feed pump ksb

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Contents OIM Pages 3 1 / 7

CONTENTSDESCRIPTION PAGE REFERENCE

Chapter : General OIMPG General 1

1. General Information OIMPG General 2

2. Disposal OIMPG General 3

3. Conformity with EU Regulations (if applicable) OIMPG General 3

Chapter : SafetyMarking 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 Storage1. 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 Set3.1 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

4.4 Period of Storage over 12 Months OIMPG TRANSPORT 7

20101

Stamp

Contents OIM Pages 3 2 / 7Rev. 17.07.2007

DESCRIPTION PAGE REFERENCE

Chapter : Installation on SiteConditions Installation 1Foundation Installation 1Site management Installation 1Place of Installation Installation 1Drive way to the Place of Installation Installation 1Adequate means of Transport Installation 1Preparations Installation 1Checking the Foundation Installation 1Correct deviating foundation dimensions Installation 1Transporting the Pump set Components to the Place of Installation Installation 1Removal of Packaging Installation 2Protecting the Pump Set Components Installation 2Procedure for levelling and grouting of Base Frame at Site GEN 02.01 IMaking the Piping Installation 3Cleaning the Piping Installation 3Connecting the Coupling Installation 4Information about Readiness for connecting of the Piping Installation 4Checking the Alignment Installation 4Mounting the Instruments Installation 4Detailed description of Mounting/dismounting the connecting Coupling Installation 4General Information Installation 5Mounting Installation 5Dismantling Installation 6

Installation 7Detailed 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 12Cladding (touch guard) for the Shaft Seal Installation 13

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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 Months1.5 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 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 06

Supervision 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

Log Sheet

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Chapter : Servicing OIMPG SERVICING 01

1. 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 01

1. 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


5.7.2 HG Pump size 3 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

6.3 Dismantling the Casing Parts OIMPG MAINTENANCE 14

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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



7.4 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 27OIMPG MAINTENANCE 28

9.2 HG Pump Size 3 OIMPG MAINTENANCE 29OIMPG MAINTENANCE 30

9.3 HG Pump Sizes 4 OIMPG MAINTENANCE 31OIMPG MAINTENANCE 30

9.4 HG Pump Sizes 5 and 6 OIMPG MAINTENANCE 33OIMPG MAINTENANCE 34OIMPG MAINTENANCE 35

10. Mounting the Balancing Device OIMPG MAINTENANCE 36




10.4 HG Pump Sizes 5 and 6 OIMPG MAINTENANCE 38OIMPG MAINTENANCE 39

11. Mounting the Shaft Seal OIMPG MAINTENANCE 40

11.1 Mounting the Housing Components 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



12.2 Mounting the Radial Bearings OIMPG MAINTENANCE 44



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 47OIMPG 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 49OIMPG MAINTENANCE 50

14.2 Aligning the Connecting Coupling OIMPG MAINTENANCE 51

14.3 Mounting the Coupling Connections OIMPG MAINTENANCE 51

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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 1

1. 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





Chapter : Tables of ClearancesAntifriction BearingsDiametrical Clearance : Balancing Device OIMPG CLEAR AF 1

Theoretical Axial Clearance OIMPG CLEAR AF 2

Plane BearingsDiametrical Clearance : Balancing Device OIMPG CLEAR AF 1

Theoretical Axial Clearance OIMPG CLEAR AF 2

Bearing Clearance OIMPG CLEAR PLANE 1

Plane Bearings, HeavyTheoretical Axial Clearance OIMPG CLEAR AF 2

Bearing Clearance OIMPG CLEAR PLANE H1

Diametrical Clearance : Balancing Device OIMPG CLEAR PLANE H1

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Chapter : Table of Tightening Torque1. 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 WeightsHG Pump Size 1 OIMPG WEIGHT 1

HG Pump Size 2 OIMPG WEIGHT 2





Technical Data

Technical Appendix

OIMPG General 1

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General

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

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

This instruction manual must always be kept close to the location ofoperation 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 2

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1. General InformationThis instruction manual contains fundamental information which must be complied with during work on thepump set.Therefore this instruction manual must be read both by the service engineers and responsible trainedpersonnel, prior to commencement of work.All users must not only comply with the general safety instructions laid down in the chapter on “Safety”, but alsothe 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 careand are subjected to continuous quality control. If they are properly installed, serviced and maintained, thepumps will give reliable and trouble-free operation.

We recommend to call our specialist personnel for installation and commissioning/start-up. KSB will onlyassume responsibility for faultless execution of the work and for the safety of the personnel involved ifdismantling/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 theoperation in accordance with the instructions laid down in this manual. The operator must take into account theinformation given in Technical Appendix, or in other parts of the instruction manual or in the contractdocumentation.

It is of vital importance to observe the specified electrical connection values as well as thedismantling/reassembly and servicing instructions. In particular, it must be ensured that all necessary measuresare 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. pumpor pump set). This instruction manual does not cover all possible eventualities or events which might occurduring installation, maintenance, servicing and operation of the machine.

Neither does the instruction manual take into account any safety regulations applicable at the place ofinstallation; the Operator must ensure that such regulations are strictly observed by all, including the personnelcalled 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 allqueries, repeat orders and particularly when ordering spare parts.

If you need any additional information or instructions exceeding the scope of this instruction manual, pleasecontact KSB’s nearest customer service centre.

In case of problems please contact your nearest customer service centre or the manufacturing works.

OIMPG General 3

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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. thoseposed by residues of the medium handled in the pump).

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Caution All measuring instruments supplied with the pump should be calibrated before commissioning of the pump set.

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Set points of the instruments, wherever conveyed through operating instruction manual, are only as guideline, andfinal values are to be set on the site as per observations and requirements.

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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.

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2. DisposalAccording 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 Safety 1

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Safety

Marking of Instructions in the Instruction ManualThe 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 instructionsmust always be complied with and be kept in perfectly legible condition at all times.

Personnel Qualification and TrainingAll 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 InstructionsNon-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 AwarenessIt 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/UserAny 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 personsand the environment caused by hot, toxic or explosive media. Pertinent legal provisions must be

Caution

OIMPG Safety 2

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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 SetThe 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 cooleddown 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 PartsAny 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 OperationThe warranty relating to the operating reliability and safety of the supplied pump set is only valid if it is usedin 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 0FIt is imperative to observe the information plate on the pump.

Transport / Interim Storage

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 brakingunder load.

After fastening the ropes, align the crane hook in such a manner thatthe crane hoisting ropes are suspended vertically.

Loads must be lifted at a right angle to the drum axis of the ropewinch. Loads must not be lifted at an angle.

Keep the period of tome for which the load is in free suspension to aminimum.

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 notpermitted.

The permissible lifting capacity of the lifting equipment must not beexceeded.

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 belifted.

1.1.2 Do not use chains, if possible.

Hoisting tackle, and any transport device that might be required, mustonly 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 responsiblefor this.

1.2 Signals during TransportOnly follow the instructions given by responsible for giving signals during transporting.

OIMPG TRANSPORT 3

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3.1 Transport of the Pump Set

For transporting the pump set components mounted on the base plate, shacklesmust 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 4

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3.2 Transport of the PumpAttach 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.

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OIMPG TRANSPORT 5

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3.3 Transport of the Other Pump Set Components3.3.1 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 Rotor3.4.1 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 pumprotor.

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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

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3.5 Transport of Pump Set AccessoriesAttach 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.

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<120°

<120°<120°

OIMPG TRANSPORT 7

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4. Interim Storage4.1 Prerequisites

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Caution The load carrying capacity of the floor of the storage area must be adequately designed.

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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

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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 anycontact 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 ultravioletrays.

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4.3 Period of Storage up to 12 MonthsThe pimp is supplied duly preserved for storage up to 12 months (standard preservation).

4.4 Period of Storage over 12 MonthsIf the pump is to be stored more than 12 months, it must be preserved appropriately. If therequisite 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.

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Installation 1

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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.

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Installation 2

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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)

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

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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.

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- Completely cover the pump set components to protect them for the full duration of the installation workon site against construction site dirt, spark discharge, grinding dust and other harmful ambientinfluences.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 areprotected from dirt accumulation, humidity and damage.

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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.

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6

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 contact area between base frameand the foundation. To achieve this conventionally, blue matching procedure is adopted between packerplates 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 thenumber of foundation bolts ) are in scope of KSB. Otherwise, the user is requested to follow thepreparation as under :

l The base frame is provided with the pads, which are welded at the bottom, machined in one settingand drilled to 15 mm. Dia. ( Ref. Fig. 1).

l Machined packer plates, having 0.02 mm. face parallality, and of the dimensions equal to thewelded pads at the bottom of the base frame, are required with tapping of M 10. These packer platesare 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

GEN 02.01I 6a

Fig. 4 : Grouting of packer plate

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

Fig. 1 : Base frame bottom pad

View from W

Fig. 2 : Packer plates in pairs, machined for Fig. 2A : Packer plates in pairs, machined forfor 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

Foundbolt

View from Z

➮

Z

M10Packer plate

Foundbolt

M10

Base frame for bottom padsmachined with ∅15 plain holes

Base frame

Weld

Base frame

∅15

M20 throughfor leveling M10 bolts

Installation 3

_____________________________________________________________________

Making the pipingGeneral 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 pipingGeneral 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 pipingGeneral 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 least0.5 bar higher than the suction pressure (at the pump suction nozzle), and the permissible damping pressuremust 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 4

_____________________________________________________________________

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 instrumentsGeneral 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 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.

- In case of a cylindrical shaft with key, smear the shaft end and coupling hub end with an adequate antiseizeagent.

- 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

-0.3

mm

Clearance between groove and key

Installation 6

_____________________________________________________________________

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 facematch.

___________________________________________________________________________________________

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.

Installation 8

_____________________________________________________________________

Detailed description of connecting coupling alignment1. 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 ofmounting/dismantling the connecting coupling guards, and store them appropriately.

- Separate the couplings mounted to the pump set as described under Detailed description ofmounting/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 9

_____________________________________________________________________

4. Alignment of couplingGeneral 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 positionbetween 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 10

_____________________________________________________________________

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)

___________________________________________________________________________________________

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

Smax – Smin

∆ kh = _________________

2Angular misalignment of the coupling hubs in vertical direction- Permissible value : ∆kv ≤ 0.04 mm

Smax – Smin ∆ kv = _________________

2

5. Alignment correctionsVertical correctionPump :

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 guardsCoupling 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

CDPinning the pump feet

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) :- Remove the guard and store it appropriately.

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 Information1.2.1 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 Preservation1.3.1 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 Oil1.5.1 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 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 theminimum 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, seefigure 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 accessoriesFill 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

Constant level oiler

OIMPG COMM 33

_____________________________________________________________________

1.6.1 Prerequisites1.6.1.1 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 Rotation1.6.2.1 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 thedirection 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 Indicator1.6.4.1 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.____________________________________________________________

Arrangement of spacer plates (example)

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 asrequired by the actual magnetic center. If coupling has a spacer, it must be possible to mount and removeit.

1.7 Rotatibility of the Pump Rotor1.7.1 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 pumprotor.

1.7.4 In case the pump with balancing disc without lift off device, move the pump rotor towards the driven end byapprox. 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 CouplingMount the spacer of the connecting coupling as described in the manufacturer’s documentation.

1.9 Mounting Guards Preventing Accidental ContactsMount all guards preventing accidental contact.

1.10 Functional Test and Adjustment of The Instruments1.10.1 Check all the instruments in accordance with the individual manufacturer’s documentation for correct

measuring data and adjust the instruments, if required.

OIMPG COMM 35

_____________________________________________________________________

_____________________________________________________________________________________

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-up2.1 Prerequisites2.1.1 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 Priming2.2.1 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 Starting2.3.1 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.

OIMPG COMM 37

_____________________________________________________________________

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 thecirculation liquid remains constant.

3. Shutdown3.1 Pump set remains ready for Operation3.1.1 Close the valve in the discharge pipe.3.1.2 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 In the case of a pump set with variable speed coupling reduce the speed until the minimum head orminimum speed is reached.

3.1.4 Switch off the drive, making sure it runs smoothly down to a standstill.3.1.5 Note the run down time.3.1.6 The cooling water remains on!

3.2 For Maintenance of the Pump Set or Prolonged Standstill3.2.1 Close the valve in the discharge pipe.3.2.2 Make sure the minimum flow control valve works.

_____________________________________________________________________________________

! The minimum flow pipe gets hot.____________________________________________________________

OIMPG COMM 38

____________________________________________________________________________________________________________________________________________

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.3.2.4 Switch off the drive, making sure it runs smoothly down to a standstill.3.2.5 Note the run down time.

_____________________________________________________________________________________

! Secure the drive against unintentional starting._______________________________________________________________________

3.2.6 Close the shut-off valve in the tapping pipe, if applicable.3.2.7 Close the shut-off valves of the standby heating system, if applicable.3.2.8 Close the shut-off valves in the minimum flow line.3.2.9 Close the shut-off valves in inlet pipe.3.2.10 Turn off the cooling water when the casing temperature, measured the pump nozzles, is lower than 500 C.3.2.11 Close the other pipes.

4. Work after shutdown4.1 During Readiness for Instant Start-up4.1.1 General Information

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

4.1.2 Every 4 to 6 weeks4.1.2.1 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 themanufacturer’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 Secure all valves against opening.4.2.2 Open all drains and/or drain pipes.4.2.3 Collect the fill in an appropriate container and dispose off according to local anti-pollution regulations.

OIMPG COMM 39

__________________________________________________________________________________________________________________________________________________________

! 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 speedcoupling must be protected against water ingress and humidity as described in the manufacturer’spreservation 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 Weeks4.3.2.1 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.

Important : This mixture ensures protection against frost up to approx. – 200C. 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 SUPERVISION 02

_____________________________________________________________________

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 PositionIndicators.The first and most commonly used by KSB India, consists of the indicator bush (623) screwed on the bearingend 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

0

Rotor position indicator Rotor position indicator

Time to shut down the pump

623 624

OIMPG SUPERVISION 06

_____________________________________________________________________

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

Point to be supervised Supervisory action Value to be met

Checking the temperature once a week < 900 CChecking the oil level once a week(only for pumps with ring oil lubrication)

Middle between minimum andmaximum marks

Pump Bearings : Plain

Checking for smooth operationOnce a week

The pump set shall run smoothand free from vibrations.

Checking the temperature once a week < 900 CThrust Bearing – Tilting pads

(if applicable)

Checking for smooth operationOnce a week


Checking the temperature once a week < 900 CChecking the oil level once a week Middle of oil level sight glass

Lift-off device with antifriction bearings

(if applicable)Checking for smooth operationOnce a week


Checking the temperature once a week < 900 CLift-off device with Tilting pads bearings

(if applicable)Checking for smooth operationOnce a week


Indicator(only for pumps with balancing disc)

Checking the rotor position once a week See section Rotor Position inthis chapter

Checking the temperature once a week ≤ 800 CMechanical seal (433)Checking the leakage once a week 15 drops per minute

Differential pressure gaugeStrainer I suction pipe (if applicable)

Checking the differential pressureOnce a week

< 0.3 bar

Differential pressure gaugeDuplex filter (if applicable)

Checking the differential pressureOnce a week

Measuring instrument, suction side ps

(gauge holder ) (if applicable)Checking the pressure once a week

Measuring instrument, discharge side pd

(gauge holder ) (if applicable)Checking the pressure once a week

Measuring instrument, tapping(gauge holder ) (if applicable)

Checking the pressure once a week

Measuring instrument, balancing water pE

(gauge holder ) (if applicable)Checking the pressure once a week PE ≥ ps + 0.5 bar

Thermometer(Suction nozzle/discharge nozzle) (if applicable)

Checking the temperature once a week

Thermometer(cooling water inlet) (if applicable )

Checking the temperature once a week ≤ 450 C

Cooling water pipe(supply and return flow) (if applicable)

Checking the temperature once a week ∆t ≤ 100 C

Sight glass(cooling water inlet pipe) (if applicable)

Checking the cooling water flow once aweek

Water is flowing

Oil pressure gauge(gauge holder) (if applicable)

Checking the pressure once a week

Level indicator(Oil supply system) (if applicable)

Checking the oil level once a week - 20 mm

Connecting coupling(only for coupling with pressure oil lubr.)

Checking for leakage once a week No leakage permitted

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

We recommend recording the information tabulated above in a logbook, in the form of enclosedLOG SHEET.

LOG SHEETPUMP TYPE CUSTOMER ITEM NO.

NO. DESCRIPTION UNITPRESSURE AT

1 Suction nozzle kg/cm22 Differential across suction strainer kg/cm23 Discharge nozzle kg/cm24 Balancing line kg/cm25 Oil inlet to bearing (forced oil lubrication)

5.1 Suction side bearing kg/cm25.2 Discharge side bearing kg/cm25.3 Lift off / Thrust bearing kg/cm2

TEMPERATURE AT6 Suction nozzle Deg C7 Discharge nozzle Deg C8 Balancing line Deg C9 Bearings

9.1 Suction side Deg C9.2 Discharge side Deg C9.3 Lift off / Thrust Deg C

10 Oil inlet to bearing (forced oil lubrication)10.1 Suction side Deg C10.2 Discharge side Deg C10.3 Lift off / Thrust Deg C

11 Flushing liquid11.1 Shaft seal - Suction Deg C11.2 Shaft seal - Discharge Deg C

Cooling Water Inlet / outlet11.3 Suction Deg C11.4 Discharge Deg C11.4 Lift off / Thrust Deg C

12 ROTOR POSITION

13VIBRATIONS AT

H V A H V A13.1 Suction side bearing housing13.2 Discharge side bearing housing13.3 Lift off / Thrust bearing housing13.4 Suction flange13.5 Discharge flange13.6 Suction side support foot13.7 Discharge side support foot13.8 Base Frame

H = Horizontal ; V = Vertical ; A = Axial.

SIGNATURE OF OPERATORDATE / TIME

Amplitude

READING

RMS Velocitymicrons (peak to peak)

SERIAL NO.

mm / s

LOG SHEETB1

OIMPG SERVICING 01

_____________________________________________________________________

Servicing

1. General InformationWe recommend that KSB’s specialist personnel be present during the servicing of thepump!________________________________________________________________________________________

Caution Improper handling of preservatives, oil and grease causes hazardous environmental impact. Handling and disposal only by qualified personnel!

_________________________________________________________________________


1.2 Required documentation1.2.1 The following documents are necessary for servicing of pump set.

Sectional Drawing, PumpList of Components, PumpDocumentation of the Mechanical Seal (if applicable)

1.2.2 Documentation of Connecting Coupling1.2.3 Documentation of Drive1.2.4 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 Prerequisites1.3.1 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 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.

1.4.2 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 ContactDismantle / remove the guards preventing accidental contact mounted to the pump set as described in theDismantling the Guards Preventing Accidental Contact section in chapter “Maintenance”.

OIMPG SERVICING 02

_____________________________________________________________________

3. Pump Servicing Planafter Commissioning/Start-up and Stand-by

Location to beserviced

Checks Servicing Intervals Servicing Work

First oil change after 300operating hours

Bearing(Ring oil lubricated)

(if applicable)

Oil level, oil quality

Subsequent oil changesafter 8000 operating hours,at least after 1 year

See the Servicing Worksection in this chapter

First oil change after 300operating hours

Bearing(Forced oil lubricated)

(if applicable)

Oil level, oil quality

Subsequent oil changesafter 8000 operating hours,at least after 2 years

Grease fill(if applicable)

See manufacturer’sdocumentation


Connecting Coupling

(if applicable)Checking the axialmovability

After approx. 8000operating hours


Drive(if applicable)




Instruments

(if applicable)

Perfect condition andfunctioning


Replace defective equipment;see manufacturer’sdocumentation

Pressure gauge(if applicable)

Perfect condition andfunctioningPerfect condition andfunctioning

Differential pressuregauge

(if applicable)Opening and closingpointsPerfect condition andfunctioning

Temperature measuringinstruments

(if applicable) Switching pointsVibration measurement

(if applicable)Perfect condition andfunctioning

Shaft positioningmonitoring (if applicable)


Every 3 months;See the manufacturer’sdocumentation


Inspection(axial thrust measurement)

(if applicable)


After approx. 8000operating hours, at leastafter 2 years


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

OIMPG SERVICING 03

_____________________________________________________________________

4. Servicing Work

4.1 Oil Change4.1.1 General Information4.1.1.1 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, seefigure 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.

_______________________________________________________________________

4.1.4 Other Pump set ComponentsFill the oil in accordance with the manufacturer’s documentation.

Oil level



OIMPG SERVICING 04

_____________________________________________________________________

4.2 Re-lubrication4.2.1 General Information4.2.1.1 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 The oil level may drop during start-up of the pump. If the minimum mark is underrun, top up with oil.

_____________________________________________________________________________________4.2.1.1 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).4.2.1.2 Fit the vent plug (913.01 or 672) back again.4.2.2 Bearing with Constant Level Oiler4.2.3.1 Remove the vent plug (913.01 or 913.02 or 672).4.2.3.2 Hinge down the constant level oiler (638).4.2.3.3 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 connecting elbow of the constant level oiler, see figureConstant level oiler.

4.2.3.4 Fill the reservoir of the constant level oiler with oil and snap it back into operating position.4.2.3.5 Fit the vent plug (913.01 or 913.02 or 672) back again.4.2.3.6 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 arrangedat the top of the connection elbow. Make sure the opening is always perfectly dry._______________________________________________________________________

4.2.4 Other Pump Set ComponentsTop up with oil in accordance with the manufacturer’s documentation.

4.3 Connecting Coupling (if applicable)4.3.1 Perform all dismantling and reassembly work in accordance with the Dismantling of the Connecting

Coupling and Mounting the Connecting Coupling in chapter “Maintenance”.4.3.2 Perform all servicing work in accordance with the manufacturer’s documentation.

Oil level



OIMPG MAINTENANCE 01

_____________________________________________________________________

Maintenance

1. General Information________________________________________________________________________________________

Caution During the warranty period, pumps should be dismantled only by KSB personnel!

_________________________________________________________________________


1.2 Required documentation1.2.1 The following documents are necessary for servicing of pump set.

Sectional Drawing, PumpList of Components, PumpDocumentation of the Mechanical Seal (if applicable)

1.2.2 Documentation of Connecting Coupling1.2.3 Documentation of Drive1.2.4 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 Prerequisites1.3.1 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 Contact2.1 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 Remove all pipes on the cover.2.2.2 Remove the taper pins and screw of the cover split joint.2.2.3 Use the eye bolt as transport aid as shown in the figure Coupling cover.2.2.4 Unscrew the screws in the upper part of the flange.2.2.5 Remove the upper half of the coupling cover.2.2.6 Remove the internal injection lines.2.2.7 Disconnect the lower half of the coupling cover from the flange and store it.

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

3. Dismantling the Connecting Coupling3.1 Dismantling the Coupling Connection3.1.1 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 Hubs3.2.1 Dismantle the retaining ring, if applicable, from the coupling hub.3.2.2 Remove the grub screws (if provided).3.2.3 To facilitate removing, 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.

_______________________________________________________________________

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 Mark the keys prior to removing them.3.2.7 Store the coupling hubs and keys appropriately.

3.3 Run-out Check of the Shaft Ends3.3.1 After removing the coupling hubs check the shaft ends for run-out, see figure Run-out check of shaft ends.3.3.2 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 InstallationThe work described in sections 4.1 to 4.3 is required only if the pump is to beremoved from the installation for maintenance.

4.1 Dismantling the Piping and Instruments


_____________________________________________________________________

_____________________________________________________________________________________

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

_____________________________________________________________________________________4.1.1 Undo the connections between discharge nozzle and discharge pipe & between suction nozzle and suction

pipe.4.1.2 Fasten the suction and discharge pipes to temporary holders.4.1.3 Dismantle the minimum flow control valve, if necessary.4.1.4 Disconnect the tapping pipe, if applicable.4.1.5 Detach and dismantle any auxiliary lines such as circulation, cooling liquid and oil pipes as well as

measuring lines as far as necessary.4.1.6 Dismantle the measuring devices and instruments as far as necessary, and store them appropriately.4.1.7 If required, dismantle the cooler of the shaft seal including support.

4.2 Removing the Pump from Baseframe4.2.1 Unscrew the fastening studs at the pump feet; see the figure Fastening of the pump feet.

1 2 3

6 5 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_______________________________________________________________________________________ The pumps have to be lifted and transported in accordance with the Caution 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 assemblysupports._____________________________________________________________________________________

! Secure the pump against overturning._____________________________________________________________________________________

_____________________________________________________________________________________ Mark the matching shims between the pump feet and baseframe so that Caution they can be inserted in the same place on subsequent reassembly, and

store them appropriately._______________________________________________________________________


_____________________________________________________________________

5. Dismantling the Bearings

5.1 Preparations5.1.1 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.5.1.2 If applicable, dismantle the cooling liquid pipes and oil supply pipes as far as necessary.5.1.3 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.5.1.4 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 positionindicator, 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 Unscrew the hex nut (920.08) and remove the bearing end cover (361) including O-ring (412.11).5.3.2 Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).5.3.3 Pull the bearing cartridge (381) including the two angular contact 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 Take the springs out of the thrust bearing housing (354).5.3.5 Take away the thrust bearing housing (354) including O-ring (412.10).5.3.6 If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).5.3.7 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 Unscrew the hex nuts (920.08) and remove the bearing end cover (361) including O-ring (412.11).5.4.2 Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03).5.4.3 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 thework 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 Take the springs out of the thrust bearing housing (354).5.4.5 Take away the thrust bearing housing (354) including O-ring (412.10).5.4.6 If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08).5.4.7 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 Unscrew the hex nuts (920.11) and remove the bearing end cover (361) including thrust bearing (314), O-

ring (412.11), circlip (932.03) and shaft seal (420.01, 562.02).5.5.2 Screw nut (920.09) from the shaft (210).5.5.3 Remove the spacer sleeve (525.05) from the shaft (210).


_____________________________________________________________________

5.5.4 Remove the thrust bearing plate (384) from the shaft (210) using the appropriate device as described in thework instruction UA3 13475 01 or UA3 14758 01.

5.5.5 Take the key (940.05) out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).5.5.6 Unscrew two opposite hex socket head cap screws between the segments of the thrust bearing (314) and

remove them together with the adjoining segments.5.5.7 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 01.5.5.8 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 25.6.1.1 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 65.6.2.1 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 Housings5.7.1 HG Pump Sizes 1 and 25.7.1.1 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 35.7.2.1 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 PreparationsDismantle 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 Poonawalla6.2.1.1 Shaft Seal6.2.1.1.1 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 Sanmar6.2.2.1 Shaft Seal6.2.2.1.1 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 : Burgmann6.2.3.1 Shaft Seal6.2.3.1.1 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 Parts6.3.1 HG Pump Sizes 1 and 26.3.1.1 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 66.3.2.1 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, ifapplicable).

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 capscrews (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 27.1.1 Remove the spacer ring (504.02) and if applicable spacer sleeve (525.02) from the shaft (210).7.1.2 Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the

work instruction UA2 13474 017.1.3 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 017.1.4 Check the balancing disc (601.01) and counter balancing disc (602.01) for signs of damage.

7.2 HG Pump Size 37.2.1 Pull the retainer ring (505.01) from the shaft (210) and remove key (940.07) and split ring (501.01).7.2.2 Remove the spacer ring (504.02) or spacer sleeve (525.02) from the shaft (210).7.2.3 Remove the balancing disc (601.01) from the shaft (210) using the appropriate device as described in the

work instruction UA2 14761 01.7.2.4 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 01.7.2.5 If applicable, take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from

the shaft (210).7.2.6 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 47.3.1 Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.07) out of the shaft keyway.7.3.2 Unscrew the hex socket head cap screws (914.10) and pull off the retainer ring (505.01).7.3.3 Take the split ring (501.01) out of the shaft groove and pull the spacer ring (504.02) from the shaft (210).7.3.4 Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the

work instruction UA2 14765 01.7.3.5 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 01.7.3.6 Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft.7.3.7 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 67.4.1 Remove the spacer sleeve (525.02) from the shaft (210) and take the key (940.06) out of the shaft keyway.7.4.2 Unscrew the hex socket head cap screws (914.10) and remove the retainer ring (505.01).7.4.3 Take the split ring (501.01) out of the shaft groove and remove the spacer ring (504.02) from the shaft

(210).7.4.4 Remove the balancing disc (603101) from the shaft (210) using the appropriate device as described in the

work instruction UA2 14765 027.4.5 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 02.7.4.6 Take the key (940.04) out of the shaft keyway and remove the throttle sleeve (522.01) from the shaft (210).7.4.7 Pull the throttle bush (542.01) out of the discharge casing (107) using the appropriate device as described

in the work instruction UA2 14765 02.7.4.8 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 Place the dial gauge holder on a firm base (for example flange or discharge nozzle) and position the dialgauge on the seat of the balancing piston as shown in the figure Measuring the approximate radialclearance.

7.5.2 Carefully lift the shaft until it abuts on the top. Shaft deflection must not be increased (incorrectmeasurement).

7.5.3 The diametrical clearance determined this way must not exceed 0.8 mm; if it does, the pump must bedismantled and overhauled.

8. General Information on Reassembly8.1 Meticulously clean all dismantled components, in particular the fit and sealing surface areas.

________________________________________________________________________________________

Caution Do not damage the locating and sealing surfaces!________________________________________________________________________________________

8.2 If required, remove any lime and incrustation from the cooling chambers.8.3 Check all dismantled components for signs of damage.8.4 If required, use new parts.8.5 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!

_________________________________________________________________________ _________________________________________________________________________ Caution Do not fit the O-rings in dry condition but wet them with silicone grease! In

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 Contact Fluid “Engineers Blue”.The steps 9.1 to 9.3 are required only if balancing piston (603.02) or counterbalancing disc (602.02) were remachined or replaced.

9.1 HG Pump Sizes 1 and 29.1.1 Meticulously clean the axial running face of the counter balancing disc (602.02).9.1.2 Insert the grooved pin (561.03) in the discharge casing (107).

HG Pump Sizes 1 - 3

Measuring the approximate radial clearanceHG Pump Sizes 4 - 6


_____________________________________________________________________

9.1.3 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).

9.1.4 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

A d j u s t i n g t h e p u m p r o t o r p o s i t i o n

S a 2

S a 1

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 non-driven 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.

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 ofthe last stage.

9.1.5.2 Shorten the balancing disc (601.01) to the dimension “b1” as sown in the figure Adapting the balancingdisc: b1 = a1 – SL2 (SL2, see table of clearances).

9.1.6 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.

a1

602.01

b1 Sl2

Machine here

601.01504.02


_____________________________________________________________________

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 Insert the key (940.04).9.1.8 Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the

balancing piston (601.01) without O-ring (412.02) on the shaft (210).9.1.9 Slide the spacer sleeve (525.02, if applicable) and spacer ring (504.02) over the shaft (210)9.1.10 Mount the casing part (130, if applicable) and seal casing (441) without O-rings.9.1.11 Mount the shaft sleeve (524.01, pump with gland packings).9.1.12 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.9.1.13 For the check with the contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it

slowly.9.1.14 Move the pump rotor to the non-driven end and dismantle all pump components including the counter

balancing disc (602.01) in reverse order.9.1.15 At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the

contact fluid in the upper zone. If this is not the case, remachining the counter balancing disc (602.01) on alathe and repeat the contact fluid checks.

9.1.16 After completion of the contact fluid check, clean the axial running faces of the balancing piston (601.01)and counter balancing disc (602.01).

9.2 HG Pump Size 39.2.1 Meticulously clean the axial running face of the counter balancing disc (602.02).9.2.2 Insert the grooved pin (561.03) in the discharge casing (107).9.2.3 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).9.2.4 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).9.2.5 Adjust the pump rotor position; see figure Adjusting the pump rotor position.

b

x

a

504.02 601.01 602.01

Varient without spacer sleeve Varient with spacer sleeve (525.02)

602.01601.01525.02504.02

a

x

by


_____________________________________________________________________

5 0 2 . 0 2 2 3 0 . 0 2

1 7 1 . 0 2

A d j u s t i n g t h e p u m p r o t o r p o s i t i o n

S a 2

S a 1

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 non-driven 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 orfigure Adjusting the balancing disc.

Machine here

Machine here

522.01601.01504.02

Adapting the throttle sleeve

602.01

Adapting the balance disc

504.02 601.01602.01


_____________________________________________________________________

9.2.6.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller ofthe 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 thethrottle sleeve and/or the balancing disc (601.01) in accordance with the figure Adapting the balancing disc: b1 = a1 – c1 – Sl2 or b1 = a1 – Sl2 (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 figureAdapting 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 Insert the key (940.04).9.2.9 Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the

balancing disc (601.01) without O-ring (412.02) on the shaft (210).9.2.10 Slide the spacer ring (504.02) or spacer sleeve (525.02, if applicable) over the shaft (210).9.2.11 Insert the key (940.07) and split ring (501.01) into the shaft groove, slide the retainer ring (505.01) over

them.9.2.12 Mount the casing part (130, if applicable) and seal casing (441) without O-rings.9.2.13 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.9.2.14 For the check with contact fluid “engineer’s blue”, move the rotor towards the driven end and turn it slowly.9.2.15 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing

disc (602.01) in reverse order.9.2.16 At least ¾ of the axial running face of the counter balancing disc (602.01) must have a uniform print of the

contact fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.02) on alathe and repeat the contact fluid check.

9.2.17 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) andcounter balancing disc (602.01).

9.3 HG Pump Size 49.3.1 Meticulously clean the axial running face of counter balancing disc (602.01).

504.02 601.01 602.01 522.01

Adapting the spacer ring

525.02 601.01

Adapting the spacer sleeve

602.01 522.01


_____________________________________________________________________

9.3.6.1 Shorten the throttle sleeve (522.01) to the dimension “b1” in accordance with the figure Adapting the throttlesleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances).



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._____________________________________________________________________________________


9.3.8 Insert the key (940.04).9.3.9 Coat the axial running face of balancing disc (601.01) thinly with the contact fluid and slide the balancing

disc (601.01) without O-ring (412.02) on the shaft (210).9.3.10 Slide the spacer ring (504.02) over the shaft (210).9.3.11 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).9.3.12 Mount the casing part (130) and seal casing (441) without O-rings.9.3.13 Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so





9.4 HG Pump Sizes 5 and 69.4.1 Meticulously clean the axial running face of the counter balancing disc (602.01).9.4.2 Fit the throttle bush (542.01) without O-ring (412.05).9.4.3 Insert the parallel pin (562.03) in the discharge casing (107).9.4.4 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).

a b

x

504.02 601.01 602.01 522.01



_____________________________________________________________________

9.4.5 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).

9.4.6 Place the pump rotor in the center of the overall axial clearance ( Sa1 + Sa2); see figure Adjusting the pumprotor 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.

502.02171.02

230.02

Adjusting the pump rotor position

Sa2

Sa1

a1c1 b1 Sl2

Machine here

522.01601.01504.02542.01602.01

Adapting the throttle sleeve


_____________________________________________________________________

9.4.7.1 Measure the distance “a1” from the running face of the counter balancing disc (602.01) to the impeller oflast 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 throttlesleeve : b1 = a1 – c1 - Sl2 (Sl2 see table of clearances).



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._____________________________________________________________________________________


9.4.9 Insert the key (940.04).9.4.10 Coat the axial running face of balancing disc (601.01) thinly with the contact 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





a b

x

504.02 601.01 602.01 522.01 542.01



_____________________________________________________________________

10. Mounting the Balancing Device______________________________________________________________________________________

If the throttle sleeve (522.01), balancing disc (601.01) or counter balancing Caution disc (602.01) were remachined or replaced, the check with the contact

fluid “engineer’s blue” as outlined in sections 9.1 to 9.4 must be performed!_____________________________________________________________________________________

10.1 HG Pump Sizes 1 and 210.1.1 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.

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 thenon-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 310.2.1 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.

502.02 230.02171.02

3mm



_____________________________________________________________________

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 thenon-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 410.3.1 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 pumprotor position.

10.3.5 Insert the key (940.04).

502.02 230.02171.02

3mm



_____________________________________________________________________

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 relevantwork 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 610.4.1 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 pumprotor position.

10.4.6 Insert the key (940.04).

Sa2

Sa1

502.02

171.02

230.02



_____________________________________________________________________

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 relevantwork instruction.

10.4.10 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.

Sa2

Sa1

502.02

171.02

230.02



_____________________________________________________________________

11. Mounting the Shaft Seal11.1 Mounting the Housing Components11.1.1 HG Pump Size 1 to 311.1.1.1 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 grooveof 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 headcap screws (914.09, if applicable).

11.1.2 HG Pump Sizes 4 to 611.1.2.1 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 workinstruction.

11.1.2.4 Depending upon the execution, fit again the studs (902.01 or 602.05) on the non driven end, if theyhave 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 capscrews (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 Poonawalla11.2.1.1 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 Sanmar11.2.2.1 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 : Burgmann11.2.3.1 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 Rotor12.1.1 HG Pump Sizes 1 and 212.1.1.1 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 bearinghousing.

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 rotorhas increased within the permissible limits, half the clearance increase must be added to the liftingvalues.

_____________________________________________________________________________________

Caution When the bearing shells and labyrinth rings are dismantled the shaft mustnot 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 pumprotor 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 headbolts (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. Themeasured 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 beplaced 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 thehex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction.

12.1.2 HG Pump Sizes 3 to 612.1.2.1 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 increasedwithin 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 mustnot 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 instructionUA7 23.062 01and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting ofthe 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 headbolts (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 measuredvalues 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 hexbolts (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); ifnecessary, drill out and ream the holes. Position the splash ring (507.01 and/or 507.02) and tighten thegrub 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 212.2.1.1 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 toppart (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 tightenthe 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 612.2.2.1 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 mustengage 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.

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

z

y

b

a

Adjusting the lift-off device

c


_____________________________________________________________________

12.3.4.2 Calculate the auxiliary dimension “x” : x = a – b – 30 mm. (30 mm = installation length of the prestressedsprings).

12.3.4.3 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation fromparallelism is 0.02 mm.

_____________________________________________________________________________________

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

12.3.5 Slide the spacer ring (504.01) over the shaft (210).12.3.6 Mount the bearing cartridge (381) including two angular contact 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 figureAdjusting 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 Bearing12.4.1 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.

12.4.1.1 Measure the dimension “a” from the face of the thrust bearing housing (354) to the bottom faces ofsprings (950), dimension “b” from the thrust bearing plate (384) to the springs’ contact faces on thebearing cartridge (381), distance “c” from the face of the thrust bearing housing (354) to shaft collar aswell 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 pre-stressed springs.

12.4.4.2 Shorten the spacer ring (504.01) to the dimension “y” y = c – x. The maximum permissible deviation fromparallelism is 0.02 mm.

_____________________________________________________________________________________

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

z

d

y

b

a

f

x

e

Adjusting the lift-off device with tilting-pad thrust bearing

c

Slg1


_____________________________________________________________________

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 contact 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); seefigure 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 thetightening 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.


_____________________________________________________________________

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 contactface of the bearing end cover (361), distance “d” from the bearing face of the thrust bearing (314, in thethrust bearing housing) to the contact face of the thrust bearing housing (354), and width “e” of the thrustbearing 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 contact face of the bearing end cover (361) must beremachined. If the clearance is too small, the contact face of the thrust bearing (314) in the bearing endcover (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.

c

d

e

bSlg2

a

Adjusting the thrust bearing


_____________________________________________________________________

13. Mounting the Piping and InstrumentsAll pipes and instruments, which have been dismantled in connection with maintenance work, must be re-installed as described in the chapter Installation on Site.

14. Mounting the Connecting Coupling14.1 Fitting the Coupling Hubs14.1.1 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.

_____________________________________________________________________________________

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.

Run-out check of the shaft ends (example)

0.2-

0.3m

m

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 facesare 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 CouplingAlign the connecting coupling in accordance with the Connecting Coupling Alignment section in the chapterInstallation on Site.

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

15. Mounting the Guards Preventing Accidental Contact15.1 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 (upto 1200 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 Contact for Shaft Seal_____________________________________________________________________________________

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

_____________________________________________________________________________________

Fasten the guard preventing accidental contact 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 Components16.1 Maintenance of the Connecting Coupling

See the manufacturer’s documentation.

16.2 Maintenance of DriveSee the manufacturer’s documentation.


_____________________________________________________________________

16.3 Maintenance of the Minimum Flow SystemSee the manufacturer’s documentation.

16.4 Maintenance of the Instruments and ValvesMaintenance 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 Parts17.1 Ordering Spare Parts

Please direct your orders to the nearest KSB Customer Service Center or Sales Office.

When ordering spare parts, please quote17.1.1 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 StockFor quick elimination of possibly occurring problems, we recommend to keep a stock of spare parts.

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

OIMPG TROUBLE-SHOOTING 1

_____________________________________________________________________

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 andaccessories supplied by KSB, please refer to P & I Diagram.

1.2 Requisite DocumentationFor the elimination of problems described in the tables on the subsequent pages, the technical documentationof the order pump set components is required in addition to this instruction manual. If these components areincluded 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 Prerequisites1.3.1 All spare parts required are available.1.3.2 Proper hoisting tackle and means of transport are available and ready for use.1.3.3 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 TROUBLESHOOTING 2

_____________________________________________________________________

In case of problems not described in the following table, consultation withKSB’s Customer service is required.

Problem (what) Possible causes Measures

Pump delivers against an excessive high Open the valve in the discharge pipe further until theDuty point is adjustedMount larger impeller(s)Contact KSB’s Service CenterIncrease the speed of the turbine or internal combustionengine

Excessive back pressure

Check plant for impuritiesPump or piping are not completely vented orprimed

Vent and/or prime

Inlet pipe or impeller(s) clogged Remove deposits in the pump and/or pipingAlter the piping layoutFormation of air pockets in the pipingFit a new valveCorrect the liquid levelFully open the valve in the inlet pipeChange the inlet pipe, if the resistances in the inlet pipeare too highInlet pipe is too bigCheck the strainers installed

NPSHavailable too low (inlet)

Observe the permissible speed of pressure fallClean the strainer element and inlet pipeCorrect the liquid levelChange the inlet pipe

Suction head is too high

Check the strainers installedAir intake at the gland packing Replace the gland packing

See chapter ‘Commissioning Startup/Shutdown’ &Maintenance

Wrong direction of rotation Interchange 2 phases of the power supplyIncrease the speedIncrease the voltage

Speed is too low

Alter the impeller diameterContact KSB’s Service Center

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

Replace defective parts

Contact KSB’s Service CenterReplace defective fuses

Flow rate of pump > specifiedvalue

Motor is running on 2 phases onlyCheck the power cable connections

Pump discharge pressure >specified value

Speed is too high Alter the impeller diameterContact KSB’s Service Center


_____________________________________________________________________



Damaged measuring instrument Replace the measuring instrumentDifferential pressure in the strainer element istoo high

Dismantle and clean the strainer element

Valve in the inlet pipe is not fully open Open the valve

Pressure ps > specified value

Pressure in the inlet vessel is too low Check the inlet vessel and/or increase the pressureDamaged measuring instrument Replace the measuring instrumentSpeed is too low Check the driveInlet pressure is too low Check the inlet pressure and inlet vesselIn case of tapping, quantity tapped is too high Throttle the tapping quantityTemperature of the medium pumped is too lowor too high

Increase or reduce the temperature

Pressure pd > specified value

Defective minimum flow system Check the minimum flow systemDefective shaft seal Check; replace, if requiredScore marks or roughness on shaft protectionsleeve (524) and/or sleeve of mechanical seal

Replace the shaft protection sleeve (524) or sleeve ofmechanical seal

Gland (gland plate / gland ring) have beentightened incorrectly

Check

Wrong packing material ReplaceSee chapter ‘Commissioning/Startup/Shutdown’ &MaintenanceCorrect the suction conditionsRe-align the pumpRe-balance the pump rotor

Pump runs rough

Increase pressure at the suction nozzlePump set alignment Check the coupling; re-align, if requiredPump is warped Check the piping connections and the fastening of the

pumpInsufficient quantity of cooling liquid Increase the cooling liquid quantity

Clean the cooling liquid chamber and/or coolerDirty cooling liquid chamber or coolerCheck the cooling liquid; purify/clean, if requiredIncrease the effective cross sectionFault in the circulation liquid pipeCheck the pipes

Shaft seal leakage

Surface pressure on the sealing clearance istoo high, lack of lubricant or circulation liquid

Check the installation dimensions

Contact KSB’s Service Center


_____________________________________________________________________



Defective bearing Check; replace, if requiredSee chapter ‘Maintenance’

Oil quantity Check the oil quantity; top up or replace, if requiredSee chapter ‘Servicing’ and Technical Appendix

Oil quality CheckSee chapter ‘Servicing’ and Technical Appendix

Increased axial thrust Replace the casing wearing ringsContact KSB’s Service Center

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

Replace the defective parts

Contact KSB’s Service CenterClean the pump rotorUnbalance of the pump rotorBalance the pump rotor

Pump set not correctly aligned Check the coupling and re-align, if requiredPump is warped Check the piping connections and the fastening of the

pump

Increased bearing temperature

Coupling hub distance Check the coupling hub distance for compliance with theGA Drawing; correct, if required

Pump or piping are not completely vented orprimed

Vent and/or prime

Correct the liquid levelFully open the valve in the inlet pipe

Change in the inlet pipe, if resistances in the inlet pipeare too highInlet pipe is too longCheck the strainers installed


Observe the permissible speed of pressure fall

Temperature of pump >specified value

Flow rate < specified value Increase the minimum flowDefective O-rings and/or metallic sealingsurfaces

Replace O-rings and/or remachine the metallic sealingsurfaces


Pump leakage

Tie rods have loosened Tighten

In accordance with the relevant work instruction



_____________________________________________________________________




Vent and/or prime

Correct the liquid levelFully open the valve in the inlet pipeChange the inlet pipe, if the resistances in the inlet pipeare too highInlet pipe is too longCheck the strainers installed


Observe the permissible speed of pressure fallWear of internal pump parts ( check inaccordance with the Tables of clearances)

Replace defective parts

Contact KSB’s Service CenterAdjust the duty point accurately by means of the valve inthe discharge pipe

Backpressure of pump is lower than specifiedin the purchase order

In the case of permanently overload, turn down theimpeller(s), if necessary

Contact KSB’s Service CenterPump set alignment Check the coupling and re-align, if requiredPump is warped Check the piping connections and the fastening of the

pumpOil quantity Check the oil quantity; top or replace, if required

Contact KSB’s Service CenterOil quality Check

See Technical AppendixClean the pump rotorUnbalance of the pump rotorBalance the pump rotor

Defective bearing Replace

Pump runs rough

Flow rate < specified value Increase the minimum flowDamaged inlet pipe Check the inlet pipeValve in the inlet pipe is not fully open Open the valvePressure in the inlet vessel is too low Check the inlet vessel and/or increase the pressure

Check the inlet pipeChange the inlet pipe

NPSHavailable / NPSHrequired too low

Excessive speed of pressure fallAir intake at the seal elements/valves/shaft seal Check the piping; check shaft seal for leakage

Cavitation noise in the pumpand/or piping


Vent and/or prime


_____________________________________________________________________




Vent and/or prime

Correct the liquid levelFully open the valve in the inlet pipeChange the inlet pipe, if resistances in the inlet pipe aretoo highInlet pipe is too longCheck the strainers installed


Observe the permissible speed of pressure fallWear of internal pump parts ( check inaccordance with the Tables of clearances)


Contact KSB’s Service CenterIncreased axial thrust Replace the casing wearing ring


Pressure and/or quantity ofbalancing liquid fluctuates

Change in cross section of balancing liquid pipeExcessive resistancesJoining of several pipes near the pumpBalance flow leakage counter balancing disc /final stage diffuserWear on the balancing device

Check the mode of operationCheck the return pipe

Check the pump pressures

Check the rotor clearances and balancing deviceWear of internal pump parts ( check inaccordance with the Tables of clearances)


Contact KSB’s Service CenterBack pressure of pump is lower than specifiedin the purchase order

Adjust the duty point accurately by means of the valve inthe discharge pipe

In the case of permanently overload, turn down theimpeller(s), if necessary

Contact KSB’s Service CenterHigher density or viscosity of the mediumpumped than specified in the purchase order


Gland tightened excessively or askew AlterAlter the impeller diameter


Speed is too high

Reduce the speed of the turbine or internal combustionengine

Pump is warped Check the piping connections and the fastening of thepump

Operating voltage is low Check the power cable connectionsReplace defective fuses

Drive is overloaded

Motor is running on 2 phases onlyCheck the power cable connections

OIMPG CLEAR AF 1

_____________________________________________________________________

Tables of Clearances

Diametrical Clearances :

Nominal diametrical clearances [mm]Pump size HydraulicsS6 S7 S8 S9 Sl2 Sl3

1 1 ; 2 0.90 – 1.402 3 ; 4

0.25 – 0.34 0.35 – 0.50 0.27 – 0.360.90 – 1.50

5 0.30 – 0.3636 0.30 – 0.37

0.40 – 0.51 0.35 – 0.45 1.0 – 1.50.50 – 1.0

4 7 ; 8 0.32 – 0.395 9 ; 10

0.35 – 0.41 0.45 – 0.510.35 – 0.47

6 11;12;13 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48

1.0 – 1.60.80 – 1.2

0.25 – 0.40

Max. permissible diamet-rical clearance (mm)

1.0 1.0 1.0 2.0

Sl2

S8 2

S7 2

S6 2

Sl3 Sl2

Clearance between balance disc seat and throttle sleeve or balance disc

Clearance between double balance drum and balance disc seat

S9 2

Clearance between suction casing or inlet ring and shaft

OIMPG CLEAR AF 2

_____________________________________________________________________

Theoretical Total Axial Clearance

Sa1 + Sa2 [mm]Impeller materialPump size Hydraulic

CI Cr Steel1 8.5 – 8.0 8.5 – 8.012 7.5 – 7.0 7.5 – 7.03 9.0 – 8.5 8.5 – 8.024 7.0 – 6.5 6.5 – 6.05 9.0 – 8.5 8.5 – 8.036 7.0 – 6.5 6.0 – 5.57 ---48 --- 6.5 – 8.09 ---5

10 --- 8.5 – 10.011 ---612 --- 10.0

Sa2

Sa1

502.02

171.02

230.02

Total axial clearance of pump rotor

OIMPG CLEAR PLANE 1

_____________________________________________________________________

Tables of ClearancesBearing ClearancesBearing design : Tilting-pad Thrust Bearing

Pump size Bearing Clearance Slg2 [mm](Diametrical clearance)

1 , 2 0.33 – 0.583, 4 0.34 – 0.605, 6 0.40 – 0.75

Bearing design : Lift-off Device with Tilting-pad Thrust Bearing

Pump size Bearing clearance Slg1 [mm]1 - 6 0.30 - 0.50

Slg2

Tilting-pad Thrust Bearing

Slg1

Lift-off Device with Tilting-pad Thrust Bearing

OIMPG CLEAR PLANE H 1

_____________________________________________________________________

Tables of Clearances

Bearing Clearances

Bearing design : Tilting-pad Thrust Bearing

Pump sizeBearing clearance Slg2 [mm]

(Diametrical clearance)3, 4 0.34 - 0.605, 6 0.40 - 0.75

Diametrical Clearances :

Nominal diametrical clearances [mm]Pump size HydraulicsS6 S7 S8 S9 Sl2 Sl3

1 1 ; 2 0.90 – 1.402 3 ; 4

0.25 – 0.34 0.35 – 0.50 0.27 – 0.360.90 – 1.50

5 0.30 – 0.3636 0.30 – 0.37

0.40 – 0.51 0.35 – 0.45 1.0 – 1.50.50 – 1.0

4 7 ; 8 0.32 – 0.395 9 ; 10

0.35 – 0.41 0.45 – 0.510.35 – 0.47

6 11;12;13 0.40 – 0.50 0.45 – 0.51 0.40 – 0.48

1.0 – 1.60.80 – 1.2

0.25 – 0.40

Max. permissiblediamet-rical clearance (mm)

1.0 1.0 1.0 2.0

OIMPG TIGHT TRQ 1

_____________________________________________________________________

Table of Tightening Torques

Tightening Torques [Nm]

HG Pump Sizes 1 – 6

1. Prerequisites1.1 The threads of the screws/bolts and nuts are not damaged.1.2 The threads and bearing surfaces of the screws/bolts and nuts are plane, deburred and cleaned thoroughly.1.3 The threads move smoothly.1.4 The washers are plane, deburred and cleaned thoroughly.

2. PumpObserve the tightening torques for the screwed/bolted connections as per relevant work instruction.

3. Fastening of Pump FeetThread Tightening torque MA [Nm]M 20 190M 24 330M 30 660M 36 1160

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

OIMPG TIGHT TRQ 2

_____________________________________________________________________

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

Flanges as per DINNominal diameter DN [mm] Nominal pressure PN [bar] Tightening torque MA [Nm]

160 9025 250 140

64 140160 16040250 24064 160160 27050250 24064 140160 24065250 27064160 25080250 37064160 350250 530320400

100

500160 500250 490320400125500160 490250 650320400

150

500160 660250 1150320400

200

500160 1260250320

250

400

OIMPG TIGHT TRQ 3

_____________________________________________________________________

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

Flanges as per ANSINominal diameter DN [inch] Nominal pressure PN [class] Tightening torque MA

[Nm]600 80

1” 1500 240600 140

1 ½” 1500 350600 90

2” 1500 240600 140

2 ½” 1500 270600900 2403”1500 490600 4909001500 650

4” 2500900 6501500 1100

5” 2500900 4901500 830

6” 2500900 8301500 1350

8” 2500900 840150010”2500

OIMPG TIGHT TRQ 4

_____________________________________________________________________

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

Flanges as per DINNominal diameter DN [mm] Nominal pressure PN [bar] Tightening torque MA [Nm]

16 5065 40 70

16 5080 40 70

16 70125 40 150

16 130150 40 200

16 13025 19020040 24016 21025 290

250 40 38016 21025 240

300 40 320

Flanges as per ANSINominal diameter DN [inch] Nominal pressure PN [class] Tightening torque MA [Nm]

2 ½” 300 903” 300 905” 300 2106” 300 1208” 300 210

10” 300 26012” 300 320

OIMPG WEIGHT 1

_____________________________________________________________________

Table of WeightsHG Pump Size 1

_____________________________________________________________________________________

Caution Weights ≥≥ 25 kg_____________________________________________________________________________________

Pump Components

Part No. Designation Weights (reference values in kg)106 Suction Casing 35.0107 Discharge Casing 58.0210 Shaft for 3 stages

each additional stage17.91.2

350.01 Bearing Housing 25.0Rotor 3 stagesEach additional stage

31.04.0

Pump

Weights (reference values in kg)Number of stagesWithout water fill Water fill

3 234 8.04 250 8095 266 9.76 282 10.67 298 11.58 314 12.49 330 13.3

10 346 14.211 362 15.112 378 16.013 394 16.914 410 17.815 426 18.716 442 19.617 458 20.518 474 21.419 490 22.320 506 23.2

OIMPG WEIGHT 2

_____________________________________________________________________


_____________________________________________________________________________________


Pump Components

Part No. Designation Weights (reference values in kg)106 Suction Casing 54.1107 Discharge Casing 140.0108 Stage Casing 25.0210 Shaft for 3 stages


350.01 Bearing Housing 25.0Rotor 3 stagesEach additional stage

52.06.0

Pump


3 410 19.04 440 21.65 470 24.26 500 26.87 530 29.48 560 32.09 590 34.6

10 620 37.211 650 39.812 680 42.413 710 45.014 740 47.615 770 50.216 800 52.817 830 55.418 860 58.0

OIMPG WEIGHT 3

_____________________________________________________________________


_____________________________________________________________________________________


Pump Components

Part No. Designation Weights (reference values in kg)106 Suction Casing 161.0107 Discharge Casing 225.0108.01 Stage Casing 38.00108.02 Stage Casing 28.0130 Casing Part, for double piston

For mechanical seal25.030.5

210 Shaft for 3 stageseach additional stage

51.43.0

350.01 Bearing Housing 57.0354 Thrust Bearing Housing, thrust bearing/plain bearing 25.0361 Bearing End Cover, thrust bearing/plain bearing 29.0441 Seal Casing 39.0

Rotor 3 stagesEach additional stage

83.09.0

Pump


3 736 27.04 774 30.05 812 33.06 850 36.07 888 39.08 926 42.09 964 45.0

10 1002 48.011 1040 51.012 1078 54.013 1116 57.014 1154 60.015 1192 63.016 1230 66.0

OIMPG WEIGHT 4

_____________________________________________________________________


_____________________________________________________________________________________


Pump Components

Part No. Designation Weights (reference values in kg)106 Suction Casing < 320 bar

≤ 420 bar210.0250.0

107 Discharge Casing < 320 bar DN 80 < 250 bar DN 100

>320 bar DN 100≤ 420 bar DN 100 DN 125

255.0285.0315.0530.0550.0

108.01 Stage Casing 31.0108.02 Stage Casing 38.0130 Casing Part, for double piston

For mechanical seal25.030.5

131 Inlet Ring 80.0210 Shaft for 3 stages


350.01 Bearing Housing, suction side Heavy bearing housing

57.061.0

350.02 Bearing Housing, discharge side 150.0354 Thrust Bearing Housing, thrust bearing/plain bearing 25.0361 Bearing End Cover, thrust bearing/plain bearing

Heavy bearing housing29.035.0

441 Seal Casing 39.0Rotor 3 stagesEach additional stage

83.09.0

Pump


3 736 27.04 774 30.05 812 33.06 850 36.07 888 39.08 926 42.09 964 45.0

10 1002 48.011 1040 51.012 1078 54.013 1116 57.014 1154 60.015 1192 63.016 1230 66.0

OIMPG WEIGHT 5

_____________________________________________________________________


_____________________________________________________________________________________


Pump Components

Part No. Designation Weights (reference values in kg)106 Suction Casing 290.0107 Discharge Casing 395.0

108.01 Stage Casing 60.0108.02 Stage Casing 68.0130 Casing Part 33.0131 Inlet Ring 110.0210 Shaft for 3 stages


350.01 Bearing Housing, suction side Heavy bearing housing

57.061.0

350.02 Bearing Housing, discharge side 150.0354 Thrust Bearing Housing, thrust bearing/plain bearing 25.0361 Bearing End Cover, thrust bearing/plain bearing

Heavy bearing housing29.035.0

441 Seal Casing 39.0603.02 Balancing Piston 28.0905 Tie Rods for 3 Stages M 45

Each additional stage10.31.3


130.016.0

Pump


3 1380 41.84 1477 47.45 1574 53.06 1671 58.67 1768 64.28 1865 69.89 1962 75.4

10 2059 81.011 2156 86.612 2253 92.213 2350 97.814 2447 103.415 2544 109.016 2641 114.6

OIMPG WEIGHT 6

_____________________________________________________________________


_____________________________________________________________________________________


Pump Components

Part No. Designation Weights (reference values in kg)106 Suction Casing DN 200

≤ 420 bar DN 200 DN 250

622.0819.0635.0

107 Discharge Casing ≤ 420 bar DN 150 ≤ 420 bar DN 200

821.01020.01170.0

108.02 Stage Casing, Hydraulic 9 Hydraulic 10

93.084.0

108.03 Stage Casing, Hydraulic 9 100.013-6 Casing Insert 96.0130 Casing Part 59.0131 Inlet Ring 180.0171.01 Diffuser 25.0171.02 Diffuser 25.0210 Shaft for 3 stages


350.01 Bearing Housing 124.0350.02 Bearing Housing 165.0354 Thrust Bearing Housing, thrust bearing/plain bearing 32.0360.01 Bearing Cover 36.0361 Bearing End Cover 44.0441 Seal Casing 29.0601 Balancing Disc 25.0603.01 Balancing Piston 43.0603.02 Balancing Piston 57.0905 Tie Rods for 3 Stages M 45

Each additional stageTie Rods for 3 Stages M 52Each additional stage

12.91.617.52.1


243.025.0

Pump


3 2775 804 2930 905 3085 1006 3240 1107 3395 1208 3550 1309 3705 140

10 3860 15011 4015 16012 4170 17013 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 toCompetitor’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 highertemperatures by using proper grade of oil or grease.

♦ Can be dynamically balanced to the required grade as perISO-1940.

1JAN-02

GEAR-FLEX COUPLING

AT A GLANCE

SIZESFull Flexible Type LFG - 101 to 119 (19 sizes)Half Flexible Type LHG - 101 to 110 (10 sizes)

RATING RANGETYPE LFG - 157 kW to 232808 kW @ 1500 rpmTYPE LHG - 157 kW to 12846 kW @ 1500 rpm

TORQUE RANGETYPE LFG - 100.2 kg.m to 149000 kg.mTYPE LHG - 100.2 kg.m to 8220 kg.m

BORE RANGETYPE 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.

JAN-022

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

3JAN-02

GEAR-FLEX COUPLING

STANDARD MATERIAL OF CONSTRUCTION

Hubs & Sleeves - Forged Steel EN-9 BS 970

Bolts & Nuts - Closed tolerance connectingBolts in Carbon Steel

Seals - Nitril Rubber ( SH - 60)

Gasket - Paronite Paper

For other requirements of material ofconstruction, consult LOVEJOY.

4JAN-02

GEAR-FLEX COUPLING

CROWNING OF GEAR TEETH (OPTIONAL)

The straight line tooth form is known to transmit high torque when thecenters of axis are in complete alignment. Where there is anydisplacement, however, this will cause the contact area to localize on toothsurface (at the end of tip of the tooth) thereby causing damage to surfacesof the teeth.

While rotating the load is continually changing location, introducingsliding between the two gears. Crowned gear teeth resist the wear thusdeveloped. Because of the fully crowned design, end bearing does notoccur, 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 surfacewhich is designed after full consideration of the relationship between toothforms & tooth width so that the contact stress on the tooth surface will notvary significantly even where relative movement is present. As for thetooth tip, the crowning is applied & the tooth is designed to minimise thetop clearance between teeth when they are mated.

The LOVEJOY Gear coupling has a crown tooth form so as to givemaximum tooth thickness at its center. Where there is a relativemisalignment between the driver & driven shaft, it is necessary that thetooth which comes between the teeth of its counterpart be permitted tooscillate. The internal teeth of the sleeves have a std. form whereas theexternal teeth of the hub take a special form.

5JAN-02

GEAR-FLEX COUPLING

RATINGS FOR STANDARD COUPLING

Sr. Coupling Rated Torque Rated PowerNo. Size Nm kg m Lbs-inch @100 RPM @1500 RPM

(LFG/*LHG) Kw HP Kw HP1 101 999.5 101.9 8843 10.5 14.1 157 2112 102 2495 254.3 22075 26.1 35.1 392 5263 103 4488 457.5 39709 47 63 705 9454 104 8480 864.4 75029 89 119 1332 17865 105 12968 1321.9 114737 136 182 2037 27306 106 19945 2033.1 176468 209 280 3133 42007 107 34906 3558.2 308838 366 490 5483 73508 108 44881 4575.0 397094 470 630 7050 94509 109 55850 5693.2 494145 585 784 8773 1176010 110 81780 8336.4 723566 856 1148 12846 1722011 111 109442 11156.2 968311 1146 1536 17188 2304012 112 146250 14908.3 1293978 1532 2053 22973 3079513 113 198988 20284.2 1760589 2084 2793 31257 4190014 114 284524 29003.5 2517387 2980 3994 44693 5991015 115 345646 35234.0 3058177 3620 4852 54294 7278016 116 596831 60839.0 5280589 6250 8378 93750 12567017 117 848940 86538.2 7511177 8890 11917 133351 17875518 118 1123990 114575.9 9944741 11770 15778 176556 23667019 119 1482101 151080.6 13113204 15521 20805 232808 312075

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

6JAN-02

GEAR-FLEX COUPLING

WEIGHT & M.I. FOR STANDARD COUPLING

COUPLING Wt. M.I. GD2

SIZE kg kg m2 kg m2

LFG-101 11 0.14 0.56LFG-102 15 0.20 0.8LFG-103 25 0.48 1.92LFG-104 39 0.95 3.8LFG-105 57 1.95 7.8LFG-106 85 3.00 12LFG-107 103 5.25 21LFG-108 138 8.50 34LFG-109 210 15.00 60LFG-110 277 30.50 122LFG-111 550 58.00 232LFG-112 710 88.00 352LFG-113 980 138.0 552LFG-114 1320 291.0 1164LFG-115 1700 353.0 1412LFG-116 2550 690.7 2762.8LFG-117 3620 1235.3 4941.2LFG-118 4860 1965.7 7862.8LFG-119 6380 3012.3 12049.2

Note : Weight & M.I. are with solid hubs.

WEIGHT & M.I. FOR HALF GEAR COUPLINGS

COUPLING Wt. M.I. GD2

SIZE kg kg m2 kg m2

LFG-101 11 0.15 0.6LFG-102 15 0.24 0.96LFG-103 20 0.51 2.04LFG-104 40 1.0 4LFG-105 60 2.0 8LFG-106 80 3.3 13.2LFG-107 106 5.8 23.2LFG-108 149 9.5 38LFG-109 170 16.8 67.2LFG-110 264 35.0 140

Note : Weight & M.I. are with solid hubs.

JAN-027

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.

8JAN-02

GEAR-FLEX COUPLING

HALF FLEX COUPLINGS WITH FLOATING SHAFTS

A floating shaft can eliminate the need for additional bearing support alongspanning shaft because shaft is supported at ends by connectedequipment through the half flex couplings. These are generally used forthe applications of cooling tower fans.

Flexible hubs on floating shaft (Fig. 3a )Assembly of flexible hubs on the floating shaft allows for easierreplacement in case of wear & allows the rigid hubs with their increasedbore capacities to be used on the connected equipment shafts. Thisfrequently 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 beaccommodated. Since the flexible hubs are outboard, the planes of gearmesh are further apart, providing greater misalignment capacity.

9JAN-02

GEAR-FLEX COUPLING

SPACER COUPLINGS

Used on pumps & compressors for ease of servicing withoutdisturbing either of the shafts.

10JAN-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

11JAN-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 withextra high pressure additive. Where the coupling is used under extremeoverload operation, severe reversing operation or bigger angular and offsetmisalignment, 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 overhauledand drained of used oil to remove abrasion particles, and refilled withfresh oil.

C. Subsequent refilling or replacing of oil should be made every 1 year byuse 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 untilthe teeth are submerged in grease, assemble the coupling, tighten the boltsand then supplement grease through oil plug hole by use of grease gunand so on.

Replacing time of grease is same as gear oil, but replace old grease withnew grease in full by overhauling the coupling.

3. RECOMMENDED LUBRICANTS

Recommended Grease is RSG (Rathi Special Grease) havingδδδδg = 910 Kg/m3.

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

12JAN-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 shallpermit total axial displacement of at least 1/4” ( 6.4 mm).

• Antifly Spacer (fail-safe design)

• The coupling design shall ensure that all components arepositively centered. The gear meshes shall be centered atthe crown diameter of the external teeth & at the rootdiameter of the internal teeth.

• The involute tooth form shall be used at the vendor’sdiscretion. External teeth shall be relieved or chamfered atthe tips and edges to provide the required misalignmentcapability & torque capacity.

• The hardness of the gear teeth shall be at least 45 Rc. Thehardness of the teeth with the greater face width ( generallythe sleeve teeth) shall be greater than or equal to thehardness of the mating teeth.

13JAN-02

GEAR-FLEX COUPLING

SELECTION OF SIZE OF COUPLING

Requirements

Application : Driver -Driven -

Application Rating : kW - RPM -

Shaft sizes : Driver - Driven -

Distance between shaft ends (DBSE) if reqd. :

Service Factor (S.F.) to be taken :

Selection Procedure

(a) Service FactorDetermine appropriate SERVICE FACTOR from table

(b) Design PowerMultiply running power of driven machinery by the service factor. Thisgives DESIGN POWER which is used as a basis for coupling selection.

(c) Coupling SizeRefer to rating table for your required coupling size and read from theappropriate speed column until a power equal to or greater than theDESIGN POWER is found.

(d) Bore SizeRefer respective coupling dimensional table to check that the requiredbores can be accommodated. If bore size of selected coupling can’taccommodate the shaft size, then go for next coupling size where shaft sizecan be accommodated.

14JAN-02

GEAR-FLEX COUPLING

TYPICAL SERVICE FACTORS

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

Typical TypicalService Service

Application Factor Application Factor

AGITATORS DREDGES Pure Liquids 1 Cable Reels 1.75 Liquids & Solids 1.25 Conveyors 1.5Liquids-Variable Density 1.25 Cutter Head Jig Drives 2.5

BLOWERS Maneuvering Winches 1.75 Centrifugal 1 Pumps 1.75 Lobe 1.5 Screen Drives 1.75 Vane 1.25 Stackers 1.75

BRIQUETTE MACHINES 2 Utility Winches 1.5

CAR PULLERS-Intermittent Duty 1.5 ELEVATORSCLAY WORKING MACHINERY 1.75 Bucket 1.75

COMPRESSORS Centrifugal & Gravity Discharge 1.5 Centrifugal 1 Escalators 1.5 Centriaxial 1.25 Freight 2.5 Lobe 1.5 FANS Reci-procating-Multi Cylinder 2 Centrifugal 1

CONVEYORS-Light Duty Uniformly Fed Cooling Towers 1.5 Apron, Bucket, Chain, Flight, Screw 1.25 Forced Draft 1.5 Assembly, Belt 1.25 Induced Draft without Damper Oven 2.5 Control 2

CONVEYORS-Heavy Duty FEEDERS Not Uniformly Fed Apron, Belt, Disc, Screw 1.25 Apron, Bucket, Chain, Flight, Oven 1.5 Reciprocating 2.5 Assembly, Belt 1.25 GENERATORS- Reciprocating Shaker 2.5 (Not Welding) 1

CRANES AND HOISTS HAMMER MILLS 2 Main Hoists, Reversing 2.5 LAUNDRY WASHERS Skip Hoists, Trolley & Bridge Drives 2 Reversing 2 Slope 2 LAUNDRY TUMBLERS 2

CRUSHERS LINE SHAFT 1.5 Ore Stone 3

JAN-0215

GEAR-FLEX COUPLING




LUMBER INDUSTRY METAL ROLLING MILLS Barkers-Drum Type 2 Coilers, hot mill 2 Edger Feed 2 Coilers, cold mill 1.5 Live Rolls 2 Cold Mills 2 Log Haul-Incline 2 Cooling Beds 1.75 Log Haul-Well Type 2 Door Openers 2 Off bearing Rolls 2 Draw Benches 2 Planer Feed Chains 1.75 Edger Drives 1.75 Planer Floor Chains 1.75 Feed Rolls, Reversing Mills 3.5 Planer Tilting Hoist 1.75 Furnace Pushers 2.5 Slab Conveyor 1.5 Hot Mills 3 Sorting Table 1.5 Ingot Cars 2.5 Trimmer Feed 1.75 Kick-outs 2.5

MACHINE TOOLS Manipulators 3 Bending Roll 2 Merchant Mills 3 Plate Planer 1.5 Piercers 3 Punch Press-Gear Driven 2 Pusher Rams 2.5 Tapping Machines 2.5 Reel Drives 1.75 Other Machine Tools Reel Drums 2 Main Drives 1.5 Reelers 3 Auxiliary Drives 1.25 Rod and Bar Mills 3

METAL MILLS Roughing Mill Delivery Table 3 Draw Bench-Carriage 2 Runout Tables 2.5 Draw Bench-Main Drive 2 Saws, hot & cold 2.5 Forming Machines 2 Screwdown Drives 3 Slitters 1.5 Skelp Mills 3 Table Conveyors Slitters 3 Non-reversing 2.25 Slabbing Mills 3 Reversing 2.5 Soaking Pit Cover Drives 3 Wire Drawing & Flattening Machine 2 Straighteners 2.5 Wire Winding Machine 1.75 Tables, transfer & runout 2.5

MILLS, ROTARY TYPE Thrust Block 3 Ball 2.25 Traction Drive 3 Dryers & Coolers 2 Tube Conveyor Rolls 2.5 Hammer 1.75 Unscramblers 2.5 Kilns 2 Wire Drawing 1.75 Pebble & Rod 2 PRINTING PRESSES 1.5 Pug 1.75 PULLERS-Barge Haul 2 Tumbling Barrels 2 OIL INDUSTRYMIXERS Chillers 1.25 Concrete Mixers 1.75 Paraffin Filter Press 1.75 Drum Type 1.5

JAN-0216

GEAR-FLEX COUPLING




RUBBER INDUSTRY PUMPS Mixed-Banbury 2.5 Centrifugal 1 Rubber Calender 2 Reciprocating Rubber Mill (2 or more) 2.25 Single Acting Sheeter 2 1 or 2 Cylinders 2.25 Tire Building Machines 2.5 3 or more Cylinders 1.75 Tire & Tube Press Openers 1 Double Acting 2 Tubers & Strainers 2 Rotary, Gear, Lobe, Vane 1.5

PAPER MILLS SCREEN Barker Auxiliaries, Hydraulic 2 Air Washing 1 Barker, Mechanical 2 Grizzly 2 Barking Drum Spur Gear Only 2.25 Rotary-Stone or Gravel 1.5 Beater & Pulper 1.75 Traveling Water Intake 1.25 Bleacher 1 Vibrating 2.5 Calenders 2 SEWAGE DISPOSAL

EQUIPMENT Chippers 2.5 Bar Screens 1.25 Coaters 1 Chemical Feeders 1.25 Converting Machines, except Collectors, Circuline or

Straightime1.25

Cutters, Platers 1.5 Dewatering Screens 1.25 Couch Roll 1.75 Grit Collectors 1.25 Cutters, Platers 2 Scum Breakers 1.25 Cylinders 1.75 Slow or Rapid Mixers 1.25 Disc Refiners 1.75 Sludge Collectors 1.25 Dryers 1.75 Thickeners 1.25 Felt Stretcher 1.25 Vacuum Filters 1.25 Felt Whipper 2 STEERING GEAR 1 Jordans 1.75 STOKERS 1 Line Shaft 1.5 WINCH 1.5 Log Haul 2 WINDLASS 1.75 Pulp Grinder 1.75 Press Roll 2 Reel 1.5 Stock Chests 1.5 Suction Roll 1.75 Washers & Thickeners 1.5 Winders 1.5

JAN-0217

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 - BoreB - Keyway DepthC - Keyway Width

Basic Size (mm.) H7 JS9 ForAbove Upto &

includingFor Bores

(mm.)For Keyway Width

(mm.)Keyway Depth

(mm.)3 6 + 0.012

0± 0.015

6 10 + 0.0150

± 0.018 + 0.10

10 18 + 0.0180

± 0.021

18 30 + 0.0210

± 0.026

30 50 + 0.0250

± 0.031+ 0.2

50 80 + 0.0300

± 0.037 0

80 120 + 0.0350

± 0.043

120 180 + 0.0400

± 0.050+ 0.3

180 250 + 0.0460

± 0.057 0

250 315 + 0.0520

± 0.065+ 0.4

315 400 + 0.0570

± 0.070 0

400 500 + 0.0630

± 0.077 + 0.50

18 JAN-02

GEAR-FLEX COUPLING

APPLICATIONS

Gear-flex couplings can be used effectively & economically fortransmission of mechanical power for :

Agitators Hammer millsBlowers Line shaftsConveyors Machine toolsCrushers Metal forming machinesElevators MixersEscalators PulverisersExtruders PumpsFeeders ScreensGenerators 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 INSTRUCTIONSFOR STD. LFG / LHG COUPLINGS

(A) BEFORE INSTALLATION

1. Remove the coupling from packing & thoroughly inspect forsigns of damage.

2. Disassemble the coupling by removing nuts & bolts. Clean allthe parts carefully.

3. Remove protective coatings / lubricants from bores &keyways.

(B) MOUNTING PROCEDURE

1. Slide the sleeves with internal teeth with rubber O ring onshafts before mounting the hubs.

2. Mount the hubs with external teeth on their respective shaftsflushed 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 ata distance ‘G’ (refer table A & B) between shaft ends by using aspacer bar equal in thickness to the required gap ‘G’ as shownin fig. 2.

Deviation in standard DBSE is defined as axial misalignment (endfloat). For normal applications the shaft end should be flushed withinner face of the adpater. In some special cases the shaft ends mayprotrude beyond the inner face of the adapter or may remain inside,if required. The distance between two faces of adapter flanges is tobe maintained as specified. The variation in this distance should notexceed 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 presentat the same time.

IMPORTANT : The misalignment capabilities shown in drawings or inproduct 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 maximumallowable misalignments limits. Allowance should be made for anyanticipated movements which will occure during operation (e.g. Thermalmovements).

For Permissible INITIAL misalignments refer table A

For Permissible MAXIMUM misalignments refer table B

JAN-0222

GEAR-FLEX COUPLING

(I) CHECKING PARALLEL /RADIAL ALIGNMENT

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

(II) CHECKING ANGULAR ALIGNMENT

Check the angular misalignment with the help of slip gauges byinserting in the gap at 4 places 90° apart. The deviation in thevalues of standard gap ‘G’ is Total Indicated Reading (TIR). Theangular misalignment ‘X’ in mm is half the Total IndicatedReading. The values of angular misalignment should not exceedpermissible initial misalignments mentioned in table A. (Referfig. 4).

23JAN-02

GEAR-FLEX COUPLING

(D). ASSEMBLY PROCEDURE

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

1. Insert the gasket between the flanges. Position the flangedsleeves with lubrication plugs.

2. Insert the bolts & tighten the nuts.

Remember: Assemble only with the help of the fastenersfurnished with the coupling.

Fig. 5

3. Fill with recommended grease/oil (RSG/RSL with reqd. qty.)for lubrication. For grease quantity for respective couplingsize, refer table No. C.

4. Change the grease after the interval of 6 months & the oilafter 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 individualinstallations. The owner or user must provide the required safety guards. Safetyguards or shields are not furnished by us with this equipments.

24JAN-02

GEAR FLEX COUPLING

TABLE ‘A’

PERMISSIBLE INITIAL MISALIGNMENTS FOR GEAR COUPLINGS

TYPE LFG TYPE LHG GAP‘G’

COUPLING ANGULAR PARALLEL/RADIAL

AXIAL ANGULAR AXIAL Std

SIZE degreesper gear

mesh

‘X’

(mm)

‘P’

(mm)

(mm) degreespergearmesh

X’

(mm)

(mm) (mm)

101 0.5 0.2 0.5 5

102 0.6 0.2 0.6 5

103 0.7 0.3 ±0.12 0.7 ±0.06 5

104 0.8 0.3 0.8 5

105 0.9 0.3 ±0.37° 0.9 10

106 1.0 0.4 1.0 10

107 1.1 0.4 1.1 10

108 1.2 0.5 ±0.25 1.2 ±0.12 10

109 1.4 0.5 1.4 10

110 0.37 1.6 0.6 1.6 10

111 1.8 0.8 10

112 1.9 0.9 10

113 2.2 1.6 ±0.5 15

114 2.4 1.8 NOT 15

115 2.5 2.0 AVAILABLE 15

116 2.9 2.1 20

117 3.2 2.3 ±0.75 20

118 3.6 2.4 20

119 4.0 2.5 20

• Half Flexible Gear Couplings Type LHG cannot accommodate parallelmisalignment.

Gap ’G’ in the above table is given when angular & axial misalignments are zero.

JAN-0225

JAN-02

GEAR FLEX COUPLING

TABLE ‘B’PERMISSIBLE MAXIMUM MISALIGNMENTS FOR GEAR COUPLINGS

TYPE LFG TYPE LHG GAP‘G’

COUPLING ANGULAR PARALLEL/RADIAL

AXIAL ANGULAR AXIAL Std

SIZE degreesper gear

mesh

‘X’

(mm)

‘P’

(mm)

(mm) degreesper gear

mesh

‘X’

(mm)

(mm) (mm)

101 2.2 0.8 2.2 5

102 2.4 0.95 2.4 5

103 2.9 1.1 ±0.5 2.9 ±0.25 5

104 3.2 1.3 3.2 5

105 3.7 1.45 ±1.5° 3.7 10

106 4.2 1.55 4.2 10

107 4.6 1.8 4.6 10

108 5.0 1.9 ±1.0 5.0 ±0.5 10

109 5.6 2.2 5.6 10

110 ±1.5° 6.4 2.6 6.4 10

111 7.1 3.3 10

112 7.7 3.5 10

113 8.9 6.6 ±2.0 15

114 9.5 7.3 NOT 15

115 10.2 8.1 AVAILABLE 15

116 11.8 8.5 20

117 13.1 9.1 ±3.0 20

118 14.4 9.6 20

119 16.3 10.2 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.

JAN-0226

GEAR FLEX COUPLING

TABLE ‘C’

GREASE FOR GEAR COUPLING (LFG/ LHG)

Sr. No. COUPLING SIZE GREASE QTY.1 101 47 gms.2 102 90 gms.3 103 216 gms.4 104 375 gms.5 105 460 gms.6 106 715 gms.7 107 1 Kg.8 108 1.3 Kg.9 109 2.2 Kg.10 110 3 Kg.11 111 4.5 Kg.12 112 6.6 Kg.13 113 8.8 Kg.14 114 11.3 Kg.15 115 14.8 Kg.16 116 22.5 Kg.17 117 32 Kg.18 118 44.5 Kg.19 119 53 Kg.

RECOMMANDED GREASE – RATHI SPECIAL GREASE (RSG) (δg = 910 Kg/m3)

27 JAN-02

GEAR FLEX COUPLING

COMPETITORS FOR GEAR-FLEX COUPLING

SR COMPETITOR MAX. kW @1500 RPM

MAX. BORE(mm.)

1 David Brown Link MasterGear Coupling(AUSTRALIA)

46050 300

2 Fenner Power Tran(INDIA)

190500 600

3 Lovejoy Flanged SleeveSeries Type - F(USA)

32451 340

4 Hi-CliffTrueline Series 100(INDIA)

232892 710

5 ALLIANCEAll Flex Type AFG

232892 710

28JAN-02

GEAR FLEX COUPLING

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

LINK MASTER GEAR LOVEJOY GEAR-FLEX LFG

COUPLING kW AT MAX.BORE

O.D. TOT. LGTH COUPLING kW AT MAX.BORE

O.D. TOT.LGTH

SIZE 1500 RPM (MM.) (MM.) (MM.) SIZE 1500 RPM (MM.) (MM.) (MM.)

02 315 50 152 101 102 392 60 185 145

03 559.5 65 178 127 103 705 75 220 175

04 984 80 213 158 104 1332 90 250 215

05 1680 95 240 187 105 2037 110 290 230

06 2235 110 279 218 106 3133 125 320 260

07 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.

29JAN-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


30JAN-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

1 ½ 335.7 56 102 392 60

2 559.5 73 103 705 75

2 ½ 1007 88 104 1332 90

3 1678.5 107 105 2037 110

3 ½ 2685.6 124 106 3133 125

4 3916.5 143 107 5483 140

4 ½ 5371.2 162 108 7050 160

5 7721 176 109 8773 180

5 ½ 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

NOT AVAILABLE 117 133351 520

118 176556 610

119 232808 710


31 JAN-02

GEAR FLEX COUPLING

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

HI-CLIFF TRUELINE SERIES 100 LOVEJOY GEAR FLEX COUPLING - LFG



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


32JAN-02

GEAR FLEX COUPLING

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

ALLFLEX TYPE AFG LOVEJOY GEAR FLEX COUPLING - LFG



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 Montagevorschriftfür das Freilaufrückschlagventil

Baureihe TDM

Deutsch: Seite 1-10

Spezial-Armaturen

Installation and Maintenance Instructionsfor TDM

English: Page 11-20

TDM

C O N T E N T S

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

- 11 -

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 doneaccording the necessary safety precautions.

1.1. Danger to persons and materials

The minimum flow valves should only be operated within their limits ofdesign and layout.

No changes are to be made without our approval.Only use original spare parts.

Safety regulations, site regulations and installation safety precautions areto be followed.

Please follow the instructions as given in this “Installation-, Maintenanceand Assembly instructions”.

1.2 Avoid dangers

Maintenance of the Automatic Recirculation Valve shall only be done bytrained personnel.

Before disassembly, the installation has to be shut off and the valvepressureless and cooled down. Please make sure that these safetyprecautions can only be cancelled after ending the assembly of the valve.

Please be aware that also in a pressureless valve there might still bemedium.

Wear protective clothing.

- 12 -

TDM

2. Description

The Schroedahl automatic-recirculation-valve model TDM is appliedin centrifugal pump systems in order to provide an automaticleak-off flow in case of low load conditions.

The application range of the series TDM with a multistage pressurelet-down section is, independent of the temperature, for theoperating 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 providedwith a flange. The bypass housing, and as an option also the start-uphousing, are located horizontally at the side of the valve. The valve trimcomprises 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 valveactivates, by means of a lever, a vortex plug.When lifted of its seat, the vortex plug allows a flow through thepressure reduction section to the suction tank (or condensate tank).

The opening characteristic is linear; the bypass flow increases whenthe check valve moves from its switch point further into the closesposition. Because of the modulation bypass control, the total ofprocess flow and minimum flow remains approximately constant.

The check valve, shaped like a differential control piston and springloaded, has such a high own frequency, that waterhammer is avoided.The check valve dampens pulsations because of its throttling effecton the mainflow and stabilises unstable pump characteristics in thepartial load range.

The housing is made from forged steel and is provided with a chromiumsteel liner in the check valve area.All moving parts and guides consist of alloy steel which arecompatible. Alternative materials are available as options(see drawing and parts lists).

- 13 -

TDM

3. Packing and marking

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

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

- 14 -

TDM

4. Assembly and disassembly

The automatic recirculation valve type TDM is usually installedvertically, with the mainflow upward, and directly on the pumpdischarge flange.The bypass housing is connected to the bypass piping (and the pipingconsequently to the feedwater tank or other tank), so that a recirculationflow will be possible.Other installation positions of the valve (horizontal, upside-down) arepossible, if so ordered only!No special tools are required for the installation, assembly or disassemblyof the valve.

4.1 Installation at the jobsite

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

4.2 Disassembly of the TDM

Remove the TDM from the piping system. Disassemble bypass housingPos. 09. Pull the bypass 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) byloosening the hexagon nuts (pos. 28).The check valve (pos. 07) and spring (pos. 06) can now be removedfrom the lower body (pos. 01).Clean all parts and check for any damages. In case of damagedseats (check valve seat or bypass seat), this should be repairedby 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 thelower 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 sectionaldrawing!).Carefully insert the bypass section „M“ in the valve body andas certain, that lever (pos. 13) fits (slides) in the slot in thecheck valve (pos. 07).The bypass housing (pos. 09) with the bypass orifice (pos. 23) is nowcarefully replaced and tightened to the housing (pos. 01) with thehexagon nuts (pos. 29).

4.4 Disassembly of the bypass section

Occasionally, and because of contamination of the fluid, a completedisassembly of the bypass trim may be required. At each inspectionthe bypass should be checked for proper operation. In case ofdamages, the bypass section should be removed, disassembled andthe 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 bereplaced as an unit.

- Check glyd-rings pos. 33.1, 34.1 and 35.1 for any damages.

NoteIn case of doubt the complete bypass assembly pos. 10-16, 21, 23,31-36 may be replaced and the dissassemdled bypass may be sendto the factory for repair.Check the drill plate pos. 23 for any damages. Replace the completeseal set.

4.5 Assembly of the bypass 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 mainshut-off valve in the pump discharge piping (to the boiler or process)the specified bypass flow is maintained through the bypass section(and to the piping of the bypass system).By closing or opening the main shut-off valve, the opening and closingof the bypass can be checked. The switch point of the valve can beestablished acoustically (use a technical stethoscope or even ascrewdriver to the ear will do).In case a manual start-up connection is provided on the valve, theminimum flow is achieved through this section. The automatic bypass isclosed during commissioning and the manual start-up is opened. Theautomatic bypass section is spared (protected) during commissioning inthis 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 pumpat regular intervals.After disassembly of the valve, all seals should be replaced (by newseals) before re-assembly of the valve.

7. Warranty conditions

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

- 17 -

TDM

8. Instructions in case of damages

In order to judge the damages (and the cause), the followinginformation is required:

a) The production number of the valve (K .....).This number is stamped on each valve body.

b) Valve model number and sizee.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, thefollowing persons can be addressed during office hours:

Internationalsales organisation: Schroedahl International B.V.

St. Josephstr. 65Lucernaflat 9th floorNL - 4611 MK Bergen op Zoom

Phone number + 31 / 1 64 25 50 40Fax number + 31 / 1 64 25 98 85

Schroedahl International Corp.2400 Augusta Dr., Suite 280Houston, Texas 77057Phone number + 001 / 713-975-8351Fax number + 001 / 713-780-0421

- 18 -

TDM

10.1 Sectional drawing

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P = pump endR = pipeline endB = by-pass end

Installation P_R vertical

TDM

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MaterialPos. Description CS SS

01 Lower body 1.0460 1.455002 Upper body 1.0460 1.455003 Valve stemguide 1.4552 1.455204 Guide bolt 1.4021 4) 1.4021 4)06 Spring 1.4310 1.4310 x07 Check valve (assy.) 1.4550 1.4550 x

07.1 Check valve 1.4550 1.455007.2 Stem 1.4550 5) 1.4550 5)0 8 Liner 1.4301 1.430109 Bypass branch 1.0460 1.455025 Guide pin 1.4305 1.430526 Bolt 1) 1)27 Bolt 1) 1)28 Hexagon nut 2) 2)29 Hexagon nut 2) 2)30 O-Ring 3) 3) x

BypassPos. Description Material Recommended

10 Vortex bushing 1.4122 1.412211 Control head 1.4122 1.412212 Vortex plug 1.4122 1.412213 Lever 1.4313 1.431314 Pivot pin 1.4021 1.402115 Bushing 1.4122 1.412216 Piston 1.4122 1.412221 Disc 1.4122 1.412223 Bypass orifice 1.4122 1.412231 O-Ring 3) 3)32 O-Ring 3) 3)33 O-Ring 3) 3)

33.1 Glyd-Ring PTFE/Carbon PTFE/Carbon34 O-Ring 3) 3)



10.2 Parts list

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1) 8.8 to DN 150 PN 40, DIN 1.7709 from PN 63 and from DN 200 PN 102) 8 to DN 150 PN 40, W-Nr. 1.7258 from PN 63 and from DN 200 PN 103) EPDM, BUNA, VITON, ZALAK, KALREZ4) made from SS acc. DIN 1.4550 with ceramic coating in case of horizontal installation5) With ceramic coating in case of horizontal installation

Housing

Spare parts

Spare parts

Recommended

x

feed pump ksb

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