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KSB MEGAFLOW 50-160 User Manual

KSB MEGAFLOW 50-160
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Operating Instructions Manual
NºA2370.8E/2
KSB MEGAFLOW
Pumps for Sewage, Effluents and Mixtures
1. Application
The KSB MEGAFLOW centrifugal pump is
recommended for industrial and municipal waste water,
as well as all kinds of pulps not liable to plait, sewage
water, chemical effluents.
- Municipal and industrial waste-water treatment
- Drainage
- Pulp and paper
- Food processing
- Sugar and alcohol
- Mining and manufacturing
- Civil construction
2. Design
Horizontal, single-stage, simple horizontal suction and
vertical upwards discharge. The “back-pull-out” design
allows maintenance and repair services through the back
side, without dismantling piping and alignment.
The available hydraulics and impeller types allow proper
selection for the handled liquid and required application.
3. Designation
KSB Megaflow 50 - 160 K
Trade Mark
Model / Type
Discharge Nozzle Diameter (mm)
Nominal Impeller Diameter (mm)
Rotor
4. Operating Data
Sizes - DN 50 up to 350
(2 ½” to 14” )
Flow - to 11,000 gpm
(2,500 m
3
/h)
Head - to 328 ft (100m)
Temperature - to 221
º
F (105
º
C)
Max. Suction pressure - to 43 psi (3 bar)
Speed - to 3,500 rpm
LINE: Mega

Table of Contents

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KSB MEGAFLOW 50-160 Specifications

General IconGeneral
Impeller Diameter160 mm
Speed2900 rpm
Frequency50 Hz
Max Liquid Temperature120 °C
Housing MaterialCast Iron
Seal TypeMechanical Seal
Pump TypeCentrifugal
Nominal Diameter50 mm
Voltage400 V

Summary

Application

Design

Designation

Operating Data

Introduction

Technical Data

Bearings

Details on bearing types, brackets, and maximum allowable p/n for different pump sizes and speeds.

Maximum speed

Lists maximum allowable impeller diameters for various pump sizes, impeller types, and fluid densities at different speeds.

Constructive Details

Casing

Describes the casing design, including clearance, one-piece casting, and replaceable wear plate on the suction side.

Nozzle Layout

Details the axial suction and radial vertical discharge nozzle configuration, with optional features.

Impeller

Explains the three available impeller types (K, O, E) and their recommended applications based on fluid characteristics.

Shaft

Describes the dry-type shaft design, isolation from pumped liquid, and protection sleeve.

Axial Thrust Balancing

Explains the axial thrust balancing mechanism using back vanes and bearing absorption.

Shaft seal

Covers standard gland packing or optional mechanical seals, selection criteria, and functions of the lantern ring circulation.

Shaft Seal Selection

Pressure of seal liquid / Wash for pumps with impellers type K / O / E.

Provides pressure requirements for seal liquid and wash for different impeller types.

Sealing Flow / Wash

Illustrates sealing flow and wash requirements for pumps with Impellers K and O using a graph.

Mechanical Seal

Transportation

Service / Storage

Additional procedures of Service and Storage

Outlines periodic servicing for pumps stored over a year and specific cleaning for mechanical seals.

Installation

Base Grouting

Details the process of placing foundation bolts, metallic chocks, and using grout to secure the pump base.

Base Leveling

Explains how to check and adjust the base plate leveling using shims and foundation bolts.

Grouting

Specifies the requirements for grout composition and application to ensure a secure, vibration-free pump base.

Coupling alignment

Describes the procedure for remaking the factory alignment using dial indicators for radial and axial displacements.

Suction Pipe Line - Recommendations

Provides guidelines for installing suction piping, including slope, diameter, pipe connections, and avoiding air pockets.

Discharge Pipeline - recommendations

Offers recommendations for discharge pipeline installation, including overpressure control, flange connections, and vent valves.

Auxiliary piping and connections

Details the connections for auxiliary piping, such as manometers, drain, priming, and external sealing lines.

Accessories (Optionals)

Coupling

Lists options for pump couplings, including KSB standard, other manufacturers, with or without spacers.

Electrical Motor, Turbine, Diesel Motor, etc.

Mentions various drive options available for the pumps.

KSB standard of structural welded steel with under drain channel.

Specifies a particular type of base construction offered by KSB.

Operation

First start-up procedure

Outlines the essential steps and checks required before and during the initial start-up of the pump.

Immediate steps after first start-up

Details checks and adjustments to be performed immediately after the pump begins running.

Operation supervision

Recommends supervision schedules (weekly, monthly, semestral, annual) for monitoring pump operation.

Shutdown procedure

Provides a sequential guide for safely shutting down the pump and its associated systems.

Maintenance

Bearing Maintenance

Explains how to maintain bearings, including oil filling, level checks, and lubrication procedures.

Lubrication intervals and oil specifications

Specifies oil change intervals and recommended oil types for bearings based on manufacturer and speed.

Oil Quantity

Lists the required oil volume for different KSB Megaflow bearing brackets.

Shaft Sealing Maintenance

Covers maintenance for shaft seals, including mechanical seals and gasket packing.

Wear Parts Maintenance

Discusses the maintenance and replacement of wear parts like the wear plate.

Dismantling instructions

Provides detailed steps for dismantling the pump and its components.

Assembly Instructions

Outlines the general procedures and specific steps for assembling pump components.

Operational problems, Probable Causes and Solutions

Cross Sectional Drawing / Parts List / Materials

Execution with K Impeller – Bearing Brackets CS40 and CS50

Presents a cross-sectional drawing and parts list for pumps with K impeller and CS40/CS50 bearing brackets.

Parts List – K Impeller – Bearing Brackets CS40 and CS50

Detailed parts list for K Impeller with CS40 and CS50 bearing brackets, including part numbers and quantities.

Execution with K Impeller – AK Bearing Bracket

Cross-sectional drawing for pumps with K impeller and AK bearing bracket.

Execution with O Impeller – AK Bearing Bracket

Cross-sectional drawing for pumps with O impeller and AK bearing bracket.

Parts List – K/O Impeller – AK Bearing Bracket

Parts list for K/O Impeller with AK bearing bracket, detailing components and quantities.

Execution with Impeller K/O Bearing Bracket P65/160

Cross-sectional drawing for pumps with K/O impeller and P65/160 bearing bracket.

Parts List – K/O Impellers – Bearing Bracket P 65/160 X

Parts list for K/O Impellers with P65/160X bearing bracket, including part numbers and quantities.

Execution with Impeller K and Bearing Bracket P80/200S

Cross-sectional drawing for pumps with K impeller and P80/200S bearing bracket.

Parts List - K Impeller – Bearing bracket P 80/200S

Detailed parts list for K Impeller with P80/200S bearing bracket, specifying part numbers and quantities.

Execution with Impeller E - Bearing Bracket AK

Cross-sectional drawing for pumps with E impeller and AK bearing bracket.

Parts List - E Impeller - Bearing Bracket AK

Parts list for E Impeller with AK bearing bracket, including part numbers and quantities.

Execution with Impeller E and Bearing Bracket P65/160X

Cross-sectional drawing for pumps with E impeller and P65/160X bearing bracket.

Parts List - Impeller E – Bearing Bracket P65/160X

Detailed parts list for E Impeller with P65/160X bearing bracket, specifying components and quantities.

Parts Interchangeability

Recommended Spare Parts

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