KSB Trialine Installation instructions

In-line Pump;In-line Twin Pump
Trialine / Trialine Z
Installation/Operating
Manual

Legal information/Copyright
Installation/Operating Manual Trialine / Trialine Z
Original operating manual
KSB Aktiengesellschaft Pegnitz
All 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.
© KSB Aktiengesellschaft Frankenthal 23.06.2010

Contents
Glossary ................................................................................................ 5
1 General ................................................................................................ 6
1.1 Principles .......................................................................................................... 6
1.2 Target group ................................................................................................... 6
1.3 Other applicable documents .......................................................................... 6
1.4 Symbols ............................................................................................................ 6
2 Safety ................................................................................................... 7
2.1 Key to safety symbols/markings ..................................................................... 7
2.2 General ............................................................................................................ 7
2.3 Intended use .................................................................................................... 7
2.4 Personnel qualification and training ............................................................. 8
2.5 Consequences and risks caused by non-compliance with these operating
instructions ...................................................................................................... 8
2.6 Safety awareness ............................................................................................. 8
2.7 Safety information for the operator/user ...................................................... 9
2.8 Safety information for maintenance, inspection and installation work ..... 9
2.9 Unauthorised modes of operation ................................................................. 9
3 Transport/Temporary Storage/Disposal ........................................... 10
3.1 Transport ....................................................................................................... 10
3.2 Storage and preservation ............................................................................. 10
3.3 Return to supplier ......................................................................................... 11
3.4 Disposal .......................................................................................................... 11
4 Description of the Pump (Set) .......................................................... 12
4.1 General .......................................................................................................... 12
4.2 Designation ................................................................................................... 12
4.3 Name plate .................................................................................................... 12
4.4 Design details ................................................................................................ 12
4.5 Configuration and function ......................................................................... 13
4.6 Noise characteristics ...................................................................................... 14
4.7 Scope of supply ............................................................................................. 14
4.8 Dimensions and weights ............................................................................... 14
5 Installation at Site ............................................................................. 15
5.1 Installing the pump set ................................................................................. 15
5.2 Piping ............................................................................................................. 15
5.3 Protective equipment ................................................................................... 16
5.4 Connection to power supply ........................................................................ 16
5.5 Checking the direction of rotation .............................................................. 17
Contents
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6 Commissioning/Start-up/Shutdown ................................................. 18
6.1 Commissioning/start-up ................................................................................ 18
6.2 Shutdown/storage/preservation ................................................................... 21
6.3 Returning to service after storage ............................................................... 21
7 Servicing/Maintenance ...................................................................... 22
7.1 Safety regulations ......................................................................................... 22
7.2 Servicing/inspection ...................................................................................... 22
7.3 Drainage/disposal .......................................................................................... 24
7.4 Dismantling the pump set ............................................................................ 24
7.5 Reassembling the pump set .......................................................................... 26
8 Trouble-shooting ............................................................................... 28
9 Related Documents ........................................................................... 30
9.1 Typical installation positions ........................................................................ 30
9.2 General assembly drawing with list of components ................................... 31
10 EC Declaration of Conformity .......................................................... 32
11 Certificate of Decontamination ....................................................... 33
Index .................................................................................................. 34
Contents
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Glossary
Back pull-out design
The complete back pull-out unit can be pulled
out without having to remove the pump casing
from the piping.
Back pull-out unit
Pump without pump casing; partly completed
machinery
Certificate of decontamination
A certificate of decontamination certifies that
the pump (set) has been properly drained to
eliminate any environmental and health
hazards arising from components in contact
with the fluid handled.
Close-coupled design
Motor directly fitted to the pump via a flange
or a drive lantern
Discharge line
The line which is connected to the discharge
nozzle
Hydraulic system
The part of the pump in which the kinetic
energy is converted into pressure energy
Pool of pumps
Pumps which are purchased and stored
independently of their later use
Pump set
Complete pump set consisting of pump, drive,
additional components and accessories
Suction lift line/suction head line
The line which is connected to the suction
nozzle
Glossary
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1 General
1.1 Principles
This manual is supplied as an integral part of the type series and variants indicated
on the front cover. It describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series/size and the main operating data.
In the event of damage, contact your nearest KSB service centre immediately to
maintain the right to claim under warranty.
Noise characteristics (⇨ Section 4.6 Page 14)
1.2 Target group
This manual is aimed at the target group of trained and qualified specialist technical
personnel. (⇨ Section 2.4 Page 8)
1.3 Other applicable documents
Table 1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manuals and other documentation of
accessories and integrated machinery components
1.4 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 General
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk situation which, if not
avoided, will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazardous situation which, if not
avoided, could damage the machine and its functions.
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 voltages and provides information
about protection against electrical voltages.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazardous situation for the machine and its functions.
2.2 General
This manual contains general installation, operating and maintenance instructions
that must be observed to ensure safe pump operation and prevent personal injury
and damage to property.
The safety information in all sections of this manual must be complied with.
This manual must be read and completely understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this manual must be available to the specialist personnel at the site
at all times.
Information attached directly to the pump must always be complied with and be
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 which
are not taken into account in this manual.
2.3 Intended use
The pump set must only be operated within the operating limits described in the
other applicable documents.
▪Only operate pump sets which are in perfect technical condition.
▪Do not operate partially assembled pump sets.
▪Only use the pump set to handle the fluids described in the data sheet or product
literature of the pump model.
2 Safety
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▪Never operate the pump set without the fluid to be handled.
▪Observe the minimum flow rates indicated in the data sheet or product literature
(to prevent overheating, bearing damage, etc).
▪Observe the maximum flow rates indicated in the data sheet or product
literature (to prevent overheating, mechanical seal damage, cavitation damage,
bearing damage, etc).
▪Do not throttle the flow rate on the suction side of the pump set (to prevent
cavitation damage).
▪Consult the manufacturer about any use or mode of operation not described in
the data sheet or product literature.
Prevention of foreseeable misuse
▪Never open discharge-side shut-off elements further than permitted.
– The maximum flow rate specified in the data sheet or product literature
would be exceeded.
– Risk of cavitation damage
▪Never exceed the permissible operating limits specified in the data sheet or
product literature regarding pressure, temperature, etc.
▪Observe all safety information and instructions in this manual.
2.4 Personnel qualification and training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the machinery this manual refers to.
The responsibilities, competence and supervision of all personnel involved in
installation, operation, maintenance and inspection must be clearly defined by the
operator.
Deficits in knowledge must be rectified by sufficiently trained specialist personnel
training and instructing the personnel who will carry out the respective tasks. 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.
2.5 Consequences and risks caused by non-compliance with these operating
instructions
▪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
2.6 Safety awareness
In addition to the safety information contained in this manual and the intended use,
the following safety regulations shall be complied with:
▪Accident prevention, health and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards and laws
2 Safety
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2.7 Safety information for the operator/user
▪The operator shall fit contact guards for hot, cold and moving parts and check
that the guards function properly.
▪Never remove a contact guard while the pump is running.
▪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.)
2.8 Safety information for maintenance, inspection and installation work
▪Modifications or alterations of the pump are only permitted with the
manufacturer's prior consent.
▪Use only original spare parts or parts authorised by the manufacturer. The use of
other parts can invalidate any liability of the manufacturer for consequential
damage.
▪The operator ensures that all maintenance, inspection and installation work is
performed by authorised, qualified specialist personnel who are thoroughly
familiar with the manual.
▪Carry out work on the pump set during standstill only.
▪The pump casing must have cooled down to ambient temperature.
▪Pump pressure must have been released and the pump must have been drained.
▪When taking the pump set out of service always adhere to the procedure
described in the manual. (⇨ Section 6.2.1 Page 21)
▪Decontaminate pumps which handle fluids posing a health hazard. (⇨ Section 7.3
Page 24)
▪As soon as the work is completed, re-install and/or re-activate any safety-relevant
and protective devices. Before returning the product to service, observe all
instructions on commissioning. (⇨ Section 6.1 Page 18)
2.9 Unauthorised modes of operation
Never operate the pump set outside the limits stated on the data sheet and in this
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. (⇨ Section
2.3 Page 7)
2 Safety
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3 Transport/Temporary Storage/Disposal
3.1 Transport
DANGER
The pump set could slip out of the suspension arrangement.
Danger to life from falling parts!
▷Always transport the pump set in horizontal position.
▷Never attach the suspension arrangement to the free shaft end or the motor
eyebolt of the pump set.
▷Refer to the weights given in the general arrangement drawing.
▷Observe the local health and safety regulations.
▷Use suitable, permitted lifting tackle, e.g. self-tightening lifting tongs.
To transport the pump set suspend it from the lifting tackle as shown below.
Fig. 1: Transporting the pump set
3.2 Storage and preservation
If commissioning is to take place some time after delivery, we recommend that the
following measures be taken for pump (set) storage.
CAUTION
Damage during storage by humidity, dirt, or vermin
Corrosion/contamination of the pump (set)!
▷For outdoor storage cover the packed or unpacked pump (set) and accessories
with waterproof material.
CAUTION
Wet, contaminated or damaged openings and connections
Leakage or damage to the pump set!
▷Only remove caps/covers from the openings of the pump set at the time of
installation.
Store the pump (set) in a dry, protected room where the atmospheric humidity is as
constant as possible.
Rotate the shaft by hand once a month, e.g. via the motor fan.
If properly stored indoors, the pump set is protected for a maximum of 12 months.
For storing a pump (set) which has already been operated, observe the instructions
given in this manual. (⇨ Section 6.2.1 Page 21)
3 Transport/Temporary Storage/Disposal
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