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KSB MEGACHEM - User Manual

KSB MEGACHEM
12 pages
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MEGACHEM
THANK YOU CUSTOMER
You are a proud owner of a MEGACHEM pump.
The pump's nameplate shows the type series, pump size, version, works order no. & main operating data.
Please quote the above information in all queries, repeat orders and particularly when ordering spares.
Type - MEGACHEM
Sr. No. / 75
Ex.
KSB PUMPS LTD.
Type
Sr. No - 75
Q
n
Ex.
rpm
m /hr.
3
KSB Pumps Limited
H
kW
m
CONTENTS
Point No. Description Page No. Point No. Description Page No.
1 General 1
1.1 Handling 1
2 Installation (on site) 1
2.1 Foundation 1
2.2 Mounting 1
2.3 Aligning pump / motor 1
2.4 Connecting the piping 1
2.4.1 Auxiliary connections 2
2.4.2 Vacuum balance line 3
2.5 Coupling guard 3
2.6 Final Check 3
3 Commissioning/start-up, Shutdown 3
3.1 Preparations 3
3.1.1 Procedure 3
3.1.2 Shaft seal 3
3.1.3 Priming & associated checks 3
3.1.4 Checking the direction of rotation. 3
3.2 Start-up 4
3.3 Shutdown 4
4 Maintenance & Lubrication 4
4.1 Supervision & Operation 4
4.2 Lubrication & lubricant change 4
4.2.1 Grease change 4
4.2.2 Oil change 4
5 Dismantling 4
5.1 General 4
5.2 Dismantling 4
5.3 Dismantling the bearing unit 5
5.4 Removal of mechanical seal 5
6 Reassembly 5
6.1 Pump 5
6.2 Clearance table 5
6.3 Replacing of bearings 5
6.3.1 Deep groove ball bearings & 6
lubricant fill
6.4 Stuffing box compartment 6
6.5 Mechanical seal 6
6.6 Conversion kit 6
7 Cooling 6
8 Spare parts 6
8.1 Ordering spare parts 6
9 Interchangeability of components 7
10 Sectional drawing & list of components 8
10.1 Sandwiched discharge cover & 8
cooling cover details
11 Pump sectional drawing 9
11.1 List of components 9
12 Faults-cause & remedy 10 & 11
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KSB MEGACHEM Specifications

General IconGeneral
Operating PressureUp to 25 bar
ApplicationChemical processing
Casing MaterialStainless steel
Impeller MaterialStainless steel
TemperatureUp to 180 °C
Temperature Range-20°C to +180°C
Pressure RatingPN16, PN25

Summary

General

Handling

Instructions on how to safely handle the pump and motor during transport and installation.

Installation (on site)

Foundation

Specifies requirements for a stable and level concrete foundation for the pump.

Mounting

Steps for correctly positioning and securing the pumpset on the foundation.

Aligning pump; motor

Procedure for achieving precise radial and axial alignment between pump and motor shafts.

Connecting the piping

Guidelines for connecting suction and discharge piping without stressing the pump.

Auxiliary connections

Vacuum balance line

Coupling guard

Final Check

Commissioning, startup, shutdown

Preparations

Essential preparations including lubrication and checking fluid levels before operation.

Procedure

Step-by-step guide for filling the oil level in the bearing bracket correctly.

Shaft Seal

Information on shaft sealing types and potential conversions.

Priming & associated checks

Steps to ensure the pump and suction line are filled with liquid before startup.

Checking the direction of rotation

Method to verify the motor's rotation direction matches the pump arrow.

Start-up

Correct procedure for starting the pump, including valve operation.

Shutdown

Safe steps to follow when stopping the pump and motor.

Maintenance and lubrication

Supervision of operation

Monitoring pump performance, temperature, and operational limits.

Lubrication and lubricant change

Details on bearing lubrication, grease requirements, and oil change intervals.

Grease change

Note on maintenance-free grease-packed bearings.

Oil change (if applicable)

Procedures and schedule for changing oil in oil-lubricated bearings.

Dismantling

General

Safety precautions and initial steps before starting dismantling.

Dismantling Procedure

Step-by-step guide for taking apart the pumpset and its components.

Dismantling the bearing unit

Removing of Mechanical seal

Reassembly

Pump

General practices for reassembling pump components correctly.

Clearance table

A table listing recommended component clearances for various sizes.

Replacing of bearings

Deep groove ball bearings & lubricant fill

Specific bearing types and oil quantities for different pump sizes.

Stuffing box compartment

Dimensions related to the stuffing box compartment.

Mechanical seal

Critical points for correctly mounting a mechanical seal to ensure proper function.

Conversion kit

Lists parts needed to switch between gland packing and mechanical seal configurations.

Cooling

Spare parts

Ordering spare parts

How to quote information for ordering spare parts.

Recommended spare parts of 2 years of continuous operation

A list of suggested spare parts for typical operational periods.

Interchangeability of components

Sectional drawing & list of component

Sandwiched discharge cover & cooling cover details

Specific diagrams showing discharge and cooling cover assemblies.

Pump cross sectional drawing

List of components

A comprehensive list of all parts with their corresponding part numbers.

Faults-cause & remedy

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