KSB WK Series User Manual

WK
Contents
Point Description Page
No. No.
0 Introduction 1
1 Pump construction 1
1.1 Casing 1
1.2 Rotor 1
1.3 Bearing arrangement 2
1.4 Lubrication 3
1.4.1 Oil lubrication 3
1.4.2 Grease lubrication 4
1.5 Shaft seal 4
1.5.1 Stuffing boxes 4
1.5.1.1 Cooling liquid for stuffing boxes 5
1.5.1.2 Packing the stuffing boxes 5
1.5.1.3 Packing material 7
1.5.2 Mechanical seals 7
1.6 Coupling 7
2 Mode of operation of pump 7
3 Drive 8
4 Transport 8
5 Painting 8
6 Condition of equipment as supplied 8
7 Accessories 9
8 Installing the pumping set 9
8.1 Description of site prior to
commencement of erection 9
8.2 Installation and preliminary levelling up 9
8.3 Aligning the coupling 9
8.4 Grouting in the baseplate 10
8.5 Final alignment 10
9 Piping 11
9.1 Suction lift line and positive
Suction head line 11
9.1.1 Strainers in suction head line/suction lift line 11
9.2 Isolating valves 12
9.3 Non-return valves 12
9.3.1 Automatic recirculation valve 12
9.4 Final coupling check 13
9.5 Measuring instruments 13
10 Commissioning 13
10.1 Preliminary remarks regarding
commissioning 13
10.2 Start-up 13
10.3 Operation and supervision of pump 14
Point Description Page
No. No.
10.4 Shutting the pump down 14
10.5 Preserving the pump 15
10.6 Sending the pump back to our Works 15
11 Dismantling the pump 15
11.1 Preparations prior to dismantling 15
11.2 Dismantling the bearing 15
11.2.1 Dismantling the drive end bearing 15
11.2.2 Dismantling the end side bearing 16
11.2.2.1 Standard bearing construction 16
11.2.2.2 Heavy duty bearing construction 17
11.3 Removing the shaft seal 17
11.3.1 Soft-packed stuffing box construction 17
11.4 Dismantling the pump body 17
11.5 Inspection of individual pump components 19
11.6 Dynamic balancing of pump rotor 20
12 Assembly of pump 20
12.1 Preparations prior reassembly 20
12.2 Assembling the pump body 20
12.3 Assembly of shaft seal 22
12.3.1 Pump construction with soft-packed
stuffing box 22
12.4 Assembly of bearings 23
12.4.1 Assembly of end side bearing 23
12.4.2 Assembly of drive end bearing 23
13 Operating troubles, causes and remedies 25
13.1 Operating troubles 25
13.2 Causes for damage 25
13.3 Suggested remedies 26
14 Spare parts 27
15 Check list 28
15.1 Pre-requisites for initial commissioning 28
15.2 Initial start-up with cold water 28
15.3 Priming the boiler 28
15.4 Initial operation with hot fluid 28
15.5 Supervision of operations & maintenance 28
16 Sectional drawings and list of
components 29
Balancing liquid piping 31

KSB WK Series Specifications

General

Brand	KSB
Model	WK Series
Category	Water Pump
Language	English

Summary

Pump Construction

Casing

Details the construction of the pump casing.

Rotor

Describes the components of the pump rotor.

Bearing Arrangement

Explains different bearing types and their application.

Lubrication

Covers oil and grease lubrication for bearings.

Shaft Seal

Details stuffing boxes and mechanical seals.

Coupling

Explains the flexible coupling used.

Mode of Operation of Pump

Installing the Pumping Set

Description of Site prior to Commencement of Erection

Site requirements before starting pump installation.

Installation and preliminary Levelling Up

Steps for placing and leveling the pump set.

Aligning the Coupling

Procedure for aligning pump and driver couplings.

Grouting in the Baseplate

How to grout the baseplate.

Final Alignment

Final checks and adjustments for pump alignment.

Piping

Suction Lift Line and Positive Suction Head Line

Guidelines for suction piping.

Isolating Valves

Installation and use of isolating valves.

Non-Return Valves (in the discharge line)

Role and type of non-return valves.

Final Coupling Check

Final check of coupling alignment.

Measuring Instruments

Recommended measuring instruments.

Commissioning

Preliminary Remarks regarding Commissioning

Initial checks before commissioning the pump.

Start-up

Step-by-step guide for pump start-up.

Operation and Supervision of Pump

Guidelines for pump operation and monitoring.

Shutting the pump down

Procedures for safely shutting down the pump.

Preserving the Pump

Instructions for pump preservation during storage.

Dismantling the Pump

Preparations prior to Dismantling

Steps before starting pump disassembly.

Dismantling the Bearings

Detailed steps for bearing disassembly.

Removing the Shaft Seal

How to remove shaft seals.

Dismantling the Pump Body

Procedures for disassembling pump casings.

Inspection of individual Pump Components

Checks for components after disassembly.

Dynamic Balancing of Pump Rotor

Process for balancing the pump rotor.

Assembly of Pump

Preparations prior to Reassembly

Checks and preparations before reassembly.

Assembling the Pump Body

Steps for reassembling the pump casing.

Assembly of Shaft Seal

Installing shaft seals.

Assembly of Bearings

Procedures for assembling pump bearings.

Operating Troubles, Causes and Remedies

Operating Troubles Cause and suggested remedy

Overview of operating troubles and remedies.

Cause of Damage

Lists common causes for pump damage.

Suggested Remedies

Recommended solutions for identified causes.

Spare Parts

Check List

Pre-requisites for Initial Commissioning

Initial checks before commissioning the pump.

Initial Start-up with Cold Water

Steps for initial pump start-up with cold water.

Initial Operation with Hot Fluid

Procedures for initial operation with hot fluid.

Supervision of Operations & Maintenance

Monitoring pump operation and maintenance.

Sectional Drawings and List of Components

Balancing Liquid Piping

Field of Application

Where balancing liquid piping is required.

Requirement and Connection

How balancing liquid piping is connected.

Size

Recommended pipe line sizes for balancing piping.

Accessories

Necessary accessories for balancing liquid piping.

Illustrations

Visual aids for balancing liquid piping.

Precautionary Notes

Important notes regarding balancing liquid piping.