ATURIA TK User manual

LTK0E01D 05/2017 1
T
TK K
M
MU UL LT TI IS ST TA AG GE E
C
CE EN NT TR RI IF FU UG GA AL L P PU UM MP PS S
I
IN NS ST TR RU UC CT TI IO ON N M MA AN NU UA AL L
20060 Gessate (MILANO), ITALY / Piazza Aturia, 9
Tel. [phone] /Fax [phone]
www.gruppoaturia.com
Gruppo Aturia S.p.A.
Gruppo Aturia
AU D OL I &
BERTOLA
ARIS
CHIAPPA

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CONTENTS
CAP.1 GENERAL DESCRIPTION
1.1 Construction Features
1.2 Fields of applications
1.3 Noise levels
CAP.2 TRANSPORT AND STORAGE
2.1 Transport
2.2 Site installations
2.3 Storage
CAP.3 GENERAL SAFETY INSTRUCTIONS
3.1 General Instructions
3.2 Precautions during Operation
3.3 Residual Risks
3.4 In case of emergency
CAP.4 INSTALLATION
4.1 Installation
4.2 Alignment
4.3 Electrical Connections
CAP.5 COMMISSIONING AND STARTUP
5.1 Startup
CAP.6 MAINTENANCE
6.1 Ordinary Maintenance
6.2 Pump stop
CAP.7 PUMP DISASSEMBLY
7.1 Before disassembly
7.2 Pump disassembly
CAP.8 REASSEMBLIG
8.1 Before reassembly
CAP.9 SPARE PARTS
CAP.10 FAULT FINDING CHART
CAP.11 DECOMMISSIONING
10.1 Decommissioning and dismantlement
ENCLOSED:
SECTION DRAWINGS
TABLE OF ADMISSIBLE EXTERNAL FORCES AND TORQUES ON PUMP FLANGES
DECLARATION OF INCORPORATION
DECLARATION OF CONFORMITY

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FOREWORD, WARRANTIES AND LIMITATIONS
1) FOREWORD
Purpose of this instruction manual is to ease as much as possible the installation, operation and servicing of
TK multistage centrifugal pumps.
We strongly recommended to read it attentively and consult it whenever work is done on the pump, to
guarantee the correct operation of the pump and the maximum safety for the personnel in charge of pump
installation, starting and maintenance.
Remember that TK pumps are potentially dangerous to the person and to the things due to the presence of :
- High speed rotating parts
- High pressure and temperature - Electrical connections
- Dangerous fluids
UNOBSERVANCE OF THE INSTRUCTIONS HERE REPORTED OR IMPROPER USE OF THE PUMP BY
UNSKILLED PERSONNEL MAY RESULT IN HEAVY DAMAGE TO THINGS AND/OR INJURIES TO THE
PEOPLE.
ATURIA TECHNICAL ASSISTANCE IS READILY AVAILABLE, FOR ANY PROBLEM PLEASE
CONTACT US ALSO BY PHONE.
2) SHIPPING DOCUMENTS CHECK
Check the equipment at delivery against the accompanying documents, paying paticular attention to its
completeness and to possible damages occured during transport.
The same should be done for any ancillary equipment.
3) WARRANTY AND LIMITATIONS
The warranty does not include possible damages or failure caused by mishandling, worn electrical
connections and uncorrect assembly.
The warranty also excludes in all cases the reimbursement for consequential damages to the equipments or
to the plants.
ATURIA declines any responsibility for damages to persons and things due to improper use of the machinery
here described.
Consumables are not subject to warranty.
!
ATTENTION !

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CH HA AP PT TE ER R 1 1
GENERAL DESCRIPTION
1.1 Construction Features
TK pumps are centrifugal multistage pumps for high pressures.
Coupling to the drive, generally an electric motor, is ensured by a flexible joint.
Pump nameplate reports the following information :
Manufacturer - Pump type
Serial number - Capacity (m3/h)
Head (meters) - Month/ year of construction
Shaft speed (Rpm)
TK are multistage pumps with more elements in line, and they are divided into perpendicular planes to the
rotation axis. Sealing between the different elements is ensured by O-rings tightened by sturdy outer tie rods.
The supporting feet on delivery side are located beneath the delivery casing.
For sizes up to 65-100, the supporting feet on suction side are located under the first stage to allow different
orientations of suction nozzle, while for larger sizes they are located under the suction casing.
In this latter case, orientation of suction nozzle should be specified by the customer at pump ordering.
Hydraulical balancing of each impeller guarantees full absorption of axial thrust.
The shaft is supported by sturdy, grease-lubricated roller bearings. In standard constructions, shaft sealing is
ensured by gland packing.
Upon request, it is possible to install a mechanical seal.
1.2 Fields of applications
TK pumps range are mainly employed in the following applications:
-Hydraulic power plants -Boiler feeding
-Hydraulic press plants -Condense pumping
-Fire-fighting equipments - Cold and warm water pumping
-Irrigation and reclaiming installations
The performance are described in the technical specification enclosed in the ATURIA order confirmation.

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1.3 Noise levels
The following table reports the noise level produced by TK pumps running within their operating limits and
installed according to the instructions given in this manual.
(Average values measured at 1 meter from the pump and elaborated according to ISO curve A - standard R
1680).
MOTOR NOISE LEVELS Db (A) MOTOR NOISE LEVELS Db (A)
SIZE 2 POLES 4 POLES SIZE 2 POLES 4 POLES
63 65 61 180L 83 71
71 67 62 200 83 71
80 71 64 225 88 74
90 73 66 250 88 74
100 77 68 280 89 83
112 79 69 315S 89 83
132 80 69 315M 90 84
160 81 69 355 91 87
180M 81 69 400 93 89
For other motors the table values shall be compared to the actual used motors.

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CH HA AP PT TE ER R 2 2
TRASPORT AND STORAGE
2.1 Transport
Before transportation, please perform the following checks:
-Weight of pump/motor group
-Overall dimensions of pump/motor group
-Suitability of lifting points
The pump can be dispatched in the following ways:
A) Single pallet
B) Wood box
The pump should be transported with equipment fit for its weight and for the shape of its packing case (see
side pictures).
Hand lifting is allowed only for weights lower than 20 kilograms.
2.2 Site installations
During site installation and maintenance a safety transport of all components must be done.
The specialized personnel must use proper slings in order to avoid any damage to the pump
and to the people.
The lifting eyebolts of pumping set components must be used for lifting each related component; please refer
to above pictures in order to move the whole skid.
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2.3 Storage
The deivered pump is generally suitable for immediate installation.
STORAGE FOR A PERIOD OF LESS THAN 3 MONTHS :
- Store the pump in a dry and sheltered area.
- Check that ambient temperature never falls below 5°C.
- It is recommended that the pump shaft is rotated at regular intervals ( every 30 days ); this prevents
damage to the bearings and seizure of the rotating parts.
STORAGE FOR A PERIOD EXCEEDING 3 MONTHS :
- Rise the pump by means of wooden supports.
- Open the package, if any, remove the protection from the pump nozzles and clean by compressed air, then
dry carefully inside the pump, if necessary.
- Protect the pump inside with anti-condensation products and close the flanges so that no foreign objects
can enter the pump.
- Cover the pump with a plastic film and put inside some products the prevent water condensation.
- Check protections periodically.
- It is recommended that the pump shaft is rotated at regular intervals ( every 30 days ); this prevents
damage to the bearings and seizure of the rotating parts.
STORAGE ( AFTER OPERATION ) :_
- In case of long periods after operation, drain the pipings and the pump through the drain hole in the lower
part of the pump casing.
- Follow above instruction according to circumstances.
The delivered pump is generally suitable for immediate installation.

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CH HA AP PT TE ER R 3 3
GENERAL SAFETY INSTRUCTIONS
3.1 General Instructions
The pump(s) should be used only for the applications specified in par. 1.2. Recommended
operational limits must be strictly observed. In case of applications not specified on this manual,
please contact ATURIA to check for pump suitability, installation safety and pump life.
3.2 Precautions during operation
Never put your hands or any kind of object into pump openings where the shaft rotates (see side
picture).
In case of gland packing, pay attention when adjusting the gland as gland nuts are very close to
the shaft.
If warm water is pumped, do not touch the pump.
Protect motor and electric parts in general according to current regulations.
WE RECOMMEND BESIDES TO INSTALL THE PUMP IN A SAFE PLACE.
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3.3 Residual risks
Inobservance of the safety instructions here reported or improper use of the pump may result in heavy
damage to things and/or injuries to the person.
Always keep to the following directions :
- Don’t kick the pump
- Don’t damage the pump by wrong handling
- Don’t pressurize the pump beyond recommended limits
- Avoid dry running, operation at lower capacity than allowed, or running with closed gate
valve at discharge
- Avoid cold fluids uneven contact with the warm surfaces of the pump
- Don’t use the pump unproperly with dangerous fluids or different from what specified in
the order data sheets
3.4 In case of emergency
- Switch off line voltage
- Warn service personnel responsible of the plant
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CH HA AP PT TE ER R 4 4
INSTALLATION
4.1 Installation
For what concerns pump handling at the installation site, please refer to section 2.1.
The pump/motor group, coupled on a single steel-sections baseplate, must be properly fastened to its
concrete slab in which the foundation bolts have been previously bedded.
The group should be installed on a levelled plane. To this purpose, check levelling when anchoring the group
baseplate to the concrete slab by placing a level (bubble tube) on the pump delivery flange (see side
pictures).
PIPINGS
We recommend to support adequately the pipings to avoid any kind of stress to the pump suction and
delivery nozzles, with resulting difficulties to proper pump operation.
Pipe dimensions should not be determined according to the pumps nozzles diameters, but only according to
friction losses. Avoid narrow bends and elbows, and conical joints wrongly placed.
The suction pipe should be absolutely airtight, without counterslopes where harmful air bubbles can collect.
We recommend the use of gate valves upstream and downstream the pump. Leave enough space for motor
ventilation.
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4.2 Alignment
After positioning the pump unit on the foundation and connecting the pipes, it is necessary to
align it with due precision before starting.
To this purpose, remove the coupling guard and measure the concentricity and the
parallelism of the half coupling joints with a ruler and a thickness gauge.
Place the ruler in positions 1-2-3-4 ( see below picture ) and check radial offset “a” it should not exceed
0,1 mm
Measure then the distance “ b “ with a thickness gauge at positions 1-2-3-4.
The difference between readings in positions 1-3 and 2-4 should not exceed 0,1 mm.
Group alignment can be checked more accurately by using a millesimal comparator (millesimal dial
indicator).
THE COUPLING GUARD MUST BE FITTED ON BASEPLATE AFTER ALIGNMENT.
4.3 Electrical connections.
Electrical connections should be made only by specialized personnel, strictly following the
instructions of motor and electrical equipments manufacturers.
In case of three-phase line make sure that voltage is the same in the three phases.
Connect motor earthing correctly.
Remove the terminal board cover, connect electrical lines as shown inside the terminal
board, then put back the terminal board cover.
We recommend to install a safety switch upstream the motor to protect the motor against voltage drop or
overload.
Please refer to current data on motor nameplate for its correct sizing.
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CH HA AP PT TE ER R 5 5
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CO OM MM MI IS SS SI IO ON NI IN NG G A AN ND D S ST TA AR RT TU UP P
5.1 Startup
Before starting the pump it is necessary to fill it with water through the suited filling hole, located on suction
casing. Once the pump has been primed, close delivery gate valve and start the pump for a fraction of a
second to check rotation direction. Open gradually but within a minute the delivery gate valve, as running
with the valve closed may cause water overheating leading to pump seizing (startup with gate valve closed
reduces the initial transient voltage peak).
Check rotation direction against the arrow on pump/motor casing; if motor rotation does not match the one
shown by the arrow, reverse two motor phases (in case of three-phases motors).
Once started the group, open delivery gate valve slowly but fully till reaching the required pressure shown on
pressure gauge.
Avoid dry running.
During operation, check shaft seal. If a mechanical seal is installed, there should be no leaks; with gland
packing, there should be a continuous dropping to ensure lubrication between packing and shaft sleeve.
Check also that the pump runs within its operating limits and that voltage rates reported on control panel do
not exceed motor nameplate rated values. If necessary, partially close gate valve or adjust the intervention of
pressure switches.
However, if some malfunctioning is detected during startup, stop immediately the pump and
investigate the problem starting with the Fault Finding chart (chapter 7).
Attention: The system should be fully completed before starting the pump, especially for what concerns
electrical, mechanical an hydraulic components. All safety systems must be correctly operating.
STARTING THE PUMP WITHOUT COUPLING GUARD AND MOTOR TERMINAL BOARD COVER IS
ABSOLUTELY PROHIBITED.
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CH HA AP PT TE ER R 6 6
MAINTENACE
6.1 Ordinary Maintenance
Once started the pump, check it as frequently as possible by means of plant instruments like pressure
gauges, vacuum meters and ammeters. The pump needs normally no maintenance, except a periodical
check to:
- Seal operation (either mechanical or packing)
- Bearing operation
- Periodical renew of lubricant grease in bearings
PACKING SEAL
The quantity of leakage of medium should be sufficient to ensure correct cooling and lubrication of the
packing and shaft sleeve; generally 30-60 drops a minute is correct.
If necessary vary the quantity by adjusting the packing follower and, if fitted, check for a correct flow of the
flushing connections. If this adjustment has no effect, all the packing rings should be replaced. If also the
shaft sleeve is worm it should be replaced.
The number and dimensions of new packing rings must be the same of the original.
Replace the packing whenever needed.
Size and quality of the new packing must absolutely suit the service.
It is important to replace all the packing and not only those at the ends.
To replace the packing, remove the gland and then the packing with a flexible extractor, available by seals
manufacturers. Do not over tighten the packing. as that will cause their immediate failure.
Check shaft sleeve: it should be smooth also under the packing. If the sleeve is scratched or shows any sign
of surface roughness, it should be machined again or replaced according to the situation.
MECHANICAL SEAL
During the first running hours the mechanical seal can have small leak but after no leaks should be occur.
The mechanical seal must be checked every 4.000 hours running; in case of leakage check the seal faces
and the seal shaft sleeve that must be perfectly smooth, especially on O-Ring contact zone.
If it is worn it should be replaced.
LUBRICATION
It is very important to check the bearing operation, their temperature and the level.
Check bearing housing temperature: it can raise up to 50°C above the ambient temperature, but it should
never exceed 90°C.
Bearings are grease-lubricated. Every 2,000 running hours, 5-10 grams of grease (depending on the size of
the pump) has to be let in through the grease nipples. Use grease lithium SKF 65-2 or similar.
Replace the bearings only if they are noisy.

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Check bearing housing temperature: it should never exceed 70°C. If this happens, check group alignment or
remove bearing housing cover as the cause might be an excessive amount of grease or a failed bearing.
If a danger of frost exists, drain the pump completely during idle periods by unscrewing the draining plug
(see picture aside). Fill then the pump again as described in sect. 5.1.
6.2 Pump stop
Before any stop it is necessary to:
-Switch off the line voltage
-Close suction and delivery gate valves
-Drain the pump through the hole on the lower side of the pump casing.

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CH HA AP PT TE ER R 7 7
DISASSEMBLY
Disassembly and reassembly operation must be carried out by skilled personnel only.
Before any intervention on the pump it is necessary to:
- Switch the voltage off
- Close pump suction and delivery gate valve
- If the pump transports hot liquids let it cool at ambient temperature
- Discharge pump bowl from pumped liquid through a discharge hole.
7.1 Disassembly of the pump from the plant:
-Remove the joint protection and, if necessary, free the motor from its screws, remove it from the
baseplate using a tackle.
-Remove the bolts from suction and delivery flange.
-Disconnect all auxiliary supplies and possible sockets for instruments check.
-Disassembly the pump by loosing the baseplate fixing screws; use a tackle to move and lift (see
chapter 2) and send the pump to a local authorized workshop or to the manufacturer.
7.2 Pump disassembly (ref. dwg. EKY0101, EKY0201):
Start disassembly from delivery side removing the cover (3266) from the bearing housing (3200), after
removing the relative fixing screws.
Unscrew the bearing nut (6586) and, after loosening the bearing housing (3200) remove it complete with
radial ball bearing (3011), strike it on the sides using a lead hammer.
Remove the shaft (2110) , the spacer sleeve (2461.2) and the shaft sleeve (2450.2).
Free the tie bolt (6571), the discharge casing (1140) and remove it from the shaft.
Remove as follows: impeller (2200), stage casing (1150), diffuser (1450), spacer sleeve (2461.1), and go on
like this until the last impeller.
After loosening the bearing housing (3200) take it off complete with shaft (2110) and remove it from the
suction casing (1130).
Remove the spacer sleeve (2461.1) and the shaft sleeve (2450.1).
Remove the radial roller bearing (3012).
It is advisable, at any disassembly, to substitute all gaskets in the pump, bowl O-rings (4610) and sleeves O-
ring (4610.19, gaskets (4590.4) and gland packing (4130).
!

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Check conditions of impellers (2200), wear rings (1500), impeller rings (if any 2300), spacer sleeves (2461)
and bearings (3011-3012), which must be without linings or, on the contrary, must be replaced.
Diametric clearance between bowl wear ring and impeller collar, or between bowl wear ring and impeller
wear ring (if any) must be as indicated in the following table:
CLEARANCE REFERENCE MINIMUM DIAMETER
DIAMETER CLEARANCE
< 50 mm 0.25mm
from 50 < 65 0.28mm
from 65 < 80 0.30mm
from 80 < 90 0.33mm
from 90 < 100 0.35mm
from 100 < 115 0.38mm
from 115 < 125 0.40mm
from 125 < 150 0.43mm
from 150 < 175 0.45mm
from 175 < 200 0.48mm
from 200 < 225 0.50mm
from 225 < 250 0.53mm
from 250 < 275 0.55mm
During operation this clearance is bound to rise, with consequent performance and efficiency drop and
relative bearings overheating.
It is advisable to provide a set of spare parts to restore optimal performances.

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CH HA AP PT TE ER R 8 8
For reassembly proceed in the opposite direction disassembly.
8.1 PUMP REASSEMBLY
Lock the radial roller bearing (3012) on the shaft (2110) using the circlip (6545), the retaining ring, split
(2531) and the relative sleeve (2483), insert the bearing in the bearing housing (3200) and close the bearing
cover (3261).
Slide on the shaft the gland (4120), the spacer sleeve (2461) and the shaft sleeve (2450); insert everything
through the suction casing (1130) and start assembly as follows: bush (4132.2), impeller 82200), diffuser
(1413), key (6710.2), spacer sleeve (2461) and stage casing (1150) with the proper O-ring (4610).
Go on in this way up to the discharge casing (1140) and remember to insert the bush (4132.1).
Insert the shaft sleeve (2450.2), the spacer sleeve (2461.2) and let the gland (4120) slide on the axis.
Close the pump with the proper tie-bolt (6571), reassembly the bearing housing (3200), where the bearing
(3011) has been inserted.
Lock everything with the proper bearing nut (6586) and close the cover (3266).
- Before starting check the pump free rotation
-- Reconnect gland packing flow pipings and close all drainage gate valves
-- Proceed with filling and pump start
-- It is always necessary to review group alignment (see Chapter 4.2).
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CH HA AP PT TE ER R 9 9
SPARE PARTS
For a faster processing of Your order, when ordering spare parts please specify:
- Pump type
-.Pump serial number
-.Part name and number as listed on sectional drawing.
Pump type and serial number are printed on the nameplate.
For recommended spare parts see part list (EKY0102 – EKY0103 – EKY0202 – EKY0203).

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CH HA AP PT TE ER R 1 10 0
FAULT FINDING CHART
PROBLEM PROBABLE CAUSE REMEDY
1 . 1.1 Pump and suction pipe not well primed, with
air trapped in the system Prime again pump and suction pipe
THE PUMP GIVES
NO WATER
1.2 Air enters the system through suction pipe
open taps or through foot valve not enough
submersed Correct installation
1.3 Foot valve clogged by mud, leaves or other
debris Clean foot valve
1.4 Defected foot valve allows water to pass
through with loss of suction power Repair or change foot valve
1.5 Too high suction head Correct installation
1.6 Wrong rotation direction See par 5.1.
1.7 The total head required by the system is
higher than rated pump head The pump is not suited to the duty required
2. 2.1 Foreign bodies at impeller channels or the
same causes as points 1.1, 1.3, 1.5, 1.6, 1.7.
Clean impeller channels.
See mentioned points and
suggested remedies
UNSUFFICIENT
DELIVERY
2.2 Undersized suction pipe or foot valve, or
wrong positioning of suction pipe Correct installation
2.3 Worn impeller and/or pump casing Replace impeller Repair
pump casing (see section 8)
3. 3.1 Liquid viscosity higher than specified or the
same causes as points 1.6, 1.7, 2.3.
Pump not suited for operation
with higher viscosity and/or
see mentioned points and
suggest remedies
UNSUFFICIENT
PRESSURE
4. 4.1 Pump performances are different than rated Close partially the delivery
gate valve
EXCESSIVE BREAK
POWER
4.2 Liquid SG higher than specified Pump not suited to the service/close partially the
delivery gate valve
4.3 Abnormal internal rubbing (rotating parts rub
against fixed parts) Repair the pump - see section 8

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PROBLEM PROBABLE CAUSE REMEDY
5.
5.1 Worn seal Replace (See section
8)
THE SEAL LEAKS
EXCESSIVELY
5.2 Worn sleeve at seal position Repair the pump - see
section 8.
6.
6.1 Unbalanced rotating assembly Repair the pump - see
chapter 8
THE PUMP VIBRATES
AND IT IS NOISY
6.2 Worn pump bearings See chapter 8
6.3 The pump runs with too low or too high
capacity; also, the same causes as points: 1.5,
2.1,2.2 .
Operate the pump
differently; remove the
causes of the malfunctioning