KSB GIW MDX Installation instructions

Installation/Operating Manual
2017.01 MDX [en-US]
Pump Type:
Pump Serial Number:
Date:
Purchaser:
Purchaser’s Order Number:
GIW / KSB Work Order Number:
Shipped To:
Include the pump’s serial number when ordering replacement parts
This is a standard maintenance manual provided for your convenience
This manual may include additional documentation not applicable to your specific pump
GIW INDUSTRIES, INC.
5000 Wrightsboro Road
Grovetown, GA 30813 USA
[phone]
FAX [phone]
www.giwindustries.com
KSB AG
Johann-Klein-Str. 9
D-67227 Frankenthal, Germany
[phone] .
FAX [phone]
www.ksb.com

MDX [en-US]
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Legal Information/Copyright
Installation/Operating Manual MDX
Original operating manual (English)
In case of conflict between the local language version and the original operating manual, the original operating manual prevails.
A
ll 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.
© GIW Industries, Inc

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Contents
Section Page Section Page
1General 5
2Safety 6
2.1Safety Markings 6
2.2Personnel Qualification and Training 6
2.3Non-compliance with Safety Instructions 7
2.4Safety Awareness 7
2.5Safety Instructions for Operators 7
2.6Safety Instructions for Maintenance, Inspection &
Installation 7
2.7Unauthorized Modification and Manufacture of Spare Parts 7
2.8Unauthorized Modes of Operation 7
2.9Assembly & Disassembly Safety 7
3Transport and Storage 9
3.1Transport & Handling Safety 9
3.2Storage Requirements 9
3.2.1Storage of New Pumps - Pumps under Warranty 9
3.2.2Pump Storage 9
3.2.3Pump Parts Storage 11
3.2.4Removal from Storage 12
3.3Recommended Lifting 13
4Description 14
4.1Technical Specification 14
4.2Designation 14
4.3Design Features 14
4.4Noise Characteristics 14
4.5Accessories 15
4.6Dimensions and Weights 15
4.7Forces and Moments at Nozzles 16
5Installation at Site 17
5.1Safety Regulations 17
5.2Foundation 17
5.3Installing the Baseplate and Pump 17
5.3.1Aligning the Pump / Drive Train for Horizontal Pump
Application 17
5.3.2Place of Installation 18
5.4Connecting the Piping 19
5.4.1Auxiliary Connections 19
5.5Safety Guards 19
5.6Oil Temperature Monitoring 19
5.7Final Check 19
5.8Connection to Power Supply 19
6Commissioning / Operation 20
6.1Commissioning / Return to Service 20
6.1.1Bearing Lubrication 20
6.1.2Shaft Seal Commissioning 21
6.1.3Checking the Direction of Rotation 21
6.1.4Cleaning the Plant Piping 22
6.1.5Suction Strainer 22
6.2Start-up 22
6.2.1Priming the Pump 22
6.3Shutdown 23
6.3.1Measures to be taken for Prolonged Shutdown 23
6.4Operating Limits 23
6.4.1Temperature Limits 23
6.4.2Switching Frequency 23
6.4.3Density of the Medium Handled 24
6.5Underwater Pump Operation 24
7Maintenance 25
7.1Supervision of Operation 25
7.2Drainage / Disposal 25
7.3Lubrication and Lubricant Change 25
7.3.1Underwater Operation 25
7.4Procedures for Maximum Parts Life 26
7.5Operational Problems and Solutions 26
8Mechanical End 28
8.1Mechanical End Overview 28
8.2Mechanical End Disassembly 28
8.3Mechanical End Assembly 29
8.3.1Mounting the Bearings 29
8.3.2Closing the Housing 30
8.3.3Installing End Covers and Seals 31
8.4Bearing Assembly Mounting 31
9Shaft Seal 34
9.1Mechanical Seal 34
9.1.1Mechanical Seal Assembly and Disassembly 34
9.2Stuffing Box 34
9.2.1Stuffing Box Packing 35
9.2.2Stuffing Box Assembly 35
9.2.3Stuffing Box Maintenance 35
10Wet End 37
10.1Wet End Overview 37
10.2Wet End Disassembly 37
10.2.1Adjustable Suction Liner Removal 37
10.2.2Impeller Removal with Release Ring Assemblies 38
10.2.3Impeller Removal with Optional Release Ring Tool 38
10.2.4Impeller Break-Loose Device 40
10.2.5Impeller Removal with Impeller Lifting Device 40
10.2.6Casing Removal 40
10.3Wet End Assembly 40
10.3.1Mounting the Shaft Sleeve 41
10.3.2Hub Plate (if applicable) 42
10.3.3Mounting the Casing 42
10.3.4Impeller Installation 43
10.3.5Mounting the Suction Plate / Liner 43
10.3.6Snap Ring Gasket 45
10.3.7Suction Liner Adjustment 46
10.4Setting the Nose Gap 47
11Tooling 49
11.1Torque Requirements 49
11.2Spare Parts Stock 50
12Troubleshooting 51
14Notes 53

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Index
Section Page Section Page
Accessories 15
Alignment 17
Assembly Safety 7
Assembly, Mechanical End 29
Assembly, Wet End 40
Auxiliary Connections 19
Baseplate 17
Bearing Assembly Mounting 31
Bearing Housing Assembly 30
Bearing Installation 29
Bearing Lubrication, Commissioning 20
Casing 37
Casing Installation 42
Casing Removal 40
Cavitation / NPSH Performance 26
Commissioning 20
Commissioning / Return to Service 20
Commissioning, Bearing Lubrication 20
Density of the Medium Handled 24
Dimensions 15
Direction of Rotation 21
Disassembly Safety 7
Disassembly, Mechanical End 28
Disassembly, Wet End 37
Drainage / Disposal 25
End Covers and Seals, Installation 31
Foundation 17
Hub Plate Installation 42
Impeller 37
Impeller Installation 43
Impeller Removal, Break-Loose Device 40
Impeller Removal, Lifting Device 40
Impeller Removal, Optional Release Ring Tooling 38
Impeller Removal, Release Ring 38
Impeller, Parts Life 26
Inspection, Safety 7
Installation 17
Installation, Location 18
Installation, Safety 7
Lifting 13
Lubricant Change 25
Maintenance Equipment 49
Maintenance, Safety 7
Mechanical End 28
Mechanical End Assembly 29
Mechanical End Disassembly 28
Mechanical Seal 34
Mechanical Seal Assembly and Disassembly 34
Mechanical Seals, Commissioning 21
Mounting the Bearings 29
Noise Characteristics 14
Nose Gap Adjustment 47
Oil Temperature Monitoring 19
Operating Conditions of Flow and Head 27
Operating Limits 23
Operation 20
Operation, Unauthorized Modes 7
Operational Problems and Solutions 26
Packing 35
Parts Life 26
Personnel 6
Piping System Design 26
Piping, Allowable Forces and Moments 16
Piping, Cleaning 22
Piping, Connecting 19
Power Supply 19
Priming the Pump 22
Pump Casing, Parts Life 26
Pump Description 14
Pump Design Features 14
Pump Designation 14
Pump Specification 14
RTD Installation 19
Safety Awareness 7
Safety Guards 19
Safety Markings 6
Safety, Final Check 19
Safety, Non-compliance 7
Safety, Operators 7
Safety, Regulations 17
Safety, Transport & Handling 9
Seal Water Requirements 35
Shaft Seal 34
Shaft Seal, Commissioning 21
Shaft Sleeve, Mounting 41
Shutdown 23
Shutdown, Prolonged 23
Snap Ring Gasket 45
Spare Parts Stock 50
Spare Parts, Unauthorized Modification 7
Start-up 22
Storage Requirements 9
Stuffing Box 34
Stuffing Box Assembly 35
Stuffing Box Maintenance 35
Stuffing Box, Commissioning 21
Suction Liner Adjustment 46
Suction Liner Installation 43
Suction Liner, Parts Life 26
Suction Plate / Liner Removal 37
Suction Strainer 22
Sump Design 26
Switching Frequency 23
Temperature Limits 23
Tooling 49
Torque Requirements 49
Transport, Storage & Handling 9
Troubleshooting 51
Underwater Operation 25
Underwater Pump Operation 24
Wear Problems and Solutions 26
Weights 15
Wet End 37
Wet End Assembly 40
Wet End Disassembly 37

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1 General
CAUTION
This manual contains important information for reliable, proper and efficient operation. Compliance with the
operating instructions is of vital importance to ensure reliability and long service life of the pump, and to avoid
any risks.
These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly
observed by all, including the personnel called in for installation.
WARNING
This pump / unit must not be operated beyond the limit values specified in the technical documentation for the
medium handled, capacity, speed, density, pressure, temperature and motor rating. Make sure that operation is
in accordance with the instructions given in this manual or in the contract documentation.
The nameplate indicates the type series / size, main operating data and serial number. Please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
This manual may contain information not applicable to your pump/unit. Your pump/unit may not be equipped with all features or
auxillary components as described in this manual. Consult your pump/unit drawings and Bill of Materials for details.
If you need any additional information or instructions exceeding the scope of this manual or in case of damage, please contact
your GIW / KSB representative.

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2 Safety
These operating instructions contain fundamental information that must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible
trained personnel / operators prior to installation and commissioning, and it must always be kept close to the operating location
of the machine / unit for easy access.
Not only must the general safety instructions given in this chapter of "Safety" be complied with, but also the safety instructions
outlined under specific headings.
2.1 Safety Markings
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.
Instructions attached directly to the machine, such as:
 Arrow indicating the direction of rotation
 Marking for fluid connections 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 already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer / supplier to provide such training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions are fully understood by the responsible personnel.

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2.3 Non-compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-
compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
In particular, non-compliance can, for example, result in:
Failure of important machine / unit functions
 Failure of prescribed maintenance and servicing practices
 Hazard to persons by electrical, mechanical and chemical effects
 Hazard to the environment due to leakage of hazardous substances.
2.4 Safety Awareness
It is imperative to comply with the safety instructions contained in this manual, the relevant national and local health and safety
regulations and the operator’s own internal work, operation and safety regulations.
2.5 Safety Instructions for Operators
 Any hot or cold components that could pose a hazard must be equipped with a guard by the operator.
 Guards that are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed while the
machine is operating.
 Leakages (e.g. at the shaft seal) of hazardous media handled (e.g. explosive, toxic, hot) must be contained so as to
avoid any danger to persons and the environment. Pertinent legal provisions must be adhered to.
 Electrical hazards must be eliminated. (Refer to the relevant safety regulations applicable to different countries and /
or the local energy supply companies.)
 Mixing unsuitable media may cause a chemical reaction resulting in a pressure buildup and potential explosion.
2.6 Safety Instructions for Maintenance, Inspection & Installation
 The operator is responsible for ensuring that all maintenance, inspection and installation work is performed by
authorized and qualified personnel who are thoroughly familiar with the manual.
 Work on the machine must be carried out only during standstill. The shutdown procedure described in the manual for
taking the machine out of service must be adhered to without fail.
 Pumps or pump units handling media injurious to health must be decontaminated.
 Immediately following completion of the work, all safety / protective devices must be re-installed and / or re-activated.
 Please observe all instructions set out in the Section 6 "Commissioning" before returning the machine to service.
2.7 Unauthorized Modification and Manufacture of Spare Parts
Modifications or alterations of the machine are only permitted after consultation with the manufacturer. Original spare parts and
accessories authorized by the manufacturer ensure safety. The use of other parts can invalidate any liability of the manufacturer
for damage or warranty.
2.8 Unauthorized Modes of Operation
Any warranty of the operating reliability and safety of the pump / unit supplied is only valid if the machine is operated in
accordance with its designated use as described in the following sections. The limits stated in the data sheet must not be
exceeded under any circumstances.
2.9 Assembly & Disassembly Safety
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
For sectional drawings and bills of material relating to your specific pump and equipment, locate an official copy of the
documentation 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 rules of sound engineering practice
and the relevant sectional drawings. Any work on the motor, gear reducer, mechanical seal or other non-pump
equipment shall be governed by the specifications and regulations of the respective supplier.
 Before assembly thoroughly clean all dismantled part mating surfaces and check them for signs of wear. Damaged or
worn components are to be replaced by original equipment spare parts. Make sure that the seal faces are clean and
the o-rings and gaskets are properly fitted. It is recommended that new seal elements (o-rings and gaskets) be used
whenever the pump is reassembled. Make sure that new gaskets have the same thickness as the old ones.

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 Avoid the use of mounting aids as much as possible. Should a mounting aid be required, use a commercially available
contact adhesive. The adhesive should only be applied at selected points (three to four spots) and in thin layers. Do
not use cyanoacryiate adhesives (quick-setting adhesives). If in certain cases mounting aids or anti-adhesives other
than those described are required, please contact the sealing material manufacturer.
 The operator is responsible for ensuring that all maintenance inspection and installation work is carried out by
authorized, duly qualified staff who are thoroughly familiar with these operating instructions.
 A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of
the pump with a minimum of maintenance expenditure.
 Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original
equipment spare parts.
WARNING
 Proper lifting, rigging and safety practices must be observed at all times. Do not attempt to lift heavy
components by hand as this may result in personal injury and damage to equipment.
 Work on the unit 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.
 Before dismantling or reassembly, secure the pump so as to make sure it cannot be switched on
accidentally. The shut-off elements in the suction and discharge nozzles must be closed. The pump
must have cooled down to ambient temperature, drained, and its pressure must be released.
 Before dismantling or reassembly of vertical cantilever pumps, remove the motor and pull the assembly
out of the sump.
 Upon completion of the work, all safety-related and protective equipment must be properly refitted
and/or reactivated before starting the pump set.
 Always ensure that lifting equipment does not bind the swivel hoist ring. Binding can cause the ring to
fail. When lifting a plate that contains two swivel hoist rings, do not allow the angle between the lines
of tension from the rings to exceed 120°. This could cause the hoist rings to fail.
Do NOT bind lifting equipment Do NOT exceed 120° between lines of tension
120
°

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3 Transport and Storage
3.1 Transport & Handling Safety
WARNING
 Proper rigging, lifting and safety practices must be observed at all times.
 If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage
to property.
 Follow proper lifting practice and safety rules at all times, including:
 Verification of the lift weight and load rating of the lift equipment.
 Suitability and stability of the attachment points.
 Be aware of the location of the center of gravity, which is usually NOT located at the physical center of the unit. In
general, the following guidelines will apply, although common sense and testing of the lift before movement should be
used to verify:
 Bare shaft pump (without motor): Near the shaft seal area.
 Pump with overhead mounted motor: Between the pump and motor, slightly behind (towards the drive end) of
the shaft seal.
 Vertical cantilever pump: between the pump and bearing assembly, but closer to the bearing assembly.
 Space the lifting points evenly about the center of gravity and as far apart as practical. This will result in the most stable
lift. Note that certain lift points on the pedestal or bearing housing may be intended for use in handling the pedestal or
bearing house alone and are not necessarily optimum balance points for the entire pump unit.
 See Section 3.3 or any addendums for suggested lifting methods. Actual safe lifting method will vary with pump
configuration and type of lifting equipment.
 Ensure secure attachments and test the lifting method for stability before moving pump.
 For horizontal pumps, ensure that the unit remains in the horizontal position during lifting and cannot slip out of the
suspension arrangement.
 Ensure that the pump is firmly strapped down during shipment. Pump should be protected from direct contact with the
elements. Motors and gear reducers may require Immediate cover (consult manufacturer). After arrival on site, consult
GIW Pump Storage recommendations for further storage instructions.
 In corrosive environments be sure to remove all lifting devices from the pump and store in a non-corrosive environment
until needed.
 DO NOT: Use eyebolt or shackle locations on the bearing assembly, motor or pump plates. These are intended for
lifting those items alone and must not be used when lifting the entire pump.
 DO NOT: Place excessive side loads on cast lifting eyes. The side loading angle on any lifting eye should not exceed
30 degrees.
3.2 Storage Requirements
3.2.1 Storage of New Pumps - Pumps under Warranty
Consult your sales contract documents and/or your GIW / KSB representative for detailed instructions. Note that failure to follow
proper storage procedures will void your warranty.
3.2.2 Pump Storage
CAUTION
 In freezing environments, water must be prevented from collecting in the pump casing.
 Pumps with elastomer linings should be stored in a cool dark location free from electrical equipment
such as motors, or any other ozone generating devices. Exposure to direct sunlight or temperatures in
excess of 50°C (120°F) must be avoided.
 If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other
auxilarily equipment be sure to consult the manufacturer’s maintenance manual for any additional
storage instructions.
 Auxiliary systems should be regularly tested according to manufacturer’s recommendations.

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Storage Upon Receipt and up to 3 Months:
 Pump should stored indoors and out of the weather until ready for installation.
 In construction environments where indoor storage is not available, store the pump on blocks or pallets, build a frame
around it and cover with tarpaulin.
o Frame must be able to withstand snow and wind, anchored and built in a manner to last the entire time pump
is in storage. Shelter must be continuously maintained in a stable and leak free condition.
o Ensure the tarpaulin does not touch the pump, since this can lead to condensation. Leave the bottom open
for ventilation. Minimum Tarp requirements: 610gsm (18oz) Vinyl, 0.5mm (20mil) thick, Water proof & UV
(ultraviolet) resistant
Storage Exceeding 3 Months
 If pump is exposed to the weather at any time the frame requirements still stand.
 The Wet End pump parts should be drained and isolated from reaction vessel gasses.
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 Check that the threaded holes are protected with grease and plugged.
 Oil lubricated bearing assemblies with GIW Blue Oil (requires shaft rotation):
o GIW Blue Oil supplied with the pump should be added to the bearing housing until the level is halfway of the
Oil Sight Glass (642).
o Pump shaft should be manually rotated approximately 5 turns each month to keep the bearings coated.
o Vertical pumps should have the Lubrication Oil System running while the shaft is rotated 5 turns each month.
o The oil should be replaced if shutdown duration exceeds 12 months.
 Oil lubricated bearing assemblies with GIW Storage Oil (alternative to shaft rotation):
o GIW Storage Oil should be added to the bearing housing until the level is halfway of the Oil Sight Glass (642)
and rotate the shaft several times. No further shaft rotation is needed
o The bearing assembly must remain sealed in the factory assembled condition. The oil fill plug must be securely
replaced and no breather or other vent added to the bearing housing.
o Vertical pumps should be stored horizontally and filled with Storage Oil to the center of the sight glass or
25mm (1 inch) below the largest diameter Inpro/Seal bearing isolator, whichever is lower.
o The storage oil should be replaced if shutdown duration exceeds 12 months.
 Grease lubricated bearing assemblies do not require monthly rotation.
 If the pump is fitted with a mechanical seal, precautions may need to be taken before rotating the shaft. Refer to the
seal manufacturer’s maintenance manual for instructions.
 Pumps with InPro/Seal® bearing isolators must be coated externally with white grease or petroleum jelly to seal the
gap between the rotor and stator. Units equipped with a vent kit must have the vents either removed and plugged, or
blocked to prevent air exchange.
 Vertical pumps should be stored horizontally, and the blocking on the shaft should be left in place until the pump is
ready to be installed.
Storage Exceeding 12 Months (Long Term Storage)
The following information on long term storage pertains to GIW pump assemblies only and does NOT cover any auxiliary
equipment such as motors, gearboxes, lube oil systems, etc... Long term storage for auxiliary equipment must be included in
the contract and negotiated with sub-vendors at time of order.
At 12 months storage and again at 24 months of storage, the following additional actions should be taken:
 Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
 Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
 Replace the GIW Oil and/or Storage Oil, if applicable.
Installed Spares (Idle Pumps)
 After being idle to 1 or more months, shafts must be rotated through five (5) or more revolutions, either manually or by
a short duration start-up. If regularly exposed to moisture (weather or process related), monthly oil analysis is
recommended since idle bearing assemblies are subject to breathing and internal condensation due to ambient
temperature fluctuations.
 After being idle for 3 or more months, oil change or oil analysis is recommended for all pumps to ensure against
condensation.
 After being idle for 12 months or more, the oil should be replaced.