Feed Pump KSB
Feed Pump KSB
Feed Pump KSB
CONTENTS
DESCRIPTION PAGE REFERENCE
OIMPG General 1 OIMPG General 2 OIMPG General 3 OIMPG General 3
Chapter : General
1. General Information 2. Disposal 3. Conformity with EU Regulations (if applicable)
Chapter : Safety
Marking of Instructions in the Instruction Manual Personnel Qualification and Training Non-compliance with Safety Instructions Safety Awareness Safety Instructions for the Operator/User Safety Instructions for Work on the Pump Set Unauthorized Modification and Manufacture of Spare Parts Unauthorized Modes of Operation
OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 1 OIMPG Safety 2 OIMPG Safety 2 OIMPG Safety 2
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DESCRIPTION
PAGE REFERENCE
Conditions Foundation Site management Place of Installation Drive way to the Place of Installation Adequate means of Transport Preparations Checking the Foundation Correct deviating foundation dimensions Transporting the Pump set Components to the Place of Installation Removal of Packaging Protecting the Pump Set Components Procedure for levelling and grouting of Base Frame at Site Making the Piping Cleaning the Piping Connecting the Coupling Information about Readiness for connecting of the Piping Checking the Alignment Mounting the Instruments Detailed description of Mounting/dismounting the connecting Coupling General Information Mounting Dismantling Detailed description of Connecting Coupling Alignment 1. Conditions 2. Preparations 3. Runout Check of the Coupling Hubs 4. Alignment of Coupling 5. Alignment Corrections 6. Pinning the Feet Cladding (touch guard) for the Shaft Seal
Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 1 Installation 2 Installation 2 GEN 02.01 I Installation 3 Installation 3 Installation 4 Installation 4 Installation 4 Installation 4 Installation 4 Installation 5 Installation 5 Installation 6 Installation 7 Installation 8 Installation 8 Installation 8 Installation 8 Installation 9 Installation 10 Installation 11 Installation 12 Installation 13
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DESCRIPTION
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DESCRIPTION
PAGE REFERENCE
OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 01 OIMPG SERVICING 02 OIMPG SERVICING 03 OIMPG SERVICING 03 OIMPG SERVICING 04
Chapter : Servicing
1. General Information 1.2 Requirement of Documentation 1.3 Prerequisites 1.4 Service Intervals 2. Dismantling the Guards Preventing Accidental Contact 3. Pump Servicing Plan 4. Servicing Work 4.1 Oil Changes 4.2 Re-lubrication
Chapter : Maintenance
1. General Information 1.2 Required Documentation 1.3 Prerequisites 2. Dismantling the Guards Preventing Accidental Contact 2.1 Sound Insulation Hood 2.2 Coupling Guard/Cover 2.3 Guard Preventing Accidental Contact for Shaft Seal 3. Dismantling the Connecting Coupling 3.2 Removing the Coupling Hubs 3.3 Run-out Check of the Shaft Ends 4. Removing the Pump from the Installation 4.1 Dismantling the Piping and Instruments 4.2 Removing the Pump from Baseframe 4.3 Transporting the Pump to the Place of Dismantling 5. Dismantling the Bearings 5.1 Preparations 5.2 Dismantling the Add-on Parts 5.3 Dismantling the Lift-off Device, with Antifriction Bearings 5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing 5.5 Dismantling the Thrust Bearing 5.6 Dismantling the Radial Bearings 5.6.1 HG Pump Sizes 1 and 2 5.6.2 HG Pump Sizes 3 to 6 5.7 Dismantling the Bearing Housings 5.7.1 HG Pump Sizes 1 and 2 5.7.2 HG Pump size 3 5.7.3 HG Pump Sizes 4 to 6 6. Dismantling the Shaft Seal 6.1 Preparations 6.2 Dismantling the Mechanical Seal 6.2.1 Make : Eagle Poonawalla 6.2.2 Make : Flowserve Sanmar 6.2.3 Make : Burgmann 6.3 Dismantling the Casing Parts
OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 01 OIMPG MAINTENANCE 02 OIMPG MAINTENANCE 02 OIMPG MAINTENANCE 02 OIMPG MAINTENANCE 03 OIMPG MAINTENANCE 03 OIMPG MAINTENANCE 03 OIMPG MAINTENANCE 04 OIMPG MAINTENANCE 05 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 06 OIMPG MAINTENANCE 07 OIMPG MAINTENANCE 07 OIMPG MAINTENANCE 07 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 08 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 13 OIMPG MAINTENANCE 14 OIMPG MAINTENANCE 14
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DESCRIPTION
7. Dismantling the Balancing Device 7.1 HG Pump Sizes 1 and 2 7.2 HG Pump Size 3 7.3 HG Pump Size 4 7.3 HG Pump Sizes 5 and 6 7.4 Measuring the Approximate Radial Clearance 8. General Information on Reassembly 9. Checking the Balancing Device with Contact Fluid 9.1 HG Pump Sizes 1 and 2 9.2 HG Pump Size 3 9.3 HG Pump Sizes 4 9.4 HG Pump Sizes 5 and 6
PAGE REFERENCE
OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 26 OIMPG MAINTENANCE 27 OIMPG MAINTENANCE 27 OIMPG MAINTENANCE 27 OIMPG MAINTENANCE 28 OIMPG MAINTENANCE 29 OIMPG MAINTENANCE 30 OIMPG MAINTENANCE 31 OIMPG MAINTENANCE 30 OIMPG MAINTENANCE 33 OIMPG MAINTENANCE 34 OIMPG MAINTENANCE 35 OIMPG MAINTENANCE 36 OIMPG MAINTENANCE 36 OIMPG MAINTENANCE 36 OIMPG MAINTENANCE 37 OIMPG MAINTENANCE 38 OIMPG MAINTENANCE 39 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 40 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 43 OIMPG MAINTENANCE 44 OIMPG MAINTENANCE 44 OIMPG MAINTENANCE 45 OIMPG MAINTENANCE 45 OIMPG MAINTENANCE 46 OIMPG MAINTENANCE 47 OIMPG MAINTENANCE 48 OIMPG MAINTENANCE 49 OIMPG MAINTENANCE 49 OIMPG MAINTENANCE 49 OIMPG MAINTENANCE 50 OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 51
10. Mounting the Balancing Device 10.1 HG Pump Sizes 1 and 2 10.2 HG Pump Size 3 10.3 HG Pump Size 4 10.4 HG Pump Sizes 5 and 6 11. Mounting the Shaft Seal 11.1 Mounting the Housing Components 11.1.1 HG Pump Sizes 1 to 3 11.1.2 HG Pump Sizes 4 to 6 11.2 Assembling the Shaft Seal 11.2.1 Make Eagle Poonawalla 11.2.2 Make : Flowserve Sanmar 11.2.3 Make : Burgmann 12. Mounting the Bearings 12.1 Mounting the Bearing Housings and Lifting the Pump Rotor 12.1.1 HG Pump Sizes 1 and 2 12.1.2 HG Pump Sizes 3 to 6 12.2 Mounting the Radial Bearings 12.2.1 HG Pump Sizes 1 and 2 12.2.2 HG Pump Sizes 3 to 6 12.3 Mounting the Lift-off Device (if applicable) with Antifriction Bearings 12.4 Mounting the Lift-off Device (if applicable) with Tilting-pad Bearing 12.5 Mounting the Thrust Bearing (if applicable) 13. Mounting the Piping and Instruments 14. Mounting the Connecting Coupling 14.1 Fitting the Coupling Hubs 14.2 Aligning the Connecting Coupling 14.3 Mounting the Coupling Connections
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DESCRIPTION
15. Mounting the Guards Preventing Accidental Contact 15.1 Coupling Guard 15.2 Coupling Cover 15.3 Guard Preventing Accidental Contact for Shaft seal 15.4 Sound Insulating Hood 16. Maintenance of the Other Pump Set Components 16.1 Maintenance of Connecting coupling 16.2 Maintenance of Drive 16.3 Maintenance of Minimum Flow System 16.4 Maintenance of Instruments and Valves 16.5 Maintenance of Oil Supply Unit, etc. (if applicable) 16.6 Maintenance of the Gear/Variable Speed Coupling (if applicable) 17. Spare Parts 17.1 Ordering Spare Parts 17.2 Spare Parts Stock 17.3 Storage
PAGE REFERENCE
OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 51 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 52 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53 OIMPG MAINTENANCE 53
OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 1 OIMPG TROUBLE-SHOOTING 2 OIMPG TROUBLE-SHOOTING 3 OIMPG TROUBLE-SHOOTING 4 OIMPG TROUBLE-SHOOTING 5 OIMPG TROUBLE-SHOOTING 6
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DESCRIPTION
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General
Non-compliance with the regulations laid down in the instruction manual leads to forfeiture of any and all rights to claim for damages.
All work on the pump set must only be performed by properly trained personnel who are familiar with the dismantling/reasembly work required.
This instruction manual must always be kept close to the location of operation of the pump set for easy access.
We recommend to call in KSBs experienced personnel for installation, commissioning/start-up, maintenance, and in case of problems.
OIMPG General 1
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1. General Information
This instruction manual contains fundamental information which must be complied with during work on the pump set. Therefore this instruction manual must be read both by the service engineers and responsible trained personnel, prior to commencement of work. All users must not only comply with the general safety instructions laid down in the chapter on Safety, but also the specific safety instructions included elsewhere in the instruction manual. KSB pumps are developed in accordance with state-of-the-art technology, are manufactured with utmost care and are subjected to continuous quality control. If they are properly installed, serviced and maintained, the pumps will give reliable and trouble-free operation. We recommend to call our specialist personnel for installation and commissioning/start-up. KSB will only assume responsibility for faultless execution of the work and for the safety of the personnel involved if dismantling/reassembly and maintenance have been performed by KSBs specialist personnel. This pump set must not be operated beyond the limit values specified in the data sheets. Make sure that the operation in accordance with the instructions laid down in this manual. The operator must take into account the information given in Technical Appendix, or in other parts of the instruction manual or in the contract documentation. It is of vital importance to observe the specified electrical connection values as well as the dismantling/reassembly and servicing instructions. In particular, it must be ensured that all necessary measures are taken and the regulations in accordance with the relevant legislation are complied with. ________________________________________________________________________________________
Caution
The temperature of the medium handled must not exceed the values indicated on the pump name plate. Operation of the pump set outside the conditions mentioned above may lead to overloads which, in turn, may result in personal injury and damage to property.
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The descriptions and instructions set forth in this instruction manual refer to KSBs scope of supply (e.g. pump or pump set). This instruction manual does not cover all possible eventualities or events which might occur during installation, maintenance, servicing and operation of the machine. Neither does the instruction manual take into account any safety regulations applicable at the place of installation; the Operator must ensure that such regulations are strictly observed by all, including the personnel called in for execution of the work. Instructions on labels, tags and stickers attached to the pump set must be observed.
The pump name plate indicates the main data; please quote this information in all queries, repeat orders and particularly when ordering spare parts.
If you need any additional information or instructions exceeding the scope of this instruction manual, please contact KSBs nearest customer service centre. In case of problems please contact your nearest customer service centre or the manufacturing works.
OIMPG General 2
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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. those posed by residues of the medium handled in the pump). ____________________________________________________________________________ ____________________________________________________________________________ All measuring instruments supplied with the pump should be calibrated before commissioning of the pump set. ____________________________________________________________________________
Set points of the instruments, wherever conveyed through operating instruction manual, are only as guideline, and final values are to be set on the site as per observations and requirements. ___________________________________________________________________________________________
Caution
The pump should never be run below the speed of 1000 rpm (higher limit in case of mechanical seals with pumping ring), even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for the pumps with variable frequency drive & pumps with hydraulic coupling. ____________________________________________________________________________ 2. Disposal
According to the local anti-pollution regulations - packaging components must be disposed of by the consignee - lubricants no longer used, cleaning material, media handled, electric equipment, etc. must be disposed of by the Operator at their own expense.
Caution
3.
OIMPG General 3
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Safety
Marking of Instructions in the Instruction Manual
The safety instructions contained in this instruction manual which must be observed without fail to avoid hazards to persons are specially marked with the general hazard sign, namely
The word
Caution
is used to introduce safety instructions which must be observed to avoid damage to the pump set and its functions. Instructions attached directly to the pump set, e.g. - the arrow indicating the direction of rotation - markings for fluid connections and safety instructions must always be complied with and be kept in perfectly legible condition at all times.
Safety Awareness
It is imperative to comply with safety instructions contained in this manual, the relevant national health and safety regulations, and the Operators own internal work, operation and safety regulations, if any.
OIMPG Safety 1
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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.
Markings
Lifting links All lifting links are marked with the chain symbol.
Temperature > 80 C/176 F It is imperative to observe the information plate on the pump.
OIMPG Safety 2
Caution
Observe the applicable local safety regulations. Loose parts must be fastened so as to prevent them from falling down. If a crane is used, check the brake of the hoisting gear by trial braking under load. After fastening the ropes, align the crane hook in such a manner that the crane hoisting ropes are suspended vertically. Loads must be lifted at a right angle to the drum axis of the rope winch. Loads must not be lifted at an angle. Keep the period of tome for which the load is in free suspension to a minimum. Use a guide rope in addition if long objects are handled. Transport of persons together with load is not permitted. Keep out of the danger area. Work under suspended loads is not permitted. The permissible lifting capacity of the lifting equipment must not be exceeded. Lower the loads at the lowest lowering speed of the hoist.
1.1
1.1.1
1.1.2
1.1.3
For selection and attachment, only follow the instructions given by the person responsible for this.
1.2
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3.1 Transport of the Pump Set For transporting the pump set components mounted on the base plate, shackles must be attached to the lifting lugs of the pump/baseplate. __________________________________________________________________ Caution Do not damage any built-on accessories and pipes. __________________________________________________________________
OIMPG TRANSPORT 3
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3.2 Transport of the Pump Attach the hoisting tackle as shown in the figure or to the marked lifting links. _________________________________________________________________ Do not attach the ropes to the shaft ends or bearing housings. Secure the pump against overturning. _________________________________________________________________ Caution
OIMPG TRANSPORT 4
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3.3 Transport of the Other Pump Set Components 3.3.1 Transport the other pump set components in accordance with the relevant manufacturers documentation. 3.3.2 If these components are included in KSBs scope of supply, the relevant documents mentioned elsewhere in the manual. 3.4 Transport of the Pump Rotor 3.4.1 Attach hemp or plastic ropes as required by the length of the pump rotor and transport the pump rotor horizontally; see figure. _______________________________________________________________________ Do not use wire ropes or chains in order not to damage the pump rotor. _______________________________________________________________________ Caution
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 5
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3.5 Transport of Pump Set Accessories Attach the hoisting tackle as shown in the figure. ______________________________________________________________________ Do not exert pressure on the strainer element and strainer meshes or damage them. We recommend transport by hand. ______________________________________________________________________ Caution
<120 <120
<120
OIMPG TRANSPORT 6
_____________________________________________________________________ 4.
4.1
Interim Storage
Prerequisites ______________________________________________________________________ The load carrying capacity of the floor of the storage area must be adequately designed. ______________________________________________________________________ Caution
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. ______________________________________________________________________ All openings of the mounted pump set components are closed and must not be opened before they are needed during installation. _______________________________________________________________________ Place of Storage _______________________________________________________________________ Caution Caution
4.2
Protect the stored components from humidity, dirt, vermin and unauthorized access. _______________________________________________________________________ 4.2.1 All components supplied should be stored in a dry room where the atmospheric humidity is as constant as possible. 4.2.2 In case of outdoor storage it is absolutely necessary to cover the pump set and crates to form watertight barrier and to protect them against condensation of water so that any contact with humidity is avoided. ______________________________________________________________________ Elastomeric parts must not be stored together with chemicals, solvents, fuels, acids, etc. In addition, they should be kept away from Caution light, in particular sunlight, strong artificial light high in ultraviolet rays. _______________________________________________________________________ 4.3 4.4 Period of Storage up to 12 Months The pimp is supplied duly preserved for storage up to 12 months (standard preservation). Period of Storage over 12 Months If the pump is to be stored more than 12 months, it must be preserved appropriately. If the requisite preservation measures have not been performed by KSB (special preservation), they must be discussed with and approved by KSB prior to putting the pump into storage. _______________________________________________________________________ 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. _______________________________________________________________________ Caution
OIMPG TRANSPORT 7
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Site management
-
Place of installation
is cleared its condition is such that the installation can be performed without interruptions adequate devices for aligning are available is cleared is suitable for transport
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.
For transport, the guidelines of the chapters on Safety, and Transport/Interim Storage must be complied with. _______________________________________________________________________
Caution
Installation 1
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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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Components remaining on site have to be protected against dirt, humidity and damage. If components of the pump set are received damaged, wet or dirty, inform KSB. _______________________________________________________________________
Completely cover the pump set components to protect them for the full duration of the installation work on site against construction site dirt, spark discharge, grinding dust and other harmful ambient influences. Take special care to adequately protect instruments, electrical cables and wiring ducts. - Spare parts and parts which are not immediately needed must be stored in such a way that they are protected from dirt accumulation, humidity and damage. _____________________________________________________________________________________ -
Caution
Do not store elastomeric parts together with chemicals, solvents, fuels, acids etc. In addition, they should be kept away from the light, particular direct sunlight and strong artificial light high in ultraviolet light. _______________________________________________________________________
Caution
Installation 2
PROCEDURE FOR LEVELLING & GROUTING OF BASE FRAME AT SITE ( FOR HDA / HDB / HG / CHT PUMPS ONLY ) PURPOSE : High speed rotory equipment needs to be installed with maximum contact area between base frame and the foundation. To achieve this conventionally, blue matching procedure is adopted between packer plates and foundation. This calls for skilled millwright fitters to work on and consumes lot of time. Despite this, the contact area achieved is nowhere near 100%. Therefore, the following procedure is recommended which ensures : 1. Nearly 100% contact area between the foundation, the packer plates and the base frame. 2. Considerable saving in time and manpower. PREPARATION : The following preparation is followed, in case the base frame and the packer plates ( equal to the number of foundation bolts ) are in scope of KSB. Otherwise, the user is requested to follow the preparation as under : l l The base frame is provided with the pads, which are welded at the bottom, machined in one setting and drilled to 15 mm. Dia. ( Ref. Fig. 1). Machined packer plates, having 0.02 mm. face parallality, and of the dimensions equal to the welded pads at the bottom of the base frame, are required with tapping of M 10. These packer plates are to be bolted with pads at the bottom of the base frame, using M10 bolts ( Ref. Fig. 2 & 3 ).
PROCEDURE : 01.Bolt the pump on the base frame. 02.Bolt the packer plates on the bottom pads of the base frame. 03.Place the unit on the foundation. 04.Suspend foundation bolts into the pockets provided on the foundation blocks. 05.Level the pump on the delivery flange or feet, within 0.04 mm. per meter, using jacking bolts pro vided at the corners of the base frame. 06.Grout the foundation bolts and the packer plates by using quick setting non-shrink cement, ACC make Shrinkkomp or Forsoc make Cobextra-GP2 or equivalent ( Ref. Fig. 4 ). 07.Allow curing time of 24 to 72 hours depending upon the grout used. 08.Remove M 10 bolts, which are holding packer plates with the base frame. 09.Carry out final levelling by inserting shims (SS shims preferred) between packer plates and the base frame. 10.Tighten the foundation bolts and recheck the levelling. Correct it, if necessary. 11. Grout the complete base frame, including the hollow portion, if any, using conventional grouting mix, i.e., portland cement, sand and aggregate in proportion 1 : 2 : 2 and gravel size not to exceed 20 mm. 12.Plaster the foundation and apply suitable oil resistant paint.
GEN 02.01 I
Base frame
Weld
M10
View from W
Fig. 2 : Packer plates in pairs, machined for for base frame with channel
M20 through for leveling Base frame
Fig. 2A : Packer plates in pairs, machined for base frame with double channel / I beam
15
Fig. 3 : Clamping of packer plate and bottom pads with M10 bolts
20 Base frame Levelling bolts Non shrink cement grout
30
Found block
GEN 02.01I
View from Z
M10 bolts
15
80 min.
1.5xd
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Making the piping
General information - The pipes are already mounted within the dimensions of base frame. - Straight length pipes are supplied for further connection of piping, if within the scope of KSB supply. Bends and flanges are supplied loose. - Offset at flanges and pipe connections is not allowed.
Caution Pipes made on the site must be cleaned prior to final mounting. ____________________________________________________________________________ Connecting the piping
General information - Run the pipes as indicated in the G. A. Drawing. - Do not remove the covers on the pump nozzles and the desiccants till the pipes are to be actually connected. Disposal by the consignee / Operator. - The nominal diameters of the pipes shall be at least equal to the pump connections. - It is recommended to fit check valves and isolating valves. - The thermal expansions of the pipes must be compensated by suitable measures in order not to transfer them on the pump. - The suction piping must be slanting towards the pump. - The weight of the suction piping must not transfer on the pump. - Under no circumstances the pump should be used as an anchorage point for the piping. ___________________________________________________________________________________________
Connect all the pipes in cold condition and without transmitting any stresses or strains. The unbalance of the forces and moments created by the suction / discharge piping must not exceed the permissible values. (Refer G. A. Drawing) ____________________________________________________________________________
Suction piping - Not the part of KSB scope of supply. - Clean the tank and pipe prior to fitting. Balancing liquid piping - The balancing liquid piping is connected back to the suction nozzle. - If the balancing liquid piping is connected back to the suction vessel (deaerator) the flow velocity in the balancing liquid piping should on no account exceed 5 m/s. The pressure of the balancing liquid must at least 0.5 bar higher than the suction pressure (at the pump suction nozzle), and the permissible damping pressure must not exceed 2.5 % of the maximum discharge pressure. Discharge piping - Not the part of KSB scope of supply. Flushing piping - The piping is already installed. Minimum flow system - On the discharge side of the pump, a minimum flow control valve is required. G. A. Drawing indicates whether it is in KSBs scope of supply. - Refer separate operating instructions for Minimum flow control valve.
Caution
Installation 3
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Minimum flow piping - Not the part of KSBs scope of supply. Return piping - For drain and leakage liquids, the Operator must fit a return piping. Connections and dimensions are specified in the G. A. drawing. Information about readiness for connection of the piping - Inform the responsible site management that the piping is ready for connection. - Do not continue the piping unless the required piping by the Operator is completed. Checking the alignment - Repeat the alignment of the coupling, after the completion of piping by the Operator. - Enter the final measuring results in the coordinate system of the alignment / acceptance record sheet of each connecting coupling. - Record the shaft displacements due to vertical and lateral misalignment of the pump set components under remarks. - Have the alignment/acceptance record sheet confirmed by the responsible site management and distribute it to the authorized persons. - Have the table of tightening torques for all fastening screws and foundation bolts checked and confirmed by responsible site management. Mounting the instruments General information - Measuring lines with isolation valves have been installed. - Do not remove the plugs of the connection points till the actual mounting. - Just before commissioning / start up perform the functional test. - Laying of electrical cables varies according to the constructional conditions. Cables must be layed in the conduits up to the points just near the actual measuring point. - Electrical cable connections must be done by authorized personnel. Mounting the pressure gauges - Insert the sealing disc. - Select the pressure gauge with sufficient measuring range. Mounting the oil sight gauge - Remove the plug and screw in the oil sight gauge with seal. - Attach required extension piece.
Installation 4
z Mounting
Fitting the coupling hubs Thoroughly clean shaft ends and bores of the coupling hubs and check them for dimensional accuracy. Slightly deburr the hub grooves and insert the key. Check the protrudent dimension of the key. Tolerance in accordance with the figure Clearance between groove and key.
In case of a cylindrical shaft with key, smear the shaft end and coupling hub end with an adequate antiseize agent. 0 - To facilitate fitting, the coupling hub may be heated evenly to a temperature of 80 C max. Elastomeric parts must be removed before heating! ___________________________________________________________________________________________ -
Caution
Do not use elastomers which have already been heated up once. Use new parts!
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Installation 5
0.2-0.3mm
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Use safety gloves. Risk of fire in case of open fire. Remove inflammable material ____________________________________________________________________________ Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft end and the hub face match. ___________________________________________________________________________________________
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.
Caution
Connecting the coupling hubs - Assemble the connecting coupling as described in manufacturers documentation. Dismantling Preparations - Make sure that the connecting coupling is marked or mark the connecting coupling in order to avoid subsequent confusions.
Installation 6
2. Preparations
-
Installation 8
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4. Alignment of coupling
General information - Align the coupling when the pump is cold (< 500 C/ 1220 F). - In case of motors with axial tolerance, their rotors must be set in the magnetic center. For this purpose, either set the rotor to the center marking made by the manufacturer (if any) or to the center position between right and left side. - Move the pump shaft towards the suction casing until the rotor abuts.
The coupling must not be turned at the alignment device. Do not damage the shaft and hubs. ___________________________________________________________________________
Caution
Installation 9
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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)
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Angular misalignment of the coupling hubs in horizontal direction - Permissible value : kh 0.04 mm kh = Angular misalignment of the coupling hubs in vertical direction - Permissible value : kv 0.04 mm kv = Smax Smin _________________ 2 Smax Smin _________________ 2
Smax.
Smin.
5. Alignment corrections
Vertical correction Pump :
Installation 10
Kr
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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 manufacturers documentation.
Installation 12
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Dismantling the coupling guard : - Remove the guard and store it appropriately.
Caution
_____________________________________________________________________________________ Mounting the cladding (touch guard) : - Fasten the cladding (touch guard) adequately with bolts at the bearing housing. Dismantling cladding (touch guard) : - Remove the guard and store it appropriately.
Installation 13
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Commissioning, Start-up/Shutdown
1. Work to be carried out prior to Commissioning, Start-up
_________________________________________________________________________ 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.
Caution
1.4
1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6
Additional Work to Be Carried out Prior to Returning to Service after Standstill > 12 Months
Dismantle the pump-end coupling hub. Dismantle the bearing. Dismantle the mechanical seal and check it in accordance with the manufacturers documentation. If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a new seal must be fitted. Re-mount the bearing and, in case of pump with plain bearings, lift the pump rotor. Re-mount the pump-end coupling hub.
1.5
1.5.1 General Information 1.5.1.1 Oil quality, refer Technical Appendix. 1.5.1.2 After standstill > 12 months, check the oil quality. Clean or replace the oil, if required. 1.5.1.3 Filter the oil prior to topping up; filter mesh size 30 m.
_______________________________________________________________________ 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
Caution
OIMPG COMM 31
________________________________________________________________________
1.5.2.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the minimum and maximum markings of the oil sight gauge (639). 1.5.2.2 Fit the vent plug (913.01 or 672) again. 1.5.3 Lift-off Device (if applicable) 1.5.3.1 Remove the vent plug (913.01 or 672) and fill in the oil through the opening until the oil level is between the minimum and maximum markings of the oil sight glass (642.01). 1.5.3.2 Fit the vent plug (913.01 or 672) again. 1.5.4 1.5.4.1 1.5.4.2 1.5.4.3 Bearing with Constant Level Oiler (if applicable) Remove the vent plug (913.01 or 672). Hinge down the constant level oiler (638). Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of the connecting elbow of the constant level oiler, see figure Constant level oiler. 1.5.4.4 Fill the reservoir of the constant level oiler with oil and snap it back into operating position. 1.5.4.5 Fit the vent plug (913.01 or 913.02 or 672) again. 1.5.4.6 After a short time check whether oil level in the reservoir has dropped. It is important to keep at least one third of the reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________
Caution
The oil level always be below the level of the vent opening arranged at the top edge of the connecting elbow. Make sure the opening is always perfectly dry.
Oil level
OIMPG COMM 32
_____________________________________________________________________
1.6.1 Prerequisites
1.6.1.1 1.6.1.2 1.6.1.3 Check the direction of rotation prior to the final assembly of the connecting coupling. Comply with the manufacturers documentation. The electric motor is provided with a lubricant.
1.6.2.2
OIMPG COMM 33
_____________________________________________________________________
1.6.4.5 In case of electric motors with axial float, if applicable, the coupling hub of motor shaft must be realigned as required by the actual magnetic center. If coupling has a spacer, it must be possible to mount and remove it.
1.7
1.7.1 1.7.2 1.7.3
1.7.4
OIMPG COMM 34
_____________________________________________________________________
_____________________________________________________________________________________
All measuring instruments supplied with the pump should be calibrated before commissioning of the pump set. _______________________________________________________________________
1.10.2 Set the Alarm & Trip values in accordance with the Logic Diagram, in cooperation with control engineering specialists. _____________________________________________________________________________________
Caution
The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for the pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________
Caution
2. Commissioning, Start-up
2.1 Prerequisites
2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 Installation and alignment have been performed in accordance with good engineering practice, recorded and accepted by the Operator. The pump rotors rotatability by hand has been checked. All pump set components have been checked in accordance with the relevant manufacturers documentation. The direction of rotation of the drive has been checked. All guards preventing accidental contact have been mounted. All pipes have been cleaned and connected. All instruments have been fitted and checked for correct functioning.
2.2 Priming
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 Close all drains and drain pipes. Fully open the cooling water main valve and all cooling water throttle valves. Vent the complete cooling water circuit. Vent the complete mechanical seal cooling circuit. Monitor the cooling water flow at the sight glasses or flow indicators. _____________________________________________________________________________________
Do not cool the cooling chamber and heat exchangers with aggressive untreated water. _______________________________________________________________________
2.2.6 2.2.7 2.2.8 If applicable, check the filter in the mechanical seals cooling circuit and clean, if required. Open the valves in the minimum flow line. Check the oil levels and top up with oil, if required. _____________________________________________________________________________________
Caution
During operation, the oil level in the bearing housing falls! Check the oil levels only during standstill of the pump! ______________________________________________________________________ Caution
2.2.9 2.2.10 2.2.11 2.2.12 2.2.13 If there is no bypass, open the gate valve in the suction piping by 10 to 20 %. Prime the suction piping, pump and discharge piping up to the closed discharge gate valve. Vent all pressure gauge lines until there is no more air to escape. Fully open the valve in the suction piping. Check whether suction pressure is available.
OIMPG COMM 35
_____________________________________________________________________
2.3 Checks Prior to Starting
2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.3.8 2.3.9 2.3.10 2.3.11 The suction tank, suction piping, pump and discharge piping have been primed and vented. The valve in the suction piping is fully open. The valve in the discharge piping is fully closed. The connection for tapping, if applicable, is closed. The shut-off valves in the stand-by heating system, if applicable, are closed. The shut-off valves in the minimum flow line are open. The cooling water system is in operation. The cooling liquid pressure at the inlet must not exceed 6 bar. The cooling liquid temperature at the outlet must not exceed 550 C. All temperatures indicated are below the limit values. In the case of a pump set with variable speed coupling, check the scoop tube position for compliance with the manufacturers 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 _______________________________________________________________________ Should alarm signals or problems occur during starting or trial run, proceed as described in chapter Trouble shooting! _______________________________________________________________________ _______________________________________________________________________ The minimum discharge head of 150 m must not be underrun, except the start-up and shutdown phases. The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for the pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________ Caution
2.4.1 Switch on the drive as described in the manufacturers 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). _____________________________________________________________________________________
Caution
OIMPG COMM 36
_____________________________________________________________________
2.4.9 Permanently monitor the pump sets 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. _____________________________________________________________________________________
Close the shut-off valves of the standby heating system only for maintenance work of the pump. _______________________________________________________________________
2.4.11 For mechanical seals with circulating cooling : If there is a magnetic separator, check after its commissioning/start-up whether the temperature of the circulation liquid remains constant.
Caution
3. Shutdown
3.1 Pump set remains ready for Operation
3.1.1 3.1.2 Close the valve in the discharge pipe. Make sure the minimum flow control vale works. _____________________________________________________________________________________
The minimum flow pipe gets hot. _______________________________________________________________________ _______________________________________________________________________ The minimum discharge head of 150 m must not be underrun, except in the start-up and shutdown phases. The pump should never be run below the speed of 1000 rpm, even during the starting process. The acceleration time from switch on (zero rpm) to 1000 rpm should be less than 10 seconds. Specific care is necessary for pumps with variable frequency drive & pumps with hydraulic coupling. _______________________________________________________________________
3.1.3 3.1.4 3.1.5 3.1.6 In the case of a pump set with variable speed coupling reduce the speed until the minimum head or minimum speed is reached. Switch off the drive, making sure it runs smoothly down to a standstill. Note the run down time. The cooling water remains on!
Caution
OIMPG COMM 37
_____________________________________________________________________
_______________________________________________________________________ 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 3.2.4 3.2.5 In the case of a pump set with variable speed coupling reduce the speed until the minimum head or minimum speed is reached. Switch off the drive, making sure it runs smoothly down to a standstill. Note the run down time. _____________________________________________________________________________________
Caution
4.1.2 Every 4 to 6 weeks 4.1.2.1 Put the pump into operation as described in Commissioning, Start-up section of this chapter. 4.1.2.2 Switch off the pump after approx. 10 minutes as described in Shutdown section of this chapter. 4.1.2.3 Check at the connecting coupling whether pump rotor runs down smoothly to a standstill. 4.1.3 Every two months (in the case of pump set with variable speed coupling) If the scoop tube actuator was used during stand-by operation, re-lubricate the guide bush; see the manufacturers documentation.
The pump has been depressurized and the casing temperature is < 500 C, measured at the pump nozzles!
______________________________________________________________
4.2.1 4.2.2 4.2.3 Secure all valves against opening. Open all drains and/or drain pipes. Collect the fill in an appropriate container and dispose off according to local anti-pollution regulations.
OIMPG COMM 38
_____________________________________________________________________
_____________________________________________________________________________________
If the medium handled is toxic, inflammable, explosive or hazardous in a different way, the pump must be flushed thoroughly to avoid that any residues remain in the pump.
____________________________________________________________
4.2.4 If the period of standstill is longer than 2 weeks, the pump set components such as gear or variable speed coupling must be protected against water ingress and humidity as described in the manufacturers preservation instructions. General information _____________________________________________________________________________________
In the case of dander of frost, the pump must be drained and preserved as described under Detailed Description of Preservation for Standstill in this chapter. _______________________________________________________________________
4.3.1.1 Secure all valves against opening. 4.3.1.2 Close all openings and supply pipes. 4.3.2 Standstill > 2 Weeks 4.3.2.1 Preserve the pump as described under Detailed Description of Preservation for Standstill in this chapter. 4.3.2.2 Protect the pump set components such as gear or variable speed coupling against water ingress and humidity as described in the manufacturers preservation instructions.
Caution
5.1 Secure all valves against opening. 5.2 Open all drain and/or drain pipes. 5.3 Collect the fill in an appropriate container and dispose of according to anti-pollution regulations. ________________________________________________________________________________________
If the medium handled is toxic, inflammable, explosive or hazardous in a different way, the pump must be flushed thoroughly to avoid that any residues remain in the pump. _________________________________________________________________________
5.4 Close all drains and/or drain pipes. 5.5 Fill the pump with glycol/water mixture at a proportion of 1 : 2. 0 Important : This mixture ensures protection against frost up to approx. 20 C. A mixture at a proportion of 1 : 1 increases the protection up to 420C. 5.6 Dismantle and store the coupling guards mounted on the pump set. 5.7 Dismantle and store the connecting coupling spacer in accordance with the manufacturers documentation. 5.8 If necessary, fill the bearing housing with oil. 5.9 Rotate the pump rotor once or twice a month to prevent a separation of the preservation fill, check the fill level and top up, if required.
OIMPG COMM 39
_____________________________________________________________________
Supervision of Rotor Position (only for the pumps with Balancing Disc)
The Rotor Position Indicator is mounted on the discharge side of the pump. There are two types of Rotor Position Indicators. The first and most commonly used by KSB India, consists of the indicator bush (623) screwed on the bearing end cover, which is the stationary part, and the rotating indicator (624) is screwed in the shaft threading. The bush has two scriber marks, at right angles to shaft axis, which are 1.5 mm apart. 1. If the balancing device is new, the position of the indicator (624) must be as shown in the figure Pump running normally. 2. In the case of maximum wear of the balancing device the position of the indicator (624) is as shown in the figure Time to shut down the pump. Pump running normally 623 624 623
OIMPG SUPERVISION 02
Point to be supervised
Pump Bearings : Plain
Supervisory action
Checking the temperature once a week Checking the oil level once a week (only for pumps with ring oil lubrication) Checking for smooth operation Once a week Checking the temperature once a week Checking for smooth operation Once a week Checking the temperature once a week Checking the oil level once a week Checking for smooth operation Once a week Checking the temperature once a week Checking for smooth operation Once a week Checking the rotor position once a week Checking the temperature once a week Checking the leakage once a week Checking the differential pressure Once a week Checking the differential pressure Once a week Checking the pressure once a week Checking the pressure once a week Checking the pressure once a week Checking the pressure once a week Checking the temperature once a week
Value to be met
< 90 C Middle between minimum and maximum marks The pump set shall run smooth and free from vibrations. 0 < 90 C The pump set shall run smooth and free from vibrations. < 90 C Middle of oil level sight glass The pump set shall run smooth and free from vibrations. 0 < 90 C The pump set shall run smooth and free from vibrations. See section Rotor Position in this chapter 0 80 C 15 drops per minute < 0.3 bar
0 0
(if applicable) Lift-off device with Tilting pads bearings (if applicable) Indicator (only for pumps with balancing disc) Mechanical seal (433) Differential pressure gauge Strainer I suction pipe (if applicable) Differential pressure gauge Duplex filter (if applicable) Measuring instrument, suction side ps (gauge holder ) (if applicable) Measuring instrument, discharge side pd (gauge holder ) (if applicable) Measuring instrument, tapping (gauge holder ) (if applicable) Measuring instrument, balancing water pE (gauge holder ) (if applicable) Thermometer (Suction nozzle/discharge nozzle) (if applicable) Thermometer (cooling water inlet) (if applicable ) Cooling water pipe (supply and return flow) (if applicable) Sight glass (cooling water inlet pipe) (if applicable) Oil pressure gauge (gauge holder) (if applicable) Level indicator (Oil supply system) (if applicable) Connecting coupling (only for coupling with pressure oil lubr.)
PE ps + 0.5 bar
Checking the temperature once a week Checking the temperature once a week Checking the cooling water flow once a week Checking the pressure once a week Checking the oil level once a week Checking for leakage once a week
45 C
0
t 10 C
0
Water is flowing
- 20 mm No leakage permitted
In case of deviations, proceed in accordance with the Cause Remedy specified under the chapter Trouble shooting. We recommend recording the information tabulated above in a logbook, in the form of enclosed LOG SHEET. OIMPG SUPERVISION 06
LOG SHEET
PUMP TYPE CUSTOMER ITEM NO. SERIAL NO.
NO.
1 2 3 4 5
DESCRIPTION
PRESSURE AT Suction nozzle Differential across suction strainer Discharge nozzle Balancing line Oil inlet to bearing (forced oil lubrication) 5.1 Suction side bearing 5.2 Discharge side bearing 5.3 Lift off / Thrust bearing TEMPERATURE AT Suction nozzle Discharge nozzle Balancing line Bearings Suction side Discharge side Lift off / Thrust Oil inlet to bearing (forced oil lubrication) Suction side Discharge side Lift off / Thrust Flushing liquid Shaft seal - Suction Shaft seal - Discharge Cooling Water Inlet / outlet Suction Discharge Lift off / Thrust ROTOR POSITION
UNIT
kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2
READING
6 7 8 9 9.1 9.2 9.3 10 10.1 10.2 10.3 11 11.1 11.2 11.3 11.4 11.4 12 13
Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C Deg C
VIBRATIONS AT 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 Suction side bearing housing Discharge side bearing housing Lift off / Thrust bearing housing Suction flange Discharge flange Suction side support foot Discharge side support foot Base Frame
RMS Velocity mm / s H V A
V = Vertical ;
A = Axial.
SIGNATURE OF OPERATOR
LOG SHEET B1
_____________________________________________________________________
Servicing
1. General Information
We recommend that KSBs specialist personnel be present during the servicing of the pump!
________________________________________________________________________________________
Improper handling of preservatives, oil and grease causes hazardous environmental impact. Handling and disposal only by qualified personnel! _________________________________________________________________________
1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc., please refer P & I Diagram. 1.2 Required documentation 1.2.1 The following documents are necessary for servicing of pump set. Sectional Drawing, Pump List of Components, Pump Documentation of the Mechanical Seal (if applicable) 1.2.2 Documentation of Connecting Coupling 1.2.3 Documentation of Drive 1.2.4 Documentation of the Minimum Flow System (if applicable) 1.2.5 Documentation of Valves and Equipment (if applicable) 1.2.6 Documentation of the Instrumentation (if applicable) 1.3 Prerequisites 1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown sections of chapter Commissioning, Start-up/Shutdown) and has been prepared for the servicing work. _____________________________________________________________________________________
Caution
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. In the case of problems and unusual operating conditions that represent electric or mechanical overloads, off-schedule servicing must be performed.
1.4.2
OIMPG SERVICING 01
_____________________________________________________________________
3. Pump Servicing Plan after Commissioning/Start-up and Stand-by Location to be serviced
Bearing (Ring oil lubricated)
Checks
Servicing Intervals
Servicing Work
(if applicable) Drive (if applicable) Instruments (if applicable) Pressure gauge (if applicable) Differential pressure gauge (if applicable) Temperature measuring instruments (if applicable) Vibration measurement (if applicable) Shaft positioning monitoring (if applicable) Inspection (axial thrust measurement) (if applicable)
Grease fill (if applicable) Checking the axial movability See manufacturers documentation Perfect condition and functioning Perfect condition and functioning Perfect condition and functioning Opening and closing points Perfect condition and functioning Switching points Perfect condition and functioning Perfect condition and functioning Perfect condition and functioning
First oil change after 300 operating hours Subsequent oil changes after 8000 operating hours, at least after 1 year First oil change after 300 operating hours Subsequent oil changes after 8000 operating hours, at least after 2 years See manufacturers documentation After approx. 8000 operating hours See manufacturers documentation See manufacturers documentation
See manufacturers documentation See manufacturers documentation See manufacturers documentation Replace defective equipment; see manufacturers documentation
In case of deviations, proceed in accordance with the (Cause Remedy specified under the chapter (Trouble shooting.
OIMPG SERVICING 02
The oil level must always be below the level of the vent opening arranged at the top edge of the connecting elbow. Make sure the opening is always dry. _______________________________________________________________________
Position of reservoir for topping up oil
Caution
Oil level
OIMPG SERVICING 03
_____________________________________________________________________
4.2 Re-lubrication
4.2.1 General Information 4.2.1.1 Oil quantity and quality, see Technical Appendix. 4.2.1.2 Filter the oil prior to topping up; filter mesh size 30m. _____________________________________________________________________________________
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
Caution
4.2.1.1 4.2.1.2 4.2.2 4.2.3.1 4.2.3.2 4.2.3.3
The oil level may drop during start-up of the pump. If the minimum mark is underrun, top up with oil.
_____________________________________________________________________________________ Remove the vent plug (913.01 or 672) and fill in oil through the opening until the oil level is between the minimum and maximum markings of the oil sight gauge (639). Fit the vent plug (913.01 or 672) back again. Bearing with Constant Level Oiler Remove the vent plug (913.01 or 913.02 or 672). Hinge down the constant level oiler (638). Pour in the oil through the vent plug tapping hole after having hinged down the reservoir of the constant level oiler until oil appears in the vertical portion of connecting elbow of the constant level oiler, see figure Constant level oiler. Fill the reservoir of the constant level oiler with oil and snap it back into operating position. Fit the vent plug (913.01 or 913.02 or 672) back again. After a short time check whether the oil level in the reservoir has dropped. It is important to keep at least one third of reservoir filled at all times. If the oil level is underrun, top up with oil. _____________________________________________________________________________________
Caution The oil level must always be below the level of the vent opening arranged at the top of the connection elbow. Make sure the opening is always perfectly dry. _______________________________________________________________________
Position of reservoir for topping up oil
Oil level
Constant level oiler 4.2.4 4.3 4.3.1 4.3.2 Other Pump Set Components Top up with oil in accordance with the manufacturers documentation. Connecting Coupling (if applicable) Perform all dismantling and reassembly work in accordance with the Dismantling of the Connecting Coupling and Mounting the Connecting Coupling in chapter Maintenance. Perform all servicing work in accordance with the manufacturers documentation.
OIMPG SERVICING 04
_____________________________________________________________________
Maintenance
1. General Information
________________________________________________________________________________________
During the warranty period, pumps should be dismantled only by KSB personnel! _________________________________________________________________________
1.1 For exact description of the pump as well as scope of supply of accessories & instrumentation etc., please refer P & I Diagram. 1.2 Required documentation 1.2.1 The following documents are necessary for servicing of pump set. Sectional Drawing, Pump List of Components, Pump Documentation of the Mechanical Seal (if applicable) 1.2.2 Documentation of Connecting Coupling 1.2.3 Documentation of Drive 1.2.4 Documentation of the Minimum Flow System (if applicable) 1.2.5 Documentation of Valves and Equipment (if applicable) 1.2.6 Documentation of the Instrumentation (if applicable) 1.3 Prerequisites 1.3.1 The pump set has been taken out of service in accordance with Shutdown and Work after Shutdown sections of chapter Commissioning, Start-up/Shutdown) and has been prepared for the servicing work. 1.3.2 All spare parts required are available. 1.3.3 Proper hoisting tackle and means of transport are available and ready for use. 1.3.4 Sufficient room space and appropriate tools are available. 1.3.5 The drive has been secured against unintentional starting.
Caution
Caution Do not damage the seal elements and sealing surfaces! _________________________________________________________________________
OIMPG MAINTENANCE 01
_____________________________________________________________________
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 Remove all pipes on the cover. Remove the taper pins and screw of the cover split joint. Use the eye bolt as transport aid as shown in the figure Coupling cover. Unscrew the screws in the upper part of the flange. Remove the upper half of the coupling cover. Remove the internal injection lines. Disconnect the lower half of the coupling cover from the flange and store it.
3.1.2
Dismantle the connecting coupling spacer as described in the manufacturers documentation. ____________________________________________________________________________________
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! _____________________________________________________________________________________
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.
Caution
OIMPG MAINTENANCE 02
_____________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________ _____________________________________________________________________________________
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. _______________________________________________________________________
Caution
3.2.6 3.2.7
Mark the keys prior to removing them. Store the coupling hubs and keys appropriately.
OIMPG MAINTENANCE 03
_____________________________________________________________________
_____________________________________________________________________________________
!
4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.1.7
Operating fluids can run out when unscrewing the pipes and instruments. These are to be collected and properly disposed of by the Operator.
_____________________________________________________________________________________ Undo the connections between discharge nozzle and discharge pipe & between suction nozzle and suction pipe. Fasten the suction and discharge pipes to temporary holders. Dismantle the minimum flow control valve, if necessary. Disconnect the tapping pipe, if applicable. Detach and dismantle any auxiliary lines such as circulation, cooling liquid and oil pipes as well as measuring lines as far as necessary. Dismantle the measuring devices and instruments as far as necessary, and store them appropriately. If required, dismantle the cooler of the shaft seal including support.
4.2
4.2.1
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.
OIMPG MAINTENANCE 04
_____________________________________________________________________
4.3 Transporting the Pump to the Place of Dismantling
_______________________________________________________________________________________
Caution
The pumps have to be lifted and transported in accordance with the guidelines laid down in the chapter Transport / Interim Storage. Do not fasten the ropes to the shaft ends or the bearing housings.
_______________________________________________________________________________________ 4.3.1 Lift the pump from the baseframe, transport it to the place of dismantling and set it down on assembly supports. _____________________________________________________________________________________
_____________________________________________________________________________________ _____________________________________________________________________________________
Mark the matching shims between the pump feet and baseframe so that they can be inserted in the same place on subsequent reassembly, and store them appropriately. _______________________________________________________________________ Caution
OIMPG MAINTENANCE 05
5.2 Dismantling the Add-on Parts (for example flanged-on oil pump, shaft position indicator, etc.) (if applicable)
5.2.1 For applicable add-on parts, refer Sectional Drawing and P&I Diagram.
5.3 Dismantling the Lift-off Device, with Antifriction Bearings (if applicable)
5.3.1 5.3.2 5.3.3 Unscrew the hex nut (920.08) and remove the bearing end cover (361) including O-ring (412.11). Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03). Pull the bearing cartridge (381) including the two angular 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 5.3.5 5.3.6 5.3.7 _____________________________________________________________________________________ Take the springs out of the thrust bearing housing (354). Take away the thrust bearing housing (354) including O-ring (412.10). If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08). Remove the spacer ring (504.01) from the shaft (210).
5.4 Dismantling the Lift-off Device with Tilting-pad Thrust Bearing (if applicable)\
5.4.1 5.4.2 5.4.3 Unscrew the hex nuts (920.08) and remove the bearing end cover (361) including O-ring (412.11). Unscrew the shaft nut (920.09) and loosen the hex socket head cap screw (914.03). Pull the bearing cartridge (381) including the thrust bearing, thrust bearing plate (384) and counter thrust bearing plate (388) out of the thrust bearing housing (354) using the appropriate device as described in the work instruction UA3 13473 01. Dismantle further, if required. _____________________________________________________________________________________
In case of slight discolourations (incl. rust stain) or any damage, the bearing segments must be replaced! _______________________________________________________________________
5.4.4 5.4.5 5.4.6 5.4.7 Take the springs out of the thrust bearing housing (354). Take away the thrust bearing housing (354) including O-ring (412.10). If applicable, take away the spacer ring (504.03) including O-ring (412.09) and remove the studs (902.08). Take away the key out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210).
Caution
OIMPG MAINTENANCE 06
_____________________________________________________________________
5.5.4 5.5.5 5.5.6 5.5.7 5.5.8 Remove the thrust bearing plate (384) from the shaft (210) using the appropriate device as described in the work instruction UA3 13475 01 or UA3 14758 01. Take the key (940.05) out of the shaft keyway and remove the spacer ring (504.01) from the shaft (210). Unscrew two opposite hex socket head cap screws between the segments of the thrust bearing (314) and remove them together with the adjoining segments. Pull the thrust bearing (314) out of the thrust bearing housing (354) using the appropriate device as described in the work instruction UA3 13475 01 or UA3 14758 01. Unscrew the hex socket head cap screws (614.04) and take the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01) circlip (932.03) and O-ring (412.10) out of the bearing housing (350.01). _____________________________________________________________________________________
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
Caution
Mark the bearing shells to ensure their correct assignment to the bearing housings! Protect the bearing shells against damage!
_____________________________________________________________________________________ _____________________________________________________________________________________
In the case of slight discolourations (incl. rust stain) or any damage, the bearing segments must be replaced! _______________________________________________________________________
5.6.1 HG Pump Sizes 1 and 2 5.6.1.1 Unscrew the hex head bolts (901.01 and 901.03) and remove the bearing cover (360) and bearing end cover (361) including O-ring (412.09). 5.6.1.2 Remove the pins (560.01) including washers (550.07) and nuts (920.07) as well as hex socket head cap screw (914.05) including circlips (932.05) and take away the upper part of the bearing housing (350.01) including the upper half of labyrinth ring (423.01). 5.6.1.3 Remove the upper bearing shell (370) and lubricating ring (644, if applicable). 5.6.1.4 Remove the lower half of labyrinth ring (423.01) and lower bearing shell (370); for that purpose lift the shaft (210) using a wooden rod. 5.6.2 HG pump sizes 3 to 6 5.6.2.1 Unscrew the hex head bolts (901.01 and 901.06) and remove the bearing cover (360) and bearing end cover (361) including O-ring (412.09). 5.6.2.2 Remove the hex head bolt (901.13) including washers (550.12) and gasket (411.03). 5.6.2.3 If applicable, undo the grub screw (904.06) and dismantle the lubricating ring (644). 5.6.2.4 Remove the bearing shell (370) and glued-in labyrinth ring (423.01) and O-ring (412.18) from the shaft, using the appropriate device as described in the work instruction UA7 23062 01.
Caution
OIMPG MAINTENANCE 07
_____________________________________________________________________
5.7 Dismantling the Bearing Housings
5.7.1 HG Pump Sizes 1 and 2 5.7.1.1 Remove the hex head bolts (901.05) and nuts (920.14). 5.7.1.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing housing (350.01). 5.7.1.3 Remove the splash ring (507.01 or 507.02) from the shaft (210). 5.7.2 HG Pump Size 3 5.7.2.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts (921.14). 5.7.2.2 Unscrew the nuts (920.04 and 920.05) at the studs (902.01 and 902.05) and take away the bearing housing (350.01). 5.7.2.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws (904.05, if applicable). 5.7.3 HG Pump Sizes 4 to 6. 5.7.3.1 Remove the hex head bolts (901.05) as well as pins (560.02) including washers ( 550.13) and nuts (921.14). 5.7.3.2 Unscrew the nuts (920.04) at the studs (902.01) and take away the bearing housing (350.01). 5.7.3.3 Remove the splash ring (507.01 or 507.02) from the shaft (210) after loosening the grub screws (904.05, if applicable).
OIMPG MAINTENANCE 08
Caution
Refer order specific sectional drawing of mechanical seal for correct part numbers as well as description! Refer Manufacturers documentation!
_______________________________________________________________________________________ 6.2.1 Make : Eagle Poonawalla 6.2.1.1 Shaft Seal 6.2.1.1.1 Loosen the hex bolt (14) and locate the sliding washer (13) into the groove provided on the sleeve (6) and tighten the hex bolt (14). 6.2.1.1.2 Loosen socket screws (12) and dog point screws (17). 6.2.1.1.3 Unscrew and remove fixing screws of gland plate (4). 6.2.1.1.4 With the help of jacking bolts, provision made on gland plate (4), remove cartridge off the shaft (210). Follow the same procedure to pull out the mechanical seal cartridge on the discharge side. 6.2.1.2 Dismantling of Cartridge (if required). 6.2.1.2.1 Remove hex bolt (14) and sliding washer (13). For removing sliding washers, slightly compress the springs (e) of the mechanical seal. 6.2.1.2.2 Remove socket screws (12) and dog point screw (17) from the drive collar (11). 6.2.1.2.3 Remove drive collar (11) from the sleeve (6). 6.2.1.2.4 Remove the mechanical seal rotary head assembly consisting of components a,b,c,d,e,f. _____________________________________________________________________________________
Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical seal components should be replaced by new ones. _______________________________________________________________________
_____________________________________________________________________________________
Caution
Caution
In the event of slight scoring marks on the rubbing faces of seal ring (b) and mating ring (2), they can be sent back to the manufacturer for touching up.
_____________________________________________________________________________________ 6.2.2 Make : Flowserve Sanmar 6.2.2.1 Shaft Seal 6.2.2.1.1 Loosen the cap screw (K) and locate retaining plate (15) into the groove provided on the sleeve (10) and tighten the cap screw (K). 6.2.2.1.2 Loosen set screws (13) of sleeve collar (9). 6.2.2.1.3 Unscrew and remove fixing screws of gland ring (1). 6.2.2.1.4 With the help of jacking bolts, provision made on gland ring (1), remove cartridge off the shaft (210). Follow the same procedure to pull out the mechanical seal cartridge on the discharge side. 6.2.2.2 Dismantling of Cartridge (if required). 6.2.2.2.1 Remove cap screw (K) and retaining plate (15). For removing retaining plate, slightly compress the springs (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.
OIMPG MAINTENANCE 13
_____________________________________________________________________
_____________________________________________________________________________________
Damaged sleeve (6), seal ring (b), mating ring (2) and other mechanical seal components should be replaced by new ones. _______________________________________________________________________
_____________________________________________________________________________________
Caution
Caution
In the event of slight scoring marks on the rubbing faces of seal ring (b) and mating ring (2), they can be sent back to the manufacturer for touching up.
____________________________________________________________________________________________ 6.2.3 Make : Burgmann 6.2.3.1 Shaft Seal 6.2.3.1.1 Loosen the hex bolt (15) and locate the assembly fixture (14) into the groove provided on the sleeve (6) and tighten the hex bolt (15). 6.2.3.1.2 Loosen set screws (13) of clamping ring (11). 6.2.3.1.3 Unscrew and remove fixing screws of gland (4). 6.2.3.1.4 With the help of jacking bolts, provision made on gland (4), remove cartridge off the shaft (210). Follow the same procedure to pull out the mechanical seal cartridge on the discharge side. 6.2.3.2 Dismantling of Cartridge (if required). 6.2.3.2.1 Remove hex bolt (15) and assembly fixture (14). For removing assembly fixture, slightly compress the springs (1.4) of the mechanical seal. 6.2.3.2.2 Remove set screws (12) and (13) from the clamping ring (11). 6.2.3.2.3 Remove clamping ring (11) from the sleeve (6). 6.2.3.2.4 Remove the mechanical seal rotary head assembly consisting of components 1.1,1.2,1.3,1.4,1.5,1.6. _____________________________________________________________________________________
Damaged sleeve (6), seal face (1.1), seat (2) and other mechanical seal components should be replaced by new ones. _______________________________________________________________________
_____________________________________________________________________________________
Caution
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.
______________________________________________________________________________________________
OIMPG MAINTENANCE 14
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.
_________________________________________________________________________________________________
OIMPG MAINTENANCE 26
_____________________________________________________________________
7.5.1 Place the dial gauge holder on a firm base (for example flange or discharge nozzle) and position the dial gauge on the seat of the balancing piston as shown in the figure Measuring the approximate radial clearance. Carefully lift the shaft until it abuts on the top. Shaft deflection must not be increased (incorrect measurement). The diametrical clearance determined this way must not exceed 0.8 mm; if it does, the pump must be dismantled and overhauled.
7.5.2 7.5.3
HG Pump Sizes 4 - 6
Caution
8.2 8.3 8.4 8.5
________________________________________________________________________________________ If required, remove any lime and incrustation from the cooling chambers. Check all dismantled components for signs of damage. If required, use new parts. As a general rule, always use new O-rings and gaskets for reassembly. ________________________________________________________________________________________
Do not take the O-rings out of their original packing until those are actually required to be fitted and protect them from mineral oil and grease! _________________________________________________________________________ _________________________________________________________________________ Do not fit the O-rings in dry condition but wet them with silicone grease! In Caution exceptional cases, soapy water may be used. ________________________________________________________________________
8.6 Prior to reassembly coat the screw/bolt connections and pipe unions as well as the fits of the individual components using respective specified lubricating agent as described in the work instruction UA4 28699 01. 8.7 Reassembly must be performed in accordance with the rules of good engineering practice.
Caution
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 counter balancing disc (602.02) were remachined or replaced. 9.1 HG Pump Sizes 1 and 2
9.1.1 9.1.2 Meticulously clean the axial running face of the counter balancing disc (602.02). Insert the grooved pin (561.03) in the discharge casing (107).
OIMPG MAINTENANCE 27
_____________________________________________________________________
9.1.3 9.1.4 Fit the counter balancing disc (602.02) without O-rings (412.04 and/or 412.05). The grooved pin (561.03) must engage in the groove of the counter balancing disc (602.02). Adjust the pump rotor position; see figure Adjusting pump rotor position.
5 0 2 .0 2 1 7 1 .0 2
2 3 0 .0 2
S a 1 S a 2 A d ju s tin g t h e p u m p r o t o r p o s itio n
9.1.4.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the nondriven end. _____________________________________________________________________________________
Caution
This rotor position must not be changed when measuring the balancing device!
_____________________________________________________________________________________ 9.1.5 Adjust the balancing disc (601.01); see figure Adapting the balancing piston.
b1
Sl2
a1
Machine here
602.01
504.02
601.01
9.1.5.1 Measure the distance a1 from the running face of the counter balancing disc (602.01) to the impeller of the last stage. 9.1.5.2 Shorten the balancing disc (601.01) to the dimension b1 as sown in the figure Adapting the balancing disc: b1 = a1 SL2 (SL2, see table of clearances). 9.1.6 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.
OIMPG MAINTENANCE 28
_____________________________________________________________________
x a b a y x b
504.02
601.01 602.01
504.02 525.02
601.01 602.01
Adjusting the spacer ring 9.1.6.1 Measure the distance x from the running face of the counter balancing disc (602.01) to the shaft collar. 9.1.6.2 Determine the dimension b between the running face and face of balancing disc (601.01) as well as the length y of the spacer sleeve (525.02, if applicable). 9.1.6.3 Shorten the spacer ring (504.02) to the dimension a : a = x b or a = x - b-y. The maximum permissible deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________
Caution As a general rule, always use a new spacer ring (504.02)! _______________________________________________________________________
9.1.7 9.1.8 9.1.9 9.1.10 9.1.11 9.1.12 9.1.13 9.1.14 9.1.15 9.1.16 Insert the key (940.04). Coat the axial running face of the balancing disc (601.01) thinly with the contact fluid and slide the balancing piston (601.01) without O-ring (412.02) on the shaft (210). Slide the spacer sleeve (525.02, if applicable) and spacer ring (504.02) over the shaft (210) Mount the casing part (130, if applicable) and seal casing (441) without O-rings. Mount the shaft sleeve (524.01, pump with gland packings). Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section so far as to make the free rotation of the pump rotor possible. For the check with the contact fluid engineers blue, move the rotor towards the driven end and turn it slowly. Move the pump rotor to the non-driven end and dismantle all pump components including the counter balancing disc (602.01) in reverse order. At least 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 a lathe and repeat the contact fluid checks. 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
9.2.1 9.2.2 9.2.3 9.2.4 9.2.5
HG Pump Size 3
Meticulously clean the axial running face of the counter balancing disc (602.02). Insert the grooved pin (561.03) in the discharge casing (107). Fit the counter balancing disc (602.01) without O-rings (412.04 or 412.05). The grooved pin (561.03) must engage in the groove of the counter balancing disc (602.01). If applicable, slide throttle sleeve (522.01) without O-ring (412.02) over the shaft (210) and hey (940.03) until abutting against the impeller (230.02). Adjust the pump rotor position; see figure Adjusting the pump rotor position.
OIMPG MAINTENANCE 29
_____________________________________________________________________
5 0 2 .0 2 1 7 1 .0 2
2 3 0 .0 2
S a 1 S a 2 A d ju s tin g t h e p u m p r o t o r p o s itio n
9.2.5.1 Move the pump rotor in the direction of the driven end until it abuts and then move it 3 mm back to the nondriven end. _____________________________________________________________________________________
The rotor position must not be changed when the measuring the balancing device! _______________________________________________________________________ 9.2.6 Adapt the throttle sleeve (522.01) and/or balancing disc (601.01); see figure Adapting the throttle sleeve or
figure Adjusting the balancing disc.
Caution
Machine here
602.01
601.01
522.01
Machine here
602.01
601.01
OIMPG MAINTENANCE 30
_____________________________________________________________________
9.2.6.1 Measure the distance a1 from the running face of the counter balancing disc (602.01) to the impeller of the last stage and, if required, the dimension c1 of the balancing disc (601.01). 9.2.6.2 Shorten the throttle sleeve (522.01) to the dimension b1 in accordance with the figure Adapting the throttle sleeve and/or the balancing disc (601.01) in accordance with the figure Adapting the balancing disc : b1 = a1 c1 Sl2 or b1 = a1 Sl 2 (Sl2 see tables of clearances). 9.2.7 Adapt the spacer ring (504.2) or spacer sleeve (525.02); see figure Adapting the spacer ring or see figure Adapting the spacer sleeve.
504.02
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. _____________________________________________________________________________________
As a general rule, always use a new spacer ring (504.02)or spacer sleeve (525.02)! _______________________________________________________________________
9.2.8 9.2.9 9.2.10 9.2.11 9.2.12 9.2.13 9.2.14 9.2.15 9.2.16 Insert the key (940.04). 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). Slide the spacer ring (504.02) or spacer sleeve (525.02, if applicable) over the shaft (210). Insert the key (940.07) and split ring (501.01) into the shaft groove, slide the retainer ring (505.01) over them. Mount the casing part (130, if applicable) and seal casing (441) without O-rings. Fit the driven-end and non-driven end bearings in accordance with the Mounting the Bearings section, so far as to make possible the free rotation of the pump rotor. For the check with contact fluid engineers blue, move the rotor towards the driven end and turn it slowly. Move the pump rotor to the non-driven end and dismantle all components including the counter balancing disc (602.01) in reverse order. At least 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 a lathe and repeat the contact fluid check. After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and counter balancing disc (602.01).
Caution
9.2.17
9.3
9.3.1
HG Pump Size 4
Meticulously clean the axial running face of counter balancing disc (602.01).
OIMPG MAINTENANCE 31
_____________________________________________________________________
9.3.6.1 Shorten the throttle sleeve (522.01) to the dimension b1 in accordance with the figure Adapting the throttle sleeve : b1 = a1 c1 - Sl2 (Sl2 see table of clearances). 9.3.7 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.
x b
504.02
601.01 602.01
522.01
9.3.7.1 Measure the distance x from the running face of the counter balancing disc (602.01) to the split ring (501.01). 9.3.7.2 Determine the dimension b between the running face and face of the balancing disc (601.01). 9.3.7.3 Shorten the spacer ring (504.02) to the dimension a : a = x b. The maximum permissible deviation from plane parallelism is 0.02 mm. _____________________________________________________________________________________
Caution As a general rule, always use a new spacer ring (504.02)! _______________________________________________________________________
9.3.8 9.3.9 9.3.10 9.3.11 9.3.12 9.3.13 9.3.14 9.3.15 9.3.16 Insert the key (940.04). 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). Slide the spacer ring (504.02) over the shaft (210). Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the balancing disc (601.01), using hex socket head cap screws (914.10). Mount the casing part (130) and seal casing (441) without O-rings. Fit the driven-end and non-driven end bearings in accordance with the Mounting the bearings section, so far as to make possible the free rotation of the pump rotor. For the check with contact fluid engineers blue, move the rotor towards the driven end and turn it slowly. Move the pump rotor to the non-driven end and dismantle all components including the counter balancing disc (602.01) in reverse order. At least of the axial running face of the counter balancing disc (602.02) must have a uniform print of the contact fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.01) on a lathe and repeat the contact fluid check. After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and counter balancing disc (602.01).
9.3.17
9.4.4
OIMPG MAINTENANCE 33
_____________________________________________________________________
9.4.5 9.4.6 Fit the counter balancing disc (602.01) without O-ring (412.16) and fasten with the hex socket cap screws (914.06). The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01). Place the pump rotor in the center of the overall axial clearance ( Sa1 + Sa2); see figure Adjusting the pump rotor position. 502.02 230.02 171.02
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.
Caution
c1 a1
b1
Sl2
Machine here
602.01
542.01
504.02
601.01
522.01
OIMPG MAINTENANCE 34
_____________________________________________________________________
9.4.7.1 Measure the distance a1 from the running face of the counter balancing disc (602.01) to the impeller of last stage and the dimension c1 of the balancing disc (601.01). 9.4.7.2 Shorten the throttle sleeve (522.01) to the dimension b1 in accordance with the figure Adapting the throttle sleeve : b1 = a1 c1 - Sl2 (Sl2 see table of clearances). 9.4.8 Adapt the spacer ring (504.02); see figure Adapting the spacer ring.
x b
504.02
601.01 602.01
522.01 542.01
Caution As a general rule, always use a new spacer ring (504.02)! _______________________________________________________________________
9.4.9 Insert the key (940.04). 9.4.10 Coat the axial running face of balancing disc (601.01) thinly with the 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 far as to make possible the free rotation of the pump rotor. 9.4.15 For the check with contact fluid engineers blue, move the rotor towards the driven end and turn it slowly. 9.4.16 Move the pump rotor to the non-driven end and dismantle all components including the counter balancing disc (602.01) in reverse order. 9.4.17 At least of the axial running face of the counter balancing disc (602.02) must have a uniform print of the contact fluid in the upper zone. If this is not the case, remachine the counter balancing disc (602.01) on a lathe and repeat the contact fluid check. 9.4.18 After completion of the contact fluid check clean the axial running faces of balancing disc (601.01) and counter balancing disc (602.01).
OIMPG MAINTENANCE 35
Caution
If the throttle sleeve (522.01), balancing disc (601.01) or counter balancing disc (602.01) were remachined or replaced, the check with the contact fluid engineers blue as outlined in sections 9.1 to 9.4 must be performed!
_____________________________________________________________________________________
502.02 171.02
230.02
3mm
OIMPG MAINTENANCE 36
_____________________________________________________________________
502.02 171.02 230.02
3mm
10.3
HG Pump Size 4
10.3.1 Insert the parallel pin (562.03) in the discharge casing (107). 10.3.2 Fit the counter balancing disc (602.01) including O-rings (412.04 and/or 412.05) and fasten with the hex socket head cap screws (914.06); tightening torque, see the relevant work instruction. The parallel pin (562.03) must engage in the groove of the counter balancing disc (602.01). 10.3.3 Insert the key (940.04) and slide the throttle sleeve (522.01) including O-ring (412.02) over the shaft (210) and key (940.04) until it abuts against the impeller (230.02). 10.3.4 Place the pump rotor in the center of the overall axial clearance (Sa1 + Sa2); see figure Adjusting the pump rotor position. 10.3.5 Insert the key (940.04).
OIMPG MAINTENANCE 37
OIMPG MAINTENANCE 38
10.4.7 Place the O-ring (412.02) in the groove of the balancing disc (601.01) and slide the balancing disc (601.01) over the shaft (210) until it abuts against the counter balancing disc (602.01). 10.4.8 Slide the spacer ring (504.02) over the shaft (210). 10.4.9 Insert the split ring (501.01) in the shaft groove, slide the retainer ring (505.01) over them and fasten to the balancing disc (601.01) using the hex socket head cap screws (914.10); tightening torque, see relevant work instruction. 10.4.10 Insert the key (940.07) and slide the spacer sleeve (525.02) over the shaft (210) until it abuts.
OIMPG MAINTENANCE 39
Caution
Refer order specific sectional drawing of mechanical seal for correct part numbers as well as description. Refer manufacturers documentation.
_______________________________________________________________________________________ 11.2.1 Make : Eagle Poonawalla 11.2.1.1 Slide mechanical seal cartridge [attached to gland plate (4)] on the shaft until the gland plate (4) gets located on seal casing (441). 11.2.1.2 Tighten the nuts of gland plate. 11.2.1.3 Tighten set screws (12 and 17) of drive collar (11). 11.2.1.4 Loosen the bolt (14) and take aside the sliding washer (13) from the groove of the sleeve (6). 11.2.1.5 Slip splash ring (507) onto the shaft. 11.2.2 Make : Flowserve Sanmar 11.2.2.1 Slide mechanical seal cartridge [attached to gland ring (1)] on the shaft until the gland ring (1) gets located on seal casing (441). 11.2.2.2 Tighten the nuts of gland plate. 11.2.2.3 Tighten set screws (13) of sleeve collar (9). 11.2.2.4 Loosen the cap screw (K) and take aside the retaining plate (15) from the groove of the sleeve (10). 11.2.2.5 Slip splash ring (507) onto the shaft. 11.2.3 Make : Burgmann 11.2.3.1 Slide mechanical seal cartridge [attached to gland (4)] on the shaft until the gland (4) gets located on seal casing (441). 11.2.3.2 Tighten the nuts of gland. 11.2.3.3 Tighten set screws (13) of clamping ring (11). 11.2.3.4 Loosen the hex bolt (15) and take aside the assembly fixture (14) from the groove of the sleeve (6). 11.2.3.5 Slip splash ring (507) onto the shaft.
OIMPG MAINTENANCE 40
Caution When the bearing shells and labyrinth rings are dismantled the shaft must not rest on the bearing housing! _______________________________________________________________________
12.1.1.7 On the driven and non driven ends insert the lower bearing shells (370) and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting the bearing shells (370), lift the shaft (210) using a wooden rod. 12.1.1.8 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head bolts (901.05). _____________________________________________________________________________________
Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________
In order to check the measured values, remove the bearing shells (370) and insert them again. The measured values must be reached again. Enter the lifting values in the check data sheet. 12.1.1.10 The bearing housings (350.01) are aligned laterally by means of the horizontally fitted hex head bolts (901.05). The exact lateral alignment has been achieved when the lower bearing shells (370) can be placed easily from either side in their fits between shaft (210) and bearing housing (350.01). ____________________________________________________________________________________ 12.1.1.9
Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________________
12.1.1.11 After having completed rotor lifting, lock the hex head bolts (901.05) with nuts (920.14) and tighten the hex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction.
12.1.2 HG Pump Sizes 3 to 6 12.1.2.1 Slide the splash ring (507.01 and/or 507.02) over the shaft (210). 12.1.2.2 Mount the bearing housing (350.01) without bearing shells (370) and labyrinth ring (423.01) and tighten the hex nuts (920.04 and/or 920.05) till it is possible to just move the bearing housing. 12.1.2.3 Fit the dial gauges to the driven and non driven ends of the shaft (210) as described in the work instruction UA7 23062 01. 12.1.2.4 The lifting values (only approximate values) are stamped on the bearing housings and marked with Lift up. They refer to the shaft position with dismantled bearings. If the overall clearance of the pump rotor has increased within the permissible limits, half the clearance increase must be added to the lifting values.
OIMPG MAINTENANCE 43
_____________________________________________________________________
_____________________________________________________________________________________
Caution When the bearing shells and labyrinth rings are dismantled the shaft must not rest on the bearing housing! _______________________________________________________________________
12.1.2.5 On the driven and non driven ends insert the half ring (tool 969.85) in accordance with the work instruction UA7 23.062 01and read the vertical pump rotor displacement at the dial gauges. To facilitate inserting of the half rings (tool 969.85), lift the shaft (210) using wooden rod. 12.1.2.6 Adjust the lifting values stamped on the bearing housing and/or calculated, by means of the hex head bolts (901.05). _____________________________________________________________________________________
Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________
12.1.2.7 In order to check the measured values, remove half rings (969.85) and insert them again. The measured values must be reached again. Enter the lifting values in the check data sheet. 12.1.2.8 Check the position of the shaft in relation to the bearing housing by means of the instrument holder (699.71) and fitted measuring instrument (690) and adjust the position, if required, by means of the hex bolts (901.05); see work instruction UA7 23062 01. ____________________________________________________________________________________
Caution This adjustment may only be effected by trained specialist personnel! _______________________________________________________________________________
12.1.2.9 After having completed rotor lifting, tighten hex nuts (920.04 and/or 920.05) uniformly; tightening torque, see the relevant work instruction; and fix the bearing housing (350.01) with the taper pins (560.02); if necessary, drill out and ream the holes. Position the splash ring (507.01 and/or 507.02) and tighten the grub screws (904.05, if applicable).
12.2
Caution
When mounting the bearings, the holes for thermometers in the bearing shells and the associated thermometer connections in the bearing housings must be aligned!
_____________________________________________________________________________________ 12.2.1 HG Pump Sizes 1 and 2 12.2.1.1 Turn the lower bearing shells (370) and lower labyrinth ring half (423.01) in the bearing housing bottom part (350.01); for that purpose lift the shaft (210) using a wooden rod. 12.2.1.2 Fit the lubricating ring (644, if applicable) and the upper bearing shell (370) including parallel pin (562.01). 12.2.1.3 Place the upper labyrinth ring half (423.01) including the parallel pin (562.10) in the bearing housing top part (350.01). 12.2.1.4 Mount the bearing housing top part (350.01) including the upper labyrinth ring half (423.01) and fix with the taper pins (560.01). The parallel pin (560.01) must engage in the groove of the bearing housing top part (350.01). 12.2.1.5 Fit the hex socket head cap screws (914.05) including circlips (932.05) and tighten them uniformly; tightening torque, see the relevant work instruction. 12.2.1.6 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten the hex head bolts (901.01 or 901.03) uniformly; tightening torque, see the relevant work instruction.
OIMPG MAINTENANCE 44
_____________________________________________________________________
Additional Work for Pumps with Balancing Disc : 12.2.1.7 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the counter balancing disc (602.01). 12.2.1.8 For rotor position indicator the description under Supervision of Rotor Position in the section Pump Supervision Plan. 12.2.2 HG Pump Sizes 3 to 6 12.2.2.1 Place the bearing shell (370) with glued-in labyrinth ring (423.01) and O-ring (412.18) in the bearing housing (350.01). _____________________________________________________________________________________
Caution
The labyrinth ring has been glued in the bearing shell with Loctite 75/AVV or equivalent!
12.2.2.2 Fit and tighten the hex head bolts (901.13) including washer (550.012) and gasket (411.03); the bolt must engage in the bearing shell groove. 12.2.2.3 If applicable, fit the lubricating ring (644). 12.2.2.4 Fit the bearing cover (360) or bearing end cover (361, if applicable) including O-ring (412.09) and tighten the hex head bolts (901.01 or 901.06) uniformly; tightening torque, see relevant work instruction. Additional Work for Pumps with Balancing Disc : 12.2.2.5 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the counter balancing disc (602.01). 12.2.2.6 For rotor position indicator the description under Supervision of Rotor Position in the section Pump Supervision Plan.
12.3
12.3.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09). 12.3.2 Fit the thrust bearing housing (354) including O-ring (412.10) and springs (950). 12.3.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against counter balancing disc (602.01). 12.3.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with rolling element bearing.
a c b y z
12.3.4.1.1 Measure the dimension a from the face of the thrust bearing housing (354) to the bottom faces of the
springs (950), dimension b between the contact face of the angular contact ball bearing and the springs contact face of the bearing cartridge (381) as well as the distance c from the face of the thrust bearing housing (354) to the shaft collar.
OIMPG MAINTENANCE 45
_____________________________________________________________________
12.3.4.2 Calculate the auxiliary dimension x : x = a b 30 mm. (30 mm = installation length of the prestressed springs). 12.3.4.3 Shorten the spacer ring (504.01) to the dimension y y = c x. The maximum permissible deviation from parallelism is 0.02 mm. _____________________________________________________________________________________
Caution
12.3.5 12.3.6
_____________________________________________________________________________________ Slide the spacer ring (504.01) over the shaft (210). 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 10.1 mm. If required, remachine the bearing end cover (361); see figure Adjusting the lift-off device with rolling element bearing. 12.3.9 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354). 12.3.10 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with tightening torque given in the relevant work instruction.
12.4
Mounting the Lift-off Device (if applicable) with Tilting-pad Thrust Bearing
12.4.1 Fit the studs (902.08) and if applicable the spacer ring (504.03) including O-ring (412.09). 12.4.2 Fit the thrust bearing housing (354) including O-ring (4121.10) and springs (950). 12.4.3 Move the pump rotor in the direction of the driven end until the balancing disc (601.01) abuts against the counter balancing disc (602.01). 12.4.4 Adjust the lift-off device as shown in the figure Adjusting the lift-off device with tilting-pad thrust bearing.
a c b d z y x Slg1 f e
Adjusting the lift-off device the tilting-pad thrust bearing 12.4.1.1 Measure the dimension a from the face of with thrust bearing housing (354) to the bottom faces of springs (950), dimension b from the thrust bearing plate (384) to the springs contact faces on the bearing cartridge (381), distance c from the face of the thrust bearing housing (354) to shaft collar as well as the dimension d of the thrust bearing plate. 12.4.1.2 Calculate the auxiliary dimension x : x = a b + d 30 mm. (30 mm = installation length of the prestressed springs. 12.4.4.2 Shorten the spacer ring (504.01) to the dimension y y = c x. The maximum permissible deviation from parallelism is 0.02 mm. _____________________________________________________________________________________
Caution
_____________________________________________________________________________________
OIMPG MAINTENANCE 46
_____________________________________________________________________
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 10.1 mm. If required, remachine the bearing end cover (361); see figure Adjusting the lift-off device with tilting-pad thrust bearing. 12.4.11 Fit the bearing end cover (361) including O-ring (412.11) in the thrust bearing housing (354). 12.4.12 Fit the washers (550.08) and hex nuts (920.08) and tighten the hex nuts with the tightening torque given in the relevant work instruction.
When mounting the bearings, the holes for thermometers in the bearing shells and the associated thermometer connections in the bearing housings and/or bearing end cover must be aligned! _______________________________________________________________________
12.5.1 Fit the thrust bearing housing (354) including parallel pin (562.02), shaft seal ring (420.01), circlip (932.03) and O-ring (412.10) in the bearing housing (350.01). 12.5.2 Fit the hex socket head cap screws (914.04) including the gaskets (411.02) and tighten the screws with the tightening torque given in the relevant work instruction. 12.5.3 Mount the thrust bearing (314) including all segments and fit it in the thrust bearing housing (354). 12.5.4 Move the pump rotor in the direction of the driven end until the balancing piston (603.02) abuts against the counter balancing disc (602.02). 12.5.5 Adjust the axial clearance Sl3 at the balancing piston and Slg2 at thrust bearing as shown in the figure Adjusting the thrust bearing.
Caution
OIMPG MAINTENANCE 47
_____________________________________________________________________
d c
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 contact face of the bearing end cover (361), distance d from the bearing face of the thrust bearing (314, in the thrust bearing housing) to the contact face of the thrust bearing housing (354), and width e of the thrust bearing plate (384). 12.5.5.4 Calculate the bearing clearance : Slg2 = c + d e. 12.5.5.5 If the bearing clearance is within the permissible limits given in the table of clearances, the thrust bearing may be mounted. If the clearance is too large, the contact face of the bearing end cover (361) must be remachined. If the clearance is too small, the contact face of the thrust bearing (314) in the bearing end cover (361) must be remachined. 12.5.6 Slide the spacer ring (504.01) over the shaft (210) and insert the key (940.05) into the shaft keyway. 12.5.7 Slide the thrust bearing plate (384) and spacer sleeve (525.05) on the shaft (210). 12.5.8 Screw the nut (920.09) on the shaft (210) and tighten it. 12.5.9 Fit the studs (902.11) to the bearing end cover (361). 12.5.10 Fit the bearing end cover (361) including thrust bearing (314), O-rings (412.11 and 412.12), parallel pin (562.02), shaft seal ring (420.01) and circlip (932.03) and tighten the hex nuts (920.11) uniformly; tightening torque, see the relevant work instruction.
OIMPG MAINTENANCE 48
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 manufacturers mounting/dismantling instructions. The pump shafts 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.
OIMPG MAINTENANCE 49
0.2-0.3mm
_____________________________________________________________________
14.1.4 To facilitate fitting, the coupling hub may be heated uniformly to a temperature of 800 C max. _____________________________________________________________________________________
Use protective gloves. ! Risk of fire in case of open flames. Remove flammable substances from the danger area. ______________________________________________________________________
14.1.5 Elastomeric parts must be removed before heating! _____________________________________________________________________________________
Caution
Elastomeric parts which have been heated must not be used anymore. Use new parts for reassembly.
_____________________________________________________________________________________ 14.1.6 Fit the coupling hubs according to the figure Fitting the coupling hubs until the shaft ends and the hub faces are in alignment. _____________________________________________________________________________________
Caution
Fit the coupling hubs using only the appropriate device to prevent the shaft bearings from damage by axial friction force. Impacts on the coupling hubs are not permitted.
OIMPG MAINTENANCE 50
_____________________________________________________________________
14.2 Aligning the Connecting Coupling
Align the connecting coupling in accordance with the Connecting Coupling Alignment section in the chapter Installation on Site.
Caution The pump must not be operated without a coupling guard. ________________________________________________________________________
Caution The pump must not be operated without a coupling cover! ________________________________________________________________________
OIMPG MAINTENANCE 51
_____________________________________________________________________
15.2.1 Meticulously clean the locating and sealing surfaces. _____________________________________________________________________________________
Caution
_____________________________________________________________________________________ 15.2.2 Insert the gasket and O-ring. 15.2.3 Mount the lower cover half and fasten it to the backing ring. 15.2.4 Adjust the injection nozzles (if applicable) as shown in the figure Installation of the injection nozzles.
15.2.5 Coat the sealing surfaces of the cover flanges with a liquid, oil and temperature resistant sealing agent (up 0 to 120 C). 15.2.6 Use eyebolt as a transport aid as shown in the figure Coupling cover. 15.2.7 Fix the cover halves with two taper pins. 15.2.8 Fasten the upper and lower halves with screws. 15.2.9 Connect the pipes to the cover.
Caution
The pump must not be operated without a guard preventing accidental contact!
_____________________________________________________________________________________ Fasten the guard preventing accidental contact to bearing housing using screws.
OIMPG MAINTENANCE 52
_____________________________________________________________________
16.3 Maintenance of the Minimum Flow System
See the manufacturers documentation.
17.3 Storage
The parts should be stored as described under Interim Storage in the chapter Transport/Interim Storage.
OIMPG MAINTENANCE 53
_____________________________________________________________________
Trouble Shooting
1. General Information
________________________________________________________________________________________
Caution
During the warranty period, pumps must be attended only by KSB personnel!
________________________________________________________________________________________
1.1 For exact description of the pump design as well as the pump set components and accessories supplied by KSB, please refer to P & I Diagram.
1.3 Prerequisites
1.3.1 1.3.2 1.3.3 All spare parts required are available. Proper hoisting tackle and means of transport are available and ready for use. Sufficient room space and appropriate tools are available. 1.3.4 For the work required as per the tables on the subsequent pages, the pump set has been taken out of service in accordance with the Shutdown and Work after Shutdown sections in chapter Commissioning,
Start-up/Shutdown.
1.3.5 The drive has been secured against unintentional starting. _____________________________________________________________________________________
Caution
Before rectifying any faults, check all measuring instruments for proper functioning!
_____________________________________________________________________________________
OIMPG TROUBLE-SHOOTING 1
_____________________________________________________________________ In case of problems not described in the following table, consultation with KSBs Customer service is required.
Problem (what)
Flow rate of pump > specified value
Possible causes
Pump delivers against an excessive high Excessive back pressure
Measures
Open the valve in the discharge pipe further until the Duty point is adjusted Mount larger impeller(s)
Pump or piping are not completely vented or primed Inlet pipe or impeller(s) clogged Formation of air pockets in the piping NPSHavailable too low (inlet)
OIMPG TROUBLESHOOTING 2
_____________________________________________________________________ In case of problems not described in the following table, consultation with KSBs Customer service is required.
Problem (what)
Pressure ps > specified value
Possible causes
Damaged measuring instrument Differential pressure in the strainer element is too high Valve in the inlet pipe is not fully open Pressure in the inlet vessel is too low Damaged measuring instrument Speed is too low Inlet pressure is too low In case of tapping, quantity tapped is too high Temperature of the medium pumped is too low or too high Defective minimum flow system Defective shaft seal Score marks or roughness on shaft protection sleeve (524) and/or sleeve of mechanical seal Gland (gland plate / gland ring) have been tightened incorrectly Wrong packing material
Measures
Replace the measuring instrument Dismantle and clean the strainer element Open the valve Check the inlet vessel and/or increase the pressure Replace the measuring instrument Check the drive Check the inlet pressure and inlet vessel Throttle the tapping quantity Increase or reduce the temperature Check the minimum flow system Check; replace, if required Replace the shaft protection sleeve (524) or sleeve of mechanical seal Check Replace See chapter Commissioning/Startup/Shutdown & Maintenance Correct the suction conditions Re-align the pump Re-balance the pump rotor Increase pressure at the suction nozzle Check the coupling; re-align, if required Check the piping connections and the fastening of the pump Increase the cooling liquid quantity Clean the cooling liquid chamber and/or cooler Check the cooling liquid; purify/clean, if required Increase the effective cross section Check the pipes Check the installation dimensions Contact KSBs Service Center
Pump set alignment Pump is warped Insufficient quantity of cooling liquid Dirty cooling liquid chamber or cooler Fault in the circulation liquid pipe Surface pressure on the sealing clearance is too high, lack of lubricant or circulation liquid
OIMPG TROUBLESHOOTING 3
_____________________________________________________________________ In case of problems not described in the following table, consultation with KSBs Customer service is required.
Problem (what)
Increased bearing temperature
Possible causes
Defective bearing Oil quantity Oil quality Increased axial thrust Wear of internal pump parts (check in accordance with the Tables of clearances)
Measures
Check; replace, if required See chapter Maintenance Check the oil quantity; top up or replace, if required See chapter Servicing and Technical Appendix Check See chapter Servicing and Technical Appendix Replace the casing wearing rings Contact KSBs Service Center Replace the defective parts
Pump leakage
Flow rate < specified value Defective O-rings and/or metallic sealing surfaces
OIMPG TROUBLESHOOTING 4
_____________________________________________________________________ In case of problems not described in the following table, consultation with KSBs Customer service is required.
Problem (what)
Pump runs rough
Possible causes
Pump or piping are not completely vented or primed NPSHavailable too low (inlet)
Measures
Vent and/or prime Correct the liquid level Fully open the valve in the inlet pipe Change the inlet pipe, if the resistances in the inlet pipe are too high Inlet pipe is too long Check the strainers installed Observe the permissible speed of pressure fall Replace defective parts
Wear of internal pump parts ( check in accordance with the Tables of clearances)
Contact KSBs Service Center Adjust the duty point accurately by means of the valve in the discharge pipe In the case of permanently overload, turn down the impeller(s), if necessary Contact KSBs Service Center Check the coupling and re-align, if required Check the piping connections and the fastening of the pump Check the oil quantity; top or replace, if required Contact KSBs Service Center Check See Technical Appendix Clean the pump rotor Balance the pump rotor Replace Increase the minimum flow Check the inlet pipe Open the valve Check the inlet vessel and/or increase the pressure Check the inlet pipe Change the inlet pipe Excessive speed of pressure fall Check the piping; check shaft seal for leakage Vent and/or prime
Oil quality Unbalance of the pump rotor Defective bearing Flow rate < specified value Damaged inlet pipe Valve in the inlet pipe is not fully open Pressure in the inlet vessel is too low NPSHavailable / NPSHrequired too low
Air intake at the seal elements/valves/shaft seal Pump or piping are not completely vented or primed
OIMPG TROUBLESHOOTING 5
_____________________________________________________________________ In case of problems not described in the following table, consultation with KSBs Customer service is required.
Problem (what)
Pressure and/or quantity of balancing liquid fluctuates
Possible causes
Pump or piping are not completely vented or primed NPSHavailable too low (inlet)
Measures
Vent and/or prime Correct the liquid level Fully open the valve in the inlet pipe Change the inlet pipe, if resistances in the inlet pipe are too high Inlet pipe is too long Check the strainers installed Observe the permissible speed of pressure fall Replace the defective parts
Wear of internal pump parts ( check in accordance with the Tables of clearances)
Increased axial thrust Change in cross section of balancing liquid pipe Excessive resistances Joining of several pipes near the pump Balance flow leakage counter balancing disc / final stage diffuser Wear on the balancing device Wear of internal pump parts ( check in accordance with the Tables of clearances)
Contact KSBs Service Center Replace the casing wearing ring Contact KSBs Service Center Check the mode of operation Check the return pipe Check the pump pressures Check the rotor clearances and balancing device Replace the defective parts
Drive is overloaded
Contact KSBs Service Center Adjust the duty point accurately by means of the valve in the discharge pipe In the case of permanently overload, turn down the impeller(s), if necessary Contact KSBs Service Center Contact KSBs Service Center Alter Alter the impeller diameter Contact KSBs Service Center Reduce the speed of the turbine or internal combustion engine Check the piping connections and the fastening of the pump Check the power cable connections Replace defective fuses Check the power cable connections
Higher density or viscosity of the medium pumped than specified in the purchase order Gland tightened excessively or askew Speed is too high
OIMPG TROUBLESHOOTING 6
_____________________________________________________________________
Tables of Clearances
Diametrical Clearances :
Pump size 1 2 3 Hydraulics Nominal diametrical clearances [mm] S6 S7 S8 S9 0.25 0.34 0.35 0.50 0.27 0.36 0.90 1.40 0.90 1.50 0.30 0.36 0.40 0.51 0.35 0.45 1.0 1.5 0.30 0.37 0.35 0.41 0.45 0.51 0.32 0.39 1.0 1.6 0.35 0.47 0.40 0.50 0.45 0.51 0.40 0.48 1.0 1.0 1.0 2.0 Sl2 0.50 1.0 0.25 0.40 0.80 1.2 Sl3
S8 2
S7 2
Sl2
Clearance between balance disc seat and throttle sleeve or balance disc
Sl3
Sl2
OIMPG CLEAR AF 1
S9 2
S6 2
_____________________________________________________________________
Theoretical Total Axial Clearance
Pump size Hydraulic CI Sa1 + Sa2 [mm] Impeller material Cr Steel
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12
502.02 171.02
8.5 8.0 7.5 7.0 9.0 8.5 7.0 6.5 9.0 8.5 7.0 6.5 ------------230.02
8.5 8.0 7.5 7.0 8.5 8.0 6.5 6.0 8.5 8.0 6.0 5.5 6.5 8.0 8.5 10.0 10.0
Sa1 Sa2
Total axial clearance of pump rotor
OIMPG CLEAR AF 2
_____________________________________________________________________
Tables of Clearances
Bearing Clearances
Bearing design : Tilting-pad Thrust Bearing
Bearing Clearance Slg2 [mm] (Diametrical clearance) 0.33 0.58 0.34 0.60 0.40 0.75
Slg2
Tilting-pad Thrust Bearing
Bearing design : Pump size 1-6 Lift-off Device with Tilting-pad Thrust Bearing Bearing clearance Slg1 [mm] 0.30 - 0.50
Slg1
_____________________________________________________________________
Tables of Clearances
Bearing Clearances
Bearing design : Tilting-pad Thrust Bearing
Pump size 3, 4 5, 6
Bearing clearance Slg2 [mm] (Diametrical clearance) 0.34 - 0.60 0.40 - 0.75
Diametrical Clearances :
Pump size 1 2 3 4 5 6 Hydraulics 1; 2 3;4 5 6 7;8 9 ; 10 11;12;13 Nominal diametrical clearances [mm] S6 S7 S8 S9 0.25 0.34 0.35 0.50 0.27 0.36 0.90 1.40 0.90 1.50 0.30 0.36 0.40 0.51 0.35 0.45 1.0 1.5 0.30 0.37 0.35 0.41 0.45 0.51 0.32 0.39 1.0 1.6 0.35 0.47 0.40 0.50 0.45 0.51 0.40 0.48 1.0 1.0 1.0 2.0 Sl2 0.50 1.0 0.25 0.40 0.80 1.2 Sl3
_____________________________________________________________________
2. Pump Observe the tightening torques for the screwed/bolted connections as per relevant work instruction. 3. Fastening of Pump Feet Thread Tightening torque MA [Nm] M 20 190 M 24 330 M 30 660 M 36 1160
4. Flange Connection If the bolting for the flanged connections are in the KSBs scope of Supply, the tightening torques will be as specified in the table on the following pages.
_____________________________________________________________________
Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle
The tightening torques apply only if the bolts and screws are part of KSBs scope of supply.
50
65
80
100
500 490
125
490 650
150
660 1150
200
1260
250
_____________________________________________________________________
Bolts for Flange Connection, Discharge Nozzle and Tapping Nozzle
The tightening torques apply only if the bolts and screws are part of KSBs scope of supply.
1 1 2 2 3
8 10
_____________________________________________________________________
Bolts for Flange Connection, Suction Nozzle
The tightening torques apply only if the bolts and screws are part of KSBs scope of supply.
250
300
_____________________________________________________________________
Table of Weights
HG Pump Size 1
_____________________________________________________________________________________
Weights 25 kg
_____________________________________________________________________________________
Designation Suction Casing Discharge Casing Shaft for 3 stages each additional stage Bearing Housing Rotor 3 stages Each additional stage
Weights (reference values in kg) 35.0 58.0 17.9 1.2 25.0 31.0 4.0
Pump
Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Weights (reference values in kg) Without water fill Water fill 234 8.0 250 809 266 9.7 282 10.6 298 11.5 314 12.4 330 13.3 346 14.2 362 15.1 378 16.0 394 16.9 410 17.8 426 18.7 442 19.6 458 20.5 474 21.4 490 22.3 506 23.2
OIMPG WEIGHT 1
_____________________________________________________________________
Table of Weights
HG Pump Size 2
_____________________________________________________________________________________
Weights 25 kg
_____________________________________________________________________________________
Designation Suction Casing Discharge Casing Stage Casing Shaft for 3 stages each additional stage Bearing Housing Rotor 3 stages Each additional stage
Weights (reference values in kg) 54.1 140.0 25.0 21.1 1.6 25.0 52.0 6.0
Pump
Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Weights (reference values in kg) Without water fill Water fill 410 19.0 440 21.6 470 24.2 500 26.8 530 29.4 560 32.0 590 34.6 620 37.2 650 39.8 680 42.4 710 45.0 740 47.6 770 50.2 800 52.8 830 55.4 860 58.0
OIMPG WEIGHT 2
_____________________________________________________________________
Table of Weights
HG Pump Size 3
_____________________________________________________________________________________
Weights 25 kg
_____________________________________________________________________________________
Designation Suction Casing Discharge Casing Stage Casing Stage Casing Casing Part, for double piston For mechanical seal Shaft for 3 stages each additional stage Bearing Housing Thrust Bearing Housing, thrust bearing/plain bearing Bearing End Cover, thrust bearing/plain bearing Seal Casing Rotor 3 stages Each additional stage
Weights (reference values in kg) 161.0 225.0 38.00 28.0 25.0 30.5 51.4 3.0 57.0 25.0 29.0 39.0 83.0 9.0
Pump
Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Weights (reference values in kg) Without water fill Water fill 736 27.0 774 30.0 812 33.0 850 36.0 888 39.0 926 42.0 964 45.0 1002 48.0 1040 51.0 1078 54.0 1116 57.0 1154 60.0 1192 63.0 1230 66.0
OIMPG WEIGHT 3
_____________________________________________________________________
Table of Weights
HG Pump Size 3
_____________________________________________________________________________________
Weights 25 kg
_____________________________________________________________________________________
108.01 108.02 130 131 210 350.01 350.02 354 361 441
Designation Suction Casing < 320 bar 420 bar Discharge Casing < 320 bar DN 80 < 250 bar DN 100 >320 bar DN 100 420 bar DN 100 DN 125 Stage Casing Stage Casing Casing Part, for double piston For mechanical seal Inlet Ring Shaft for 3 stages each additional stage Bearing Housing, suction side Heavy bearing housing Bearing Housing, discharge side Thrust Bearing Housing, thrust bearing/plain bearing Bearing End Cover, thrust bearing/plain bearing Heavy bearing housing Seal Casing Rotor 3 stages Each additional stage
Weights (reference values in kg) 210.0 250.0 255.0 285.0 315.0 530.0 550.0 31.0 38.0 25.0 30.5 80.0 51.4 3.0 57.0 61.0 150.0 25.0 29.0 35.0 39.0 83.0 9.0
Pump
Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Weights (reference values in kg) Without water fill Water fill 736 27.0 774 30.0 812 33.0 850 36.0 888 39.0 926 42.0 964 45.0 1002 48.0 1040 51.0 1078 54.0 1116 57.0 1154 60.0 1192 63.0 1230 66.0
OIMPG WEIGHT 4
_____________________________________________________________________
Table of Weights
HG Pump Size 4
_____________________________________________________________________________________
Weights 25 kg
_____________________________________________________________________________________
Designation Suction Casing Discharge Casing Stage Casing Stage Casing Casing Part Inlet Ring Shaft for 3 stages each additional stage Bearing Housing, suction side Heavy bearing housing Bearing Housing, discharge side Thrust Bearing Housing, thrust bearing/plain bearing Bearing End Cover, thrust bearing/plain bearing Heavy bearing housing Seal Casing Balancing Piston Tie Rods for 3 Stages M 45 Each additional stage Rotor 3 stages Each additional stage
Weights (reference values in kg) 290.0 395.0 60.0 68.0 33.0 110.0 74.7 4.8 57.0 61.0 150.0 25.0 29.0 35.0 39.0 28.0 10.3 1.3 130.0 16.0
Pump
Number of stages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Weights (reference values in kg) Without water fill Water fill 1380 41.8 1477 47.4 1574 53.0 1671 58.6 1768 64.2 1865 69.8 1962 75.4 2059 81.0 2156 86.6 2253 92.2 2350 97.8 2447 103.4 2544 109.0 2641 114.6
OIMPG WEIGHT 5
_____________________________________________________________________
Table of Weights
HG Pump Size 5
_____________________________________________________________________________________
Weights 25 kg
_____________________________________________________________________________________
Designation Suction Casing 420 bar Discharge Casing 420 bar 420 bar
107
Weights (reference values in kg) 622.0 819.0 635.0 821.0 1020.0 1170.0 93.0 84.0 100.0 96.0 59.0 180.0 25.0 25.0 109.0 7.0 124.0 165.0 32.0 36.0 44.0 29.0 25.0 43.0 57.0 12.9 1.6 17.5 2.1 243.0 25.0
108.02 108.03 13-6 130 131 171.01 171.02 210 350.01 350.02 354 360.01 361 441 601 603.01 603.02 905
Stage Casing, Hydraulic 9 Hydraulic 10 Stage Casing, Hydraulic 9 Casing Insert Casing Part Inlet Ring Diffuser Diffuser Shaft for 3 stages each additional stage Bearing Housing Bearing Housing Thrust Bearing Housing, thrust bearing/plain bearing Bearing Cover Bearing End Cover Seal Casing Balancing Disc Balancing Piston Balancing Piston Tie Rods for 3 Stages M 45 Each additional stage Tie Rods for 3 Stages M 52 Each additional stage Rotor 3 stages Each additional stage
Pump
Number of stages 3 4 5 6 7 8 9 10 11 12 13 Weights (reference values in kg) Without water fill Water fill 2775 80 2930 90 3085 100 3240 110 3395 120 3550 130 3705 140 3860 150 4015 160 4170 170 4325 180
OIMPG WEIGHT 6
INDEX
CONTENTS
Standard Features At a Glance Gear-flex Family Std. Material of Construction Crowning of Gear Teeth (Optional) Ratings for Standard couplings Weight & M.I. for standard couplings Customised Gear-flex Specials Half Flex Couplings with Floating Shafts Spacer Couplings Reversed Hub Combinations Lubricants Requirements of API-671 Selection of Size of Coupling Typical Service Factors Std. Tolerances for Finish Bore & Keyway Applications Installation Instructions Gear-flex couplings equivalent to Competitors couplings. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15-17 18 19 20-27 28-33
PAGE
JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02 JAN-02
GEAR-FLEX COUPLING
Less backlash. High power to weight ratio. Compact assembly. Accommodates angular, parallel & axial misalignments. Generally used upto 120C. Can be used for higher temperatures by using proper grade of oil or grease. Can be dynamically balanced to the required grade as per ISO-1940.
JAN-02
GEAR-FLEX COUPLING
AT A GLANCE
RATING RANGE TYPE LFG - 157 kW to 232808 kW @ 1500 rpm TYPE LHG - 157 kW to 12846 kW @ 1500 rpm TORQUE RANGE TYPE LFG - 100.2 kg.m to 149000 kg.m TYPE LHG - 100.2 kg.m to 8220 kg.m BORE RANGE TYPE LFG - 20 mm. to 710 mm. TYPE LHG - 20 mm. to 260 mm. ANGULAR MISALIGNMENT - 1.5 per gear mesh
JAN-02
GEAR-FLEX COUPLING
1. 2. 3. 4. 5. 6. 7.
Hubs with external teeth Sleeves with internal teeth Seal Bolts Nuts Lubrication plugs Gasket FULL FLEXIBLE TYPE - LFG
JAN-02
GEAR-FLEX COUPLING
Hubs & Sleeves - Forged Steel EN-9 BS 970 Bolts & Nuts Seals Gasket - Closed tolerance connecting Bolts in Carbon Steel - Nitril Rubber ( SH - 60) - Paronite Paper
JAN-02
GEAR-FLEX COUPLING
The LOVEJOY Gear coupling has a unique crowning for the tooth surface which is designed after full consideration of the relationship between tooth forms & tooth width so that the contact stress on the tooth surface will not vary significantly even where relative movement is present. As for the tooth tip, the crowning is applied & the tooth is designed to minimise the top clearance between teeth when they are mated. The LOVEJOY Gear coupling has a crown tooth form so as to give maximum tooth thickness at its center. Where there is a relative misalignment between the driver & driven shaft, it is necessary that the tooth which comes between the teeth of its counterpart be permitted to oscillate. The internal teeth of the sleeves have a std. form whereas the external teeth of the hub take a special form.
JAN-02
Rated Torque
Nm 999.5 2495 4488 8480 12968 19945 34906 44881 55850 81780 109442 146250 198988 284524 345646 596831 848940 1123990 1482101 kg m Lbs-inch Kw 10.5 26.1 47 89 136 209 366 470 585 856 1146 1532 2084 2980 3620 6250 8890 11770 15521
Rated Power
@100 RPM @1500 RPM HP Kw HP 14.1 157 211 35.1 392 526 63 705 945 119 1332 1786 182 2037 2730 280 3133 4200 490 5483 7350 630 7050 9450 784 8773 11760 1148 12846 17220 1536 17188 23040 2053 22973 30795 2793 31257 41900 3994 44693 59910 4852 54294 72780 8378 93750 125670 11917 133351 178755 15778 176556 236670 20805 232808 312075
101.9 8843 254.3 22075 457.5 39709 864.4 75029 1321.9 114737 2033.1 176468 3558.2 308838 4575.0 397094 5693.2 494145 8336.4 723566 11156.2 968311 14908.3 1293978 20284.2 1760589 29003.5 2517387 35234.0 3058177 60839.0 5280589 86538.2 7511177 114575.9 9944741 151080.6 13113204
*Note :- LHG type couplings are available from size 101 to 110 only.
JAN-02
Wt. kg
11 15 25 39 57 85 103 138 210 277 550 710 980 1320 1700 2550 3620 4860 6380
M.I. kg m2
0.14 0.20 0.48 0.95 1.95 3.00 5.25 8.50 15.00 30.50 58.00 88.00 138.0 291.0 353.0 690.7 1235.3 1965.7 3012.3
GD2 kg m2
0.56 0.8 1.92 3.8 7.8 12 21 34 60 122 232 352 552 1164 1412 2762.8 4941.2 7862.8 12049.2
COUPLING SIZE
LFG-101 LFG-102 LFG-103 LFG-104 LFG-105 LFG-106 LFG-107 LFG-108 LFG-109 LFG-110
Wt. kg
11 15 20 40 60 80 106 149 170 264
M.I. kg m2
0.15 0.24 0.51 1.0 2.0 3.3 5.8 9.5 16.8 35.0
GD2 kg m2
0.6 0.96 2.04 4 8 13.2 23.2 38 67.2 140
Note :
GEAR-FLEX COUPLING
1.
2.
3.
4.
5.
6.
7.
JAN-02
GEAR-FLEX COUPLING
A floating shaft can eliminate the need for additional bearing support along spanning shaft because shaft is supported at ends by connected equipment through the half flex couplings. These are generally used for the applications of cooling tower fans.
JAN-02
GEAR-FLEX COUPLING
SPACER COUPLINGS Used on pumps & compressors for ease of servicing without disturbing either of the shafts.
10
JAN-02
GEAR-FLEX COUPLING
11
JAN-02
GEAR-FLEX COUPLING
LUBRICANTS
1. OIL LUBRICATION For the gear coupling, use gear oil of viscosity of 35 to 45 cst at 99C with extra high pressure additive. Where the coupling is used under extreme overload operation, severe reversing operation or bigger angular and offset misalignment, use gear oil of viscosity of 70 to 110 cst at 99C. A. First filling must be ample. B. After about 3 months operation, the coupling should be overhauled and drained of used oil to remove abrasion particles, and refilled with fresh oil. C. Subsequent refilling or replacing of oil should be made every 1 year by use of oil plug holes. 2. GREASE LUBRICATION Grease lubrication is somewhat inferior to application of gear oil. Coat the coupling case and coupling center with the specified grease until the teeth are submerged in grease, assemble the coupling, tighten the bolts and then supplement grease through oil plug hole by use of grease gun and so on. Replacing time of grease is same as gear oil, but replace old grease with new grease in full by overhauling the coupling. 3. RECOMMENDED LUBRICANTS Recommended Grease is RSG (Rathi Special Grease) having g = 910 Kg/m3.
12
JAN-02
GEAR-FLEX COUPLING
Double engagement type couplings Material of construction - Alloy Steel EN-19 Component balancing - Gr. 2.5 as per ISO-1940 Unless otherwise specified, the coupling assembly shall permit total axial displacement of at least 1/4 ( 6.4 mm). Antifly Spacer (fail-safe design) The coupling design shall ensure that all components are positively centered. The gear meshes shall be centered at the crown diameter of the external teeth & at the root diameter of the internal teeth. The involute tooth form shall be used at the vendors discretion. External teeth shall be relieved or chamfered at the tips and edges to provide the required misalignment capability & torque capacity. The hardness of the gear teeth shall be at least 45 Rc. The hardness of the teeth with the greater face width ( generally the sleeve teeth) shall be greater than or equal to the hardness of the mating teeth.
13
JAN-02
GEAR-FLEX COUPLING
Requirements
Application : Driver Driven kW RPM Driven -
Driver -
Distance between shaft ends (DBSE) if reqd. : Service Factor (S.F.) to be taken :
Selection Procedure
(a) Service Factor Determine appropriate SERVICE FACTOR from table (b) Design Power Multiply running power of driven machinery by the service factor. This gives DESIGN POWER which is used as a basis for coupling selection. (c) Coupling Size Refer to rating table for your required coupling size and read from the appropriate speed column until a power equal to or greater than the DESIGN POWER is found. (d) Bore Size Refer respective coupling dimensional table to check that the required bores can be accommodated. If bore size of selected coupling cant accommodate the shaft size, then go for next coupling size where shaft size can be accommodated.
14
JAN-02
Application AGITATORS Pure Liquids Liquids & Solids Liquids-Variable Density BLOWERS Centrifugal Lobe Vane BRIQUETTE MACHINES CAR PULLERS-Intermittent Duty CLAY WORKING MACHINERY COMPRESSORS Centrifugal Centriaxial Lobe Reci-procating-Multi Cylinder CONVEYORS-Light Duty Uniformly Fed Apron, Bucket, Chain, Flight, Screw Assembly, Belt Oven CONVEYORS-Heavy Duty Not Uniformly Fed Apron, Bucket, Chain, Flight, Oven Assembly, Belt Reciprocating Shaker CRANES AND HOISTS Main Hoists, Reversing Skip Hoists, Trolley & Bridge Drives Slope CRUSHERS Ore Stone
Application DREDGES Cable Reels Conveyors Cutter Head Jig Drives Maneuvering Winches Pumps Screen Drives Stackers Utility Winches ELEVATORS Bucket Centrifugal & Gravity Discharge Escalators Freight FANS Centrifugal Cooling Towers Forced Draft Induced Draft without Damper Control FEEDERS Apron, Belt, Disc, Screw Reciprocating GENERATORS(Not Welding) HAMMER MILLS LAUNDRY WASHERS Reversing LAUNDRY TUMBLERS LINE SHAFT
1 1.25 1.25 1 1.5 1.25 2 1.5 1.75 1 1.25 1.5 2 1.25 1.25 2.5
1.75 1.5 2.5 1.75 1.75 1.75 1.75 1.5 1.75 1.5 1.5 2.5 1 1.5 1.5 2 1.25 2.5 1 2 2 2 1.5
15
JAN-02
Application LUMBER INDUSTRY Barkers-Drum Type Edger Feed Live Rolls Log Haul-Incline Log Haul-Well Type Off bearing Rolls Planer Feed Chains Planer Floor Chains Planer Tilting Hoist Slab Conveyor Sorting Table Trimmer Feed MACHINE TOOLS Bending Roll Plate Planer Punch Press-Gear Driven Tapping Machines Other Machine Tools Main Drives Auxiliary Drives METAL MILLS Draw Bench-Carriage Draw Bench-Main Drive Forming Machines Slitters Table Conveyors Non-reversing Reversing Wire Drawing & Flattening Machine Wire Winding Machine MILLS, ROTARY TYPE Ball Dryers & Coolers Hammer Kilns Pebble & Rod Pug Tumbling Barrels MIXERS Concrete Mixers Drum Type
Application METAL ROLLING MILLS Coilers, hot mill Coilers, cold mill Cold Mills Cooling Beds Door Openers Draw Benches Edger Drives Feed Rolls, Reversing Mills Furnace Pushers Hot Mills Ingot Cars Kick-outs Manipulators Merchant Mills Piercers Pusher Rams Reel Drives Reel Drums Reelers Rod and Bar Mills Roughing Mill Delivery Table Runout Tables Saws, hot & cold Screwdown Drives Skelp Mills Slitters Slabbing Mills Soaking Pit Cover Drives Straighteners Tables, transfer & runout Thrust Block Traction Drive Tube Conveyor Rolls Unscramblers Wire Drawing PRINTING PRESSES PULLERS-Barge Haul OIL INDUSTRY Chillers Paraffin Filter Press
2 2 2 2 2 2 1.75 1.75 1.75 1.5 1.5 1.75 2 1.5 2 2.5 1.5 1.25 2 2 2 1.5 2.25 2.5 2 1.75 2.25 2 1.75 2 2 1.75 2 1.75 1.5
2 1.5 2 1.75 2 2 1.75 3.5 2.5 3 2.5 2.5 3 3 3 2.5 1.75 2 3 3 3 2.5 2.5 3 3 3 3 3 2.5 2.5 3 3 2.5 2.5 1.75 1.5 2 1.25 1.75
16
JAN-02
Application RUBBER INDUSTRY Mixed-Banbury Rubber Calender Rubber Mill (2 or more) Sheeter Tire Building Machines Tire & Tube Press Openers Tubers & Strainers PAPER MILLS Barker Auxiliaries, Hydraulic Barker, Mechanical Barking Drum Spur Gear Only Beater & Pulper Bleacher Calenders Chippers Coaters Converting Machines, except Cutters, Platers Couch Roll Cutters, Platers Cylinders Disc Refiners Dryers Felt Stretcher Felt Whipper Jordans Line Shaft Log Haul Pulp Grinder Press Roll Reel Stock Chests Suction Roll Washers & Thickeners Winders
Application PUMPS Centrifugal Reciprocating Single Acting 1 or 2 Cylinders 3 or more Cylinders Double Acting Rotary, Gear, Lobe, Vane SCREEN Air Washing Grizzly Rotary-Stone or Gravel Traveling Water Intake Vibrating SEWAGE DISPOSAL EQUIPMENT Bar Screens Chemical Feeders Collectors, Circuline or Straightime Dewatering Screens Grit Collectors Scum Breakers Slow or Rapid Mixers Sludge Collectors Thickeners Vacuum Filters STEERING GEAR STOKERS WINCH WINDLASS
1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1 1 1.5 1.75
1.5 1.75 2 1.75 1.75 1.75 1.25 2 1.75 1.5 2 1.75 2 1.5 1.5 1.75 1.5 1.5
17
JAN-02
Basic Size (mm.) Above Upto & including 3 6 6 10 18 30 50 80 120 180 250 315 400 10 18 30 50 80 120 180 250 315 400 500
H7 For Bores (mm.) + 0.012 0 + 0.015 0 + 0.018 0 + 0.021 0 + 0.025 0 + 0.030 0 + 0.035 0 + 0.040 0 + 0.046 0 + 0.052 0 + 0.057 0 + 0.063 0
JS9 For Keyway Width (mm.) 0.015 0.018 0.021 0.026 0.031 0.037 0.043 0.050 0.057 0.065 0.070 0.077
+ 0.1 0
+ 0.2 0
+ 0.3 0
+ 0.4 0 + 0.5 0
18
JAN-02
GEAR-FLEX COUPLING
APPLICATIONS
Gear-flex couplings can be used effectively & economically for transmission of mechanical power for : Agitators Blowers Conveyors Crushers Elevators Escalators Extruders Feeders Generators In industries like Cement Brewing & Distilling Food Rolling Mills Oil & Petroleum Chemical & Fertiliser Paper Mills Rubber Sewage Disposal, Sugar, Textile Thermal Power Houses Hammer mills Line shafts Machine tools Metal forming machines Mixers Pulverisers Pumps Screens Wenches
19
JAN-02
GEAR-FLEX COUPLING
(A)
BEFORE INSTALLATION
1. Remove the coupling from packing & thoroughly inspect for signs of damage. 2. Disassemble the coupling by removing nuts & bolts. Clean all the parts carefully. 3. Remove protective coatings / lubricants from bores & keyways. (B) MOUNTING PROCEDURE
1. Slide the sleeves with internal teeth with rubber O ring on shafts before mounting the hubs. 2. Mount the hubs with external teeth on their respective shafts flushed with the faces of hubs as shown in fig. 1.
20
JAN-02
GEAR-FLEX COUPLING 3. With one machine firmly bolted down, set the equipments at a distance G (refer table A & B) between shaft ends by using a spacer bar equal in thickness to the required gap G as shown in fig. 2.
Deviation in standard DBSE is defined as axial misalignment (end float). For normal applications the shaft end should be flushed with inner face of the adpater. In some special cases the shaft ends may protrude beyond the inner face of the adapter or may remain inside, if required. The distance between two faces of adapter flanges is to be maintained as specified. The variation in this distance should not exceed the permissible initial axial misalignment given in table 1.
21
JAN-02
GEAR-FLEX COUPLING
(C)
ALIGNMENT PROCEDURE
Alignment procedure is given separately for each type of alignment, for simplicity. However all 3 types of misalignments may be present at the same time.
IMPORTANT : The misalignment capabilities shown in drawings or in product literature are for dynamic conditions and variations. For optimum service from the coupling the installation misalignment (Initial misalignment) should not be more than 25% of the maximum allowable misalignments limits. Allowance should be made for any anticipated movements which will occure during operation (e.g. Thermal movements).
For Permissible INITIAL misalignments refer table A For Permissible MAXIMUM misalignments refer table B
22
JAN-02
GEAR-FLEX COUPLING
(I)
Check the parallel/Radial alignment with the help of straight edge resting squarely on both the hubs at 4 places 90 apart. The deviation in the readings should not exceed the permissible initial parallel misalignment mentioned in table A. (Refer fig. 3)
(II)
Check the angular misalignment with the help of slip gauges by inserting in the gap at 4 places 90 apart. The deviation in the values of standard gap G is Total Indicated Reading (TIR). The angular misalignment X in mm is half the Total Indicated Reading. The values of angular misalignment should not exceed permissible initial misalignments mentioned in table A. (Refer fig. 4).
23
JAN-02
GEAR-FLEX COUPLING
(D). ASSEMBLY PROCEDURE
IMPORTANT : If the coupling is dynamically balanced, ensure that the matchmarks are in straight line & unidirectional before bolting the assembly.
1. Insert the gasket between the flanges. Position the flanged sleeves with lubrication plugs. 2. Insert the bolts & tighten the nuts. Remember: Assemble only with the help of the fasteners furnished with the coupling. Fig. 5
3. Fill with recommended grease/oil (RSG/RSL with reqd. qty.) for lubrication. For grease quantity for respective coupling size, refer table No. C. 4. Change the grease after the interval of 6 months & the oil after the interval of 1 year or after 8000 working hours.
Use Loctite to prevent the loosening of threads, if required.
IMPORTANT: The necessity for shields & guards varies with individual installations. The owner or user must provide the required safety guards. Safety guards or shields are not furnished by us with this equipments.
24
JAN-02
TABLE A
PERMISSIBLE INITIAL MISALIGNMENTS FOR GEAR COUPLINGS
TYPE LFG
COUPLING SIZE ANGULAR degrees per gear mesh X (mm) PARALLEL/ RADIAL P (mm) AXIAL (mm)
TYPE LHG
ANGULAR degrees per gear mesh X AXIAL (mm)
(mm)
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 0.37
0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.4 1.6 1.8 1.9 2.2 2.4 2.5 2.9 3.2 3.6 4.0
0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.8 0.9 1.6 1.8 2.0 2.1 2.3 2.4 2.5 0.75 0.5 0.25 0.37 0.12
0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.4 1.6 0.12 0.06
5 5 5 5 10 10 10 10 10 10 10 10 15
NOT AVAILABLE
15 15 20 20 20 20
Half Flexible Gear Couplings Type LHG cannot accommodate parallel misalignment. Gap G in the above table is given when angular & axial misalignments are zero.
25
JAN-02
TABLE B
PERMISSIBLE MAXIMUM MISALIGNMENTS FOR GEAR COUPLINGS
TYPE LFG
COUPLING ANGULAR PARALLEL/ RADIAL P (mm) AXIAL
TYPE LHG
ANGULAR AXIAL
GAP G Std
SIZE
X (mm)
(mm)
X (mm)
(mm)
(mm)
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 1.5
2.2 2.4 2.9 3.2 3.7 4.2 4.6 5.0 5.6 6.4 7.1 7.7 8.9 9.5 10.2 11.8 13.1 14.4 16.3
0.8 0.95 1.1 1.3 1.45 1.55 1.8 1.9 2.2 2.6 3.3 3.5 6.6 7.3 8.1 8.5 9.1 9.6 10.2 3.0 2.0 1.0 1.5 0.5
2.2 2.4 2.9 3.2 3.7 4.2 4.6 5.0 5.6 6.4 0.5 0.25
5 5 5 5 10 10 10 10 10 10 10 10 15
NOT AVAILABLE
15 15 20 20 20 20
Half flexible Gear Couplings type LHG cannot accommodate parallel misalignment. GapG in the above table is given when angular & axial misalignments are zero.
26
JAN-02
TABLE C
GREASE FOR GEAR COUPLING (LFG/ LHG) Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 COUPLING SIZE 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 GREASE QTY. 47 gms. 90 gms. 216 gms. 375 gms. 460 gms. 715 gms. 1 Kg. 1.3 Kg. 2.2 Kg. 3 Kg. 4.5 Kg. 6.6 Kg. 8.8 Kg. 11.3 Kg. 14.8 Kg. 22.5 Kg. 32 Kg. 44.5 Kg. 53 Kg.
(g = 910 Kg/m3)
27
JAN-02
SR
COMPETITOR
46050
300
2 3
Fenner Power Tran (INDIA) Lovejoy Flanged Sleeve Series Type - F (USA)
190500 32451
600 340
232892
710
232892
710
28
JAN-02
EQUIVALENT LOVEJOY GEAR-FLEX COUPLING FOR DAVID BROWN LINK MASTER GEAR COUPLING
LINK MASTER GEAR
COUPLING SIZE kW AT 1500 RPM MAX. BORE (MM.) O.D. (MM.) TOT. LGTH COUPLING (MM.) SIZE
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23
315 559.5 984 1680 2235 3360 4470 6150 8400 12750 16200 19800 30750 35100 46050 79200 94050 107400 120750 190500 219000 250500
50 65 80 95 110 130 140 155 175 200 220 240 260 280 300 320 340 360 380 400 420 440
152 178 213 240 279 318 346 389 421 475 505 560 605 630 690
101 127 158 187 218 247 278 314 344 408 450 490 530 562 602
102 103 104 105 106 107 107 108 109 110 111 112 113 114 115 116 116 116 117 119 119
392 705 1332 2037 3133 5483 5483 7050 8773 12846 17188 22973 31254 44693 54294 93750 93750 93750 133351 232808 232808
60 75 90 110 125 140 140 160 180 220 260 300 330 370 410 455 455 455 520 710 710
185 220 250 290 320 350 350 380 430 490 545 590 680 730 780 900 900 900 1000 1250 1250
145 175 215 230 260 260 290 320 340 370 410 490 535 575 655 720 720 720 820 1000 1000
NOT AVAILABLE
NOTE : Above comparison is done on the basis of both, kW rating & maximum bore sizes.
29
JAN-02
EQUIVALENT LOVEJOY GEAR-FLEX COUPLING (Type LFG) FOR FENNER POWER TRAN
FENNER POWER TRANS. - NGC
COUPLING SIZE kW AT 1500 RPM MAX. BORE (MM.) O.D. (MM.)
NGC 1 NGC 2 NGC 3 NGC 4 NGC 5 NGC 6 NGC 7 NGC 8 NGC 9 NGC 10 NGC 11 NGC 12 NGC 13 NGC 14 NGC 15 NGC 16 NGC 17 NGC 18 NGC 19
172.5 427.5 772.5 1447.5 2250 3450 5850 7725 9660 13950 18975 24000 43200 59700 71475 102000 125625 160950 190500
50 60 75 90 110 125 140 160 200 220 260 300 320 340 360 450 490 540 600
170 190 220 250 290 330 350 380 430 490 545 590 680 730 760 900 1000 1100 1250
LFG-101 LFG-102 LFG-103 LFG-104 LFG-105 LFG-106 LFG-107 LFG-108 LFG-109 LFG-110 LFG-111 LFG-112 LFG-113 LFG-114 LFG-115 LFG-116 LFG-117 LFG-118 LFG-119
157 392 705 1332 2037 3133 5483 7050 8773 12846 17188 22973 31257 44693 54294 93750 133351 176556 232808
50 60 75 90 110 125 140 160 180 220 260 300 330 370 410 455 520 610 710
170 185 220 250 290 320 350 380 430 490 545 590 680 730 780 900 1000 1100 1250
NOTE : Above comparison is done on the basis of both, kW rating & maximum bore sizes.
30
JAN-02
EQUIVALENT LOVEJOY FULL GEAR COUPLING (LFG Type) FOR LOVEJOY FLANGED SLEEVE SERIES (Type - F) COUPLINGS
LOVEJOY FLANGED SLEEVE COUPLING (TYPE - F) SIZE TYPE - F kW @ 1500 RPM MAX. BORE (MM.) LOVEJOY FULLGEAR (LFG) SIZE TYPE - LFG kW @ 1500 RPM MAX. BORE (MM.)
7/8 1 2 2 3 3 4 4 5 5 6 7 8 9
134.3 335.7 559.5 1007 1678.5 2685.6 3916.5 5371.2 7721 10183 13316 17904 23499 32451
42 56 73 88 107 124 143 162 176 201 225 254 312 340
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116
157 392 705 1332 2037 3133 5483 7050 8773 12846 17188 22973 31257 44693 54294 93750 133351 176556 232808
50 60 75 90 110 125 140 160 180 220 260 300 330 370 410 455 520 610 710
NOT AVAILABLE
NOTE : Above comparison is done on the basis of both, kW rating & maximum bore sizes.
31
JAN-02
EQUIVALENT LOVEJOY GEAR-FLEX COUPLING (Type LFG) FOR HI-CLIFF TRUELINE SERIES 100
HI-CLIFF TRUELINE SERIES 100
COUPLING SIZE kW AT 1500 RPM MAX. BORE (MM.) O.D. (MM.)
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119
157 392 688 1310 2048 3134 5396 7052 8776 12850 17194 22981 31265 44709 54314 93784 133400 176619 232892
50 60 75 90 110 125 140 160 180 220 260 300 330 370 410 455 520 610 710
170 185 220 250 290 320 350 380 430 490 545 590 680 730 780 900 1000 1100 1250
LFG-101 LFG-102 LFG-103 LFG-104 LFG-105 LFG-106 LFG-107 LFG-108 LFG-109 LFG-110 LFG-111 LFG-112 LFG-113 LFG-114 LFG-115 LFG-116 LFG-117 LFG-118 LFG-119
157 392 705 1332 2037 3133 5483 7050 8773 12846 17188 22973 31257 44693 54294 93750 133351 176556 232808
50 60 75 90 110 125 140 160 180 220 260 300 330 370 410 455 520 610 710
170 185 220 250 290 320 350 380 430 490 545 590 680 730 780 900 1000 1100 1250
NOTE : Above comparison is done on the basis of both, kW rating & maximum bore sizes.
32
JAN-02
EQUIVALENT LOVEJOY GEAR-FLEX COUPLING (Type LFG) FOR ALLFLEX TYPE AFG
ALLFLEX TYPE AFG
COUPLING SIZE kW AT 1500 RPM MAX. BORE (MM.) O.D. (MM.)
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119
157 392 705 1332 2037 3134 5485 7052 8776 12850 17194 22981 31265 44709 54313 93783 133400 176619 232892
50 60 75 90 110 125 140 160 180 220 260 300 330 370 410 455 520 610 710
170 185 220 250 290 320 350 380 430 490 545 590 680 730 780 900 1000 1100 1250
LFG-101 LFG-102 LFG-103 LFG-104 LFG-105 LFG-106 LFG-107 LFG-108 LFG-109 LFG-110 LFG-111 LFG-112 LFG-113 LFG-114 LFG-115 LFG-116 LFG-117 LFG-118 LFG-119
157 392 705 1332 2037 3133 5483 7050 8773 12846 17188 22973 31257 44693 54294 93750 133351 176556 232808
50 60 75 90 110 125 140 160 180 220 260 300 330 370 410 455 520 610 710
170 185 220 250 290 320 350 380 430 490 545 590 680 730 780 900 1000 1100 1250
NOTE : Above comparison is done on the basis of both, kW rating & maximum bore sizes.
33
JAN-02
TDM
Spezial-Armaturen
TDM
CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Dangers and safety precautions Valve description Packing and marking Assembly and disassembly Commissioning Maintenance instructions Warranty Conditions Instruction in case of damages Customer services Attachments 10.1 Sectional drawing 10.2 Parts list
Page 19 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 done according the necessary safety precautions.
- 12 -
TDM
2. Description
The Schroedahl automatic-recirculation-valve model TDM is applied in centrifugal pump systems in order to provide an automatic leak-off flow in case of low load conditions. The application range of the series TDM with a multistage pressure let-down section is, independent of the temperature, for the operating pressures from 64 bar (a) to 250 bar (a) (900 psig to 3600 psig). The valve consists of an upper and a lower housing, each provided with a flange. The bypass housing, and as an option also the start-up housing, are located horizontally at the side of the valve. The valve trim comprises a check valve as also a control- and throttle section. The valve protects centrifugal pumps, especially boiler feed pumps, against overheating, by maintaining, automatically, a minimum flow. At flows, lower than the required minimum flow the check valve activates, by means of a lever, a vortex plug. When lifted of its seat, the vortex plug allows a flow through the pressure reduction section to the suction tank (or condensate tank). The opening characteristic is linear; the bypass flow increases when the check valve moves from its switch point further into the closes position. Because of the modulation bypass control, the total of process flow and minimum flow remains approximately constant. The check valve, shaped like a differential control piston and spring loaded, has such a high own frequency, that waterhammer is avoided. The check valve dampens pulsations because of its throttling effect on the mainflow and stabilises unstable pump characteristics in the partial load range. The housing is made from forged steel and is provided with a chromium steel liner in the check valve area. All moving parts and guides consist of alloy steel which are compatible. Alternative materials are available as options (see drawing and parts lists).
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TDM
3. Packing and marking
The automatic recirculation valve is shipped, depending on size, in an aluminium box (reusable), skid-carton or in a wooden crate. The standard factory conservation is sufficient to protect the valve for a period of approx. 6 month (the stocking area should be dry and ventilated). If special packing or conservation is required, this should be stated with the order. Specific valve data are indicated on the valve nameplate as per sample below. The valve nameplate is attached to every valve housing.
If spare parts are required, the following valve date should be provided with the inquiry (order): production number K ........ (stamped in valve body), valve model number and part number (check parts list).
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TDM
4. Assembly and disassembly
The automatic recirculation valve type TDM is usually installed vertically, with the mainflow upward, and directly on the pump discharge flange. The bypass housing is connected to the bypass piping (and the piping consequently to the feedwater tank or other tank), so that a recirculation flow will be possible. Other installation positions of the valve (horizontal, upside-down) are possible, if so ordered only! No special tools are required for the installation, assembly or disassembly of the valve.
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TDM
4.3 Assembly of the TDM
Replace the check valve (pos. 07) with the spring (pos. 06) in the lower body (pos. 01). Now the upper body (pos. 02) is placed on the lower body (pos. 01) and the hexagon nuts (pos. 28) are tightened (check cross sectional drawing!). Carefully insert the bypass section M in the valve body and as certain, that lever (pos. 13) fits (slides) in the slot in the check valve (pos. 07). The bypass housing (pos. 09) with the bypass orifice (pos. 23) is now carefully replaced and tightened to the housing (pos. 01) with the hexagon nuts (pos. 29).
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TDM
5. Commissioning of the TDM
The valve is commissioned together with the pump. When the main shut-off valve in the pump discharge piping (to the boiler or process) the specified 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 closing of the bypass can be checked. The switch point of the valve can be established acoustically (use a technical stethoscope or even a screwdriver to the ear will do). In case a manual start-up connection is provided on the valve, the minimum flow is achieved through this section. The automatic bypass is closed during commissioning and the manual start-up is opened. The automatic bypass section is spared (protected) during commissioning in this way, as the fluid might still be contaminated and/or carry solids!
6.
Maintenance instructions
The TDM has been designed so, that no special maintenance is required. Maintenance is restricted to cleaning the trim together with the pump at regular intervals. After disassembly of the valve, all seals should be replaced (by new seals) before re-assembly of the valve.
7.
Warranty conditions
If no special conditions have been agreed upon the order, the warranty is limited to 24 month after shipment or 8000 hours of operation. The warranty does not include damage caused by improper handling, dirt in the system or normal wear.
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TDM
8. Instructions in case of damages
In order to judge the damages (and the cause), the following information is required: a) The production number of the valve (K .....). This number is stamped on each valve body. b) Valve model number and size e.g. TDM ... c) A description of the system in which the valve is installed.
9.
Customer services
In case information is required, or in case of breakdown, the following persons can be addressed during office hours: International sales organisation: Schroedahl International B.V. St. Josephstr. 65 Lucernaflat 9th floor NL - 4611 MK Bergen op Zoom Phone number + 31 / 1 64 25 50 40 Fax number + 31 / 1 64 25 98 85 Schroedahl International Corp. 2400 Augusta Dr., Suite 280 Houston, Texas 77057 Phone number + 001 / 713-975-8351 Fax number + 001 / 713-780-0421
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TDM
10.1 Sectional drawing
P = pump end R = pipeline end B = by-pass end Installation P_R vertical
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TDM
10.2 Parts list
Housing
Material Pos. 01 02 03 04 06 07 07.1 07.2 08 09 25 26 27 28 29 30 Description Lower body Upper body Valve stemguide Guide bolt Spring Check valve (assy.) Check valve Stem Liner Bypass branch Guide pin Bolt Bolt Hexagon nut Hexagon nut O-Ring Description Vortex bushing Control head Vortex plug Lever Pivot pin Bushing Piston Disc Bypass orifice O-Ring O-Ring O-Ring Glyd-Ring O-Ring Glyd-Ring O-Ring Glyd-Ring O-Ring CS 1.0460 1.0460 1.4552 1.4021 4) 1.4310 1.4550 1.4550 1.4550 5) 1.4301 1.0460 1.4305 1) 1) 2) 2) 3) Material 1.4122 1.4122 1.4122 1.4313 1.4021 1.4122 1.4122 1.4122 1.4122 3) 3) 3) PTFE/Carbon 3) PTFE/Carbon 3) PTFE/Carbon 3) 1.4122 1.4122 1.4122 1.4313 1.4021 1.4122 1.4122 1.4122 1.4122 3) 3) 3) PTFE/Carbon 3) PTFE/Carbon 3) PTFE/Carbon 3) SS 1.4550 1.4550 1.4552 1.4021 4) 1.4310 1.4550 1.4550 1.4550 5) 1.4301 1.4550 1.4305 1) 1) 2) 2) 3)
Recommended Spare parts
x x
Bypass
Pos. 10 11 12 13 14 15 16 21 23 31 32 33 33.1 34 34.1 35 35.1 36
1) 2) 3) 4) 5)
8.8 to DN 150 PN 40, DIN 1.7709 from PN 63 and from DN 200 PN 10 8 to DN 150 PN 40, W-Nr. 1.7258 from PN 63 and from DN 200 PN 10 EPDM, BUNA, VITON, ZALAK, KALREZ made from SS acc. DIN 1.4550 with ceramic coating in case of horizontal installation With ceramic coating in case of horizontal installation
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