MEGA

THANK YOU CUSTOMER

You are a proud owner of a MEGA pump

The nameplates punched on the pump shows the Pump type (series & size), serial no. (works order no. ) and main operating data. Please quote the above information in all queries, repeat orders and particularly when ordering spares.

&

MEGA

CONTENTS
Sr. no.
1 1.1 2 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.5 2.6 3 3.1 3.1.1 3.1.2 3.1.2.1 3.1.2.2 3.1.3 3.1.4 3.2 3.3 4 4.1 4.2 4.2.1 4.2.2 5 5.1 5.2 5.3 5.4 6 6.1 6.2 6.3 6.3.1 6.4 6.4.1 6.5 7 7.1 8

Description
General Handling Installation(on site) Foundation Mounting Aligning Pump / motor Connecting the piping Auxillary connections Vacuum balance line Coupling guard Final check Commissioning / start-up, shutdown Preparations Procedure Shaft seal Stuffing box Packing the stuffing box Priming & associated checks Checking the direction of rotation Start-up Shutdown Maintenance & lubrication Suprevision & operation Lubrication & lubricant change Grease change Oil change (if applicable) Dismantling General Dismantling Dismantling the bearing unit Removal of mechanical seal Reassembly Pump Replacement of wearing rings Replacing of bearings Deep groove ball bearings & lubricant fill Mecahnical seal Conversion kit Stuffing box compartment Spare parts Ordering spare parts Interchangeability of components & recommended spares for 2 years of continuous operation Sectional drawing List of components Faults- Cause & remedy

Page no.
1 1 1 1 1 1 2 3 3 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 5 5 6 6 6 6 6 7 7 7 7 7 7 7

8 9 10 11 & 12

9 9.1 10

MEGA 1 General 2
2.1

Installation (on site)

Foundation

Your centrifugal pumps will only give you completely trouble free and satisfactory service on condition that it is installed with due care and properly maintained. It is absolutely essential that the instructions contained in this manual be strictly observed and that the pumps are not operated under conditions which differ from those specified under our `Operating Conditions'. This operating instruction manual dose not take any account of any safety regulations which may apply to the installation site, and the site engineer & the site operator is responsible for notifying our erection staff of any such regulations and seeing that they are complied with. The type series, pump sizes, main operating data and the works order number are all stamped on the name plate affixed to the pump. Please make sure to quote this information every time you write to us in respect of queries, repeat orders and more particularly when ordering spare parts. In case you are using the pump for applications other than water, please ensure that you have a specific confirmation from the dealer or KSB.

Make sure the concrete foundation has set before mounting the pumpset. The surface of the foundation must be completely horizontal and perfectly flat.

2.2

Mounting

Position the pumpset on the foundation and level using a precision spirit level on the discharge nozzle of pump. Ensure the gap between the two coupling halves is as given on the general arrangement drawing. Always fit shims to the left and right of the anchor bolts, between the baseplate / foundation frame and the foundation. If the shims are more than 800 mm apart, position extra shims equidistant between them. All shims must seat perfectly flush with the baseplate / frame.

1.1

Handling

When handling the complete pumpset or bare pump attach ropes to the pump and motor as shown (not through the motor eyebolt).
Fig. no. 3 : Fitting shims

Uniformly tighten up securing means.Baseplates have to be grouted with non-shrinking mortar up to the upper edge of the frame after having been fixed in position.

2.3

Aligning pump / motor

After the baseplate has been fixed in position carefully check the coupling and if necessary, realign the pumpset (with the motor). Prior to checking the alignment and /or aligning, loosen supporting foot (183) and tighten again without transmitting any strain. Please check the alignment of pump motor and coupling even though they are supplied ready mounted on baseframe. The pumpset to be aligned radially and axially within 0.1 mm by installing dial indicaters as shown in fig. no. 4 and without pipe connection.The gap between the two coupling halves must be the same at all points (minimum 3 points) on the circumference; this can be measured using calipers or a feeler gauge. The alignment should be carried with & without pipe connections and should be within limits. For liquids handling more than 1050C; cold alignment & hot alignment both should be carried out on pumpset.

Fig. no. 1 : Bare pump

Fig. no. 2 : Pump & motor on a common baseframe

Fig. 4 : Aligning a coupling

MEGA
2.4 Connecting the piping

Never use the pump itself as an anchorage for the piping. Suction lift lines should be laid with a rising slope towards the pump and suction head line with a downward slope towards the pump.(Fig. 5c, 5b, 5d). Any thermal expansion of the piping (due to high temperatures) must be compensated by suitable means, so as not to impose any additional load on the pump. The pipelines should be anchored in close proximity to the pump and should be connected to the latter without transmitting any stress or strain, nor should weight of the piping be loaded on to the pump. Fig. 5a - The nominal sizes of the pipelines should be atleast equal to the nominal sizes of the pump nozzles.(fig. 5a, 5d) or as recommended in the performance curve. Please ask dealer or KSB incase the nominal sizes are not conveyed. We recommend the incorporation of suitable pressure gauges close to suction & discharge flanges and also check valves or non-return valves and isolating valves in the system, depending on the type of the installation and pump.

Fig.5c : Suction pit below the pump, suction pipe with rising slope towards pump.

Fig. 5d : Suction pipe connections

Fig.5a : Piping & supporting of piping 1 2 3 4 5 Suction line Strainer holder Fine strainer Coarse strainer Pump suction nozzle

Fig. 6 : Conical strainer for suction line

Before commissioning a new installation, thoroughly clean, flush and blow through all vessels, piping & connections. Welding beads, scale and other impurities get dislodged after a certain period of operation; it is necessary to fit a strainer in the suction line to prevent these entering the pump. The total cross section of the holes in the strainer should be three times the cross section of the piping in order to avoid excessive pressure loss across the strainer due to clogging.
Fig. 5b : Suction pit above the pump, suction pipe with downward slope towards pump.

The conical strainer consists of a coarse strainer fronted by a fine strainer with a 2.0 mm mesh and 0.5 mm diameter wire, made of corrosion resistant material, (i.e. Stainless Steel) ref. fig. 6.

MEGA
2.4.1 Auxiliary connections
The size and location (connection code) of all auxiliary connections are shown in the fig. no.7 & table no. 1.

Fig. 8 : Suction line and vacuum balance line. A. Main isolation valve, suction B. Vacuum balance line R. Non- return valve C. Isolation valve E. Vaccum tight isolation valve V. Vacuum vessel Z. Intermediate flange

2.5

Coupling guard

In compliance with the accident prevention regulations, the pump may only be operated if it is fitted with a coupling guard. If the customer states specifically that the coupling guard is not to be supplied by us, it must be provided by the customer.
Fig. no. 7 : Auxillary connections of pump

2.6

Final check

Conn. Code 1M1 1M2 3M 6D 7E 7S 8D 10E 10S 13E* 13D*

Description Pressure guage Pressure guage Pressure guage Casing drain Cooling inlet Cooling outlet Drain (leakage) External sealing in External sealing out Oil filling / Dip stick Oil drain

Conn. type NPT NPT NPT NPT NPT NPT NPT NPT NPT G

Size A-30 A-40 A-50 A-60 3/8" 3/8" 1/2" 1/2" 3/8" 3/8" 1/2" 1/2" 3/8" 3/8" 1/2" 1/2" 3/8" 3/8" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 3/8" 3/8" 3/4" 3/4" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" 20 mm 1/4" 1/4" 1/4" 1/4"

Recheck alignment as described in 2.3 It must be possible to rotate the coupling easily by hand. Check the integrity of all connections.

Commissioning / startup, shutdown

3.1 Preparations Grease lubricated bearings : Grease lubricated bearings

are pre-packed with grease for life time. No greasing is required at site. Do not fill oil for grease lubricated bearings.

Oil lubricated bearings : The bearing bracket should be

filled with oil of the types & specifications as mentioned in 4.2.2.

Table no. 1

* MEGA pumps are supplied with grease lubricated bearings as a standard supply. If in doubt of type of bearings supplied please check with the dealer or KSB.

2.4.2 Vacuum balance line

If the pump has to pump a liquid out of vessel under vacuum, it is advisable to install a vacuum balance-line. This line 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 the permissible liquid level. An additional line starting at the pump discharge-nozzle facilitates venting of the pump before start up. The vacuum tight isolating valve E in the connecting line should be closed after the venting procedure and should remain closed while the pump is running. The main isolating valve C in the vacuum balance line must remain open at all times when the pump is running and should only be closed when the pump is shut down. 3
Fig. no. 9 : Oil fill level

3.1.1 Procedure
Pull out dipstick. Fill in oil through the hole left by the dipstick (fig.no. 9 & 10). After a short time check whether the oil level in the bearing bracket has dropped; then put more oil up to marking on the dipstick. Fix the dipstick back in.

3.1.2 Shaft Seal

The shaft is sealed at its exit though the casing by a soft packed stuffing box or a mechanical seal. Changeover from gland packing execution to mechanical seal & viceversa is possible by using conversion kit. For details refer dealer or KSB.

MEGA
3.1.2.1. Stuffing Box
Soft-packed stuffing box reduce the flow of leakage liquid at the clearance gap between casing cover and shaft protection sleeve when the pressure inside the pump is higher than atmospheric. Conversely, on pumps which operate on suction lift pressure, the soft-packed stuffing box prevents the ingress of air into the pump. Sealing is effected by means of soft packings arranged in a number of rings in the annular space between the discharge cover (163) and the shaft protection sleeve (524) and lightly compressed by the stuffing box gland (452). A lantern ring (458) is also inserted in the packing compartment, at the position shown in the cross-sectional drawing. The lantern ring must register beneath the drilled hole in the discharge cover (163), to enable the sealing liquid to enter. The pressure of the liquid should be 1 to 4 bar above the pressure existing in the packing compartment of the stuffing box. The packing of the stuffing box should be carried out with great care, to avoid an excessively high radial pressing force of the packing rings against the shaft protection sleeve, which might damage the latter. If the shaft protection sleeve is scored or grooved, even a new packing cannot be expected to last very long in service. A newly packed stuffing box should leak profusely at first. If this leakage does not cease of its own after a relatively short period of operation, the nuts on the stuffing box (452) gland should be tightened slowly and evenly while the pump is running, until the stuffing box only drips slightly. Make sure that the stuffing box gland (452) is tightened evenly and not a skew, as otherwise the shaft protection sleeve (524) might be damaged. If the newly packed stuffing box starts to emit smoke when the pump is started up for the first time, the pump should be switched off. If the smoking persists after the pump has been started up again and operated several times in succession, the nuts on the gland should be slackened slightly, or the stuffing box should be inspected if necessary.

3.1.2.2 Re-Packing the Stuffing Boxes Caution :

The pump is despatched from our Works with the stuffing box packed. Before repacking, thoroughly clean stuffing box gland (452), packing compartment and shaft protection sleeve (524). Cut the packing ring to correct length and ends at 45. Ensure that the packing rings ends come into contact with one another on fitment. (See below "cutting the gland packing") If the packing rings are either too long or too short, the stuffing box will not be able to perform its function properly. In the case of asbestos-graphite packing material, the rubbing faces of the individual rings should be lightly coated with MOLYKOTE before insertion in the packing compartment. The first packing ring is then inserted and pushed home into the compartment with aid of the stuffing box gland (452).

3.1.3 Priming & associated checks

Vent and prime the pump and suction line before startup. The shutoff valve in the suction line must be completely open. (Open the shutoff valve in the vacuum line; if fitted and closed the vacuum tight shutoff valve E; fig.no. 8).

3.1.4 Checking the direction of rotation

The direction of rotation of the prime mover must match with the arrow on the pump. Check this by switching the motor on and immediately switching it off again. Mount the coupling guard.

3.2
Cutting the gland packing

Start-up

Start the pump against a closed discharge valve only. Once the pump has reached full speed, slowly open the discharge valve to set the duty point flow indicated on the name plate. After the pump has reached its working temperature and/ or if leakage occurs, tighten bolts (901.01) with the pump disconnected / switched off.

The following packing rings are then inserted into the packing compartment one by one, making sure that the butt joint of each ring is offset by 900 approx. in relation to the butt joint of the preceding ring. The individual rings are pushed home into the packing compartment with the aid of the stuffing box gland (452). The packing rings should only be pressed lightly against one another. They should be inser ted in the packing compartment in such a way that a clear gap of 6 to 8 mm is left at the outer end of the compartment for the positive guide of the stuffing box gland (452). The inserted packing rings should then be compressed moderately with the aid of the stuffing box gland (452) and the nuts (920). Then the nuts (920) should be slackened again by one to two complete turns, and thereafter tightened lightly by hand. The correct and even seating of the stuffing box gland (452) should be checked when the pump is subjected to suction pressure, by inserting a feeler gauge between the stuffing box gland (452) and the shaft protection sleeve (524).

3.3

Shutdown

Close the discharge isolating valve. The discharge isolating valve can remain open if the discharge line is fitted with a non-return device on condition there is back-pressure. Switch off the motor, making sure the pump set runs down smoothly and evenly to a stand still. If the pumpset is to remain out of service for long periods, close the isolating valve in the suction line and close all connections. If there is danger of freezing and/or if the pump is to be out of service for long period, then the pump must be drained or otherwise protect it against freezing.

MEGA 4
4.1

Maintenance and lubrication

Supervision and operation

5.2

Dismantling

Procedure : 1. Disconnect from power supply. 2. For oil-lubricated pumps drain-off the oil as described in 4.2.2. 3. Detach all auxiliary supply pipe lines. 4. Remove coupling guard. 5. Remove coupling half from the pump shaft. Refer fig.no.11

The pump must run quietly and evenly at all times. The pump must never run dry. The bearing temperature may be allowed 500C above room temperature, but must not exceed 800C(measured at the outside of the bearing housing). Do not run the pump for a long period against a closed discharge valve. Pumps with mechanical seals experience minor or invisible (vapour) leakage. The seal is maintenance-free. Stand-by pumps should be started up and immediately shut down again once a week to keep them operational. Flexible parts of coupling which shows signs of wear should be replaced in good time.

4.2 Lubrication and lubricant change 4.2.1 Grease change

The anti-friction bearings are prepacked with grease by the manufacturer; no necessity of greasing it for life time.

4.2.2 Oil change ( If applicable )

The first oil change must be carried out after 300 hours of operation; all subsequent oil changes after 3000 hours. The bearing bracket should be filled up to the mark with oil of any one of the following types and specifications. For quantity; refer table no. 2 & 4. Indian Oil Hindustan Petroleum Bharat Petroleum
Table no.2

Fig. no. 11 : Dismantling the pumpset

For coupling without spacer / intermediate sleeve: 1. Disconnect motor from power supply. 2. Remove discharge and suction branch from pipe line. 3. Uncouple pump and motor. 4. Loosen and remove motor form baseplate. 5. Remove supporting foot (183) from the baseplate and loosen bolts (901.01) on discharge cover. Refer fig.no.11. 6. Pull out bearing bracket with discharge cover and complete rotor (assembled unit). (With larger pumps, suspend or support bearing bracket to prevent the rotating assembly from falling over.) For coupling with spacer/intermediate sleeve During dismantling, the volute casing baseplate and in the pipeline. can remain on the

: Servosystem 46 : Enclo 46 : Bharat Hydrol 46

1. Remove spacer/intermediate sleeve of the coupling. 2. Remove supporting foot (183) from the baseplate and loosen bolts (901.01) on discharge cover. Refer fig.no.11 & Cross sectional drawing. 3. Pull out bearing bracket with discharge cover and complete rotor (assembled unit). If the pump has been in operation for a long time some parts may be difficult to remove. In this case use a brand name penetrating oil or suitable pull-off device.

Fig. no. 10 : Oil lubrication

Procedure : Remove the drain plug (903.06) and drain off the oil. When the bearing bracket is empty, refit the drain plug & refill the bearing bracket with oil from vent plug hole. Check oil level with dipstick (fig. no. 9).

Under no circumstances use force!

5
5.1

Dismantling
General

Before dismantling, make sure the motor is disconnected from the power supply and cannot be switched on accidentally. The suction and discharge shutoff valves must be closed. The pump casing must have cooled down to ambient temperature. The pump casing must be empty and not under pressure. 5

Fig. no. 12 : Removal of impeller from pump shaft

MEGA
5.3 Dismantling the bearing unit
Check oil seal & o-rings for its damage; replace if necessary. All gaskets must be renewed; make sure the new ones have the same thickness as the old ones. Replace wearing rings(502.01) & (502.02) if neccessary. For permissible limits of diametrical wearing clearance between Impeller and wearing ring refer 6.2. New wearing ring clearances are MEGA - 0.3 mm on diameter MEGA GC - 0.5 mm on diameter

6.2
Fig.no.13a : dismantling the bearing unit

Replacement of Wearing Rings

1. Remove bearing covers ( 360.01/02) and gaskets by unscrewing of hex. bolt ( 901.05). Refer fig. no. 13a. 2. Fasten the bearing unit ( 330 ) firmly to the bench vice refer fig. no. 13b. Strike the pump shaft end with a soft hammer. 3. Fasten the shaft (with bearings) to the bench vice and detach bearings from shaft with an extractor or by means of a hammer and a punch. fig.no.13c. Note : Always replace the bearings once they have been removed from the shaft with new ones.

The wearing rings have to be repalced when the clearences between the wearing ring (502.1,2) & the impeller, & the discharge cover (163) exceed three times the max. value as shown in the table no.3 or when the reduciton of efficiency of the pump is noticed. In MEGA GC wearing ring 502.2 is not provided.

Pump size 32-125 32-160 32-200 40-125 40-160 40-200 50-125 50-160 50-200 65-125 32-250 40-250 50-250 65-160 65-200 80-160 40-315 50-315 65-250 80-200 80-160 80-200 100-200 65-315 80-315 80-400 100-250 100-315 100-400 125-200 125-250 125-315 125-400 150-200 150-250 150-315 150-400
Table no. 3

Fig. no. 13b : Dismantling the pump shaft from bearing bracket

Fig. no. 13b : Dismantling the bearings from the pump shaft.

5.4

Removing of Mechanical seal

To replace the mechanical seal, it is necessary to dismantle the pump. After removing the impeller (230) draw the mechanical seal (433) from the shaft by hand.

6
6.1

Reassembly
Pump

Reassembly in accordance with standard engineering practice. Coat the fits and screw connections with graphite or similar before reassembly.

Original clearances on the diameter Casing side Impeller side Maximum Minimum Miximum Minimum 0.405 0.31 0.42 0.32 0.405 0.31 0.42 0.32 0.405 0.31 0.42 0.32 0.425 0.32 0.42 0.32 0.425 0.32 0.42 0.32 0.405 0.31 0.42 0.32 0.425 0.32 0.42 0.32 0.425 0.32 0.42 0.32 0.425 0.32 0.42 0.32 0.425 0.32 0.42 0.32 0.405 0.31 0.4 0.31 0.425 0.32 0.4 0.31 0.425 0.32 0.4 0.31 0.425 0.32 0.42 0.32 0.425 0.32 0.445 0.32 0.445 0.33 0.42 0.32 0.425 0.32 0.42 0.32 0.425 0.32 0.42 0.32 0.425 0.32 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.42 0.32 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.425 0.32 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.445 0.33 0.47 0.35 0.445 0.33 0.47 0.35 0.445 0.33 0.47 0.35 0.445 0.33 0.47 0.35 0.445 0.33

MEGA
6.3 Replacing of bearings

1. Check the shaft ( 210 ) with its spacer sleeve (525) / or shaft protection sleeve (524) (as applicable) for eccentricity, between centres. Maximum allowable eccentricity is 0.05mm. 2. Fasten the shaft (210) to the bench vice using soft polish sheets between the vice clamp jaws to avoid damage. Refer fig.no.14. 3. Heat the bearings (321.01/02) in the oven about 800C max. and push it on to the shaft. Fig. no.14. Allow the bearings to cool down. Then tap it lightly against the shoulder using suitable pipe punch.

Fig. no. 15 : Mechanical seal

6.4.1 Conversion kit

Parts required for changeover from gland packing to mechanical seal are : 1. 2. 3. 4. 5. Spacer sleeve (525) Mechanical seal (433) Seal cover (476) Studs & nuts Set of gaskets

6.5

Stuffing box compartment

Fig. no. 14 : Mounting of bearings

6.3.1 Deep groove ball bearing & lubricant fill

(Only increase of oil lubricated bearings)
Bearing bracket A-30 A-40 A-50 A-60
Table no. 4

Grease packed Bearing no. 6306 2Z C3 6308 2Z C3 6310 2Z C3 6312 2Z C3

Oil lubrication Bearing no. Oil qty.in ltr. 6306 C3 6308 C3 6310 C3 6312 C3 0.2 0.35 0.65 0.65

Fig. no. 16 : Stuffing box compartment

Dimensions of packing compartment in mm

Bearing bracket # A - 30 A - 40 A - 50 A - 60
Table no.5 # See interchangeability of components for co-relation of shaft & pump sizes in table no. 6.

6.4

Mechanical seal

The following points should be observed when mounting the mechanical seal : Extreme care and cleanliness during assembly are the essential pre-requsites for the trouble-free operation of the mechanical seal. The guard protecting the rubbing faces should only be removed before assembly takes place. When the stationary seal rings has been inserted, check its plane parallelism in relation to the casing component. Before reassembly, clean the spacer sleeve (525). Check shaft surface under mechanical seal area. Make sure that there are no scratches or grooves. If it is found then touch up scratches / grooves. If not possible then replace the shaft by new ones. 7

d1 35 45 60 70

Dimensions d2 l 55 71 65 71 85 90.5 95 90.5

7
7.1

Spare parts
Ordering spare parts

When ordering spare parts please indicate the following information which may be taken from the name plate of the pump. If the name plate is missing then check on the discharge flange for serial/work order no. e.g. : Type Serial/work order no. : MEGA 50-250 : 955 1234-1235

MEGA 8 Interchangeability of components & recommended spares for 2 years of continuous operation
524 / 525 Shaft Prot. Sleeve / Spacer sleeve

Deep groove ball bearing

Description

Volute casing

Wearing ring

Impeller ring

Support foot

Splash ring

Seal cover

Pump Size

635 / 913 Dip stick# / vent plug

Bearing bracket

Discharge cover

Mechanical seal

Bearing bracket

Bearing cover

Cooling cover

O-ring @

Hex. bolt

Hex. bolt

Impeller

Washer

Oil seal

Gasket

Gasket

Gasket

Gasket

Shaft

Key 940.1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

Part no.

412.1/.2

901.03

400.1

400.2

400.3

400.4

502.1

502.2

901.1

32-125 32-160 32-200 40-125 40-160 40-200 50-125 50-160 50-200 65-125 32-250 40-250 40-315 50-250 50-315 65-160 65-200 65-250 80-160 80-200 80-250 100-160 100-200 65-315 80-315 80-400 100-250 100-315 100-400 125-200 125-250 125-315 125-400 150-200 150-250 150-315 150-400 A - 30

2 4 6 7 8 9 10 11 12 13 15 16 21 17 22 18 19 23 20 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

1 1 2 1 1 2 1 1 2 1 3 3 8 3 8 4 5 7 4 6 7 6 6 11 11 12 10 11 12 9 10 11 12 9 10

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 2 3 1 2 3 2 3 3 3 4 4 6 4 7 5 4 6 4 4 7 6 6 10 8 9 10 8 9 8 8 9 11 9 9 12 12

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

2 3 4 5 6 7 8 9 10 11 12 13 18 14 19 15 16 20 17 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3

1 1 1 2 2 3 4 4 4 5 1 2 2 4 5 5 5 6 7 7 7 8 8 6 7 9 8 8 8 10 10 10 10 11 12

13 13 13 13 13 13 13 13 13 13 3 3 14 3 14 15 15 16 15 18 16 18 18 17 17 10 10 17 10 10 10 17 10 10 10

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 2 2 3 2 3 2 2 3 2 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 5 5

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

A - 40

A - 50

A - 60

40 13 4 41 14 4

37 4 4 4 4 4 4 4 4 4 4 4 12 10 38 4 4 4 4 4 4 4 4 4 4 4 12 10 Recommended spare parts for 2 years of continuous operation Quantity 2 5 nos. each 8 nos. each 9 nos. each 150% @ Only for cooled

No. of pumps Up to 3 nos. Up to 5 nos. Up to 7 nos. Up to 10 nos. & above 1 1 1 2 2 2 2 3 3 30% 30% 30%

Table no. 6

2 1 2 2 2 2 3 3 3 - 50% 30% - 50% discharge covers

# Only for Oil lubricated bearings

940.2 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 4 4

102

163

165

183

210

230

321

330

360

421

433

471

507

554

Key

MEGA 9 Cross sectional drawing

Details of cooling cover 9

MEGA
9.1 List of components

Part No. 102 163 165 183 210 230 321.01 / 02 330 360.01 / 02 400.01 - 05 411.06 412.01 / 02 412.03 421.01 / 02 452 458 461 502.01 / 02 507 524 550.01 / 03 554 901.01 - 06 902 903.01 - 10 913 920 940.01 - 02

Description Volute casing Discharge cover Cooling cover ( optional ) Support foot Shaft Impeller Deep groove ball bearing Bearing bracket Bearing cover Flat gasket Gasket O-ring ( for cooling cover ) O-ring Oil seal Gland cover Lantern ring Packing Wearing ring - Casing / impeller Splash ring Shaft protection sleeve Washer Washer for impeller Hex. head bolt Stud Hex. head plug Vent plug Hex. nut Key

10

MEGA 10
Pump delivers insufficient liquid

Faults-cause & remedy

Excessive temperature rise inside the pump Excessively high pump discharge pressure Excessive shaft sealing leakage

Bearings overheating

Rough pump running

Motor overloaded

Cause

Remedy 1)

Pump leaks

The pump generates excessively high differential pressure Excessively high back pressure The pump and \ or piping are incompletely vented or primed. Suction line or impeller clogged

Reset duty point

Check the plant for dirt. Fit larger impeller 2) Vent or prime the pump and piping completely Remove the deposites in the pump and / or piping

Formation of air pockets in the piping Alter piping lyout. If necessary, fit a vent valve NPSH avaliable is too low (on positive suction head installations) Check the liquid level. Mount the pump at lower level. Open isolating valve in the suction line fully. Alter suction line, if the losses in the suction line are Sealing liquid passage is clogged; clean it out. If necessary, arrange a sealing liquid supply from an outside source, or increase sealing liquid pressure. Fit a new shaft seal \ gland packing. Change over two phases of the power supply cable. Increase the speed

Ingress of air on shaft seal

Reverse rotation Rotational speed is too low 2)

Excessive wear of the pump internals Repalce worn components by new ones. Pump back pressure is lower than that specified in the purchase order. Adjust duty point accurately. In case of persistant overloading, trim the impeller, if necessary.2) 2)

Specifc gravity or viscosity of the fluid pumped is higher than that specified in the purchase order. Gland cover too tight or tightened askew Excessive rotational speed. Defective seal

Correct. Reduce speed 2) Renew seal between volute casing and the discharge cover

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MEGA

Excessive temperature rise inside the pump

Excessively high pump discharge pressure

Excessive shaft sealing leakage

Pump delivers insufficient liquid

Bearings overheating

Rough pump running

Motor overloaded

Cause

Remedy 1)

Pump leaks

Worn shaft seal

Check flushing / sealing liquid pressure. Renew shaft sleeve. Fit new shaft seal.

Grooving, score marks or roughness Renewshaftsleeve. Fit new shaft seal. on shaft protection sleeve / shaft surface. The pump runs noisy. Correct the suction conditions. Align pump. Rebalance rotor. Increase the suction pressure at the pump suction nozzle. Rectify. Check the piping connections and pump fixing bolts. Reduce the gap between the pipe supports, if necessary. Support piping using antivibration material.

Pump set misaligned. The pump is warped or resonance vibrations in the piping.

Excessive axial thrust 2).

Clean the balance holes in impeller. Fit new casing wearing rings. Reduce quantity or top up lubricant, or change lubricant quality. Restore correct coupling gap in accordence with the data on the installation plan. Replace the defective fuse. Check the electrical connections. Clean the rotor. Rebalance the rotor dynamically. Fit new bearings. Insrease the minimum rate of flow. Increase the cross-section of the circulation in the liquid line.

Too much or too little, or unsuitable lubricant quality. The specified coupling gap has not been maintained. The motor is running on two phases only.

The rotor is out of balance. Defective bearings. Insufficient rate of flow. Faults in circulation liquid supply.

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