Operating Instructions
Mega Centrifugal Pump
Serial No. : ____________________________ ____________________________ Type Series Mega: ______________________ ______________________
KSB Ajax Pumps Pty Ltd
Mega Contents Page
2
0 0.1
General Handling
3 3
1 1.1 1.2 1.3 1.4 1.4.1 1.4.2 1.5 1.6
Installation Foundation Mounting Aligning Pump/Motor Connecting the Piping Auxiliary Connections Vacuum Balance Coupling Guard Final Check
3 3 3 3 4 4 4 4 4
2 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.2 2.3
Startup/Commissioning, Shutdown Preparations Lubricant Shaft Seal Priming the Pump and Associated Checks Checking the Direction of Rotation Startup Shutdown
4 4 4 4 4 5 5 5
3 3.1 3.2 3.2.1 3.2.2
Maintenance and Lubrication Supervision of Operation Lubrication Grease (supplied as standard) Oil (optional)
5 5 5 5 5
4 4.1 4.2 4.2.1 4.3 4.3.1 4.4 4.4.1 4.4.2 4.4.2.1 4.4.2.2 4.4.2.3 4.4.2.4 4.4.2.5 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5
Dismantling and Reassembly General Dismantling Mechanical Seal Deep Groove Ball Bearing/Lubricant Fill Grease Change Reassembly Pump Shaft Seal Stuffing Box Compartment Packing Ring Cut to Size Gland Leakage Flushing Arrangement Mechanical Seal Spare Parts Ordering Spare Parts Exploded View List of Components Recommended List of Spare Parts for 2 years Continuous Operation Recommended Impeller Nut Torques
10
5
Faults
11/12
6 6 6 6 6 6 6 6 7 7 7 7 8 8 8 8 9 10 10
Mega 0
General
Centrifugal pumps will give trouble-free, satisfactory service if they are properly installed and maintained.
0.1 Handling When handling the complete pumpset, attach ropes to the pump and motor as shown (not through the motor eyebolt) or onto the lifting lugs supplied.
Follow the instructions in this manual carefully. Do not run the pumps under operating instructions which differ from those specified by us.
This manual does not take into account any on site safety regulations which may apply. The nameplate attached to the pump indicates the type series/size, identification number, impeller dimension and serial number. Please always indicate this data in case of inquiries, supplement orders and especially when ordering spare parts. Fig. 1 Pump and motor and common baseplate
Do not operate this pumpset above the limit values for capacity, speed, pressure and temperature etc. shown on the nameplate.
Ensure that operation is in accordance with the instructions contained in this manual (contract documentation). It is essential that the electrical connection values are as specified and that the instructions on installation and maintenance are followed.
1 Installation (Installation on site) 1.1 Foundation Make sure the concrete foundation has set before mounting the pumpset. The surface of the foundation must be completely horizontal and perfectly flat. 1.2 Mounting Position the pumpset on the foundation and align using a precision spirit level (on the discharge nozzle). Always fit shims to left and right of the anchor bolts near the bolts, between the baseplate/foundation frame and the foundation. If the shims are more than 800mm apart, position extra shims equal distant between them. All shims must be perfectly flush.
Operation of this unit beyond the above conditions may result in excess load and subsequent failure. Failure to heed these warnings can result in personal injury and damage to equipment.
N.B. The instructions and descriptions in this manual refer to the industrial pump model. This manual does not cover all details or eventualities which might occur during installation, operating or maintenance. The pump set must only be handled by skilled, trained personnel. For any information and instructions not contained in this manual, please contact KSB Ajax Pumps. The manufacturer accepts no liability for the pumpset if the instructions in this manual are not complied with.
Fig. 2 Fitting shims Uniformly tighten up securing means. Baseplates have to be grouted with non-shrinking mortar up to the upper edge of the frame after having been fixed in position. 1.3 Aligning Pump/Motor The coupling must be checked and the pumpset realigned even if the pump and motor are supplied ready mounted on a common baseplate.
3
Mega 1.4 Connecting the Piping Never use the pump as anchorage point for the piping.
A Main shutoff valve B Vacuum balance line C Shutoff valve E Vacuum-tight shutoff valve R Non-return flap valve V Vacuum vessel Z Intermediate flange
Suction lift lines should be run with a rising slope towards the pump, positive suction lines with a downward slope towards the pump to avoid the formation of air locks. The pipes should be supported very near the pump and connected without transmitting any stresses and strains to it. The pump must not bear the weight of the piping. The nominal diameters of short pipelines should at least correspond to those of the pump connections. In case of long pipelines, the most economical nominal diameter is to be determined for the application. Adaptors to larger nominal diameters should be designed with an extension angle of approx. 8 to avoid increased pressure losses. ˚
The installation of non-return devices and suction and discharge valves is recommended according to the type of plant and pump. Thermal expansion of the pipework should be accommodated by suitable means so as not to impose any extra load on the pump. Before commissioning a new installation, thoroughly clean, flush and blow through all vessels, piping and connections. Welding beads, scale and other impurities frequently only become dislodged after a certain period of time; it is necessary to fit a strainer in the suction line to prevent these entering the pump. The total cross-section of the holes in the strainer should be three times the cross-section of the piping in order to avoid excessive pressure loss across the strainer due to clogging.
1.4.1 Auxiliary Connections The size and locations of all auxiliary connections for sealing, flushing and leakage liquid are shown in the general arrangement drawing or piping diagram.
1.4.2 Vacuum Balance If the pump has to pump from a vessel under vacuum it is advisable to fit a vacuum balance line. This line should have a minimum diameter of 25mm and be arranged to lead into the vessel above the maximum advisable level. An additional pipeline that can be shut off - a pump discharge nozzle vacuum balance line - facilitates the venting of the pump prior to start up.
4
Fig. 3 Suction line and vacuum balance line 1.5 Coupling Guard Safety regulations specify that the pump must be fitted with a coupling guard. 1.6 Final Check Recheck alignment as described in 1.3. It must be possible to rotate the coupling easily by hand. Check the integrity of all connections.
2 Startup/Commissioning, Shutdown 2.1
Preparations
2.1.1 Lubricant Grease lubricated bearings Bearings are already packed with grease. Standard Grease for life bearings. Oil lubricated bearings (optional) Fill the bearing bracket with IS viscosity grade 68 or equivalent lubricating oil suitable for rolling element bearings. Procedure Remove vent plug. Pour oil in through the hole left by vent plug until oil appears in the vertical section of the elbow connecting the bearing bracket and the reservoir. Fill up the reservoir and place back in position. Replace the vent plug. After a short time check whether the oil level in the reservoir has dropped. The reservoir must always be kept topped up. Shaft Unit
A*
B
A30 A40 A50 A60
1 2 0 0
28.6 35 44.9 53
*Tolerance +1,-0. 2.1.2 Shaft Seal For information on shaft seal please refer to 4.2.1 and 4.4.2. 2.1.3 Priming the Pump and Associated Checks Vent and prime the pump and suction line before start up. The shutoff valve in the suction line must be completely open. Fully open all auxiliary lines (sealing, flushing liquid) and check they are functioning properly. Open the shutoff valve in the vacuum line (if fitted) and close the vacuum tight shutoff valve ‘E’ (Fig 3).
Mega 2.1.4 Checking the Direction of Rotation The direction of rotation of the driver must match the arrow on the pump. Check this by switching the pump on and immediately switching it off again. Fit the coupling guard.
2.2 Startup Start the set up against a closed discharge valve only. Once the pump has reached full speed slowly open the valve and set to the duty point. After the pump has reached its working temperature and/or if leakage occurs, tighten nuts (920) with the set disconnected.
2.3 Shutdown Close the discharge gate valve.
If the gland is leaking too heavily after a long period of operation, uniformly tighten the gland nuts up by 1/6 of a turn, then observe the leakage. If the nuts cannot be tightened up any further, install a new packing ring. It is usually not necessary to replace the complete packing. Pumps with mechanical seals experience minor or invisible (vapour) leakage. The seal is maintenance free. Standby pumps should be started up and run for ten minutes once a week to keep them operational. Also check the integrity of the auxiliary connections. Flexible parts of the coupling which show signs of wear should be replaced in good time.
3.2
Lubrication
3.2.1 Grease (supplied as standard) The discharge gate valve can remain open if the discharge line is fitted with a non return device and pressure is maintained in the discharge pipe.
Mega pumps are fitted as standard with grease lubricated - sealed for life bearings.
Switch off the motor, making sure the pumpset runs down smoothly and evenly to a stand-still.
Grease Nipple (Option) Item 636 - Bearing Cap fitted with Grease Nipple.
If the pumpset is to remain out of service for long periods, close the shut-off valve in the suction line and close all auxiliary connections.
3.2.2 Oil (optional)
On pumps supplied with product under vacuum, there must be sealant supply to the shaft seal even at standstill. If there is a danger of freezing and/or if the pump is to be out of service for a long period, then drain the pump or otherwise protect it against freezing.
The first oil change must be carried out after 300 hours of operation; all subsequent oil changes after 3000 hours.
Procedure Remove the plug below the constant level oiler and drain off the oil. When the bearing bracket is empty, replace the drain plug and fill with oil as described in 2.1.1.
3 Maintenance and Lubrication 3.1 Supervision of Operation The pump must run quietly and evenly at all times. The pump must never run dry. The bearing temperature may be 50°C above room temperature, but must not exceed 90°C (measured at the outside of the bearing housing). Do not run the pump for more than three minutes against a closed discharge valve. If the pump has gland packing, this must drip during operation. The gland nuts should only be lightly tightened up. If a packing ring of pure graphite is used there must always be leakage.
5
Mega 4 Dismantling and Reassembly 4.1 General Before dismantling, make sure the pump is disconnected from the power supply and cannot be switched on accidentally.
Under no circumstances use force. Dismantle the pump in the sequence shown in the exploded view diagram. 4.2.1 Mechanical seal To replace the mechanical seal it is necessary to dismantle the pump.
The suction and discharge shutoff valves must be closed.
After removing the impeller 230 draw the mechanical seal 433 from the shaft by hand.
The pump casing must have cooled down to ambient temperature.
Before reassembly, touch up any grooves or scratches: if it is not possible to remove any grooves or indentations completely, fit a new shaft. Clean the stationary seal ring seat on the seal holder. Refer 4.4.2.5.
The pump casing must be empty and not under pressure.
4.3 4.2 1 2 3
Dismantling On oil lubricated pumps drain off the oil as de scribed in 3.2.2. Detach all auxiliary supply lines. Remove coupling guard.
4 For coupling without spacer: 4.1 Dismantling of complete pump. 4.1.2 Remove discharge and suction branch from pipeline. 4.2 Loosen pump from baseplate. 4.2.1 During dismantling the volute casing can remain on the baseplate and in the pipline. 4.2.2 Uncouple pump from motor. 4.2.3 Disconnect motor power supply cables. 4.2.4 Loosen motor from baseplate. 4.2.5 Remove supporting foot 183 from the baseplate and loosen nuts on discharge cover. 4.2.6 Pull out bearing bracket with discharge cover and complete rotor (assembled unit). With larger pumps, suspend or support bearing bracket to prevent the rotating bracket from falling over.
Deep Groove Ball Bearing/Lubricant Fill
4.3.1 Grease Change Use a lithium soap based grease, resin and acid free, not liable to crumble, with good rust preventative properties. It should have a penetration number between 2 and 3, corresponding to a worked penetration between 220 and 295mm/10. Its drop point must be above 175° C. The hollow spaces around the bearings must not be more than half packed with grease. For example: Shell Alvania R2, Mobil Mobilux 2, B.P. Energrease LS2, Caltex Multifak 2.
Shaft unit
Bearing Size
A30 A40/A40R A50 A60
6306 6308 6310 6312
Shaft Unit A30
5
5.1 5.2 5.3
For coupling with spacer: During dismantling the volute casing can remain on the baseplate and in the pipeline. Remove spacer of the coupling. Remove supporting foot 183 from the baseplate and loosen nuts on the discharge cover. Pull out bearing bracket with discharge cover and complete rotor (assembled unit). With larger pumps, suspend or support bearing bracket to prevent the rotating bracket from falling over.
If the pump has been in operation for a long time some parts may be difficult to move. In this case use a brand name penetrating oil or suitable pull off device.
A40 A40R A50
A60 A50HD
4.4
Lubrication Quantity Grease Approx.gms
Oil Approx.litre
5 10 15 15
0.2 0.35 0.65 0.65
Model M32-160, M32-200, M32-250, M40-160, M40-200, M50-160, M50-200 M40-250, M50-250, M65-160, M65-200, M80-160 M40-315, M50-315, M65-250, M80-200, M80-250, M100-160, M100-200 M65-315, M80-315, M80-400, M100-250, M100-315, M100-400, M125-200, M125-250, M125-315, M125-400, M150-200, M150-250 M150-315,M150-400 MH100-315, MH100-400, MH125-250, MH125315, MH125-400
Reassembly
4.4.1 Pump Reassemble in accordance with standard engineering practice. Coat the fits and screw connections with graphite or similar before reassembly. Check o-rings for wear and replace if necessary. All gaskets must be renewed; make sure the new ones are the same thickness as the old ones.
6
Mega Dimensions of packing compartment/packing rings, number of rings.
Shaft unit
If the sealing area between impeller neck and casing wear ring is worn, replace the casing wear rings 502.1 and 502.2 where fitted.
Gap clearances: New 0.3mm on diameter, maximum wear to 0.9mm on diameter.
Reassemble the pump in reverse order to dismantling. Make sure you reassemble in the right sequence.
Packing ring
Number rings 1)
di
da
l
35
55
73
10
5 Packing rings 1 Lantern ring
A40 45 A40R
65
73
10
5 Packing rings 1 Lantern ring
A30
Fig. 4 Mounting the deep groove ball bearings
Packing compartment
A50
60
85
90.5
12.5
A60
70
95
90.5
12.5
5 Packing rings 1 Lantern ring
Dimensions (in mm) 1) With positive suction operation and suction pressure above 0.5 bar, the lantern ring is replaced by 2 packing rings.
4.4.2.2
Packing Ring Cut to size
Fig. 6 Packing ring cut to size.
Insert the first packing ring and push home. Fit each subsequent ring separately with its joint staggered through 90 in relation to the previous one using the stuffing box ring. ˚
4.4.2 Shaft Seal Thoroughly clean the packing compartment and shaft sleeve before packing the gland.
4.4.2.1
Stuffing Box Compartment
Tighten the gland nuts lightly and evenly. It must be possible to rotate the rotor without difficulty.
4.4.2.3 Gland Leakage Gland leakage must occur in any operating condition. A normal leakage rate would be between 10 to 20 cm3 / minute. This is approximately 100 to 150 drops per minute.
Slacken off the gland nuts is there is insufficient leakage. If leakage ceases entirely: - Switch pump off immediately - Slacken gland nuts and repeat the startup procedure.
After adjustment, observe the leakage for around 2 hours with the temperature of the product at its maximum. Fig. 5 Stuffing Box Compartment. Then with the pressure of the product at its minimum check whether there is sufficient leakage. 7
Mega 4.4.2.4
Flushing Arrangement
Code
Packing
Application
0
Clean, non aggressive liquids, temperature up to 105 C Internal sealing
1
Liquids which are toxic, aggressive and/or with bad smell. Also pumps with suction from a vacuum tank. Sealing with a clean liquid from an external source. (max. temp. = 105 C)
˚
˚
2
Liquids having particles in suspension, or when a major contamination from the external source is to be avoided. (Sealing t max. = 105 C) ˚
3
Liquids with abrasive particles or with tendency to crystallization. Flushing with clean liquid from an external source. (max. temp. = 105 C) ˚
g
10E - Flushing liquid inlet 10S - Flushing liquid outlet
4.4.2.5 Mechanical Seal Reassemble in reverse order to dismantling. When fitting a mechanical seal bear the following points in mind: Maximum care and maximum cleanliness are mandatory. Do not remove the guard on the seal faces until just before fitting. The seal faces and o-rings must not be damaged. Clean or carefully remove any deposits from the shaft and stationary ring seat in the bearing housing. The shaft 210 may be oiled to reduce friction when mounting the seal.
8
Mechanical Seal
Fit the o-ring to the stationary seal ring, then push the stationary seal ring into the seal plate, applying pressure evenly to all sides. 4.5
Spare Parts
4.5.1 Ordering Spare Parts When ordering spare parts please always indicate the following information which may be taken from the nameplate of the pump e.g. Pump Type
MEGA 2000
Pump Size
80 - 200
ID No.
140428
Ser. No.
9401234
Impeller Dia.
196
Mega 4.5.2
Exploded View
Packed Gland
Mechanical Seal
9
Mega 4.5.3
List of Components
PART NO
DESCRIPTION
PART NO
DESCRIPTION
102 163 183 210 230 321 330 360 400.1/2/3/4 411.1/2/3/4 412.1/2 421 433 452 458 461 471
CASING BACK COVER SUPPORT FOOT SHAFT IMPELLER BEARING BEARING BRACKET BEARING COVER GASKET GASKET O-RING OIL SEAL MECHANICAL SEAL GLAND LANTERN RING PACKING SEAL PLATE
502.1 502.2 507 524 525 554.1/2/3 565 636 901.2/4 901.3 901.5/6/7 902 903.1/2/3/4/5 920 922 940.1/2 970
CASING WEAR RING IMPELLER WEAR RING SLINGER SHAFT PROTECTIVE SLEEVE SPRING SLEEVE WASHER DRIVE SCREW GREASE NIPPLE (OPTIONAL) SETSCREW SETSCREW * SETSCREW STUD PLUG NUT IMPELLER NUT KEY NAME PLATE
* Jacking screw- Use 901.2 or 901.4 as applicable On some models part numbers 922 Imp. Nut, may be substituted with 901.7 Setscrew, 554.2 Impeller washer and 412.20 o-ring-Imp. bolt
4.5.4
Recommended List of Spare Parts for 2 Years’ Continuous Operation
Part no.
Part designation
Number of pumps (including stand-by pumps) 2
3
4
5
Pumps with gland packing 210 230 321 330 461 502.1 524 -
6 and 7
8 and 9
10 and more
Quantity of spare parts
Shaft Impeller (including impeller wear ring 502.2) Deep groove ball bearing Bearing bracket Gland packing (set) Casing wear ring Shaft protecting sleeve Gaskets (set)
1 1 2 4 2 2 4
1 1 2 6 2 2 6
2 1 4 8 2 2 8
2 2 4 8 3 3 8
2 2 6 9 3 3 9
3 3 8 1 12 4 4 12
30% 30% 100% 2 off 150% 50% 50% 150%
2 2
2 3
2 4
3 5
3 6
4 7
50% 90%
Pumps with mechanical seal 525 433
Spring Sleeve (Replaces part 524) Mechanical seal, complete (Replaces part 461)
4.5.5
Recommended Impeller Nut Torques
Shaft Unit
A30
A40/A40R
A50/A50HD
A60
Impeller Nut Across FIat (mm)
24
30/36
41
41
Torque (Nm)
70
80/90
110
110
16
19
24
24
15
25
65
65
Impeller Bolt Across Flat (mm) Torque (Nm) Casing Bolts/Nuts
10
Across FIat (mm)
17
19
24
Torque (Nm)
16
27
43
Mega 5 Faults
11
Mega
KSB Ajax Pumps Pty Ltd
ABN: 29 006 414 642
Victorian Head Office 27 Indwe St, Tottenham, 3012 Tel: +61 (03) 9314 0611 Fax: +61 (03) 9314 7435
New South Wales Unit 1, 28 Skinner Ave, Riverwood, 2210 Tel: +61 (02) 9584 2099 Fax: +61 (02) 9584 2111
Queensland Carberry St, Ebbw Vale, 4304 Tel: +61 (07) 3282 1766 Fax: +61 (07) 3816 0225
Western Australia Unit 2, 86 Catalano Circuit, Canning Vale, 6155 Tel: +61 (08) 9455 7900 Fax: +61 (08) 9455 7800
South Australia Unit 4, 348 Richmond Rd, Netley, 5037 Tel: +61 (08) 8234 0066 Fax: +61 (08) 8443 5411
New Zealand Unit 2, 5 Civil Place, Albany, Auckland Tel: +64 (09) 476 4047 Fax: +64 (09) 476 4048
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
[email protected]
WEBSITE: www.ksbajax.com.au Due to our policy of constant research and development, product specification may change without notice
24 HOUR EMERGENCY SERVICE LINE: 1300 301 356 Publication 1045 08/05 1K AGP Part No. 99100
