KSB Omega Installation instructions

Axially Split Volute Casing Pump
Omega / Omega V
Horizontal Installation Type 3E
Vertical Installation Types DB, DK, DP, DJ
Installation/Operating Manual
Mat. No.: 01059616

Legal information/Copyright
Installation/Operating Manual Omega / Omega V
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 2023-04-25

Contents
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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 .............................................................................................................................................................7
1.6 Key to safety symbols/markings.......................................................................................................................7
2 Safety...................................................................................................................................................... 8
2.1 General..............................................................................................................................................................8
2.2 Intended use .....................................................................................................................................................8
2.3 Personnel qualification and training...............................................................................................................8
2.4 Consequences and risks caused by non-compliance with this manual .........................................................9
2.5 Safety awareness ..............................................................................................................................................9
2.6 Safety information for the operator/user.......................................................................................................9
2.7 Safety information for maintenance, inspection and installation ................................................................9
2.8 Unauthorised modes of operation................................................................................................................10
2.9 Explosion protection ......................................................................................................................................10
2.9.1 Marking ............................................................................................................................................. 10
2.9.2 Temperature limits............................................................................................................................ 11
2.9.3 Repair................................................................................................................................................. 11
3 Transport/Storage/Disposal ................................................................................................................ 12
3.1 Checking the condition upon delivery..........................................................................................................12
3.2 Transport.........................................................................................................................................................12
3.3 Storage/preservation......................................................................................................................................14
3.4 Return to supplier...........................................................................................................................................15
3.5 Disposal ...........................................................................................................................................................16
4 Description of the Pump (Set)............................................................................................................. 17
4.1 General description ........................................................................................................................................17
4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................17
4.3 Designation.....................................................................................................................................................17
4.4 Name plate......................................................................................................................................................18
4.5 Design details..................................................................................................................................................18
4.6 Configuration and function...........................................................................................................................19
4.7 Noise characteristics .......................................................................................................................................19
4.8 Scope of supply...............................................................................................................................................21
4.9 Dimensions and weights ................................................................................................................................21
5 Installation at Site................................................................................................................................ 22
5.1 Safety regulations...........................................................................................................................................22
5.2 Checks to be carried out prior to installation...............................................................................................22
5.3 Installing the pump set ..................................................................................................................................23
5.3.1 3E installation.................................................................................................................................... 23
5.3.2 DJ installation.................................................................................................................................... 27
5.3.3 DJ installation with universal-joint shaft......................................................................................... 29
5.3.4 DB installation and DK installation.................................................................................................. 29
5.3.5 DP installation ................................................................................................................................... 31
5.4 Connecting the piping ...................................................................................................................................36
5.5 Enclosure/insulation .......................................................................................................................................37
5.6 Aligning the pump and motor ......................................................................................................................38
5.6.1 Aligning the motor with adjusting screws ...................................................................................... 38
5.6.2 Aligning the motor without adjusting screws ................................................................................ 40
5.7 Permissible forces and moments at the pump nozzles ................................................................................41

Contents
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5.8 Auxiliary connections .....................................................................................................................................42
5.9 Connection to power supply..........................................................................................................................44
5.9.1 Earthing ............................................................................................................................................. 44
5.10 Checking the direction of rotation................................................................................................................45
5.11 Removing the transport lock .........................................................................................................................45
6 Commissioning/Start-up/Shutdown................................................................................................... 47
6.1 Commissioning/Start-up.................................................................................................................................47
6.1.1 Prerequisites for commissioning/start-up ........................................................................................ 47
6.1.2 Priming and venting the pump........................................................................................................ 47
6.1.3 Start-up.............................................................................................................................................. 48
6.1.4 Checking the shaft seal..................................................................................................................... 49
6.1.5 Shutdown .......................................................................................................................................... 50
6.2 Operating limits..............................................................................................................................................51
6.2.1 Maximum operating pressure .......................................................................................................... 51
6.2.2 Hydraulic operating range ............................................................................................................... 52
6.2.3 Frequency of starts............................................................................................................................ 53
6.2.4 Fluid handled .................................................................................................................................... 53
6.3 Shutdown/storage/preservation ....................................................................................................................54
6.4 Returning to service .......................................................................................................................................54
7 Servicing/Maintenance........................................................................................................................ 55
7.1 Safety regulations...........................................................................................................................................55
7.2 Servicing/inspection........................................................................................................................................56
7.2.1 Supervision of operation .................................................................................................................. 56
7.2.2 Inspection work................................................................................................................................. 58
7.3 Drainage/cleaning ..........................................................................................................................................62
7.4 Dismantling the pump set..............................................................................................................................62
7.4.1 General information/Safety regulations.......................................................................................... 62
7.4.2 Preparing the pump set.................................................................................................................... 63
7.4.3 Opening the volute casing ............................................................................................................... 68
7.4.4 Removing the rotor .......................................................................................................................... 68
7.4.5 Dismantling the rotor ....................................................................................................................... 69
7.5 Reassembling the pump set...........................................................................................................................70
7.5.1 General information/Safety regulations.......................................................................................... 70
7.5.2 Installing the rotor ........................................................................................................................... 71
7.5.3 Mounting the pump set on the baseplate ...................................................................................... 76
7.6 Tightening torques.........................................................................................................................................76
7.7 Spare parts stock.............................................................................................................................................77
7.7.1 Ordering spare parts......................................................................................................................... 77
7.7.2 Recommended spare parts stock for 2 years' operation to DIN24296.......................................... 78
8 Trouble-shooting.................................................................................................................................. 80
8.1 Explanation of faults......................................................................................................................................84
9 Related Documents.............................................................................................................................. 85
9.1 Weights of individual components ...............................................................................................................85
9.2 General assembly drawing with list of components ....................................................................................86
9.2.1 Horizontally installed pump............................................................................................................. 86
9.2.2 Vertically installed pump, installation type DJ................................................................................ 89
9.2.3 Vertically installed pump, installation type DB............................................................................... 92
9.2.4 Vertically installed pump, installation type DK............................................................................... 95
9.2.5 Vertically installed pump, installation type DP ............................................................................... 98
10 EU Declaration of conformity............................................................................................................ 101
11 Certificate of Decontamination......................................................................................................... 102
Index ................................................................................................................................................... 103

Glossary
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Glossary
Certificate of decontamination
A certificate of decontamination is enclosed by the
customer when returning the product to the
manufacturer to certify that the product has been
properly drained to eliminate any environmental
and health hazards arising from components in
contact with the fluid handled.
Discharge line
The pipeline which is connected to the discharge
nozzle
Drive end
The side of the pump which faces the motor
Hydraulic system
The part of the pump in which the kinetic energy
is converted into pressure energy
Non-drive end
The side of the pump which faces away from the
motor
Pool of pumps
Customers/operators’ pumps which are purchased
and stored regardless 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 pipeline which is connected to the suction
nozzle

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating 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 facility to
maintain the right to claim under warranty.
1.2 Installation of partly completed machinery
To install partly completed machinery supplied by KSB refer to the sub-sections under
Servicing/Maintenance.
1.3 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel. (ðSection2.3,Page8)
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 dimensions and installation
dimensions for the pump (set), weights
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
describing 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
Assembly drawing1) Sectional drawing of the installed shaft seal
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1If included in agreed scope of supply

1 General
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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.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product
1.6 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 EU Directive
2014/34/EU (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 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and 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 not
taken into account.
2.2 Intended use
▪The pump (set) must only be operated in the fields of application and within the
use limits specified in the other applicable documents. (ðSection1.4,Page6)
▪Only operate pumps/pump sets which are in perfect technical condition.
▪Do not operate the pump (set) in partially assembled condition.
▪Only use the pump (set) to handle the fluids described in the data sheet or
product literature of the pump variant.
▪Never operate the pump (set) without the fluid to be handled.
▪Observe the minimum flow rate and maximum flow rate indicated in the data
sheet or product literature (to prevent overheating, mechanical seal damage,
cavitation damage, bearing damage, etc).
▪Always operate the pump (set) in the direction of rotation it is intended for.
▪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.
2.3 Personnel qualification and training
All personnel involved must be fully qualified to transport, install, operate, maintain
and inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
transport, installation, operation, maintenance and inspection must be clearly
defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. 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.

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2.4 Consequences and risks caused by non-compliance with this manual
▪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
2.5 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws
2.6 Safety information for the operator/user
▪Fit protective equipment (e.g. contact guards) supplied by the operator for hot,
cold or moving parts, and check that the equipment functions properly.
▪Do not remove any protective equipment (e.g. contact guards) during operation.
▪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.)
▪If stopping the pump does not increase potential risk, fit an emergency-stop
control device in the immediate vicinity of the pump (set) during pump set
installation.
2.7 Safety information for maintenance, inspection and installation
▪Modifications or alterations of the pump (set) are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts/components authorised by the
manufacturer. The use of other parts/components can invalidate any liability of
the manufacturer for resulting damage.
▪The operator ensures that maintenance, inspection and installation are
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Only carry out work on the pump (set) during standstill of the pump.
▪Only perform work on the pump set when it has been disconnected from the
power supply (de-energised).
▪The pump (set) must have cooled down to ambient temperature.
▪Pump pressure must have been released and the pump must have been drained.

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▪When taking the pump set out of service always adhere to the procedure
described in the manual. (ðSection6.3,Page54)
▪Decontaminate pumps which handle fluids posing a health hazard.
(ðSection7.3,Page62)
▪As soon as the work has been completed, re-install and re-activate any safety-
relevant devices and protective devices. Before returning the product to service,
observe all instructions on commissioning. (ðSection6.1,Page47)
2.8 Unauthorised modes of operation
Never operate the pump (set) outside the limits stated in the data sheet and in this
operating manual.
The warranty relating to the operating reliability and safety of the pump (set)
supplied is only valid if the equipment is used in accordance with its intended use.
(ðSection2.2,Page8)
2.9 Explosion protection
!DANGER
Always observe the information on explosion protection given in this section when
operating the product in potentially explosive atmospheres.
Pumps/Pump sets must not be used in potentially explosive atmospheres unless
marked as explosion-proof and identified as such in the data sheet.
Special conditions apply to the operation of explosion-proof pump sets in accordance
with EU Directive 2014/34/EU (ATEX).
Especially adhere to the sections in this manual marked with the symbol opposite and
the following sections, (ðSection1.6,Page7) to (ðSection2.9.3,Page11)
The explosion-proof status is only assured if the product is used in accordance with its
intended use.
Never operate the product outside the limits stated in the data sheet and on the
name plate.
Prevent impermissible modes of operation at all times.
For information on application options of individual components (if any) in
potentially explosive atmospheres, refer to the manufacturer's product literature.
2.9.1 Marking
Pump The marking on the pump refers to the pump part only.
Example of such marking:
II 2G Ex h IIC T5-T1 Gb
Refer to the Temperature limits table for the maximum temperatures permitted for
the individual pump variants. (ðSection2.9.2,Page11)
The pump complies with the requirements of type of protection constructional safety
"c" to ISO80079-37.
Shaft coupling An EC manufacturer's declaration is required for the shaft coupling; the shaft
coupling must be marked accordingly.
Motor The motor must be considered separately.