KSB WKTR Istruzioni per l'installazione
Process Pump
WKTR
Installation/Operating
Manual
Legal information/Copyright
Installation/Operating Manual WKTR
Original operating manual
KSB Aktiengesellschaft Frankenthal
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited
or processed for any other purpose, nor otherwise transmitted, published or made available to a third
party without KSB´s express written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 14.10.2011
Contents
Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Target group ................................................................................................... 6
1.3 Other applicable documents .......................................................................... 6
1.4 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 8
2.1 Key to safety symbols/markings ..................................................................... 8
2.2 General ............................................................................................................ 8
2.3 Intended use .................................................................................................... 8
2.4 Personnel qualification and training ............................................................. 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 9
2.6 Safety awareness ........................................................................................... 10
2.7 Safety information for the operator/user .................................................... 10
2.8 Safety information for maintenance, inspection and installation work ... 10
2.9 Unauthorised modes of operation ............................................................... 11
2.10 Explosion protection ..................................................................................... 11
3 Transport/Temporary Storage/Disposal ........................................... 14
3.1 Checking the condition upon delivery ......................................................... 14
3.2 Transport ....................................................................................................... 14
3.3 Storage/Preservation ..................................................................................... 17
3.4 Return to supplier ......................................................................................... 18
3.5 Disposal .......................................................................................................... 18
4 Description of the Pump (Set) .......................................................... 19
4.1 General description ....................................................................................... 19
4.2 Designation ................................................................................................... 19
4.3 Name plate .................................................................................................... 19
4.4 Design details ................................................................................................ 19
4.5 Configuration and function ......................................................................... 21
4.6 Scope of supply ............................................................................................. 22
4.7 Noise characteristics ...................................................................................... 22
4.8 Dimensions and weights ............................................................................... 23
5 Installation at Site ............................................................................. 24
5.1 Safety regulations ......................................................................................... 24
5.2 Checks to be carried out prior to installation ............................................. 25
5.3 Installing the sole plate and can .................................................................. 26
5.4 Grouting the sole plate ................................................................................. 27
Contents
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5.5 Lowering the pump ..................................................................................... 28
5.6 Mounting the motor ..................................................................................... 31
5.7 Connection to power supply ........................................................................ 31
5.8 Checking the direction of rotation .............................................................. 32
5.9 Connecting the piping .................................................................................. 33
5.10 Fitting the monitoring equipment ............................................................... 35
5.11 Fitting the auxiliary connections .................................................................. 36
5.12 Fitting the protective equipment ................................................................. 37
5.13 Installation checklist ...................................................................................... 37
6 Commissioning/Start-up/Shutdown ................................................. 39
6.1 Work to be carried out prior to commissioning .......................................... 39
6.2 Prerequisites for commissioning/start-up .................................................... 42
6.3 Start-up .......................................................................................................... 43
6.4 Operating limits ............................................................................................ 44
6.5 Measures to be taken for shutdown ............................................................ 46
6.6 Returning to service ...................................................................................... 48
7 Servicing/Maintenance ...................................................................... 49
7.1 Safety regulations ......................................................................................... 49
7.2 Maintenance/inspection ............................................................................... 50
7.3 Drainage/cleaning ......................................................................................... 53
7.4 Dismantling the pump set ............................................................................ 53
7.5 Removing the pump set ................................................................................ 57
7.6 Removing a pump set with large installation depth .................................. 58
7.7 Reassembling the pump set .......................................................................... 59
7.8 Spare parts stock ........................................................................................... 63
8 Trouble-shooting ............................................................................... 64
9 Related Documents ........................................................................... 67
9.1 Tightening torques ....................................................................................... 67
9.2 General assembly drawing with list of components ................................... 70
9.3 Weights of pump assemblies ........................................................................ 71
9.4 Related Documents ...................................................................................... 73
9.5 Pump signage ................................................................................................ 73
10 EC Declaration of Conformity .......................................................... 75
11 Certificate of Decontamination ....................................................... 76
Index .................................................................................................. 77
Contents
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Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by
the customer when returning the product to
the manufacturer to certify that the product
has been properly drained to eliminate any
environmental and health hazards arising from
components in contact with the fluid handled.
Discharge line
The line which is connected to the discharge
nozzle
Suction lift line/suction head line
The line which is connected to the suction
nozzle
Glossary
WKTR 5 of 78
1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series and size, the main operating data, the order
number and the order item number. The order number and order item number
uniquely identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
Noise characteristics. (⇨ Section 4.7 Page 22)
1.2 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel. (⇨ Section 2.4 Page 9)
1.3 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump
(set)
General arrangement drawing/
outline drawing
Description of mating and installation dimensions
for the pump (set), weights
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
describing accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components
For accessories and/or integrated machinery components observe the product
literature of the relevant manufacturer.
1.4 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
1) If agreed to be included in the scope of supply
1 General
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Symbol Description
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1 General
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2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information
about protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the specialist personnel/
operators responsible prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
kept in a perfectly legible condition at all times. This applies to, for example:
▪Arrow indicating the direction of rotation
▪Markings for connections
▪Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits described in the
other applicable documents.
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate the pump (set) in partially assembled condition.
!DANGER
2 Safety
8 of 78 WKTR
▪Only use the pump to handle the fluids described in the data sheet or product
literature of the pump model.
▪The pump must only be operated with the components selected by KSB.
▪Never operate the pump without the fluid handled.
▪Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪Do not throttle the flow rate on the suction side of the pump (to prevent
cavitation damage).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪The pressure of the fluid handled must not exceed the maximum permissible
pump discharge pressure.
▪The temperature of the fluid handled must not exceed the permissible maximum
value.
▪Observe the information on minimum flow rates specified in the data sheet (to
prevent overheating, damage to seal elements, damage to bearings, etc).
▪Observe the information on maximum flow rates specified in the data sheet (to
prevent overheating, damage to seal elements, cavitation damage, damage to
bearings, etc).
▪Take appropriate measures in compliance with the local regulations to prevent
operation above or below the operating limits due to operating errors,
malfunctions or procedural errors.
▪The pump must only be operated when in perfect technical condition.
Immediately remedy any faults which could compromise the safety.
▪The pump must not be operated in partially assembled condition.
▪The pump or its components must not be altered in any way.
▪Regularly check that all monitoring and alarm equipment is in perfect condition.
▪Generally observe the operating limits given.
Also see
• Other applicable documents [⇨ 6]
2.4 Personnel qualification and training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with these operating
instructions
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
2 Safety
WKTR 9 of 78
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
–Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2.7 Safety information for the operator/user
▪The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪Do not remove any contact guards during operation.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
▪If shutting down the pump does not increase potential risk, fit an emergency-
stop control device in the immediate vicinity of the pump (set) during pump set
installation.
▪Observe all warning labels/plates/signs attached. Especially observe the additional
plate: pumps for fluid temperatures > 80 °C / 176 °F:
1
2
1 Maximum temperature at the
pump
2 Safety distance in cm
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for resulting damage.
2 Safety
10 of 78 WKTR
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