KSB WKTR Montageanleitung

Process Pump

WKTR

Installation/Operating

Manual

Legal information/Copyright

Installation/Operating Manual WKTR

Original operating manual

KSB Aktiengesellschaft Frankenthal

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.

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

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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

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

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

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▪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 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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