Supplementary operating instructions

1070.87/4-10 G3 Explosion protection

Supplementary operating instructions on explosion protection as per EC directive

94/9/EC

for pump types

Etanorm
Etanorm-R
Etanorm-RSY
Etanorm SYA
Etachrom NC

Order No. / Works No.: ___________________________________________________

Type series: Etanorm, Etanorm-R, Etanorm-RSY, Etanorm SYA, Etachrom NC

(delete inapplicable)

Caution These supplementary operating instructions

cover only the main issues concerning
explosion protection. The specific operating instructions for the
relevant pump type must also be complied with.
 Explosion protection

Contents
Page
1 General 3
2 Safety 3
2.1 Marking of instructions in the
supplementary operating manual 3
2.2 Personnel qualification and training 3
2.3 Safety instructions 3
2.4 Safety awareness 3
2.5 Additional safety instructions for the
operator / user 3
2.6 Safety instructions for maintenance,
inspection and installation work 3
3 Instructions concerning product and
accessories 3
3.1 Pump casing (pressure enclosure) 3
3.2 Coupling, coupling guard 3
4 Instructions concerning installation
and commissioning 4
4.1 Coupling 4
4.2 Connection to power supply 4
4.3 Earthing 4
4.4 Belt drive 4
5 Instructions concerning operation and
servicing 4
5.1 Unauthorized modes of operation 4
5.2 Explosion protection 4
5.3 Pump fill 4
5.4 Marking 4
5.5 Fluid handled 4
5.6 Checking the direction of rotation (see
also pump-specific operating manual) 4
5.7 Pump operating mode 5
5.8 Temperature limits 5
5.9 Maintenance 6

2

1 General
Caution These supplementary operating instructions
contain important information for safe and
reliable pump operation in hazardous areas. If the pump is
operated in hazardous areas, compliance with these operating
instructions is of vital importance to avoid any risks.
These supplementary 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.
If you need any additional information or instructions exceeding
the scope of this manual or in case of damage please contact
KSB’s nearest customer service centre.
2 Safety
These supplementary operating instructions contain
fundamental information concerning pump operation in
hazardous areas which must be complied with during
installation, operation, monitoring and maintenance. Therefore
this supplementary 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 location
of operation of the machine / unit for easy access.
Not only must the general safety instructions laid down in this
chapter on ”Safety” be complied with, but also the safety
instructions outlined under specific headings as well as the
safety instructions contained in the specific operating manual
of the relevant pump type.
2.1 Marking of instructions in the
supplementary operating manual
The safety instructions contained in this supplementary
operating manual concerning explosion protection are marked
The word
Caution
is used to introduce safety instructions whose non-observance
may lead to damage to the machine and its functions.
2.2 Personnel qualification and training
All personnel involved in the operation, maintenance,
inspection and installation of the unit must be fully qualified to
carry out work in hazardous areas.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question
is 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 take care of such training. In addition, the operator
is responsible for ensuring that the contents of the
supplementary operating manual are fully understood by the
responsible personnel.
2.3 Non-compliance with safety instructions
Non-compliance with safety instructions can jeopardize the
safety of personnel, the environment and the machine / unit
itself. Non-compliance with these safety instructions will also
lead to forfeiture of any and all rights to claims for damages.
Explosion protection
In addition to the hazards indicated in the operating manual of
the relevant pump type, non-compliance may also result in
hazards to persons by explosion.
2.4 Safety awareness
It is imperative to comply with the safety instructions contained
in this supplementary operating manual, the operating manual
of the pump type concerned, the relevant national and
international explosion protection regulations, health and
safety regulations and the operator’s own internal work,
operation and safety regulations.
Ex symbol relates to additional requirements which
must be adhered to when the pump is operated in
hazardous areas.
2.5 Additional safety instructions for the
operator / user
In addition to the safety instructions for the operator/user
indicated in the pump’s operating manual, the following must be
observed:
If the pumps/units are located in hazardous areas, it is
imperative to make sure that unauthorized modes of
operation are prevented. Non-compliance may result in the
specified temperature limits being exceeded.
2.6 Safety instructions for maintenance,
inspection and installation work
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the pump’s operating manual and this supplementary operating
manual.
If necessary, additional explosion protection regulations must
be heeded.
3 Instructions concerning product
and accessories
3.1 Pump casing (pressure enclosure)
For handling combustible fluids, the pressure-retaining
casing components (casing, discharge cover, bearing
bracket for Etanorm SYA and Etanorm-RSY) must be made of
ductile material.
The materials used must contain less than 7.5 % magnesium.
This requirement is fulfilled by KSB.
3.2 Coupling, coupling guard
In compliance with the accident prevention regulations the
pump must not be operated without a coupling guard. If the
customer specifically requests not to include a coupling guard
in our delivery, then the operator must supply one.
In this case, it is important to make sure that the materials
selected for coupling and coupling guard are non-sparking in
the event of mechanical contact. KSB’s scope of supply meets
this requirement.
If coupling parts are made of aluminium, a brass
coupling guard must be used.
3

4 Instructions concerning installation
and commissioning
4.1 Coupling
Misalignment of the coupling may result in inadmissible
temperatures at the coupling or bearings. Make sure
that the coupling is correctly aligned at all times.
4.2 Connection to power supply
Connection to the power supply must be effected by a
trained electrician only. Check available mains voltage
against the data on the motor rating plate and select appropriate
start-up method.
We strongly recommend to use a motor protection device
(motor protection switch).
In hazardous areas, compliance with IEC 60079-14 is
an additional requirement for electrical connection.
4.3 Earthing
To eliminate any risk due to electrostatic charging, the
pump unit must be earthed at the earthing terminal
provided.
4.4 Belt drive
Belt-driven pump sets must always be earthed.
The condition of the belts must be checked regularly.
The belts must include some conductive material.
5 Instructions concerning operation
and servicing
5.1 Unauthorized modes of operation
The warranty relating to the operating reliability and safety of the
unit supplied is only valid if the equipment is used in accordance
with its designated use as described in the following sections of
this supplementary operating manual and the pump-specific
operating manual. The limits stated in the data sheet must not
be exceeded under any circumstances.
Any operation of the pump outside the permissible
operating range and any unauthorized modes of
operation may result in the specified temperature limits being
exceeded (observe section 5.8).
5.2 Explosion protection
If the pumps/units are installed in hazardous areas
where compliance with EC directive 94/9/EC is required,
the measures and instructions given in the following sections
5.3 to 5.9 must be adhered to without fail, to ensure explosion
protection.
5.3 Pump fill
It is assumed that the system of suction and discharge
lines and thus the wetted pump internals incl. seal
chamber (on Etanorm SYA and Etanorm-RSY pumps incl.
bearing bracket) and auxiliary systems are completely filled
with the fluid to be handled at all times during pump operation,
so that an explosive atmosphere is prevented.
If the operator cannot warrant this condition, appropriate
monitoring devices must be used.
4
Explosion protection
Improper installation (e.g. vertical installation) may
impair the self-venting properties of the seal chamber,
so that gas bubbles may collect in the pump and cause the
mechanical seal to run dry.
High negative pressure on the suction side (e.g. due to
clogged suction-side strainers or low system pressure)
may result in air intake at the shaft seal and thus gas bubbles
in the pump. This may also cause the mechanical seal to run dry
(in the case of Etanorm SYA and Etanorm-RSY pump type).
Suitable monitoring facilities shall be installed, if necessary.
For design-inherent reasons, however, it is not always
possible to preclude the existence of a certain residual
volume not filled with liquid after the pump has been filled prior
to commissioning. However, once the motor is started up the
pumping effect will immediately fill this volume with pumped
fluid.
It is imperative to make sure that the seal
Note
chambers and auxiliary shaft seal systems are
properly filled.
5.4 Marking
The Ex marking on the pump only refers to the pump
part, i.e. the coupling and motor must be regarded
separately.
The coupling must have an EC manufacturer’s declaration. The
driver must be regarded separately.
Example of marking on the pump part:
CE Ex II 2 G T1 - T5
The safety instructions set forth in section 5.8 must be complied
with.
5.5 Fluid handled
Abrasive particles in the fluid handled may erode the
casing walls to such an extent that fluid may escape.
This risk applies in particular to thin-walled casings made of
stainless steel sheet (Etachrom type series). When handling
combustible media, make sure that the fluid does not contain
any abrasive particles.
5.6 Checking the direction of rotation (see also
pump-specific operating manual)
If the explosion hazard also exists during the installation
phase, the direction of rotation must never be checked
by starting up the unfilled pump unit, even for a short period, to
prevent temperature increases resulting from contact between
rotating and stationary components. If it is not possible to fill the
pump, the direction of rotation must be checked with the
pump/motor coupling removed.

5.7 Pump operating mode
Make sure that the pump is always started up with the
suction-side shut-off valve fully open and the discharge-side
shut-off valve slightly open. However, the pump can also be
started up against a closed swing check valve. Only after the
pump has reached full rotational speed shall the discharge-side
shut-off valve be adjusted to comply with the duty point.
Caution Pump operation with closed shut-off valves in
the suction and/or discharge pipes is not
permitted.
In this condition, there is a risk of the pump casing taking
on high surface temperatures after a very short time,
due to a rapid temperature rise in the pumped fluid inside the
pump.
Note Additionally, the resulting rapid pressure
build-up inside the pump may cause excessive
stresses on the pump materials or even bursting.
The minimum flows indicated in the relevant pump operating
manuals refer to water and water-like liquids. Longer operating
periods with these liquids and at the flow rates indicated will not
cause an additional increase in the temperatures on the pump
surface. However, if the physical properties of the fluids handled
are different from water, it is essential to check if an additional
heat build-up may occur and if the minimum flow rate must
therefore be increased.
The calculation formula below can be used to check if an
additional heat build-up may lead to a dangerous temperature
increase at the pump surface.
TO = Tf + D J
g*H
DJ = * (1 - h )
c *h
c Specific heat [J / kg K]
g Acceleration due to gravity [m@/s]
H Pump head [m]
Tf Temperature of fluid handled [°C]
TO Temperature of casing surface [°C]
h Pump efficiency [-]
DJ Temperature difference [°C]
5.8 Temperature limits
In normal pump operation, the highest temperatures are
to be expected on the surface of the pump casing, at the
shaft seal and in the bearing areas.
Unless the pump is equipped with an additional heating facility,
the surface temperature at the pump casing will correspond to
the temperature of the fluid handled, assuming that the pump
surface is freely exposed to the atmosphere.
If the pump is heated, it must be ensured that the temperature
classes stipulated for the plant are observed.
In any case, responsibility for compliance with the specified fluid
temperature (operating temperature) lies with the plant
operator. The maximum permissible fluid temperature depends
on the temperature class to be complied with.
Explosion protection
The following limits for the max. permissible fluid
temperature must be observed for the individual
temperature classes as per EN 13463-1 given below
(temperature increase in the shaft seal area, if any, has been
taken into consideration):
Temperature class Max. permissible fluid
as per EN 13463-1: temperature for compliance
with temperature class
T5 85 °C
T4 120 °C
T3 185 °C
T2 280 °C
T1 Temperature limit of pump
Safety note:
The permissible operating temperature of the
Caution
pump in question is indicated on the data
sheet. If the pump is to be operated at a higher temperature, the
data sheet is missing or if the pump is part of a pool of pumps,
the maximum permissible operating temperature must be
enquired from the pump manufacturer.
The motor is usually rated for continuous operation at
the data indicated in the data sheet. Frequent motor
start-ups may result in increased surface temperatures at the
motor. Contact the motor manufacturer, if necessary.
Based on ambient temperatures of max. 40 °C and assuming
that the pump unit is properly serviced and operated and that
the surfaces in the bearing area are freely exposed to the
atmosphere, compliance with temperature class T5 is
warranted for surfaces in the area of the rolling element
bearings.
If temperature classe T6 (85 °C) have to be complied with,
special measures may have to taken with regard to bearing
temperature. In such cases, and if ambient temperatures are
higher, contact the manufacturer.
Operator’s errors or malfunctions may result in substantially
higher temperatures.
Mechanical seals may exceed the specified
temperature limits if run dry. Dry running may not only
result from an inadequately filled seal chamber, but also from
excessive gas content in the fluid handled.
Operation with packings is not permissible.
Pump operation outside its specified operating range
may also result in dry running.
Shaft seals shall be regularly checked for leakage.
If combustible fluids are to be pumped with pumps
equipped with single-acting mechanical seals,
ventilation of the space between the discharge cover and the
bearing cover must be ensured. Ventilation is effected by the
perforations in the contact guards on the bearing bracket. The
contact guards must not be closed or covered (e.g. by insulating
material).
Verify that V-rings are properly seated on the shaft. Only
gentle contact shall be established between the sealing
lip and the shaft.
5
 Explosion protection

5.9 Maintenance
Only a pump unit which is properly serviced and maintained in
perfect technical condition will give safe and reliable operation.
This also applies to the reliable function of the rolling element
bearings whose actual lifetime largely depends on the
operating mode and operating conditions.
Regular checks of the lubricant and the running noises
will prevent the risk of excessive temperatures as a re-
sult of bearings running hot or defective bearing seals.
The correct function of the shaft seal must be checked
regularly. Any auxiliary systems installed must be moni-
tored, if necessary, to make sure they function correctly.
Static sealing elements shall be regularly checked for leakage.
The coupling guard and any other guards of fast rotating
components must be regularly checked for deformation
and sufficient distance from rotating elements.
Regularly verify the correct position of plastic components ex-
posed to the atmosphere which are fitted to fast rotating compo-
nents or which might come into contact with fast rotating com-
ponents.
We strongly recommend to draw up a maintenance
schedule which includes the above-mentioned points.

Subject to technical modification without prior notice.

1.7.2005
1070.87/4-10

KSB Aktiengesellschaft
P.O. Box 1361, 91253 Pegnitz · Bahnhofplatz 1, 91257 Pegnitz (Germany)
Tel. +49 9241 71-0 · Fax +49 9241 71-1791 · www.ksb.com