WKFI

CONTENTS

Point Description Page Point Description Page

No. No. No. No.

0 General 1 4.2.1 Gland Packing 5

0.1 Transport 1 4.2.2 Bearings 5
4.2.2.1 Movable Bearings (motor side) 5
1 Assembly / Installation at Site 1
4.2.2.2 Bearing Sizes 6
1.1 Foundation 1
4.2.2.3 Lubrication Quantities 6
1.2 Installation 1
4.2.3 Pump Body 6
1.3 Aligning the Pump and Motor 1
4.2.4 Shaft 6
1.4 Connecting the Piping 2
4.2.5 Rotor Clearance 6
1.4.1 Vacuum Balance Line 3
4.2.6 Pump Rotor 6
1.4.2 Minimum Flow 3
4.3 Reassembly 6
1.5 Checking the Direction of Rotation 3
4.3.1 Pump 6
1.6 Coupling Guard 3
4.3.2 Shaft Seal 6
1.7 Final Check 3
4.3.2.1 Stuffing Box Compartment 6
2 Start-up / Commissioning, Shutdown 4 4.3.2.2 Packing Ring 7
2.1 Preparations for Start-up 4 4.3.2.3 Packing Ring of Aramid 7
2.1.1 Lubricants 4 4.3.2.4 Stuffing Box Cooling 7
2.1.2 Shaft Seal 4 4.4 Tightening Torques of the Tiebolts 7
2.1.3 Priming the pump and Associated Checks 4 4.5 Switching Frequency 7
2.2 Start-up 4 4.6 Speeds 7
2.3 Shutdown 4 4.7 Spare Parts 8
4.7.1 Ordering Spare Parts 8
3. Maintenance and Lubrication 5
4.7.2 Recommended stock of spart parts
3.1 Supervision of Operation 5
for 2 years continuous operation 8
3.2 Lubrication and Grease / Oil Change 5
3.2.1 Lubrication 5 5 Sectional drawing and list of components 9
3.2.2 Oil change 5
6 Faults 11
4. Special Instructions and Recommendations 5
Annexure I
4.1 Basic Instructions / Recommendations 5
4.2 Dismantling 5
 WKFI

0 General 1 Assembly / Installation at Site

Centrifugal pumps will give trouble-free, satisfactory service 1.1 Foundation
if they are property installed and maintained.
Make sure that the concrete foundation has set hard before
Follow the instructions in this manual carefully. Do not run mounting the pump set. The surface of the foundation must
the pumps under operating conditions differing from those be completely leveled and prefectly smooth.
specified by us.
1.2 Installation
This manual does not take into account any site safety
regulations which may apply. The site manager or site Position the pump set on the foundation and align using a
operator is responsible for notifying our erection staff of any precision spirit level (on the shaft / discharge nozzle). Ensure
such regulations and ensuring they are complied with. that the gap between the two coupling halves is as given on
the installation plan. Shims should always be fitted to the left
The type series, pump size, main operating data, product no. and right of the bolts in close proximity to the bolts, between
and serial no. are all stamped on the nameplate attached to the baseplate/baseframe and foundation. If the bolts are more
the pump. Please quote this information whenever you have than 800 mm apart, position extra shims equi-distant between
queries or repeat orders and in particular when ordering spare them. All shims must lie perfectly flush.
parts. In the case of damage please contact the nearest KSB
Shim
service center. Shim Shim

Do not operate this pump set above the limit values

for capacity, speed, pressure and temperature etc.
shown on the nameplate. Ensure that operation is in
accordance with the instructions contained in this manual
(contract documentation). It is essential that the electrical
connection values are as specified and that the instructions > 800
on installation and maintenance are complied with. Operation
of the pump set beyond above conditions may lead to Fig. 2 Fitting shims
overloads the pump set cannot withstand.
Uniformly tighten up the bolts.
Disregard of this warning may result in personal injury and
property damage. Grout in the baseplate (non-shrinking mortar is highly
recommended), ensuring no cavities remain.
N.B.
1.3 Aligning the Pump and Motor
The instructions and descriptions in this manual refer to the
standard pump model. This manual does not cover all design After the baseplate has been fixed in position
details or eventualities which might occur during installation, carefully check the coupling and if necessary, realign
operation or maintenance. The pump set must only be the pump set (at the motor).
handled by skilled, trained personnel.
Before doing so, loosen pump feet and tighten again without
For any information and instructions not contained in this transmitting any stresses and strains.
manual, please contact KSB.
The coupling must also be checked and the pump set
The manufacturer accepts no liability for the pump set if the realigned if the pump and motor are supplied ready mounted
instructions in this manual are not complied with. on a common baseplate.

0.1 Transport Straight edge

When transporting the complete pump set attach ropes to

the pump and motor as illustrated (not through the motor
eyebolt). a1 b1

a b

Straight edge Gauge

E

Fig. 3 Aligning a non-spacer type flexible coupling

Fig. 1 Pump and motor on a commom baseplate

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 WKFI

Straight edge
Directions in which the moments are acting :
MX = around the horizontal axis, parallel to the pump axis
MY = around the vertical nozzle axis
D D MZ = around the horizontal axis at right angles to the
pump axis
DN = nominal diameter of the suction and discharge
nozzle

Dimensions :
F in N
M in Nm
Gauge DN in mm

Fig. 4 Aligning a flexible spacer coupling Suction and discharge nozzles have to be considered
separately.
The axial and radial deviation between the two coupling
halves must not exceed 0.1 mm.
max. permissible piping forces
This must also be ensured at operating temperature and under WKF 40
actual inlet pressure.
Suction nozzle
If the temperature of the medium handled is > 1000C, the FX 600
pump must be pinned to the baseplate (see Fig. 5). Tighten FY [N] 1400
foundation bolts at the discharge side pump feet slightly only FZ 600
to facilitate free thermal expansion. MX 400
MY [Nm] 300
MZ 400
Discharge nozzle
Y X FX 600
FY [N] 1400
FZ 600
MX 400
Discharge Suction
side side
MY [Nm] 300
MZ 500
Z
Fig. 5 Pinning the pump to the baseplate
The suction line should be run with a rising slope towards
1.4 Connecting the Piping the pump, under inflow conditions with a downward slope
towards the pump.
Never use the pump as an anchorage point for the piping.
The pipes should be supported very near to the pump and
Forces and moments of the piping may act both on suction should be connected to the pump without transmitting any
and discharge nozzles at the same time. stresses and strains to it. The pump must not bear the weight
DN of the piping.
MY The nominal diameters of short pipelines shall correspond
FY at least to those of the pump connections for long pipelines
MX
FZ the most economic nominal diameters shall be determined
depending on the respective requirements.
FX MZ
We recommend installing non-return devices and shut-off
valves, depending on the type of plant and pump.

The thermal expansion of the pipework must be compensated

MY for by suitable means so as not to impose any extra load on
the pump.
FY
MX Before commissioning a new plant, thoroughly clean, flush
MZ and blow through all vessels, piping and connections. As
FX FZ DN welding beads, scale and other impurities frequently only
become dislodged after a certain period of time, it is necessary
to fit a strainer in the suction line to prevent these from entering
Fig. 6 Max. permissible forces and moments acting on the
the pump. The total cross-section of the holes in the strainer
pump nozzles
should be three times the cross-section of the piping in order
Directions in which the forces are acting : to avoid excessive pressure loss across the strainer due to
X = horizontal, parallel to the pump axis clogging. The conical strainer consists of a coarse strainer
Y = vertical to the pump axis fronted by a fine strainer with a 2.0 mm mesh and 0.5 mm
Z = horizontal at right angles to the pump axis diameter wire, made of corrosion-resistant material.

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 WKFI

1.4.2 Minimum Flow

If it is possible that the pump will have to operate against a
closed shut-off valve arranged in the discharge line, a
minimum flow of

t -10 to +1000C = 15% of Qopt.

t > 100 to +1400C = 20% of Qopt.
t > 140 to 2000C = 25% of Qopt.

must be provided during that time.

1 2 5 3 4
If special cases require a detailed calculation, contact KSB.
1 Strainer holder 4 Pump suction nozzle
2 Fine strainer 5 Differential pressure gauge 1.5 Checking the Direction of Rotation
3 Coarse strainer
The rotational direction must correspond to the arrow on the
Fig. 7 Conical strainer for suction line pump. Check this by switching the pump on and then off
immediately.
1.4.1 Vacuum Balance Line Always check the direction of rotation with the motor
disconnected.
If the pump has to pump a liquid out of a vessel under vacuum,
it is advisable to install a vacuum balance line. This line 1.6 Coupling Guard
should have a nominal size of 25 mm at least. It should be
arranged to lead back into the vacuum vessel at a point above Safety regulations specify that the pump must be fitted with a
the highest permissible liquid level. An additional line starting coupling guard. If the purchaser stipulates that he does not
at the pump discharge nozzle facilitates venting of the pump want us to supply a guard, then this must be provided by the
before start up. The vacuum-tight isolating valve E in this operator.
connecting line should be closed after the venting procedure
and should remain closed while the pump is running. The 1.7 Final Check
main isolating valve C in the vacuum balance line must
remain open at all times when the pump is running and should Re-check alignment as described in 1.3. It must be possible
be closed when the pump is shutdown. Refer fig. 8. to rotate the coupling easily by hand.

Check if all connections are correct and function properly.

V B
C
R

Pump

A Z

A Main isolating valve R Check valve

B Vacuum balance line V Vacuum vessel
C Isolating valve Z Intermediate flange
E Vacuum-tight isolating valve

Fig. 8 Suction line and vacuum balance line

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 WKFI

2. Start-up / Commissioning, Shutdown Open minimum flow line of the non-return valve (if fitted).
Secure minimum flow line against accidental closing.
2.1 Preparations for Start-up
Non-return valve with hand-operated line, open valve of this
2.1.1 Lubricants line. If the pump is fitted with a hand-operated minimum flow
line (by-pass) then open this line. If a check valve is fitted and
The bearing bracket should be filled with oil of any one of the start-up is to be effected with shut-off valve open the check
following types and specifications : valve must be closed under the counter-pressure (e.g. boiler
pressure). If prior to start-up there is not sufficient counter
Indian Oil : Servosystem 46 pressure then start-up with closed shut-off valve.
Hindustan Petroleum : Enklo 46
2.2 Start-up
Bharat Petroleum : Bharat Hydrol 46
Start the set up only if the shut-off valve in the discharge line
is closed. Once the pump has reached full speed slowly open
Vent or filler the valve and set to the duty point.
plug
N.B.

After the pump has reached its operating temperature and/or

if the pump leaks tighten the tie bolts with the pump set shut-
down.

2.3 Shutdown
Close the shut-off valve in the discharge line.

If a check valve is installed in the discharge line, the shut-off

valve can remain open as long as there is a counter-pressure.
Drain plug Oil level in bearing
bracket and connection elbow Switch off the motor making sure the pump set runs smoothly
and evenly down to a standstill.
Fig. 9 Oil fill
If the pump set is to remain out of service for long periods,
Procedure : close the shut-off valve in the suction line. Close off the
auxiliary connections.
Unscrew vent plug. Pour in oil through the vent plug aperture
after removing the reservoir of the constant level oiler, until On pumps supplied with medium under vacuum, sealing
oil appears in the vertical portion of the connection elbow of liquid must be supplied to the stuffing box even during
the constant level oiler (see fig. 9). standstill.
Then fill the reservoir of the constant level oiler with oil and fit If there is a danger of freezing and / or if the pump is to be out
it back into operating position. Screw vent plug in again. After of service for long periods, drain the pump or otherwise protect
a short time has elasped, check whether the oil level in the against freezing.
reservoir has sunk. The reservoir should always remain filled.
If the vent plug is inaccessible orf difficult to reach e.g. the oil
can be filled into the bearing bracket through the connection
elbow of the constant level oiler.

Caution :

The oil level should always be situated below the level of the
vent slot arranged at the top edge of the connection elbow
and this slot should always be perfectly dry. Do not tighten
the elbow by applying force on the reservoir use lock nut for
this purpose.

2.1.2 Shaft Seal

Shaft seal (see 4.3.2)

2.1.3 Priming the pump and Associated Checks

Pumps and suction line must be vented and filled with the
medium handled prior to start-up. The shut-off valve in the
suction line must be fully open.

Fully open all auxiliary connections and check the flow. Open
shut-off valve in the vacuum balance line (if fitted) and close
vacuum-tight shut-off valve E (Fig. 9).

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 WKFI

3. Maintenance and Lubrication 4. Special Instructions and

Recommendations
3.1 Supervision of Operation
4.1 Basic Instructions / Recommendations
The pump must run quietly and evenly at all times.
Before dismantling, make sure the pump set is
Max. permissible room temperature 400C.
disconnected from the power supply and cannot be
The bearing temperature may exceed the room temperature switched on accidentally.
rise by up to 500C, but must not go above 900C (measured
The suction and discharge shut-off valves must be closed.
externally on the bearing housing).
Make sure that the pump casing has cooled down to ambient
Never allow the pump to run dry. temperature and that it is empty and not under pressure.

Do not run the pump against a closed shut-off valve for a 4.2 Dismantling
prolonged period.
1. Drain oil as described under 3.2.3 if oil lubrication is
The shut-off valves in the auxiliary feed lines must not be provided.
closed during operation.
2. Dismantle auxiliary connections.
If the pump has gland packing this should leak slightly during
operation. The gland cover should only be lightly tightened. 3. Remove coupling guard.

In case of prolonged periods of standstill, the pimp should be 4. If coupling is not fitted with intermediate sleeve :
started up and then shut down immediately to ensure it is in Disconnect pump from motor and detach from baseplate.
constant readiness for operation.
5. If coupling is fitted with intermediate sleeve :
- Fire fighting water 1 start-up/shutdown/month For work on the shaft seals, bearings or shaft protecting
- Drinking water 1 start-up/shutdown/48 hrs sleeves or shaft sleeves respectively, the pump may
remain on the baseplate and connected to the pipeline.
- Standby pumps 1 start-up/shutdown/week
If the pump has been in operation for a long time it may be
Check proper functioning of the auxiliary connections. difficult to remove certain parts from the shaft. If this is the
The flexible coupling elements should be regularly checked case, use a brand name penetrating oil or suitable pull-off
and replaced as soon as they show signs of wear. device.

Never use force !

3.2 Lubrication and Grease / Oil Change
4.2.1 Gland Packing
3.2.1 Lubrication
Remove hex. nut 920.2, gland cover 452, gland packing 461,
The antifriction bearings are lubricated by means of oil. For
lantern ring 458.
required quantities see 4.2.2.3.
4.2.2 Bearings
3.2.2 Oil Change
First oil change after 300 operating hours, all further changes
Angular Contact Ball Bearing
every 3000 operating hours. Remove hex. head bolt 901.1, end bearing cover 361.2,
Procedure : spacer disc 551.1, withdrawal nut (920), lock washer (931).
Press bearing casing 350.2 off discharge casing 107 and
Remove threaded plug below bearing housing 350.1 and withdraw with centering sleeve 525 angular contact ball
drain oil. After draining of the bearing housing screw in the bearing 320, spacer disc 551.1, spacer ring 504.1, gasket
plug again and fill in oil as described under 2.1.1. 411.4.

4.2.2.1 Movable Bearing (motor side)

Withdraw coupling half using a pull-off device :
Remove (gasket 411.4), hex. head bolt 901.1, bearing cover
360, spacer disc 551.2 loosen clamping sleeve 531, hex. nut
920.1. Withdraw bearing housing 350.1 with cylindrical roller
bearing 322 and clamping sleeve 531 (WKFI 40 - 100) from
suction casing 106. Remove gasket 411.4.

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 WKFI

4.2.2.2 Bearing Sizes 4.2.5 Rotor Clearance

WKFI Stationary Bearing Movable Bearing New max. admissible
Angular contact Cylindrical rotor bearing Cast iron Chrome Cast iron Chrome
ball bearing with clamping sleeve bronze steel bronze steel
DIN 628 DIN 5412 DIN 5415 mm in Ø mm in Ø
40 7305 BUA NU 206 K C3 H 206 Casing wear ring
0.35
impeller neck

Diffuser impeller
4.2.2.3 Lubrication Quantities 0.40 0.80 0.80
hub
Oil lubrication
Throttle sleeve /
WKFI Code Oil per bearing 0.30
throttling bush
in Ltrs.
Suction
Stationary Bearing 7305 BUA 0.18
40 Shaft / lift 0.35 2.00 2.00
Movable Bearing NU 206 K C3 0.16 suction operation
casing Suction
4.2.3 Pump Body 0.80 0.80
operation
Always dismantle the pump from the discharge side.
4.2.6 Pump Rotor
Stacken hex. nuts 920.3 allowing a slight pretension to
remain. Loosen pump feet attachment screws. Mount impeller 230.1/.2 (keywayed nut 920.4, spacer
sleeve 525.2 or throttle sleeve 522), shaft protecting
Lift pump off the baseplate.
sleeve 524.1 / shaft sleeve 523.1, adjusting discs
550.2, circlip 932.1 and pump side coupling half onto shaft
Do not handle with ropes attached to the pump shaft.
210.
Fully loosen hex. nuts 920.3. Remove disc 550.1 withdraw 4.3 Reassembly
tiebolts 905.
4.3.1 Pump
Place wedge or frame under stage casing 108.1 so
as to allow free access to the parts to be dismantled. Reassemble in accordance with standard engineering
practice. Coat fits of individual components and screw
Prior to dismantling position the stage casings 108.1 against connections with graphite or similar prior to assembly.
each other and number consecutively to ensure when
assembling suction casing 106, stage casing 108.1 and Check the O-rings for wear and replace if necessary.
discharge casing 107 are fitted again in the same order and
position. Reassemble the pump in reverse order to dismantling and
ensure the components are fitted in the correct sequence
Remove discharge casing 107, casing wear ring 502.2, O- Preheat bush 540.2 prior to assembly. When mounting new
ring 412.2 and diffuser 171.3 at the same time : if not yet parts align pump rotor in the casing center with respect to the
dismantled, withdraw circlip 932.1 and shaft protecting sleeve existing axial clearance. For this purpose displace the rotor -
524.1 (shaft sleeve 523.1, hex nut 920.4, spacer sleeve the pump being assembled but the (discharge side)
525.2). Dismantle in the following order : stage casing 108.1, stationary bearing dismantled - first to the suction side then
O-ring 412.1, casing wearring 502.1/.2, diffuser 171.1/.2, to the discharge side to its stop and take the axial
impeller 230.1/.2. measurements. From both measurements obtain the center
position and fix with adequate number of spacer discs 551.1
Store stage casing in such a way that damage to the sealing (see general drawing page 12).
surfaces is avoided.
4.3.2 Shaft Seal
4.2.4 Shaft
4.3.2.1 Stuffing Box Compartment
Check for true running on turning lathe.
Max. admissible out-of-truth tolerance 0.03 mm. Thoroughly clean the packing compartment and shaft
Re-conditioning of shaft 210 not allowed protecting sleeve before packing the gland.

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 WKFI

4.3.2.4 Stuffing Box Cooling

Use cleaned cooling water without the tendency to
precipitate. Difference in temperature between inlet and
outlet ~ 15 0C. Max. admissible outlet temperature 80 0C.
Pressure up to 10 bar.

Water cooling from external source with medium handled >

700C.

For cooling water required see Fig. 14.

Fig. 11 Stuffing box compartment with neck ring

mm d d1 l
Packing
compartment 35 51 54
No. of rings 4 packing rings
1 lantern ring

4.3.2.2 Packing Ring

Fig. 12 Packing ring cut to size

Packing required on each side : Fig. 13 Cooling water required for jacket cooling
WKF 40
Cord thickness s mm 82 4.4 Tightening Torques of the Tiebolts
Cord length l mm ~ 580
Material Torque Nm
Insert first packing ring and push it home using the gland EN 8 70
cover.
EN 24 V 80
Fit each subsequent ring separately with its joint offset by 900
to the preceding one pushing it home with the gland cover. 4.5 Switching Frequency
Put L. ring as per the position shown.
Reference value max. 30 switchings/h
Tighten the gland cover slightly and uniformly. It must be
possible to rotate the rotor without difficulty.
4.6 Speeds
4.3.2.3 Packing Ring of Aramid
Max. admissible speed n = 1/min as per fig. below.
Before cutting the packing cord wrap the cut faces with PTFE
(polytetrafluorethylene) tape and cut in vertical direction to
the longitudinal axis tof the cord. The PTFE tape must not be
removed from the cut faces again.

Insert lantern ring as well as the first packing ring with cut
face, press straight inwards and tighten slightly only.

Fit each subsequent packing ring with its joint offset by approx.
900 to the preceding one, pushing it home with the gland
cover.

Tighten the gland cover by hand and subsequently loosen

by ½ turn. Use thickness gauge to check uniform seat of the
gland cover under pressure. Set leakage during approx. 30
Fig. 14 Max. admissible speed
minutes while the pump is operating.

Leakage value : ~ 2 - 2.5 l/h

If the leakage value is too low, the nuts at the gland cover
must be loosened.

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 WKFI

4.7 Spare Parts

4.7.1 Ordering Spare Parts

When ordering spare parts please always indicate the
following information, which may be taken from the nameplate
of the pump :

Type : WKFI Pump size / No. of stages (e.g. 40/5)

Spate part No.:
No.:

4.7.2 Recommended stock of spare parts for 2 years

continuous operation

Part Part Description No. of pumps incl. standby pumps

No. 2 3 4 5 6, 7 8, 9 10 & >10
210 Shaft with Keys 1 1 2 2 2 3 30%
230 Impellers (set) 1 1 1 2 2 3 30%
320 Angular Contact Ball Brg. (set) 1 1 2 2 3 4 50%
322 Cylindrical Roller Bearing 1 1 2 2 3 4 50%
411 Gasket 2 2 4 4 4 6 50%
412 O Ring (set) 4 6 8 8 9 12 150%
461 Stuffing Box Packing 4 4 6 6 6 8 40%
502.1/.2 Wearing Rings (2 x S) 2 2 2 3 3 4 50%
504 Spacer Ring 1 1 2 2 3 4 50%
524.1 Shaft Protection Sleeve 2 2 2 3 3 4 50%
526 Centering Sleeve 1 1 2 2 3 4 30%
551.1 Spacer Washer 1 1 2 2 3 4 50%

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 WKFI

5. Sectional drawing and list of components

920
920 526 350.01 913 902/920 905 550 902/920 902/920 718 901
718 461 107 452 106 913 400.02 210

940

901 320 504 411 524.1 522 171.02 108 230 903 524 412.3 411 350 531 940
361 931 551 731 412.04 458.01 412.02 542 171 412.01 502 940 452.01 932 731 322 360

Part No. Part designation Part No. Part designation

106 Suction casing 522 Throttle sleeve
107 Discharge casing 524.01 Shaft prot. sleeve
108.01 Stage casing 524.02 Shaft prot. sleeve
108.02 Stage casing 526 Centering ring
171.01 Diffuser 531 Adaptor sleeve
171.02 Diffuser / Last stage 542 Throttle bush
210 Shaft 550 Washer
230.01 Impeller stage 551 Spacer disc
230.02 Impeller / Last stage 718 Socket
320 Angl. cont. ball bearing 731 Square head plug
322 Cylin. roller bearing 901 Hex. bolt
350.01 Bearing housing / Suc. 902.01 Stud
350.02 Bearing housing / Dis. 902.02 Stud
360 Bearing cover 903 Hex. head plug
361 Bearing cover 905 Tie rod
400.02 Gasket 913 Vent plug
411.01 V-Ring 920.01 Hex. nut
411.02 V-Ring 920.02 Hex. nut
412.01 O-Ring 920.03 Hex. nut
412.02 O-Ring 920.04 Slotted nut
412.04 O-Ring 932 Circlip
452 St. Box Housing 940.01 Key
458 Lantern ring 940.02 Key
461 Gland packing 940.03 Key
502 Wearing ring 940.04 Key
504 Spacer ring

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 WKFI

l3 e f

a l2 l1

DN2 5B

13D 7A.1 7A.1 13D

1M.1
h2

DN1 14E

t
d1k6
1M.2 14A

d1
h1

d2
13B 8B 7E.1 7E.1 8B 13B
6B
s

b b m2 m2

n2 l5 m1 l4

n1

WKFI DN1 DN2 a b d2 f h1 h2 l1 l2 l3 l4 l5 m2 n1 n2 d1 s t u

N HWD N HWD N HWD N HWD N HWD
40 50 40 185 60 16 264 293 140 185 60 194 223 215 244 169 198 190 219 50 300 250 24 20 27 8

NO. OF STAGES
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
e 80 135 185 235 285 335 385 435 485 535 585 635 685 735 785 835
m1 130 185 235 285 335 385 435 485 535 585 635 685 735 785 835 885

Connction Designation WKFI 40

1 M.1/.2 Pressure gauge G 1/2"
5B Vent connection G 1/4"
6B Casing Drain G 1/4"
7 A.1/7 E.1 Cooling water outlet / inlet G 1/4"
8B Leakage drain G 1/2"
13 B/13 D Oil drain / Topping up - venting G 1/8"
14 A / 14 E Balancing liquid outlet / inlet G 1/4"

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 WKFI

6. Faults

Excessive temperature increase in the pump

Pump delivers insufficient liquid

Increased bearing temperature

Pump runs noisily and roughly

Excessive shaft seal leakage
Pump does not deliver
Motor overloaded

Pump leaks

Cause Remedy 1)

l l l Pump generates an excessively high Reset duty point

differencial pressure Check plant for contamination
Fit larger impeller(2)2)
Increase speed (of turbine or combusion engine)
l l l l Pump and / or piping inadequately vented Vent or prime
or primed
l l Suction line or impeller(s) clogged Remove deposits in the pump and / or piping
l l Formation of air pockets in the piping Alter the piping layout
Fit a vent valve
l l l l l Suction head too high / NPSH pump - Correct the liquid level
is too low Fully open the suction side shut-off valve
Modify the suction line if the piping losses are
excessive
Check the suction strainers / suction aperture
Ensure that the permissible rate of pressure
decrease is not exceeded
l l Ingress of air at the shaft seal Clean out the sealing liquid passage, possibly
introduce an external source sealing liquid or
increase the pressure
Fit a new shaft seal.
l l l Reverse rotation Change over two phases of the power supply
2)
l l Speed too low Increase the speed
l l l l Excessive wear of pump internals Replace the worn components
l l Pump back pressure is lower than Reset the duty point correctly
specified in purchase order
2)
l l Specific gravity or viscosity of the medium
handled is higher than specified in the
purchase order
l l l Gland cover is too tight or tightened askew Rectify, allow larger leakage quantity

l Speed too high Reduce the speed2)

l Tiebolts / gaskets Tighten up the tiebolts
Fit new gaskets
l Worn shaft seal Fit a new shaft seal
Check the pressure of the flushing / sealing liquid
l Surface of the shaft protecting sleeve / Fit a new shaft protecting sleeve / shaft sleeve
shaft sleeve is scored or rough Fit a new shaft seal
l Uneven running of pump Rectify the suction conditions
Realign the pump
Rebalance the rotor
Increase the pressure at the suction nozzle
l l l Pump set misalighed Realign
1) The pump should be made pressureless before attempting to remedy faults in parts under pressure. 2) Please contact KSB

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Excessive temperature increase in the pump

Pump delivers insufficient liquid

Increased bearing temperature

Pump runs noisily and roughly

Excessive shaft seal leakage
Pump does not deliver
Motor overloaded

Pump leaks

Cause Remedy 1)

l l l The pump is warped or there are Check the piping connections and the pump
resonance vibrations in the piping holding bolts, if necessary, reduce the gap
between the pipe clamps
Fix piping over vibration absorbing material
2)
l Excessive axial thrust Clean out the balance holes in the impeller
Check impeller tolerances and axial impeller
adjustment
l l Excessive, insufficient or unsuitable Reduce or increase the lubricant quantity or
lubricant change the lubricant
l Specified coupling gap not respected Correct the coupling gap as per the installation\
plan
l l Motor runs on two phases Replace the defective fuse
Check the electrical connections
l l l Rotor unbalanced Rebalance the rotor
l l l Bearings defective Fit new bearings
l l l Insufficient flow rate Increase the minimum flow rate
l Faults in the circulation liquid supply Increase the cross-section of the line supply
l l l l Check valve defective or not fitted Check
for operation in parallel
l Stuffing box packed incorrectly, Check
wrong packing material
l l l Stuffing box space cooling defective Check cross-section of cooling liquid supply
l l l Change in the cross section of the balance Check balance line
liquid recirculating line Check clearance at shaft in the discharge
wear in the balance device casing

1) The pump should be made pressureless before attempting to remedy faults in parts under pressure.
2) Please contact KSB

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Annexure I - Environment Protection - Pruduct Disposal after useful life

Products manufactured by KSB Pumps are designed with utmost care for environmental protection. Innovative designs and
wide product range takes care of specific customer requirements reducing material and electrical energy consumption.
Product materials are recyclable. Our customers are educated with environment friendly methods of disposing product ingredients
at the end of their useful life. Please find herewith methods of disposing used pump ingredients.

Environment Protection measures during product disposal

Sr. Product Ingredients Disposal Methods

1. Pumps Paint : Pump body, Base frame Sludge to be disposed through authorised re processor

Non ferrous parts :

a) Impellers, Diffusers
b) Bushes
c) Stage sleeves
d) Thrust plate To be disposed through authorized re-processor
e) Wearing ring
f) Coupling Guard
g) Brg. Guard

Rubber / Plastic Parts :

a) Cover for NRV
b) Plastic cap To be disposed through authorized re-processor
c) Nozzle blanking
d) Cooling Fan

2. Motor Paint : Motor body, Rotor Sludge to be disposed through authorised re-processor

Non ferrous parts :

a) Support bushes
b) Copper sticks and stampings To be disposed through authorized re-processor
c) Balancing rings
d) Winding wire with varnish

Rubber / Plastic Parts :

a) Oil seal
b) Sand guard To be disposed through authorized re-processor
c) Notch keys, slot insulators
d) Overhang protection pipe