KSB MAMMOUTH 25 User manual

Double Mechanical Seals
Back-to-back Arrangement
With Seal Supply System
Supplementary Operating
Manual

Legal information/Copyright
Supplementary Operating Manual Double Mechanical Seals
Original operating manual
All rights reserved. The 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 the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 19/01/2018

Contents
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Double Mechanical Seals
Contents
1 Supplementary Operating Manual....................................................................................................... 4
1.1 General..............................................................................................................................................................4
1.2 Technical data...................................................................................................................................................4
1.3 Removing the shaft seal...................................................................................................................................4
1.3.1 Removing the shaft seal - shaft units 25/35 .......................................................................................4
1.4 Installing the shaft seal ....................................................................................................................................5
1.5 Seal supply system ............................................................................................................................................6
1.5.1 Applications..........................................................................................................................................6
1.5.2 Connections..........................................................................................................................................7
1.5.3 Requirements to be met by the seal supply system...........................................................................7
1.6 General assembly drawing with list of components ......................................................................................9
1.6.1 Shaft units 25/35 ..................................................................................................................................9

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1 Supplementary Operating Manual
1.1 General
This supplementary operating manual accompanies the installation/operating
manual. All information contained in the installation/operating manual must be
observed.
Table1: Relevant operating manuals
Type series Reference number of the installation/operating
manual
Etaprime L 2753.81
Etaprime B 2753.82
1.2 Technical data
Design details The shaft is sealed by 2 unbalanced single bi-directional mechanical seals to EN12756
in back-to-back arrangement, with barrier fluid system.
Seal size/ material variant Table2: Material variant
Shaft unit
Mechanical seal
Outboard (433.02) Inboard (433.01)
Seal size Material variant1) Seal size Material variant
25 KU028S-M7-N Q1BVGG KU028S-M7-G49 Q1Q1K9GG-G
35 KU038S-M7-N KU038S-M7-G49
Material code Table3: Material code
Item Description Code Materials
1 Primary ring Q1 SiC, silicon carbide, sintered without
pressure
2 Mating ring B Resin-impregnated hard carbon
Q1 SiC, silicon carbide, sintered without
pressure
3 Secondary seal V Fluoroelastomer (Viton)
K9 Perfluoroelastomer
4 Spring G CrNiMo steel
5 Other
components
G CrNiMo steel
1.3 Removing the shaft seal
1.3.1 Removing the shaft seal - shaft units 25/35
üDismantle the pump as described in operating manual 2753.81 or 2753.82.
üThe back pull-out unit has been placed in a clean and level assembly area.
1. Take hexagon nut 920.95, disc 550.95 (shaft unit 25 only), safety device 930.95,
impeller 230 and discs 550.02/.04 off shaft 210.
2. Take key 940.01 out of the shaft keyway.
3. Take spacer sleeve 525 (shaft unit 35 only) off shaft 210.
4. Remove fitting 720.13/.14 and joint ring 411.13/.14.
5. Undo hexagon nut 920.02 at seal cover 471. Abut the seal cover against the
bearing bracket or motor, as applicable.
1) For units with closed thermosyphon system: material variant Q1Q1K9GG

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6. On models with a clamped casing cover: Undo bolt 901.98 (long-coupled
design) or screw 914.22 (close-coupled design) and remove. Separate casing
cover 161 from the locating fit of bearing bracket 330 or from the locating fit of
drive lantern 341, as applicable. Pull it off shaft 210.
On models with a bolted casing cover: Undo hexagon nut 920.15. Use forcing
screws 901.31 to separate casing cover 161 from bearing bracket 330 or drive
lantern 341. Pull it off shaft 210.
7. Pull shaft sleeve 523 with the two rotating assemblies of mechanical seals
433.01/433.02 off shaft 210.
8. Remove seal cover 471 with the mating ring of outboard mechanical seal 433.02
from shaft 210.
9. Remove circlip 932.05 and the ring from casing cover 161.
10. Remove the stationary mating ring of mechanical seal 433.01 from the casing
cover.
11. Remove the stationary mating ring of mechanical seal 433.02 from seal cover
471.
12. Loosen and remove the rotating assembly of mechanical seals 433.01 and 433.02
from shaft sleeve 523.
13. Remove and dispose of gasket 400.15 (for SU25: joint ring 411.15) and gasket
400.75.
1.4 Installing the shaft seal
Installing the
mechanical seal
The following rules must be observed when installing the mechanical seal:
▪Work cleanly and accurately.
▪Only remove the protective wrapping of the contact faces immediately before
installation takes place.
▪Prevent any damage to the sealing surfaces or O-rings.
Fig.1: Adjusting dimension A
Table4: Adjusting dimension
Bearing bracket Adjusting dimension A
WS25 53,5
WS35 63
üObserve / carry out the notes and steps given in operating manual 2753.81/.82.
üThe bearing assembly as well as the individual parts have been placed in a clean
and level assembly area.
üAll dismantled parts have been cleaned and checked for wear.
üAny damaged or worn parts have been replaced by original spare parts.
üThe sealing surfaces have been cleaned.
1. Clean shaft sleeve 523 and the mating ring location in casing cover 161 and seal
cover 471. Gently remove any deposits. If score marks or scratches are still
visible, replace the affected parts.

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NOTE
To reduce friction forces when assembling the seal, wet the shaft sleeve and the
location of the stationary ring with water.
CAUTION
Elastomers in contact with oil/grease
Shaft seal failure!
▷Use water as assembly lubricant.
▷Never use oil or grease as assembly lubricant.
2. Fit the rotating assembly of mechanical seals 433.01 and 433.02 on shaft sleeve
523 (observe distance A).
3. Carefully position the stationary assembly (mating ring) of mechanical seal
433.01 with the O-ring in casing cover 161. Make sure to apply pressure evenly.
4. Insert the ring and circlip 932.05 in casing cover 161.
5. Carefully position the stationary assembly (mating ring) of mechanical seal
433.02 with the O-ring in seal cover 471. Make sure to apply pressure evenly.
6. Position gasket 400.15 (for SU25: joint ring 411.15) in seal cover 471.
7. Slide seal cover 471 onto shaft 210 until it rests against bearing bracket 330 or
the motor.
8. Slide shaft sleeve 523 (with the rotating assemblies) with new gasket 400.75
onto shaft 210.
9. On models with a bolted casing cover: Screw back but do not remove forcing
screws 901.31. Slide casing cover 161 onto bearing bracket 330 or drive lantern
341, as applicable. While doing so, carefully slide seal cover 471 onto casing
cover 161.
On models with a clamped casing cover: Slide casing cover 161 onto bearing
bracket 330 or drive lantern 341, as applicable. While doing so, carefully slide
seal cover 471 into casing cover 161. Insert bolts 901.98 (long-coupled design) or
screws 914.22 (close-coupled design) and tighten to fasten casing cover 161 in
place.
10. Fit and tighten hexagon nuts 920.15 at casing cover 161.
11. Fit and tighten nuts 920.02 at seal cover 471.
12. Slide spacer sleeve 525 (shaft unit 35 only) onto shaft 210.
13. Place key 940.01 in the shaft keyway.
14. Slide discs 550.02/.04, impeller 230, disc 550.95 (shaft unit 25 only) and safety
device 930.95 onto the shaft. Tighten with hexagon nut 920.95.
15. Position fittings 720.13/.14 with joint rings 411.13/.14 in seal cover 471 or casing
cover 161, as applicable, and tighten.
16. Carry out all other relevant steps given in operating manual 2753.81 or 2753.82.
1.5 Seal supply system
1.5.1 Applications
In order to function properly, the mechanical seals require a barrier fluid. The barrier
fluid completely fills the space between the inboard and the outboard mechanical
seal. It serves two purposes:
▪Dissipate friction heat
▪Prevent the fluid handled from entering the sealing gap

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1.5.2 Connections
10A
10E
901.98
550.74
AA
UG1385256-D01_002
Fig.2: Connections of seal supply system
Table5: Connections
Connection2) Description Size3)
10A Barrier fluid outlet G 1/4
10E Barrier fluid inlet G 1/4
1.5.3 Requirements to be met by the seal supply system
Pipework routing
requirements
When routing pipework and flexible tubing, prevent any high points or ensure that
high points can be vented separately to prevent dry running of the mechanical seal.
The connecting pipes between the main pipe and the pump must be routed with a
continuously rising slope to assure self-venting of the pipe and the mechanical seal,
respectively.
Barrier fluid pressure Table6: Barrier fluid pressure
Type of system Barrier fluid pressure4) Calculating barrier fluid pressure
during operation
Phosphatising plant 1.5 to 2bar higher than
system pressure of fluid
to be sealed
Pbarrier=3.5 bar+Pinlet
(measured at the suction nozzle)
E-coating plant Approx. 4bar higher
than system pressure of
fluid to be sealed
Pbarrier=5.5 bar+Pinlet
(measured at the suction nozzle)
2) Plugged during transport
3) According to ISO 228
4) Also during pump standstill

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Large-scale industrial plants
Barrier fluid ▪Ultrafiltrate (residual solvent content approx. 50% of the solvent in the paint)
▪Return barrier fluid to ultrafiltration stage.
Monitor the ultrafiltrate for contamination (clouding). In the event of a
malfunction make sure the ultrafiltrate does not reach the barrier fluid vessel.
Barrier fluid pressure ▪Install a pressure boosting pump to ensure the barrier fluid pressure required.
▪Fit a by-pass valve in the return line, for instance, to maintain the minimum
pressure. This valve must close tightly during idle periods and be used in
conjunction with a sufficiently sized bladder accumulator to maintain the
pressure in the system (e.g. in the event of a power failure or operating errors).
▪To ensure equal distribution of the barrier fluid, install orifice plates in the lines
downstream of the mechanical seals. Use downstream valves for fine-tuning only.
▪Secure the barrier fluid system against barrier pressure failure (e.g. due to power
failure), as the absence of barrier pressure will result in mechanical seal failure.
Barrier fluid temperature ▪The temperature of the barrier fluid should be within the processing range of
the paint (normally 25 to +30°C).
Circulation flow ▪To prevent the formation of paint deposits in the seal supply system and to
stabilise the temperature in the sealing gap, we recommend a circulation flow of
2.5 - 5 l/min per seal.
Small systems
Barrier fluid ▪Ultrafiltrate
▪DI water with a slightly increased solvent content, e.g. 5 – 10 % butyl glycol
Barrier fluid pressure Ensure sufficient barrier fluid pressure by means of a continuous nitrogen supply or
compressed air supply via a suitable pressure regulating valve.
Thermosyphon system ▪The thermosyphon vessel should be located approximately 1metre above the
centreline of the pump and connected with pipework.
▪Install pipes made of chrome nickel molybdenum cast steel with an inside
diameter≥9mm and a steady rise, in order to avoid air pockets and consequent
dry running of the mechanical seals.
▪Each pump must be provided with its own thermosyphon system so that the
mechanical seals can be monitored individually and failure of one mechanical
seal will not pose a risk to the others.
▪The pipe bend radius must be as large as possible to keep pipe friction losses as
low as possible.
▪In order to stabilise the temperature, a circulating pump must be installed in the
system. (Contact operator about explosion protection requirements.)
▪Monitor the barrier fluid level by means of a level switch (contact operator about
explosion protection requirements).
▪Barrier fluid refill is by means of a manual refill pump.
▪When a closed thermosyphon system is used, we recommend to use a SiC/SiC
combination on the outboard mechanical seal as well, to avoid wear or damage
to the seal faces caused by paint deposits or sticking.
Cooling Cooling of the thermosyphon system is required if the following limits are exceeded:
▪Speeds > 1450rpm
▪Seal diameter > 60mm
▪Barrier fluid pressure >6bar
▪Ambient temperature >30℃

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1.6 General assembly drawing with list of components
1.6.1 Shaft units 25/35
411.13
720.13
471
400.15
523
902.02
920.02
433.02
433.01
411.14
720.14
10A
10E
161
525
400.75
932.05
UG1385256_D01_001
Fig.3: Variant with double mechanical seal in back-to-back arrangement
550.24
901.24
575
UG1385256_D01_004
Fig.4: Position of anti-rotation device SU25
550.24
901.24
575 UG1385256_D01_005
Fig.5: Position of anti-rotation device SU35
Part number Description Part number Description
161 Casing cover 720.13/.14 Fitting
400.155)/.75 Gasket 901.24 Hexagon head bolt
411.13/.14 Joint ring 902.02 Stud
433.01 Mechanical seal (inboard) 920.02 Nut
433.02 Mechanical seal (outboard) 932.05 Circlip
471 Seal cover
523 Shaft sleeve Auxiliary connections
5256) Spacer sleeve 10A Barrier fluid outlet
550.24 Disc 10E Barrier fluid inlet
575 Strip
5) Only for shaft unit25: joint ring 411.15
6) For shaft unit35 only; shaft unit see data sheet.

KSB SE & Co. KGaA
Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. [phone]
www.ksb.com
2753.812/02-EN (01688194)