HFO Transfer Pump-Komprimiert

Behrens Pumpen
Technical specification
Foreign Economy & Technical Coop. Co. of QS 20060301
Item 3
Service FO transfer pump
Type: KV 851 + 160
Description 3 spindle screw pump foot mounted
Technical data Serial no.: 69092
Medium
Temperature (°C) : 90
Viscosity (cst) : 25,80 - 1.000,00
Density (kg/cbm) : 870
Capacity (cbm/h) : 45,00 - 45,00
Suction pressure (bar) : -0,50 - 0,50
Delivery pressure (bar) : 4,00 - 4,00
Difference pressure (bar) : 4,50 - 4,50
Power consumption (kW) : 8,60 - 12,10
Motor required (kW) : 15,00 - 15,00
Speed (rpm) : 1460
NPSH (r) (m) : 2,80 - 5,80
Materials
Pump Casing : nodular CI
Screws : nitrated steel
Shaft : nitrated steel
:
Bearings Type : Rolling contact
:
Coupling Type : flexible
Shaft seal Type : Mechanical seal
Material : SiC-SiC FFKM
Connections DN PN
suction side : 150 16
pressure side 125 16
Prime mover
E-Motor Type : CSM 160L-4 E-Motor No.
Execution : IM V1, IP 55, ISO F to B
Starting : DOL
Power supply (V / Hz) : 380 / 50 PTC :
Power (kW) : 15,00 SPM : no
Rated current (A) : 29,30 Space heater : 230V/48W
Starting current (A) : 179,00
Weights
Pump / e-motor (kg) : 204,00 / 130,00 Total (kg) : 334,00
Classification GL, certificate for pump
Pump
Motor
12.09.2007 Dirksen
Operating Instructions
Screw pumps
K Series
OIK 08B
02_02/2005 Edition
Kräutler GmbH & Co., Bildgasse 40, A-6893 Lustenau, Austria, Telefon: +43 / (0) 55 77 / 8 66 44-0, Telefax: +43 / (0) 55 77 / 8 84 33
www.kral.at, E-mail: [email protected]
Functional description
General drawing of a screw pump
2 3 4 5
1
13
12
000003
11 10 9
Fig. 1 Structure of a screw pump
<1> setscrew <8> ball bearing

<2> overflow valve <9> flange cover
<3> pump casing <10>thrust pin
<4> compensating cylinder <11>balancing hole
<5> vent of seal housing <12>end cover
<6> shaft seal <13>idle screw
<7> main screw
13
General drawing of a screw pump with coupling and motor
K1 K2 K3 K4 K5
000100
Fig. 2 Structure of a screw pump with coupling and motor
<K1>pump <K4>motorside coupling part

<K2>pumpside coupling part <K5>motor
<K3>coupling intermediate ring
Characteristics of screw pumps
• High power density

The axial flow allows comparatively good delivery rates relative to the pump size. This, together
with the high pressures that can be obtained, ensures high power density compared to other
types of pump and a correspondingly compact design.
• Operating with lubricating media
The sleeve bearing of the idle screws is an essential requirement of the compact design.
However, to ensure adequate lubrication, the pump must have a steady supply of pumped media
of adequate viscosity.
• Low-noise and low-pulsation operating
In each time unit, a constant volume of fluid is displaced by the set of screws. The uniformity of
the medium flow is thus an important characteristic of this type of pump. Screw pumps work
very quietly and virtually without pulsation. In addition, this positive displacement principle allows
low-turbulence and low-shear delivery, a quality that is particularly valuable when the pumped
media are highly viscous or sensitive.
• Greater efficiency demands liquids without solids
The precision with which the screws and the casings are made allows strict tolerances to be
applied to the clearances for these parts. Correspondingly, there is greater volumetric efficiency
and the pump can also be self-priming. Because of these tight clearances, however, screw
pumps are not suitable for delivering media containing solids and impurities.
• Easily adjusted
Screw pumps have that "constant" Q = f(n) characteristic curve typical of positive displacement
pumps. So by controlling the rotation speed, you have an excellent opportunity to regulate the
volume flow.
14
Screw set and casing
Screw pumps belong to the group of pumps known as rotary positive displacement pumps. The
special shaping of these pumps allows virtually leakproof engagement of the three intermeshing
screws <7>, <13>. Closed volumes are formed in conjunction with the pump casing <3> covering
the set of screws.
The standard rotation direction for the pump is to the right, taken from the driver, i.e. clockwise
(indicated by the arrow on the flange cover <9>). When the main screw <7> is driven by a motor,
the idle screws <13> follow, because they interlink with the main screw. The displacement action
of the pump comes from the rotation of the screws, which calls for the volumes mentioned above
to be continuously admitted, moved in an axial direction and emptied. The free cross-section of the
set of screws is constant throughout its length so that the delivery rate can be easily calculated
from the product of the free cross-section, the rotation speed and the pitch of the screws. All the
rotating parts are rinsed and lubricated by the pumped medium.
The geometry of the pump casing <3> and the connections integrated there determine the options
available for introducing and removing the pumped medium. On the casing itself, arrows on the
flanges indicate the direction of the flow.
Shaft seal
The pump is sealed at the main screw outlet by a shaft seal. The following types of seal may be
used, depending on the type of construction involved:
• Mechanical seal, unidirectional, not relieved

• Radial shaft seal, Domsel AC type
• Magnetic coupling
In each case, the seal has a pressure relief at the discharge side to increase its service life. The seal
chamber is connected to the pump suction chamber by a generously proportioned balancing hole
<11>. This ensures that the pressure at the shaft seal <6> is virtually the same as that at the
suction side of the pump. In addition to this, the seal chamber is connected to the pressure
chamber via the annular gap of a compensating cylinder <4> that rotates together with the main
screw. As a result of the differential pressure at the pump, there is a constant leakage flow coming
from the compensating cylinder, past the seal and being fed back to the suction side of the pump
via the balancing hole. This leakage flow is necessary to relieve the seal chamber as well as for
cooling and lubricating the seal
Mechanical seal:
Mechanical seals need constant lubrication. The inevitable minimal leakage caused by the
lubrication of the mechanical seal is only a few cubic centimetres per hour and is imperative for the
proper functioning of the seal. Generally this leakage will evaporate and not even be noticeable.
However, with low-volatility media such as heavy oil, the leakage will be visible. The leakage vent
holes in the flange cover allow the drain of this regular leakage. At use of a mechanical seal the
permeability of the leakage vent holes has to be ensured. Dry running must be avoided at all costs,
as the seal will overheat and be destroyed in a matter of minutes.
15
Radial shaft seal:
R1
R2
R3
000101
R4
Fig. 3 Structure of a K-pump with radial shaft seal
<R1>plugscrew <R3>circlip
<R2>radial shaft seal <R4>plugscrew
At the use of a radial shaft seal the leakage holes are closed, as this type of shaft seal is positioned
so close to the motor, that the drain chamber is included in the sealing chamber.
Mechanical seal with quench:
V1
000102
V5 V4 V3 V2
Fig. 4 Structure of a K-pump with mechanical seal and quench
<V1>connection to quench container <V4>plugscrew

<V2>circlip <V5>mechanical seal
<V3>radial shaft seal
16
At the operation of non-volatile media or liquids, which are likely to harden at contact with the
atmosphere, a mechanical seal can be used together with a radial shaft seal. Thus the sealing
chamber is joined with a quench container via the leakage holes. As a result the liquid side of the
mechanical seal can always be hold under exclusion of air.
Magnetic coupling:
The magnetic coupling is used as an alternative to the shaft seal. The shaft end of the pump is
enclosed by a containment can, the connection of which is hermetically sealed against the motor-
side flange of the pump. Thus it is unnecessary to seal a rotating shaft end against a stationary
sealing chamber. The transmission of the torque from motor to pump is effected by special rotors,
which are equipped with strong permanent magnets. The inner rotor is fixed at the shaft end and
driven by the outer rotor, which in turn is fixed at the shaft of the motor. Thus the transmission of
the torque is effected without contact, only by means of the magnetic field between inner and
outer rotor.
The containment can is made of an unmagnetic stainless steel, which does not interfere with the
formation of the magnetic fields between the rotors. The pressure relief of the containment can is
effected via a center hole in the main screw. Therefore it is assumed that the pressure in the
containment can corresponds approximately to the pressure at the suction side of the pump.
Main screw bearing
The main screw is fixed in position in the casing by means of a ball bearing <8>. In order to keep
the loading on the main screw symmetrical, this bearing is largely floating in the radial direction.
With a compensating cylinder of an appropriate size, it is then also possible to have a virtually total
hydraulic balance of forces in the axial direction. This means that there is relatively little load on this
bearing, which basically ensures that the set of screws is securely positioned. However, the axial
load increases noticeably as the suction pressure rises, as in this situation, it is no longer possible
to fully balance the forces hydraulically. High external radial loads (for example by pulleys or
toothed wheels) can only be absorbed if the bearing design is specially adapted.
Bearing of the idle screws
The buildup of pressure in the set of screws leads to a radial force component which acts on the
idle screws. In addition to this, the drag effect of the idle screws produces a radial force
component, so that the resultant radial force pushes the idle screws away from the main screw
into the pump casing. The contact surface in the pump casing operates as a sleeve bearing and
absorbs this radial force. With screw pumps, damage is often caused by overloading this sleeve
bearing. The operating criteria taken from the rating of the sleeve bearing, especially with regard to
viscosity and pressure, are therefore particularly important for safe pump operation.
The idle screws are not floating in the axial direction either. The differential pressure that has built
up in the pump produces a resultant axial force going towards the suction side of the pump. This
force is absorbed by the axial thrust faces in the end cover <12>. It only takes very low differential
pressures for the drag action of the main screw to produce an axial force going towards the
pressure side of the pump. This gentle force which basically occurs during transient operating
conditions, is introduced into the pump casing by a thrust pin <10> in the end face of the screw.
17
Overflow valve
2 3 4
<1> plugscrew
<2> setscrew
<3> spring
000004
<4> valve cone
Fig. 5 Overflow valve mounting position
Extremely high pressures can build up in positive displacement pumps if a feed pipe becomes
blocked and the parts under pressure may even rupture. These pumps must therefore be fitted
with a overflow valve to protect them against this type of malfunction during operation. KRAL
screw pumps of the K series have an integrated valve of this type. The valve is accessible via a
plugscrew <1> in the end cover and can be adjusted from the outside. When it leaves the factory,
the opening pressure of the valve is set at 110% of the nominal pressure.
These valves are purely there as safety elements and should not be used for control or regulation,
for example, to maintain pressure. If the valve is kept open for too long under adverse operating
conditions (high differential pressures and/or low viscosities) it will only take a few minutes for the
valve and the valve seating to become damaged. As a result, the valve will leak permanently and
there will be a corresponding reduction in the delivery rate. In addition to this, circulation through
the overflow valve for too long can heat the pump to excess. This reduces viscosity and can
ultimately lead to pump failure.
So it is up to the user to ensure that the differential pressure in the pump cannot exceed the valve
opening pressure under normal operating conditions. If this requirement is not met, the valve
opening pressure must be adjusted accordingly by means of the setscrew <2> , see "Adjusting the
overflow valve", page 33.
18
Heating
As an option, pumps can be equipped with ancillary heating. This is advisable for high-viscosity
media, which unless heated do not flow freely enough, which would lead to excessive power
consumption and to problems with cavitation or sealing.
Electrical and medium heating systems are described below.
<1> heating cover

<2> heating element
000005
<3> connecting lead
Fig. 6 Electrical heating
The electrical heating system comprises two heating elements <2> integrated in a heating cover
<1> additionally attached to the end cover. The output of the elements corresponds to the radiation
and convection losses of the pump in the desirable temperature range, so that overheating is not
possible.
<1> heating cover
000006
<2> pipeline connections
Fig. 7 Medium heating
Medium heating comprises a heating cover <1> through which a heating medium (steam, thermal
oil, etc.) flows, additionally attached to the end cover. The permissible limits for the pump
temperature must be taken into account when setting the mass flow to be admitted and its
temperature, see Tab. 1, page 5.
19
Transportation, storage and disposal

Transportation
Raising the pump
000023
Fig. 1 Raising a pump with free shaft end
Requirement:
• Separate lifting accessories of the correct size

• The hoisting gear used must comply with local directives and accident prevention regulations
DANGER!
Risk of injury and/or damage to equipment should the pump fall.
☞ Use correctly proportioned and intact separate lifting accessories.

☞ Attach the separate lifting accessories properly to the pump.
1. Screw the eyebolts into the two holes on opposite sides of the flange cover.
2. Secure the slinging devices to the eyebolts.
3. Secure the crane hook to the slinging device.
4. Raise the pump.
21
Raising the pump unit
000026
000025
000024
Fig. 2 Raising a pump unit
Requirement:
• Separate lifting accessories of the correct size

• The hoisting gear used must comply with local directives and accident prevention regulations
DANGER!
Risk of injury and/or damage to equipment should the pump unit fall.
☞ Use correctly proportioned and intact separate lifting accessories.

☞ Attach the separate lifting accessories properly to the pump unit.
1. Fasten the slinging devices at the pump unit to give a 60° to 90° angle between the slings. Make
sure that the centre of gravity of the pump unit is between and below the attachment points. If
this is not possible, you must find another way to stop the pump unit tilting, for example, by
gripping the pump unit more tightly in the slinging devices.
2. Do not let the slinging devices slip; with KF pump units, for example, you could position them in
front of the flange of the pump bracket and behind one of the motor ribs. With pump units of the
KV and KH series, you can use eyebolts for this, screwing them into the hole provided for the
purpose on the motor and on the base frame.
3. Secure the crane hook to the slinging device.
4. Raise the pump uni
22
Storage and preservation

Storage
During the test run, the internal components of the pump are wetted with test oil, which has a
preservative effect. The pipe connections are fitted with protective caps. Unless otherwise
specified, the external components of the pump are preserved with a single-coat PU-based two-
pack paint. The preservative applied at the factory will protect the pump for about six weeks, if it is
stored somewhere dry and clean. Adverse ambient conditions, such as high humidity, salty air,
etc., will noticeably reduce the possible storage time. If storage over longer periods and in adverse
storage conditions is necessary, the pump will have to be preserved.
Preserving the internal surfaces of the pump
1. Set up the pump so that the pressure-face connection is pointing upward.

2. Close the suction side of the pump with a cover plate.
3. Pour non-corrosive, resin-free oil into the pressure flange until the oil reaches the pressure flange
and the air bubbles stop rising, while slowly turning the main screw against the direction of
rotation.
4. Close the pressure-side pump connection with a cover plate.
If the pump is being kept in storage for a long time, every six months you should check the oil
level in the pump and top it up if necessary.
Preserving the external surfaces of the pump
Resources:
• Castrol Rustilo DWX 33 or other preservative offering comparable protection
☞ Paint or spray the preservative onto all plain and unpainted parts.
At intervals of about six months, check the preservative effect and if necessary paint or spray the
plain und unpainted parts with the preservative again.
Removing the preservative
Resources:
• Solvents such as diesel fuel, alcohol, industrial cleaner or steam-jet cleaning device with wax-
dissolving additives
• Container to collect the preservative oil
1. Clean the outside of the pump with the solvent, if necessary using a steam-jet cleaning device.
2. Remove the cover plate on the pressure side.
3. Drain the pump, collecting the preservative oil in a suitable container.
4. Remove the cover plate on the suction side.
5. To remove the residual oil, rinse the pump with the pumped medium.
23
Disposal
Safe disposal
It is essential to comply with the following safety instruction during disposal:
• Comply with local disposal regulations.
Disposing of the pump
Resources:
• Solvent or industrial cleaner suitable for the pumped medium
1. Dismantle the pump.

2. Clean the individual parts of any residual pumped media.
3. Remove sealing elements made of elastomer and ceramics (SiC) from the pump and take them
to a residual waste station.
4. Take any iron components to a material recycling station.
24
Installation, removal and connection

Installation
Locating the pump
Screw pumps can be operated in any mounting position. However, we recommend that you do not
mount the pump above the motor, as should there be a leak, the pumped medium could get inside
the motor.
There are three types of construction:
000010
2
000009
000011
1 3
Fig. 1 Types of construction
<1> type KV with a pump base

<2> type KH with a base frame
<3> type KF with a pump pedestal
Requirement:
• The pump connections are protected against dirt accumulation, for example, by protective covers
fitted at the factory
WARNING!
Leaking pumped medium may cause damage to the motor.
☞ Do not mount the pump above the motor.
WARNING!
With insufficient attachment, the pump and the piping may become damaged.
☞ Only attach the pump to a stable substrate.

☞ Make sure that the fastening elements are adequately secured.
1. Put the pump in position. Pay attention to the direction of flow, which is indicated by the
arrows on the flanges.
2. Secure the fastening elements on the substrate.
25
Installing the pump
If the piping system has to be flushed out with the pump, the pump must be protected by a startup
filter to stop particles of dust getting inside. The mesh width of the startup filter is relevant to the
size of the pump.
Pump size Medium Max. mesh width

up to K 275 light fuel oil 0,025 mm
heavy fuel oil 0,050 mm
from K 370 light fuel oil 0,035 mm
heavy fuel oil 0,070 mm
Tab. 1 Mesh width of the startup filter
The pump connections to the piping system must be stress free, as otherwise there is no
guarantee that the pump will operate safely. The following drawings show how to make a stress-
free connection between flange and pump.
Fig. 2 Correct flange connection
<1> linear offset

<2> vertical offset
<3> angular offset
Fig. 3 Incorrect flange connections
WARNING!
Accumulated dirt in the piping system may damage the equipment.
☞ Make sure that the piping system has been carefully cleaned.
☞ When welding, attach cover plates in front of the connecting flanges.
☞ Make sure when welding that welding beads and abrasive dust cannot get into the piping
system and the pump.
26
WARNING!
Any mechanical tension may damage equipment or impair operation.
☞ Make sure that the pump mounting on the piping system is free of mechanical stress.
1. Turn the pump shaft or the fan impeller of the motor. This is to test that the pump runs
smoothly.
If the pump cannot be turned by hand, remedy the fault before installing the pump, see
"Faultfinding reference", page 75.
2. If piping has to be adapted, attach cover plates in front of the connecting flanges when
welding.
3. Place the piping in position.
4. Support the weight of the pipeline.
5. Check the clearance and the angular, vertical and linear alignment, adjusting where necessary.
If the screws tighten easily, this is a sure sign that the installation is stress free.
6. Tighten the connecting bolts crosswise.
Aligning and checking the shaft coupling
Requirement:
• Pump, shaft coupling and motor fitted by the customer
<a> lateral offset

<b> angular offset
<c> linear offset
Fig. 4 Measuring points for coupling alignment tolerances
Coupling diameter Lateral offset <a> Angular offset <b> Linear offset <c>
[mm] max. [mm] max. [°] min. [mm] max. [mm]
40 0,2 0,9 2 3
55 0,2 0,9 2 3,5
65 0,25 0,9 2,5 4
80 0,3 1,0 3 4,5
95 0,3 1,0 3 5
120 0,4 1,1 4 6
135 0,4 1,2 4,5 7
160 0,5 1,2 5 8
Tab. 2 Limits for shaft coupling alignment
DANGER!
If the shaft coupling is not aligned correctly, this will cause noise, vibration and damage to the
bearing.
☞ Check the alignment of the coupling.
27
1. Check the linear offset <c> of the coupling with a slide gauge or feeler gauge.
If the limits in the above table are exceeded, loosen the pump or motor attachment and move
the unit to accomodate the linear offset <c>.
2. Check the lateral offset <a> with a straight edge and a feeler gauge. Check at several points on
the circumference of the coupling.
the unit to reduce the lateral offset <a>.
3. Check the angular offset <b> of the coupling with a straight edge.
the unit to reduce the angular offset <b>.
Electrical connection
Connecting the pump
Requirement:
• An adequately sized cable
DANGER!
Electric shock can endanger life.
☞ Only allow authorised and qualified personnel to connect the pump.

☞ Make sure that the electricity supply is not live.
☞ Connect the pump carefully to ground.
1. Comply with the operating instructions for the pre-fitted motor.

2. If the motor and the pump have been delivered separately, connect the motor in accordance
with the operating instructions for the motor.
3. Make sure that the operating data on the motor nameplate match the operating data for the
pump.
4. Make sure that the operating data on the motor nameplate match the local mains supply.
5. Open the terminal box on the motor.
6. Make sure that the connecting cable is not live.
7. Follow the wiring diagram in the terminal box for phase and neutral conductor connections.
8. Close the motor terminal box.
Pump Removal
Removing the Pump
Requirement:
• Pump is switched off
Resource:
• Containers to collect the escaping pumped medium
28
DANGER!
Electric shock can endanger life.
☞ Only allow authorised and qualified personnel to disconnect the pump.

☞ Make sure that the electricity supply is not live.
DANGER!
When removing the pump, you are at risk of injury from escaping hot, toxic or caustic pumped
media.
☞ Comply with the safety instructions applicable to handling hazardous liquids.
1. When operating at raised temperatures, wait until the unit has cooled down to the ambient
temperature.
2. Disconnect the pump from the power supply.
3. Open the terminal box on the motor.
4. Disconnect the connecting cable.
5. Close the shut-off devices on the pressure and suction sides.
6. Loosen the connecting bolts of the pipe connection on the pressure side. Collect the escaping
medium in a suitable trough.
7. Once all the medium has drained out, dismantle the flange on the pressure side.
8. Loosen the connecting bolts of the pipe connection on the suction side. Collect the escaping
medium in a suitable trough.
9. Once all the medium has drained out, dismantle the flange on the suction side.
10. Loosen the unit attachment on the foundation.
11. Dismantle the motor and the pump bracket.
29
Operation
Operation
Startup
Filling the pump
There are three possible ways to fill the pump:
• via the shut-off device on the suction side

• via the shut-off device on the pressure side
• via the vent holes
000017
3 2
<1> seal vent hole

<2> suction side vent hole
<3> pressure side vent hole
Fig. 1 Vent holes
Requirement:
• Pump securely attached

• Pump connection to the piping system is free of mechanical stress
• Pump motor is connected correctly to the electrical power supply
• Piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the
pump
WARNING!
Dry-running can damage pump equipment.
☞ Before you start it, make sure that the pump is full.
1. Open one of the vent holes on the pump casing.

2. If the pumped medium on the suction side is under inlet pressure, open the shut-off device on
the suction side and fill the pump. Turn the pump shaft or the fan impeller of the motor by hand
to speed up the filling process.
- or -
☞If there is already pumped medium available, open the shut-off device on the pressure side and
fill the pump. Turn the pump shaft or the fan impeller of the motor by hand to speed up the
filling process.
- or -
☞If there is no pumped medium at either the pressure or the suction side flange, fill the pump
via the vent hole. Turn the pump shaft or the fan impeller of the motor by hand to speed up the
filling process.
3. Fill the pump until pumped medium escapes at the vent hole.
4. Close the vent hole
5. Open vent hole of the seal <1> and wait until medium escapes.
6. Close vent hole of the seal.
31
Operation
Checking the direction of rotation
The direction of rotation and the direction of flow are indicated by arrows on the pump. The
direction of rotation of the motor gives the direction of rotation of the pump. That is to say, the fan
impeller of the motor must rotate in the direction in which the arrow on the pump is pointing to
indicate direction of rotation. Normally the direction of rotation of the pump is to the right
(clockwise), as seen from motor side.
<1> leakage
<2> arrow to indicate
direction of rotation
000018
3 3
<3> arrows to indicate

direction of flow
Fig. 2 Identifying direction of rotation and direction of flow
Requirement:
• Pump securely attached

• Pump connection to the piping system is stress free
• Pump motor is connected correctly to the electrical power supply
• Piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be flushed by the
pump
• Pump is full
WARNING!
☞ Turn the pump on (for max. 1 sec.) and then off again immediately (checking the direction of
rotation).
1. Switch on the power supply and then turn it off again immediately.
2. When the fan impeller of the motor moves slowly after switching off, compare the direction of
rotation of the fan impeller with the arrow indicating direction of rotation on the pump flange.
If the directions do not match, swap over two electrical connection phases. Repeat steps 1 and
2.
32
Operation
Commissioning the pump
Requirement:
• The ambient conditions correspond to the operating data, see "Operating data", page 4
• The pump is securely attached
• The pump is connected to the piping system without stress or strain
• The pump motor is connected correctly to the electrical power supply
• The piping system contains no pollutants or particles of dirt
• A startup filter of the prescribed mesh width is fitted if the piping system is to be cleaned by the
pump
• The pump is full
• If there are shut-off devices in the suction and pressure pipes, they are open
WARNING!
☞ Before commissioning the pump, take note of these operating instructions.

☞ Before commissioning, make sure that the pump is full.
☞ If the pump does not deliver after 10–15 seconds, abort commissioning.
1. Switch on the pump.

The pump will deliver when the pressure on the pressure side of the pump rises or when a flow
indicator, which is available from the factory, responds.
2. If the pump does not deliver after 10–15 seconds of operation, abort commissioning, establish
the cause of the fault and only then continue the startup procedure. Follow the instructions in the
fault diagnosis charts, see "Faultfinding reference", page 75.
3. Run the pump for a few minutes to allow the piping system to vent fully.
The piping system is fully vented when there is a smooth operating noise and a pressure gauge
on the pressure side of the pump shows no more fluctuations.
Adjusting the overflow valve
2 3 4
<1> plugscrew
<2> setscrew
<3> spring
000004
<4> valve cone
Fig. 3 Mounting position of the overflow valve
If the delivery pipe on the pressure side of the pump is blocked, extremely high pressure can build
up which could possibly lead to the parts under pressure rupturing. An overflow valve is integrated
into KRAL pumps of the K series. The overflow valve prevents too high a pressure building up in
the pump. The overflow valve is set to 110 % of nominal pressure at the factory. This opening
pressure must not be exceeded in normal pump operation, otherwise the opening pressure of the
valve will have to be reset.
33
Operation
Requirement:
• Pump in operation
• Pressure gauge on the pressure side of the pump
Resource:
• Allen key for each pump size in accordance with the following table
Pump size DIN 908 Hexagon socket

K 5–20 R 1/4 " SW 6
K 32– 42 R 3/4 " SW 8
K 55–118 R 3/4 " SW 17
K 160–275 R 3/4 " SW 10
K 370– 450 R 3/4 " SW 17
K 550–660 R 3/4" SW 10
K 851–1301 R 3/4 " SW 17
K 1501–1701 R 3/4" SW 17
Tab. 1 Allen key widths for the various pump sizes
DANGER!
Risk of injury or fire, should pumped medium escape during overflow valve adjustment.
☞ Follow the safety instructions for handling hazardous liquids.
1. Check that the factory setting of the overflow valve meets the requirements of the installation. If
necessary, reset the safety valve.
2. Switch on the pump.
3. Open the plugscrew <1> of the overflow valve on the end cover.
4. Increase the delivery pressure step by step to check the opening pressure of the valve. Keep an
eye on the pressure gauge and make sure that the pressure stays within the operational limits.
When the overflow valve opening pressure is reached, the displayed pressure noticeably drops.
5. Turn the setscrew to adjust the opening pressure.
Turn it clockwise to increase the opening pressure.
Turn it anticlockwise to decrease the opening pressure.
6. Repeat steps 4 and 5 until the desired opening pressure is reached.
7. Tighten the plugscrew in the end cover again.
34
Operation
Pump shutdown
Switching off the pump
Requirement:
• Pump in operation
WARNING!
Pressurizing the pump while it is at a standstill may damage the pump seals.
☞ Make sure that while the pump is at a standstill, the pressure in the pump does not exceed
the inlet pressure during operation.
1. Disconnect the motor from the mains.

2. If there is no return valve fitted in the pressure pipe, close the shut-off device on the pressure
side.
Resuming pump operation

Restarting the pump
Requirement:
• A return valve incorporated in the suction pipe, if it is possible to drain the suction pipe when the
pump is at a standstill
• The requirements for commissioning are met, see "Commissioning the pump", page 33
WARNING!
☞ Before starting the pump, make sure that the pump is full.
☞ Switch on the pump.

Under the requirements mentioned above, the pump is ready for operation at any time.
35
Servicing
Servicing
Maintenance
Maintenance requirement
The service life of the pump is heavily dependent on the pump operating conditions. If the
operational limits are adhered to, see "Operating data", page 4, the pump will last for many years.
Symptoms of advanced wear in individual pump components can be detected in accordance with
the following table.
Findings Cause Remedy

Running noise increases Onset of bearing damage Replace bearing
Increased leakage Onset of seal damage Replace shaft seal
Abrasive components at the Non-volatile media Clean seal
seal
Increased shaft coupling play Advanced wear in the Replace intermediate ring
intermediate coupling ring
Drop in delivery rate and Advanced wear of screws and Replace screws and casing
pressure during constant casing
operating conditions
Tab. 1 Chart for testing the maintenance requirement
1. Check the pump regularly every four weeks, both by looking at it and by listening to it.
2. Check for symptoms of premature wear in accordance with the above chart and eliminate the
cause.
37
Servicing
Maintenance of seal
Maintaining the mechanical seal
When operating the pump with low volatile liquids (e.g. heavy fuel oil) the regular small amounts of
leakage may form solid deposits on the atmospheric side of the seal. During long-term operation
the increasing abrasive components may pile up to such an extent that a free drainage of the
leakage is not ensured anymore. As a result the leakage may contaminate and destroy the bearing.
To ensure a safe drain the permeability of the leakage vent holes has to be checked regularly.
Requirement:
• Pump dismantled, see "Removing the Pump", page 28
WARNING!
Bearing damage due to insufficient drainage of shaft seal leakage.
☞ Check permeability of leakage vent holes regularly.
1. If applicable, disassemble drainage pipe.

2. Check permeability of leakage pipe: e.g. observe
drainage of a small amount of liquid poured into
the pipe
- or -
☞ check by visual inspection
- or -
☞ introduce plug of soft material (wood, polymer
etc.).
3. Clean drainage pipe and/or vent hole, if not per-
meable.
4. Re-assemble leakage pipe, if applicable.
38
Assistance with problems

Troubleshooting
Faultfinding reference
Malfunctions can have different causes. The following table lists the symptoms of a fault, the
possible causes and measures for elimination.
Findings Cause and remedy

No pump suction Pump suction pipe closed
☞ Check shut-off devices in the suction pipe and open it, if
necessary.
Suction valve or pipe obstructed
☞ Check for clear passage through the suction valve and pipe.
Level of liquid in the intake container too low
☞ Top-up the pumped medium.
Dirty filter
☞ Clean the filter.
Pump intake capacity reduced by inadequate wetting
☞ Fill pump with medium.
Incorrect pump rotation direction
☞ Make the electrical connection such that the direction of pump
rotation matches that of the arrow on the flange cover.
Leaking suction pipe or shaft seal
☞ Check suction pipe or shaft seal for leaks. Pay particular
attention to leakage at valves and connection points. If
necessary, replace parts.
Suction head too high
☞ Reduce difference of level
- or -
☞reduce pipe length
- or -
☞increase pipe diameter
- or -
☞heat the medium to reduce viscosity
- or -
☞fit a suction filter with greater mesh width. Make sure that
the permissible mesh width is not exceeded, see Tab. 1,
page 26.
Pump does not vent
☞ Vent the pressure pipe at the highest point.
75

Delivery rate too low Differential pressure at the pump too high
☞ Check the installation and reduce the differential pressure.
Viscosity of the pumped medium too high
☞ Raise the temperature of the medium
- or -
☞reduce the rotation speed.
Viscosity of the pumped medium too low
☞ Lower the temperature of the medium
- or -
☞increase the rotation speed
Dirty filter
- or -
- or -
- or -
- or -
page 26.
Motor running at wrong voltage or frequency
1. Make sure that the motor voltage and frequency match the
operating voltage.
2. Compare the speed of the motor with the pump nameplate. If
the data does not match, adjust the speed of the motor.
Airlock or gas in the medium
1. Test the piping system for air admission and if necessary,
replace parts.
2. Reduce the suction head
- or -
☞increase the inlet pressure.
Overflow valve opens during normal operation
☞ Set opening pressure above value of operating pressure.
Overflow valve leaking
☞ Clean overflow valve and if necessary, re-seat.
Advanced wear of rotating pump components
☞ Check set of screws and casing and replace if necessary.
76

Pump runs noisily Dirty filter
- or -
- or -
- or -
- or -
☞fit suction filter with greater mesh width. Make sure that the
permissible mesh width is not exceeded, see Tab. 1, page
26.
Viscosity of pumped medium too high
- or -
☞reduce the rotation speed
replace parts.
- or -
Inadequate alignment of shaft coupling
☞ Align the shaft coupling correctly, see "Aligning and checking
the shaft coupling", page 27.
Pump deflected
1. Support the weight of the pipeline.
2. Loosen pipeline connections and assemble stress free, see
"Installing the pump", page 26.
Resonance in the installation
☞ Provide a flexible bearing arrangement for the unit
- or -
☞make the connections with hoses.
Speed of flow in suction or pressure pipe too high
1. Set the flow speed in the suction pipe so that it does not
exceed 1 m/s.
2. Set the flow speed in the pressure pipe so that it does not
exceed 3 m/s.
Ball bearing damaged
☞ Replace the ball bearing, see "Removing ball bearings", page
63.
77

Motor overload Motor running at wrong voltage or frequency
1. Make sure that the motor voltage and frequency match the
operating voltage.
2. Compare the speed of the motor with the pump nameplate. If
the data does not match, adjust the speed of the motor.
Differential pressure too high
☞ Check the installation and reduce the differential pressure.
High viscosity of pumped medium
- or -
Lack of lubrication or foreign bodies have caused superficial
damage to rotating pump components
☞ Check the set of screws and the casing and replace if
necessary.
Damaged rolling bearing
☞ Replace the rolling bearing, see "Removing ball bearings", page
63.
Uneven pump capacity Dirty filter
- or -
- or -
- or -
- or -
page 26.
Viscosity of the pumped medium is too high
- or -
replace parts.
- or -
Overflow valve leaks
☞ Clean the overflow valve and if necessary, re-seat.
78

Leaking shaft seal Dry running has damaged the shaft seal
☞ Replace the shaft seal, see "Removing the mechanical seal",
page 48. When starting up the pump, pay attention to venting.
Inlet pressure too high
☞ Reduce the inlet pressure at the installation end.
Thermal or chemical loading of elastomer seals exceeded
1. Check the maximum operating temperature.
2. Check the resistance of the elastomer with regard to the
pumped medium.
Cold start when delivering high-viscosity media
☞ Install pump heating.
Seal overload during heating process
☞ To prevent thermal expansion of the media causing a buildup
of pressure, open the pressure or suction side shut-off
devices.
Leaking return valve causes seal overload when pump is at a
standstill
☞ Clean the return valve and if necessary, replace it.
Advanced wear of sealing surfaces
☞ Replace the seal and if necessary, check the pumped medium
for abrasive content.
Pump is stuck Foreign bodies in the pump
☞ Dismantle the pump and clean it.
☞ Smooth the superficial damage to the casing and the rotating
parts with an oilstone and if necessary, replace the set of
screws and/or the casing.
Differential pressure is too high and has overloaded the sleeve
bearing
☞ Dismantle the pump.
☞ Reduce the differential pressure.
Viscosity is too low and has overloaded the sleeve bearing
☞ Increase the viscosity, for example by reducing the operating
temperature.
Dry running has damaged the pump
☞ When resuming operation, take action to prevent dry running,
see "Resuming pump operation", page 35.
Tab. 1 Fault diagnosis chart
79
Appendix
Appendix
General drawings
Exploded view of pump with coupling and motor
K6
K5 K7
K4
K3
K2
K1
K8
K9
000098
K10
K11
Fig. 1 Exploded view of a K-pump with coupling and motor
Item no. Part Spare part no. Item no. Part Spare part no.
<K1> pump 001 <K7> motor 529
<K2> socket screws 914,1 <K8> hexagon screws 900,1
<K3> distance sleeve 039 <K9> socket screws 914,2
<K4> pumpside coupling part 52,1 <K10> pump bracket 180
<K5> coupling intermediate ring 525 <K11> pump pedestal 225
<K6> motorside coupling part 52,2
81
Appendix
Exploded view of the pump
15
11 12 14
13 16 17
8 10
18
7 9
20 19
6
21
22
5
4 23
3
2
25 24
28
1
29 26
38
39 37
31
27
40 36
41
30
32
33
34
35
000099
Fig. 2 Exploded view of a K-pump
<1> socket screws 914,2 <22> dowel pin 859
<2> plug screw 165,1 <23> flat gasket* 729,3
<3> flat gasket 729,1 <24> plug screw* 165,3
<4> end cover 070 <25> straight pin 879
<5> flat gasket 729,4 <26> circlip* 471,4
<6> pump casing 131 <27> radial shaft seal* 745
<7> flat gasket 729,2 <28> flat gasket 729,2
<8> plug screw 165,2 <29> plug screw 165,2
<9> flat gasket 729,5 <30> mechanical seal 457
<10> flat gasket 729,2 <31> spacer 062
<11> plug screw 165,2 <32> circlip 471,1
<12> plug screw 165,3 <33> balancing cylinder 042
<13> flat gasket 729,3 <34> main screw 661
<14> flange cover 074 <35> idle screws
82
Appendix
<15> plug screw* 165,3 <36> key 866
<16> flat gasket* 729,3 <37> plug screw 165,2
<17> circlip 471,2 <38> flat gasket 729,2
<18> support ring 056 <39> valve cone 305
<19> circlip 471,3 <40> spring 501
<20> ball bearing 817 <41> adjusting screw 164
<21> socket screws 914,1
*only for version radial shaft seal
Tab. 1 Spare part numbers
83

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Behrens Pumpen

Fig. 1 Structure of a screw pump

<1> setscrew <8> ball bearing

General drawing of a screw pump with coupling and motor

<K1>pump <K4>motorside coupling part

Characteristics of screw pumps

• High power density

Screw set and casing

• Mechanical seal, unidirectional, not relieved

Radial shaft seal:

Fig. 3 Structure of a K-pump with radial shaft seal

Mechanical seal with quench:

Fig. 4 Structure of a K-pump with mechanical seal and quench

<V1>connection to quench container <V4>plugscrew

Main screw bearing

Bearing of the idle screws

Fig. 5 Overflow valve mounting position

Electrical and medium heating systems are described below.

<1> heating cover

Fig. 6 Electrical heating

<1> heating cover

Fig. 7 Medium heating

Transportation, storage and disposal

• Separate lifting accessories of the correct size

☞ Use correctly proportioned and intact separate lifting accessories.

Raising the pump unit

• Separate lifting accessories of the correct size

☞ Use correctly proportioned and intact separate lifting accessories.

Storage and preservation

Preserving the internal surfaces of the pump

1. Set up the pump so that the pressure-face connection is pointing upward.

Preserving the external surfaces of the pump

• Castrol Rustilo DWX 33 or other preservative offering comparable protection

Removing the preservative

It is essential to comply with the following safety instruction during disposal:

• Comply with local disposal regulations.

Disposing of the pump

• Solvent or industrial cleaner suitable for the pumped medium

1. Dismantle the pump.

Installation, removal and connection

Fig. 1 Types of construction

<1> type KV with a pump base

☞ Do not mount the pump above the motor.

☞ Only attach the pump to a stable substrate.

Installing the pump

Pump size Medium Max. mesh width

Tab. 1 Mesh width of the startup filter

Fig. 2 Correct flange connection

<1> linear offset

Fig. 3 Incorrect flange connections

Aligning and checking the shaft coupling

<a> lateral offset

Fig. 4 Measuring points for coupling alignment tolerances

Tab. 2 Limits for shaft coupling alignment

☞ Check the alignment of the coupling.

☞ Only allow authorised and qualified personnel to connect the pump.

1. Comply with the operating instructions for the pre-fitted motor.

☞ Only allow authorised and qualified personnel to disconnect the pump.

☞ Comply with the safety instructions applicable to handling hazardous liquids.