Oil Plant (if applicable) Documentation of Gear/Variable Speed Coupling (if applicable)

1.3 Prerequisites 1.3.1 1.3.2 1.3.3

All spare parts required are available. Proper hoisting tackle and means of transport are available and ready for use. Sufficient room space and appropriate tools are available. 1.3.4 For the work required as per the tables on the subsequent pages, the pump set has been taken out of service in accordance with the Shutdown and Work after Shutdown sections in chapter Commissioning,

Start-up/Shutdown. 1.3.5

The drive has been secured against unintentional starting. _____________________________________________________________________________________

Caution

Before rectifying any faults, check all measuring instruments for proper functioning!

_____________________________________________________________________________________

OIMPG TROUBLE-SHOOTING 1

_____________________________________________________________________ In case of problems not described in the following table, consultation with KSB’s Customer service is required. Problem (what)

Possible causes

Measures

Flow rate of pump > specified value

Pump delivers against an excessive high

Open the valve in the discharge pipe further until the Duty point is adjusted Mount larger impeller(s)

Excessive back pressure

KSB’s Service Center

Pump or piping are not completely vented or primed Inlet pipe or impeller(s) clogged Formation of air pockets in the piping NPSHavailable too low (inlet)

Suction head is too high

Air intake at the gland packing

Wrong direction of rotation Speed is too low

Increase the speed of the turbine or internal combustion engine Check plant for impurities Vent and/or prime Remove deposits in the pump and/or piping Alter the piping layout Fit a new valve Correct the liquid level Fully open the valve in the inlet pipe Change the inlet pipe, if the resistances in the inlet pipe are too high Inlet pipe is too big Check the strainers installed Observe the permissible speed of pressure fall Clean the strainer element and inlet pipe Correct the liquid level Change the inlet pipe Check the strainers installed Replace the gland packing See chapter ‘Commissioning Startup/Shutdown’ & Maintenance Interchange 2 phases of the power supply Increase the speed Increase the voltage Alter the impeller diameter

KSB’s Service Center Wear of internal pump parts (check in accordance with the Tables of clearances)

Replace defective parts

KSB’s Service Center Motor is running on 2 phases only Pump discharge pressure > specified value

Speed is too high

OIMPG TROUBLESHOOTING 2

Replace defective fuses Check the power cable connections Alter the impeller diameter

KSB’s Service Center


Possible causes

Measures

Pressure ps > specified value

Damaged measuring instrument Differential pressure in the strainer element is too high Valve in the inlet pipe is not fully open Pressure in the inlet vessel is too low Damaged measuring instrument Speed is too low Inlet pressure is too low In case of tapping, quantity tapped is too high Temperature of the medium pumped is too low or too high Defective minimum flow system Defective shaft seal Score marks or roughness on shaft protection sleeve (524) and/or sleeve of mechanical seal Gland (gland plate / gland ring) have been tightened incorrectly Wrong packing material

Replace the measuring instrument Dismantle and clean the strainer element

Pressure p d > specified value

Shaft seal leakage

Pump runs rough

Pump set alignment Pump is warped Insufficient quantity of cooling liquid Dirty cooling liquid chamber or cooler Fault in the circulation liquid pipe Surface pressure on the sealing clearance is too high, lack of lubricant or circulation liquid

Open the valve Check the inlet vessel and/or increase the pressure Replace the measuring instrument Check the drive Check the inlet pressure and inlet vessel Throttle the tapping quantity Increase or reduce the temperature Check the minimum flow system Check; replace, if required Replace the shaft protection sleeve (524) or sleeve of mechanical seal Check Replace See chapter ‘Commissioning/Startup/Shutdown’ & Maintenance Correct the suction conditions Re-align the pump Re-balance the pump rotor Increase pressure at the suction nozzle Check the coupling; re-align, if required Check the piping connections and the fastening of the pump Increase the cooling liquid quantity Clean the cooling liquid chamber and/or cooler Check the cooling liquid; purify/clean, if required Increase the effective cross section Check the pipes Check the installation dimensions KSB’s Service Center



Possible causes

Measures

Increased bearing temperature

Defective bearing

Check; replace, if required See chapter ‘Maintenance’ Check the oil quantity; top up or replace, if required See chapter ‘Servicing’ and Technical Appendix Check See chapter ‘Servicing’ and Technical Appendix Replace the casing wearing rings KSB’s Service Center Replace the defective parts

Oil quantity Oil quality Increased axial thrust Wear of internal pump parts (check in accordance with the Tables of clearances)

KSB’s Service Center Unbalance of the pump rotor Pump set not correctly aligned Pump is warped Coupling hub distance Temperature of pump > specified value

Pump leakage

Pump or piping are not completely vented or primed NPSHavailable too low (inlet)

Clean the pump rotor Balance the pump rotor Check the coupling and re-align, if required Check the piping connections and the fastening of the pump Check the coupling hub distance for compliance with the GA Drawing; correct, if required Vent and/or prime Correct the liquid level Fully open the valve in the inlet pipe

Flow rate < specified value Defective O-rings and/or metallic sealing surfaces

Change in the inlet pipe, if resistances in the inlet pipe are too high Inlet pipe is too long Check the strainers installed Observe the permissible speed of pressure fall Increase the minimum flow Replace O-rings and/or remachine the metallic sealing surfaces

Tie rods have loosened

KSB’s Service Center Tighten In accordance with the relevant work instruction KSB’s Service Center



Possible causes

Measures

Pump runs rough


Vent and/or prime

Wear of internal pump parts ( check in accordance with the Tables of clearances)

Backpressure of pump is lower than specified in the purchase order

Pump set alignment Pump is warped Oil quantity

Oil quality Unbalance of the pump rotor

Cavitation noise in the pump and/or piping

Defective bearing Flow rate < specified value Damaged inlet pipe Valve in the inlet pipe is not fully open Pressure in the inlet vessel is too low NPSHavailable / NPSHrequired too low

Air intake at the seal elements/valves/shaft seal Pump or piping are not completely vented or primed


Correct the liquid level Fully open the valve in the inlet pipe Change the inlet pipe, if the resistances in the inlet pipe are too high Inlet pipe is too long Check the strainers installed Observe the permissible speed of pressure fall Replace defective parts

KSB’s Service Center Adjust the duty point accurately by means of the valve in the discharge pipe In the case of permanently overload, turn down the impeller(s), if necessary KSB’s Service Center Check the coupling and re-align, if required Check the piping connections and the fastening of the pump Check the oil quantity; top or replace, if required KSB’s Service Center Check See Technical Appendix Clean the pump rotor Balance the pump rotor Replace Increase the minimum flow Check the inlet pipe Open the valve Check the inlet vessel and/or increase the pressure Check the inlet pipe Change the inlet pipe Excessive speed of pressure fall Check the piping; check shaft seal for leakage Vent and/or prime


Possible causes

Measures

Pressure and/or quantity of balancing liquid fluctuates


Vent and/or prime

Wear of internal pump parts ( check in accordance with the Tables of clearances)

Increased axial thrust

Drive is overloaded

Change in cross section of balancing liquid pipe Excessive resistances ing of several pipes near the pump Balance flow leakage counter balancing disc / final stage diff Wear on the balancing device Wear of internal pump parts ( check in accordance with the Tables of clearances)

Back pressure of pump is lower than specified in the purchase order

Correct the liquid level Fully open the valve in the inlet pipe Change the inlet pipe, if resistances in the inlet pipe are too high Inlet pipe is too long Check the strainers installed Observe the permissible speed of pressure fall Replace the defective parts

KSB’s Service Center Replace the casing wearing ring KSB’s Service Center Check the mode of operation Check the return pipe Check the pump pressures Check the rotor clearances and balancing device Replace the defective parts

KSB’s Service Center Adjust the duty point accurately by means of the valve in the discharge pipe In the case of permanently overload, turn down the impeller(s), if necessary

Higher density or viscosity of the medium pumped than specified in the purchase order Gland tightened excessively or askew Speed is too high

Pump is warped Operating voltage is low Motor is running on 2 phases only


KSB’s Service Center KSB’s Service Center Alter Alter the impeller diameter KSB’s Service Center Reduce the speed of the turbine or internal combustion engine Check the piping connections and the fastening of the pump Check the power cable connections Replace defective fuses Check the power cable connections

_____________________________________________________________________

Tables of Clearances Diametrical Clearances : Pump size

Hydraulics

1; 2 3;4 5 6 4 7;8 5 9 ; 10 6 11;12;13 Max. permissible diametrical clearance (mm)

Sl2

Sl3

0.50 – 1.0 0.25 – 0.40 0.80 – 1.2

S7 2

S6 2

S8 2

1 2 3

Nominal diametrical clearances [mm] S6 S7 S8 S9 0.25 – 0.34 0.35 – 0.50 0.27 – 0.36 0.90 – 1.40 0.90 – 1.50 0.30 – 0.36 0.40 – 0.51 0.35 – 0.45 1.0 – 1.5 0.30 – 0.37 0.35 – 0.41 0.45 – 0.51 0.32 – 0.39 1.0 – 1.6 0.35 – 0.47 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48 1.0 1.0 1.0 2.0

Sl3

Sl2

Clearance between double balance drum and balance disc seat

S9 2

Clearance between balance disc seat and throttle sleeve or balance disc

Clearance between suction casing or inlet ring and shaft

OIMPG CLEAR AF 1

Sl2

_____________________________________________________________________ Theoretical Total Axial Clearance Pump size

1 2 3 4 5 6

Sa1 + Sa2 [mm] Impeller material

Hydraulic

1 2 3 4 5 6 7 8 9 10 11 12 502.02

CI

Cr Steel

8.5 – 8.0 7.5 – 7.0 9.0 – 8.5 7.0 – 6.5 9.0 – 8.5 7.0 – 6.5 -------------

8.5 – 8.0 7.5 – 7.0 8.5 – 8.0 6.5 – 6.0 8.5 – 8.0 6.0 – 5.5

230.02 171.02

Sa1 Sa2 Total axial clearance of pump rotor

OIMPG CLEAR AF 2

6.5 – 8.0 8.5 – 10.0 10.0

_____________________________________________________________________

Tables of Clearances Bearing Clearances Bearing design :

Tilting-pad Thrust Bearing

Pump size

Bearing Clearance Slg2 [mm] (Diametrical clearance) 0.33 – 0.58 0.34 – 0.60 0.40 – 0.75

1,2 3, 4 5, 6

Slg2 Tilting-pad Thrust Bearing Bearing design :

Lift-off Device with Tilting-pad Thrust Bearing

Pump size 1-6

Bearing clearance Slg1 [mm] 0.30 - 0.50

Slg1

Lift-off Device with Tilting-pad Thrust Bearing

OIMPG CLEAR PLANE 1

_____________________________________________________________________

Tables of Clearances Bearing Clearances Bearing design :

Pump size 3, 4 5, 6

Tilting-pad Thrust Bearing

Bearing clearance Slg2 [mm] (Diametrical clearance) 0.34 - 0.60 0.40 - 0.75

Diametrical Clearances : Pump size

Hydraulics

1 2 3

1; 2 3;4 5 6 7;8 9 ; 10 11;12;13

4 5 6

Max. permissible diamet-

Nominal diametrical clearances [mm] S6 S7 S8 S9 0.25 – 0.34 0.35 – 0.50 0.27 – 0.36 0.90 – 1.40 0.90 – 1.50 0.30 – 0.36 0.40 – 0.51 0.35 – 0.45 1.0 – 1.5 0.30 – 0.37 0.35 – 0.41 0.45 – 0.51 0.32 – 0.39 1.0 – 1.6 0.35 – 0.47 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48 1.0 1.0 1.0 2.0

rical clearance (mm)

OIMPG CLEAR PLANE H 1

Sl2

Sl3

0.50 – 1.0 0.25 – 0.40 0.80 – 1.2

_____________________________________________________________________

Table of Tightening Torques Tightening Torques [Nm] HG Pump Sizes 1 – 6 1. 1.1 1.2 1.3 1.4

Prerequisites The threads of the screws/bolts and nuts are not damaged. The threads and bearing surfaces of the screws/bolts and nuts are plane, deburred and cleaned thoroughly. The threads move smoothly. The washers are plane, deburred and cleaned thoroughly.

2. Pump Observe the tightening torques for the screwed/bolted connections as per relevant work instruction. 3. Fastening of Pump Feet Thread Tightening torque MA [Nm] M 20 190 M 24 330 M 30 660 M 36 1160

4. Flange Connection If the bolting for the flanged connections are in the KSB’s scope of Supply, the tightening torques will be as specified in the table on the following pages.

OIMPG TIGHT TRQ 1

_____________________________________________________________________ Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle The tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.

Flanges as per DIN Nominal diameter DN [mm] 25 40

50

65

80

100

125

150

200

250

OIMPG TIGHT TRQ 2

Nominal pressure PN [bar] 160 250 64 160 250 64 160 250 64 160 250 64 160 250 64 160 250 320 400 500 160 250 320 400 500 160 250 320 400 500 160 250 320 400 500 160 250 320 400

Tightening torque MA [Nm] 90 140 140 160 240 160 270 240 140 240 270 250 370 350 530

500 490

490 650

660 1150

1260

_____________________________________________________________________ Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle The tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.

Flanges as per ANSI Nominal diameter DN [inch]

1” 1 ½” 2” 2 ½” 3”

4”

5”

6”

8” 10”

OIMPG TIGHT TRQ 3

Nominal pressure PN [class] 600 1500 600 1500 600 1500 600 1500 600 900 1500 600 900 1500 2500 900 1500 2500 900 1500 2500 900 1500 2500 900 1500 2500

Tightening torque MA [Nm] 80 240 140 350 90 240 140 270 240 490 490 650 650 1100 490 830 830 1350 840

_____________________________________________________________________ Bolts for Flange Connection, Suction Nozzle The tightening torques apply only if the bolts and screws are part of KSB’s scope of supply.

Flanges as per DIN Nominal diameter DN [mm] 65 80 125 150 200

250

300

Nominal pressure PN [bar] 16 40 16 40 16 40 16 40 16 25 40 16 25 40 16 25 40

Tightening torque MA [Nm] 50 70 50 70 70 150 130 200 130 190 240 210 290 380 210 240 320

Flanges as per ANSI Nominal diameter DN [inch] 2 ½” 3” 5” 6” 8” 10” 12”

OIMPG TIGHT TRQ 4

Nominal pressure PN [class] 300 300 300 300 300 300 300

Tightening torque MA [Nm] 90 90 210 120 210 260 320

_____________________________________________________________________

Table of Weights HG Pump Size 1 _____________________________________________________________________________________

Caution

Weights ≥ 25 kg

_____________________________________________________________________________________

Pump Components Part No. 106 107 210 350.01

Designation Suction Casing Discharge Casing Shaft for 3 stages each additional stage Bearing Housing Rotor 3 stages Each additional stage

Weights (reference values in kg) 35.0 58.0 17.9 1.2 25.0 31.0 4.0

Pump Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

OIMPG WEIGHT 1

Weights (reference values in kg) Without water fill Water fill 234 8.0 250 809 266 9.7 282 10.6 298 11.5 314 12.4 330 13.3 346 14.2 362 15.1 378 16.0 394 16.9 410 17.8 426 18.7 442 19.6 458 20.5 474 21.4 490 22.3 506 23.2

_____________________________________________________________________


Caution

Weights ≥ 25 kg

_____________________________________________________________________________________

Pump Components Part No. 106 107 108 210 350.01

Designation Suction Casing Discharge Casing Stage Casing Shaft for 3 stages each additional stage Bearing Housing Rotor 3 stages Each additional stage

Weights (reference values in kg) 54.1 140.0 25.0 21.1 1.6 25.0 52.0 6.0

Pump Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

OIMPG WEIGHT 2

Weights (reference values in kg) Without water fill Water fill 410 19.0 440 21.6 470 24.2 500 26.8 530 29.4 560 32.0 590 34.6 620 37.2 650 39.8 680 42.4 710 45.0 740 47.6 770 50.2 800 52.8 830 55.4 860 58.0

_____________________________________________________________________


Caution

Weights ≥ 25 kg

_____________________________________________________________________________________

Pump Components Part No. 106 107 108.01 108.02 130 210 350.01 354 361 441

Designation Suction Casing Discharge Casing Stage Casing Stage Casing Casing Part, for double piston For mechanical seal Shaft for 3 stages each additional stage Bearing Housing Thrust Bearing Housing, thrust bearing/plain bearing Bearing End Cover, thrust bearing/plain bearing Seal Casing Rotor 3 stages Each additional stage

Weights (reference values in kg) 161.0 225.0 38.00 28.0 25.0 30.5 51.4 3.0 57.0 25.0 29.0 39.0 83.0 9.0

Pump Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16

OIMPG WEIGHT 3

Weights (reference values in kg) Without water fill Water fill 736 27.0 774 30.0 812 33.0 850 36.0 888 39.0 926 42.0 964 45.0 1002 48.0 1040 51.0 1078 54.0 1116 57.0 1154 60.0 1192 63.0 1230 66.0

_____________________________________________________________________


Caution

Weights ≥ 25 kg

_____________________________________________________________________________________

Pump Components Part No. 106 107

108.01 108.02 130 131 210 350.01 350.02 354 361 441

Designation Suction Casing < 320 bar ≤ 420 bar Discharge Casing < 320 bar DN 80 < 250 bar DN 100 >320 bar DN 100 ≤ 420 bar DN 100 DN 125 Stage Casing Stage Casing Casing Part, for double piston For mechanical seal Inlet Ring Shaft for 3 stages each additional stage Bearing Housing, suction side Heavy bearing housing Bearing Housing, discharge side Thrust Bearing Housing, thrust bearing/plain bearing Bearing End Cover, thrust bearing/plain bearing Heavy bearing housing Seal Casing Rotor 3 stages Each additional stage

Weights (reference values in kg) 210.0 250.0 255.0 285.0 315.0 530.0 550.0 31.0 38.0 25.0 30.5 80.0 51.4 3.0 57.0 61.0 150.0 25.0 29.0 35.0 39.0 83.0 9.0


OIMPG WEIGHT 4


_____________________________________________________________________


Caution

Weights ≥ 25 kg

_____________________________________________________________________________________

Pump Components Part No. 106 107

Designation Suction Casing Discharge Casing

108.01 108.02 130 131 210

Stage Casing Stage Casing Casing Part Inlet Ring Shaft for 3 stages each additional stage Bearing Housing, suction side Heavy bearing housing Bearing Housing, discharge side Thrust Bearing Housing, thrust bearing/plain bearing Bearing End Cover, thrust bearing/plain bearing Heavy bearing housing Seal Casing Balancing Piston Tie Rods for 3 Stages M 45 Each additional stage Rotor 3 stages Each additional stage

350.01 350.02 354 361 441 603.02 905

Weights (reference values in kg) 290.0 395.0 60.0 68.0 33.0 110.0 74.7 4.8 57.0 61.0 150.0 25.0 29.0 35.0 39.0 28.0 10.3 1.3 130.0 16.0


OIMPG WEIGHT 5


_____________________________________________________________________


Caution

Weights ≥ 25 kg

_____________________________________________________________________________________

Pump Components Part No. 106

Designation Suction Casing ≤ 420 bar

107

Discharge Casing ≤ 420 bar ≤ 420 bar

108.02

DN 200 DN 200 DN 250 DN 150 DN 200

Stage Casing, Hydraulic 9 Hydraulic 10 Stage Casing, Hydraulic 9 Casing Insert Casing Part Inlet Ring Diff Diff Shaft for 3 stages each additional stage Bearing Housing Bearing Housing Thrust Bearing Housing, thrust bearing/plain bearing Bearing Cover Bearing End Cover Seal Casing Balancing Disc Balancing Piston Balancing Piston Tie Rods for 3 Stages M 45 Each additional stage Tie Rods for 3 Stages M 52 Each additional stage Rotor 3 stages Each additional stage

108.03 13-6 130 131 171.01 171.02 210 350.01 350.02 354 360.01 361 441 601 603.01 603.02 905

Weights (reference values in kg) 622.0 819.0 635.0 821.0 1020.0 1170.0 93.0 84.0 100.0 96.0 59.0 180.0 25.0 25.0 109.0 7.0 124.0 165.0 32.0 36.0 44.0 29.0 25.0 43.0 57.0 12.9 1.6 17.5 2.1 243.0 25.0

Pump Number of stages 3 4 5 6 7 8 9 10 11 12 13

OIMPG WEIGHT 6

Weights (reference values in kg) Without water fill Water fill 2775 80 2930 90 3085 100 3240 110 3395 120 3550 130 3705 140 3860 150 4015 160 4170 170 4325 180

INDEX CONTENTS

PAGE

• Standard Features

1

JAN-02

• At a Glance

2

JAN-02

• Gear-flex Family

3

JAN-02

• Std. Material of Construction

4

JAN-02

• Crowning of Gear Teeth (Optional)

5

JAN-02

• Ratings for Standard couplings

6

JAN-02

• Weight & M.I. for standard couplings

7

JAN-02

• Customised Gear-flex Specials

8

JAN-02

• Half Flex Couplings with Floating Shafts

9

JAN-02

• Spacer Couplings

10

JAN-02

• Reversed Hub Combinations

11

JAN-02

• Lubricants

12

JAN-02

• Requirements of API-671

13

JAN-02

• Selection of Size of Coupling

14

JAN-02

• Typical Service Factors

15-17

JAN-02

• Std. Tolerances for Finish Bore & Keyway

18

JAN-02

• Applications

19

JAN-02

• Installation Instructions

20-27

JAN-02

• Gear-flex couplings equivalent to Competitor’s couplings.

28-33

JAN-02

GEAR-FLEX COUPLING

STANDARD FEATURES OF GEAR-FLEX COUPLING

♦ Less backlash. ♦ High power to weight ratio. ♦ Compact assembly. ♦ Accommodates angular, parallel & axial misalignments. ♦ Generally used upto 120°C. Can be used for higher temperatures by using proper grade of oil or grease. ♦ Can be dynamically balanced to the required grade as per ISO-1940.

1

JAN-02

GEAR-FLEX COUPLING

AT A GLANCE

SIZES Full Flexible Type LFG Half Flexible Type LHG

- 101 to 119 (19 sizes) - 101 to 110 (10 sizes)

RATING RANGE TYPE LFG - 157 kW to 232808 kW @ 1500 rpm TYPE LHG - 157 kW to 12846 kW @ 1500 rpm TORQUE RANGE TYPE LFG - 100.2 kg.m to 149000 kg.m TYPE LHG - 100.2 kg.m to 8220 kg.m BORE RANGE TYPE LFG - 20 mm. to 710 mm. TYPE LHG - 20 mm. to 260 mm. ANGULAR MISALIGNMENT

- 1.5° per gear mesh

COMPLIANCE WITH API-671 SPECIFICATIONS, IF REQD.

2

JAN-02

GEAR-FLEX COUPLING

GEAR FLEX FAMILY

1.

Hubs with external teeth

2.

Sleeves with internal teeth

3.

Seal

4.

Bolts

5.

Nuts

6.

Lubrication plugs

7.

Gasket FULL FLEXIBLE TYPE - LFG

3

JAN-02

GEAR-FLEX COUPLING

STANDARD MATERIAL OF CONSTRUCTION

Hubs & Sleeves - Forged Steel EN-9 BS 970 Bolts & Nuts

- Closed tolerance connecting Bolts in Carbon Steel

Seals

- Nitril Rubber ( SH - 60)

Gasket

- Paronite Paper

For other requirements of material of construction, consult LOVEJOY.

4

JAN-02

GEAR-FLEX COUPLING

CROWNING OF GEAR TEETH (OPTIONAL) The straight line tooth form is known to transmit high torque when the centers of axis are in complete alignment. Where there is any displacement, however, this will cause the area to localize on tooth surface (at the end of tip of the tooth) thereby causing damage to surfaces of the teeth. While rotating the load is continually changing location, introducing sliding between the two gears. Crowned gear teeth resist the wear thus developed. Because of the fully crowned design, end bearing does not occur, and the tooth bearing remains near the center section of the tooth, thus utilizing the additional strength available at the tooth centre.

The LOVEJOY Gear coupling has a unique crowning for the tooth surface which is designed after full consideration of the relationship between tooth forms & tooth width so that the stress on the tooth surface will not vary significantly even where relative movement is present. As for the tooth tip, the crowning is applied & the tooth is designed to minimise the top clearance between teeth when they are mated. The LOVEJOY Gear coupling has a crown tooth form so as to give maximum tooth thickness at its center. Where there is a relative misalignment between the driver & driven shaft, it is necessary that the tooth which comes between the teeth of its counterpart be permitted to oscillate. The internal teeth of the sleeves have a std. form whereas the external teeth of the hub take a special form.

5

JAN-02

GEAR-FLEX COUPLING RATINGS FOR STANDARD COUPLING

Sr. Coupling No. Size 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

(LFG/*LHG) 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119

Rated Torque Nm 999.5 2495 4488 8480 12968 19945 34906 44881 55850 81780 109442 146250 198988 284524 345646 596831 848940 1123990 1482101

kg m

Rated Power

Lbs-inch

101.9 8843 254.3 22075 457.5 39709 864.4 75029 1321.9 114737 2033.1 176468 3558.2 308838 4575.0 397094 5693.2 494145 8336.4 723566 11156.2 968311 14908.3 1293978 20284.2 1760589 29003.5 2517387 35234.0 3058177 60839.0 5280589 86538.2 7511177 114575.9 9944741 151080.6 13113204

@100 RPM Kw 10.5 26.1 47 89 136 209 366 470 585 856 1146 1532 2084 2980 3620 6250 8890 11770 15521

@1500 RPM

HP Kw HP 14.1 157 211 35.1 392 526 63 705 945 119 1332 1786 182 2037 2730 280 3133 4200 490 5483 7350 630 7050 9450 784 8773 11760 1148 12846 17220 1536 17188 23040 2053 22973 30795 2793 31257 41900 3994 44693 59910 4852 54294 72780 8378 93750 125670 11917 133351 178755 15778 176556 236670 20805 232808 312075

*Note :- LHG type couplings are available from size 101 to 110 only.

6

JAN-02

GEAR-FLEX COUPLING WEIGHT & M.I. FOR STANDARD COUPLING COUPLING SIZE

Wt. kg

M.I. kg m2

GD2 kg m2

LFG-101

11

0.14

0.56

LFG-102

15

0.20

0.8

LFG-103

25

0.48

1.92

LFG-104

39

0.95

3.8

LFG-105

57

1.95

7.8

LFG-106

85

3.00

12

LFG-107

103

5.25

21

LFG-108

138

8.50

34

LFG-109

210

15.00

60

LFG-110

277

30.50

122

LFG-111

550

58.00

232

LFG-112

710

88.00

352

LFG-113

980

138.0

552

LFG-114

1320

291.0

1164

LFG-115

1700

353.0

1412

LFG-116

2550

690.7

2762.8

LFG-117

3620

1235.3

4941.2

LFG-118

4860

1965.7

7862.8

LFG-119

6380

3012.3

12049.2

Note : Weight & M.I. are with solid hubs. WEIGHT & M.I. FOR HALF GEAR COUPLINGS

COUPLING SIZE

Wt. kg

M.I. kg m2

GD2 kg m2

LFG-101

11

0.15

0.6

LFG-102

15

0.24

0.96

LFG-103

20

0.51

2.04

LFG-104

40

1.0

4

LFG-105

60

2.0

8

LFG-106

80

3.3

13.2

LFG-107

106

5.8

23.2

LFG-108

149

9.5

38

LFG-109

170

16.8

67.2

LFG-110

264

35.0

140

Note :

Weight & M.I. are with solid hubs. 7

JAN-02

GEAR-FLEX COUPLING

CUSTOMISED GEAR-FLEX SPECIALS

1.

Floating shaft couplings (Fig. 3a & 3b)

2.

Spacer couplings (Fig. 4a & 4b)

3.

LFG - Type Couplings with one hub reversed (Fig. 5)

4.

LFG - Type Couplings with both hub reversed (Fig. 6)

5.

LHG - Type with flexible hub reversed (Fig. 7)

6.

Couplings with cut off hubs (Fig. 8)

7.

Compliance with API 671, if reqd.

8

JAN-02

GEAR-FLEX COUPLING

HALF FLEX COUPLINGS WITH FLOATING SHAFTS

A floating shaft can eliminate the need for additional bearing along spanning shaft because shaft is ed at ends by connected equipment through the half flex couplings. These are generally used for the applications of cooling tower fans.

Flexible hubs on floating shaft (Fig. 3a ) Assembly of flexible hubs on the floating shaft allows for easier replacement in case of wear & allows the rigid hubs with their increased bore capacities to be used on the connected equipment shafts. This frequently means a smaller coupling size to be utilised.

Rigid hubs on floating shaft (Fig. 3b ) When the rigid hubs are on floating shaft, shorter shaft spans can be accommodated. Since the flexible hubs are outboard, the planes of gear mesh are further apart, providing greater misalignment capacity.

9

JAN-02

GEAR-FLEX COUPLING

SPACER COUPLINGS Used on pumps & compressors for ease of servicing without disturbing either of the shafts.

10

JAN-02

GEAR-FLEX COUPLING

REVERSED HUBS COMBINATIONS

1. LFG - ONE HUB REVERSED

2 . LFG - BOTH HUBS REVERSED

3. LHG - FLEX. HUB REVERSED

4. LONG HUB CUT OFF

11

JAN-02

GEAR-FLEX COUPLING

LUBRICANTS 1. OIL LUBRICATION For the gear coupling, use gear oil of viscosity of 35 to 45 cst at 99°C with extra high pressure additive. Where the coupling is used under extreme overload operation, severe reversing operation or bigger angular and offset misalignment, use gear oil of viscosity of 70 to 110 cst at 99°C. A. First filling must be ample. B. After about 3 months’ operation, the coupling should be overhauled and drained of used oil to remove abrasion particles, and refilled with fresh oil. C. Subsequent refilling or replacing of oil should be made every 1 year by use of oil plug holes. 2. GREASE LUBRICATION Grease lubrication is somewhat inferior to application of gear oil. Coat the coupling case and coupling center with the specified grease until the teeth are submerged in grease, assemble the coupling, tighten the bolts and then supplement grease through oil plug hole by use of grease gun and so on. Replacing time of grease is same as gear oil, but replace old grease with new grease in full by overhauling the coupling. 3. RECOMMENDED LUBRICANTS Recommended Grease is RSG (Rathi Special Grease) having δg = 910 Kg/m3.

Refer Table ‘C’ for grease qty. reqd. per coupling size.

12

JAN-02

GEAR-FLEX COUPLING

REQUIREMENTS OF API 671

• Double engagement type couplings • Material of construction - Alloy Steel EN-19 • Component balancing - Gr. 2.5 as per ISO-1940 • Unless otherwise specified, the coupling assembly shall permit total axial displacement of at least 1/4” ( 6.4 mm). • Antifly Spacer (fail-safe design) • The coupling design shall ensure that all components are positively centered. The gear meshes shall be centered at the crown diameter of the external teeth & at the root diameter of the internal teeth. • The involute tooth form shall be used at the vendor’s discretion. External teeth shall be relieved or chamfered at the tips and edges to provide the required misalignment capability & torque capacity. • The hardness of the gear teeth shall be at least 45 Rc. The hardness of the teeth with the greater face width ( generally the sleeve teeth) shall be greater than or equal to the hardness of the mating teeth.

13

JAN-02

GEAR-FLEX COUPLING

SELECTION OF SIZE OF COUPLING

Requirements Application :

Driver Driven -

Application Rating : Shaft sizes :

kW -

RPM -

Driver -

Driven -

Distance between shaft ends (DBSE) if reqd. : Service Factor (S.F.) to be taken :

Selection Procedure (a) Service Factor Determine appropriate SERVICE FACTOR from table (b) Design Power Multiply running power of driven machinery by the service factor. This gives DESIGN POWER which is used as a basis for coupling selection. (c) Coupling Size Refer to rating table for your required coupling size and read from the appropriate speed column until a power equal to or greater than the DESIGN POWER is found. (d) Bore Size Refer respective coupling dimensional table to check that the required bores can be accommodated. If bore size of selected coupling can’t accommodate the shaft size, then go for next coupling size where shaft size can be accommodated.

14

JAN-02

GEAR-FLEX COUPLING TYPICAL SERVICE FACTORS Values listed are intended only as a general guide, and are typical of usual service requirements. For systems which frequently utilize the peak torque capability of the power source, that the magnitude of this peak torque does not exceed the 1.0 Service Factor Rating of the coupling selected. Applications which involve extreme repetitive shock or high-energy load absorption characteristics should be referred - with full particulars - to GEAR-FLEX. Values contained in the table are to be applied to smooth power sources such as electric motors and steam turbines. For drives involving internal combustion engines of four or more cylinders, add 1.0 to the values listed, for six or more cylinders, add 0.5 to the values listed.

Application AGITATORS Pure Liquids Liquids & Solids Liquids-Variable Density BLOWERS Centrifugal Lobe Vane BRIQUETTE MACHINES CAR PULLERS-Intermittent Duty CLAY WORKING MACHINERY COMPRESSORS Centrifugal Centriaxial Lobe Reci-procating-Multi Cylinder CONVEYORS-Light Duty Uniformly Fed Apron, Bucket, Chain, Flight, Screw Assembly, Belt Oven CONVEYORS-Heavy Duty Not Uniformly Fed Apron, Bucket, Chain, Flight, Oven Assembly, Belt Reciprocating Shaker CRANES AND HOISTS Main Hoists, Reversing Skip Hoists, Trolley & Bridge Drives Slope CRUSHERS Ore Stone

Typical Service Factor

1 1.25 1.25 1 1.5 1.25 2 1.5 1.75 1 1.25 1.5 2 1.25 1.25 2.5

1.5 1.25 2.5 2.5 2 2

Application DREDGES Cable Reels Conveyors Cutter Head Jig Drives Maneuvering Winches Pumps Screen Drives Stackers Utility Winches ELEVATORS Bucket Centrifugal & Gravity Discharge Escalators Freight FANS Centrifugal Cooling Towers Forced Draft Induced Draft without Damper Control FEEDERS Apron, Belt, Disc, Screw Reciprocating GENERATORS(Not Welding) HAMMER MILLS LAUNDRY WASHERS Reversing LAUNDRY TUMBLERS LINE SHAFT


1.75 1.5 2.5 1.75 1.75 1.75 1.75 1.5 1.75 1.5 1.5 2.5 1 1.5 1.5 2 1.25 2.5 1 2 2 2 1.5

3

15

JAN-02

GEAR-FLEX COUPLING TYPICAL SERVICE FACTORS

Application LUMBER INDUSTRY Barkers-Drum Type Edger Feed Live Rolls Log Haul-Incline Log Haul-Well Type Off bearing Rolls Planer Feed Chains Planer Floor Chains Planer Tilting Hoist Slab Conveyor Sorting Table Trimmer Feed MACHINE TOOLS Bending Roll Plate Planer Punch Press-Gear Driven Tapping Machines Other Machine Tools Main Drives Auxiliary Drives METAL MILLS Draw Bench-Carriage Draw Bench-Main Drive Forming Machines Slitters Table Conveyors Non-reversing Reversing Wire Drawing & Flattening Machine Wire Winding Machine MILLS, ROTARY TYPE Ball Dryers & Coolers Hammer Kilns Pebble & Rod Pug Tumbling Barrels MIXERS Concrete Mixers Drum Type


2 2 2 2 2 2 1.75 1.75 1.75 1.5 1.5 1.75 2 1.5 2 2.5 1.5 1.25 2 2 2 1.5 2.25 2.5 2 1.75 2.25 2 1.75 2 2 1.75 2 1.75 1.5

16

Application METAL ROLLING MILLS Coilers, hot mill Coilers, cold mill Cold Mills Cooling Beds Door Openers Draw Benches Edger Drives Feed Rolls, Reversing Mills Furnace Pushers Hot Mills Ingot Cars Kick-outs Manipulators Merchant Mills Piercers Pusher Rams Reel Drives Reel Drums Reelers Rod and Bar Mills Roughing Mill Delivery Table Runout Tables Saws, hot & cold Screwdown Drives Skelp Mills Slitters Slabbing Mills Soaking Pit Cover Drives Straighteners Tables, transfer & runout Thrust Block Traction Drive Tube Conveyor Rolls Unscramblers Wire Drawing PRINTING PRESSES PULLERS-Barge Haul OIL INDUSTRY Chillers Paraffin Filter Press


2 1.5 2 1.75 2 2 1.75 3.5 2.5 3 2.5 2.5 3 3 3 2.5 1.75 2 3 3 3 2.5 2.5 3 3 3 3 3 2.5 2.5 3 3 2.5 2.5 1.75 1.5 2 1.25 1.75

JAN-02

GEAR-FLEX COUPLING TYPICAL SERVICE FACTORS

Application RUBBER INDUSTRY Mixed-Banbury Rubber Calender Rubber Mill (2 or more) Sheeter Tire Building Machines Tire & Tube Press Openers Tubers & Strainers PAPER MILLS Barker Auxiliaries, Hydraulic Barker, Mechanical Barking Drum Spur Gear Only Beater & Pulper Bleacher Calenders


2.5 2 2.25 2 2.5 1 2 2 2 2.25 1.75 1 2

Chippers Coaters Converting Machines, except

2.5 1

Cutters, Platers Couch Roll Cutters, Platers Cylinders Disc Refiners Dryers Felt Stretcher Felt Whipper Jordans Line Shaft Log Haul Pulp Grinder Press Roll Reel Stock Chests Suction Roll Washers & Thickeners Winders

1.5 1.75 2 1.75 1.75 1.75 1.25 2 1.75 1.5 2 1.75 2 1.5 1.5 1.75 1.5 1.5

17

Application PUMPS Centrifugal Reciprocating Single Acting 1 or 2 Cylinders 3 or more Cylinders Double Acting Rotary, Gear, Lobe, Vane SCREEN Air Washing Grizzly Rotary-Stone or Gravel Traveling Water Intake Vibrating SEWAGE DISPOSAL EQUIPMENT Bar Screens Chemical Feeders Collectors, Circuline or Straightime Dewatering Screens Grit Collectors Scum Breakers Slow or Rapid Mixers Sludge Collectors Thickeners Vacuum Filters STEERING GEAR STOKERS WINCH WINDLASS


1

2.25 1.75 2 1.5 1 2 1.5 1.25 2.5

1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1 1 1.5 1.75

JAN-02

GEAR-FLEX COUPLING STANDARD TOLERANCES FOR FINISH BORE & KEYWAY Unless otherwise specified, couplings are supplied with finish bore & keyway (as per IS 2048 : 1962) and tolerances in H7 & JS9 (as per IS 919 (part 2) : 1993 standard).

∅A - Bore B - Keyway Depth C - Keyway Width

Basic Size (mm.) Above Upto & including 3 6 6

10

10

18

18

30

30

50

50

80

80

120

120

180

180

250

250

315

315

400

400

500

H7 For Bores (mm.) + 0.012 0 + 0.015 0 + 0.018 0 + 0.021 0 + 0.025 0 + 0.030 0 + 0.035 0 + 0.040 0 + 0.046 0 + 0.052 0 + 0.057 0 + 0.063 0

JS9 For Keyway Width (mm.) ± 0.015

For Keyway Depth (mm.)

± 0.018

+ 0.1 0

± 0.021 ± 0.026 ± 0.031 ± 0.037

+ 0.2 0

± 0.043 ± 0.050 ± 0.057

+ 0.3 0

± 0.065 ± 0.070 ± 0.077

18

+ 0.4 0 + 0.5 0

JAN-02

GEAR-FLEX COUPLING

APPLICATIONS

Gear-flex couplings can be used effectively & economically for transmission of mechanical power for : Agitators Blowers Conveyors Crushers Elevators Escalators Extruders Feeders Generators

Hammer mills Line shafts Machine tools Metal forming machines Mixers Pulverisers Pumps Screens Wenches

In industries like -

Cement Brewing & Distilling Food Rolling Mills Oil & Petroleum Chemical & Fertiliser Paper Mills Rubber Sewage Disposal, Sugar, Textile Thermal Power Houses

19

JAN-02

GEAR-FLEX COUPLING

INSTALLATION INSTRUCTIONS FOR STD. LFG / LHG COUPLINGS

(A)

BEFORE INSTALLATION

1. Remove the coupling from packing & thoroughly inspect for signs of damage. 2. Disassemble the coupling by removing nuts & bolts. Clean all the parts carefully. 3. Remove protective coatings / lubricants from bores & keyways. (B)

MOUNTING PROCEDURE

1. Slide the sleeves with internal teeth with rubber O ring on shafts before mounting the hubs. 2. Mount the hubs with external teeth on their respective shafts flushed with the faces of hubs as shown in fig. 1.

20

JAN-02

GEAR-FLEX COUPLING 3. With one machine firmly bolted down, set the equipments at a distance ‘G’ (refer table A & B) between shaft ends by using a spacer bar equal in thickness to the required gap ‘G’ as shown in fig. 2.

Deviation in standard DBSE is defined as axial misalignment (end float). For normal applications the shaft end should be flushed with inner face of the adpater. In some special cases the shaft ends may protrude beyond the inner face of the adapter or may remain inside, if required. The distance between two faces of adapter flanges is to be maintained as specified. The variation in this distance should not exceed the permissible initial axial misalignment given in table 1.

21

JAN-02

GEAR-FLEX COUPLING

(C)

ALIGNMENT PROCEDURE

Alignment procedure is given separately for each type of alignment, for simplicity. However all 3 types of misalignments may be present at the same time. IMPORTANT : The misalignment capabilities shown in drawings or in product literature are for dynamic conditions and variations. For optimum service from the coupling the installation misalignment (Initial misalignment) should not be more than 25% of the maximum allowable misalignments limits. Allowance should be made for any anticipated movements which will occure during operation (e.g. Thermal movements).

For Permissible INITIAL misalignments refer table A For Permissible MAXIMUM misalignments refer table B

22

JAN-02

GEAR-FLEX COUPLING

(I)

CHECKING PARALLEL /RADIAL ALIGNMENT

Check the parallel/Radial alignment with the help of straight edge resting squarely on both the hubs at 4 places 90° apart. The deviation in the readings should not exceed the permissible initial parallel misalignment mentioned in table A. (Refer fig. 3)

(II)

CHECKING ANGULAR ALIGNMENT

Check the angular misalignment with the help of slip gauges by inserting in the gap at 4 places 90° apart. The deviation in the values of standard gap ‘G’ is Total Indicated Reading (TIR). The angular misalignment ‘X’ in mm is half the Total Indicated Reading. The values of angular misalignment should not exceed permissible initial misalignments mentioned in table A. (Refer fig. 4).

23

JAN-02

GEAR-FLEX COUPLING (D).

ASSEMBLY PROCEDURE

IMPORTANT : If the coupling is dynamically balanced, ensure that the matchmarks are in straight line & unidirectional before bolting the assembly.

1. Insert the gasket between the flanges. Position the flanged sleeves with lubrication plugs. 2. Insert the bolts & tighten the nuts. : Assemble only with the help of the fasteners furnished with the coupling. Fig. 5

3. Fill with recommended grease/oil (RSG/RSL with reqd. qty.) for lubrication. For grease quantity for respective coupling size, refer table No. C. 4. Change the grease after the interval of 6 months & the oil after the interval of 1 year or after 8000 working hours. Use Loctite to prevent the loosening of threads, if required. IMPORTANT: The necessity for shields & guards varies with individual installations. The owner or must provide the required safety guards. Safety guards or shields are not furnished by us with this equipments.

24

JAN-02

GEAR FLEX COUPLING

TABLE ‘A’ PERMISSIBLE INITIAL MISALIGNMENTS FOR GEAR COUPLINGS TYPE LFG COUPLING SIZE

ANGULAR degrees per gear mesh

‘X’ (mm)

TYPE LHG

PARALLEL/ RADIAL

AXIAL

‘P’

(mm)

(mm)

ANGULAR degrees per gear mesh

GAP ‘G’ AXIAL

Std

(mm)

(mm)

X’

(mm)

101

0.5

0.2

0.5

5

102

0.6

0.2

0.6

5

103

0.7

0.3

104

0.8

0.3

105

0.9

0.3

106

1.0

107

±0.12

0.7

±0.06

5

0.8

5

0.9

10

0.4

1.0

10

1.1

0.4

1.1

10

108

1.2

0.5

109

1.4

0.5

1.4

10

1.6

0.6

1.6

10

111

1.8

0.8

10

112

1.9

0.9

10

113

2.2

1.6

114

2.4

1.8

NOT

15

115

2.5

2.0

AVAILABLE

15

116

2.9

2.1

117

3.2

2.3

118

3.6

2.4

20

119

4.0

2.5

20

110

0.37

±0.37°

±0.25

1.2

±0.5

±0.12

10

15

20 ±0.75

20

•

Half Flexible Gear Couplings Type LHG cannot accommodate parallel misalignment. Gap ’G’ in the above table is given when angular & axial misalignments are zero.

25

JAN-02

GEAR FLEX COUPLING

TABLE ‘B’ PERMISSIBLE MAXIMUM MISALIGNMENTS FOR GEAR COUPLINGS

TYPE LFG COUPLING

SIZE

ANGULAR

degrees per gear mesh

‘X’ (mm)

GAP ‘G’

TYPE LHG

PARALLEL/ RADIAL

AXIAL

‘P’

(mm)

(mm)

ANGULAR

degrees per gear mesh

‘X’

AXIAL

Std

(mm)

(mm)

(mm)

101

2.2

0.8

2.2

5

102

2.4

0.95

2.4

5

103

2.9

1.1

104

3.2

1.3

105

3.7

1.45

106

4.2

107

±0.5

2.9

±0.25

5

3.2

5

3.7

10

1.55

4.2

10

4.6

1.8

4.6

10

108

5.0

1.9

109

5.6

2.2

5.6

10

6.4

2.6

6.4

10

111

7.1

3.3

10

112

7.7

3.5

10

113

8.9

6.6

114

9.5

7.3

NOT

15

115

10.2

8.1

AVAILABLE

15

116

11.8

8.5

117

13.1

9.1

118

14.4

9.6

20

119

16.3

10.2

20

110

±1.5°

±1.5°

±1.0

5.0

±2.0

±0.5

10

15

20 ±3.0

20

• Half flexible Gear Couplings type LHG cannot accommodate parallel misalignment. Gap’G’ in the above table is given when angular & axial misalignments are zero.

26

JAN-02

GEAR FLEX COUPLING

TABLE ‘C’ GREASE FOR GEAR COUPLING (LFG/ LHG) Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

COUPLING SIZE 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119

GREASE QTY. 47 gms. 90 gms. 216 gms. 375 gms. 460 gms. 715 gms. 1 Kg. 1.3 Kg. 2.2 Kg. 3 Kg. 4.5 Kg. 6.6 Kg. 8.8 Kg. 11.3 Kg. 14.8 Kg. 22.5 Kg. 32 Kg. 44.5 Kg. 53 Kg.

RECOMMANDED GREASE – RATHI SPECIAL GREASE (RSG)

(δg = 910 Kg/m3)

27

JAN-02

GEAR FLEX COUPLING COMPETITORS FOR GEAR-FLEX COUPLING

SR

1

COMPETITOR

David Brown Link Master

MAX. kW @ 1500 RPM

MAX. BORE (mm.)

46050

300

190500

600

32451

340

232892

710

232892

710

Gear Coupling (AUSTRALIA) 2

Fenner Power Tran (INDIA)

3

Lovejoy Flanged Sleeve Series Type - F (USA)

4

Hi-Cliff Trueline Series 100 (INDIA)

5

ALLIANCE All Flex Type AFG

28

JAN-02

GEAR FLEX COUPLING

EQUIVALENT LOVEJOY GEAR-FLEX COUPLING FOR DAVID BROWN LINK MASTER GEAR COUPLING LINK MASTER GEAR COUPLING

kW AT

SIZE

02

O.D.

LOVEJOY GEAR-FLEX LFG

1500 RPM

MAX. BORE (MM.)

TOT. LGTH COUPLING

(MM.)

(MM.)

SIZE

315

50

152

101

102

03

559.5

65

178

127

04

984

80

213

05

1680

95

06

2235

07

kW AT 1500 RPM

MAX. BORE (MM.)

O.D. (MM.)

TOT. LGTH (MM.)

392

60

185

145

103

705

75

220

175

158

104

1332

90

250

215

240

187

105

2037

110

290

230

110

279

218

106

3133

125

320

260

3360

130

318

247

107

5483

140

350

260

08

4470

140

346

278

107

5483

140

350

290

09

6150

155

389

314

108

7050

160

380

320

10

8400

175

421

344

109

8773

180

430

340

11

12750

200

475

408

110

12846

220

490

370

12

16200

220

505

450

111

17188

260

545

410

13

19800

240

560

490

112

22973

300

590

490

14

30750

260

605

530

113

31254

330

680

535

15

35100

280

630

562

114

44693

370

730

575

16

46050

300

690

602

115

54294

410

780

655

17

79200

320

116

93750

455

900

720

18

94050

340

116

93750

455

900

720

19

107400

360

116

93750

455

900

720

20

120750

380

117

133351

520

1000

820

21

190500

400

119

232808

710

1250

1000

22

219000

420

119

232808

710

1250

1000

23

250500

440

NOT AVAILABLE

NOTE : Above comparison is done on the basis of both, kW rating & maximum bore sizes.

29

JAN-02

GEAR FLEX COUPLING

EQUIVALENT LOVEJOY GEAR-FLEX COUPLING (Type LFG) FOR FENNER POWER TRAN FENNER POWER TRANS. - NGC

LOVEJOY GEAR FLEX COUPLING - LFG

COUPLING

kW AT

MAX. BORE

O.D.

COUPLING

kW AT

MAX. BORE

O.D.

SIZE

1500 RPM

(MM.)

(MM.)

SIZE

1500 RPM

(MM.)

(MM.)

NGC 1

172.5

50

170

LFG-101

157

50

170

NGC 2

427.5

60

190

LFG-102

392

60

185

NGC 3

772.5

75

220

LFG-103

705

75

220

NGC 4

1447.5

90

250

LFG-104

1332

90

250

NGC 5

2250

110

290

LFG-105

2037

110

290

NGC 6

3450

125

330

LFG-106

3133

125

320

NGC 7

5850

140

350

LFG-107

5483

140

350

NGC 8

7725

160

380

LFG-108

7050

160

380

NGC 9

9660

200

430

LFG-109

8773

180

430

NGC 10

13950

220

490

LFG-110

12846

220

490

NGC 11

18975

260

545

LFG-111

17188

260

545

NGC 12

24000

300

590

LFG-112

22973

300

590

NGC 13

43200

320

680

LFG-113

31257

330

680

NGC 14

59700

340

730

LFG-114

44693

370

730

NGC 15

71475

360

760

LFG-115

54294

410

780

NGC 16

102000

450

900

LFG-116

93750

455

900

NGC 17

125625

490

1000

LFG-117

133351

520

1000

NGC 18

160950

540

1100

LFG-118

176556

610

1100

NGC 19

190500

600

1250

LFG-119

232808

710

1250


30

JAN-02

GEAR FLEX COUPLING

EQUIVALENT LOVEJOY FULL GEAR COUPLING (LFG Type) FOR LOVEJOY FLANGED SLEEVE SERIES (Type - F) COUPLINGS LOVEJOY FLANGED SLEEVE COUPLING (TYPE - F)

LOVEJOY FULLGEAR (LFG)

SIZE

kW @

MAX. BORE

SIZE

kW @

MAX. BORE

TYPE - F

1500 RPM

(MM.)

TYPE - LFG

1500 RPM

(MM.)

7/8

134.3

42

101

157

50

1½

335.7

56

102

392

60

2

559.5

73

103

705

75

2½

1007

88

104

1332

90

3

1678.5

107

105

2037

110

3½

2685.6

124

106

3133

125

4

3916.5

143

107

5483

140

4½

5371.2

162

108

7050

160

5

7721

176

109

8773

180

5½

10183

201

110

12846

220

6

13316

225

111

17188

260

7

17904

254

112

22973

300

8

23499

312

113

31257

330

9

32451

340

114

44693

370

115

54294

410

116

93750

455

117

133351

520

118

176556

610

119

232808

710

NOT AVAILABLE


31

JAN-02

GEAR FLEX COUPLING

EQUIVALENT LOVEJOY GEAR-FLEX COUPLING (Type LFG) FOR HI-CLIFF TRUELINE SERIES 100 HI-CLIFF TRUELINE SERIES 100


COUPLING

kW AT

MAX. BORE

O.D.

COUPLING

kW AT

MAX. BORE

O.D.

SIZE

1500 RPM

(MM.)

(MM.)

SIZE

1500 RPM

(MM.)

(MM.)

101

157

50

170

LFG-101

157

50

170

102

392

60

185

LFG-102

392

60

185

103

688

75

220

LFG-103

705

75

220

104

1310

90

250

LFG-104

1332

90

250

105

2048

110

290

LFG-105

2037

110

290

106

3134

125

320

LFG-106

3133

125

320

107

5396

140

350

LFG-107

5483

140

350

108

7052

160

380

LFG-108

7050

160

380

109

8776

180

430

LFG-109

8773

180

430

110

12850

220

490

LFG-110

12846

220

490

111

17194

260

545

LFG-111

17188

260

545

112

22981

300

590

LFG-112

22973

300

590

113

31265

330

680

LFG-113

31257

330

680

114

44709

370

730

LFG-114

44693

370

730

115

54314

410

780

LFG-115

54294

410

780

116

93784

455

900

LFG-116

93750

455

900

117

133400

520

1000

LFG-117

133351

520

1000

118

176619

610

1100

LFG-118

176556

610

1100

119

232892

710

1250

LFG-119

232808

710

1250


32

JAN-02

GEAR FLEX COUPLING

EQUIVALENT LOVEJOY GEAR-FLEX COUPLING (Type LFG) FOR ALLFLEX TYPE AFG ALLFLEX TYPE AFG


COUPLING

kW AT

MAX. BORE

O.D.

COUPLING

kW AT

MAX. BORE

O.D.

SIZE

1500 RPM

(MM.)

(MM.)

SIZE

1500 RPM

(MM.)

(MM.)

101

157

50

170

LFG-101

157

50

170

102

392

60

185

LFG-102

392

60

185

103

705

75

220

LFG-103

705

75

220

104

1332

90

250

LFG-104

1332

90

250

105

2037

110

290

LFG-105

2037

110

290

106

3134

125

320

LFG-106

3133

125

320

107

5485

140

350

LFG-107

5483

140

350

108

7052

160

380

LFG-108

7050

160

380

109

8776

180

430

LFG-109

8773

180

430

110

12850

220

490

LFG-110

12846

220

490

111

17194

260

545

LFG-111

17188

260

545

112

22981

300

590

LFG-112

22973

300

590

113

31265

330

680

LFG-113

31257

330

680

114

44709

370

730

LFG-114

44693

370

730

115

54313

410

780

LFG-115

54294

410

780

116

93783

455

900

LFG-116

93750

455

900

117

133400

520

1000

LFG-117

133351

520

1000

118

176619

610

1100

LFG-118

176556

610

1100

119

232892

710

1250

LFG-119

232808

710

1250


33

JAN-02

TDM

Einbau-,Wartungs- und Montagevorschrift für das Freilaufrückschlagventil Baureihe TDM Deutsch: Seite 1-10

Installation and Maintenance Instructions for TDM English: Page 11-20

Spezial-Armaturen

TDM CONTENTS

1.

Dangers and safety precautions

Page 12

2.

Valve description

Page 13

3.

Packing and marking

Page 14

4.

Assembly and disassembly

Page 15

5.

Commissioning

Page 17

6.

Maintenance instructions

Page 17

7.

Warranty Conditions

Page 17

8.

Instruction in case of damages

Page 18

9.

Customer services

Page 18

10.

Attachments 10.1 Sectional drawing

Page 19

10.2 Parts list

Page 20

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TDM 1.0 Dangers and safety precautions Minimum flow valves have the same potential danger as pressure vessels. Therefore planning, installation, operation and maintenace shall be done according the necessary safety precautions.

1.1. Danger to persons and materials The minimum flow valves should only be operated within their limits of design and layout. No changes are to be made without our approval. Only use original spare parts. Safety regulations, site regulations and installation safety precautions are to be followed. Please follow the instructions as given in this “Installation-, Maintenance and Assembly instructions”.

1.2 Avoid dangers Maintenance of the Automatic Recirculation Valve shall only be done by trained personnel. Before disassembly, the installation has to be shut off and the valve pressureless and cooled down. Please make sure that these safety precautions can only be cancelled after ending the assembly of the valve. Please be aware that also in a pressureless valve there might still be medium. Wear protective clothing.

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TDM 2.

Description The Schroedahl automatic-recirculation-valve model TDM is applied in centrifugal pump systems in order to provide an automatic leak-off flow in case of low load conditions. The application range of the series TDM with a multistage pressure let-down section is, independent of the temperature, for the operating pressures from 64 bar (a) to 250 bar (a) (900 psig to 3600 psig). The valve consists of an upper and a lower housing, each provided with a flange. The by housing, and as an option also the start-up housing, are located horizontally at the side of the valve. The valve trim comprises a check valve as also a control- and throttle section. The valve protects centrifugal pumps, especially boiler feed pumps, against overheating, by maintaining, automatically, a minimum flow. At flows, lower than the required minimum flow the check valve activates, by means of a lever, a vortex plug. When lifted of its seat, the vortex plug allows a flow through the pressure reduction section to the suction tank (or condensate tank). The opening characteristic is linear; the by flow increases when the check valve moves from its switch point further into the closes position. Because of the modulation by control, the total of process flow and minimum flow remains approximately constant. The check valve, shaped like a differential control piston and spring loaded, has such a high own frequency, that waterhammer is avoided. The check valve dampens pulsations because of its throttling effect on the mainflow and stabilises unstable pump characteristics in the partial load range. The housing is made from forged steel and is provided with a chromium steel liner in the check valve area. All moving parts and guides consist of alloy steel which are compatible. Alternative materials are available as options (see drawing and parts lists).

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TDM 3.

Packing and marking The automatic recirculation valve is shipped, depending on size, in an aluminium box (reusable), skid-carton or in a wooden crate. The standard factory conservation is sufficient to protect the valve for a period of approx. 6 month (the stocking area should be dry and ventilated). If special packing or conservation is required, this should be stated with the order. Specific valve data are indicated on the valve nameplate as per sample below. The valve nameplate is attached to every valve housing.

If spare parts are required, the following valve date should be provided with the inquiry (order): production number K ........ (stamped in valve body), valve model number and part number (check parts list).

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TDM 4.

Assembly and disassembly The automatic recirculation valve type TDM is usually installed vertically, with the mainflow upward, and directly on the pump discharge flange. The by housing is connected to the by piping (and the piping consequently to the feedwater tank or other tank), so that a recirculation flow will be possible. Other installation positions of the valve (horizontal, upside-down) are possible, if so ordered only! No special tools are required for the installation, assembly or disassembly of the valve.

4.1 Installation at the jobsite In order to prevent damage to the flange finish and/or the bolts the complete valve should be installed in the piping free of tension/ stress. Before tightening the bolts with a torque wrench (torques as recommended by the factory!), please ensure that the machined flange surfaces and packing rings are clean.

4.2 Disassembly of the TDM Remove the TDM from the piping system. Disassemble by housing Pos. 09. Pull the by trim „M“ out of the assembly (careful!). Apply a screwdriver between the collar of the control head (pos. 11) and the valvebody (pos. 01). Remove the upper body (pos. 02) from the lower body (pos. 01) by loosening the hexagon nuts (pos. 28). The check valve (pos. 07) and spring (pos. 06) can now be removed from the lower body (pos. 01). Clean all parts and check for any damages. In case of damaged seats (check valve seat or by seat), this should be repaired by lapping the respective parts on the seats. Replace ring (pos. 30) if required.

- 15 -

TDM 4.3 Assembly of the TDM Replace the check valve (pos. 07) with the spring (pos. 06) in the lower body (pos. 01). Now the upper body (pos. 02) is placed on the lower body (pos. 01) and the hexagon nuts (pos. 28) are tightened (check cross sectional drawing!). Carefully insert the by section „M“ in the valve body and as certain, that lever (pos. 13) fits (slides) in the slot in the check valve (pos. 07). The by housing (pos. 09) with the by orifice (pos. 23) is now carefully replaced and tightened to the housing (pos. 01) with the hexagon nuts (pos. 29).

4.4 Disassembly of the by section Occasionally, and because of contamination of the fluid, a complete disassembly of the by trim may be required. At each inspection the by should be checked for proper operation. In case of damages, the by section should be removed, disassembled and the damaged parts replaced. Inspection - Check the seating of the vortex plug (pos. 12) and the vortex bushing (pos.10) for any damages. - When damaged the vortex plug and vortex bushing should be replaced as an unit. - Check glyd-rings pos. 33.1, 34.1 and 35.1 for any damages. Note In case of doubt the complete by assembly pos. 10-16, 21, 23, 31-36 may be replaced and the dissassemdled by may be send to the factory for repair. Check the drill plate pos. 23 for any damages. Replace the complete seal set.

4.5 Assembly of the by sections Proceed in the reverse order as per disassembly instruction above.

- 16 -

TDM 5.

Commissioning of the TDM The valve is commissioned together with the pump. When the main shut-off valve in the pump discharge piping (to the boiler or process) the specified by flow is maintained through the by section (and to the piping of the by system). By closing or opening the main shut-off valve, the opening and closing of the by can be checked. The switch point of the valve can be established acoustically (use a technical stethoscope or even a screwdriver to the ear will do). In case a manual start-up connection is provided on the valve, the minimum flow is achieved through this section. The automatic by is closed during commissioning and the manual start-up is opened. The automatic by section is spared (protected) during commissioning in this way, as the fluid might still be contaminated and/or carry solids!

6.

Maintenance instructions The TDM has been designed so, that no special maintenance is required. Maintenance is restricted to cleaning the trim together with the pump at regular intervals. After disassembly of the valve, all seals should be replaced (by new seals) before re-assembly of the valve.

7.

Warranty conditions If no special conditions have been agreed upon the order, the warranty is limited to 24 month after shipment or 8000 hours of operation. The warranty does not include damage caused by improper handling, dirt in the system or normal wear.

- 17 -

TDM 8.

Instructions in case of damages In order to judge the damages (and the cause), the following information is required: a) The production number of the valve (K .....). This number is stamped on each valve body. b) Valve model number and size e.g. TDM ... c) A description of the system in which the valve is installed.

9.

Customer services In case information is required, or in case of breakdown, the following persons can be addressed during office hours: International sales organisation: Schroedahl International B.V. St. Josephstr. 65 Lucernaflat 9th floor NL - 4611 MK Bergen op Zoom Phone number + 31 / 1 64 25 50 40 Fax number + 31 / 1 64 25 98 85 Schroedahl International Corp. 2400 Augusta Dr., Suite 280 Houston, Texas 77057 Phone number + 001 / 713-975-8351 Fax number + 001 / 713-780-0421

- 18 -

TDM 10.1 Sectional drawing P = pump end R = pipeline end B = by- end Installation P_R vertical

- 19 -

TDM 10.2 Parts list Housing Material Pos.

Description

CS

SS

01 02 03 04 06 07 07.1 07.2 08 09 25 26 27 28 29 30

Lower body Upper body Valve stemguide Guide bolt Spring Check valve (assy.) Check valve Stem Liner By branch Guide pin Bolt Bolt Hexagon nut Hexagon nut O-Ring

1.0460 1.0460 1.4552 1.4021 4) 1.4310 1.4550 1.4550 1.4550 5) 1.4301 1.0460 1.4305 1) 1) 2) 2) 3)

1.4550 1.4550 1.4552 1.4021 4) 1.4310 1.4550 1.4550 1.4550 5) 1.4301 1.4550 1.4305 1) 1) 2) 2) 3)

Recommended Spare parts

x x

x

By

1) 2) 3) 4) 5)

Pos.

Description

10 11 12 13 14 15 16 21 23 31 32 33 33.1 34 34.1 35 35.1 36

Vortex bushing Control head Vortex plug Lever Pivot pin Bushing Piston Disc By orifice O-Ring O-Ring O-Ring Glyd-Ring O-Ring Glyd-Ring O-Ring Glyd-Ring O-Ring

Material 1.4122 1.4122 1.4122 1.4313 1.4021 1.4122 1.4122 1.4122 1.4122 3) 3) 3) PTFE/Carbon 3) PTFE/Carbon 3) PTFE/Carbon 3)

1.4122 1.4122 1.4122 1.4313 1.4021 1.4122 1.4122 1.4122 1.4122 3) 3) 3) PTFE/Carbon 3) PTFE/Carbon 3) PTFE/Carbon 3)

8.8 to DN 150 PN 40, DIN 1.7709 from PN 63 and from DN 200 PN 10 8 to DN 150 PN 40, W-Nr. 1.7258 from PN 63 and from DN 200 PN 10 EPDM, BUNA, VITON, ZALAK, KALREZ made from SS acc. DIN 1.4550 with ceramic coating in case of horizontal installation With ceramic coating in case of horizontal installation

- 20 -

Recommended Spare parts

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