KSB Trialine - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The KSB Trialine / Trialine Z is an in-line pump and in-line twin pump designed for various fluid handling applications. This installation and operating manual provides comprehensive information on its function, technical specifications, usage, and maintenance.

Function Description

The Trialine / Trialine Z pump is designed to transport fluids, converting kinetic energy into pressure energy. It features a back pull-out unit, allowing the complete rotating assembly to be removed from the pump casing without disturbing the piping. This design simplifies maintenance and servicing. The pump set consists of the pump, drive, and additional components and accessories. The motor is directly flanged to the pump via a flange or a drive lantern, and the suction line is connected to the suction nozzle, while the discharge line is connected to the discharge nozzle.

The pump operates by drawing fluid into the suction nozzle (9) and accelerating it outward in a cylindrical path by the rotating impeller (8). The flow profile of the pump casing converts the kinetic energy of the fluid into pressure energy. The fluid is pumped to the discharge nozzle (2), where it leaves the pump. A clearance gap (1) prevents any fluid from flowing back from the casing into the inlet. At the rear side of the impeller, the shaft (7) passes through the motor flange (3). The shaft linkage through the cover is sealed to the atmosphere with a dynamic shaft seal (10). The shaft runs in rolling element bearings (5 and 6), which are supported by a motor housing (4).

Important Technical Specifications

The Trialine / Trialine Z pumps are available in various type series and variants. Key technical specifications include:

Type Series: Trialine
Nominal Suction/Discharge Nozzle Diameter: Available in sizes such as 40, 100, and 052 mm.
Nominal Impeller Diameter: Specified in millimeters.
Motor Rating: Available in various kW ratings, e.g., 2 x 10 (example 0.55 kW).
Number of Motor Poles: Specified as 2.
Qmax: Maximum flow rate, e.g., 22 m³/h.
Hmax: Maximum head, e.g., 6.6 m.
Max. Temperature: 120°C.
PN: Pressure nominal, e.g., PN 10.
Surface Sound Pressure Level (LpA): For a pump set with a rated power input of 1450 rpm, the max. LpA is 50. For 2900 rpm, the max. LpA is 61. These values are spatial averages as per ISO 3744 and EN 12639, valid for pump operation in the Q/Qopt = 0.80 - 1.1 range and for non-cavitating operation. If noise levels are to be warranted, add 3 dB for measuring and constructional tolerance.
Design: Close-coupled design/in-line design, single-stage, horizontal/vertical installation, back pull-out design, rigid connection between pump and motor, pump and motor on a common shaft.
Impeller Type: Closed radial impeller.
Shaft Seal: Mechanical seal.
Bearings: Radial ball bearings in the motor housing, grease lubrication.

Usage Features

The Trialine / Trialine Z pumps offer several usage features designed for ease of installation, operation, and safety:

Installation at Site:
- Motor Direction: For dry running or ingress of leakage into the motor, ensure the pump set is installed with the "motor below" configuration.
- Rotation Direction: For dual or twin pumps, specified performance data may not be achieved if the direction of rotation is incorrect. Always check the direction of rotation.
- Air in Pump Set: For air in the pump set, the direction of flow from top to bottom is recommended. Fit a vent valve at the highest point upstream of the pump's suction nozzle.
- Piping: Excessive loads acting on the pump nozzles can lead to leakage of hot fluids. Do not use the pump as an anchorage point for the piping. Anchor the pipelines in close proximity to the pump and connect them without transmitting any stresses or strains. Take appropriate measures to compensate thermal expansion of the piping.
- Welding: Incorrect earthing during welding work can damage rolling element bearings. Never earth the electric welding equipment on the pump or baseplate. Prevent current flowing through the rolling element bearings.
- Cleanliness: It is recommended to install check and shut-off elements in the system, depending on the type of plant and pump. Thoroughly clean, flush, and blow through all vessels, pipelines, and connections (especially for new installations).
- Suction Line/Auction Head: The suction lift line/auction head line has been laid with a rising/downward slope towards the pump.
- Nominal Diameter: The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzle.
- Permissible Forces and Moments: No piping-induced forces and moments (from warped pipelines or thermal expansion, for example) must act on the pump set.
- Auxiliary Connections: Malfunction of the pump can occur due to failure to use or incorrect use of auxiliary connections. Use only the auxiliary connections provided.
- Protective Equipment: The volute casing and casing/discharge cover can reach high temperatures. Insulate the volute casing and fit protective equipment.
- Drive Lantern: Heat build-up inside the drive lantern can cause damage to the bearing. Never insulate the casing cover and the drive lantern.
- Connection to Power Supply: Work on the pump set by unqualified personnel can lead to danger of death from electric shock. Always have the electrical connections installed by a trained electrician. Observe regulations IEC 30364 (DIN VDE 0100) and, for explosion-proof pump sets, IEC 60079 (DIN VDE 0165).
- Mains Voltage: Incorrect connection to the mains can cause damage to the mains network or short circuit. Observe the technical specifications of the local energy supply companies. Check the available mains voltage against the data on the name plate. Select an appropriate start-up method.
- Motor Protection: It is recommended to fit a motor protection device.
- Direction of Rotation: The pump's direction of rotation is indicated by an arrow on the pump. Start the pump set and stop it again immediately to determine the motor's direction of rotation. Check the direction of rotation. The motor's direction of rotation must match the arrow indicating the direction of rotation on the pump. If the motor runs in the wrong direction of rotation, check the electrical connection of the motor and the control system, if applicable.
Commissioning/Start-up:
- Prerequisites: The pump set must be properly connected to the power supply and equipped with all protection devices. The pump has been primed with the fluid to be handled. The direction of rotation has been checked. All auxiliary connections required are connected and operational. After prolonged shutdown of the pump set, the activities described in Section 6.3 (Page 21) have been carried out.
- Shaft Seal: The mechanical seal only leaks slightly or invisibly (as vapor) during operation. Mechanical seals are maintenance-free.
- Priming and Venting: Increased wear due to dry running can damage the pump set. Never operate the pump set without liquid fill. Never close the shut-off element in the suction line and/or supply line during pump operation. Vent the pump and suction line and prime both with the fluid to be handled. Fully open the shut-off element in the suction line.
- Hot Fluid Escaping: Hot fluid escaping under pressure when the vent plug is opened can cause risk of electric shock and scalding. Protect the electric components against escaping fluid. Wear protective clothing (e.g., gloves).
- Gas Volume: For design-inherent reasons, a remaining gas volume in the hydraulic system cannot be excluded after the pump has been primed for commissioning/start-up. However, once the pump is started up, the pumping effect will immediately fill this volume with the fluid handled.
- Start-up: Non-compliance with permissible pressure and temperature limits can damage the pump. Leakage of hot fluids can occur. Never operate the pump with the shut-off elements in the suction line and/or discharge line closed. Only start up the pump set with the discharge-side gate valve slightly or fully open.
- Dry Running: Excessive temperatures due to dry running can damage the pump set. Never operate the pump set without liquid fill. Prime the pump as specified. Always operate the pump within the permissible operating range.
- Abnormal Noises, Vibrations, Temperatures or Leakage: Can damage the pump. Switch off the pump set immediately. Eliminate the causes before returning the pump set to service.
- Piping: The system piping has been cleaned. Pump, suction line, and inlet tank, if any, have been vented and primed with the fluid to be handled. The filling and venting lines have been closed. Fully open the shut-off element in the suction head/suction lift line. Close or slightly open the shut-off element in the discharge line. Start up the motor.
- Seal Leakage: Seal leakage at operating temperature can cause hot fluid to escape. Once the operating temperature has been reached, re-tighten the hexagon nuts between casing and casing cover. When the operating temperature has been reached and/or in the event of leakage, switch off the pump set and re-tighten the bolts between lantern and casing.
- Shutdown: Heat build-up inside the pump can damage the shaft seal. Depending on the type of installation, the pump set requires sufficient after-run time until the heat source switched off and the fluid handled has cooled down. The shut-off element in the suction line is and remains open. Close the shut-off element in the discharge line.
- Standstill: Switch off the motor and make sure the pump set runs down smoothly to a standstill.
- Check Valve: If the discharge line is equipped with a non-return or check valve, the shut-off element may remain open as long as there is some back pressure.
- Prolonged Shutdown: For prolonged shutdown periods, close the shut-off element in the suction line.
- Freezing: Risk of freezing during prolonged pump shutdown periods can damage the pump. Drain the pump and the cooling/heating chambers (if any) or otherwise protect them against freezing.
- Operating Limits: Non-compliance with operating limits for pressure, temperature, and speed can cause hot fluid to escape. Comply with the operating data indicated in the data sheet. Avoid prolonged operation against a closed shut-off element. Never operate the pump at product temperatures exceeding those specified in the data sheet or on the name plate.
- Ambient Temperature: Operation outside the permissible ambient temperature can damage the pump set. Observe the specified limits for permissible ambient temperatures.
- Density of Fluid Handled: The power input of the pump increases in proportion to the density of the fluid handled.
- Motor Overload: Impermissibly high density of the fluid handled can cause motor overload. Observe the information on fluid density indicated in the data sheet. Make sure the power reserve of the motor is sufficient.

Maintenance Features

Regular maintenance is crucial for the longevity and optimal performance of the Trialine / Trialine Z pump.

Servicing/Maintenance:
- Improperly Serviced Pump Set: Can cause damage to the pump set. Service the pump set regularly. Prepare a maintenance schedule with special emphasis on lubricants, shaft seal, and bearing.
- Unqualified Personnel: The operator ensures that all maintenance, inspection, and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.
- Pump Set Started Up Inadvertently: Risk of injury by moving parts! Make sure that the pump set cannot be started up accidentally. Always make sure the electrical connections are disconnected before carrying out work on the pump set.
- Hot Fluids: Fluids posing a health hazard or hot fluids can cause risk of personal injury. Observe all relevant laws. When draining the fluid, take appropriate measures to protect persons and the environment. Decontaminate pumps handling fluids posing a health hazard.
- Maintenance Schedule: A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump set with a minimum of maintenance expenditure and work.
- Service and Installation Work: All maintenance, service, and installation work can be carried out by KSB Service. Find your contact in the attached "Addresses" booklet or on the Internet at www.ksb.com/contact.
- Dismantling and Reassembling: Never use force when dismantling and reassembling a pump set.
- Supervision of Operation:
  - Incorrectly Serviced Shaft Seal: Fire hazard, leakage of hot fluids, and damage to the pump set can occur. Regularly service the shaft seal.
  - Excessive Temperatures: Excessive temperatures as a result of bearings running hot or defective bearing seals can cause fire hazard and damage to the pump set. Regularly check the rolling element bearings for running noises.
  - Increased Wear Due to Dry Running: Can damage the pump set. Never operate the pump set without liquid fill. Never close the shut-off element in the suction line and/or supply line during pump operation. Observe the temperature limits in the data sheet and in the section on operating limits.
  - Impermissibly High Temperature of Fluid Handled: Can damage the pump. Prolonged operation against a closed shut-off element is not permitted (heating up of the fluid). Observe the temperature limits in the data sheet and in the section on operating limits.
  - Pump in Operation: While the pump is in operation, observe and check the following: the pump must run quietly and free from vibrations at all times. Check the shaft seal. Check the static seals for leakages. Check the rolling element bearings for running noises. Vibrations, noise, and an increase in current input occurring unchanged operating conditions indicate wear. Monitor the bearing temperature. The bearing temperature must not exceed 90 °C (measured at the motor housing).
  - Operation Outside Permissible Bearing Temperature: Can damage the pump. The bearing temperature of the pump set must never exceed 90 °C (measured on the outside of the motor housing).
  - Grease-Lubricated Rolling Element Bearings: After commissioning, increased temperatures may occur at grease-lubricated rolling element bearings due to the running-in process. The final bearing temperature is only reached after a certain period of operation (up to 48 h depending on the conditions).
  - Excessive Temperatures Caused by Friction, Impact or Frictional Sparks: Fire hazard and damage to the pump set. Regularly check the cover plates, plastic components, and other guards of rotating parts for deformation and sufficient distance from rotating parts.
Drainage/Disposal:
- Health Hazard: Fluids posing a health hazard are hazardous to persons and the environment. Collect and properly dispose of flushing liquid and any fluid residues. Wear safety clothing and a protective mask, if required. Observe all legal regulations on the disposal of fluids posing a health hazard.
- Flushing: Always flush the pump if it has been used for handling noxious, hot, or other hazardous fluids. Always flush and clean the pump before transporting it to the workshop. Provide a cleaning record for the pump.
- Dismantling: Unqualified personnel performing work on the pump set can cause risk of personal injury. Always have repair and maintenance work performed by specially trained, qualified personnel.
- Hot Surface: Risk of personal injury! Allow the pump set to cool down to ambient temperature.
- General Safety Instructions: Observe the general safety instructions and information.
- Relevant Manufacturer: For any work on the motor, observe the instructions of the relevant motor manufacturer.
- Exploded View: For dismantling and reassembly, observe the exploded view and the general assembly drawing.
- Certificate of Decontamination: If required, a blank certificate of decontamination can be downloaded from the KSB web site at: www.ksb.com/certificate_of_decontamination.
- Insufficient Preparation of Work: Risk of personal injury! Properly shut down the pump set. Close the shut-off elements in the suction and discharge line. Drain the pump and release the pump pressure. Allow the pump set to cool down to ambient temperature.
- Prolonged Period of Operation: After a prolonged period of operation, the individual parts may be hard to pull off the shaft. If this is the case, use a brand name penetrating agent and/or if possible an appropriate pull-off device.
- Pump Casing: The pump casing can remain installed in the piping for further dismantling.
- Notes and Steps: The notes and steps stated in Section 7.4.1 (Page 24) to Section 7.4.2 (Page 25) have been observed/carried out. Disconnect the discharge and suction nozzles from the piping. Depending on the pump/motor size, remove the supports from the pump set. Remove the complete pump set from the piping.
- Removing the Back Pull-Out Unit: Back pull-out unit tipping over can cause risk of squashing hands and feet. Suspend or support the back pull-out unit at the pump end. The notes and steps stated in Section 7.4.1 (Page 24) to Section 7.4.3 (Page 25) have been observed/carried out. If required, suspend or support the back pull-out unit to prevent it from tipping over. Undo nut 920.2 (with bolted discharge cover) or 920.1 (with clamped discharge cover) at the volute casing. Pull the back pull-out unit out of the volute casing. Remove and dispose of gasket 400.1. Place the back pull-out unit on a clean and level surface.
- Removing the Impeller: The notes and steps stated in Section 7.4.1 (Page 24) to Section 7.4.4 (Page 25) have been observed/carried out. The back pull-out unit is kept in a clean and level assembly area. Undo impeller nut 920.5 (right-hand thread). Take washer 930 and disc 550.1 off the impeller hub. Remove impeller 230 with an impeller removal device. Place impeller 230 on a clean and level surface. Remove key 940 from shaft 210.
- Removing the Mechanical Seal: The notes and steps stated in Section 7.4.1 (Page 24) to Section 7.4.5 (Page 25) have been observed/carried out. The back pull-out unit is kept in a clean and level assembly area. Impeller 230 has been removed. Remove shaft sleeve 523.3 with the rotating part of the mechanical seal (spring-loaded ring) from shaft 210. Unscrew hexagon nuts 920.3 and 920.1 on drive lantern 341. Remove discharge cover 163 from drive lantern 341.
- Removing Stationary Part of Mechanical Seal: Remove the stationary part of the mechanical seal (seat ring) from discharge cover 163.
- Reassembling the Pump Set:
  - General Notes/Safety Regulations: Improper reassembly can cause damage to the pump. Reassemble the pump set in accordance with the general rules of sound engineering practice. Use original spare parts only.
  - Sequence: Always reassemble the pump in accordance with the corresponding general assembly drawing or exploded view.
  - Seal Elements: Check the O-rings for any damage and replace them by new O-rings, if required. Always use new gaskets, making sure that they have the same thickness as the old ones. Always fit gaskets of asbestos-free materials or graphite without using lubricants (e.g., copper grease, graphite paste).
  - Assembly Adhesives: Avoid the use of assembly adhesives, if possible. Should an assembly adhesive be required after all, use a commercially available contact adhesive (e.g., "Pattex") or sealant (e.g., HYLOMAR or Epple 33). Only apply adhesive at selected points and in thin layers. Never use quick-setting adhesives (cyanoacrylate adhesives). Coat the locating surfaces of the individual components with graphite or similar before reassembly.
  - Tightening Torques: When reassembling the pump set, tighten all screws/bolts as indicated.
  - Installing the Mechanical Seal: Always observe the following rules when installing the mechanical seal: Work cleanly and accurately. Only remove the protective wrapping of the contact faces immediately before assembly takes place. Prevent any damage to the sealing surfaces or O-rings. The notes and steps stated in Section 7.5.1 (Page 26) have been observed/carried out. The assembled bearing as well as the individual parts are kept in a clean and level assembly area. All dismantled components have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. The sealing surfaces have been cleaned. Clean the seat ring location in discharge cover 163 and seat ring holder 476.
  - Elastomers in Contact with Oil/Grease: Shaft seal failure! Use water as assembly lubricant. Never use oil or grease as assembly lubricant.
  - Seat Ring: Carefully insert seat ring and seat ring holder 476. Press them in evenly. Fit discharge cover 163 into the locating surface of drive lantern 341.
  - Friction Forces: To reduce friction forces when assembling the seal, wet the seat ring location with water.
  - Spring-Loaded Ring: Fit the rotating part of the mechanical seal (spring-loaded ring) on shaft 210.
  - Fitting the Impeller: The notes and steps stated in Section 7.5.1 (Page 26) to Section 7.5.2 (Page 26) have been observed/carried out. The pre-assembled unit (motor, shaft, drive lantern/motor stool, discharge cover) as well as the individual parts are kept in a clean and level assembly area. All disassembled parts have been cleaned and checked for wear. Any damaged or worn parts have been replaced by original spare parts. The sealing surfaces have been cleaned. Slip impeller 230 onto shaft 210. Fasten impeller nut 920.5, washer 930, and disc 550.1, if any.
  - Installing the Back Pull-Out Unit: Back pull-out unit tipping over can cause risk of squashing hands and feet. Suspend or support the back pull-out unit at the pump end. The notes and steps stated in Section 7.5.1 (Page 26) to Section 7.5.3 (Page 27) have been observed/carried out. Any damaged or worn parts have been replaced by original spare parts. The sealing surfaces have been cleaned. If required, suspend or support the back pull-out unit to prevent it from tipping over. Fit new gasket 400.1 into the recess of volute casing 102. Push the back pull-out unit into volute casing 102. Fasten hexagon nut 920.2 (for bolted discharge cover) at volute casing 102.
Trouble-shooting:
- A comprehensive trouble-shooting table is provided, linking possible causes to remedies for common issues such as pump delivers insufficient flow rate, motor is overloaded, motor protection switch/thermistor trip device trips the unit, increased bearing temperature, leakage at the pump, excessive leakage at the shaft seal, vibrations during pump operation, and impermissible rise of temperature inside the pump.
- Possible Causes: Pump delivers against an excessively high discharge pressure, pump and/or piping are not completely vented or primed, suction line/impeller clogged, formation of air pockets in the piping, suction head is too high/NPSH available (positive suction head) is too low, wrong direction of rotation, wear of internal pump parts, pump back pressure lower than specified in purchase order, density or viscosity of fluid handled higher than stated in purchase order, tie bolts/seal element defective, worn shaft seal, score marks or roughness on shaft sleeve, vibrations during pump operation, pump warped or sympathetic vibrations in piping, increased axial thrust, insufficient or excessive quantity of lubricant or unsuitable lubricant, motor running on two phases only, rotor out of balance, defective bearing, insufficient flow rate, incorrect setting of motor protection switch, transport lock has not been removed from the shaft slot.
- Remedies: Re-adjust to duty point, check system for impurities, vent/prime, remove deposits in pump and/or piping, alter piping layout, fit vent valve, check/alter fluid level, increase system pressure, fully open shut-off element in the suction line, check suction line if the friction losses in the suction line are too high, interchange two of the phases of the power cable, replace worn parts by new ones, re-adjust to duty point, in the case of persistent overloading, turn down impeller, fit new seal between volute casing and discharge cover, tighten the bolts, replace shaft seal, replace shaft sleeve, replace shaft seal, correct suction conditions, re-balance impeller, increase pressure at the pump suction nozzle, check piping connections and secure fixing of pump if required, reduce distances between the pipe clamps, fix the pipeline using anti-vibration material, check balancing holes in the impeller, replace casing wear rings, top up, reduce or change lubricant, replace the defective fuse, check cable connections, check the motor winding, clean impeller, re-balance impeller, fit new bearing, increase minimum flow rate, check setting, fit new motor protection switch, remove.
- Important Note: Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure. Contact KSB for further assistance.
Storage and Preservation:
- Damage Due to Humidity, Dirt, or Vermin: Can cause corrosion/contamination of the pump (set). For outdoor storage, cover the packed or unpacked pump (set) and accessories with waterproof material.
- Leakage or Damage: Wet, contaminated, or damaged openings and connections can cause leakage or damage to the pump set. Only remove caps/covers from the openings of the pump set at the time of installation.
- Storage Environment: Store 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.
- Indoor Storage: If properly stored indoors, the pump set is protected for a maximum of 12 months.
- Instructions for Storing: For storing a pump (set) which has already been operated, observe the instructions given in this manual.
- Shutdown/Storage/Preservation:
  - Measures to be Taken for Shutdown: The pump (set) remains installed. Sufficient fluid is supplied for the operation check run of the pump. Start up the pump (set) regularly between once a month and once every three months for approximately five minutes during prolonged shutdown periods. This will prevent the formation of deposits within the pump and the pump intake area.
  - Pump (Set) is Removed from the Pipe and Stored: The pump has been properly drained. The safety instructions for dismantling the pump have been observed. Spray coat the inside wall of the pump casing, and in particular the impeller clearance areas, with a preservative. Spray the preservative through the suction and discharge nozzles. It is advisable to then close the pump nozzles (e.g., with plastic caps or similar). Oil or grease all blank parts and all faces of the pump with silicone-free oil and grease. Read-approved (if required) to protect them against corrosion. Observe the additional instructions.
  - Wet Components: If the pump set is to be stored temporarily, only preserve the wetted components made of low alloy materials. Commercially available products can be used for this purpose. Observe the manufacturer's instructions for application/removal. Observe any additional instructions and information provided.
  - Returning to Service After Storage: For returning the pump to service, observe the sections on commissioning/start-up and the operating limits. In addition, carry out all servicing/maintenance operations before returning the pump (set) to service.
  - Failure to Reinstall or Re-activate Protective Devices: Risk of personal injury from moving parts or escaping fluid! As soon as the work is completed, re-install and/or re-activate any safety-relevant and protective devices.
  - Pump Out of Service: If the pump has been out of service for more than one year, replace all elastomer seals.