KSB LCC Oim Manual
KSB LCC Oim Manual
KSB LCC Oim Manual
Pump Type:
Date:
Purchaser:
Shipped To:
This manual may include additional documentation not applicable to your specific pump
Legal Information/Copyright
All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose,
nor otherwise transmitted, published or made available to a third party without KSB´s express written consent.
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LCC [en-US]
Contents
Section Page Section Page
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LCC [en-US]
Index
Section Page Section Page
Accessories 15 Operation 20
Alignment 17 Operation, Unauthorized Modes 7
Assembly Safety 7 Operational Problems and Solutions 27
Assembly, Mechanical End 31 Packing 37
Assembly, Wet End 43 Parts Life 27
Auxiliary Connections 19 Personnel 6
Baseplate 17 Piping System Design 28
Bearing Assembly Mounting 34 Piping, Allowable Forces and Moments 16
Bearing Installation 31 Piping, Cleaning 22
Bearing Lubrication, Commissioning 20 Piping, Connecting 19
Casing 42 Power Supply 19
Casing Installation 44 Priming the Pump 23
Casing Removal 43 Pump Casing, Parts Life 27
Cavitation / NPSH Performance 28 Pump Description 14
Commissioning 20 Pump Design Features 15
Commissioning / Return to Service 20 Pump Designation 14
Commissioning, Bearing Lubrication 20 Pump Specification 14
Density of the Medium Handled 24 RTD Installation 19
Dimensions 15 Safety Awareness 7
Direction of Rotation 22 Safety Guards 19
Disassembly Safety 7 Safety Markings 6
Disassembly, Mechanical End 30 Safety, Final Check 19
Disassembly, Wet End 42 Safety, Non-compliance 7
Drainage / Disposal 26 Safety, Operators 7
Elastomer Lined Wet End Assembly 44 Safety, Regulations 17
Elastomer Lined Wet End Removal 43 Safety, Transport & Handling 9
End Covers and Seals, Installation 34 Seal Water Requirements 37
Expeller 39 Shaft Seal 36
Expeller Assembly 40 Shaft Seal, Commissioning 21
Expeller Disassembly 40 Shaft Sleeve, Mounting 44
Expeller Running Clearance 41 Shutdown 23
Expeller, Maintenance 27 Shutdown, Prolonged 23
Foundation 17 Spare Parts Stock 48
Impeller 42 Spare Parts, Unauthorized Modification 7
Impeller Installation 45 Start-up 22
Impeller Removal 42 Storage Requirements 9
Impeller Removal, Break-Loose Device 43 Stuffing Box 36
Impeller Removal, Lifting Device 43 Stuffing Box Assembly 37
Impeller, Parts Life 27 Stuffing Box Maintenance 37
Inspection, Safety 7 Stuffing Box, Commissioning 22
Installation 17 Suction Liner, Parts Life 27
Installation, Location 18 Suction Plate & Liner Assembly (LCC-H only) 45
Installation, Safety 7 Suction Strainer 22
Lifting 13 Sump Design 27
Lubricant Change 26 Switching Frequency 24
Maintenance Equipment 47 Temperature Limits 24
Maintenance, Safety 7 Thrust Bearing Installation (Back to Back) 31
Mechanical End 30 Thrust Bearing Installation (Face to Face) 33
Mechanical End Assembly 31 Tooling 47
Mechanical End Disassembly 30 Torque Requirements 47
Mechanical Seal 36 Transport, Storage & Handling 9
Mechanical Seal Assembly and Disassembly 36 Troubleshooting 49
Mechanical Seals, Commissioning 21 Underwater Operation 27
Mounting the Bearings 31 Underwater Pump Operation 24
Noise Characteristics 15 Wear Problems and Solutions 27
Nose Gap Adjustment 46 Weights 15
Oil Temperature Monitoring 19 Wet End 42
Operating Conditions of Flow and Head 28 Wet End Assembly 43
Operating Limits 24 Wet End Disassembly 42
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LCC [en-US]
1 General
CAUTION
This manual contains important information for reliable, proper and efficient operation. Compliance with the
operating instructions is of vital importance to ensure reliability and long service life of the pump, and to avoid
any risks.
These operating instructions do not take into account local regulations; the operator must ensure that such regulations are strictly
observed by all, including the personnel called in for installation.
WARNING
This pump / unit must not be operated beyond the limit values specified in the technical documentation for the
medium handled, capacity, speed, density, pressure, temperature and motor rating. Make sure that operation is
in accordance with the instructions given in this manual or in the contract documentation.
The nameplate indicates the type series / size, main operating data and serial number. Please quote this information in all
queries, repeat orders and particularly when ordering spare parts.
This manual may contain information not applicable to your pump/unit. Your pump/unit may not be equipped with all features or
auxillary components as described in this manual. Consult your pump/unit drawings and Bill of Materials for details.
If you need any additional information or instructions exceeding the scope of this manual or in case of damage, please contact
your GIW / KSB representative.
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LCC [en-US]
2 Safety
These operating instructions contain fundamental information that must be complied with during installation, operation and
maintenance. Therefore this operating manual must be read and understood both by the installing personnel and the responsible
trained personnel / operators prior to installation and commissioning, and it must always be kept close to the operating location
of the machine / unit for easy access.
Not only must the general safety instructions given in this chapter of "Safety" be complied with, but also the safety instructions
outlined under specific headings.
Symbol Description
DANGER
DANGER This signal word indicates a high-risk hazard which, if not avoided, will result in death or
serious injury.
WARNING
WARNING This signal word indicates a medium-risk hazard which, if not avoided, could result in death
or serious injury.
CAUTION
CAUTION This signal word indicates a hazard which, if not avoided, could result in damage to the
machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in potentially explosive
atmospheres in accordance with EC Directive 94/9/EC (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a hazard which will or could
result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a hazard involving electrical
voltage and identifies information about protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates a hazard for the machine
and its functions.
Personnel responsibilities, competence and supervision must be clearly defined by the operator. If the personnel in question are
not already in possession of the requisite know-how, appropriate training and instruction must be provided. If required, the
operator may commission the manufacturer / supplier to provide such training. In addition, the operator is responsible for
ensuring that the contents of the operating instructions are fully understood by the responsible personnel.
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LCC [en-US]
2.3 Non-compliance with Safety Instructions
Non-compliance with safety instructions can jeopardize the safety of personnel, the environment and the machine itself. Non-
compliance with these safety instructions will also lead to forfeiture of any and all rights to claims for damages.
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
For sectional drawings and bills of material relating to your specific pump and equipment, locate an official copy of the
documentation provided by GIW / KSB. This may be shipped separately from the pump and will include drawings and bills
of material as attachments to this basic manual.
Dismantling and reassembly must always be carried out in accordance with the rules of sound engineering practice
and the relevant sectional drawings. Any work on the motor, gear reducer, mechanical seal or other non-pump
equipment shall be governed by the specifications and regulations of the respective supplier.
Before assembly thoroughly clean all dismantled part mating surfaces and check them for signs of wear. Damaged or
worn components are to be replaced by original equipment spare parts. Make sure that the seal faces are clean and
the o-rings and gaskets are properly fitted. It is recommended that new seal elements (o-rings and gaskets) be used
whenever the pump is reassembled. Make sure that new gaskets have the same thickness as the old ones.
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LCC [en-US]
Avoid the use of mounting aids as much as possible. Should a mounting aid be required, use a commercially available
contact adhesive. The adhesive should only be applied at selected points (three to four spots) and in thin layers. Do
not use cyanoacryiate adhesives (quick-setting adhesives). If in certain cases mounting aids or anti-adhesives other
than those described are required, please contact the sealing material manufacturer.
The operator is responsible for ensuring that all maintenance inspection and installation work is carried out by
authorized, duly qualified staff who are thoroughly familiar with these operating instructions.
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.
Repair and maintenance work to the pump must only be carried out by specially trained personnel, using original
equipment spare parts.
WARNING
Proper lifting, rigging and safety practices must be observed at all times. Do not attempt to lift heavy
components by hand as this may result in personal injury and damage to equipment.
Work on the unit must only be carried out with the electrical connections disconnected and locked out.
Make sure that the pump set cannot be switched on accidentally.
Pumps handling liquids posing health hazards must be decontaminated. When draining the medium
ensure there is no risk to persons or the environment. All relevant laws must be adhered to.
Before dismantling or reassembly, secure the pump so as to make sure it cannot be switched on
accidentally. The shut-off elements in the suction and discharge nozzles must be closed. The pump
must have cooled down to ambient temperature, drained, and its pressure must be released.
Before dismantling or reassembly of vertical cantilever pumps, remove the motor and pull the assembly
out of the sump.
Upon completion of the work, all safety-related and protective equipment must be properly refitted
and/or reactivated before starting the pump set.
Always ensure that lifting equipment does not bind the swivel hoist ring. Binding can cause the ring to
fail. When lifting a plate that contains two swivel hoist rings, do not allow the angle between the lines
of tension from the rings to exceed 120°. This could cause the hoist rings to fail.
120°
Do NOT bind lifting equipment Do NOT exceed 120° between lines of tension
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LCC [en-US]
WARNING
Proper rigging, lifting and safety practices must be observed at all times.
If the pump / unit slips out of the suspension arrangement, it may cause personal injury and damage
to property.
Follow proper lifting practice and safety rules at all times, including:
Verification of the lift weight and load rating of the lift equipment.
Suitability and stability of the attachment points.
Be aware of the location of the center of gravity, which is usually NOT located at the physical center of the unit. In
general, the following guidelines will apply, although common sense and testing of the lift before movement should be
used to verify:
Bare shaft pump (without motor): Near the shaft seal area.
Pump with overhead mounted motor: Between the pump and motor, slightly behind (towards the drive end) of
the shaft seal.
Vertical cantilever pump: between the pump and bearing assembly, but closer to the bearing assembly.
Space the lifting points evenly about the center of gravity and as far apart as practical. This will result in the most stable
lift. Note that certain lift points on the pedestal or bearing housing may be intended for use in handling the pedestal or
bearing house alone and are not necessarily optimum balance points for the entire pump unit.
See Section 3.3 or any addendums for suggested lifting methods. Actual safe lifting method will vary with pump
configuration and type of lifting equipment.
Ensure secure attachments and test the lifting method for stability before moving pump.
For horizontal pumps, ensure that the unit remains in the horizontal position during lifting and cannot slip out of the
suspension arrangement.
Ensure that the pump is firmly strapped down during shipment. Pump should be protected from direct contact with the
elements. Motors and gear reducers may require Immediate cover (consult manufacturer). After arrival on site, consult
GIW Pump Storage recommendations for further storage instructions.
In corrosive environments be sure to remove all lifting devices from the pump and store in a non-corrosive environment
until needed.
DO NOT: Use eyebolt or shackle locations on the bearing assembly, motor or pump plates. These are intended for
lifting those items alone and must not be used when lifting the entire pump.
DO NOT: Place excessive side loads on cast lifting eyes. The side loading angle on any lifting eye should not exceed
30 degrees.
CAUTION
In freezing environments, water must be prevented from collecting in the pump casing.
Pumps with elastomer linings should be stored in a cool dark location free from electrical equipment
such as motors, or any other ozone generating devices. Exposure to direct sunlight or temperatures in
excess of 50°C (120°F) must be avoided.
If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other
auxilarily equipment be sure to consult the manufacturer’s maintenance manual for any additional
storage instructions.
Auxiliary systems should be regularly tested according to manufacturer’s recommendations.
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LCC [en-US]
Storage Upon Receipt and up to 3 Months:
Pump should stored indoors and out of the weather until ready for installation.
In construction environments where indoor storage is not available, store the pump on blocks or pallets, build a frame
around it and cover with tarpaulin.
o Frame must be able to withstand snow and wind, anchored and built in a manner to last the entire time pump
is in storage. Shelter must be continuously maintained in a stable and leak free condition.
o Ensure the tarpaulin does not touch the pump, since this can lead to condensation. Leave the bottom open
for ventilation. Minimum Tarp requirements: 610gsm (18oz) Vinyl, 0.5mm (20mil) thick, Water proof & UV
(ultraviolet) resistant
At 12 months storage and again at 24 months of storage, the following additional actions should be taken:
Check the rust inhibitor coatings on bare metal surfaces and renew exposed areas.
Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
Replace the GIW Oil and/or Storage Oil, if applicable.
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LCC [en-US]
3.2.3 Pump Parts Storage
CAUTION
All pump parts must be stored indoors. The only exception is for large castings such as pedestals, pump casings,
impellers, etc… See chart below for details.
Pedestal
Casing
Casing Half
Outdoor storage with monthly inspection permitted for these parts only
Liner
Plate Lay sub-bases flat and do not stack
Impeller
Sub-base
Shaft Sleeve
Lantern Ring Coat complete part with rust protector
Wear Plate
Shaft Coat complete part with rust protector and wrap with 6mil/0.15mm VCI (Vapor
Corrosion Inhibitor ) plastic
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LCC [en-US]
3.2.4 Removal from Storage
Remove rust from machined surfaces using a wire brush.
Remove rust inhibitor from all machined surfaces prior to installation/assembly.
Check the painted surfaces for any signs of corrosion or breaks in the coatings and touch-up as needed.
It is recommended that the bearing assembly be drained before shipment and refilled after relocation or installation.
If GIW Blue Oil with rotation was used and the pump is stored for less than 12 months, the same oil may be used for
initial commissioning and break in. Otherwise, it is recommended that the oil be replaced prior to commissioning to
remove any moisture.
If GIW Storage Oil was used, it should be drained and replaced with GIW Blue Oil before start-up.
For grease lubricated units, a fresh application of grease in the amount recommended by the maintenance manual for
a normal lubrication interval should be applied.
Stuffing Box should be checked before start-up and replaced if necessary. Packing may have dried out and need
multiple readjustments during the start-up process.
If the pump is fitted with a mechanical seal, motor, sheave, bushing, coupling, gear reducer, or other auxilarily
equipment be sure to consult the manufacturer’s maintenance manual for any additional storage removal and
commissioning instructions.Consult the Section 6 "Commissioning" before putting the pump into service.
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LCC [en-US]
WARNING
Actual safe lifting method will vary with pump configuration and type of lifting equipment
1 Alternate
2 DO NOT USE
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LCC [en-US]
4 Description
4.1 Technical Specification
This pump range is an international product and has been designed, in most respects, to the Metric system of units using
metric components. All sealing elements and fasteners are Metric and will require metric tooling. Please consult your
arrangement drawings and bills-of-material for details concerning your equipment.
Centrifugal pump for handling coarse or fine particles from solids-laden waste water to aggressive slurries of an abrasive or
corrosive nature. Applications include process pumping and tailings disposal for mining, dredging and other industrial operations.
4.2 Designation
Example Designation: LCC-M 300-710.5M C M1
Pump Type
Hydraulic Type
Discharge Nozzle (mm)
Nominal Impeller Diameter (mm)
Mechanical Size
Seal Type
Options
Material Code
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LCC [en-US]
4.3 Design Features
Horizontal, end suction, modified volute casing pump with 3-vane impeller for large solids passage. Available in interchangeable
elastomer, metal and extra-heavy designs.
WARNING
The addition of coarse solids, froth or cavitating conditions can significantly increase the noise levels in both the
pump and piping. If accurate noise levels are required for these conditions, field-testing will be required.
If running within the normal limits of operation and with clear water, the noise level for the pump alone (with gear box and motor
noises shielded) does not exceed 85 dB(A) at one meter.
Noise levels from motor and gear reducer must be added to the above in accordance with standard acoustic formulas, taking
into account the distance between units. For belt driven units, add an additional 2 dB.
4.5 Accessories
Couplings, pulleys, belts, motor mounts and/or base plates may be provided. Refer to the bill-of-materials, data sheets and/or
drawings for further information.
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Fxs Mys
Fys
12 300 3420 15230 2740 12180 5070 22560 5210 7070 5210 7070 7900 10710
14 350 3890 17300 3110 13830 5540 24640 5710 7740 5710 7740 8650 11730
16 400 4440 19760 3550 15790 6090 27100 6200 8410 6200 8410 9400 12750
18 450 5110 22750 4090 18190 6760 30090 6690 9070 6690 9070 10140 13750
20 500 5900 26240 4720 20990 7550 33580 7170 9730 7170 9730 10870 14740
22 550 6680 29730 5350 23790 8330 37070 7650 10380 7650 10380 11600 15720
24 600 7350 32720 5890 26190 9000 40060 8120 11020 8120 11020 12310 16700
26 650 7900 35170 6330 28150 9550 42510 8590 11650 8590 11650 13020 17660
30 750 8780 39090 7030 31260 10430 46430 9510 12900 9510 12900 14410 19540
36 900 9860 43890 7890 35090 11510 51230 10850 14710 10850 14710 16440 22290
38 950 10150 45170 8120 36150 11820 52580 11280 15300 11280 15300 17100 23190
3 75 3410 15180 1760 7840 1410 6270 4390 5960 2900 3930 2900 3930
4 100 3580 15930 1930 8590 1550 6890 4790 6500 3160 4290 3160 4290
6 150 3920 17450 2270 10110 1820 8090 5580 7570 3680 4990 3680 4990
8 200 4280 19040 2630 11700 2100 9340 6360 8620 4200 5690 4200 5690
10 250 4660 20730 3010 13390 2410 10710 7130 9670 4700 6380 4700 6380
12 300 5070 22560 3420 15230 2740 12180 7900 10710 5210 7070 5210 7070
14 350 5540 24640 3890 17300 3110 13830 8650 11730 5710 7740 5710 7740
SUCTION PIPE
16 400 6090 27100 4440 19760 3550 15790 9400 12750 6200 8410 6200 8410
18 450 6760 30090 5110 22750 4090 18190 10140 13750 6690 9070 6690 9070
20 500 7550 33580 5900 26240 4720 20990 10870 14740 7170 9730 7170 9730
22 550 8330 37070 6680 29730 5350 23790 11600 15720 7650 10380 7650 10380
24 600 9000 40060 7350 32720 5890 26190 12310 16700 8120 11020 8120 11020
26 650 9550 42510 7900 35170 6330 28150 13020 17660 8590 11650 8590 11650
28 700 10020 44590 8370 37250 6700 29800 13720 18600 9050 12280 9050 12280
30 750 10430 46430 8780 39090 7030 31260 14410 19540 9510 12900 9510 12900
34 850 11170 49710 9520 42370 7620 33890 15770 21390 10410 14110 10410 14110
36 900 11510 51230 9860 43890 7890 35090 16440 22290 10850 14710 10850 14710
38 950 11820 52580 10150 45170 8120 36150 17100 23190 11280 15300 11280 15300
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LCC [en-US]
5 Installation at Site
5.1 Safety Regulations
WARNING
Electrical equipment operated in hazardous locations must comply with the applicable explosion protection
regulations. This is indicated on the motor rating plate. If the equipment is installed in hazardous locations, the
applicable local explosion protection regulations and the regulations of the test certificate supplied with the
equipment and issued by the responsible approval authorities must be observed and complied with. The test
certificate must be kept close to the location of operation for easy access.
5.2 Foundation
WARNING
Appropriate personal protective equipment should be worn when handling concrete and grouting materials.
All structural work required must have been prepared in accordance with the dimensions stated in the dimension table /
installation plan.
The concrete foundation shall have sufficient strength for the pump and be completely cured before installation. The mounting
surface must be flat and level. Anchor bolts must be located according to the installation plan. This can be done when the
concrete is poured, or by drilling holes in existing foundations and grouting the bolts in place.
WARNING
Do not install the baseplate and pump on unpaved or unsupported foundations. Injury can result from vibration
or shifting equipment.
After placing the baseplate on the foundation, it must be leveled by shimming. Shims should be fitted between the baseplate
and the foundation itself; they should always be inserted to the left and right of the foundation bolts and in close proximity to
these bolts. For a bolt-to-bolt clearance of more than 800mm (30 inch), additional shims should be inserted halfway between
the adjoining holes. All shims must lie perfectly flush.
Insert the foundation bolts and set them into the foundation using concrete. When the mortar has set, tighten the foundation
bolts evenly and firmly and grout the baseplate using low shrinkage grout.
1 2 1
1 Shim
2 Foundation Bolts
3 ≤ 800 mm
5.3.1 Aligning the Pump / Drive Train for Horizontal Pump Application
WARNING
Use of the mounting bolts to close gaps between motor feet and the mounting plate (in place of
shimming) is not recommended and may result in twisting of the motor frame, "soft foot" mounting and
excessive vibration.
Care must be taken when removing drive components to avoid personal injury or damage to the
equipment. Avoid contact with hot surfaces such as couplings, which may heat up during normal
operation and cause injury.
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LCC [en-US]
CAUTION
All components must be level during system operation unless special provisions for bearing lubrication
and oil sealing have been made. After attaching the unit to the foundation and connecting the piping,
the pump and drive train must be thoroughly checked and, if necessary, realigned.
Improper alignment of the unit can cause damage to both the coupling and the unit itself.
Proper alignment must be taken into consideration when using an overhead motor mount accessory. Motor feet
must be firmly supported at each mounting bolt location before the bolts are tightened. Shims should be used to
fill any gaps and ensure solid mounting and vibration prevention.
For optimum performance, the pump should be mounted directly to the
baseplate without shims. The rest of the drive train is then aligned to the pump.
For this reason, GIW baseplate designs generally allow space for shimming
under the gear reducer and motor, but not under the pump itself. The only
exception occurs in cases where regular removal and replacement of the entire
pump is stipulated during the equipment design stage. In these cases, special 1
instructions for alignment and shimming of the pump may be given on the pump
assembly and/or general arrangement drawings.
Checks and realignment must be done even if pump and motor are supplied
completely assembled and aligned on a common base plate. The correct
distance between the coupling halves and pulleys as specified in the
installation plan must be observed.
The pump set is correctly aligned if a straightedge placed axially on both
coupling halves is the same distance from each shaft at all points around the
circumference. In addition, the distance between the two coupling halves must
remain the same all around the circumference. Use a feeler gauge, a wedge
gauge or a dial micrometer to verify.
2
The radial and axial deviation (tolerance) between the two coupling halves
should not exceed 0.1 mm (0.004 inch). V-belt Pulley Alignment
Ensure that coupling gaps are properly set in the case of motors with sleeve
bearings. 1 Align
For V-belt installations, the pulleys are correctly aligned if a straightedge placed 2 Maximum 1mm
vertically shows a deviation of no more than 1.0 mm (0.04 inch). Both pulleys 3 Straight Edge
must be parallel. 4 Gauge
WARNING
The volute casing and shaft seal take on roughly the same temperature as the medium handled.
The shaft seal seal, bearing assembly and bearing housing must not be insulated.
Take the necessary precautions to avoid burns to personnel and adjacent equipment.
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LCC [en-US]
5.4 Connecting the Piping
WARNING
CAUTION
Never use the pump itself as an anchorage point for the piping.
Permissible forces and moments must not be exceeded (see to section 4.7).
Refer to your drawing for spool piece recommendation to ease maintenance.
Thermal expansions of the pipelines must be compensated by appropriate measures so as not to impose any extra
loads on the pump exceeding the permissible pipeline forces and moments.
An excessive, impermissible increase in the pipeline forces may cause leaks on the pump where the medium handled
can escape into the atmosphere.
The flange covers on the pump suction and discharge nozzles must be removed prior to installation in the piping.
CAUTION
These connections are required for proper functioning of the pump and are therefore of vital importance!
The dimensions and locations of the auxiliary connections (cooling, heating, sealing liquid, flushing liquid, etc.)
are indicated on the installation plan or piping layout.
WARNING
In compliance with the accident prevention regulations the pump must not be operated without coupling and
drive guards. If the customer specifically requests not to include guards in our delivery, then the operator must
supply them.
WARNING
A trained electrician must make the connection to the power supply. Check available main voltage
against the data on the motor rating plate and select the appropriate start-up method. The use of a
motor protection device is strongly recommended.
An emergency shut off switch should be installed to prevent damage to the personnel and environment
in the event of hazardous pump operation.
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LCC [en-US]
6 Commissioning / Operation
CAUTION
Compliance with the following requirements is of paramount importance. Damage resulting from non-compliance
shall not be covered by the scope of warranty. This manual applies to single stage pumps. Procedures for
multistage pumps should be obtained from the GIW/KSB sales office.
WARNING
Before starting up the pump make sure that the following requirements are checked and fulfilled:
1) If the pump has been in long term storage (more than 3 months), ensure proper storage procedures were
followed, including instructions for removing the pumps from storage (see contract documents and/or
contact your GIW / KSB representative). Failure to follow proper storage procedures will void your warranty.
See Section 3.2 "Storage Requirements".
2) For elastomer lined pumps ensure that the piping has been installed and the torqueing of the piping bolts
has been completed. For all metal pumps this step may be completed during Step 5.
3) The impeller nose clearance has been properly set.
See Section 10.4 "Setting Impeller Nose Gap" for details.
4) Pump drive train final alignment is complete.
See Section 5.3.1 "Alignment" for details.
5) Final torquing of all bolts has been completed.
See Section 11.1 "General Torque" for details.
6) All electrical and power supply connections are in order, including fuses and overload protection devices.
See Section 5.1 "Safety Regulations" for details.
7) All required auxiliary connections, such as shaft seal water, oil coolers, etc. are made, tested and ready to
function.
See Section 5.4.1 "Auxillary Connection" for details.
8) All safety guards and equipment are in place.
See Section 5.5 "Safety Guards" for details.
9) Any required instrumentation has been properly installed.
See Section 5.6 "Oil Temperature Monitoring" for details on RTD installation.
10) Bearing assembly lubrication is completed.
See Section 6.1.1 "Bearing Lubrication" for details.
11) Shaft seal is ready for operation.
See Section 6.1.2 "Shaft Seal Commissioning" for details.
12) Drive train direction of rotation at the pump is correct.
See Section 6.1.3 "Checking the Direction of Rotation" for details.
13) The pump set is primed.
See Section 6.2.1. "Priming the Pump"
14) The desired operating conditions do not exceed those allowed by the pump.
See Section 6.4 "Operating Limits" for details.
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LCC [en-US]
Use high-quality lithium-soap grease, free of resin and acid, not liable to crumble and with good rust-preventive
characteristics.
Oil-lubricated bearings
CAUTION
Pump bearing units are shipped empty of oil. Before starting the pump, fill them to the center of the oil level sight
gauge using the GIW Blue 150 synthetic bearing oil supplied with the unit. For vertical pumps, fill the oil reservoir.
If locally obtained oil is desired, use an equivalent synthetic or a high quality ISO220 or 320 mineral oil suitable for use
with heavy industrial equipment, anti-friction bearings and oil circulating systems. Such oil typically has high
temperature stability, resistance to oxidation and foaming, and inhibits rust, corrosion, and the formation of deposits.
Oils with EP (Extreme Pressure) additives are not generally recommended. Detailed bearing oil specifications and GIW
Blue replacement oil are available from GIW.
Oil operating temperatures for GIW bearing assemblies will depend on pump size, speed and ambient conditions.
Under typical conditions, they will run from 50 °C – 85 °C (125 °F – 185°F). For oil temperatures above 85 °C (185 °F)
or for severe load conditions, a high quality synthetic lubricant (such as GIW Blue) should be used. At higher speeds,
or in hotter ambient conditions, temperatures can rise to 100 °C (210 °F). Slightly higher temperatures may be seen for
a brief period during the breaking in of new bearings. The unit should be shut down immediately if temperatures rise to
120 °C (250 °F).
Do not overfill the bearing assembly. The capacities listed are approximate. When filling the bearing housing, the oil
level must be at the centerline of the oil level sight glass when the shaft is not turning. This is the ”cold level” and will
change as the pump runs and the oil becomes suspended in the bearings.
The oil should be initially drained after 50 to 100 hours operation. Before refilling, the bearings should be flushed by
filling the bearing housing with a lightweight oil, turning the pump shaft several rotations, and then draining. This should
be repeated until the flushed oil appears clean.
Bearing assemblies for use underwater should be completely filled with oil and slightly pressurized by an oil recirculation
and filtering system. As a result, their capacities will be several times greater than shown above and a thinner oil will
be required. Depending upon the water temperature at the location at which the pumps are operating, the ISO viscosity
grade should be altered as follows for mineral oil-based lubricants. See Section 6.5 for more details on Underwater
Pump Operation.
Mechanical seals require safety checks prior to start-up such as removing seal assembly fixtures, checking axial
alignment, checking torques etc. Refer to the mechanical seal operating manual for all required safety checks.
Mechanical seals are precision devices which require special care for their proper operation. The instruction manual
for the seal should be consulted for special storage, start-up, and maintenance requirements.
If the pump is equipped with a deaeration chamber (HVF), the mechanical seal must be of the double faced type with
barrier fluid. This will prevent dry running and seal face destruction.
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Stuffing Box Commissioning
Prior to commissioning, the gland packing supplied with the pump must be adjusted. Preformed packing rings sets from
GIW / KSB are recommended. For alternate brands, refer to packing manufacturer’s instructions regarding installation
and use.
For gland flush supply, use suitable non-aggressive clean water not liable to form deposits and not containing
suspended solids. Hardness should average 5 with a pH>8. It should be conditioned and neutral with regards to
mechanical corrosion.
An Inlet Temperature of 10 °C – 30 °C (50 °F – 85 °F) should produce a maximum Outlet Temperature 45 °C (115 °F)
when the gland is properly adjusted.
CAUTION
If motive power is applied to the pump, and it is run in the wrong direction of rotation, even momentarily, the
impeller may unscrew causing extensive damage to the entire unit. This is especially important during initial
start-up as the impeller may not be fully torqued onto the pump shaft.
The impeller must rotate in the correct direction of rotation. This must be verified by briefly running the motor with the coupling
or belt drive disconnected. If the motor runs in the wrong direction of rotation, have it corrected and verify direction of rotation
before reconnecting coupling or belts.
If a Variable Frequency Drive (VFD) or other controller is used, it is recommended to permanently disable REVERSE and BRAKE
function during controller set up.
WARNING
Cleaning operations for flushing and pickling service must be matched to the casing and seal materials used.
Any chemicals or high temperatures used must be compatible with all pump parts.
6.2 Start-up
WARNING
Start-up, shutdown, filling and draining procedures must be designed to prevent any possibility of negative
torque being experienced on the pump shaft. Negative torque can cause the impeller to unscrew, leading to
severe damage throughout the rotating assembly and drive train. In particular, the following practices must be
avoided:
1) Any flow through the idle pump, in any direction, in excess of 5% of the normal operating flow rate before
the impeller has been tightened by running under normal loads. This includes flow due to filling or draining
of the system and/or flow caused by the equalization of different levels between the sump and discharge
line after the opening of any valves in the piping.
2) Any attempt to restrict the flow after shutdown, by either manual or automatic systems, until the pump
comes to a complete standstill.
3) Any braking or re-energizing of the drive train after shutdown, until the system has reached a complete
static condition.
Prolonged operation at zero or low flow, typically due to closed valve or unintended pipeline blockage, is not
permitted. Danger of steam generation and explosion.
Start-up and shutdown procedures must be designed to prevent any possibility of water hammer. Water hammer
can place excessive loads on the piping, resulting in damage to the pump flanges. The pressure waves
generated by water hammer can also cause damage to the pressure containing components of the pump, the
mechanical end and/or the mechanical seal.
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CAUTION
During the initial commissioning, once the pump and bearing assembly stabilize at normal operating
temperature, or in the event of system leaks, stop the unit and re-tighten all bolts. Check the coupling alignment
and re-align if necessary.
Before starting the pump verify that the shut-off element in the suction line is fully open.
The pump may be started up against a closed discharge shut-off element. Once the pump has reached full rotational
speed, open the discharge valve slowly and adjusted to the duty point.
When starting up against an open discharge-side shut-off element, take the resulting increase in input power
requirements into account.
WARNING
The pump should never be run dry and air intake must be minimized using proper sump design. May result in
excess temperatures and escape of medium into the atmosphere due to shaft seal failure.
Before start-up, the pump, suction line and (if applicable) the tank must be vented and primed with the liquid to be pumped. Any
valve in the suction line must be fully open. Open all auxiliary connections (flushing, sealing, cooling liquid, etc.) and check the
through flow.
6.3 Shutdown
CAUTION
Pipe system design and pump operation should prevent damage to the pump during a scheduled or
emergency shutdown.
In the event of shutdown where a significant static discharge head exists in the system, the impeller
can begin to run back-wards as the flow reverses in the pipeline. This creates a positive torque on the
shaft so the impeller connection will not unscrew. Until the flow stops, do not close any main line valves.
A change in fluid velocity can create a negative torque on the impeller and unscrew it from the shaft.
This can damage wet end pump parts as well as bearings, seals and other components.
Under no circumstances should the pipe system be equipped with a check valve or other device that can rapidly
decelerate the flow rate.
Switch off the drive, making sure that the unit runs smoothly down to a complete stop. Variable Frequency Drive (VFD)
and other controllers must not use any braking function to slow the pump. Diesel power trains should disengage the
clutch and allow the pump to coast to a stop.
Close any auxiliary connections. Pressurized bearing lubrication systems must remain running until all rotation has
stopped. If the any part of the system uses a cooling liquid supply, turn that off only after the pump has cooled down.
Where liquid filled shaft seals are used, consult seal maintenance manual for specific shutdown procedures.
Where temperatures may drop below freezing, the pump and system must be drained or otherwise protected against
freezing.
If the pump is equiped with an deaeration chamber (HVF) the following steps may be taken to reduce the amount of
fluid in the vent pipe and hose:
o Reduce suction pressure to 10kPa / 1.5 psig by lowering the sump level
o Close the vent valve to stop slurry from re-entering the vent hose
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6.4 Operating Limits
WARNING
The pump / unit application limits (speed, minimum and maximum flow, head, fluid density, particle size,
temperature, pH, chloride content, etc…) as stated on the data sheet must be observed. Failure to do so may
result in power overload, excessive vibration, overheating, and/or excessive corrosion or wear. If a data sheet
is not available, contact your GIW / KSB representative.
CAUTION
Any make up water or outside water supply for the system must be installed so that the GIW pump will never be
exposed to a pressure in excess of its maximum allowable operating pressure.
CAUTION
Do not operate the pump at temperatures exceeding those specified on the data sheet or the nameplate unless
the written permission of the manufacturer has been obtained.
Damage resulting from disregarding this warning will not be covered by the manufacturer’s warranty.
Bearing temperatures must be observed. Excessive bearing temperature could indicate misalignment or other technical
problem.
This tank keeps a positive pressure on the bearing side of the Duo-Cone seals to counteract the water pressure as the pump is
submerged. The tank should be mounted high enough to maintain a pressure of about 48 kPa (7 psi) above what is created by
the maximum water depth. Note that the specific gravity of oil is only about 85% of water and must be taken into account when
calculating the mounting height of the tank.
The tank should have an oil level indicator to allow the operator to see if the level changes. After the oil temperature stabilizes,
the level should remain constant and any significant change would indicate a leaking seal. This early warning can prevent oil
from leaking into the surrounding water and avoid bearing failure.
Dredge pumps are designed to run with the UCBA and Duo-Cone seals fully submerged. This enables the surrounding water to
dissipate heat generated by the bearings and seal faces. If the pump will be operated above the water line for extended periods,
the bearings can create extra heat in the oil and the seal faces may overheat. Provisions should be made to provide a supply of
cooling water to each Duo-Cone seal and a water spray onto the UCBA itself. If the pump will run continuously above water,
other sealing systems are recommended, or oil circulating and seal cooling systems will be required.
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LCC [en-US]
Care should be taken to operate the pump within the speed limitations specified by GIW on the pump drawing for the particular
seal size installed. If a seal is replaced, it must be installed with the correct gap (specified by GIW for each seal size) between
the seal holders, as this distance provides the correct seal face pressure for proper operation.
Failure to operate the seals within the above parameters may result in premature seal failure or oil leakage through the Duo-
Cone seals. Any change in the operating conditions should be discussed with your GIW / KSB representative to establish if the
new conditions are suitable for the equipment.
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LCC [en-US]
7 Maintenance
WARNING
Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump.
WARNING
Operational procedures which may cause system water hammer must be avoided. Sudden and
catastrophic failure of pump casing and plates may result.
Prolonged operation against a closed shut-off element is not permitted. Danger of steam generation
and explosion!
CAUTION
Neglect of maintenance procedures and monitoring can result in failure and leakage of the shaft seal,
bearing seals, and wear components.
The pump should run quietly and free from vibrations at all times. Unusual noise or vibration should be
investigated and corrected immediately.
If the flexible coupling elements begin to show signs of wear, they should be replaced.
When running the pump against a closed discharge-side shut-off element for a short period, the permissible pressure
and temperature values must not be exceeded.
Verify the oil level is correct.
The gland packing (if the pump is fitted with one) should drip slightly during operation. The gland should only be gently
tightened.
Any stand-by pumps installed should be switched on and off again as described in Section 6.3.1 "Measures to be taken
for Prolonged Shutdown".
CAUTION
If the pump was used for handling liquids posing health hazards, see to it that there is no risk to persons or the
environment when draining the medium. All relevant laws, local codes, and safety procedures must be heeded.
If required, wear safety clothing and a protective mask.
If the media handled by the pumps leaves residues which might lead to corrosion when coming into contact with atmospheric
humidity, or which might ignite when coming into contact with oxygen, the unit must be flushed thoroughly and neutralized.
The flushing liquid used and any liquid residues in the pump must be properly collected and disposed of without posing any risk
to persons or the environment.
Oil Changes
Refer to Section 6.1.1 "Bearing Lubrication" for bearing oil change instructions, specifications & capacities.
The first oil change should be carried out after 300 operating hours, then every 3000 hours thereafter or when it appears
or is suspected of being dirty or contaminated.
Drain the existing oil by removing the drain plug on the bottom of the housing.
Reinstall the drain plug and fill with fresh oil until the oil level reaches the center of the oil sight gauge.
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LCC [en-US]
Grease Changes
Refer to Section 6.1.1 "Bearing Lubrication" for bearing grease change instructions, specifications & capacities.
Grease lubricated bearings should be replenished after the initial 50 hours of operation, then every 1,500 hours
thereafter by an injection roughly equal to one half of the amount originally used to pack the bearings.
After 20,000 operating hours or 2.5 years the bearings should be checked, then cleaned and relubricated if required.
For more information on Underwater Bearing Assemblies see Section 6.5 "Underwater Pump Operation"
Suction Liner
The suction liner should be rotated 180° at approximately half life if localized wear occurs. If localized wear is severe,
repair as recommended by GIW / KSB before rotation.
If applicable, a new snap ring gasket or o-ring should always be used with a new suction liner or new pump casing.
Impeller
The impeller to suction liner clearance should be adjusted forward several times during its life cycle for maximum
impeller and suction liner life. See Section 10.4 "Setting the Nose Gap".
In general, an impeller does not require replacement until it fails to produce sufficient head for the application. Impellers
are sometimes changed too soon based on appearance. Vibration caused by an impeller wearing out of balance is rare
but possible. If this occurs, the impeller may be statically balanced by hand grinding on back shroud.
The impeller should never be repaired by welding.
Pump Casing
If wear is localized with a deep gouge, repair or replace as recommended by GIW / KSB. Excessive wear problems are
usually indications that the pump is not operating at the flow and head conditions originally specified for the design.
Expeller Maintenance
Proper adjustment of the impeller nose clearance as covered in the Section 10.4 "Setting the Nose Gap" should result
in proper expeller clearances in the new condition and no further adjustments should be necessary. In some cases
adjusting the impeller after excessive suction liner wear may result in the expeller rubbing against the expeller plate. In
other cases it is desired to optimize expeller performance rather than optimize the impeller clearance. Refer to Section
9.3.3 "Expeller Running Clearance" for instructions.
CAUTION
Optimizing the expeller clearances is recommended only in cases where expeller performance is marginal and
a small increment in performance is required to seal against the pump pressure. Setting of clearances for optimal
expeller performance may result in excessive impeller clearance and accelerated wear. If necessary, this may
be remedied by providing a custom fitted machined spacer with gaskets between the impeller and expeller.
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LCC [en-US]
Sump design should prevent the formation of a vortex, or other means of introducing air into the pump. Where a
submerged suction is available, the depth of water level above the pump suction is more important than the cross-
sectional area of the sump. Frothing of the sump should be eliminated by the installation of baffles, a submerged inlet
pipe or other methods to prevent air becoming entrained in the slurry. If unavoidable, frothing must be accounted for in
the system design and operation.
If the sump runs dry, the system will surge causing accelerated pump wear. Pump speed or impeller diameter should
be decreased or make up water increased. If the flow variations are too great, a variable speed motor may be required.
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LCC [en-US]
In the event problems are encountered, contact your GIW / KSB representative. The pump serial number, in addition
to the following, should be furnished to assist in evaluation of the problem:
o Pump serial number (from the nameplate on the pedestal or bearing housing), customer location, and the
approximate startup date.
o Pumped fluid SG (specific gravity), slurry information including SG and particle size, and liquid temperature.
o The approximate flow rate desired and the actual minimum and maximum flow rate of the system if known.
o The system static head (the difference in elevation between the water level on the suction side of the pump
and the point of discharge)
o The length and size of suction and discharge lines, including a description of the general arrangement
including fittings, bends and valves
o If the discharge point is not to atmosphere, what is the pressure, (e.g. cyclone backpressure).
o If suction is taken from a sump, provide the general arrangement including size dimensions and minimum and
maximum sump levels referenced to the suction centerline of the pump.
o The available driver horsepower, speed of motor and pump or description of the ratio device between the
pump and motor.
o The impeller diameter if different from that supplied with the pump.
The above items of data are especially important when a pump has been transferred from the duty for which it was
selected to some other application.
In many instances, it will be found that unusual wear in the pump, or low efficiencies, are caused by a mismatch between
the pump and the system application and can be corrected once the operating conditions are known.
Contact your GIW / KSB representative for further specific recommendations regarding system design. A useful
reference and textbook has also been published by GIW titled: "Slurry Transport Using Centrifugal Pumps", by Wilson,
Addie & Clift.
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8 Mechanical End
8.1 Mechanical End Overview
The bearing assembly is a cartridge design mounted on a concentric pedestal with an adjustment mechanism for setting
the impeller axial clearance.
Standard lubrication is grease. Oil lube is also available. See Section 6.1.1 "Bearing Lubrication" for lubrication quality
and quantity.
Basic bearing parts are listed below for reference. Note that the suffix can vary depending on configuration and vendor.
Replacement bearings are available from GIW/KSB.
Bearings Installed
Double Row Taper Roller - Back to Back Double Row Taper Roller - Face to Face
Bearing Spherical
Part number
Assembly Roller Bench End-Play Part number Bench End-Play
(TIMKEN)
(SKF)
E Type Cone / Cup / Spacer * mm inch mm inch
53177
35 mm 22209E 53376D 0.15 0.006 31309 J2/QCL7CDF 0.10 0.004
X2S53176
72225C
50 mm 22212E 72488D 0.15 0.006 31312 J2/QDF 0.12 0.005
X1S72225
9285
70 mm 22217E 9220D 0.18 0.007 31316 J1/QLC7CDF 0.14 0.006
X4S9285
HM926740
100 mm 22224E HM926710CD 0.25 0.010 31322 XJ2/DF 0.16 0.006
HM92674XA
HH932145
125 mm 22230E HH932110 0.20 0.008 31328 XJ2/DF 0.19 0.008
H932145XA**
* Koyo is also an approved supplier for the Back to Back Taper roller bearing.
** Assembled from two single row bearings.
WARNING
Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump.
Drain the oil (if applicable) by removing the drain plug on the bottom of the housing.
Remove the flingers (if any) and bearing housing end covers. Care should be taken with the Inpro oil seals, which
should not be removed from the end covers unless they have been damaged and are in need of replacement. Inspect
the seals, gaskets, and o-rings, and discard any that appear worn or broken.
The locknut and lock washer that clamp the drive side bearing should also be removed. One tab of the lock washer will
be bent into a recess on the lock ring and must be bent back to allow the lock nut to be unscrewed.
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LCC [en-US]
The shaft and bearings (which are pressed onto the shaft) may then be removed as a unit from the drive end of the
housing. Horizontal disassembly is acceptable when proper support is given to the shaft to prevent its contacting and
marring any of the finished surfaces of the shaft or bearing housing bore. Care should be taken to avoid damaging the
grease retaining ring (part 63-7, grease lubricated) or spacer ring (part 45-4, oil lubricated) that will come out on the
shaft between the two bearings.
The bearings are hot when installed on the shaft, and fit tight. It is difficult to remove them from the shaft undamaged,
and they should be removed only if a bearing needs to be replaced. Bearings are normally removed by heating, which
should be done quickly to prevent heating of the shaft as well. Flame cutting of the outer race and careful grinding of
the inner race may occasionally be required. Care must be taken, however, to avoid damaging the shaft, especially in
the oil seal area.
WARNING
Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump.
CAUTION
Before assembly, thoroughly clean all shaft, housing bore, and end cover surfaces with a suitable solvent to
remove old grease and any water, dust or grit. Clean all dismantled components and check them for signs of
wear. Damaged or worn components are to be replaced by original equipment spare parts. Make sure that the
seal faces are clean and the O-rings and gaskets are properly fitted.
WARNING
Heat radial bearing (322) to 120 °C (250 °F) by a suitable bearing heater, oil bath, or other even heating device prior
to mounting. Flame heating is not recommended.
Install radial bearing onto shaft
Press fit bearing ensuring that it is seated fully against the abutting shaft shoulder.
Use the bearing assembly drawing to determine if the bearing assembly uses the face to face or back to back taper
bearing arrangement and procede to the appropirate section. Refer to the table below for Bearing Locknut torque values
when needed.
1
2 1 2
1 Outboard Side
6 2 Inboard Side
3 Cup
3 4 Roller
7 3
5 Cone
4 4 6 Spacer
6
7 Grease Retainer Ring
5 5
Back to Back Taper Roller Bearing Face to Face Taper Roller Bearing
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LCC [en-US]
CAUTION
The grease retaining ring (63-7, for grease lubrication) or spacer ring (45-4, for oil lubrication) must be placed
on the shaft between the bearings, and in the proper orientation, before both bearings are mounted. Once the
bearings are mounted, they cannot be removed without risk of damage. The grease ring is essential in protecting
the taper bearing from loss of lubrication in the event of high loadings. Failure to install the ring may result in
significantly reduced bearing life.
Heat inboard cone to 120 °C (250 °F) and install. Ensure that the larger OD of the bearing is towards the center of the
shaft.
Install spacer and bearing cup
CAUTION
Over-tightening can damage the lock washer and allow the locknut to back off during operation.
Do not back off the locknut any amount after tightening in an attempt to set the bearing clearances.
The taper bearing has an internal spacer, which automatically sets the internal bearing clearances.
Failure to bend down one of the lock washer tabs may allow the locknut to back-off and lead to
premature bearing failure.
Ensure that the bearing outer diameters and housing bores are clean. Coat shaft between the bearings with GIW Blue
Synthetic Bearing Lubricant.
Lift shaft vertically and place into housing from drive end. It will be necessary to align the grease ring 63-7 or spacer
45-4 as it enters the housing since it has about 6mm (0.25") of clearance with the shaft.
CAUTION
The bearings should slide easily and fully into the bearing housing without excessive force that would indicate
possible dust or grit between the bearings and the housing, and result in a thrust preloading on the impeller end
spherical roller bearing. Preloading of the bearing will cause it to carry thrust loadings, which would normally be
carried by the taper roller bearing and can result in overheating and premature failure of the spherical roller
bearing.
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After both cones are installed and before the taper roller bearing has cooled on the shaft, use the lock nut without lock
washer to fully seat the bearing against the shaft shoulder (the lock washer must be left out during this step to prevent
damage).
After the bearings have cooled, remove the locknut and reinstall with lock washer against the taper roller bearing,
tightening the nut according to the torque given in Section 8.3.1 "Mounting the Bearings".
After tightening, bend down one tab of the lock washer into one of the mating grooves on the locknut. If none of the
tabs are aligned with a groove, locate the nearest one, and further tighten the locknut until the tab can be bent down.
CAUTION
Over-tightening can damage the lock washer and allow the locknut to back off during operation.
Do not back off the locknut any amount after tightening in an attempt to set the bearing clearances.
The taper bearing has an internal spacer, which automatically sets the internal bearing clearances.
Failure to bend down one of the lock washer tabs may allow the locknut to back-off and lead to
premature bearing failure.
Ensure that the bearing outer diameters and housing bores are clean. Coat shaft between the bearings with GIW Blue
Synthetic Bearing Lubricant then lift shaft vertically and place into housing from drive end.
Insert the spacer and cup for the outboard bearing using a rubber mallet.
CAUTION
The bearings should slide easily and fully into the bearing housing without excessive force that would indicate
possible dust or grit between the bearings and the housing, and result in a thrust preloading on the impeller end
spherical roller bearing. Preloading of the bearing will cause it to carry thrust loadings, which would normally be
carried by the taper roller bearing and can result in overheating and premature failure of the spherical roller
bearing.
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LCC [en-US]
Bearing Assembly inserted into Housing Drive End Use a rubber mallet to ease insertion
Install with lubrication return trough at 6 o’clock position VBX Inpro Seal
Slide end covers with gaskets and Inpro seals over the shaft at each end, again making certain that the contaminant
expulsion port and lubrication return trough are located at the bottom. Use O-Ring lubricant, Parker O-Lube or Parker
Super-O-Lube to lubricate the inner diameter o-rings against the shaft. Take special care when running the seal over
the shaft keyway to avoid cutting the o-ring. If necessary, lightly file the keyway edges to avoid this problem.
After bolting the end covers in place, rotate the shaft by hand. There should be no frictional contact between the rotating
and stationary parts of the Inpro seal. Any rubbing or axial movement in the seal may indicate misalignment. If this is
the case, tap lightly into alignment. Note that the drive side end cover clamps against the outer race of the taper roller
bearing and may not fit flush against the housing. No shimming is necessary. A gap of up to 1 mm (0.04”) is acceptable
and within the tolerance of the parts. Any larger gap may indicate that the taper roller bearing is not fully seated into
the housing.
Install grease fittings or oil plugs.
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The four bearing housing hold down clamps (732) may now be bolted on, but should remain slightly loose until the axial
adjustment of the bearing housing is complete.
Fastener torque must be accurately measured to achieve the proper clamping force. Air impact wrenches rarely deliver
the correct torque due to variations in air pressure and tool condition. These can be used to tighten the bolts, but the
final torque values should be achieved with a calibrated torque wrench. The use of a Hydraulic Torque Wrench is
recommended for larger fasteners, and these tools can be calibrated to produce the necessary accuracy.
WARNING
Failure to install the bearing housing hold down bolts at this time may result in tipping of the bearing assembly
and possibly personal injury when the impeller is screwed on to the shaft.
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LCC [en-US]
9 Shaft Seal
9.1 Mechanical Seal
CAUTION
Mechanical seals are precision devices which require special care for their proper
operation. The instruction manual for the seal should be consulted for special
storage, start-up, and maintenance requirements.
Always refer to the mechanical seal maintenance manual for further instructions.
1 1 1
1
2 3 3
1 Packing
2 Throat Bushing
3 Lantern Ring
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LCC [en-US]
9.2.1 Stuffing Box Packing
Stuffing box packing is the actual sealing element in most stuffing box assemblies. It experiences considerable friction and will
have a limited lifespan. Proper maintenance procedures are essential to avoid premature failure, wear and corrosion to nearby
parts, mechanical end contamination and unnecessary downtime. The following provides an introduction to packing basics.
Refer to your GIW Pump Maintenance Manual, GIW / KSB representative and/or packing supplier for further detail.
The packing type must be compatible with your pumping application. This includes pressure, temperature, pH and solids content.
Seal water quality can also affect packing selection. Refer to your Bill of Materials for the packing type supplied with your pump
or contact your GIW / KSB representative if a change in packing type is needed.
CAUTION
Failure to center the stuffing box may result in greatly reduced service life for the packing and shaft sleeve.
The stuffing box should be mounted so that the sealing water tap is on or near the horizontal centerline. This will position the
gland studs at 9 o’clock and 3 o’clock for easy access on smaller shaft sizes. Note that the small stuffing boxes have a single
inlet while the larger sizes have a second port that can be used for additional flow or have a pipe plug installed.
Clearance is provided between the stuffing box rabbet fit and the pedestal to allow centering of the stuffing box to the shaft
sleeve. During installation, the packing space should be equalized to within 0.25 mm (.010") at all locations before fully tightening
the stuffing box flange bolts.
In some cases, a separate stuffing box wear plate may be provided. This should be fastened into place with a fresh gasket.
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LCC [en-US]
Forward Flush and Throat Bushing stuffing boxes are generally pressure controlled, but flow control is an option. Seal
water requirements listed in the table show potential flow with worn packing.
Flow control may be achieved in different ways. A Positive Displacement pump that delivers the correct volume can be
used with a safety or “pop-off” valve so the purge pressure can never exceed 10 psi (0.7bar) above the Maximum
Working Pressure of the pump. Where water supply is adequate, install a flow meter and regulating valves in the line.
A backflow preventer is recommended to prevent reverse flow should the pump pressure exceed supply pressure. All
components must have adequate pressure ratings. Verify that components will work with the volume, pressure and
water quality supplied to the stuffing box.
For best performance each pump should be adjusted for minimum water consumption while still providing adequate
drip rate. As the volume of water is reduced, the stuffing box gland will need to be loosened slightly to maintain the
proper drip rate. This will ensure adequate flush while limiting water use. The temperature of the water exiting the
stuffing box can be a better indicator than “drip rate” or volume. This should be at a temperature that would be
comfortable for hand washing which indicates that the packing is not overheated.
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LCC [en-US]
When the stuffing box does not have flush water, the packing must be lubricated with grease or oil. Graphite packing such as
Tuf-Pak 400 is recommended. Manual or automatic grease dispensers are available depending on the application. Twisting the
cap in on the manual units will add a small amount of grease to the packing. These are refilled by removing the cap and packing
the cup with lubricant. Automatic greasers use a spring driven piston to maintain a steady supply of grease. These are refilled
by connecting a grease gun to the fitting on the side of the unit. Note that extremes in temperature can alter the amount of
lubricant supplied to the packing and must be accounted for. Springs are available for the automatic greaser with three different
tension levels to control the flow of grease.
New expeller pumps are equipped with a diverter ring pressed into the hub area of the pump casing. This acts as a baffle to help
reduce the amount of solids entering the seal chamber. The diverter can be ordered as a service part and retrofit into earlier
units. For diverter installation see supplement 11.4.
It is important to operate the expeller pump within the speed limitations and operating conditions specified in the original design
parameters. Wide variations in flow rate and solids can allow particles to accumulate in the expeller chamber, which may result
in a plugging or premature component failure. Any change in the operating conditions should be discussed with your GIW / KSB
representative to establish if the new conditions are suitable for the equipment.
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LCC [en-US]
9.3.1 Expeller Assembly
WARNING
If attempt is made to mount the expeller plate without the support of the pump casing or expeller casing studs,
it will not be properly supported and may fall without warning.
WARNING
If not removed in the manner described below, the expeller plate may fall without warning after the pump casing
is removed.
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LCC [en-US]
Removing the Expeller
Before removing the expeller, ensure that the 2 bolts in the 3 & 9 o’clock positions (901.13) that secure the expeller
casing (10-7) to the pump pedestal have not been removed.
For 2x3 and 3x4 LCC-M, use two of the holes left open and two spare bolts (not included) to secure the expeller casing
(10-7) to the pump pedestal.
If not secured in the above manner, the expeller casing may fall without warning after the expeller is removed.
The expeller (23-15) may now be removed from the shaft. The fit of this part is similar to that of a shaft sleeve (a close
sliding fit). If necessary, the expeller casing may be unfastened from the pedestal, supported as needed and used to
apply pressure to the expeller in order to force it from the shaft. This pressure must be applied at several points around
the expeller casing to prevent uneven loading and potential breakage of the hard iron parts.
With the suction plate/liner removed, adjust the bearing assembly toward the pump end until the back surface of the
expeller just begins to rub the expeller plate.
Mount a dial gauge to indicate cartridge bearing assembly axial movement and zero the dial gauge at this location.
Now adjust the bearing assembly toward the drive (or motor) end until the expeller vanes just begin to rub on the
expeller casing, or the impeller begins to rub on the hub side of the pump casing, whichever comes first.
Adjust the bearing assembly toward the pump end again approximately 1.0 mm (0.04 in.) to provide a minimal expeller
running clearance. If optimization of expeller performance is desired, lock the adjustment at this location.
Reassemble the suction plate and check the impeller to liner clearance. If not optimizing expeller clearances set the
impeller clearance as detailed in the section "Axial Adjustment of the Bearing Housing". Do not allow the dial gauge to
come closer than 1.0 mm (0.04 in.) to the original zero setting or expeller rubbing may occur. If necessary, consider
the use of a spacer as mentioned in step 4.
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LCC [en-US]
10 Wet End
10.1 Wet End Overview
Three standard configurations are available:
1) Hard Metal. Single-wall casing, impeller and suction liner of high-chrome white iron. Suitable for high-discharge head,
all particle sizes up to maximum sphere passage and mildly corrosive slurries. Custom materials available for highly
corrosive slurries.
2) Elastomer Lined. Radially split construction with ductile iron outer casing and molded-elastomer inner liners. Impeller
of high chrome white iron or polyurethane. For moderate discharge head, fine to medium particles and highly corrosive
slurries.
3) Extra Heavy Hard Metal. Similar to hard metal version, but with heavier sections and hydraulics suited to the most
severe slurry duties. Two-stage pressure capability. Available in sizes LCC 150 - 500 and above.
All casings carry 125 pound, ANSI flange bolting patterns. Adapters for conversion to DIN flanges are available.
All standard impellers are 3 vane, double shrouded designs. Open-shrouded and alternate vane number designs are available
in some sizes.
WARNING
Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump.
DANGER
Do not apply heat to the impeller hub or nose due to the sealed cavity at the impeller nose.
DANGER OF EXPLOSION!
42
LCC [en-US]
10.2.2 Impeller Break-Loose Device
WARNING 1 Impeller
2 Break-Loose Device
Energy can be released during disassembly of the tightened
Impeller. Break loose devices, lifting devices and Impeller release
rings could spring suddenly and injure nearby personnel. 1
2
Rotate the impeller until the tip of one blade is facing the pump discharge.
Insert the break loose device through the eye of the impeller and attach
to trailing edge of blade facing discharge.
Rotate the shaft in the direction opposite to normal, using the pump pulley
or a spanner wrench.
For ease of impeller removal, the shaft threads should be heavily coated
with anti-seize compound during re-assembly. Two aramid paper gaskets
should be used between the shaft sleeve and the impeller.
WARNING
For impeller removal or installation, grasp the impeller at the suction eye.
The impeller can be leveled by turning the adjusting bolt which bears
against the impeller nose. This is especially useful during re-installation.
For impeller removal ensure that the lifting line is tight prior to thread
disengagement.
WARNING
Refer to Section 2.9 "Assembly & Disassembly Safety" prior to working on the pump.
43
LCC [en-US]
10.3.1 Mounting the Shaft Sleeve
WARNING
Lubrication at any of shaft sleeve, release ring (if present) or shaft shoulder faces may result in overloading and
breakage of the shaft.
CAUTION
Do not use petroleum-based products to lubricate the liners since they can cause degradation of the elastomer.
Firmly seat the liners into the metal casings using a large rubber mallet if necessary. To seat the suction side liner, use
a wooden brace and large C-clamps, or lay the liner, flange side up, on a wooden brace and lower the metal casing
onto it, allowing the weight of the casing to seat the liner. Seat the elastomer flanges into their grooves using a blunt
tool if necessary.
The close fit of the liners, although requiring some effort in assembly, will ultimately ensure better liner support, and
longer wear life. If desired, liquid soap may be used to lubricate the liners during assembly.
Before assembling the casing halves together, check the fit of the liners in the casing to ensure that they are seated
correctly, especially in the suction, hub, and discharge flange areas. Clearance allowing for limited readjustment of
parts has been provided in the holes through which the liner studs protrude.
When bolting the casings together, ensure that the liners remain well aligned with each other on their outer perimeter,
especially in the discharge area. Some bulge may occur at the seam on the discharge flange. This may be removed,
and the sealing surface restored to flatness by lightly buffing with a coarse grade sand paper or grinding stone. If
desired, rubber gaskets may be applied at both the suction and discharge flanges, although this is typically not
necessary.
Some bulging may also occur inside the casing between liners. This is normal and does not affect performance.
44
LCC [en-US]
10.3.4 Impeller Installation
1 Suction Liner
2 Flange Gasket
2 3 Flange
3
2
3
1 1
45
LCC [en-US]
10.4 Setting the Nose Gap
CAUTION
The final movement of the bearing housing during adjustment should always be away from the impeller end, as
described above. This ensures that the threads of the adjusting screw will contain no backlash against the
forward directed thrust loading that the pump will generate during operation. It is especially important that this
convention be followed when a mechanical seal is being used.
In order to maximize the performance of your pump, the clearance between the suction face of the impeller and the suction liner
must be adjusted to an allowed minimum depending on the size and type of bearing assembly. This is done by moving the
bearing housing assembly with the adjusting screw. Setting the nose gap must be completed prior to initial commissioning of
the pump and following the replacement of any spare parts.
Before adjustment may proceed, the pump wet end must be completely assembled.
o Stuffing Boxes may be packed before or after the adjustment procedure.
o Mechanical seal axial set must be left until after the adjustment is complete.
o Pumps with urethane or rubber lined parts should also have the suction spool or suction piping installed and
torqued prior to nose gap adjustment.
Ensure that all of the bearing housing hold down bolts are slightly loosened.
Run the bearing assembly towards the impeller end by means of the adjusting screw until the impeller first begins to
rub the suction liner. It is helpful to slowly rotate the impeller during this procedure.
Reverse the adjusting screw until the clearance between the impeller and the suction liner is brought to the
recommended values shown in below.
Confirm the shaft can rotate 360° by hand with no resistance to ensure minimum nose gap has been achieved all
around. Always rotate the shaft in the direction of pump rotation. Clearance should be set from the point where free
rotation is achieved with minimal resistance.
Once the clearance is correct, lightly tighten the bolts of the four bearing housing clamps by hand, making sure that
proper contact is maintained at all four locations. Fully tighten the bolts according to the requirements of Section 8.4
“Bearing Assembly Mounting” and recheck clearance. Ensure proper contact is maintained at all four locations.
Firmly lock the adjusting screw and nut together against the bearing housing tab and again confirm that the shaft can
rotate freely 360° by hand.
1
0.0001 x Urethane Thickness (2) x ΔT(°F)(3)
2
+ Minimum Nose Gap
4
All Sizes 0.010 0.25
1 Impeller
2 Suction Liner
3 Urethane Thickness
4 Nose Gap
(1) Additional nose gap required to account for thermal expansion of urethane.
(2) Measure urethane thickness at nose gap location.
(3) ΔT = Operating Temperature - Ambient Temperature.
46
LCC [en-US]
11 Tooling
11.1 Torque Requirements
Torque requirements listed below and in previous sections are for lubricated bolting. All bolts must be lubricated to ease in pump
assembly and disassembly. Anti seize compound is preferred, but well oiled is also acceptable.
ENGLISH FASTENERS
Anti-Sieze Lubricated / Oiled
Pump Assembly Mounting Equipment Pump Assembly Mounting Equipment
Size
Fasteners to Sub Base Fasteners to Sub Base
ft-lbs N-m ft-lbs N-m ft-lbs N-m ft-lbs N-m
1/4" 3 5 5 6 5 6 7 9
3/8" 12 17 17 23 19 25 25 35
1/2" 30 40 40 55 45 60 60 85
5/8" 60 80 85 115 90 120 125 170
3/4" 105 145 150 200 160 215 220 300
7/8" 175 230 240 325 250 350 360 485
1" 260 350 360 490 385 520 540 730
1 1/8" 320 430 445 600 470 645 660 900
1 1/4" 450 610 620 850 670 910 940 1,275
1 3/8" 590 800 825 1,115 880 1,195 1,225 1,670
1 1/2" 780 1,060 1,090 1,480 1,170 1,585 1,635 2,220
1 3/4" 915 1,240 1,280 1,735 1,370 1,850 1,920 2,600
2" 1,375 1,864 1,925 2,610 2,060 2,795 2,885 3,910
2 1/4" 2,010 2,726 2,815 3,815 3,015 4,085 4,220 5,725
2 1/2" 2,750 3,729 3,850 5,220 4,125 5,590 5,775 7,825
METRIC FASTENERS
Anti-Sieze Lubricated / Oiled
Pump Assembly Mounting Equipment Pump Assembly Mounting Equipment
Size
Fasteners to Sub Base Fasteners to Sub Base
ft-lbs N-m ft-lbs N-m ft-lbs N-m ft-lbs N-m
M8 8 11 10 14 10 15 16 20
M10 15 21 20 28 20 30 30 40
M12 25 35 35 50 40 50 55 75
M16 65 90 90 125 100 130 135 180
M20 130 180 180 250 195 265 270 370
M22 175 250 240 335 260 360 370 500
M24 225 315 305 425 335 450 470 640
M27 325 455 440 615 490 660 680 925
M30 450 625 605 850 670 910 940 1,270
M36 780 1,090 1,060 1,480 1,170 1,600 1,640 2,220
M38 920 1,285 1,250 1,740 1,375 1,865 1,930 2,615
M39 995 1,390 1,350 1,885 1,490 2,020 2,090 2,830
M42 1,245 1,740 1,685 2,360 1,865 2,530 2,610 3,540
M48 1,860 2,610 2,525 3,540 2,795 3,790 3,910 5,300
M64 4,445 6,220 6,025 8,440 6,670 9,040 9,335 12,650
47
LCC [en-US]
CAUTION
After installation of spare parts it is important that the steps outlined in Section 6.1 "Commissioning / Return to
Service" are followed prior to start-up.
Due to the erosive action of the slurry, many of the wet end components of the pump may require replacement during normal
maintenance. Inspection or overhaul of the mechanical components may also require the replacement of certain parts.
The following are recommended lists of parts (whenever applicable) to have on hand for normal maintenance and inspection.
The quantities of parts kept in store will depend upon the severity of the slurry duty and the number of units operating.
Maintenance practices may also favor keeping fully built sub-assemblies or complete pumps on hand in some cases. Previous
experience in similar duties often provides the best experience. If in doubt, contact your GIW / KSB representative for specific
recommendations.
48
LCC [en-US]
12 Troubleshooting
Troubleshooting Table 1 / 2
Remedy
Increase in bearing temperature
Excessive discharge pressure
49
LCC [en-US]
Troubleshooting Table 2 / 2
Insufficient suction head (NPSH available ) Check sump level. Raise if necessary.
Fully open any valves in the suction line.
■ ■ ■ ■ Check suction line friction loss calculations. Alter
design if necessary.
Contact your GIW / KSB representative for further
advice.
Density or viscosity of the fluid pumped is higher Adjustment may be needed to system design and/or
■
than expected. pump operating conditions.
■ ■ Speed is too high. Reduce the speed.
Worn parts. Check for worn parts. Replace as needed.
■ ■ ■ Loose bolts, seals or gaskets. Tighten the bolts and/or fit new seals and gaskets if
needed.
Incorrect packing material or adjustment. Correct adjustment. Replace parts as needed.
■
Incorrect seal water pressure (too high or low). (See GIW Tech Article on this subject.)
■ ■ ■ The unit is misaligned. Check the coupling. Re-align if required.
Bearing failure. Replace bearings. Check lubricant for contamination.
Inspect and repair bearing seals as needed.
■ ■
Contact a GIW service center for factory rebuild
services.
Insufficient or excessive quantity of lubricant or Correct according to maintenance manual
■
unsuitable lubricant. recommendations.
Insulating or hot ambient conditions Remove insulation and/or dirt from bearing assembly.
■
Improve ventilation around pump.
■ Operating voltage is too low. Increase the voltage.
50
LCC [en-US]
13 Supplements
Supplements provide additional information for optional equipment. These options may not be available for your pump.
See your Bill of Materials for options that were included with your pump.
Gently stretch the toric over the metal seal rings until it seats
in the radius. Verify that the toric is not twisted by inspecting
the mold flash line on the outside diameter. Eliminate any
irregularity by gently pulling a section of the toric radially off
the ring and letting it snap back. Twisted torics will cause
nonuniform face load, resulting in leakage and bearing
contamination.
51
LCC [en-US]
Place the housing end cover and seal holder on a flat, clean surface. Verify that the grooves
are clean and free from burrs or sharp edges. Using the correct Seal Installation Tool, locate
the machined ridge in the tool over the toric and clamp together. Align the parts squarely
with the groove and carefully snap the seal assembly into place using a rapid, even push.
Isopropyl alcohol can be used as a lubricant. Allow time for the assembly lube to evaporate.
Apply a very thin film of pure Molybdenum Disulfide lubricant or light oil to the seal faces just
prior to final assembly. This will lubricate the seals during initial start up. Do not to get any
lube on the rubber toric rings. Be sure there is no debris on either of the seal faces, since
even a small piece of lint can hold the seal faces apart and cause leakage or damage to the
sealing surfaces.
Final assembly is detailed on the Bearing Housing Assembly drawing. Bolt the end covers
in place and install the two (2) studs and nuts for the installation tool. Verify that there are
no burrs or sharp edges on the shaft that could damage the o-ring. Coat the long set screws
with anti-seize and thread them into the tapped holes until the points are 1/8” (3mm) from
the inside bore. Install the o-ring in the Seal Holder. Coat the ID of the holder with RTV
silicone sealant, including the o-ring and set screw holes. Place a small bead of silicone
around the shaft diameter to help the o-ring slide. Use extra care at the shaft keyway. Place
the gap spacer over the shaft and carefully slide the holder until it contacts the spacer. Lower
the installation tool over the shaft and tighten the nuts ¼ to ½ turn past hand tight against
the tool.
The gap spacer should not move and the holder should contact it evenly on all sides. Tighten the set screws in a crisscross
pattern. Remove the installation tool and gap spacer, and then retorque the set screws. Coat the lock screws with anti-seize
and tighten them in the tapped holes. Fill the tapped holes flush to the top with silicone to protect the set screws. This will
make removal easier for future maintenance. Rotate the shaft by hand and check for smooth operation. Verify that the holders
are square to the end cover. The metal seal rings may appear cocked slightly relative to the holders. This is not a problem,
the rings will run true when the pump starts.
52
LCC [en-US]
53
LCC [en-US]
14 Notes
54