KSB GIW LCC 100-400, Maintenance Manual

Page 1: ... serial number when ordering replacement parts This manual may not be reproduced without written consent of GIW Industries Additional copies may be purchased Please contact your sales representative for details GIW INDUSTRIES INC KSB AG KSB S A 5000 Wrightsboro Road Bahnhofplatz 1 10 14 rue de la Gare Grovetown Georgia 30813 USA D 91257 Pegnitz GERMANY F 76250 Déville lès Rouen FRANCE 706 863 1011...

Page 2: ...imits 14 6 2 1 Temperature of the Medium Handled Ambient Temperature Bearing Temperature14 6 2 2 Switching Frequency 14 6 2 3 Density of the Medium Handled 14 6 3 Shutdown Storage Preservation 14 6 3 1 Storage of New Pumps 14 6 3 2 Measures to be taken for Prolonged Shutdown 14 6 3 3 Storage of Elastomer Linings 15 6 4 Returning to Service after Storage 15 7 Maintenance Repair 15 7 1 General Instr...

Page 3: ...LCC 3 11 Supplements 28 11 1 Stuffing Box Throat Bushing Option 28 11 2 Underwater Pump Operation with Duo Cone Bearing Seals 30 11 3 Duo Cone Seals 31 11 4 Diverter 33 ...

Page 4: ...Oil Changes 7 2 2 3 16 Operating Conditions of Flow and Head 7 7 24 Operating Limits 6 2 14 Operation Supervision of 7 2 1 15 Operation Unauthorized modes 2 8 6 Operational Problems and Solutions 7 7 23 Packing the gland 7 5 16 22 Personnel Qualification and Training 2 2 5 Piping System Design 7 7 24 Piping Allowable Forces and Moments 4 3 5 10 Piping Cleaning the Plant 6 1 5 13 Power Supply Conne...

Page 5: ...ons must always be complied with and be kept in legible condition at all times 2 2 Personnel Qualification and Training All personnel involved in the operation maintenance inspection and installation of the machine must be fully qualified to carry out the work involved Personnel responsibilities competence and supervision must be clearly defined by the operator If the personnel in question are not...

Page 6: ... are recommended to stabilize the load and they should be as far apart as practical Avoid excessive side loads on cast lifting eyes Note that certain lift points on the pedestal are intended for use in handling the pedestal alone and are not necessarily optimum balance points for the pump assembly Always make sure that the unit remains in the horizontal position during transport and cannot slip ou...

Page 7: ...Suitable for high discharge head all particle sizes up to maximum sphere passage and mildly corrosive slurries Custom materials available for highly corrosive slurries 2 Elastomer Lined Radially split construction with ductile iron outer casing and molded elastomer inner liners Impeller of high chrome white iron or polyurethane For moderate discharge head fine to medium particles and highly corros...

Page 8: ...d always be purged with clear water for at least 15 minutes prior to stopping the pump Starting the system on clear water will help the expeller displace solids For applications where precipitate buildup in the expeller chamber is unavoidable intermittent gland water flush may be necessary When the stuffing box does not have flush water the packing must be lubricated with grease or oil Graphite pa...

Page 9: ...ding on configuration and vendor Replacement bearings are available from GIW KSB 1 Timken Co part numbers shown Koyo is also an approved supplier 2 125 mm taper roller bearing assembled from two single row bearings Other sizes are TDO one piece cup design Bearing Bearings Installed Assembly Spherical Double row Taper roller roller E Type Part number Cone Cup Spacer 1 Bench end play mm inch 35 mm 2...

Page 10: ...afety Regulations Electrical equipment operated in hazardous locations must comply with the applicable explosion protection regulations This is indicated on the motor rating plate If the equipment is installed in hazardous locations the applicable local explosion protection regulations and the regulations of the test Allowable Forces lbs N Allowable Moments ft lbs N m Flange Size FX FY FZ MX MY MZ...

Page 11: ...verhead motor mount accessory Motor feet must be firmly supported at each mounting bolt location before the bolts are tightened Shims should be used to fill any gaps and ensure solid mounting and vibration prevention Use of the mounting bolts to close gaps between motor feet and the mounting plate in place of shimming is not recommended and may result in twisting of the motor frame soft foot mount...

Page 12: ...om GIW KSB sales office 6 1 Commissioning Before starting up the pump make sure that the following requirements are checked and fulfilled The operating data the oil level if required 6 1 1 the nose clearance and the direction of rotation 6 1 4 must be checked The pump set must be primed 6 1 3 x Make sure the unit is properly connected to the electric power supply and is equipped with all protectio...

Page 13: ...y use suitable non aggressive clean water not liable to form deposits and not containing suspended solids Hardness should average 5 with a ph 8 It should be conditioned and neutral with regard to mechanical corrosion An Inlet Temperature of 10 to 30 o C 50 to 85 o F should produce a maximum Outlet Temperature 45o C 115 o F when the gland is properly adjusted Running the pump dry will result in inc...

Page 14: ...is can damage wet end pump parts as well as bearings seals and other components Where temperatures may drop below freezing the pump and system must be drained or otherwise protected against freezing 6 2 Operating Limits The pump s unit s application limits regarding pressure temperature and speed are stated on the data sheet and must be strictly adhered to If a data sheet is not available contact ...

Page 15: ...it must only be carried out with the electrical connections disconnected and locked out Make sure that the pump set cannot be switched on accidentally Pumps handling liquids posing health hazards must be decontaminated When draining the medium ensure there is no risk to persons or the environment All relevant laws must be adhered to 7 2 Maintenance Inspection 7 2 1 Supervision of Operation The pum...

Page 16: ...mentation provided by GIW KSB This may be shipped separately from the pump and will include drawings and bills of material as attachments to this basic manual Dismantling and reassembly must always be carried out in accordance with the relevant sectional drawing Any work on the motor gear reducer mechanical seal or other non pump equipment shall be governed by the specifications and regulations of...

Page 17: ...10 7 to the pump pedestal have not been removed See Figure 4 3 5 For 2x3 and 3x4 LCC M use two of the holes left open and two spare bolts not included to secure the expeller casing 10 7 to the pump pedestal If not secured in the above manner the expeller casing may fall without warning after the expeller is removed The expeller 23 15 may now be removed from the shaft The fit of this part is simila...

Page 18: ...y against the abutting shaft shoulder In mounting the taper roller bearing it is important to heat the outer race or cup along with the inner races or cones to ensure proper seating against the inner spacer required by this preset clearance type bearing Before the taper roller bearing has cooled on the shaft use the lock nut without lock washer to fully seat the bearing against the shaft shoulder ...

Page 19: ...ng face or the face in contact with the shaft shoulder For ease of removal a light coating of anti seize compound should be applied to the inner diameter of the shaft sleeve Lubrication at any of shaft sleeve or shaft shoulder faces may result in overloading and breakage of the shaft In many cases there will be an o ring which must be placed on the shaft first As the shaft sleeve is pushed into po...

Page 20: ...wards the drive end until the expeller just begins to rub on the expeller casing Then move it back towards the pump end approx 1 0 mm 0 4 inch This is a preliminary adjustment Final adjustment will be made after wet end assembly is complete Mount the expeller plate 16 4 to the shell using two hex head bolts 901 14 at the 3 9 o clock positions Mount the expeller plate and shell to the expeller casi...

Page 21: ...according to the requirements of Section 7 5 15 Finally firmly lock the adjusting screw and nut together against the bearing housing tab Proper tightening of the bearing housing clamps and adjusting nut is essential to prevent movement of the rotating assembly during operation Failure to do so can result in severe vibration and damage to all pump components 7 5 14 Expeller Running Clearance Proper...

Page 22: ...ressure controlled Flow control can result in burning or jamming the packing Actual flow in a properly maintained and adjusted stuffing box is considerably less than shown in the Table Forward Flush and Throat Bushing stuffing boxes are generally pressure controlled but flow control is an option Seal water requirements listed in the table show potential flow with worn packing Flow control may be a...

Page 23: ...ually indications that the pump is not operating at the flow and head conditions originally specified for the design 7 7 Operational Problems and Solutions Many pump wear problems are caused by unstable system operation or off duty pump operation Although the dynamics of slurry piping systems cannot be fully addressed in this manual the following items should be considered Also refer to section 8 ...

Page 24: ...Under these conditions minor fluctuations in the system resistance caused by normal variations in solids concentration or size can result in surging flow rates Whenever possible avoid prolonged operation at flows well below the optimum flow rate This causes recirculation of slurry within the pump and encourages localized wear In the event problems are encountered contact your GIW KSB representativ...

Page 25: ...igh temperature due to packing adjusted too tight b High temperature due hot process fluid c Leaking caused by excess flush pressure d Leaking caused by wrong adjustment e Leaking caused by worn parts f Excess wear of packing or sleeve 1 Adjusting the packing too tight 2 Insufficient flush flow or pressure 3 Contaminated flush water 4 Poor quality packing 5 Failure to lubricate new packing 8 5 Ove...

Page 26: ...86 M6 X 1 95 1074 71 800 57 644 M8 X 1 25 228 2576 170 1919 137 1546 M8 X 1 239 2701 178 2012 143 1620 M10 X 1 5 468 38 5288 52 349 28 3940 38 281 23 3173 31 M10 X 1 25 38 52 28 38 23 31 M12 X 1 75 67 91 50 68 40 55 M12 X 1 25 70 95 52 71 42 57 M14 X 2 105 142 78 106 63 85 M14 X 1 5 111 150 83 112 67 90 M16 X 2 158 214 118 160 95 129 M16 X 1 5 166 225 124 168 100 135 M20 X 2 5 317 430 236 320 190 ...

Page 27: ...LCC 27 NOTES ...

Page 28: ... 10 11 Supplements Supplements provide additional information for optional equipment These options may not be available for your pump See your Bill of Materials for options that were included with your pump 11 1 Stuffing Box Throat Bushing Option See page 29 11 2 Underwater Pump Operation with Duo Cone Bearing Seals See page 30 11 3 Duo Cone Seal See pages 31 32 11 4 Diverter See page 33 ...

Page 29: ...ditions will increase the chances for problems x High operating pressure or temperature x Poor seal water quality x Chemically aggressive or highly dense and abrasive slurry The Throat Bushing option is a one piece ring made of graphite and glass filled Teflon for self lubrication good heat transfer and strength It replaces the standard lantern ring and forward ring of packing The design incorpora...

Page 30: ...l is only about 85 of water and must be taken into account when calculating the mounting height of the tank The tank should have an oil level indicator to allow the operator to see if the level changes After the oil temperature stabilizes the level should remain constant and any significant change would indicate a leaking seal This early warning can prevent oil from leaking into the surrounding wa...

Page 31: ...cs will cause nonuniform face load resulting in leakage and bearing contamination Place the housing end cover and seal holder on a flat clean surface Verify that the grooves are clean and free from burrs or sharp edges Using the correct Seal Installation Tool locate the machined ridge in the tool over the toric and clamp together Align the parts squarely with the groove and carefully snap the seal...

Page 32: ...nd cover The metal seal rings may appear cocked slightly relative to the holders This is not a problem the rings will run true when the pump starts After the assembly is complete remove one of the pipe plugs from the bearing housing Install an air line fitting and slowly pressurize the unit with dry shop air to 10 15 psi or 1 bar Check all joints and the Duo Cone seals for leaks by spraying with a...

Page 33: ...sing will be necessary for the LCC 9 Metal Rubber lined pumps see figure below Clean the face of the expeller hub Position the Diverter with the tapered ring facing into the pump as shown below Press the Diverter completely back against the expeller plate If necessary seat the Diverter using a small hammer and a smooth wood block cut to fit between the lip and casing Place a small straight edge al...

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Page 35: ...Duty Point flow 2 405 gpm head 175 ft Metso Minerals Constellation WAPC Brandon Shores PO P162737 Metso Contract 72805 72806 Equip No 0 205 P 452A1 B1 A2 B2 GIW Ser No 13012 13 14 15 ...

Page 36: ...m Jonathan Samuel 13 March 2008 THIS DOCUMENT IS NOT COVERED BY THE GIW UPDATE SERVICE Future revisions may not be forwarded automatically 5012 13012 through 13015 Mill Product Pump Constellation Energy Brandon Shores Pump Tag 0 205 P 452A1 0 205 P 452B1 0 205 P 452A2 0 205 P 452B2 13012LOC P162737 G 150234 5012 13012 through 13015 ...

Page 37: ...m Jonathan Samuel 13 March 2008 THIS DOCUMENT IS NOT COVERED BY THE GIW UPDATE SERVICE Future revisions may not be forwarded automatically 5012 13012 through 13015 Mill Product Pump Constellation Energy Brandon Shores Pump Tag 0 205 P 452A1 0 205 P 452B1 0 205 P 452A2 0 205 P 452B2 13012DT P162737 G 150234 5012 13012 through 13015 ...

Page 38: ...Special Tools for Impeller Service Impeller lift device p n 611 7272C 00 0FABS Impeller break loose jig p n 611 7963C 00 0FABS ...

Page 39: ...Special Tools for Impeller Service Impeller lift device p n 611 7272C 00 0FABS Impeller break loose jig p n 611 7963C 00 0FABS ...

Page 40: ...el pump performance data is based on the best available information for each pump Where performance guarantees are required contact your GIW representative Note Pump Solids Effect is based on a Settling Slurry Flow 2405 GPM Fluid S G 0 982 Pump Service Class 1 Head 175 0 ft Slurry S G 1 560 Abrasivity Correction 0 6 Throughput 530 1 tons hr Solids S G 2 860 D50 microns 74 Large particles 2300 micr...

Page 41: ...nts Motor Horsepower 300 0 Motor RPM 1780 Service Factor 1 5 Pump RPM minimum 940 Pump RPM maximum 987 Center distance minimum 50 0 Center distance maximum 60 0 Selection made from manufacturer Dodge General Manufacturer Manufacturer Weight Mfg Price Quantity Description Description Part Number lbs US 1 Motor Sheave 8 8V13 2 J 455459 125 0 263 23 1 Motor Bushing Jx4 1 8 KW 120632 30 0 48 20 1 Pump...

Page 42: ...plications may require a larger inventory of spare parts A KSB Company GIW PARTS ORDER INFORMATION OEM Parts offer better fit greater reliability and longer life make sure you ve got the parts you need GIW Industries Inc 5000 Wrightsboro Road Grovetown GA 30813 9750 USA Telephone 706 863 1011 Fax 706 860 5897 www giwindustries com Important Contacts For the name of your local authorized GIW Repres...

Page 43: ..._____________________ TAG NO __________________________________________________ SLURRY DESCRIPTION LIMESTONE SLURRY _______ ______ PH OF SLURRY IF ABOVE 10 OR BELOW 5 6 7 MAX CHLORIDES 1 000 PPM ______ ______ TEMPERATURE OF SLURRY IF ABOVE 120 DEG F 150 00 DEG F 65 50 DEG C DESIGN OPERATING CONDITIONS ___________________________ _________ _________ _________ FLOW 2 645 00 GPM 600 75 M3 HR 166 87 L...

Page 44: ...__________________________________________ NAME PLATE DATA _______________ PUMP LCC H200 610 5M AM1 GIW SERIAL NBR 5012 13012 CUSTOMER P O P162737 P O DATE 06 28 2007 EQUIPMENT ________________________________________________ 1 GIW TO PROVIDE PUMP W V BELT DRIVE SUBBASE GUARD SLIDE RAILS AND MOTOR ...