Operating instructions 1777.8/7-10 G3 Multitec High-pressure pumps in ring-section design Works No.: __________________________________ Type series: __________________________________ These operating instructions contain fundamental information and precautionary notes. Please read the manual thoroughly prior to installation of unit, connection to the power supply and commissioning. It is imperative to comply with all other operating instructions referring to components of this unit.
Multitec Contents Page 4 1 General 2 Safety 4 2.1 Marking of instructions in the manual 2.2 Page 6.3.1 The unit / pump remains installed; periodic check of operation 13 4 6.3.2 The pump is removed from the pipe and stored Personnel qualification and training 4 13 2.3 Non-compliance with safety instructions 4 6.4 Returning to service after storage 13 2.4 Safety awareness 4 7 Servicing / maintenance 14 2.5 Safety instructions for the operator / user 5 7.
Multitec Index Section Adjusting dimensions for coupling alignment, pump sizes 32 to 65, versions E, Ex, F, Fx, V, Vx Section Page 31 Page Reassembly of hydraulic system 7.4.2 21 Recommended spare parts stock for 2 years’ continuous operation 7.3.7 20 Repairs 7.5.2 25 Returning to service after storage 6.4 13 Safety 2 4 Safety awareness 2.4 4 2.6 5 Aligning the pump / drive 5.3.1 8 Applications 4.4 6 Bearings 7.4.4 22 Bearings and lubrication 7.2.
Multitec 1 General The Multitec pump has been developed in accordance with state-of-the-art technology; it is manufactured with utmost care and subject to continuous quality control. These operating instructions are intended to facilitate operation of the pump and help in commissioning and maintenance. The manual also contains important recommendations for reliable, proper and efficient operation.
Multitec 2.5 Safety instructions for the operator / user - Any hot or cold components that could pose a hazard must be equipped with a guard by the operator. - Guards which are fitted to prevent accidental contact with moving parts (e.g. coupling) must not be removed whilst the unit is operating. - Leakages (e.g. at the shaft seal) of hazardous fluids handled (e.g. explosive, toxic, hot) must be contained so as to avoid any danger to persons or the environment. All relevant laws must be heeded.
Multitec 4 Description accessories of 4.1 Technical specification the product and Multistage centrifugal pumps in ring-section design with suction impeller for low NPSH value (exception: MTC 32).
Multitec 5 Installation at site 5.1 Safety regulations / Special instructions Electrical equipment operated in potentially explosive atmospheres must comply with the relevant explosion protection regulations. This is indicated on the motor rating plate.
Multitec 5.3.1 Aligning the pump / drive Coupling guard Caution In compliance with health and safety regulations the pump must not be operated without a coupling guard / a guard on the drive lantern. If the customer specifically requests not to include a coupling guard / lantern guard in our delivery, then the operator must supply one. Baseplate-mounted units After fastening the baseplate on the foundation, the coupling must be thoroughly checked and the pump set be re-aligned (at the motor), if required.
Multitec 5.4 Connecting the piping Suction lift lines shall be laid with a rising slope towards the pump and suction head lines with a downward slope towards the pump, to prevent the formation of air pockets. With short pipelines, the nominal diameters should be at least equal to the nominal diameters of the pump nozzles. For long pipelines, the most economical nominal diameter has to be determined from case to case. Adapters to larger diameters should have a diffuser angle of approx.
Multitec 5.4.1 Vacuum balance line Y configuration (high voltage) 1145:32/2 Where liquid has to be pumped out of a vessel under vacuum, it is advisable to install a vacuum balance line. This line shall have a minimum nom. diameter of 25 mm and must extend above the highest permissible liquid level of the vessel. An additional pipeline fitted with a shut-off valve – from the pump discharge nozzle to the balance line – facilitates venting of the pump before start-up. Fig.
Multitec 6 Commissioning, start-up / Shutdown Instructions for boiler feed applications Limit values for boiler feed water and condensate when using cast iron pump parts: pH value ³ 9.0 (target: ³ 9.3) O2 content ≤0.02 ppm. These values must be ensured under all operating conditions before entry into the pump. Max. percentage of fresh water: 25%. Water treatment shall be in accordance with VdTÜV guidelines for feed and boiler water in steam plants of up to 64 bar.
Multitec 6.1.3 Contact guard In compliance with health and safety regulations the pump must not be operated without a coupling guard. If the customer specifically requests not to include a coupling guard in our delivery, then the operator must supply one. 6.1.4 Connection to power supply If the pump is equipped with an electric motor, connection to the power supply must be effected by a trained electrician only.
Multitec 6.2.2 Switching frequency The permissible number of start-ups in a given period of time depends on the circumstances prevailing in the plant and the operating conditions.
Multitec 7 Servicing / maintenance 7.1 General instructions The operator is responsible for ensuring that all maintenance, inspection and installation work be performed by authorized, qualified personnel who are thoroughly familiar with the manual. A regular maintenance schedule will help avoid expensive repairs and contribute to trouble-free, reliable operation of the pump with a minimum of maintenance expenditure and work.
Multitec Oil quality / Oil change Quality: ISO VG 46. The first oil change shall be carried out after 300 operating hours, the following ones every 3000 operating hours. Unscrew the screwed plug in the re-fill hole and in the drain hole. Allow the bearing housing to drain completely, then plug the drain hole again. 7.2.3 Shaft seal Mechanical seal: The mechanical seal is maintenance-free. Gland packing: The nuts at the gland cover must only be tightened slightly.
Multitec 7.3.3 Dismantling the bearings The sections below describe partial dismantling (bearings, seals, etc.) and complete dismantling of the pump unit. 7.3.3.1 Dismantling the non-drive-end bearings Plain bearing The plain bearing is removed without dismantling the hydraulic section of the pump. Axial suction nozzle: Shaft in 1.4021 / 1.4462 Fig. 19 Rolling element bearings: If the pump is oil-lubricated, drain the oil before dismantling. - Unscrew bolts 901.4 or 914.
Multitec 7.3.3.2 Dismantling the drive-end rolling element bearings N.B.: The ceramic bearing installed at the non-drive end need not be dismantled in order to remove the drive-end rolling element bearings. If the pump is oil-lubricated, the oil must be drained before dismantling. - After loosening the grub screw in the coupling hub pull out coupling half with key 940.3. Grease lubrication (figs. 26 and 27) - Remove joint ring (V-ring) 411.7. - Undo bolts 901.1. - Remove bearing cover 360.1.
Multitec 7.3.4 Dismantling and replacement of shaft seal Gland packings 7.3.4.1 Replacing the packing rings Access to packing rings without removing the bearing or the lantern: - Undo both nuts 920.3 and pull gland cover 452 out of seal housing 441.1. - Remove packing rings 461. 7.3.4.1 Replacing the shaft protecting sleeve - Remove the bearing as described in sections 7.3.3.1 and 7.3.3.2. - Remove packing rings as described in section 7.3.4.1. - On grease-lubricated pumps, pull V-ring 411.
Multitec 7.3.5.2 Removing an air-cooled mechanical seal (seal code 64) 7.3.5.3 Removing a water-cooled mechanical seal (seal code 64) Fig. 33 N.B.: This mechanical seal design is used for application temperatures from 140 to 200°C and Multitec sizes 32 to 100. The pump shall only be coupled to a motor with enclosure IP 55. - Remove the bearing as described in sections 7.3.3.1 and 7.3.3.2. - Remove O-ring 412.10. - Pull off spacer sleeve 525.1. - Loosen bolts 901.11. - Remove bearing housing 350.1.
Multitec 7.3.6 Dismantling the hydraulic system - Remove the bearings as described in sections 7.3.3.1 and 7.3.3.2 and the shaft seals as described in sections 7.3.4 and 7.3.5. If possible, place the hydraulic system in vertical position and start dismantling it from the discharge end. - Undo the four tie bolts 905. - Remove discharge casing 107, then dismantle the hydraulic elements.
Multitec 7.4.1 Tightening torques - Tie bolts, part No. 905 Material codes 10, 11, 12, 13 (casing: cast iron) Pump size Tightening torque Nm Multitec 32 Multitec 50 Multitec 65 Multitec 100 Multitec 125 Multitec 150 85 140 250 395 600 700 Material code 20 to 30 (Casing: steel or stainless steel) Pump size Operating pressure (bar) Tighten the gland cover by hand at first. Use a feeler gauge to check the level position of the gland cover. It must be easy to turn the rotor by hand.
Multitec Mechanical seals Caution Mechanical seals are precision components. The seat ring and the spring-loaded ring must always be replaced together, i.e. always replace the entire mechanical seal. To ensure trouble-free operation of the mechanical seal, the seal faces and the tools must be absolutely clean. Mechanical seals must be installed with utmost care. The contact faces shall only be cleaned immediately before assembly takes place. They must not be greasy (grease, smudges ...) or damaged.
Multitec Caution When tightening the shaft nuts, please observe the following: The shaft nuts must be tightened to the torques indicated in the table ”Tightening torques for shaft nuts”.
Multitec If there is no suitable torque wrench available for tightening the shaft nuts, proceed as follows, depending on the pump version: After installation of the bearings, the following checks shall be made: Self-locking nut on drive end (or non-drive end on versions C und D) - Grease-lubricated bearings: Check the clearance between cover 360.1 and bearing housing 350.1 after having tightened bolts 901.1. There should be a clearance between 0.2 mm and 0.8 mm. Cover 360.
Multitec Radial bearing Versions C and D are equipped with a deep-groove ball bearing as radial bearing. (The other versions are fitted with a plain bearing in the suction casing). The outer race of the deep-groove ball bearing must have axial play. The bearing is installed without spacer discs 551.1. Fig. 42 7.4.4.1 Temperature of the rolling element bearings Caution The temperature of the rolling element bearings, which run at 3000 1/min and more, can be 90°C.
Multitec Excessive rise of temperature inside the pump Vibrations during pump operation Excessive leakage at the shaft seal Leakage at the pump Excessive bearing temperature Pump is running, but does not deliver Trouble-shooting Motor is overloaded Pump delivers insufficient flow rate 8 Cause Remedy 1) Pump delivers against an excessively high discharge pressure. Re-adjust to duty point. Check plant for impurities. Fit one or several larger impellers. Increase the speed (turbine, I.C. engine).
Multitec 9 General assembly drawing Pump sizes 32 to 100 Radial suction nozzle with mechanical seal Version without balance drum Axial suction nozzle up to pump size 50 1) 2) 3) 4) 5) 6) 7) for pump models with mechanical seal only pump size 65 and above pump size 100 and above except pump size 32 pump sizes 32 and 50 only hydraulics 9.2/10.2/11.1 and 12.
Multitec Close-coupled pump up to pump size 65 Radial suction nozzle Vertical design Pump sizes 32, 50 and 65 Vertical design Pump sizes 100, 125 and 150 28 1) 2) 3) 4) 5) 6) 7) for pump models with mechanical seal only pump size 65 and above pump size 100 and above except pump size 32 pump sizes 32 and 50 only hydraulics 9.2/10.2/11.1 and 12.
Multitec Pump sizes 125 and 150 Version B Material codes 20, 21, 22, 23 and 30 Version C Return of balancing line MTC 150, 2-pole 1) 2) 3) 4) 5) 6) 7) for pump models with mechanical seal only pump size 65 and above pump size 100 and above except pump size 32 pump sizes 32 and 50 only hydraulics 9.2/10.2/11.1 and 12.
Multitec 9.1 List of components This list includes all components mentioned in this document 1) 525.1/2/4 Spacer sleeve Part No. Description Discharge casing 529 Bearing sleeve SiC 1) Stage casing 540.1/3 Bush Part No. Description 106.1/2 Suction casing 107 108.1 1) 1) 160.1/2 Cover 550. 1/2/3/4/6/8/9/10/11 Disc 171.1 Diffuser 551.1/2 Spacer disc 181 Pump stool 561.1 Grooved pin 182 Foot 565 Rivet 210 Shaft 1) 59-4 Balance drum 230.
Multitec Adjusting Dimensions for Coupling Alignment, Pump sizes 32 to 65, Pump versions E, Ex, F, Fx, V, Vx Cotes de réglage pour alignement de l’accouplement tailles 32 jusqu’à 65, Exécutions E, Ex, F, Fx, V, Vx Einstellmaße für Kupplungsausrichtung Baugrößen 32 bis 65 Ausführung E, Ex, F, Fx, V, Vx Bild 44 Fig.
1777.8/7-10 01.06.2006 Subject to technical modification without prior notice. Multitec KSB Aktiengesellschaft P.O. Box 1361, 91253 Pegnitz · Bahnhofplatz 1, 91257 Pegnitz (Germany) Tel. +49 9241 71-0 · Fax +49 9241 71-1791 · www.ksb.
