Contents OIM Pages 3 1 / 7
CONTENTS
DESCRIPTION
PAGE REFERENCE
Chapter : General
OIMPG General 11. General Information OIMPG General 2
2. Disposal OIMPG General 3
3. Conformity with EU Regulations (if applicable) OIMPG General 3
Chapter : Safety
Marking of Instructions in the Instruction Manual OIMPG Safety 1
Personnel Qualification and Training OIMPG Safety 1
Non-compliance with Safety Instructions OIMPG Safety 1
Safety Awareness OIMPG Safety 1
Safety Instructions for the Operator/User OIMPG Safety 1
Safety Instructions for Work on the Pump Set OIMPG Safety 2
Unauthorized Modification and Manufacture of Spare Parts OIMPG Safety 2
Unauthorized Modes of Operation OIMPG Safety 2
Chapter : Transport / Interim Storage
1. General Information OIMPG TRANSPORT 1
1.1 Hoisting Tackle (e.g. ropes, gear) OIMPG TRANSPORT 1
1.2 Signals during Transport OIMPG TRANSPORT 1
1.3 Transport Symbols OIMPG TRANSPORT 2
2. Transport of the Packaged Components of the Pump Set OIMPG TRANSPORT 2
3. Transport of the Partly-packaged or Unpackaged Components OIMPG TRANSPORT 2
of the Pump Set
3.1 Transport of Pump Set OIMPG TRANSPORT 3
3.2 Transport of the Pump OIMPG TRANSPORT 4
3.3 Transport of the Other Pump Set Components OIMPG TRANSPORT 5
3.4 Transport of Pump Rotor OIMPG TRANSPORT 5
3.5 Transport of Pump Set Accessories OIMPG TRANSPORT 6
4 Interim Storage OIMPG TRANSPORT 7
4.1 Prerequisites OIMPG TRANSPORT 7
4.2 Place of Storage OIMPG TRANSPORT 7
4.3 Period of Storage up to 12 Months OIMPG TRANSPORT 7
Contents OIM Pages 3 2 / 7 Rev. 17.07.2007
DESCRIPTION
PAGE REFERENCE
Chapter : Installation on Site
Conditions Installation 1
Foundation Installation 1
Site management Installation 1
Place of Installation Installation 1
Drive way to the Place of Installation Installation 1
Adequate means of Transport Installation 1
Preparations Installation 1
Checking the Foundation Installation 1
Correct deviating foundation dimensions Installation 1
Transporting the Pump set Components to the Place of Installation Installation 1
Removal of Packaging Installation 2
Protecting the Pump Set Components Installation 2
Procedure for levelling and grouting of Base Frame at Site GEN 02.01 I
Making the Piping Installation 3
Cleaning the Piping Installation 3
Connecting the Coupling Installation 4
Information about Readiness for connecting of the Piping Installation 4
Checking the Alignment Installation 4
Mounting the Instruments Installation 4
Detailed description of Mounting/dismounting the connecting Coupling Installation 4
General Information Installation 5
Mounting Installation 5
Dismantling Installation 6
Installation 7 Detailed description of Connecting Coupling Alignment Installation 8
1. Conditions Installation 8
2. Preparations Installation 8
3. Runout Check of the Coupling Hubs Installation 8
4. Alignment of Coupling Installation 9
5. Alignment Corrections Installation 10
Installation 11
6. Pinning the Feet Installation 12
Contents OIM Pages 3 3 / 7
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 IndicatorOIMPG 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 Contact 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
OIMPG SUPERVISION 06Supervision of Rotor Position (only for the pumps with Balancing Disc) OIMPG SUPERVISION 02
Supervision of Rotor Position (only for the pumps with Balancing Disc) OIMPG SUPERVISION 03
Contents OIM Pages 3 4 / 7
DESCRIPTION
PAGE REFERENCE
Chapter : Servicing
OIMPG SERVICING 011. General Information OIMPG SERVICING 01
1.2 Requirement of Documentation OIMPG SERVICING 01
1.3 Prerequisites OIMPG SERVICING 01
1.4 Service Intervals OIMPG SERVICING 01
2. Dismantling the Guards Preventing Accidental Contact OIMPG SERVICING 01
3. Pump Servicing Plan OIMPG SERVICING 02
4. Servicing Work OIMPG SERVICING 03
4.1 Oil Changes OIMPG SERVICING 03
4.2 Re-lubrication OIMPG SERVICING 04
Chapter : Maintenance
OIMPG MAINTENANCE 011. General Information OIMPG MAINTENANCE 01
1.2 Required Documentation OIMPG MAINTENANCE 01
1.3 Prerequisites OIMPG MAINTENANCE 01
2. Dismantling the Guards Preventing Accidental Contact OIMPG MAINTENANCE 01
2.1 Sound Insulation Hood OIMPG MAINTENANCE 01
2.2 Coupling Guard/Cover OIMPG MAINTENANCE 01
2.3 Guard Preventing Accidental Contact for Shaft Seal OIMPG MAINTENANCE 02
3. Dismantling the Connecting Coupling OIMPG MAINTENANCE 02
3.2 Removing the Coupling Hubs OIMPG MAINTENANCE 02
3.3 Run-out Check of the Shaft Ends OIMPG MAINTENANCE 03
4. Removing the Pump from the Installation OIMPG MAINTENANCE 03
4.1 Dismantling the Piping and Instruments OIMPG MAINTENANCE 03
4.2 Removing the Pump from Baseframe OIMPG MAINTENANCE 04
4.3 Transporting the Pump to the Place of Dismantling OIMPG MAINTENANCE 05
5. Dismantling the Bearings OIMPG MAINTENANCE 06
5.1 Preparations OIMPG MAINTENANCE 06
5.2 Dismantling the Add-on Parts OIMPG MAINTENANCE 06
5.3 Dismantling the Lift-off Device, with Antifriction Bearings OIMPG MAINTENANCE 06
5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing OIMPG MAINTENANCE 06
5.5 Dismantling the Thrust Bearing OIMPG MAINTENANCE 06
5.6 Dismantling the Radial Bearings OIMPG MAINTENANCE 07
5.6.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 07
5.6.2 HG Pump Sizes 3 to 6 OIMPG MAINTENANCE 07
5.7 Dismantling the Bearing Housings OIMPG MAINTENANCE 08
5.7.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 08
5.7.2 HG Pump size 3 OIMPG MAINTENANCE 08
5.7.3 HG Pump Sizes 4 to 6 OIMPG MAINTENANCE 08
6. Dismantling the Shaft Seal OIMPG MAINTENANCE 13
6.1 Preparations OIMPG MAINTENANCE 13
6.2 Dismantling the Mechanical Seal OIMPG MAINTENANCE 13
6.2.1 Make : Eagle Poonawalla OIMPG MAINTENANCE 13
6.2.2 Make : Flowserve Sanmar OIMPG MAINTENANCE 13
6.2.3 Make : Burgmann OIMPG MAINTENANCE 14
Contents OIM Pages 3 5 / 7
DESCRIPTION
PAGE REFERENCE
7. Dismantling the Balancing Device OIMPG MAINTENANCE 26
7.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 26
7.2 HG Pump Size 3 OIMPG MAINTENANCE 26
7.3 HG Pump Size 4 OIMPG MAINTENANCE 26
7.3 HG Pump Sizes 5 and 6 OIMPG MAINTENANCE 26
7.4 Measuring the Approximate Radial Clearance OIMPG MAINTENANCE 26
8. General Information on Reassembly OIMPG MAINTENANCE 27
9. Checking the Balancing Device with Contact Fluid OIMPG MAINTENANCE 27
9.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 27
OIMPG MAINTENANCE 28
9.2 HG Pump Size 3 OIMPG MAINTENANCE 29
OIMPG MAINTENANCE 30
9.3 HG Pump Sizes 4 OIMPG MAINTENANCE 31
OIMPG MAINTENANCE 30
9.4 HG Pump Sizes 5 and 6 OIMPG MAINTENANCE 33
OIMPG MAINTENANCE 34 OIMPG MAINTENANCE 35
10. Mounting the Balancing Device OIMPG MAINTENANCE 36
10.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 36
10.2 HG Pump Size 3 OIMPG MAINTENANCE 36
10.3 HG Pump Size 4 OIMPG MAINTENANCE 37
10.4 HG Pump Sizes 5 and 6 OIMPG MAINTENANCE 38
OIMPG MAINTENANCE 39
11. Mounting the Shaft Seal OIMPG MAINTENANCE 40
11.1 Mounting the Housing Components OIMPG MAINTENANCE 40
11.1.1 HG Pump Sizes 1 to 3 OIMPG MAINTENANCE 40
11.1.2 HG Pump Sizes 4 to 6 OIMPG MAINTENANCE 40
11.2 Assembling the Shaft Seal OIMPG MAINTENANCE 40
11.2.1 Make Eagle Poonawalla OIMPG MAINTENANCE 40
11.2.2 Make : Flowserve Sanmar OIMPG MAINTENANCE 40
11.2.3 Make : Burgmann OIMPG MAINTENANCE 40
12. Mounting the Bearings OIMPG MAINTENANCE 43
12.1 Mounting the Bearing Housings and Lifting the Pump Rotor OIMPG MAINTENANCE 43
12.1.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 43
12.1.2 HG Pump Sizes 3 to 6 OIMPG MAINTENANCE 43
12.2 Mounting the Radial Bearings OIMPG MAINTENANCE 44
12.2.1 HG Pump Sizes 1 and 2 OIMPG MAINTENANCE 44
12.2.2 HG Pump Sizes 3 to 6 OIMPG MAINTENANCE 45
12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings OIMPG MAINTENANCE 45
12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Bearing OIMPG MAINTENANCE 46
12.5 Mounting the Thrust Bearing (if applicable) OIMPG MAINTENANCE 47 OIMPG MAINTENANCE 48
13. Mounting the Piping and Instruments OIMPG MAINTENANCE 49
14. Mounting the Connecting Coupling OIMPG MAINTENANCE 49
14.1 Fitting the Coupling Hubs OIMPG MAINTENANCE 49
OIMPG MAINTENANCE 50
14.2 Aligning the Connecting Coupling OIMPG MAINTENANCE 51
Contents OIM Pages 3 6 / 7
DESCRIPTION
PAGE REFERENCE
15. Mounting the Guards Preventing Accidental Contact OIMPG MAINTENANCE 51
15.1 Coupling Guard OIMPG MAINTENANCE 51
15.2 Coupling Cover OIMPG MAINTENANCE 51
15.3 Guard Preventing Accidental Contact for Shaft seal OIMPG MAINTENANCE 52
15.4 Sound Insulating Hood OIMPG MAINTENANCE 52
16. Maintenance of the Other Pump Set Components OIMPG MAINTENANCE 52
16.1 Maintenance of Connecting coupling OIMPG MAINTENANCE 52
16.2 Maintenance of Drive OIMPG MAINTENANCE 52
16.3 Maintenance of Minimum Flow System OIMPG MAINTENANCE 53
16.4 Maintenance of Instruments and Valves OIMPG MAINTENANCE 53
16.5 Maintenance of Oil Supply Unit, etc. (if applicable) OIMPG MAINTENANCE 53
16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable) OIMPG MAINTENANCE 53
17. Spare Parts OIMPG MAINTENANCE 53
17.1 Ordering Spare Parts OIMPG MAINTENANCE 53
17.2 Spare Parts Stock OIMPG MAINTENANCE 53
17.3 Storage OIMPG MAINTENANCE 53
Chapter : Trouble Shooting
OIMPG TROUBLE-SHOOTING 11. General Information OIMPG TROUBLE-SHOOTING 1
1.2 Requisite Documentation OIMPG TROUBLE-SHOOTING 1
1.3 Prerequisites OIMPG TROUBLE-SHOOTING 1
Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 2
Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 3
Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 4
Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 5
Problem / Possible causes / Measures OIMPG TROUBLE-SHOOTING 6
Chapter : Tables of Clearances
Antifriction Bearings
Diametrical Clearance : Balancing Device OIMPG CLEAR AF 1
Theoretical Axial Clearance OIMPG CLEAR AF 2
Plane Bearings
Diametrical Clearance : Balancing Device OIMPG CLEAR AF 1
Theoretical Axial Clearance OIMPG CLEAR AF 2
Bearing Clearance OIMPG CLEAR PLANE 1
Plane Bearings, Heavy
Theoretical Axial Clearance OIMPG CLEAR AF 2
Bearing Clearance OIMPG CLEAR PLANE H1
Contents OIM Pages 3 7 / 7
DESCRIPTION
PAGE REFERENCE
Chapter : Table of Tightening Torque
1. Prerequisites OIMPG TIGHT TRQ 1
2. Pump OIMPG TIGHT TRQ 1
3. Fastening of Pump Feet OIMPG TIGHT TRQ 1
4. Flange Connections OIMPG TIGHT TRQ 1
Bolts for Flange Connection, Discharge Nozzle and Tapping OIMPG TIGHT TRQ 2
Nozzle; Flanges as per DIN
Bolts for Flange Connection, Discharge Nozzle and Tapping OIMPG TIGHT TRQ 3
Nozzle; Flanges as per ANSI
Bolts for Flange Connection, Suction Nozzle OIMPG TIGHT TRQ 4
Chapter : Table of Weights
HG Pump Size 1 OIMPG WEIGHT 1
HG Pump Size 2 OIMPG WEIGHT 2
HG Pump Size 3 OIMPG WEIGHT 3
HG Pump Size 3 OIMPG WEIGHT 4
HG Pump Size 4 OIMPG WEIGHT 5
HG Pump Size 5 OIMPG WEIGHT 6
Technical Data
OIMPG General 1
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.
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 users 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 account 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 account 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 contact KSB’s nearest customer service centre.
OIMPG General 3
__________________________________________________________________________________________
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)
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
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/User
Any hot or cold components of the pump set that could pose a hazard must be equipped with a guard preventing accidental contact by the Operator.
Guards which are fitted to prevent accidental contact 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
Caution
OIMPG Safety 2
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 contact 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 safety-relevant 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.
Temperature > 80 0C/176 0F
1.
General Information
Check the load carrying capacity of the floor (consult the building drawing) before Caution 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.
1.1.2 Do not use chains, if possible.
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
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.
__________________________________________________________________
OIMPG TRANSPORT 4
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.
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 supported so that it is not damaged and is
secured against overturning/rolling.
OIMPG TRANSPORT 6
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°
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 All openings of the mounted pump set components are closed and
must not be opened before they are needed during installation.
_______________________________________________________________________
4.2
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
contact with humidity is avoided.
______________________________________________________________________
Elastomeric parts must not be stored together with chemicals,
Caution
solvents, fuels, acids, etc. In addition, they should be kept away from
light, in particular sunlight, strong artificial light high in ultraviolet
rays.
_______________________________________________________________________
4.3
Period of Storage up to 12 Months
The pimp is supplied duly preserved for storage up to 12 months (standard preservation).
4.4
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.
_______________________________________________________________________
Installation 1
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.
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.
6 ( FOR HDA / HDB / HG / CHT PUMPS ONLY )
PURPOSE :
High speed rotory equipment needs to be installed with maximum contact 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 contact area achieved is nowhere near 100%.
Therefore, the following procedure is recommended which ensures :
1. Nearly 100% contact 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 user is requested to follow the preparation as under :
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).
l 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.
Fig. 4 : Grouting of packer plate
Note : 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
Fig. 1 : Base frame bottom pad
View from W
Fig. 2 : Packer plates in pairs, machined for Fig. 2A : Packer plates in pairs, machined for for base frame with channel base frame with double channel / I beam
➮
W
Fig. 3 : Clamping of packer plate and bottom pads with M10 bolts
Base frame Levelling bolts Non shrink cement grout
80 min. 15 1.5xd 20 30 ∅ d Found block Packer plate Found bolt View from Z
➮
Z M10 Packer plate Found bolt M10Base frame for bottom pads machined with ∅15 plain holes Weld
Base frame
∅15 M20 through
Installation 3
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 account 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.
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 5
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 90
0turn.
____________________________________________________________________________
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.
- In case of a cylindrical shaft with key, smear the shaft end and coupling hub end with an adequate antiseize agent.
- To facilitate fitting, the coupling hub may be heated evenly to a temperature of 800 C max. Elastomeric parts must be removed before heating!
___________________________________________________________________________________________
Caution Do not use elastomers which have already been heated up once. Use new parts!
______________________________________________________________________________________________________0.2-0.3mm
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. DismantlingPreparations
-
Make sure that the connecting coupling is marked or mark the connecting coupling in order to avoid subsequent confusions.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
Installation 9
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.
___________________________________________________________________________
Radial misalignment of the coupling hubs
- Permissible value : ∆kr≤ 0.04 mm, measured at 4 points at a distance of 90 0
.
___________________________________________________________________________________________
Caution
∆
k
r< 0.04 mm/0.016 inch + vertical/lateral misalignment. (For dimensions,
please refer to the section Alignment corrections)
___________________________________________________________________________________________
Angular misalignment of the coupling hubs in horizontal direction - Permissible value : ∆kh≤ 0.04 mm
Smax – Smin
∆ kh = _________________
2 Angular misalignment of the coupling hubs in vertical direction
- Permissible value : ∆kv ≤ 0.04 mm Smax – Smin ∆ kv = _________________ 2
5. Alignment corrections
Vertical correction Pump : Kr Smin. Smax.Installation 12
6. Pinning the feet
Pump
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 )
A
C D
Installation 13
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) :
OIMPG COMM 31
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 Additional Work to Be Carried out Prior to Returning to Service after Standstill
> 12 Months
1.4.1 Dismantle the pump-end coupling hub. 1.4.2 Dismantle the bearing.
1.4.3 Dismantle the mechanical seal and check it in accordance with the manufacturer’s documentation. 1.4.4 If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a new seal must be
fitted.
1.4.5 Re-mount the bearing and, in case of pump with plain bearings, lift the pump rotor. 1.4.6 Re-mount the pump-end coupling hub.
1.5 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!
_______________________________________________________________________
OIMPG COMM 32
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 Bearing with Constant Level Oiler (if applicable) 1.5.4.1 Remove the vent plug (913.01 or 672).
1.5.4.2 Hinge down the constant level oiler (638).
1.5.4.3 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.
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.
_______________________________________________________________________
Oil level Position of
reservoir for topping up oil
OIMPG COMM 33
1.6.1 Prerequisites
1.6.1.1 Check the direction of rotation prior to the final assembly of the connecting coupling. 1.6.1.2 Comply with the manufacturer’s documentation.
1.6.1.3 The electric motor is provided with a lubricant.
1.6.2 Direction of Rotation
1.6.2.1 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.
1.6.2.2 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 phase-sequence 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.
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 34
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.
1.7.2 Prior to start of the work, check the oil level in the bearing housings.
1.7.3 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.
1.7.4 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.
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 Contacts
Mount all guards preventing accidental contact.
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.
_____________________________________________________________________________________
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 engineeringspecialists.
_____________________________________________________________________________________
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 Installation and alignment have been performed in accordance with good engineering practice, recorded and accepted by the Operator.
2.1.2 The pump rotor’s rotatability by hand has been checked.
2.1.3 All pump set components have been checked in accordance with the relevant manufacturer’s documentation.
2.1.4 The direction of rotation of the drive has been checked. 2.1.5 All guards preventing accidental contact have been mounted. 2.1.6 All pipes have been cleaned and connected.
2.1.7 All instruments have been fitted and checked for correct functioning.
2.2 Priming
2.2.1 Close all drains and drain pipes.
2.2.2 Fully open the cooling water main valve and all cooling water throttle valves. 2.2.3 Vent the complete cooling water circuit.
2.2.4 Vent the complete mechanical seal cooling circuit.
2.2.5 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 If applicable, check the filter in the mechanical seal’s cooling circuit and clean, if required.2.2.7 Open the valves in the minimum flow line.
2.2.8 Check the oil levels and top up with oil, if required.
_____________________________________________________________________________________
Caution
During operation, the oil level in the bearing housing falls!
Check the oil levels only during standstill of the pump!
______________________________________________________________________
2.2.9 If there is no bypass, open the gate valve in the suction piping by 10 to 20 %.
2.2.10 Prime the suction piping, pump and discharge piping up to the closed discharge gate valve. 2.2.11 Vent all pressure gauge lines until there is no more air to escape.
2.2.12 Fully open the valve in the suction piping. 2.2.13 Check whether suction pressure is available.
OIMPG COMM 36
2.3 Checks Prior to Starting
2.3.1 The suction tank, suction piping, pump and discharge piping have been primed and vented. 2.3.2 The valve in the suction piping is fully open.
2.3.3 The valve in the discharge piping is fully closed. 2.3.4 The connection for tapping, if applicable, is closed.
2.3.5 The shut-off valves in the stand-by heating system, if applicable, are closed. 2.3.6 The shut-off valves in the minimum flow line are open.
2.3.7 The cooling water system is in operation.
2.3.8 The cooling liquid pressure at the inlet must not exceed 6 bar. 2.3.9 The cooling liquid temperature at the outlet must not exceed 550 C. 2.3.10 All temperatures indicated are below the limit values.
2.3.11 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!
_______________________________________________________________________
_______________________________________________________________________
Caution
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.
_______________________________________________________________________
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.
