CEP - WKT Manual - PDF

Vertical Barrel - Type
High Pressure Centrifugal Pumps
WKT
Installation/Operating
Manual
Legal information/Copyright
Installation/Operating Manual WKT

Original operating manual
KSB Pumps Ltd., Pune, India.
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 India 25.07.2012.
WKT
Contents
1 General ...........................................................................................................................................................4
1.1 Principles ........................................................................................................................................................ 4
1.2 Target group ................................................................................................................................................... 4
1.3 Symbols .......................................................................................................................................................... 4
2 Safety ............................................................................................................................................................ 5
2.1 Key to safety symbols/markings .................................................................................................................... 5
2.2 General .......................................................................................................................................................... 5
2.3 Intended use .................................................................................................................................................. 5
2.4 Personnel qualification and training ............................................................................................................... 6
2.5 Consequences and risks caused by non-compliance with these operating instructions ............................... 7
2.6 Safety awareness .......................................................................................................................................... 7
2.7 Safety information for the operator/user ........................................................................................................ 7
2.8 Safety information for maintenance, inspection and installation work ........................................................... 7
2.9 Unauthorized modes of operation .................................................................................................................. 8
3 Transport/Temporary Storage/Disposal ..................................................................................................... 9
3.1 Checking the condition upon delivery ............................................................................................................ 9
3.1.1 Markings ......................................................................................................................................................... 9
3.1.2 Lifting Accessories (e.g. ropes, lifting gear) ................................................................................................. 10
3.1.3 Transport Symbols ....................................................................................................................................... 10
3.2.1 Condition on Delivery ................................................................................................................................... 11
3.2.2 Transport Options ......................................................................................................................................... 11
3.2.3 Transporting pump in horizontal / vertical position ....................................................................................... 12
3.3 Storage/Preservation ................................................................................................................................... 14
3.3.1 Period of storage longer than 12 months ..................................................................................................... 15
3.4 Return to supplier ......................................................................................................................................... 15
3.5 Disposal ....................................................................................................................................................... 15
4 Description of the Pump (Set) .................................................................................................................. 16
4.1 General description ...................................................................................................................................... 16
4.2 Designation .................................................................................................................................................. 16
4.3 Name plate ................................................................................................................................................... 16
4.4 Design details .............................................................................................................................................. 16
4.5 Configuration and function ........................................................................................................................... 18
4.6 Scope of supply ........................................................................................................................................... 19
4.7 Dimensions and weights .............................................................................................................................. 19
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5 Installation at Site ...................................................................................................................................... 20
5.1 Safety regulations ........................................................................................................................................ 20
5.2 Checks to be carried out prior to installation ................................................................................................ 21
5.3 Installing the base frame .............................................................................................................................. 22
5.4 Fitting Can .................................................................................................................................................... 24
5.5 Lowering the pump ...................................................................................................................................... 25
5.6 Mounting the Drive ....................................................................................................................................... 27
5.7 Mounting the Drive End coupling Hub ......................................................................................................... 27
5.8 Connection to power supply ......................................................................................................................... 29
5.9 Checking the direction of rotation ................................................................................................................ 29
5.10 Connecting the piping & strainer .................................................................................................................. 30
5.11 Fitting the monitoring equipment (if applicable and not fitted at the factory) ............................................... 36
5.12 Fitting the auxiliary connections ................................................................................................................... 38
5.13 Fitting the protective equipment ................................................................................................................... 38
5.14 Installation checklist ..................................................................................................................................... 39
5.15 Preservation for standstill ............................................................................................................................. 39
6 Commissioning/Start-up/Shutdown ......................................................................................................... 40
6.1 Work to be carried out prior to commissioning ............................................................................................. 40
6.2 Commissioning/start-up ............................................................................................................................... 44
6.3 Operating limits ............................................................................................................................................ 48
6.4 Measures to be taken for shutdown ............................................................................................................. 49
6.5 Returning to service ..................................................................................................................................... 52
7 Supervision /Servicing/Maintenance ....................................................................................................... 53
7.1 Monitoring schedule ..................................................................................................................................... 53
7.2 Servicing schedule ....................................................................................................................................... 54
7.3 Gland packing variant .................................................................................................................................. 55
7.4 Dismantling the pump set ............................................................................................................................ 61
7.5 Dismantling pump set with large installation depth ...................................................................................... 69
7.6 Reassembling the pump set ........................................................................................................................ 71
7.7 Examination of individual Components ........................................................................................................ 79
7.8 Spare parts stock ......................................................................................................................................... 84
8 Trouble-shooting ........................................................................................................................................ 86
9 Related Documents ................................................................................................................................... 89
9.1 Tightening torques ....................................................................................................................................... 89
9.2 General assembly drawings and lists of components .................................................................................. 94
9.3 Table of clearances ...................................................................................................................................... 98
9.4 Bearing Lubrication .................................................................................................................................... 102
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Chapter 1 General
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.
1.2 Target group

This manual is aimed at the target group of trained and qualified specialist technical
personnel. (⇨ Chapter 2)
1.3 Symbols
Table 1 : 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
Cross-references
Symbol Description
1. Step-by-step instructions
Note
Recommendations and important information on how to
handle the product
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Chapter 2 Safety
2 Safety
All the information contained in this chapter refers to hazardous situations.
2.1 Key to safety symbols / markings

DANGER Table 2 : Definition of safety symbols / markings
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.
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 chapters 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
2.3 Intended use

The pump (set) must only be operated within the operating limits described in the other
applicable documents.
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Chapter 2 Safety
§ Only operate pumps/pump sets which are in perfect technical condition.

§ Do not operate the pump (set) in partially assembled condition.
§ 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 equipments are in perfect condition.
§ Generally observe the operating limits given.
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 instructions provided by

sufficiently trained specialist personnel.
Training on the pump (set) must always be supervised by technical specialist personnel.
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Chapter 2 Safety
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:
– 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 substance
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.
§ 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.
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 authorized by the manufacturer. The use of other
parts can invalidate any liability of the manufacturer for resulting damage.
§ The operator ensures that all maintenance, inspection and installation work is
performed by authorized, qualified specialist personnel who are thoroughly familiar with
the manual.
§ If maintenance work is carried out in potentially explosive atmospheres, the operator is
responsible for taking all required precautionary measures.
§ Only carry out work on the pump (set) during standstill of the pump.
§ The pump casing must have cooled down to ambient temperature.
§ Pump pressure must have been released and the pump must have been drained.
§ When taking the pump set out of service always adhere to the procedure described in
the manual.
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Chapter 2 Safety
§ As soon as the work is completed, re-install and/or re-activate any safety-relevant and
protective devices. Before returning the product to service, observe all instructions on
commissioning.
2.9 Unauthorized modes of operation

Never operate the pump (set) outside the limits stated in the data sheet and in this
manual. The warranty relating to the operating reliability and safety of the supplied pump
(set) is only valid if the equipment is used in accordance with its intended use.
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Chapter 3 Transport / Temporary Storage / Disposal
3 Transport / Temporary Storage / Disposal

3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and notify
KSB or the supplying dealer (as applicable) and the insurer about the damage in
writing immediately.
DANGER
The pump or individual components could slip out of the suspension arrangement
Danger to life from falling parts!
Ø Always transport the pump or components in the specified position.
Ø Refer to the weights indicated for the individual components.
Ø Use suitable permitted lifting accessories, e.g. self-tightening lifting tongs.
Ø Never attach the suspension arrangement to the free shaft end of the pump.
Ø Observe the applicable local accident prevention regulations.
Ø Use appropriate personal protective equipment.
DANGER
Improper transport
Risk of personal injury from lifting heavy components!
Ø Select lifting accessories which are suitable for the component weight.
Ø Always use the attachment points provided for the lifting accessories.
Ø Comply with the applicable health and safety regulations.
DANGER
Installation on installation surfaces which are unsecured and cannot support the load
Personal injury and damage to property!
Ø Use a concrete make ACC cement ”SHRINKKOMP “ / FORSORC
“CONBEXTRA - GP2” Or Equivalent Portland cement
Ø Make sure the concrete of the installation surface has set firmly and the surface is
truly horizontal and even.
Ø Observe the weights indicated.
3.1.1 Markings
Fastening points
The fastening points of the individual transport crates are
indicated by the chain symbol.
Centre of gravity
The centre of gravity of packaged pump and pump set
components is marked on the crate by the centre of gravity
symbol.
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3.1.2 Lifting Accessories (e.g. ropes, lifting gear)

To determine the lifting capacity, give due consideration to the position of the centre of
gravity, the angle of spread and bending radii of the lifting links attached to the load to
be lifted.
P For selection and attachment of the lifting accessories, only follow the instructions given
by the person responsible for this.
P If the lifting accessories come into contact with sharp edges, edge protectors must be
fitted at the contact points.
NOTE
Damage to the pump components, coat of paint or protective coating!
§ Do not place any chains or steel ropes around the pump components with nothing in
between.
§ Do not use chains, if possible.
DANGER
Improper selection or handling of lifting accessories may result in the
pump or pump set components falling down.
§ Use sufficiently dimensioned and suitable lifting accessories.
§ Do not use any damaged or untested lifting accessories.
§ Never attach the ropes to the free shaft end, the column pipes or the bearing
housings.
§ Secure against overturning.
§ Make sure the lifting accessories are used correctly in accordance with the
manufacturer's instructions.
§ Observe the weights indicated, for example, in the tables of weights and the
installation plan in chapter 9
3.1.3 Transport Symbols

The pictographs according to DIN 55402 on the packaging must be observed, e.g.:
1 2 3 4 5 6 7
8 9
Transport symbols
1 This way up 6 Centre of gravity
2 Fragile 7 Fasten here
3 Keep dry 8 Do not use forklift truck here
4 Store away from heat 9 Do not destroy barrier
5 No hand hooks
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3.2.1 Condition on delivery

The individual components of the pump set are supplied as follows:
§ Pump
§ Can
§ Drive
§ Accessories
The individual components are supplied in transport boxes. Refer to the packing list
for the exact contents and weight of each box.
NOTE
The pump set is supplied by the manufacturer/supplier in packaging which largely.
Prevents sagging or other damage during transport and/or storage.
3.2.2 Transport Options

Transport boxes P The weights of the individual components to be transported have been identified in the
packing list.
P Suitable hoisting tackle has been selected.
Transport the transport boxes as indicated.
Hoisting the transport box Hoisting the transport box
Unpacking the pump (set)
WARNING
Improper unpacking of transport boxes
Risk of injury from falling parts and/or transport boxes tipping over
Ø Observe the applicable local accident prevention regulations.
Ø Secure parts against tipping over backwards (e.g. box lids).
Ø Wear suitable protective clothing such as a safety helmet and safety shoes with toe
caps as well as safety goggles and protective gloves.
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Transporting the pump set
The pump set is generally supplied as individual components.

(Pump, Can, Drive ,Motor Stool, Accessories ) Due to the weights of the individual
components, the pump set is only assembled at the site.
1. Refer to the weights of the individual components stated in the general arrangement
drawing.
2. Select suitable hoisting tackle.
NOTE
For transporting the drive or other accessories the respective manufacturer's product
literature must be observed.
Transport the pump and individual components as illustrated.
Transporting the pump horizontally on a substructure
< 120o
3.2.3 Transporting pump in horizontal / vertical position

Transporting the pump in horizontal position
1 = Suitable locations for Horizontal Support
1 Location of supports for placing the pump in horizontal position
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Transporting the pump in vertical position
DANGER
Pump in vertical position tipping over
Danger to life from pump tipping over!
Ø Never place the pump in vertical position.
Transporting the Can If the can is included in KSB's scope of supply, observe the following transport options.
1 = Location of support for placing the

pump in horizontal position
Transporting the can in Transporting the can in
horizontal position vertical position
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Transporting the base frame Attach the lifting accessories as illustrated.
3.3 Storage / Preservation
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion / contamination of the pump (set)!
Ø For outdoor storage cover the packed or unpacked pump (set) and accessories with
waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
Ø Only remove caps/covers from the openings of the pump set at the time of
installation.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
New pumps/pump sets are supplied by our factory duly prepared for storage.
For storing a pump (set) which has already been operated, observe the instructions.
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3.3.1 Period of storage longer than 12 months
WARNING
If stored for more than five years, the sealing function could be impaired
Risk of injury, e.g. cuts caused by fluid jets, scalds by hot, pressurized fluid escaping!
Ø After a storage period of more than five years, dismantle the pump before it is
installed and replace the sealing elements, e.g. O-rings.
Ø Check sealing elements, e.g. O-rings, for any damage before fitting them.
Preservation 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.
3.4 Return to supplier

1. Drain the pump as per operating instructions.
2. Always flush and clean the pump.
3. If the fluids handled by the pump (set) leave residues which might lead to Corrosion
when coming into contact with atmospheric humidity.
3.5 Disposal
WARNING
Fluids posing a health hazard and/or hot fluids
Hazard to persons and the environment!
Ø Collect and properly dispose of flushing liquid and any residues of the fluid handled.
Ø Wear safety clothing and a protective mask, if required.
Ø Observe all legal regulations on the disposal of fluids posing a health hazard.
1. Dismantle the pump (set). Collect greases and other lubricants during dismantling.
2. Separate and sort the pump materials, e.g. by:
- Metal / Plastics
- Electronic waste
- Greases and other lubricants
3. Dispose of materials in accordance with local regulations or in another controlled
Manner.
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Chapter 4 Description of the Pump (Set)
4 Description of the Pump (Set)

4.1 General description
§ Pump type WKT
§ Pump sizes 40 -150
§ Pump for handling condensate in power stations and industrial plants
§ Canned, vertical high-pressure centrifugal pump
4.2 Designation
Example : WKT 80 / 6
Table 3 : Key to the designation
Code Description
WKT Type series
80 Size
6 Number of stages
4.3 Name plate
KSB PUMPS LTD.

Sr.No.
Type
Year
o
Working Temp. C
Max. Test pr. bar
Capacity ltrs
IN 03083 D B74x37
Name plate (example)
4.4 Design details

Design
§ Radially split pump with radial impellers
§ Pump in can
§ Single-entry
§ Multistage
§ Suspended vertically
§ Sealing between the casings by means of O-rings or gaskets
§ Nozzle positions
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– Suction nozzle: horizontal, above the mounting surface

– Discharge nozzle: horizontal, above the mounting surface
Installation
§ The can is installed in a pit below the mounting surface.
§ The pump is connected to the structure by means of the Base frame.
Bearings
§ Radial bearing
– Product-lubricated radial plain bearing in the pump
§ Thrust bearing
– Rolling element bearing, oil bath lubrication above the shaft seal
Shaft seal
Depending on pump size and design:
§ Single or double mechanical seal
§ Gland packing with lantern ring to prevent ingress of air
Flanges
§ Mating dimensions to ASME
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4.5 Configuration and Function

The fluid enters the can (151) via the suction nozzle of the distributor casing(10-1). In the
suction casing (106) it is accelerated outward by the rotating impeller (231). In the flow
passage of the stage casing (108) and the diffuser (171) the kinetic energy of the fluid is
converted into pressure energy. The fluid is guided to the next impeller by the return guide
vanes of the diffuser. This process is repeated in all stages until the fluid has passed the
last diffuser. The fluid then passes through the discharge casing (107) and is guided
upwards through the column pipe (711) to the discharge nozzle of the distributor casing
(10-1), where it leaves the pump.
The hydraulic axial thrust is balanced by means of two casing wear rings and balancing
holes in the impellers. Above the distributor casing the fluid area is sealed off by a shaft
seal housing (441) or Gland packing (461) through which the shaft (213) passes. The
shaft passage is sealed towards the atmosphere with a dynamic seal. The shafts (211,
212, etc.) are supported by product-lubricated radial plain bearings and rolling element
bearings (320). The rolling element bearings (320) are located in a bearing housing (350),
which is mounted on the distributor casing
Sectional drawing
350 320
441 213
461
10-1
211 212
711
107
108
151
171
231 106
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4.6 Scope of supply

As a general rule, the following items are supplied with the pump :
- Motor lantern
- Special tools and tackles for assembly / dis-assembly of conical coupling
On request the following items can be supplied amongst others

- Coupling : Flexible coupling with spacer
- Coupling guard
- Coupling extractor device
- Motor
- Base plate : Welded construction
- Pressure gauges for suction & discharge
- ARC valve
- Suction strainer
4.7 Dimensions and weights

For dimensions and weights please refer to the general arrangement drawing/outline
drawing of the pump/pump set.
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Chapter 5 Installation at Site
5 Installation at Site
5.1 Safety regulations
The operator ensures that all maintenance, inspection and installation work is performed
by authorized, qualified specialist personnel who are thoroughly familiar with the manual.
For all work involving assembly, reassembly and installation, observe the following safety
information:
DANGER
Operation of the pump in combination with an impermissible component, especially can
or base frame
Danger to life!
Ø The pump must only be operated with matching components selected by KSB,
especially can and base frame.
DANGER
Work on the pump set carried out at great heights
Risk of personal injury from falling down!
Ø Provide suitable safety measures, e.g. scaffolding, barriers.
Ø Wear suitable protective clothing.
Ø Comply with all relevant safety regulations.
DANGER
Improper transport
Ø Select lifting accessories which are suitable for the component weight.
Ø Always use the attachment points provided for the lifting accessories.
DANGER
Vertically positioned pump (set) could tip over
Danger to life from pump or components tipping over!
Ø Attach the components to be installed to the hoisting tackle and keep them secured
until the screwed connections have been fastened.
Ø Always install the pump (set) in the sequence described.
Ø Always place components in their centre of gravity position on a suitable surface to
prevent them from tipping over.
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NOTE
The vibration values and noise emissions indicated by KSB are based on proper
installation of the pump (set) in accordance with this chapter. Improper isolation of the
pump (set) from the building/plant or an inappropriate piping layout may increase noise
emission and/or the vibration level.
5.2 Checks to be carried out prior to installation
Place of installation
WARNING
Installation on installation surfaces which are unsecured and cannot support the load
Personal injury and damage to property!
Ø Make sure the concrete of the installation surface has set firmly and the surface is
truly horizontal and even.
Ø Observe the weights indicated.
1. Check structural requirements.

All structural work required must have been prepared in accordance with the
dimensions stated in the outline drawing/general arrangement drawing. The area
surrounding the foundation holes must be horizontal and even.
2. The place of installation and the way there to have to be cleared and suitable for
transport of the pump set components.
3. Suitable means of transport and lifting accessories are available.
4. Suitable alignment devices are available.
5. The manufacturers' product literature for the drive and accessories is available.
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5.3 Installing the base frame

High speed rotary equipment need to be installed with maximum contact area between the
base frame and the foundation. To achieve this conventionally. blue matching procedure is
adopted between base frame and Can. This call for skilled mill-Wright fitters to work on
and consumes lot of time. In spite of This, the contact area achieved is no where near to
100%.
Therefore, the following procedure is recommended which ensures:-

Nearly 100% contact area between the base frame and Can considerable saving in time
and manpower.
Preparation:
The following preparation is followed in case the Base frame and Can. (equal to the
number of foundation bolts) are in scope of KSB. Otherwise the user is requested to follow
the preparation as under:
Ø The base frame is provided with the pads, having surface finish 25 micron & 50 micron
face parallality which are welded at the top of base frame, machined in one setting.
Ø Reinforced plate of are welded in the channel( Ref. Fig1)
Ø 12 holes drilled to of dia 22 mm (Ref. Fig1)
12 Tapped Holes
M20 x 30 Deep
Flat Pad
Reinforcement
Plate
Plate
Channel (ISMC)
Flat Pad
Fig. 1
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DANGER
Improper transport
Ø Select hoisting tackles/lifting accessories which are suitable for the component
weight.
Ø Always use the attachment points provided for suspending components from the
hoisting tackle.
WARNING
People falling into the unsecured pump pet.
Risk of personal injury!
Ø Take suitable precautions during the entire installation/dismantling process to
protect people from falling into the open discharge tube.
Ø Fence off the work area appropriately.
Master Level
Straight Edge EL+###
~###
T.O. Floor
EL+###
~ ###
Fig. 2
Straight Edge
Master Level
Fig. 2a
EL+###
~###
T.O. Floor
EL+###
~ ###
Fig. 3
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P Suitable hoisting tackle incl. lifting accessories are available and ready for use
1. Attach lifting accessories to base frame
2. Carefully lower base frame on the concrete block. (Ref. Fig2)
3. Check the levels by master level on machine pads. Level should be 0.04mm per meter.
4. Place the straight edge on the base frame on X & Y direction. (Ref. Fig 2 & 2a)
5. Grout the entire base frame up to top of the base frame. Using conventional grouting
mix i.e. Portland cement, sand and aggregate in proportion 1:2:2 and gravel size not
exceed 20mm (Ref. Fig 3)
6. Complete grouting without major interruptions.
7. Use a vibrator to make sure that no cavities remain.
8. Allow curing time of min 72 hrs depending upon the grout used.
CAUTION
Improper handling of the vibrator
Possible misalignment!
Ø Make sure the vibrator does not touch the base frame and the fastening/aligning
parts.
NOTE
When grouting the recess in the base frame, make sure that no concrete enters the
pump sump.
5.4 Fitting the can
DANGER
Improper transport
weight.
hoisting tackle.
WARNING
People falling into the pump sump
protect people from falling into the pump sump.
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Fixing Stud M20x70L

Barrel Top Plate
Base Frame Pad

Welded on Channel
Reinforcement Plate
Welded on Channel
Concrete Block
Square Base Frame
Channel ISMC 200
Foundation Detail
Fig. 4
P The base frame has been mounted and aligned.

P Suitable hoisting tackle and lifting accessories are available and ready for use.
Observe the weights indicated in General arrangement drawing.
1. Attach the lifting accessories to can (151). (_ Chapter 3)
2. Carefully place can (151) into vertical position.
3. Carefully lower can (151) into the recess of base frame (891) and place it down onto
the base frame. (Ref. Fig 4)
4. Carry out the leveling by master level. Level should be within 0.04 mm per meter.
5. Place the straight edge on the base frame on X & Y direction. Use shims (SS shims
proffered) if required between Can bottom plate & base frame.
6. Use hexagon nuts (3) to fasten can (151).
NOTE
Observe the required tightening torque. (_ Chapter 9)
5.5 Lowering the pump
NOTE
The numbers in parentheses, e.g. (412.17), refer to pump components shown in the
general assembly drawings. (_ Chapter 9)
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DANGER
Improper transport
weight.
hoisting tackle.
WARNING
People falling into the unsecured Can
protect people from falling into the Can
P Base frame and can have been mounted and aligned.

P The base frame has been grouted.
P The concrete has been set.
P Suitably dimensioned hoisting tackle and lifting accessories are available.
1. Remove the fall protection from the can opening.
2. Make sure that the inside of the can is clean.
3. Thoroughly clean the flange facing of the can and the grooves.
4. Insert gasket (400).
5. For horizontal transport, carefully place the pump in vertical position. (_ Chapter 3)
6. Lower the completely mounted pump into can (151). Make sure that the contact
between the flange of distributor (10-1) and the leveled flange of can (151) is plane and
even.
7. Recheck the levels by master level on the motor lantern. Level should be within
0.04mm per meter. Note:-Place the straight edge on the frame on X & Y direction
8. Tighten the fixing bolts and re-check the leveling.
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N2 N1
Fig. 5
5.6 Mounting the drive
The driver is automatically centered in the flange of the motor lantern after being placed
and bolted on the motor lantern.
Also see
§ Relevant documentation [_ Chapter 9]
5.7 Mounting the drive-end coupling hub
DANGER
Improper transport
weight.
hoisting tackle.
WARNING
Components heated up for installation
Risk of burns at hands!
Ø Wear protective gloves suitable for installation work.
Ø Let components cool down after installation.
NOTE
Observe the coupling manufacturer’s product literature. (_ Chapter 9)
Observe the motor manufacturer’s product literature. (_ Chapter 9)
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1. Determine the installation dimension (distance of the drive-end/pump-end coupling

hub) as per general arrangement drawing and mark it on the drive shaft.
2. Thoroughly clean and debur the shaft end and the keyway, if required.
3. Insert the key.
4. Push the coupling hub onto the drive shaft until it reaches the marking.
5. If the coupling hub is hard to push on, a puller can be used or the coupling half can be
heated up slightly.
6. Secure the coupling hub against sliding with a grub screw.
Fig. 6 : Sliding on the coupling hub
7. Fit the flexible elements of the coupling and the spacer sleeve to the pump-end
coupling hub.
8. Place the drive including the fitted coupling hub on motor stool (341).
9. Temporarily fasten the drive with hexagon nuts (920) to allow alignment of the
connecting coupling.
NOTE
Observe the coupling manufacturer’s product literature. (_ Chapter 9)
Observe the motor manufacturer’s product literature. (_ Chapter 9)
The pump is connected to the driver by a flexible coupling. In most cases, a meta flex
coupling with spacer is used. The pump and drive shafts must be aligned very accurately,
because any misalignment, whether lateral or angular of the shafts can only be
compensated to a limited extent by the flexibility of the coupling at the prevailing rotational
speeds, and may therefore result in damage to the transmission elements and to the
pump. The alignment of the shafts is effected automatically by a centering fit on the motor
lantern. The coupling requires no special maintenance during operation.
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5.8 Connection to power supply
DANGER
Work on the pump set by unqualified personnel
Danger of death from electric shock!
Ø Always have the electrical connections installed by a trained and qualified
electrician.
Ø Observe the motor manufacturer's operating instructions.
WARNING
Unintentional starting of pump set
Risk of injury by moving parts!
Ø Make sure that the pump set cannot be started up unintentionally.
Ø Always make sure the electrical connections are disconnected before carrying out
work on the pump set.
NOTE
It is recommended to fit a motor protection device.
1. Check the available mains voltage against the data on the motor name plate.
2. Select an appropriate start-up method
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
Ø Observe the technical specifications of the local energy supply companies.
5.9 Checking the direction of rotation
CAUTION
Incorrect direction of rotation with non-reversible mechanical seal
Damage to the mechanical seal and leakage!
Ø Separate the pump from the motor to check the direction of rotation.
CAUTION
Drive and pump running in the wrong direction of rotation
Damage to the pump!
Ø Refer to the arrow indicating the direction of rotation on the pump.
Ø Check the direction of rotation. If required, check the electrical connection and
correct the direction of rotation.
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The correct direction of rotation of the motor and pump is anti clockwise
(viewed from driver to pump).
1. Start the motor and stop it again immediately to determine the motor's direction of
rotation.
2. Check the direction of rotation.
The motor's direction of rotation must match the arrow indicating the direction of
rotation on the pump.
3. If the motor runs in the wrong direction of rotation, check the electrical connection of the
motor and the control system, if applicable.
5.10 Connecting the piping & Strainer
NOTE
KSB's scope of supply as well as the arrangement of piping and valves are illustrated
in the general arrangement drawing and in the P+I diagram in chapter 9.
(_ Chapter 9)
DANGER
Impermissible loads acting on the pump nozzles
Danger to life from leakage of hot, toxic, corrosive or flammable fluids!
Ø Do not use the pump as an anchorage point for the piping.
Ø Anchor the pipelines in close proximity to the pump and connect them without
transmitting any stresses or strains.
Ø Observe the permissible forces and moments at the pump nozzles.
Ø Take appropriate measures to compensate thermal expansion of the piping.
CAUTION
Incorrect earthing during welding work at the piping
Destruction of rolling element bearings (pitting effect)!
Ø Never earth the electric welding equipment on the pump or base plate.
Ø Prevent current flowing through the rolling element bearings.
§ Remove the temporary holders and fit the pipes to the pump nozzles.
§ The pipes must be fully supported by the supports or spring hangers provided.
§ The spring hangers must have full adjustment and must not be at their lower limit.
1. Observe the tightening torques! (_ Chapter 9)
P If short pipes are used in the plant, their nominal diameters should be at least equal to
the nominal diameters of the pump nozzles. For long pipelines, the most economical
nominal diameter has to be determined from case to case.
P Adapters to larger diameters should have a diffuser angle of approximately 8o in order
to avoid any pressure losses caused by the formation of air pockets. Prevent harsh
transitions.
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P The suction lift line/suction head line has been laid with a rising/downward slope
towards the pump.
P It is recommended to install check valves and shut-off elements.
P The internal piping is supplied completely fitted. See general arrangement drawing.
(_ Chapter 9)
P Do not remove blind flanges or closure covers on pump nozzles and pipe
connections including any packaging with desiccants possibly attached to them until
immediately before the relevant pipes are connected. The responsibility for disposal of
the parts supplied lies with the consignee.
P Make and adapt any possibly required connecting pipes in accordance with the
general arrangement drawing. Offset at flange connections and pipe unions is not
permitted.
P Pipes supplied by KSB have been cleaned and closed. Nevertheless their interiors
must be checked for impurities which might have been caused afterwards and be
cleaned, if required.
P As a general rule, pipes made on site must be cleaned prior to final mounting.
1. Connect the pump nozzles with the piping.
5.10.1 Cleaning the piping
CAUTION
Welding beads, scale and other impurities in the piping
Damage to the pump!
Ø Free the piping from any impurities.
1. Blow the piping through with compressed air.
NOTE
Do not clean the valves in the piping with a high-pressure steam-jet air ejector as the
valves' plastic parts cannot handle the steam temperature.
5.10.2 Installing a strainer in the inlet pipe (If applicable)
NOTE
The strainer in the inlet pipe is destined to stop welding beads, scale and other
impurities (that come off the piping with time) from entering the pump. It is not destined
to remove any inadmissible particles entrained in the fluid handled due to an excessive
solids content.
For installing the strainer refer to the manufacturer's product literature. (_ Chapter 9)
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CAUTION
Improper handling Damage to the strainer
Ø Do not exert pressure on the strainer element and strainer meshes or damage them.
Ø Transport by hand is recommended. If this is not an option because of the weight,
observe the transport options described in this manual. (_ Chapter 3)
1. Prior to installation, perform a visual inspection of the inlet pipe between strainer and
pump. Clean it, if required.
2. Install the strainer in the inlet pipe as close to the pump nozzle as possible.
3. For differential pressure monitoring a drilled hole is provided upstream and
downstream of the strainer insert or at the strainer housing.
Installation example C C
conical strainer
A B
D
Fig. 7 : Installation example
A Inlet pipe B Inlet pipe

Connection, differential pressure
C D Strainer housing
monitoring
E Strainer insert
Installation example
Y-strainer
E
A C D C B
Fig. 8 : Installation example
A Inlet pipe B Suction pipe, pump

Connection, differential pressure
C D Strainer housing
monitoring
E Strainer insert
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Also see
§ Relevant documentation [_ Chapter 9]
5.10.3 Installing the minimum flow valve/minimum flow system

1. Fit the minimum flow valve (if applicable) to the pump's discharge line as stated in the
manufacturer's product literature. (_ Chapter 9)
Isolating Valves
An isolating valve (gate valve) should be provided in the suction line, to cut the supply of
fluid to a pump if necessary. An isolating valve should also be incorporated in the
discharge line of every pump, as close as possible to the pump itself. This valve can be
used to adjust the operating point (rate of flow) apart from its function of isolating the
discharge line. Isolating valves in suction line should only be used to isolate the line. (in
the event of repairs etc.) They must always remain fully open when the pump is running. If
the pump operates under vacuum, the isolating valve should be provided with a sealing
liquid connection or with a closed water seal, to prevent any ingress of air into the stuffing
box of the valve stem. To facilitate venting the isolating valves should be fitted in the line
with their stems horizontal.
2
15
6
18
16
21
3
8
19
11
10
20
9
23
22
13
12
17
14
1
Fig. 9
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24 25
Operation with manual

operation nozzle
Fig. 10
Part No. Designation
1 Bottom half of body 9 Lever 17 O-ring

2 Top half of body 10 Taper grooved dowel pin 18 *) O-ring
3 Valve cone 11 Bottom spider 19 Valve
4 Guide shank 12 Top spider 20 Cylindrical helical spring
5 Slide valve head 13 Cylindrical helical spring 21 Manual operation nozzle
6 Nozzle 14 Socket head cap screws 22 Multistage throttle
7 Throttle 15 Socket head cap
8 Rotary slide valve 16 Taper grooved dowel pin
*) Not applicable for temperature above 130o C and valve pressure rating above PN 100
(Metal to metal sealing provided). Parts 8-13 (complete leak-off nozzle) can be replaced
individually.
Non-return valves (in the discharge line)

A check valve or non-return valve should be incorporated between the pump and the
isolating valve. Depending on the circumstance, this can be either a check valve, or a non-
return valve or an automatic re-circulation valve. The object of the non-return valve is to
prevent a reflux of fluid through the pump when the latter stops suddenly.
Automatic Recirculation valve

The Schroeder system automatic re-circulation valve(minimum flow device) is a safety
device, the purpose of which is to ensure a safe minimum flow through the pump at any
point of time irrespective of the system demand. It should always be installed immediately
downstream of the pump, always upstream of the isolating valve, and always vertical, with
the direction of flow from bottom to top. Each automatic re-circulation valve is supplied in
accordance with the operating conditions of the pump concerned. Automatic recirculation
valve has a built-in non return valve. Therefore, once an automatic recirculation valve has
been installed, a separate non return valve is not required. The greater the flow of fluid,
the higher the valve cone is lifted by the fluid pumped. A connecting rod in the shape of a
lever the slide valve lever is connected at one end to the valve cone and at the other end
to the shut off valve (slide valve) on the bypass (leak-off) outlet. As the valve cone rises
and falls, the shut-off valve is actuated by this lever, and the opening of the bypass is
controlled in such a way that the bypass closes when the rate of flow has attained a given
value, and opens when it drops below this value. The minimum flow rate is calculated and
adjusted so as to avoid any excessive.
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2. Arrange the minimum flow system (if applicable) as shown on the P + I diagram.
(_ Chapter 9)
(For the protection of the pump when operating at low loads).
General :-
The power absorbed by the pump does not decrease proportionately with decreasing rate
of flow, but on the contrary still amounts to more than 50% of the power absorbed at the
design duty point at zero flow (pump shut off point). In order to carry off this energy which
is converted into heat inside the pump, it is necessary to maintain a minimum rate of flow
through the pump. In the case of pumps with discharge nozzles of nominal sizes between
40 and 150 this minimum rate of flow normally amounts to 0.15 Qopt, taking the heat
conditions and the pattern of the characteristic curve into account. In the case of pumps
with larger sizes of discharge nozzle, this minimum rate of flow amounts to 0.2 Qopt. Qopt
= Rate of flow at maximum efficiency of the pump.
N.B.
The pump should only be operated at rates of flow below the minimum rate of flow during
the switching on and switching off process. Excessive wear and damage to the pump
cannot be excluded under these circumstances.
Minimum flow circulation via a permanent bypass.

The permanent bypass recirculation is selected for plants with relatively low pressures and
low minimum flow rates. This system is very attractive from the point of view of low first
cost, but is uneconomic in operation because the minimum flow (or bypass flow) has to be
circulated over the entire operating range of the pump. When sizing the pump, the bypass
rate of flow must be added to the pump capacity. In order to ensure the minimum flow, an
orifice plate is fitted in the bypass line between the pump and the suction vessel.
Minimum Flow Circulation via an automatic Recirculation Valve.

The automatic recirculation valve ensures the minimum flow protection requirement simply
and reliably. It is mounted vertically in the discharge line between the pump discharge
nozzle and the isolating valve, in such a way that the fluid flows through it from bottom to
top. As soon as the rate of flow of the pump falls below a given minimum value, the
bypass outlet on the automatic recirculation valve opens sufficiently wide for a
predetermined minimum flow quantity to pass through and be maintained even when the
rate of flow through the main discharge line is reduced to zero.
Switching off
Close valve in discharge line. If a non return valve or check valve is incorporated in the
discharge line, the isolating valve may remain open, provided that adequate back
pressure is present. Switch off the driver and observe the pump running down to a
standstill smoothly and quietly. In the event of prolonged shutdowns, close the isolating
valve in the suction line. Close the auxiliary connections and only turn off the cooling liquid
supply (if provided) after the pump has cooled down. In case of frost and / or of a
prolonged shutdown, the pump and any cooling compartments provided on it should be
drained or safeguarded by other means against freezing.
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5.10.4 Installing the bypass line
CAUTION
Damage to the minimum flow valve caused by impermissible piping layout
Damage to the machinery!
Ø When installing the bypass line, observe the minimum flow diagram.
Ø Install an orifice immediately upstream of the capacitor to avoid vaporization in the
bypass line.
1. Route the bypass line back to the capacitor.
5.11 Fitting the monitoring equipment (if applicable and not fitted at the
factory)
If available and not already fitted, fit the monitoring equipment (measuring instruments) as
follows:
§ Thermometer (bearings):
Insert the seal element. Screw in the thermometer.
§ Pressure gauge :
Insert the sealing washer and fasten the pressure gauge with a lock nut.
§ Constant-level oiler:
Apply sealing tape or liquid seal and screw in the Constant-level oiler.
Any extensions, if required, are included in the scope of supply
§ Resistance thermometer or thermocouple:

– For the required sensor length refer to the list of measuring points. Verify the length
at the site of installation.
– Insert the sealing element. Screw in the resistance thermometer or thermocouple.
– Run the connecting cables in cable ducts until just before reaching the measuring
point and have them connected by authorized personnel.
§ Differential pressure measurement:

– Fasten the monitoring equipment for the differential pressure to the holder.
– Connect the instrument leads to the connecting points provided and install them in
accordance with the conditions on site.
– Run the connecting cables in cable ducts until just before reaching the measuring
point and have them connected by authorized personnel.
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4M.3
4M.1 4M.2
1M.1 1M.2
Connection Instrument Measuring location

1M.1 Pressure gauge Suction nozzle
1M.2 Pressure gauge Discharge nozzle
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5.12 Fitting the auxiliary connections

15E 15A 10E
7A.2
7A.1
5B 7E.1 8B 7E.2
Fig. 11 : Installing the connecting lines (example)
5B Venting 8B Leakage drain

7A.1 Outlet, cooling liquid 10E Inlet, sealing liquid
7A.2 Outlet, cooling liquid 15A Outlet, balancing liquid
7E.1 Inlet, cooling liquid 15E Inlet, balancing liquid
7E.2 Inlet, cooling liquid
P The mechanical seal has been properly installed.
P The bearings have been fitted properly.
5.13 Fitting the protective equipment
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts.
Ø As soon as the work is completed, re-install and/or re-activate all safety-relevant
and protective devices.
CAUTION
Heat build-up in the bearing housing
Damage to the bearing!
Ø Never insulate the bearing housing and bearing cover.
1. Fit all protective equipment, such as guards, monitoring devices, etc.
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5.14 Installation checklist
NOTE
The final check required to release the pump set must be performed by KSB personnel.
Carry out the following checks:

§ Check the tightening torques of pump, drive and connecting coupling. (_ Chapter 9)
§ Check the tightening torques of the suction and discharge side flange connections.
§ Check that all auxiliary and supply lines are connected properly, see general
arrangement drawing and P+I diagram (_ Chapter 9).
§ Check that all measuring instruments are connected properly, see general
arrangement drawing and P+I diagram (_ Chapter 9).
§ Have the alignment data sheet/transfer log confirmed by the responsible site
management.
5.15 Preservation for standstill

If the pump is not commissioned immediately after its installation, carry out the measures
for preservation. (_ Chapter 6)
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Chapter 6 Commissioning / Start-up / Shutdown
6 Commissioning / Start-up / Shutdown

6.1 Work to be carried out prior to commissioning
6.1.1 Removing the preservation
WARNING
Hazardous to persons and the environment!
Ø Collect and properly dispose of flushing liquid and any liquid residues.
Ø Wear safety clothing and a protective mask, if required.
Ø Observe all legal regulations on the disposal of fluids posing a health hazard.
Internal preservation
If the pump has been filled with a glycol / water mixture for preservation, this mixture has
to be drained prior to any further work.
NOTE
Observe the manufacturer's instructions for application/removal of the preservative.
P A container for collecting the preservative is on hand.

1. Open the drain (6B) of the pump.
2. Drain the pump.
3. Collect the drained fluid in a suitable container and dispose of it in accordance with the
environmental regulations.
4. Close the drain (6B) of the pump.
5. Flush the pump sufficiently to remove all residues of the preservative.
6. Remove the grease on the outsides of all pump set components.
External preservation
Remove the preservation of the pump set components in accordance with the relevant
manufacturer's product literature. (_ Chapter 9)
1. Wash the preserved exterior parts with petrol, petroleum, diesel oil or general purpose
cleaner such as Shell Collina 2306.
6.1.2 Work to be carried out prior to restart after standstill > 12 months
WARNING
If stored for more than five years, the sealing function could be impaired Risk of injury,
e.g. cuts caused by fluid jets, eye injuries, burns, scalds, and respiratory system burns!
Ø After a storage period of more than five years, dismantle the pump before it is
installed and replace the sealing elements, e.g. O-rings.
Ø Check sealing elements, e.g. O-rings, for any damage before fitting them.
1.Check sealing elements, e.g. O-rings, for any damage before fitting them.
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Additional work for variants with mechanical seal
Observe the safety notes given in the respective chapters on dismantling/reassembly.

1. Dismantle the pump-end coupling hub. (_ Chapter 7)
2. Dismantle the bearings. (_ Chapter 7)
3. Remove the mechanical seal. (_ Chapter 7)
Check the mechanical seal as described in the manufacturer's product literature.
(_ Chapter 9)
4. If the mechanical seal is clean and undamaged, it may be re-installed. Otherwise a
new mechanical seal must be installed. (_ Chapter 7)
5. Re-install the bearings. (_ Chapter 7)
6. Re-mount the pump-end coupling hub.
6.1.3 Filling in lubricants
CAUTION
Insufficient lubricating oil in the reservoir of the constant-level oiler
Damage to the bearings!
Ø Regularly check the oil level.
Ø Always fill the oil reservoir completely.
Ø Keep the oil reservoir properly filled at all times.
CAUTION
Too much lubricating oil
Leakage of the fluid handled or oil
Ø Regularly check the oil level.
After a standstill of > 12 months, check the quality of the oil. If required, clean or replace
the oil.
Do not clean the oil until immediately before commissioning/start-up! If
Commissioning / start-up is delayed by more than one month, clean the oil again.
Filter the oil prior to topping up; filter mesh size 30 µm.
Thrust bearing unit of the pump
Oil quantity and quality see table on lubricants. (_ Chapter 9)
P The oil has been filtered.

1. Remove vent plug (913) at bearing cover (360) and fill in oil through the opening. The
required oil level has been reached when the oil is visible in the opened / hinged down
constant-level oiler (638).
2. Fit vent plug (913) again.
3. Fill oil into the reservoir of constant-level oiler (638).
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6.1.4 Vacuum Balance Line

If the pump has to pump liquid out of a vessel under vacuum it is advisable to install a
vacuum balance line. The suction area (Can and distributor casing) is vented via a line
which remains open all the time. This line should have a nominal site of 25 mm minimum.
It should be arranged to lead back into the vacuum vessel in vapour phase.
5B
Back to suction
(in vapour state)
6.1.5 Gland Packing (If applicable)

§ The stuffing box is not packed when the pump is delivered.
The packing is supplied loose.
§ When adjusting the leakage of the gland packing after having performed any
maintenance work, check whether the studs have been fitted in the shaft seal housing.
Packing the stuffing box of the pump:
NOTE
Faulty alignment through packed stuffing box.
The stuffing boxes shall not be packed before the final alignment of the pump set has
been effected and not until commissioning/start-up.
NOTE
The leakage of the gland packing is adjusted later. (See chapter 6)
6.1.6 Fitting the protective equipment
WARNING
Failure to re-install or re-activate protective devices
Risk of personal injury from moving parts or escaping fluid!
Ø As soon as the work is completed, re-install and/or re-activate all safety-relevant
and protective devices.
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1. Mount cover plates (68-2) to motor stool (341) by means of bolts (901) and discs (550).
In compliance with the accident prevention regulations the pump must not be operated
without a coupling guard. If the customer specifically requests not to include a coupling
guard in our delivery, then the operator must supply one. In this case, it is important to
make sure that the materials selected for coupling and coupling guard are non
sparking in the event of mechanical contact. KSB's scope of supply meets this
requirement.
Fig. 12 : Driver disconnected from pump.
6.1.7 Priming the pump and piping
CAUTION
Increased wear due to dry running
Damage to the pump (set)/bearings!
Ø Never operate the pump set without liquid fill.
Ø Never operate the pump set in incompletely primed or incompletely vented
condition.
Ø Never close the shut-off element in the suction line and/or supply line during pump
operation.
P All preparatory measures have been completed.

1. Close all drains and drain lines.
2. Completely open the cooling water main valve and all cooling water throttle valves.
3. Vent the entire cooling water circuit.
4. Vent the entire barrier fluid system of the mechanical seal.
5. Monitor the cooling water flow by means of sight glasses and/or flow indicators.
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NOTE
Do not cool down cooling chambers and heat exchangers with aggressive raw water.
6. If fitted, check the filter in the barrier fluid system of the mechanical seal. Clean it, if
required.
7. Open the valves in the minimum flow system.
8. Check the oil levels and top up with oil, if required. (_ Chapter 6)
9. Fully open the valve in the inlet pipe.
10. Fill the inlet pipe, pump and discharge line with cold condensate.
11. Vent the pump at connection (5B) by loosening the screwed plug of the vent hole until
no more air escapes.
NOTE
The screwed plug (connection 5B) must not be opened if the system is under vacuum,
otherwise air would enter the system.
12. Vent all pressure gauge lines until there is no more air to escape.
13. Check whether inlet pressure is available.
NOTE
For design-inherent reasons, the existence of some spaces not filled with liquid after
the pump has been filled prior to commissioning cannot be excluded. However, once
the drive is started up the pumping effect will immediately fill these spaces with the
fluid handled.
6.2 Commissioning/start-up
6.2.1 Prerequisites for commissioning/start-up

§ Installation and alignment have been performed in accordance with sound engineering
practice, recorded and accepted by the operator.
§ The rotatability of the pump rotor by hand has been checked.
§ All pump set components have been checked in accordance with the relevant
manufacturer's product literature.
§ The electrical connection of the pump set has been checked by a trained, authorized
electrician.
§ Check that the thrust and radial bearing of the pump and any other bearings of other
pump set components have been filled to the specified level with the appropriate
lubricant.
§ The direction of rotation of the drive has been checked; the pump is connected to the
drive.
§ 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.
§ The pump, supply lines and circuits have been primed and vented.
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Checks to be carried out prior to start - up / commissioning
§ The inlet tank, inlet pipe, pump and discharge line have been primed and vented.
§ The screwed plug (connection 5B) has been closed.
§ The valve of the inlet pipe has been opened completely.
§ The valve in the discharge line is closed. If the discharge line is equipped with a check
valve, the valve in the discharge line may remain open as long as there is some back
pressure.
§ The vacuum balance line (connection 25A) has been opened.
§ The barrier fluid line (connection 10A) has been opened.
§ The barrier fluid pressure must not exceed the value indicated in the general
arrangement drawing. (_ Chapter 9)
§ Open the shut-off valves in the bypass line, if any.
§ The cooling water system (connection 7E/7A) is in operation.
§ The cooling liquid pressure and temperature must not exceed the values indicated in
the general arrangement drawing. (_ Chapter 9)
§ All temperatures indicated are below the limit values.
§ All pipes, flanges, screw/bolt connections and pipe unions have been checked for
leakage.
§ Disengage locking discs (552) by swivelling them out of the groove in shaft sleeve
(523) and secure them with bolts (901).
§ Mechanical seal variant: Locking discs (552) must have been disengaged from the
groove in shaft sleeve (523) and secured by means of fastening bolts (901).
§ Gland packing variant: The gland packing must drip.
6.2.2 Start-up and trial run
WARNING
Non-compliance with operating limits for pressure, temperature and speed
Hot fluid could escape!
Explosion hazard!
Ø Comply with the operating data indicated in the data sheet.
Ø Avoid prolonged operation against a closed shut-off element.
Ø Never operate the pump at temperatures exceeding those specified in the data
sheet or on the name plate unless the written consent of the manufacturer has been
obtained.
WARNING
Sound pressure level above 85 dB(A) when starting up the pump set
Injury to or impairment of hearing!
Ø Wear ear protection.
Ø Access to the pump set permitted to authorized specialist personnel only.
Ø Observe the applicable local occupational health and safety regulations.
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WARNING
The pump casing takes on the same temperature as the fluid handled
Heat or freeze burns!
Ø Fit additional protective devices.
CAUTION
Abnormal noises, vibrations, temperatures or leakage
Damage to the pump!
Ø Switch off the pump (set) immediately.
Ø Eliminate the causes before returning the pump set to service.
P All checks described in the previous chapters have been completed with successful
outcomes.
1. Switch the drive on as described in the manufacturer's product literature.
(_ Chapter 9)
2. Check the temperature and smooth running of the bearings.
3. Check the pump pressures and differential pressures.
4. Pay attention to the power output and the current input of the drive motor.
5. Monitor the measuring and monitoring instruments.
6. If fitted, monitor the minimum flow valve (hydrodynamic noise).
7. Check the mechanical seal or Gland packing
8. After the mechanical seal has been checked for correct functioning, slowly open the
valve of the discharge line until it is completely open. When starting against an open
valve in the discharge pipe, consider the higher power input required.
9. Continuously monitor the operating behavior and smooth running of the pump set.
NOTE
Should warning signals or problems occur during starting or trial run, proceed as
described in the chapter on "Trouble-shooting". (_ Chapter 8)
6.2.2.1 Checking the mechanical seal
DANGER
Contact with unprotected rotating parts
Ø Do not reach into rotating parts.
Ø Always have this work performed by trained specialist personnel.
Ø Take particular caution when performing this work.
After start-up and as part of maintenance work, check the mechanical seal for leakage.
The mechanical seal must only leak slightly during operation (< 15 drops/minute).
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46
6.2.2.2 Gland packing variant:

Check the gland packing leakage and re--tighten hexagon nuts (920.31), if Required.
CAUTION
Damage to the shaft seal components!
Ø Excessive and non-uniform tightening of gland follower (452) causes premature
wear of packing material (461) and shaft protecting sleeve (524).
Ø Tighten the gland follower (452) uniformly and not too firmly.
NOTE
The gland packing must drip during operation! Leakage approximately 2-3 l/h.
Adjusting the leakage:

1. Only slightly tighten nuts (920) of gland follower (452) by hand.
2. Use a feeler gauge to verify that the gland follower is mounted centered and at a right
angle to the shaft.
The gland must leak after the pump has been primed.
Reduce the leakage after starting.
1. Tighten the nuts (920) of gland follower (452) by 1/6 turn.
2. Monitor the leakage for another five minutes.
Excessive leakage:
Repeat steps 1 and 2 until the minimum value has been reached.
Not enough leakage:

Slightly loosen the nuts at the gland follower.
No leakage:
Immediately switch off the pump set.
Loosen the gland follower and repeat start-up.
Checking the leakage:

After the leakage has been adjusted, monitor the leakage for about two hours at maximum
fluid temperature.
Check that enough leakage occurs at the gland packing at minimum inlet pressure of the
pumped medium.
NOTE
On variable--speed pumps, the necessary gland packing leakage must be set for the
minimum fluid pressure; higher leakage rates are to be expected for other operating
conditions.
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47
6.3 Operating limits
DANGER
Non-compliance with operating limits for pressure, temperature and speed
Explosion hazard!
Hot fluid could escape!
Ø Avoid prolonged operation against a closed shut-off element.
Ø Never operate the pump at temperatures exceeding those specified in the data
sheet or on the name plate unless the written consent of the manufacturer has been
obtained.
6.3.1 Frequency of starts

§ Maximum 25 starts are permitted per day.
§ In systems with more than one pump ensure an even distribution of the pump
operating hours (pump changeover)
NOTE
These values apply to the pump only.
The frequency of starts is usually determined by the maximum temperature increase of
the motor. This largely depends on the power reserves of the motor in steady-state
operation and on the starting conditions (DOL, star-delta, moments of inertia, etc). See
the manufacturer's instructions. (_ Chapter 9)
CAUTION
Re-starting while motor is still running down
Damage to the pump (set)!
Ø Do not re-start the pump set before the pump rotor has come to a standstill.
Also see
§ Relevant documentation [_ chapter 9]
6.3.2 Ambient temperature

Observe the following parameters and values during operation:
Table 4 : Permissible ambient temperatures
Permissible ambient temperature Value

Maximum 50 oC
Minimum 0 oC
For operation at temperatures outside the permissible limits, contact KSB.
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48
DANGER
The operating limits have been exceeded
Explosion hazard!
Ø Avoid operation against a closed shut-off element.
Ø Never operate the pump at ambient or fluid temperatures specified in the data sheet
or on the name plate.
Ø Never operate the pump set outside the limits specified.
6.4 Measures to be taken for shutdown
6.4.1 Shutdown - pump set remains ready for operation
DANGER
Insufficient preparation of work on the pump (set)
Ø Properly shut down the pump set.
Ø Close the shut-off elements in the suction and discharge line.
Ø Drain the pump and release the pump pressure.
Ø Close any auxiliary connections.
Ø Allow the pump set to cool down to ambient temperature.
WARNING
Hot fluid may escape
Scalding!
Ø Wear appropriate protective clothing (e.g. safety gloves, safety goggles) when
venting the pump set.
Ø Protect the electric components against escaping fluid.
WARNING
Ø Observe all relevant laws.
Ø When draining the fluid take appropriate measures to protect persons and the
environment.
WARNING
Hot surface
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49
1. Close the shut-off element in the discharge line.

2. Monitor the function of the minimum flow system (if any).
3. Switch off the drive, making sure the rotor runs down smoothly to a standstill.
4. Note the run-down time.
NOTE
The cooling water system remains ON!
NOTE
Keep the shut-off element in the inlet pipe open.
The shut-off valve should only be closed if the pump is taken out of service for a
prolonged period of time and drained.
The screwed plug (connection 5B) must not be opened if the system is ready for
operation (under vacuum), otherwise air would enter the system.
If the period of standstill is longer than 2 weeks, the other pump set components must be
protected against water ingress and humidity as described in the manufacturer's
preservation instructions.
Further work
Carry out the following measures every 4 to 6 weeks:
1. Start up the pump set. (Chapter 6)
2. After approximately 10 minutes shut down the pump set. (Chapter 6)
3. Make sure that the rotor runs down smoothly to a standstill.
6.4.2 Shut down for maintenance of the pump set or prolonged standstill
DANGER
WARNING
Hot fluid may escape
Ø Wear appropriate protective clothing (e.g. safety gloves, safety goggles) when
venting the pump set.
Ø Protect the electric components against escaping fluid.
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50
WARNING
Ø Observe all relevant laws.
Ø When draining the fluid take appropriate measures to protect persons and the
environment.
Ø Decontaminate pumps which handle fluids posing a health hazard.
WARNING
Hot surface
1 Close the shut-off element in the discharge line.

2. Monitor the function of the minimum flow system (if any).
3. Switch off the drive, making sure the rotor runs down smoothly to a standstill.
4. Note the run-down time.
5. Close the shut-off element in the bypass line (if any).
6. Close the shut-off element in the inlet pipe.
7. Turn off the cooling water system when the casing temperature has dropped to below
o
30 C .
8. Close the other pipes.
Final work
P The pump set has been shut down.
P The drive has been secured against start-up.
P A container for collecting the fluid is on hand.
1. Secure all shut-off elements against opening.
2. Place suitable containers under the drain holes.
3. Open all drains and/or drain pipes.
If the period of standstill is longer than 2 weeks, the other pump set components must be
protected against water ingress and humidity as described in the manufacturer's
preservation instructions.
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51
6.4.3 Preservation for standstill

Preservation for standstill is required if:
§ The pump set is not commissioned immediately after its installation
§ The standstill time of the pump set exceeds two weeks
§ There is any risk of freezing
Preservative Use a preservative which fulfils the following criteria:

§ Mixture of glycol and water, ratio 1:1
NOTE
o
This mixture ensures protection against freezing up to approximately -42 C.
P The pump set has been shut down.

P The drive has been secured against start-up.
P A container for collecting the fluid is on hand.
P Sufficient preservative is available.
1. Secure all shut-off elements against opening.

2. Place suitable containers under the drain holes.
3. Open all drains and/or drain pipes.
4. Collect and properly dispose of the fluid.
5. Close all drains and drain lines.
6. Fill the pump with preservative.
7. Undo the screwed connection of the spacer sleeves at the connecting coupling to
disconnect the drive from the pump.
8. Store the connecting elements appropriately.
9. Undo, remove, mark and store the spacer (if any) of the connecting coupling as
described in the manufacturer's product literature.
10. If required, fill the bearing housing with oil.
11. Rotate the pump rotor once or twice per month to prevent the separation of the
preservation fill.
To do so, remove contact guard (680) from motor stool (341). After the work has been
completed, fit the guard again.
12. Check the fill level of the preservative once or twice a month; top it up, if required.
6.5 Returning to service

For returning the pump to service observe the chapters on commissioning/start-up
(_ Chapter 6) and the operating limits.
In addition, carry out all servicing / maintenance operations before returning the pump
(set) to service. (_ Chapter 7).
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Chapter 7 Supervision / Servicing / Maintenance
7 Supervision / Servicing / Maintenance

7.1 Monitoring schedule
KSB recommends the following schedule for monitoring the pump set:
Table 5 : Monitoring schedule
What/where How Value to be met Interval

o
Radial/thrust bearing unit Check the temperature. < 75 C Weekly
Check the oil level. Middle between the minimum Weekly
and maximum marks
Check smooth running. The pump must run quietly Weekly
and free from vibrations.
Mechanical seal 1) Check for leakage. 15 drops/minute Weekly
Temperature measurement at Check the temperature. See data provided by the Weekly
the mechanical seal 1) manufacturer.
Gland packing (if applicable) Checking the leakage. 2-3 l/h Daily
Differential pressure gauge at Check the differential See list of measuring points. Weekly
pressure.
Measuring instrument, Check the pressure. See data sheet and Weekly
suction side ps 1) characteristic curve.
Measuring instrument, Check the pressure. See data sheet and Weekly
discharge side pd 1) characteristic curve.
Measuring instrument, Check the pressure. See general arrangement Weekly
barrier fluid system drawing.
Measuring instrument, Check the pressure. See general arrangement Weekly
cooling water system drawing.
Thermometer, suction and Check the temperature. See data sheet. Weekly
discharge nozzles 1)
Thermometer, cooling water Check the temperature. < 30 oC Daily
system 1)
Thermometer, supply and Check the temperature. r t < 30 oC Daily
return 3)
Sight glass for monitoring the Check the cooling water See general arrangement Daily
flow (cooling water line) 1) flow. drawing.
Drive See manufacturer's product See manufacturer's product See manufacturer's
literature. literature. product literature.
Static seals Check for tightness. The static seal shall be dry. Weekly
Contact guard Check Has to be fitted for Monthly
(readiness for) operation.
Earth conductor Check Connection must have been Monthly
made and marking applied.
Alarm signals Check the functioning. See the manufacturer's Daily
product literature or the
documentation on the
monitoring system.
In case of deviations, proceed in accordance with the table "Trouble-shooting".

1) (_ Chapter 8)
If any
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53
7.2 Service schedule

KSB recommends the following schedule for pump set maintenance:
Table 6 : Service schedule
Location to be serviced Checks Maintenance intervals Maint. intervals

Radial/thrust bearing unit Oil level, oil quality First oil change after 300 See chapter on
operating hours maintenance work
in the chapter.
All further oil changes after See manufacturer's
2,000 operating hours, or product literature.
after 1 year at the late
Connecting coupling See manufacturer's product After approx. 8,000 operating See manufacturer's
literature. hours. product literature.
Drive See manufacturer's product See manufacturer's See manufacturer's
literature. product literature. product literature.
Gland packing Checking the leakage. Weekly Re-adjustment,
(if applicable) if necessary.
Measuring instruments 2) Perfect condition and See manufacturer's Replace defective
functioning product literature. instruments.
See manufacturer's
product literature.
Pressure gauges 2) Perfect condition: no Every 3 months. Replace defective
mechanical damage. See manufacturer's instruments.
Electrical connections product literature. See manufacturer's
(if any) intact. product literature.
Proper functioning: local
measured value indication
available.
Differential pressure switch 2) Perfect condition: no Every 3 months. Replace defective
mechanical damage; See manufacturer's product instruments.
electrical connections intact literature. See manufacturer's
Check switching points. product literature.
Temperature measuring Perfect condition: no Every 3 months. Replace defective

instruments 2) mechanical damage. See manufacturer's instruments.
Electrical connections product literature. See manufacturer's
(if any) intact. product literature.
Proper functioning: local
available.
Check switching points.
Bearing housing vibration Perfect condition: no Every 3 months. Replace defective
measurement 2) mechanical damage. See manufacturer's instruments.
Electrical connections intact. product literature. See manufacturer's
Proper functioning: local product literature.
available.
In case of deviations, proceed in accordance with the table "Trouble-shooting".

2) (_ Chapter 8 )
If any
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54
7.3 Gland packing varient
7.3.1 Packing the box
914.31
184 X
452
524
10E
451
457
Fig. 13 : Mounting dimension X of shaft protection sleeve in mm.
CAUTION
Strong heating up of the shaft seal.
Risk of burns!
Ø The gland packing temperature should not exceed the temperature of the medium
o
handled by more than approx. 20 to 60 C.
Ø In case of a sudden temperature rise and a sudden drop in the leakage rate,
immediately unscrew the gland follower.
If the suction pressure exceeds 15 bar, we recommend the rings be die-formed. We can
supply the die on request. Pressure approx. 50 bar.
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55
a) Fitting new packing

Thoroughly clean the packing compartment and the shaft protection sleeve, and coat them
with molybdenum disuplhide. Insert neck ring (457) and press it home until it abuts Insert
the packing rings individually and push them home with the aid of the stuffing box gland
o
and the seal cage ring. The ring butt of each packing ring should be offset 90 in relation to
the joints of the adjoining rings. Insert seal cage ring (458) so that it registers opposite
connection 10E.
Then insert the remaining packing rings individually. Leave a sufficient clearance gap at
the entrance of the stuffing box for the positive guidance of the gland. The inserted
packing rings should only be lightly compressed by the gland and the nuts.
Then the nuts should be slackened and tightened again by hand. The even seating of the
gland should be checked with a feeler gauge, with the pump subjected to suction
pressure.
Now adjust the shaft protecting sleeve to the installation dimension ..X.. (see Fig. 13) with
clamping ring (184).
b) Removing the packing

Slacken clamping ring (184) and remove it from shaft protection sleeve (524), undo
stuffing box gland (452)and pull it out of stuffing box housing (451).
Pull the top packing rings out of stuffing box housing (451)with the aid of a packing ring
extractor, pull out seal cage ring (458), then remove the remaining packing rings and
examine shaft protection sleeve (524) for signs of damage.
Clean the packing compartment and coat it with molybdenum disulphide.
Pack the stuffing box as described under a) above.
N.B.
The stuffing box should drip slightly whilst the pump is running; the leakage rate should
amount to between 2 and 3 l/h. If your pump has sealing and cooling liquid connections in
use, they should be checked for unimpeded flow. When the stuffing box gland has been
repeatedly tightened in service until it abuts, it is time to renew the packing in the stuffing
box.
Packing Material
When selecting the packing material, remember to ascertain its compatibility with the
product pumped. Always use new packing material, preferably material which has been
stored for a certain period, to repack the stuffing box.
Packing Number of packing rings Width of Overall

Pump size compartment packing Length
(excluding lantern ring)
dws / da mm mm mm
40 40/60 6 10 1400
50 45/75 6 12 1500
65 45/70 6 12 1500
80 55/80 6 12 1600
100 55/80 6 12 1600
125 65/90 6 12 1750
150 65/90 6 12 1750
dws = Outer diameter of shaft protection sleeve.
da = Inner diameter of packing compartment.
Dimensions of packing compartment and packing
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56
NOTE
Do not re-pack the gland packing with fresh packing material until immediately before
commissioning.
Packing of the gland packing, see description in chapter 6
7.3.2 Gland packing variants

Depending on the temperature t of the product pumped and on the pump discharge
pressure pd, the VSM type gland packing (extra-deep with lantern ring at the centre) is
fitted to WKT pumps in the following alternative constructions :
524
914.31
902.31
184 920.31
452 451
10E
457 458
902.32 461
920.32
412.31
400.31
Fig. 14 : VSM stuffing box, normal type.

o
Application range : temperature not exceeding 105 C. pd not exceeding 25 bar.
914.31 524
184 902.31
920.31
452
451
10E
457 458
461
902.32
920.32 412.31
400.31 509.31
15A 400.31
562.31 542
Fig. 15 : VSM-E Stuffing box (relieved of pressure)

o
Application range: temperature not exceeding 105 C. pd above 25 bar
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57
914.31
452 184
461 524
902.31
914.32
920.31
411.31 451
920.33 412.33
710.31 7A.1
10E 458
7E.1 66-2
457 412.32
400.31 412.31
66-1 7A.2
7E.2
540 902.32
920.32
400.31
Fig. 16 : VSM -K Stuffing box (cooled)

o
Application range : temperature above 105 C; pd : not exceeding 25 bar.
914.31
452 184
461 524
902.31
914.32
920.31
411.31
451
920.33 412.33
710.31 7A.1
10E 458
7E.1 66-2
457 412.32
400.31 412.31
7A.2
15A 7E.2
540 902.32
920.32
66-1
152 400.31
Fig. 17 : VSM-K-E Stuffing box (cooled and relieved of pressure)

o
Application range : temperature-above 105 C. pd; above 25 bar.
Part No. Part description Part No. Part description

152 Heat Barrier 540 Bush
184 Clamping ring 542 Throttle bush
*400.31 Gasket 66-1 Heat barrier
*411.31 Gasket 66-2 Cooling cover
*412.31 O-Ring 710.31 Pipe
*412.32 O-Ring 902.31 Stud
*412.33 O-Ring 902.32 Stud
451 Stuffing box housing 914.31 Allen head screw
452 Stuffing box gland 914.32 Allen head screw
457 Neck ring 920.31 Hex Nut
458 Lantern ring 920.32 Hex Nut
*461 Gland packing 920.33 Hex Nut
509.31 Intermediate ring 7A.1 Cooling liquid outlet
*524 Shaft protection sleeve 7A.2 Cooling liquid outlet
7E.1 Cooling liquid inlet 10E Sealing liquid inlet
7E.2 Cooling liquid inlet 15A Pressure relief liquid outlet
* Recommended spare parts.
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58
7.3.3 Cooling, Sealing liquid and Relieving the Pressure on the

Shaft Seal Cooling
(see Fig 16, 17 & 18)
If the temperature of the product pumped exceeds 105oC, a heat barrier (66-1) is fitted
between the distributor casing and the stuffing box housing (451) The stuffing box housing
is provided with a cooling cover (66-2) with connections 7E/7A for the cooling liquid.
Water from an outside source with a hardness up to 8o dH Calcium hardness, or cooled

product can be used for cooling purposes. The outlet temperature of the coolant must not
exceed + 50oC.
If an aggressive coolant (e.g. saline water) is used, the parts in contact with the coolant
must be made of suitably resistant material.
Table 7 : Cooling fluid consumption in l/s and m3/h for an inlet temperature of 20oC and
t of 15oC
Pump Size 40 50/65 80/100 125/150
Rate of cooling fluid flow
l/s 0.083 0.11 0.14 0.17
3
m /h 0.3 0.4 0.5 0.6
Sealing liquid is fed to the stuffing box via connection 10E and the lantern ring, at a
pressure of 1 to 3 bar, in order to prevent the ingress of air in the case of operation under
partial vacuum, or during the shutdown of the pump. A non-return valve is installed in the
sealing liquid line to prevent the pump discharge pressure from being released via the
lantern ring during operation, thus starving the top packing rings of fluid and causing them
to run dry.
A solenoid valve can also be installed in the sealing liquid line, if the sealing liquid is
tapped from the main discharge line. This solenoid valve should be in the closed position
when the pump is running.
7.3.4 Relieving the Pressure on the Shaft Seal

If the pump discharge pressure exceeds 25 bar, the shaft seal compartment must be
relieved of pressure down to pump suction pressure via a pressure relief line.
(connections 15A/15E) - (see Fig 15, 17 & 18.)
15E 731.36 731.32 15A 10E 7A2
757.31 710.33 742.31 731.34 71-1.2
5B Venting
7A.1 Outlet, cooling liquid
7A.2 Outlet, cooling liquid
8B Leakage drain
10E Inlet, sealing liquid
15A Outlet, balancing liquid
15E Inlet, balancing liquid
71-1.1 5B 7E.1 7E.2 710.32

731.33 710.31 8B 7A.1
Fig. 18 : Auxiliary connections on VSM shaft

seals (the certified piping diagram relating to
the purchase order is binding in this respect.)
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59
7.3.5 Conical Couplings

The pump shaft, intermediate shafts and drive shaft are connected to one another by rigid
conical couplings, which transmit the torque, the axial thrust and the weight of the rotor.
Part No. Part designation

851 Conical coupling, complete, consisting of :
500 Locking ring
863 Inner sleeve
864 Outer sleeve
904 Worm screw
940 Key
864
15E 940
851
863
500
Fig. 19 : Conical coupling
7.3.6 Bearings Bushes

Carbon bearing bushes (545.1/.2) are press fitted inside steel sleeves and act as plain
bearings to support the shafts. These are lubricated by pumped medium by means of
progressive lubricating grooves provided on the inside diameter of carbon bushes.
These are fitted inside diffuser first stage (171.01), discharge casing (107), bearing spider
(383) and adaptor (145) (mechanical seal execution). These shall be replaced if clearance
is increased beyond the specified limit. (_ Chapter 9)
No special maintenance of these bearings is necessary, but the pump must not be allowed
to run dry. These shall be replaced if clearance is increased beyond the specified limit.
212
529.3
212 Intermediate shaft
545.3 383 Bearing spider
383 400.2 Gasket
529.3 Bearing sleeve
400.2
545.3 Bearing bush
711.1 711.1 Column Pipe
Fig. 20 : Bearing bush
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60
7.4 Dismantling the pump set
7.4.1 General information/Safety regulations
DANGER
DANGER
Improper transport
weight.
hoisting tackle.
WARNING
Unqualified personnel performing work on the pump (set)
Ø Always have repair and maintenance work performed by specially trained, qualified
personnel.
WARNING
Pump set started up inadvertently
Ø Make sure that the pump set cannot be started up accidentally.
WARNING
Hot surface
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61
WARNING
Components with sharp edges
Risk of cutting or shearing injuries!
Ø Always use appropriate caution for installation and dismantling work.
Ø Wear work gloves.
7.4.2 Prerequisites for dismantling

Prerequisites
§ The pump set has been properly shut down and prepared for maintenance.
§ All spare parts required are available.
§ All required documents for the pump set components are available.
§ Proper lifting accessories and means of transport are available and ready for use.
§ Sufficient room space and appropriate tools are available.
§ The drive has been secured against unintentional starting.
7.4.3 Removing the contact guard

P The drive has been switched off and secured against inadvertent re-start.
P The pump has been drained properly.
1. Undo bolts (901.04) to remove cover plates (68-2) mounted on the motor stool (341).
7.4.4 Removing the measuring instruments

1. Dismantle, mark and store the measuring devices and instruments, where required.
Observe the corresponding product literature provided by the manufacturer!
(_ Chapter 9)
7.4.5 Dismantling the piping

P The drive has been switched off and secured against inadvertent re-start.
P The pump including piping has been drained properly.
1. Loosen, remove, mark and store the piping, where required.
2. Loosen, remove, mark and store the auxiliary lines, where required.
3. Close all openings at the pump set where pipes/lines have been removed.
7.4.6 Dismantling the motor

P The measuring instruments have been removed, where required.
P The electrical connection has been properly disconnected from the mains.
P Suitable hoisting tackle incl. lifting accessories are available and ready for use.
Observe the weights indicated. (_ Chapter 9)
1. Use appropriate lifting accessories to protect the motor from falling.

2. Depending on the type of coupling, observe the marking on the coupling or mark the
coupling retrospectively to prevent any confusion.
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62
1 3 2
Fig. 21 : Marking the coupling
1 Pump-end coupling hub

2 Spacer
3 Drive-end coupling hub
X or XX Marking
NOTE
Observe the coupling manufacturer's instructions! (_ Chapter 9)
3. Undo the screwed connection of the spacer sleeves at the connecting coupling to
disconnect the drive from the pump.
4. Store the connecting elements appropriately.
5. Undo, remove, mark and store the spacer of the connecting coupling - if possible - as
described in the manufacturer's product literature.
6. Remove hexagon nuts (920.16).
7. Servicing/Maintenance
8. Lift up the drive including the drive-end coupling hub and place it on the assembly
supports.
9. Remove the flexible elements and spacer sleeves - if any - from the coupling hubs,
mark them and store them properly.
7.4.7 Dismantling the pump-end coupling hub

P The drive has been removed.
1. Use appropriate lifting accessories to protect the coupling hub from falling.
2. Dismantle the retaining ring, if applicable, from the coupling hub.
3. Remove the flexible elements and spacer sleeves - if any - from the coupling
hub, mark them and store them properly.
4. Unscrew the grub screw at the coupling hub so it protrudes by approximately 5 mm.
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63
Fig. 22 : Pulling off the coupling hub
NOTE
To facilitate removing the coupling hub may be heated uniformly to a temperature of
80oC max.
5. Always remove elastomeric parts before heating!

6. Pull off the pump-end coupling hub with a puller.
7. Mark key (940.03) prior to removing it.
8. Store the coupling hub and key appropriately.
7.4.8 Dismantling Bearing
7.4.8.1 Thrust Bearing

This dismantling procedure is applicable for pumps supplied with split centering sleeve
design. This design contains centering sleeve divided in two parts, viz.
- Centering sleeve
- Adjusting nut
P The pump is installed in the can.
P The motor stool has been removed.
P All removed connection elements have been kept.
P The oil has been drained and properly disposed of.
1. Remove key (motor end) from drive shaft.
2. Unscrew and remove oil labyrinth (270).
3. Dismantle constant level oiler (638) together with its connecting pipe.
4. Rotate either centering sleeve or adjusting nut by 90o to align lugs of adjusting nut with
key-way slots of centering sleeve.
5. Engage drive shaft key in the slots of both centering sleeve and adjusting nut
simultaneously.
6. Rotating centering sleeve with adjusting nut in anti clockwise direction will cause the
centering sleeve to rotate in its place only and adjusting nut to come out from the drive
shaft threading.
7. Continue to rotate till adjusting nut comes out completely.
8. Unlock and unscrew withdrawal nut (920.8), push antifriction bearing (320) off the
centering sleeve, clean it with wash oil and examine it.
NOTE
Antifriction bearing designation in accordance with DIN 628 bearing clearance group
C3.
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64
Adjusting Nut Centering Sleeve Assembled Position

Circular
Groove
Slots for
Assembly/Dismantling
Lugs Key-way
Slots
Key-way
Slots
213
924 Part No. Part Designation

940.2
350 Bearing Housing
526 360
360 Bearing Cover
320 526 Centering Sleeve
924 Adjusting Nut
213 Drive Shaft
940.2 Key
320 Four Point Contact Bearing
931.2
920.8 Withdraw Nut
920.8 931.2 Locking Washer
350
7.4.8.2 Dismantling Bearing bush

Refer figure no. 20
While replacing bearing bushes following steps shall be followed:
1. Unscrew the grub screw(904.3).
2. Remove the worn out bush and steel sleeve by means of hydraulic press.
As an alternative, slight hammering on the steel sleeve with the help of mallet is
acceptable.
3. Ensure the cleanliness of inside diameter of the respective parts mentioned above.
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65
7.4.9 Dismantling the motor stool

P The pump-end coupling hub has been removed.
P The bearing unit has been dismantled.
P Auxiliary lines, such as barrier fluid, cooling liquid and measuring lines have been
dismantled and removed, where required.
1. Attach the transport ropes.

2. Undo hexagon nuts (920.05) and hexagon head bolts (901.05).
3. Lift motor stool (341) per crane and carefully position it above drive shaft (213).
4. Sit the motor stool down and secure it against tipping over or rolling off.
7.4.10 Removing the mechanical seal

P The motor stool has been removed.
1. Fit the locking discs.
NOTE
The locking discs and hexagon head bolts are included in the special tools of the
pump.
2. Engage the locking discs in the groove of the shaft sleeve and fasten them on the seal
cover using hexagon head bolts.
3. Remove any dirt accumulation that has formed on the shaft or shaft sleeve.
4. Undo and remove hexagon nuts (920.15). Undo grub screws at the shaft sleeve of the
mechanical seal.
5. Use screws to force off the seal cover along with the shaft sleeve and mechanical seal
(433) and pull them off the shaft completely.
6. Undo the hexagon head bolts and swivel the locking discs to disengage them from the
groove in the shaft sleeve.
7. Separate the seal cover with the stationary parts of the mechanical seal from the shaft
sleeve with the rotating parts of the mechanical seal.
8. Check the mechanical seal.
_ If the seal faces are clean and undamaged, the mechanical seal may be reinstalled.
_ Otherwise a new mechanical seal must be installed.
NOTE
Dismantle the mechanical seal as descried in the manufacturer's product literature.
(Chapter _ 9)
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904.20
523.20 901.20
920.10 552.01
471.22
471.21
441.02
213
213 Drive shaft 552.01 Locking disc

441.02 Shaft seal housing 901.20 Hexagon head bolt
471.21/.22 Seal cover 904.20 Grub screw
523.20 Shaft sleeve 920.10 Nut
7.4.11 Dismantling the Shaft Seal

1. Unscrew screws (914.31) in clamping ring (184).
2. Pull the shaft protection sleeve together with the clamping ring off the shaft.
3. Unscrew hex nuts (920.31) and remove stuffing box gland (452).
4. Remove packing rings (461) and seal cage ring (458) from the stuffing box housing.
5. If necessary, dismantle stuffing box housing (451).
6. With design alternative VSM-E (Fig.15), remove the intermediate ring (509.31)
together with the throttle bush (542).
7. In the case of design alternatives VSM-K and VSM-K-E (see Fig. 16 & 17 ), dismantle
the shaft seal as described in points 1 to 4 above. If necessary, unscrew the fastening
of the cooling cover and remove cooling cover (66-2), dismantle stuffing box housing
(451), unscrew holder (732) and remove it together with insulating washer (689).
Dismantle heat barrier (152) together with bush (540) and gaskets.
8. Examine bush (540) and throttle bush (542) for signs of galling (seizure) and if
necessary replace them by new ones within the limits of the permissible tolerances.
Clearance gap play (shaft-bush) as .new. value : 0.3 mm; max permissible play on
diameter 0.8 mm.
7.4.12 Removing the conical coupling

Remove the stud and dismantle the conical coupling with the aid of an extractor as
illustrated in Fig. 23.
1 Extractor fork
2 Stud
3 Extractor collar plate
4 Tommy bar for box spanner
5 Nut
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Fig. 23 : Mounting and extractor device for conical couplings

(can be supplied on request).
7.4.13 Removing the pump from the can
DANGER
Ø Never attach the lifting tackle to the free shaft end of the pump.
Ø Observe the local accident prevention regulations.
Ø Use suitable, permitted lifting tackle.
DANGER
Lifting lugs of pump/motor/base frame overloaded
Ø Never transport the pump set components (pump/motor / base plate) in any way
other than those illustrated in the chapter on transport options.
Ø Refer to the weights of the individual components stated in the manufacturer's
product literature.
DANGER
Falling hazard at the open pump sump or can
Danger of death from falling!
Ø Observe the applicable local occupational safety and accident prevention
regulations.
Ø Protect installation personnel against falling by using safety harnesses and ropes.
Ø Provide protection at the opening of the can or pump sump.
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P The drive has been switched off and removed.

P The pump and piping have been drained.
P The oil has been drained.
P The piping has been disconnected. The openings (where the piping used to be
connected) have been closed.
P Auxiliary lines, such as barrier fluid, cooling liquid and measuring lines have been
removed, where required.
P Remove the measuring devices and instruments, where required.
1. Fasten lifting accessories to motor stool (341) of the pump. (_ Chapter 3)

2. Undo hexagon nuts (920.10).
3. Lift the pump off can (151).
4. Place the pump in a suitable assembly area. (_ Chapter 3)
5. Secure the pump against rolling off.
7.5 Dismantling pump set with large installation depth
7.5.1 Preparations for partial dismantling

(Inspection of thrust bearing and of shaft seal)
1. Disconnect the driver from the power supply at the terminals.

2. Drain the oil out of the bearing housing.
3. Disconnect the motor lantern from the distributor casing and lift off the motor together
with the motor lantern.
4. Set down the motor and motor lantern in such a way that the motor stub shaft rests
entirely clear and can not be damaged.
5. Pull off the pump end coupling half with the aid of an extractor. On no account use a
hummer or lead drift. As far as necessary, dismantle and remove, or close the feed
lines to the shaft seal.
7.5.2 Preparations for complete Dismantling

First proceed as described in section 7.5.1. without however, pulling off the coupling half.
Then attach hoisting ropes to the distributor casing (10-1).Unscrew the fixing bolts which
connect the distributor casing to the Can and lift the complete pumping set out of the Can,
then set it down and underpin it in the horizontal position for further dismantling (see
installation drawing for details of weights).
N.B. If the vertical can and the Column are coated with a special coating, take care not to
damage same.
7.5.3 Dismantling the Pump Body

N.B. After a prolonged period of operation, it may happen that individual rotor components
(impeller and distance bushes) are difficult to pull off the shaft, in such cases, do not use
force or hammer blows. First try using a suitable rust solvent or a puller device. If these
measures do not lead to the desired result, the components concerned can be warmed up
slightly and then pulled off or forced off. The shaft should remain as cold as possible
during the warming up process. If rotor components are dismantled by warming up, the
shaft should subsequently be checked for radial run out.
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1. Unscrew fastening bolts (902.2) between distributor casing (10-1) and column pipe
main, force off pump body together with column pipe, and dismantle distributor casing.
Carefully underpin the drive shaft (213).
2. Dismantle the column pipe.
3. Slacken conical coupling (851) with the aid of an extractor device and remove it. (see
section). Remove drive shaft (213).
4. Unscrew nuts (920.1) of tie rods (905) at suction end, remove them and pull out the tie
rods.
5. Force off suction casing (106)
6. Undo hex. bolt (901.6) and remove it together with the washer (550.2)
7. Pull suction impeller (231) off pump shaft (211), and remove key. Under pin the stage
casing.
8. Force off and remove stage casing (108) including first stage diffuser (171.1) and
suction side bearing. Do not damage the sealing faces.
9. Pull the bearing sleeve (529.1) from the shaft and remove the split ring (501).
10. Pull the impeller (230) off the pump shaft (211) and remove key.
Support the stage casing.
11. Press off and remove the stage casing (108) and diffuser(171.2).
12. Press the stage sleeve (521) from the shaft.
13. Dismantle all the remaining stages in the same way as described in points 10 to 12
above. In the case of multistage pumps, mark the impellers and stage casings in
their correct sequence, to facilitate reassembly.
14. Pull discharge casing (107) off the shaft and store the shaft with due care.
7.5.4 Dismantling of Pumps installed very deep down

1. Carry out preparations as described in section 7.5.1
2. Dismantle thrust bearing as described in section 7.4.8
3. Dismantle shaft seal as described in section 7.4.11
4. Pull the pumping set far enough out of the Can by means of the distributor casing (10-1)
to enable a pipe clip to be attached some 50 cm beneath the next column pipe joint.
Firmly fasten the pipe clip and lower the pumping set again until the pipe clip rests on
top of the Can. Unscrew the pipe joint connecting the lengths of column pipe main, and
lift the distributor casing and the upper length of column pipe main (711.1) over the
drive shaft. Slacken the intermediate shaft conical coupling and remove drive shaft
(213). Use a extractor device (See Fig. 23). Force off the complete intermediate shaft
bearing and pull it off over the shaft. Examine the bearing and shaft for signs of
galling (seizure). If necessary, raise the pumping set by a further length of column pipe
main, again fit a pipe clip and lower the pumping set until the pipe clip rests on the
Can. Then dismantle the length of column pipe main and the bearing. Lift the pump
body out of the Can then set it down and underpin it in the horizontal position for
dismantling.
5. Dismantle the pump body in accordance with section 7.5.3, points 4 to 14.
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7.6 Reassembling the pump set
7.6.1 General information/Safety regulations
DANGER
Ø Never attach the lifting tackle to the free shaft end of the pump.
Ø Use suitable, approved lifting accessories e.g. self-tightening lifting tongs.
DANGER
Improper transport
weight.
hoisting tackle.
WARNING
Unqualified personnel performing work on the pump (set)
Ø Always have repair and maintenance work performed by specially trained, qualified
personnel.
WARNING
Pump set started up inadvertently
Ø Make sure that the pump set cannot be started up accidentally.
CAUTION
Improper reassembly
Damage to the pump!
Ø Reassemble the pump (set) in accordance with the general rules of sound
engineering practice.
Ø Replace any damaged/worn parts.
Ø Use original spare parts only.
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WARNING
Components heated up for installation
Risk of burns at hands!
Ø Wear protective gloves suitable for installation work.
Ø Let components cool down after installation.
Observe the general safety instructions and information. (_ Chapter 2)
For any work on the motor, observe the instructions of the relevant motor manufacturer.
For dismantling and reassembly refer to the general assembly drawing. In the event of
damage you can always contact our service staff. Always reassemble the pump in
accordance with the corresponding general assembly drawing and installation instructions.
§ Never use O-rings that have been glued together from material sold by the meter.
§ Replace all O-rings and V-rings and clean their locating fits on the shaft. Fit all seal
elements on the relevant components before starting with the assembly.
§ Observe the installation instructions regarding cleaning, lubricating and sealing agents.
§ Remove any residues of liquid sealants before starting with the assembly. When
reassembling the pump set, tighten all screws/bolts as indicated.
7.6.2 Preparations
Before reassembly of ring section pumps, the stage sleeve E. of each stage casing (108)
and of the associated impeller (230,231) with stage sleeve (521) must be measured. Any
discrepancy in lengths must be compensated by machining the stage sleeve (521) only,
and the end result must be E1 = E2. (See Fig.27.)
A
C
B
3
2
108
230
E2
171
521
E1
1
Fig. 24
If machining of the stage sleeve is required, it should be shortened at both end faces in
one operation on the machine tool. The permissible end face whobble (deviation from
plane parallelism) is 5 microns.
Do not damage the contact faces on the casing components, diffusers, impellers, spacer
and stage sleeves before and during assembly. All pump components, particularly the end
contact faces, should be thoroughly cleaned. If new impellers are fitted, or if the old ones
are touched up, the rotor must be balanced dynamically.
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7.6.3 Assembly of Pump Body

1. Push discharge casing (107) with fitted bearing bush (542.2) and diffuser (171.2) onto
pump shaft (211) from the drive end.
2. Slide stage sleeve (521) - (sleeve (520) in the case of pump size 150) - onto pump
shaft (211) from the front end, until it abuts against the shaft shoulder.
3. Insert key and slip final stage impeller (230) onto pump shaft (211).
4. Insert diffuser (171.2) of the following stage into stage casing (108) and mount the
stage casing together with O-Ring (412) against discharge casing (107).
5. Mount the remaining stages in the sequence : stage casing with diffuser, stage
sleeve, impeller (230) – observe the markings. Insert the split ring (501) and key
(940.4), press on bearing sleeves (529.1),diffuser (171.1) with suction side bearing
and suction impeller (231).
6. Put the washer (550.2) on the shaft and tighten up the hex. bolt (901.6).
7. Fit the suction casing (106) on the stage casing (108).
8 Clamp the discharge, stage and suction casings together with the aid of the tie rods
(905). Use a torque wrench for this purpose.
9. Connect the drive shaft (213) or the intermediate shaft (212) to the pump shaft (211)
by means of conical coupling (851). (Refer to section 7.6.6. Mounting of conical
coupling). Underpin the drive shaft/intermediate.
10. If applicable, lift the column pipe with gasket (400.2) over shaft properly. the drive
shaft/intermediate shaft and mount it on the pump body.
11. Fasten the pump body with column pipe and gasket (400.2) on the distributor casing.
7.6.4 Final Assembly and Installation of Pump

1. Mount pump end half coupling on drive shaft (213) in accordance with section 5.7
2. Lay internal auxiliary piping in accordance with the installation drawing.
3. Examine Can for dirt and clean it if necessary.
4. Carefully clean the sealing faces on the Can and distributor casing and insert the
gasket. On the construction with a gasket, check the parallelism of the sealing faces
between Can flange and distributor casing flange.
5. Attach ropes to the motor lantern, carefully raise the pump to a vertical position and fit
in the Can. Check the alignment and bolt the distributor casing (10-1) on to the Can
(151)
6. Connect the suction line and discharge line, refer to section 5.10
7. Mount driver and check coupling alignment (see sections 5.6 and 5.7).
8. Fill in oil (see section 6.1.3).
9. Start up the pump in accordance with section 6.2.
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7.6.4.1 Final Assembly of Pumps installed very deep down.

If the pumping set cannot be inserted in the Can as a complete unit because of its length,
the pump body, column pipe main, distributor casing, shaft seal and bearings should be
assembled as follows.
1. Inspect Can for dirt and clean it if necessary.
N.B.
Do not damage the special coating inside Can and column pipe main.
2. Assemble pump body in accordance with section 7.6.3 points 1 to 8.

3. Connect the pump shaft to the intermediate shaft by means of a conical coupling.
4. (see section 7.6.6). Slip gasket (400.2) and column pipe (711.2) over the shaft and
attach them to discharge casing (107). Mount a pipe clip on column pipe 711.2 and
fasten it securely.
5. Carefully raise the pump body to a vertical position and lower it into the Can (151)
until the pipe clip rests on the top rim of the Can. Take care not to damage. The
sealing face of the Can flange. Then place the intermediate shaft bearing with
gaskets in position.
6. Mount the drive shaft (213) or the next length of intermediate shaft (212). Slip the
column pipe (711.1) over the shaft and fasten it. Fasten a second pipe clip on the
upper length of column pipe (711.1). Lift the pump, undo and remove the lower pipe
clip, and lower the pump into the Can until the upper pipe clip rests on the Can flange.
7. Lay the gasket (between Can and distributor casing) on the pipe clip.
8. Place the distributor casing (10-1) over the drive shaft and fit it on the top flange of the
column pipe main or on the intermediate shaft bearing and fasten it.
9. Attach hoisting ropes to the distributor casing, raise the pump, detach and remove the
pipe clip, carefully clean the sealing faces on the Can and distributor casing, insert
gasket (412.1 or 400.3) and lower the pump until the distributor casing seats in its
correct position on the Can flange. On the construction with gasket, check the
parallelism of the sealing faces between Can flange and distributor casing flange.
10. Check t he alignment and fasten the distributor casing on the Can.
11. Mount the shaft seal and the thrust bearing in accordance with sections 7.6.8 and
7.6.10
12. Adjust the axial position of the pump rotor in accordance with section 7.6.11
13. Mount the pump end coupling half on drive shaft (213) as described in section 5.7
14. Connect the suction line and discharge line, refer to section 5.10
15. Mount the driver and check the coupling alignment (see sections 5.6 and 5.7)
16. Fill in oil (see section 6.1.3).
17. Start up the pump in accordance see section 6.2
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7.6.5 Reassembly of the radial bearing and the stuffing box housing
NOTE
general assembly drawings. (Chapter _ 9)
1. Insert studs (902.12) into distributor casing (10-1).

2. Slide adapter (145) with fitted bearing bush (545.04) including new O-ring (412.03) on
bearing sleeve (529.01) of drive shaft (213). Install them in the distributor casing.
3. Attach stuffing box housing (451) including new O-ring (412.04) to the hoisting tackle
with eyebolts and a rope. Carefully guide it along drive shaft (213) and insert it.
4. Fit and tighten hexagon nuts (920.12).
Observe the tightening torques! (_ Chapter 9)
5. Make sure the connections are positioned correctly! See general arrangement drawing.
(_ Chapter 9 )
6. Insert studs (902.15) into distributor casing (451)
7.6.6 Mounting of Conical Couplings

1. Debur the ring groove and the key way if necessary.
2. Before joining the shafts together, slip the tapered outer sleeve (864) onto the upper
shaft, with its small I.D. upper most.
3. Push the two shafts together and fit the inner sleeve (863) on the ends of the shafts.
The small O.D. should be uppermost. Make sure the key and locking ring seat
correctly.
4. Slide the outer sleeve (864) from above over the two inner sleeves (863), pull it tight
with the aid of a suitable device.
5. Spot-drill the inner sleeve (863) to a depth of 2mm approx. screw an M8 worm screw
into outer sleeve (864) and secure it against slackening by centre punch blows.
7.6.7 Installing the mechanical seal

Observe the weights indicated in General arrangement drawing (_ Chapter 9)
P The radial bearing and the stuffing box housing have been fitted.
P The mechanical seal has been checked for any damage. A new mechanical seal is
available, if required.
P The manufacturer's product literature is available. (_ Chapter 9)
1. Insert the seat ring including the O-ring into the seal cover.
2. Slide the complete rotating unit onto the shaft sleeve. Apply Loctite 243 to the grub
screws and tighten them.
_ Check that the spring-loaded ring can move axially.
3. Slide the complete seal cover on the shaft sleeve.
4. Engage the locking discs in the groove of the shaft sleeve and fasten them on the seal
cover using hexagon head bolts.
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5. Clean drive shaft (213) and the holes for the shaft sleeve. Apply a thin coat of a
suitable lubricant to the area of the mechanical seal.
6. Insert the gasket in stuffing box housing (451).
7. Slide the completely assembled mechanical seal cartridge (433) on drive shaft (213)
and insert it into stuffing box housing (451). Fit and tighten hexagon nuts (920.15).
Observe the tightening torques! (_ Chapter 9)
NOTE
general assembly drawings. (Chapter _ 9)
To prevent the seal elements from jamming, slowly rotate the pump rotor when
tightening hexagon nuts (920.15).
8. Make sure the connections are positioned correctly! See general arrangement drawing.
(_ Chapter 9)
9. Fit the clamping ring, but do not tighten it.
7.6.8 Assembly of Shaft Seal

(See installation drawing for type of shaft seal fitted to your pump.)
7.6.8.1 VSM Soft-packed Stuffing Box (Fig. 14)

1. Slip stuffing box housing (451) together with gasket and neck ring (457) over drive
shaft (213) and attach it to distributor casing (10-1).
2. Slip the stuffing box gland (452) over the drive shaft (213).
3. Slip the shaft protection sleeve (524) including the O Ring and the clamping ring (184)
over shaft (213).
4. Pack the stuffing box in accordance with section7.3.2
5. Adjust the shaft protection sleeve (524) with clamping ring (184) to mounting
dimension X and secure (see Fig. 13).
7.6.8.2 VSM.K Soft-packed stuffing Box (Fig. 16)

1. Slip heat barrier (152) including pressed-in bush (540), clamping sleeve (562.31) and
gasket over drive shaft (213), fit it on distributor casing (10-1) and fasten it.
2. Slip stuffing box housing (451) and gasket over shaft (213) and attach it to heat barrier
(66-1).
3. Insert O-rings and fit cooling cover (66-2) on stuffing box housing (451) and fasten.
4. Screw pipe (710.31) into stuffing box housing (451), seal it tight at the cooling cover
(66-2) and fasten it. Slip stuffing box gland (452) over drive shaft (213).
5. Slip shaft protection sleeve (524) together with O Ring and clamping ring (184) over
shaft (213).
6. Pack the stuffing box in accordance with section 7.3.2
7. Adjust the shaft protection sleeve (524) with clamping ring (184) to mounting
dimension X and secure (See Fig. 13).
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7.6.8.3 VSM-E Soft-Packed Stuffing Box (Fig. 15)

1. Slip intermediate ring (509.31) including pressed-in throttle bush (542) and gasket over
drive shaft (213), fit it on distributor casing (10-1) and secure the throttle bush (542)
against twisting by means of clamping sleeve (562.31).
2. Slip stuffing box housing (451) including neck ring (457) and gasket over the drive shaft
and fasten them together with intermediate ring (509.31) on to the distributor casing.
3. Slip stuffing box gland (452)over drive shaft (213).
4. Slip shaft protection sleeve (524) including O Ring and clamping ring (932.31) over
shaft (213).
5. Pack the stuffing box in accordance with section 7.3.2
6. Adjust shaft protection sleeve (524) with clamping ring (184) to mounting dimension X
and secure (See Fig. 13).
7. Connect pressure relief line (710.33) in accordance with Fig. 18 (15A-15E).
7.6.8.4 VSM-K-E Soft packed Stuffing Box (Fig.17)

1. Assembly is carried out as for soft packed stuffing box VSM- K - See section 7.6.8.2
points 1 to 7.
2. Connect the pressure relief line (710.33) in accordance with Fig. 18 (15A-15E)
7.6.9 Fitting the motor stool

Observe the weights indicated in General arrangement drawing(_ Chapter 9)
P The mechanical seal has been installed.

1. Screw the eyebolts into motor stool (341).
2. Attach the transport ropes.
3. Lift motor stool (341) up by crane and carefully guide it onto drive shaft (213), place it
on distributor casing (10-1) and position it.
4. Fit and tighten hexagon nuts (920.05) and hexagon head bolts (901.05). Observe the
tightening torques! (_ Chapter 9)
5. Make sure the connections and openings are positioned correctly.
7.6.10.1 Installing the thrust bearing unit

1. Mount bearing housing on distributor casing.
2. Assemble bearing cover sub-assembly with bearing housing.
Bearing cover sub-assembly contains centering sleeve, four point contact bearing,
locking washer and withdrawal nut.
3. Slide adjusting nut onto the drive shaft and engage it in the drive shaft threading.
4. Screw in the adjusting nut till its lugs appear near the key way slots of centering
sleeve.
5. Align lugs of adjusting nut with the key-way slots of centering sleeve, and rotate both
centering sleeve and adjusting nut simultaneously in clock wise direction so that lugs of
adjusting nut slide inside the key-way slots of centering sleeve. Centering sleeve
rotates in its place only whereas adjusting nut rotates and moves inside the centering
sleeve.
6. Keep on rotating till lugs of adjusting nut engage completely inside the circular groove
of centering sleeve.
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7. Rotate either centering sleeve or adjusting nut by 900 to align key-way slots of both
parts with each other.
8. Rotor adjustment can be done with the help of drive shaft key (motor end) by
engaging it in centering sleeve and adjusting nut simultaneously. By rotating the
centering sleeve with adjusting nut.
Ø in clock wise direction, causes the rotor to move in upward direction and
Ø in anti clockwise direction, causes the rotor to move in downward direction.
9. Once the rotor adjustment is done, fix the key on the drive shaft engaging it with key
way slots on centering sleeve and adjusting nut.
7.6.10.2 Adjustment of axial position of Pump Rotor

The pump rotor position must be adjusted axially after completion of mounting of the
bearings and before the drive coupling is mounted. The total axial play of the rotor is
ascertained by lowering and raising it to its bottom and top abutments by means of the
centering sleeve (526) along with adjusting nut (924) which has a 1.5mm screw thread
pitch.
The rotor is subsequently raised to its top abutment, then lowered by an amount equal to
0.4 times the total axial play. Thereafter the centering sleeve (526) is locked in position by
means of the gib key. If the gib key cannot be slotted in because the slot in the centering
sleeve does not register immediately opposite, twist the sleeve to right or left until the
nearest slot registers with the gib key.
7.6.11 Installing the Bearing Bush

While replacing bearing bushes following steps shall be followed:
1. Insert new bearing bushes with the help of entry chamfer inside the respective parts.
Since these are interference fit use hydraulic press to fit or as an alternative slight
hammering with the mallet is acceptable.
2. Make sure that bearing bushes are aligned with the face perfectly.
3. Fix the position of bearing bush inside the part by grub screw.
4. Punch the grub screw to avoid slackening.
7.6.12 Adjusting the mechanical seal

P The mechanical seal has been installed but has not been loaded yet.
P The motor stool has been mounted.
P The bearing unit has been installed.
P The drive coupling has not been fitted.
P The pump rotor has been axially adjusted.
1. Tighten the clamping ring with the grub screws.
2. Undo the hexagon head bolts at the locking discs. Remove the bolts together with the
locking discs and store both with the special tools.
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7.6.13 Further work

Carry out the following steps as described in the relevant chapters of this manual:
Table 8 : Further work

Step See chapter...
Reassemble the pump. (_ Chapter 5)
Mount the drive. (_ Chapter 5)
Connect the piping and measuring instruments. (_ Chapter 5)
Connect the pump set to the power supply. (_ Chapter 5)
Fit the connecting coupling. (_ Chapter 5)
Fit the contact guards. (_ Chapter 6)
Return the pump set to service after storage. (_ Chapter 6)
7.7 Examination of individual Components
7.7.1 Shafts (211, 212, 213)

Inspect the bearing sleeves (529) shrunk onto the shafts for signs of galling (seizure).
Slight traces of damage can be removed by grinding within the permissible clearance
limits. If the touching up works should result in the permissible clearances being
exceeded, then new bearing sleeves (529) must be shrunk on.
Carry out an out-of-round check on a lathe between dead centres. The max. permissible
shaft whip must not exceed 0.03 mm.
N.B.
Make sure the shaft is accurately centered on the lathe, as otherwise the readings will be
erroneous.
If certain rotor components are replaced by new ones, or have been touched up, or if a
new shaft has been fitted, the pump rotor must be balanced dynamically, preferably at the
max, operating speed of the pump, but at least at 1000 1/min. The maximum permissible
residual eccentricity is 5 microns.
7.7.2 Bearing Arrangement

Antifriction Bearings (320)
Even if they only exhibit slight discoloration marks or specks of rust, or signs of damage to
the running surfaces, the bearings must be replaced by new ones. Observe the greatest
cleanliness when mounting the bearings. Use washing oil to clean the old bearings. After
washing, the bearings should be dried and immediately sprayed with oil.
Plain Bearings (Pump and intermediate shafts)

Examine the bearing bushes for signs of galling (seizure). If necessary, fit new bearing
bushes see clearance sheet (Chapter 9).
7.7.3 Shaft Seal

Soft packed stuffing box
Use new packing material every time the pump is overhauled. The shaft protection sleeve
(524) may only be touched up very lightly by grinding.
If it exhibits signs of damage, a new shaft protection sleeve should be fitted.
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7.7.4 Pump Body

Suction casing (106), discharge casing (107), stage casings (108), impellers (230, 231),
casing wearing rings (502), bearing bushes (545), stage sleeves (521).
Ensure all the sealing faces are in perfect condition. Check the plane parallelism of the
faces at 4 points on the circumference with a micrometer. The deviation must not exceed
0.02 mm. Damaged faces can be machined on a lathe. The surface roughness must not
exceed 0.8 microns.
The stage casings (108) and diffusers (171) are fitted with renewable casing wearing rings
(502).
Check the impellers and wearing rings for galling and check the rotor clearances per
(Chapter 9).
The casing wearing rings must be machined when fitted and the max. permissible
clearances must be respected. Any increase in clearance must be made uniform at all
wearing points inside the pump.
If the bearing clearances are the same as or greater than the max. permissible clearances
per (Chapter 9). Fit new oversized wearing parts and re-establish the “as new” clearances.
Fitting new casing wearing rings (502)

1. Undo the allen grub screw, press the casing wearing rings in the stage casing and
diffuser out of the fit taking care not to damage the fit. (see Fig. 25).
2. Uniformly press new wearing rings.
3. Smooth down all impellers (230, 231) in the region of the suction and discharge throttle
section to a common diameter, basing this on the most heavily scored section.
Single deep grooves can be left untouched. (See Fig. 26 & Table. 9)
Stage casing Wearing ring
Shim
Diffuser Lever
Fig. 25 : Renewing the casing wearing rings
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80
smooth here
Fig. 26 : Smoothing out the throttling sections on the impellers, See Table. 9
Rotor and Bearing Clearances
Smallest Impeller Neck Ø

Max Ø
Pump Sizes 1st Stage Impeller Stage Impeller 1)
Diffuser Bore
without wearing ring without wearing ring
40 88.2 78.2 46.5
50 103.2 88.2 49.5
65 118.2 98.2 49.5
80 128.2 113.2 53.3
100 153.2 128.2 53.5
125 178.2 148.2 66.5
150 213.2 198.2 81.5
Table 9 : Smallest permissible impeller neck dia. and max. diffuser bore dia.
1) st
not for 1 stage (for single wearing ring execution).
If these limiting values are exceeded replace with new spares.
7.7.6 Meta flex Coupling

Check the flexible transmission elements for wear and replace if necessary.
7.7.7 Pump with impeller wearing rings an inter stage bushes

Pump sizes 40 to 150 , pressure rating 20 / 40.
Pump Body
Suction casing (106), discharge casing (107), stage casings (108),impellers(230,
231),impeller wearing rings (503),casing wearing rings (502), inter stage bushes (541),
distance bushes(521), or sleeves (520) with pump size 150.
Ensure all the sealing faces are in perfect condition. Check the plane parallelism of the
faces at 4 points on the circumference with a micrometer. The deviation must not exceed
0.02 mm. Damaged faces can be machined on a lathe. The surface roughness must not
exceed 0.8 microns.
The impellers (230,231), stage casings (108), and diffusers (171), are fitted with
renewable wearing parts - impeller wearing rings (503), casing wearing rings (502), and
inter stage bushes(541). Check the wearing parts for galling and check the rotor
clearances per clearance sheet (Chapter 9).
The wearing parts must only be machined when fitted and the maximum permissible
clearances must be respected. Any increase in clearance must be made uniform at all
wearing parts inside the pump.
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81
541
(503.1)
503.2
Fig. 27 : Full Chrome design with impeller wearing rings and inter stage bushes, pressure
rating 20 / 40.
If the rotor clearances are the same as or greater than the max. permissible clearances
specified in clearance sheet (Chapter 9) fit new over sizes wearing parts and reestablish
the..as new..clearances.
Fitting new casing wearing rings (502) :

1. Undo the allen grub screw, press the casing wearing rings in the stage casing and
diffuser out of the fit, taking care not to damage the fit. (See Fig. 28)
2. Uniformly, press new oversized casing wearing rings (normally 2 mm allowance) into
the bore (cooling the rings makes this easier).
3. Smooth down all impellers (230, 231) in the region of the fitted impeller wearing rings
(503) to a common diameter, basing this on the most heavily scored impeller wearing
ring. Single deep grooves can be left untouched (See Fig. 29).
4. Calculate the average actual diameter of all smoothed down impeller wearing rings.
Adding this to the .as new. clearance per Chapter.9 gives the bore diameter for the
casing wearing rings, tolerance + 0.04 mm.
Stage casing Casting wearing ring
Shim
Diffuser
Diffuser Lever
Lever
Inter stage
bush
Fig. 28 : Renewing the casing wear rings and stage bushes.
5. Align the stage casing (108) and diffuser (171) with fitted casing wearing ring to the
outer fit and machine the wearing ring without changing the setting.
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82
smooth here
Fig. 29 : Smoothing out the throttle sections on the impeller wearing rings, See Table. 10
Smallest Impeller Neck Ø

Max inner Ø of
Pump Sizes 1st Stage Impeller 2-last Stage Impeller 1)
stage bush
with wearing ring with wearing ring
40 93 83 45.5
50 108 98 48.5
65 123 108 48.5
80 133 123 52.5
100 158 140 52.5
125 183 160 65.5
150 218 213 80.5
Table 10 : Minimum permissible impeller neck Ø

1)
not for 1st stage
If the actual diameters are greater or less than the values in Table. 10 please contact KSB.
Spares with non-standard material oversize would then be required.
7.7.8 Dynamic Balancing of Pump Rotor

For this purpose, the pump rotor should be assembled as follows :
Assembly proceeds from the front end; slip stage sleeve (521) onto pump shaft (211) until
it abuts against the shaft shoulder. Insert the key and slip final stage impeller (230) onto
the shaft until it abuts.
Mount the stage sleeve (521) (sleeve (520), on pump size 150), - keys and impellers (230)
of the remaining stages in sequence, as described above. Fit the split ring (501) and key
(940.4). Push on the bearing sleeve (529.1) and suction impeller (231)
N.B. The impellers must be mounted in their correct stage sequence.
Slip on lock washer (931.1) and clamp the mounted components together on pump shaft
(211) with the aid of shaft nut (920.2).
Before dynamic balancing, the rotor should be checked for true running (out-of-round) at
the impellers (230) and at the bearings. The measured out-of-round value must not
exceed 0.03mm. The rotor should then be balanced dynamically at max. pump operating
speed if possible but at least at 1000 1/ min. The max permissible residual eccentricity
must not exceed 5 microns. Before final assembly in the pump, the pump rotor must be
dismantled again in reverse sequence to the assembly procedure described above.
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83
7.8 Spare parts stock
7.8.1 Ordering spare parts

Always quote the following data when ordering replacement or spare parts:
§ Type series or pump set components

§ KSB order number
§ Order item number
§ Consecutive number
Refer to the name plate for all data. Link
Also supply the following data:
§ Description
§ Part No.
§ Quantity of spare parts
§ Shipping address
Mode of dispatch (freight, mail, express freight, air freight)
Refer to the general assembly drawing for part numbers and descriptions.
(_ Chapter 9)
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84
We recommend keeping the following spare parts in stock in order to remedy rapidly any
operating fault which might arise :
Part No. Part description Quantity Remarks

211 Pump shaft with key 1
212 Intermediate shaft if fitted
213 Drive shaft with key 1
23 Impeller S-1
231 Suction impeller
320 Four point contact bearing
400 Gaskets, complete 1 set
411 Gaskets, complete 1 set
412 O-Ring, complete 1 set
461 Gland packing 1 set
501 Split ring 1
502.1 Casing wearing ring 2
502.2 Casing wearing ring 2 S-2
503.1 Impeller wearing ring 2
503.2 Impeller wearing ring 2 S-2
520 Sleeve S only on pump
size 150
521 Stage sleeve S
524 Shaft protection sleeve 1
526 Centering sleeve 1
529.1 Bearing sleeve 1
541 Inter stage bush S1
541.1 Inter stage bush 1
541.2 Inter stage bush
545.1 Bearing bush 1
646 Oil elevator tube 1
851 Conical coupling complete 1
904.1 Allen grub screw 1 set
904.1 Allen grub screw 1 set
931.2 Locking washer 1
S = Number of stages
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85
Chapter 8 Trouble-shooting
8. Trouble-shooting
Fault Possible cause Remedial action
Usable flow rate Pump delivers against an excessively Keep opening the valve in the discharge line
< specified value high discharge pressure. until the duty point is re-adjusted.
Excessive back pressure Fit larger impeller(s).

Contact KSB Service.
Increase the speed of teh drive.
Check system for impurities.
Pump or piping are not completely vented or Vent and/or prime.
primed.
Formation of air pockets in the piping After the piping layout.

Fit a vent valve.
NPSH available (positive suction head) is too Adjust the fluid level in the inlet tank.
low. Completely open the valve in the inlet pipe.
Change suction line if the friction losses in
the suction line and too high.
Check any strainers installed.
Excessive speed of pressure fall Observe permissible speed of pressure fall.
Excessive suction head Clean the filter element and the inlet pipe.
Correct/alter the fluid level.
Alter the inlet pipe.
Wrong direction of rotation Interchange two phases of the power cable.
Speed too low Increase the speed.

Increase the voltage.
Wear of internal pump parts Replace defective parts.

Motor is running on two phases only. Replace defective fuses.
Check electrical connections.
Pump discharge pressure Speed is too high. Contact KSB Service.
> specified value
Pressure ps < specified value Damaged measuring instrument Replace the measuring instrument.
Excessive differential pressure in the filter. Dismantle and clean the filter element.
Valve in the inlet pipe not completely opened. Open the valve.
Pressure in the inlet tank is too low. Check the inlet tank and/or increase the
pressure.
Pressure ps < specified value Damaged measuring instrument Replace the measuring instrument.
Speed to low Check the drive.
Inlet pressure too low Check inlet pressure and inlet tank.
Fluid temperature too low or too high. Increase or reduce the temperature.
Defective minimum flow system Check the minimum flow system.
Shaft seal leakage Defective shaft seal Check and, if required, replace it.
Score marks or roughness on Check shaft sleeve 523 and, if required,

shaft sleeve 523 replace it.
Seal cover tightened incorrectly Check
Pump set alignment Check the coupling; re-align, if required.
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86

Shaft seal leakage Pump is warped. Check pipeline connections and secure pump
fastening.
Cooling liquid quantity too low Increase cooling liquid quantity.
Contaminated cooling liquid chamber or cooler Clean the cooling liquid chamber or cooler.
Check the cooling liquid and, if required,
clean it.
Malfunction of the circulation line Increase the usable cross-chapter.

Check the piping.
Excessive surface pressure at the sealing Check the installation dimensions.

clearance, insufficient lubricant or circulation Contact KSB Service.
liquid.
Excessive bearing temperature Defective bearing Check and, if required, replace it.
Oil quantity Check the oil quantity. If required, top it up

or replace it.
Oil quality Check
Increased axial thrust Check casing wear rings/balancing device

and, if required, replace them.

Rotor out of balance Clean the rotor.

Re-balance the impeller.
The pump set has not been aligned properly. Check the alignment; re-align, if required.
Pump is warped. Check pipeline connections and secure

pump fastening.
Distance of coupling hubs Verify the distance of the coupling hubs

against the general arrangement drawing;
re-adjust it, if required.
Pump temperature > specified Pump or piping are not completely vented or Vent and/or prime.
value primed.
NPSH available (positive suction head) Adjust the fluid level in the inlet tank.
is too low. Completely open the valve in the inlet pipe.
Change suction line if the friction losses in the
suction line are too high.
Flow rate < specified value Increase flow rate Q min.
Pump leakage Defective O-rings and/or metallic sealing Replace the O-rings and/or re-machine the
surfaces metallic sealing surfaces.
Pump runs rough. Pump or piping are not completely vented or Vent and/or prime.
primed.
NPSH available (positive suction head) Adjust the fluid level in the inlet tank.
is too low. Completely open the valve in the inlet pipe.
Change suction line if the friction losses in
the suction line are too high.
Excessive speed of pressure fail Observe permissible speed of pressure fail.

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87

Pump runs rough. Pump back pressure lower then specified Re-adjust to duty point by means of the
in the purchase order valve in the discharge line.
In the case of persistent overloading, turn
down impeller(s), if possible.
Alignment of the pump set Check the alignment; re-align, if required.

pump fastening.
Oil quality Check
Rotor out of balance Clean the rotor.

Re-balance the impeller.
Defective bearing Replace
Flow rate < specified value Flow rate Q min
Cavitation noise in the pump Damaged inlet pipe Check the inlet pipe.
and/or piping
Valve in the inlet pipe not completely opened Open the valve.
Pressure in the inlet tank is too low. Check the inlet vessel and/or increase the
pressure.
NPSH available/NPSH required too low Check the inlet pipe.

Alter the inlet pipe.
Air ingress at the sealing element/valves/ Check the piping. Check shaft seal
shaft seal for leakage.
Pump or piping are not completely vented Vent and/or prime.

or primed.
Motor overloaded Wear of internal pump parts Replace defective parts.

Pump back pressure lower then specified in Re-adjust to duty point by means of the
the purchase order valve in the discharge line.
In the case of persistent overloading, turn
down impeller(s), if possible.
Density or viscosity of the fluid handled Contact KSB Service.

higher than stated in the purchase order
Speed is too high. Alter the impeller diameter.

Reduce the speed of the drive.

pump fastening.
Supply voltage is too low. Check electrical connections.
Motor is running on two phases only. Replace defective fuses.

Check electrical connections.
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88
Chapter 9 Related Documents
9 Related Documents
9.1 Tightening torques
Prerequisites
§ The threads of the screws/bolts and nuts are not damaged.
§ The threads and bearing surfaces of the screws/bolts and nuts are plane, deburred
and cleaned thoroughly.
§ The threads move smoothly.
§ Lubricant has been applied to the threads of screws/bolts and nuts.
9.1.1 Tightening torques

Observe the tightening torques given for the size and material of screwed connections.
Table 11 : Tightening torques
Tightening torque MA Tightening torque MA

Thread (Nm) (ftlb)
A193 B8M CL2 A193 B7 8.8 A193 B8M CL2 A193 B7 8.8
M6 6-7 9-10 4-6 4.5-5.1 6.5-7 3-4.5
M10 33-35 44-47 20-25 24-25.5 32-34 15-18.5
M12 55-60 75-80 35-40 42-45 55-58 26-30
M16 140-150 190-200 80-100 105-112 138-147 59-74
M20 275-295 365-385 160-200 205-217 270-286 118-148
M24 395-420 630-670 270-340 292-310 464-493 199-251
M30 650-690 1270-1340 530-660 480-511 934-993 391-487
M36 875-925 2210-2340 930-1160 642-680 1628-1730 686-856
9.1.2 Tightening torques for flange bolting

Bolts for flange Connection, Suction Nozzle, Discharge Nozzle and Tapping Nozzle:
The tightening torque apply only if the bolts and screws are part of KSB's scope of supply.
NOTE
Observe the drawing in the next chapter! (_ Chapter 9.1.3)
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Table 12 : Tightening torques for flange bolting
Nominal Diameter Nominal Pressure, Tightening torque MA Tightening torque MA

DN (inch) PN class (Nm) (ftlb)
600 35 26
1/2"
300 22 16
600 63 46
3.4"
300 40 29
600 90 66
2"
300 52 38
600 120 88
3"
300 105 77
600 210 155
4"
300 143 105
600 350 258
6"
300 173 127
600 460 339
8"
300 280 206
600 650 479
10"
300 302 222
Discharge Nozzle
Nominal Bolt
Flange Rating Material Torque Nm
Diameter Size
DN
50 M16 8.8 138
80 ASME B16.5 M20 8.8 268
100 Class 300 RF M20 8.8 268
150 M20 8.8 268
200 M24 8.8 462
Suction Nozzle
Nominal Bolt
Flange Rating Material Torque Nm
Diameter Size
DN
80 M20 8.8 268
100 ASME B16.5 M20 8.8 268
150 Class 150 RF M20 8.8 268
200 M24 8.8 462
250 M24 8.8 462
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90
For item 1 Table 13 : Can to Distributor casing (Refer figure no. 30)
Size Tightening torque

WKT - A 193 BBM CL2 A 193 B7
395 - 420 Nm 630 - 670 Nm
40 / 50 / 65 M24
292 - 310 ftlb 464 - 493 ftlb
1000 - 1050 Nm 2210 - 2340 Nm
80 / 100 / 125 / 150 M36
737 - 775 ftlb 1628 - 1730 ftlb
For item 2 Table 14 : Tie bolt (Refer figure no. 30)

WKT - A 193 BBM CL2
140 - 170 Nm
40 / 50 / 65 M16
105 - 125 ftlb
300 - 350 Nm
80 / 100 M24
221 - 258 ftlb
395 - 420 Nm
125 / 150 M36
292 310 ftlb
Tightening Torque : Tie rod material EN24V

Pump No. of Torque in No. of Torque in
Size stages Nm stages Nm
40 1-10 145 11-16 150
50 1-10 155 11-15 165
65 1-10 165 11-15 170
80 1-10 290 11-14 305
100 1-10 310 11-14 320
125 1-8 330 9-11 350
150 1-8 360 9-11 450
Tightening Torque : Tie rod material EN8

Pump No. of Torque in No. of Torque in
Size stages Nm stages Nm
40 1-10 78 11-16 80
50 1-10 81 11-15 83
65 1-10 84 11-15 87
80 1-10 165 11-14 171
100 1-10 172 11-14 178
125 1-8 275 9-11 285
150 1-8 290 9-11 300
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91
For item 3 Table 15 : Adaptor / Stuffing box (Refer figure no. 30)

WKT - A 193 BBM CL2 A 193 B7
55 - 60 Nm 70 - 80 Nm
40 / 50 / 65 / 80 / 100 M12
42 - 45 ftlb 55 - 58 ftlb
140 - 170 Nm 190 - 200 Nm
125 / 150 M16
105 - 125 ftlb 138 - 147 ftlb
For item 4 Table 16 : Column Pipe (Refer figure no. 30)

WKT - A 193 BBM CL2
140 - 170 Nm
40 / 50 / 65 / 80 / 100 M16
105 - 125 ftlb
300 - 350 Nm
125 / 150 M20
221 - 258 ftlb
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92
1 4
Fig. 30 : Tightening torques location for item number 1-4
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93
9.2 General assembly Drawings and Lists of Components

Pump sizes 40 to 150
Part No. Description Part No. Description

10-1 Distributor casing *524 Shaft protection sleeve
106 Suction casing *526 Centering sleeve
107 Discharge casing 529.1/.2 Bearing sleeve
108 Stage casing *545.1/.2 Bearing bush
151 Can 550.1/.2 Disc
*171-1 Diffuser suction 638 Constant-level oiler
*171.2 Diffuser 641 Oil level pipe
184 Clamping ring 646 Oil retaining tube
*211 Pump shaft 720.1 Special pipe part
*213 Drive shaft 731.2 Pipe union
*230 Impeller 731.3 Pipe union
*231 Suction impeller *851 Conical coupling
270 Keep off device 901.3/.6 Hexagon head bolt
*320 Antifriction bearing 902.1/.2/.3/.5 Stud
341 Motor stool 902.31 Stud
350 Bearing housing 903.4 Screwed plug
360 Bearing cover 903.6 Screwed plug
*400.1/.2/.4/.5/.6/.7 Gasket *904.1/.2/.3/.4 Grub screw
411.4 Joint ring 905 Tie bolt
411.8 Joint ring 913.1 Vent plug
412.1/.31 O-ring 914.1 Socket head cap screw
433 Mechanical seal 914.31 Socket head cap screw
451 Stuffing box housing 920.1/.2/.3/.4/.11/.31 Nut
452 Gland 920.8 Withdrawal nut
457 Neck ring *931.2 Lock washer
*461 Gland packing 940.1 Key
501 Segmental ring 940.2/4 Key
502.1/.2 Casing wear ring 5B Vent
503 Impeller wear ring 8 Leakage
*521 Stage sleeve 10E Sealing liquid
* Recommended spare parts
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94
Fig. 31 : Sectional Drawings and Lists of Components Pump

sizes 40 to 150
341
924 902.5
920.11
526
940.2
904.2
913.1
270
731.3
360
320
350
400.5
901.3
901.5
646 638
914.1
400.6 731.2
641 720.1
931.2
213
914.31 920.8
920.31
411.4
451 903.4
458 184
10E
461 452
5B 902.31
457
902.3 524
411.8 920.3
903.6 412.31
8B
851
902.1
920.1
904.3
10-1
400
400
545.01 902.2
920.2 151
529.2 502.2
550.1
171.2
107 904.1
230 108
521 211
(520) 904
940.1 501
503
502
412
529.1
905
171.01
108.01 400
503 231
545.1 502.1
920.1 550.2
904.1 901.6
940.4 Directly flanged on pump
106
VSM shaft seal
Note : Sectional drawings shown in this section are only indicative. Users are requested to follow
specific cross sectional drawing submitted to them with the pump order.
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95
Fig. 32 : Sectional Drawings and Lists of Components Pump

sizes 40 to 150
151
10-1
902.1 383.4
920.1
400.2
Distributor casing with bearing spider
400.2
904.3
400.4
545.3
902.2
920.2 529.3
383.1/2/3
213
400.8
851
901.2
711.1 920.6
901.1 212
920.5
400.3 711.2
904.3
545.2
550.1
529.2
107 151
521
503
171.2 502.2
108
412.1
230
211
501, 904.2
940.1
529.1
905
171.01
545.1
400.1
940.4
904.1 108.01
231
920.4
502.1
550.2
901.6
106
Pump with upper Pump with upper column pipe main &
Column pipe main one or two lengths of Column pipe main
Distributor casing without bearing spider
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96
Part No. Description Part No. Description

10-1 Distributor casing *521 Stage sleeve
106 Suction casing *529.1 Bearing sleeve
107 Discharge casing *529.2 Bearing sleeve
108 Stage casing *529.3 Bearing sleeve
151 Can *545.1 Bearing bush
*171-1 Diffuser *545.2 Bearing bush
*171.2 Diffuser *545.3 Bearing bush
*211 Pump shaft *550.1/.2 Disc
*212 Intermediate shaft 711.1 Column pipe
*213 Drive shaft 711.2 Column pipe
*230 Impeller *851 Conical coupling
*231 Suction impeller 901.1 Hexagon heat bolt
383.1/.2/.3 Bearing spider 901.2 Hexagon head bolt
383.4 Bearing spider 901.6 Hexagon head bolt
*400.1 Gasket 902.1 Stud
*400.2 Gasket 902.2 Stud
*400.3/.4/.8 Gasket 904.1 Grub screw
*412.1 O-ring 904.2/.3 Grub screw
*501 Segmental ring 905 Tie bolt
*502.1 Casing wearing ring 920.1/.2/.3/.4/.5 Nut
*502.2 Casing wearing ring 940.1 Key
503 Impeller ring 940.4 Key
* Recommended spare parts
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97
9.3 Table of Clearances
Single Wearing Ring Execution
Diametral
Material Wearing ring Impeller
Pump clearance
ID Neck Dia.
size As new Worn out
Impeller Wearing ring (mm) (mm)
(mm) (mm)
CI/LG2 CI/BZ 15
Ø79.7 -0.05 0.3 0.6
CA6NM Ni CI +0.106
40 Ø80.0 +0.060
CA6NM/CF8M CR.H.400
Ø79.5 -0.05 0.5 0.1
CF8M CF8M Col. coated
CI/LG2 CI/BZ 15
Ø89.7 -0.05 0.3 0.6
CA6NM Ni CI +0.126
50 Ø90.0 +0.072
CA6NM/CF8M CR.H.400
Ø89.5 -0.05 0.5 0.1
CI/LG2 CI/BZ 15
Ø99.7 -0.05 0.3 0.6
CA6NM Ni CI +0.106
65 Ø100.0 +0.060
CA6NM/CF8M CR.H.400
Ø99.5 -0.05 0.5 0.1
CI/LG2 CI/BZ 15
Ø114.7 -0.05 0.3 0.6
CA6NM Ni CI +0.126
80 Ø115.0 +0.072
CA6NM/CF8M CR.H.400
Ø114.5 -0.05 0.5 0.1
CI/LG2 CI/BZ 15
Ø129.7 -0.05 0.3 0.6
CA6NM Ni CI +0.148
100 Ø130.0 +0.085
CA6NM/CF8M CR.H.400
Ø129.5 -0.05 0.5 0.1
CI/LG2 CI/BZ 15
Ø149.7 -0.05 0.3 0.6
CA6NM Ni CI +0.148
125 Ø150.0 +0.085
CA6NM/CF8M CR.H.400
Ø149.5 -0.05 0.5 0.1
CI/LG2 CI/BZ 15
Ø199.7 -0.05 0.3 0.6
CA6NM Ni CI +0.172
150 Ø200.0 +0.01
CA6NM/CF8M CR.H.400
Ø199.5 -0.05 0.5 0.1
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98
Double Wearing Ring Execution
Diametral
Material Wearing ring Impeller
Pump clearance
ID Neck Dia.
size As new Worn out
Impeller Wearing ring (mm) (mm)
(mm) (mm)
1.4024.19 Ni CI Ø84.7 -0.05 0.3 0.6
+0.126
40 1.4024.19 CR.H.400 Ø85.0 +0.072
Ø84.5 -0.05 0.5 1.0
1.4024.19 Ni CI Ø99.7 -0.05 0.3 0.6
+0.126
50 1.4024.19 CR.H.400 Ø100.0 +0.072
Ø99.5 -0.05 0.5 1.0
1.4024.19 Ni CI Ø109.7 -0.05 0.3 0.6
+0.126
65 1.4024.19 CR.H.400 Ø110.0 +0.072
Ø109.5 -0.05 0.5 1.0
1.4024.19 Ni CI Ø124.7 -0.05 0.3 0.6
+0.148
80 1.4024.19 CR.H.400 Ø125.0 +0.085
Ø124.5 -0.05 0.5 1.0
1.4024.19 Ni CI Ø141.7 -0.05 0.3 0.6
+0.148
100 1.4024.19 CR.H.400 Ø142.0 +0.085
Ø141.5 -0.05 0.5 1.0
1.4024.19 Ni CI Ø161.7 -0.05 0.3 0.6
+0.148
125 1.4024.19 CR.H.400 Ø162.0 +0.085
Ø161.5 -0.05 0.5 1.0
1.4024.19 Ni CI Ø214.7 -0.05 0.3 0.6
+0.172
150 1.4024.19 CR.H.400 Ø215.0 +0.1
Ø214.5 -0.05 0.5 1.0
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99
Clearances at Stage Sleeve
Diametral
Material ID of Stage
Pump clearance
Diffuser sleeve
size Diffuser / As new Worn out
Stage sleeve Bore (mm) OD (mm)
Interstage bush (mm) (mm)
CI/LG2 CI/BZ 15
Ø44.7 -0.03 0.3 0.6
CA6NM Ni CI
40 Ø45.0 +0.039
410 H 410 A/316 Ø44.6 -0.05 0.4 0.8
316 316 Co. coated Ø44.5 -0.05 0.5 1.0
CI/LG2 CI/BZ 15
Ø47.7 -0.03 0.3 0.6
CA6NM Ni CI
50, 65 Ø48.0 +0.039
410 H 410 A/316 Ø47.6 -0.05 0.4 0.8
316 316 Co. coated Ø47.5 -0.05 0.5 1.0
CI/LG2 CI/BZ 15
Ø51.7 -0.03 0.3 0.6
CA6NM Ni CI
80, 100 Ø52.0 +0.046
410 H 410 A/316 Ø51.6 -0.05 0.4 0.8
316 316 Co. coated Ø51.5 -0.05 0.5 1.0
CI/LG2 CI/BZ 15
Ø64.7 -0.03 0.3 0.6
CA6NM Ni CI
125 Ø65.0 +0.046
410 H 410 A/316 Ø64.6 -0.05 0.4 0.8
316 316 Co. coated Ø64.5 -0.05 0.5 1.0
CI/LG2 CI/BZ 15
Ø79.7 -0.03 0.3 0.6
CA6NM Ni CI
150 Ø80.0 +0.046
410 H 410 A/316 Ø79.6 -0.05 0.4 0.8
316 316 Co. coated Ø79.5 -0.05 0.5 1.0
WKT
100
Clearances at Bearing Bush
Suction Diffuser Discharge Casing Bearing Spider Adaptor*

Pump
Clearance Clearance Clearance Clearance
size Dim. Dim. Dim. Dim.
Min. Max. Min. Max. Min. Max. Min. Max.
40 Ø44 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178
50 Ø45 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178
65 Ø46 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178
80 Ø50 0.100 0.178 Ø42 0.100 0.178 Ø42 0.100 0.178 Ø55 0.120 0.212
100 Ø52 0.120 0.212 Ø55 0.120 0.212 Ø42 0.100 0.178 Ø55 0.120 0.212
125 Ø63 0.120 0.212 Ø70 0.120 0.212 Ø55 0.120 0.212 Ø55 0.120 0.212
150 Ø76 0.120 0.212 Ø70 0.120 0.212 Ø70 0.120 0.212 Ø55 0.120 0.212
* Applicable for pump with Mechanical seal.
Notes : 1) The fit used is E8/e8.

e.g. For WKT 40 Suction Diffuser; Sleeve OD = Ø44 e8 and Bearing Bush ID = Ø44 E8.
2) Clearances given above are Diametral clearances.
WKT
101
9.4 Bearing Lubrication

Anti-friction bearing (QJ type)
The oil used should exhibit the following characteristics :
Kinematics viscosity at 50ºC = 30 to 45 mm²/s
Density at 20ºC = 0.9 kg/dm³
Flash point = at least 150ºC
Pour point = below -5ºC
Ash content = not exceeding 0.05%
Neutralization number = not exceeding 0.3
Asphaltenes = 0%
Bearing sizes & required oil fill
Pump sizes 40 50/65 80/100 125/150

Bearing type QJ 311 QJ 312 QJ 315 QJ 317
3)
Oil fill Ltrs. 0.3 0.5 0.6 1.2
3)
Oil filling quantity (including constant level oiler and filler pipe
Table 17 : Oil requirements
WKT
102
Notes:
WKT
Notes:
WKT
1766.841/02-18 G3
KSB Pumps Limited

Mumbai-Pune Road, Pimpri, Pune - 411 018. (India)
Tel.: +91 20 27101000 Fax : +91 20 27426000 www.ksbindia.co.in
Mktg. Serv. / 01-14 / 1000

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Vertical Barrel - Type

High Pressure Centrifugal Pumps

Installation/Operating Manual WKT

KSB Pumps Ltd., Pune, India.

Subject to technical modification without prior notice.

© KSB India 25.07.2012.

1.2 Target group

2.1 Key to safety symbols / markings

2.3 Intended use

§ Only operate pumps/pump sets which are in perfect technical condition.

Prevention of foreseeable misuse

2.4 Personnel qualification and training

The responsibilities, competence and supervision of all personnel involved in installation,

Deficits in knowledge must be rectified by means of training and instructions provided by

2.5 Consequences and risks caused by non-compliance with these

2.6 Safety awareness

2.7 Safety information for the operator/user

2.8 Safety information for maintenance, inspection and installation work

2.9 Unauthorized modes of operation

3 Transport / Temporary Storage / Disposal

3.1.2 Lifting Accessories (e.g. ropes, lifting gear)

3.1.3 Transport Symbols

3.2.1 Condition on delivery

3.2.2 Transport Options

Transport the transport boxes as indicated.

Hoisting the transport box Hoisting the transport box

Unpacking the pump (set)

Transporting the pump set

The pump set is generally supplied as individual components.

Transport the pump and individual components as illustrated.

Transporting the pump horizontally on a substructure

3.2.3 Transporting pump in horizontal / vertical position

1 = Suitable locations for Horizontal Support

1 Location of supports for placing the pump in horizontal position

Transporting the pump in vertical position

1 = Location of support for placing the

Transporting the base frame Attach the lifting accessories as illustrated.

3.3 Storage / Preservation

3.3.1 Period of storage longer than 12 months

3.4 Return to supplier

4 Description of the Pump (Set)

Table 3 : Key to the designation

4.3 Name plate

KSB PUMPS LTD.

Max. Test pr. bar

Name plate (example)

4.4 Design details

– Suction nozzle: horizontal, above the mounting surface

4.5 Configuration and Function

4.6 Scope of supply

On request the following items can be supplied amongst others

4.7 Dimensions and weights

5.2 Checks to be carried out prior to installation

1. Check structural requirements.

5.3 Installing the base frame

Therefore, the following procedure is recommended which ensures:-

Ø Reinforced plate of are welded in the channel( Ref. Fig1)

Ø 12 holes drilled to of dia 22 mm (Ref. Fig1)