KSB Etanorm Installation instructions
Standardised Pump
Etanorm
Installation/Operating
Manual
Order number:
Installation/Operating Manual Etanorm
Original operating manual
KSB Aktiengesellschaft Pegnitz
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced,
processed for any other purpose, nor otherwise transmitted to a third party without KSB´s express
written consent.
Subject to technical modification without prior notice.
© KSB Aktiengesellschaft Frankenthal 01.02.2010
Contents
Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Installation of partly completed machinery .................................................. 6
1.3 Target group ................................................................................................... 6
1.4 Other applicable documents .......................................................................... 6
1.5 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 8
2.1 Key to safety symbols/markings ..................................................................... 8
2.2 General ............................................................................................................ 8
2.3 Intended use .................................................................................................... 8
2.4 Personnel qualification and training ............................................................. 9
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 9
2.6 Safety awareness ............................................................................................. 9
2.7 Safety information for the operator/user .................................................... 10
2.8 Safety information for maintenance, inspection and installation work ... 10
2.9 Unauthorised modes of operation ............................................................... 10
2.10 Explosion protection ..................................................................................... 10
3 Transport/Temporary Storage/Disposal ........................................... 13
3.1 Transport ....................................................................................................... 13
3.2 Storage and preservation ............................................................................. 13
3.3 Return to supplier ......................................................................................... 14
3.4 Disposal .......................................................................................................... 14
4 Description of the Pump (Set) .......................................................... 15
4.1 General description ...................................................................................... 15
4.2 Designation ................................................................................................... 15
4.3 Name plate .................................................................................................... 15
4.4 Design details ................................................................................................ 15
4.5 Design and function ...................................................................................... 16
4.6 Noise characteristics ...................................................................................... 17
4.7 Scope of supply ............................................................................................. 17
4.8 Dimensions and weights ............................................................................... 18
5 Installation at Site ............................................................................. 19
5.1 Safety regulations ......................................................................................... 19
5.2 Checking the site before installation ........................................................... 19
5.3 Installing the pump set ................................................................................. 19
5.4 Piping ............................................................................................................. 21
Contents
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5.5 Protective equipment ................................................................................... 24
5.6 Checking the coupling alignment ................................................................ 25
5.7 Aligning the pump and motor ..................................................................... 26
5.8 Electrical connection ..................................................................................... 27
5.9 Checking the direction of rotation .............................................................. 29
6 Commissioning/Start-up/Shutdown ................................................. 30
6.1 Commissioning/start-up ................................................................................ 30
6.2 Operating limits ............................................................................................ 34
6.3 Shutdown/storage/preservation ................................................................... 36
6.4 Returning to service after storage ............................................................... 36
7 Servicing/Maintenance ...................................................................... 37
7.1 Safety regulations ......................................................................................... 37
7.2 Servicing/inspection ...................................................................................... 37
7.3 Drainage/disposal .......................................................................................... 42
7.4 Dismantling the pump set ............................................................................ 42
7.5 Reassembling the pump set .......................................................................... 45
7.6 Tightening torques ....................................................................................... 50
7.7 Spare parts stock ........................................................................................... 52
8 Trouble-shooting ............................................................................... 55
9 Related Documents ........................................................................... 57
9.1 Exploded view / List of components: ........................................................... 57
10 EC Declaration of Conformity ......................................................... 63
11 Certificate of Decontamination ....................................................... 64
Index .................................................................................................. 65
Contents
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Glossary
Back pull-out design
The complete back pull-out unit can be pulled
out without having to remove the pump casing
from the piping.
Back pull-out unit
Pump without pump casing; partly completed
machinery
Certificate of decontamination
A certificate of decontamination certifies that
the pump (set) has been properly drained to
eliminate any environmental and health
hazards arising from components in contact
with the fluid handled.
Discharge line
The line which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy
Pool of pumps
Pumps which are purchased and stored
independently of their later use
Pump
Machine without drive, additional components
or accessories
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line
The line which is connected to the suction
nozzle
Glossary
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1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. This 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
clearly identify the pump (set) and serve as identification for all further business
processes.
In the event of damage, immediately contact your nearest KSB Service centre to
maintain the right to claim under warranty.
Noise characteristics (⇨ Section 4.6 Page 17)
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB, please refer to the sub-
sections under Servicing/Maintenance. (⇨ Section 7.5.5 Page 49)
1.3 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel. (⇨ Section 2.4 Page 9)
1.4 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Data sheet Description of the technical data of the pump
(set)
General arrangement drawing/
Outline drawing
Description of mating and installation dimensions
for the pump (set)
Drawing of auxiliary connections Description of auxiliary connections
Hydraulic characteristic curve Characteristic curves showing head, NPSH
required, efficiency and power input
General assembly drawing1) Sectional drawing of the pump
Sub-supplier product literature1) Operating manuals and other product literature
of accessories and integrated machinery
components
Spare parts lists1) Description of spare parts
Piping layout1) Description of auxiliary piping
List of components1) Description of all pump components
1.5 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1) If agreed to be included in the scope of supply
1 General
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Symbol Description
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1 General
Etanorm 7 of 66
2 Safety
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EC Directive
94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information
about protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist
personnel/operators 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 which
are not taken into account in this manual.
2.3 Intended use
The pump (set) must only be operated within the operating limits which are
described in the other applicable documents.
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate partially assembled pumps/pump sets.
!DANGER
2 Safety
8 of 66 Etanorm
▪Only use the pump to handle the fluids specified in the data sheet or product
literature of the respective design variant.
▪Never operate the pump without the fluid to be 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
▪Never open discharge-side shut-off elements further than permitted.
– The maximum flow rate specified in the data sheet or product literature
would be exceeded.
– Risk of cavitation damage
▪Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
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 sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. If
required, the operator can commission the manufacturer/supplier to train the
personnel.
Training on the pump (set) must always be supervised by technical specialist
personnel.
2.5 Consequences and risks caused by non-compliance with these operating
instructions
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
–Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
2 Safety
Etanorm 9 of 66
▪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 or moving parts and check that
the guards function properly.
▪Do not remove the contact guard while the pump is running.
▪Connect an earth conductor to the metal jacket if the fluid handled is
electrostatically charged.
▪Provide the personnel with protective equipment and make sure it is used.
▪Contain leakages (e.g at the shaft seal) of hazardous fluids handled (e.g.
explosive, toxic, hot) so as to avoid any danger to persons and the environment.
Adhere to all relevant laws.
▪Eliminate all electrical hazards. (In this respect refer to the applicable national
safety regulations and/or regulations issued by the local energy supply
companies.)
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for consequential
damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Carry out work on the pump (set) during standstill only.
▪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. (⇨ Section 6.1.7 Page 33)
▪Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 42)
▪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. (⇨ Section 6.1 Page 30)
2.9 Unauthorised 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. (⇨
Section 2.3 Page 8)
2.10 Explosion protection
Always observe the information on explosion protection given in this section when
operating the pump in potentially explosive atmospheres.
!DANGER
2 Safety
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