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INSTALLATION, SERVICE AND MAINTENANCE INSTRUCTIONS ANNEX FOR CE ATEX REGISTERED EQUIPMENT UNDER DIRECTIVE 2014/34/UE: KIBER KS Ex / KIBER KST Ex The contents of this Annex complement the information included in the instruction manual. The instructions in this Annex must be observed whenever equipment registered under Directive 2014/34/EU is used. This annex is to be added to the manuals of the ATEX-certified components that form part of the assembly (e.g. motors, etc). INOXPA, S.A.U. Telers, 60 Aptdo. 174 17820-Banyoles Tel.: +34 972 57 52 00 Fax: +34 972 57 55 02 [email protected] www.inoxpa.com Manual Original 01.610.30.08EN (C) 2022/11 01.610.30.14EN (0) 2022/11 EU Declaration of Conformity We, INOXPA, S.A.U. Telers, 60 17820 – Banyoles (Girona) Hereby declare under our sole responsibility that the machine HELICOIDAL PUMP Designation KIBER Type KS - KST From serial number IXXXXXXXXX to IXXXXXXXXX (1) Is in compliance with applicable provisions of the following directive: Directive ATEX 2014/34/EU Applicable harmonized standards: EN ISO 80079-36:2016 EN ISO 80079-37:2016 EN 1127-1:2019 EN 13237:2012 EN15198:2007 EN IEC 60079-0:2018 This Declaration of Conformity covers equipment with the following ATEX marking: II 2G Ex h IIB T4…T3 Gb II 2D Ex h IIIB T125 ºC…T200 oC Db II 2G Ex h IIB T4…T3 Gb II 2D Ex h IIIB T125 ºC…T200 oC Db The technical documentation referenced 018999/18 is on file with the notified body INERIS, Parc Technologique Alata BP 2 F-60550, Verneuil-en-Halatte, France. Reference num. 0080. The person authorized to compile the technical documentation is the signer of this document. Banyoles, 2022 David Reyero Brunet Technical Office Manager (1) Where X is a numeric character 1. Safety 1.1. INSTRUCTIONS FOR STARTING UP This Annex to the instruction manual, together with the manual, contains the basic indications to be fulfilled during installation, operation, and maintenance. Consequently, it is essential that before installation, the installer and technical personnel responsible for the plant read this Annex to the instruction manual and it must remain permanently available in the proximity of the corresponding pump or installation. Not only should the safety instructions indicated in this chapter be observed and fulfilled, but also the special measures and recommendations included in the other chapters of this manual. 1.2. SAFETY 1.2.1. WARNING SYMBOLS The safety instructions in this Annex are expressed using the symbols indicated below. Non-fulfilment of these instructions could endanger the staff, the machine, and the operation of the machine: This sign will identify all the safety instructions given in this Annex that relate to the danger of forming an explosive atmosphere and creating sources of combustion in potentially explosive atmospheres, whereby failure to comply with those instructions may threaten your safety 1.3. GENERAL SAFETY INSTRUCTIONS 1.3.1. DURING INSTALLATION In order to reduce the risk of static electricity, the equipment must be earthed to ensure electrical continuity between the pipes and the pump. 1.3.2. During operation The limits of the operating conditions in explosive atmospheres must not be exceeded. This pump was selected according to the operating conditions specified by the user. Therefore, INOXPA disclaims liability for any damage caused by use of the pump in conditions other than those stated in the order. 1.3.3. During maintenance Danger! Important indications regarding protection from explosions An explosive atmosphere may be created during disassembly of the pump. Therefore, permits to work must be issued and these jobs must only be done by qualified or trained personnel. 2 2. Safety (C) 2022/11 1.3.4. Compliance with the instructions Any non-fulfilment of the instructions may result in a risk for the operators, the environment and the machine, and may result in the loss of your right to claim damages. Non-fulfilment may cause the following risks (in addition to those indicated in the manual): • Creation of explosive atmospheres and risk of explosion. 1.3.5. Guarantee Any guarantee will be lawfully cancelled immediately; in addition, we will be compensated for any claims of civil liability presented by third parties, in the case that (further to the conditions already indicated in the manual): • The equipment has been used improperly or has not been used in accordance with the working conditions in the classified area, work has been carried out in a different classified area, or different conditions of temperature or pressure and/or different substances have been used. RESPONSIBILITY FOR THE ATEX CERTIFICATION If INOXPA, S.A.U supplies a bare shaft pump, the certification mark for protection from explosion only relates to the pump. All assembled equipment must have separate certification supplied by the equipment manufacturer and should have at least the same protection grade or one protection grade more than the pump. The complete assembly must be certified separately by the equipment manufacturer and must have a plate with characteristics different to that of the pump. If INOXPA, S.AU. supplies the entire assembly, the certification against explosion and the marking on the identification plate, fitted to the pump itself, will be for this particular group. (C) 2022/11 1. Safety 3 2. Table of Contents 1. SAFETY ...................................................................................................................................... 2 1.1. Instructions for starting up ................................................................................................. 2 1.2. Safety .............................................................................................................................. 2 1.3. General safety instructions ................................................................................................. 2 2. TABLE OF CONTENTS .................................................................................................................. 4 3. GENERAL INFORMATION ............................................................................................................. 5 3.1. Description ....................................................................................................................... 5 3.2. Application........................................................................................................................ 5 4. INSTALLATION ............................................................................................................................ 6 4.1. Receiving the pump ........................................................................................................... 6 4.2. Transport and storage ....................................................................................................... 6 4.3. Location ........................................................................................................................... 6 4.4. Pipes ................................................................................................................................ 7 4.5. Pressurisation tank ............................................................................................................ 7 4.6. Electrical installation .......................................................................................................... 7 4.7. Cooled mechanical seal ...................................................................................................... 8 5. STARTING UP ............................................................................................................................ 10 5.1. Starting up ...................................................................................................................... 10 6. MAINTENANCE ........................................................................................................................... 11 6.1. General information .......................................................................................................... 11 6.2. Cleaning .......................................................................................................................... 12 6.3. Spare parts ...................................................................................................................... 12 6.4. Paintwork ........................................................................................................................ 12 6.5. Checking de bearings ....................................................................................................... 12 6.6. Lubrication ...................................................................................................................... 12 6.7. Disassembly / assembly of the pump ................................................................................. 13 7. TECHNICAL SPECIFICATIONS ...................................................................................................... 14 4 2. Table of Contents (C) 2022/11 3. General information 3.1. DESCRIPTION For the helical pumps of the KIBER KS Ex / KIBER KST Ex series, the motors must be appropriate for working in explosive atmospheres. 3.2. APPLICATION This pump was selected for a given set of pumping conditions and operating conditions in explosive atmospheres when the order was placed. will not be responsible for any damage caused if the information provided by the buyer is incomplete or incorrect (type of liquid, viscosity, RPM, classification of the potentially explosive zone, gas generated by the potentially explosive atmosphere, etc.) (C) 2022/11 3. General information 5 4. Installation 4.1. RECEIVING THE PUMP The received pump must be checked to ensure that it is adapted to the working conditions of the classified area and the conditions of the order. 4.1.1. Pump identification The shipment should be checked in accordance with the instructions included in the manual. Also, the CE ATEX mark inscribed on the manufacturer's plate should be checked in order to verify that it matches the requirements of the order. II 2G Ex h IIB T4…T3 Gb II 2D Ex h IIIB T125ºC…T200 oC Db II 2G Ex h IIB T4…T3 Gb II 2D Ex h IIIB T125ºC…T200 oC Db CE ATEX mark inscribed on the manufacturer’s plate. If the equipment mark does not correspond to the order, INOXPA should be immediately informed of the situation. The temperature class and the maximum surface temperature depend on the temperature of the product to be pumped and the ambient temperature. Temperature class T4 T3 Temperature class for explosive gas atmospheres Product temperature (in process Room temperature or cleaning) ≤ 110 °C -20 °C to +40 °C ≤ 140 °C -20 °C to +40 °C Maximum surface temperature for explosive dust atmospheres Maximum Product temperature (in process surface Room temperature or cleaning) temperature T125 °C ≤ 125 °C -20 °C to +40 °C T200 °C ≤ 200 °C -20 °C to +40 °C 4.2. TRANSPORT AND STORAGE If the pump is not for immediate use, then it must be moved twice a week in order to prevent the impeller, mechanical seal, and bearings from seizing up. 4.3. LOCATION Place the pump near a drain on the floor. Note that the handling of inflammable fluids can create an area classified as Zone 0 in the drain area and therefore all the appropriate safety indications must be observed. 6 4. Installation (C) 2022/11 The motors used must be EC marked in accordance with Directive ATEX 2014/34/EU and with the instructions of the manufacturer and the applicable national and local regulations. When pumping inflammable or explosive liquids, a proper connection must be used. Connect the parts of the assembly with the earth connections in order to reduce the risk of static electricity. Depending on the fluid to be pumped, high temperatures may be reached inside and around the pump: Note that the surface temperature of the pump in normal operating conditions is determined by the fluid it pumps. To see 4.1.1. point. Air must be properly recirculated in order to cool the pump motor. Make sure there is no other equipment or surfaces near the motor that may radiate additional heat or affect the cooling of the motor. See the motor instructions manual. The bedplate must always have a cam for earth connection. Ensure that the earth connection is properly fitted to the bedplate. 4.4. PIPES Before starting up the pump, make sure that the suction and discharge valves of the pump are open. Before closing the suction and discharge valves, make sure that the pump is switched-off and has stopped. When hot fluids are being pumped, pay attention to thermal dilation. In this case, use expansion washers and pay special attention to avoid leaving the equipment electrically insulated (electrical equipotentiality) from the rest of the assembly. 4.4.1. Shut-off valves Use valves that are EC marked in accordance with the Directive ATEX 2014/34/EU and in accordance with the manufacturer’s instructions and the applicable national and local regulations. 4.5. PRESSURISATION TANK A pressurisation tank for double mechanical seals must always be pressurised at between 1,5 and 2,0 bar over the operating pressure of the pump when it is functioning, even when it is in operation or stopped. See instruction manual for the mechanical seal and pressurisation container. Check that the instrumentation leading to the pressurisation tank is appropriate to the work area. 4.6. ELECTRICAL INSTALLATION Before connecting and electric motor to the system, check local regulations regarding electric safety and standards EN 60204-1 and EN 60079-14. Also the motor manual. This motor should be Atex with adequate protection for the working environment in which it must run. Follow the motor manufacturer’s indications at all times. (C) 2022/11 4. Installation 7 Protection against motor overload, suitable for the motor’s nominal power must also be installed. If necessary, install a separate fan, bearing in mind the environment where it will operate (potentially explosive atmosphere). 4.6.1. Automatic circuit-breaker It must be remember that these automatic circuit-breakers have to work in a potentially explosive atmosphere. Therefore, the circuit-breakers selected must bear the CE ATEX mark in accordance with Directive 2014/34/EU The operating equipment must comply with the applicable electrical safety regulations and the instructions of the ATEX motor manufacturer. 4.6.2. Connection Before connecting the motor the mains, read the manufacturer’s instructions manual. This motor must be an ATEX motor with a protection level corresponding to the working environment where it will operate. Protection against motor overload, suitable for the motor’s nominal power, must also be installed. The electrical equipment, terminals and components of the control systems may still contain electric current when switched off. Contact may place the operator or installation in danger or cause irreparable damage to the equipment. The supplier's instructions for the safe opening of the motor should be followed at all times. Permits to work will be required to handle the equipment in potentially explosive atmospheres. It is strongly recommended that this type of work be carried out in non-classified atmospheres (i.e. there must not be an explosive atmosphere in the location of the pump when it is being handled). Proper recirculation of air must be ensured for cooling the pump motor. Make sure there are no other equipment of surfaces near the motor that may radiate additional heat or affect the cooling of the motor. See the motor’s instructions manual. The turning direction must be set when the motor is disconnected from the pump, or when the pump is completely primed and, in the case of pressurised cooled or double mechanical seals, when the seal chamber is filled with liquid. If there is a risk of explosion when the turning direction is being checked, do it with the pump completely primed. 4.7. COOLED MECHANICAL SEAL • • • Check the level of supply reserve. Check the temperature of the washing liquid. Check the condition of the washing liquid by inspecting it: in the sealing system that must be repaired. Frequent contamination is indicative of an unacceptable leak in the sealing system that must be repaired. 8 4. Installation (C) 2022/11 4.7.1. Single mechanical seal option If the single mechanical seal is working in dry conditions, its maximum operating temperature may be exceeded. This is why a simple mechanical seal must not operate under any circumstances in dry conditions. • • • Regularly check that the single mechanical seal is functioning correctly. Check that the hydraulic part of the pump is always free of liquid during operation. Avoid pumping fluids that contain large amounts of gas The end user must ensure that there is a constant flow to the pump by using a flow detector, flowmeter, or any other device in the pump intake, in order to prevent any increase in the surface temperature. Another option is to fit a temperature probe in the mechanical seal. 4.7.2. Double mechanical seal option • • • Check the level of supply. Check the temperature of the washing liquid. Check the pressure. Caution: the washing liquid must always be under pressure when the pump is operating. • Check the condition of the washing liquid: Change the washing liquid if it has been contaminated by another liquid. Contamination of the liquid means that the pump is not functioning properly and it must be inspected. For example, the sealing system may have leaks in the middle or be open due to insufficient backpressure of the washing liquid. 4.7.3. Cooled mechanical seal option • • • Check the level of supply reserve. Check the temperature of the washing liquid. Check the condition of the washing liquid by inspecting it: Change the washing liquid if it has been contaminated by another liquid. Frequent contamination is indicative of an unacceptable leak in the sealing system that must be repaired. (C) 2022/11 4. Installation 9 5. Starting up Before starting up, those responsible must be duly informed about the pump and the safety instructions. This Annex, along with the instructions manual, will be available to staff at all times. In order to carry out any type of work in potentially explosive atmospheres, it is necessary to adopt special safety measures such as permits to work. 5.1. STARTING UP An explosive atmosphere may be formed during the start-up of the pump. Therefore, permits to work will be required and these tasks must only be carried out by qualified or trained personnel. 5.1.1. Checks before starting up the pump Before starting up the pump, make sure that the suction and discharge valves of the pump are open. If there is a risk of operation in dry conditions, it is recommended that a flow-detection probe be installed in the pump intake, or any other device preventing the pump from operating in dry conditions. In the case of the (non-cooled) single seal option, the pump and the area around the seal must be covered by the pump fluid before start up. If the fluids that have to be drained are inflammable, the possible formation of potentially explosive atmospheres must be considered; permits to work should therefore be issued. 10 4. Installation (C) 2022/11 6. Maintenance 6.1. GENERAL INFORMATION The maintenance work of any equipment intended for use in potentially explosive atmospheres can only be carried out with the appropriate permit to work, as specified by ATEX 2014/34/UE. Maintenance jobs can only be done by qualified personnel. Use the proper clothing. Ensure that staff read the entire instructions manual and this Annex and, in particular, indicate those chapters that refer to the job to be done. 6.1.1. Check mechanical seals Check areas 1 and 21 daily. Check areas 2 and 22 weekly. For a double mechanical seal: - A control of temperature, level and barrier liquid pressure are essential and it is advisable to install an automatic device that stops the pump when the temperature of the liquid exceeds the temperature class in the classified area or when the liquid level is not what it should be. The instructions of the mechanical seal manufacturer, and in particular those concerning the temperature probe, must be followed at all times. 6.1.2. Environment Try to ensure that the working environment is clean, for some parts are very fragile and others have a low tolerance level. The possibility of the presence of an explosive atmosphere must also be considered. Therefore, these jobs can only be carried out after the appropriate work permit has been issued 6.1.3. Tools Use tools that are technically suitable for maintenance and repair jobs. If the area is not unclassified, all the tools must be flameproof and safe-work permits must be issued the job is started. 6.1.4. Safety Apart from the safety measures indicated in the manual given by the motor manufacturer for safely opening it must also be followed. 6.1.5. Conservation The possible existence of formation of explosive atmospheres must be taken into account when emptying the pump, so safe work permits must be issued and any possible source of ignition in the area surrounding the equipment or the work place must be eliminated (C) 2022/11 6. Maintenance 11 6.2. CLEANING The user is responsible for establishing a cleaning or disinfection plan that suits their needs. This plan should take into account all applicable laws, regulations and standards related to protection of public health and safety in the use and disposal of chemical products. An explosive atmosphere may be formed during the start-up of the pump. Therefore, permits to work will be required and these tasks must only be carried out by qualified or trained personal. 6.2.1. Outside cleaning Do not spray the hot parts of the pump with water, since some parts might crack and pump fluid could spill into the environment, thereby generating a potentially explosive atmosphere. The outside of the equipment must be cleaned in order to avoid the excessive build-up of combustible or explosive dust on the outer Surface of the equipment. The accumulated dust must never exceed 2 mm 6.3. SPARE PARTS When ordering spare parts for a pump operating within a classified area, it must be expressly stated that the pump is an ATEX pump and quote the manufacture number. Otherwise, Inoxpa cannot ensure that the pump operates with parts that are suitable for the classified. 6.4. PAINTWORK If rust appears on the painted surface of the lantern, the affected area must be repainted in order to avoid the risk of any abnormalities. The material the lantern is made of is an alloy with less than 7,5 % of light materials. 6.5. CHECKING DE BEARINGS The correct operation and assembly of the bearings must be checked regularly. The excessive production of noise, vibration, and heat is an indication of a fault or stoppage of the bearing or its lubrication. It is recommended that bearing vibrations be measured continuously or that the bearings be replaced after 4 relubrications. Regularly check that the bearing is correctly seated. Bearings must not be noisy and must not heat up. 6.6. LUBRICATION Lifetime lubrication is applied to the bearings. Nevertheless, it is advisable to periodically check that there are no leaks. If there is a lubricant leak, clean it up, and check for leaks again after approximately 24 hours. If leaks are confirmed, then the pump must be repaired immediately. 12 6. Maintenance (C) 2022/11 6.7. DISASSEMBLY / ASSEMBLY OF THE PUMP Improper assembly or disassembly of the equipment can impair operation of the pump, cause high repair costs, long downtime and even render the protective system of the equipment ineffectual. INOXPA disclaims any liability for accidents or damage caused by failure to observe the instructions of the manual and of this Annex. 6.7.1. Preparations As well as the instructions given in the manual, the possibility of the presence of an explosive atmosphere must also be considered. Therefore, these Jobs can only be carried out after the safe work permits have been issued. 6.7.2. Tools Use tools that are technically suitable for maintenance and repair jobs. If the area is not unclassified, all the tools must be flameproof and safe-work permits must be issued. 6.7.3. Cleaning Before proceeding to dismantle the pump, both the outside and the inside of the pump must be cleaned. The possibility of the presence or development of an explosive atmosphere must also be considered. Therefore, these jobs can only be carried out after the appropriate work permits have been issued. 6.7.4. Disconnection The possibility of the presence or development of an explosive atmosphere must be considered. Therefore, the appropriate work permits must be bee issued and any possible ignition source in the areas surrounding the equipment must be eliminated 6.7.5. Electrical safety In addition to the safety instructions given in the manual, the indications given by the motor manufacturer must be followed at all times in order to open the motor safely or lock it in. In addition to the instructions included in the manual, you must: Always observe the indications of the manufacturer of the motor and the mechanical seal if this has a temperature probe. CAUTION! Fluid might spill out when the pump casing is removed and a potentially explosive atmosphere might develop. (C) 2022/11 6. Maintenance 13 7. Technical Specifications To see 4.1.1. point to the maximum temperature values. Materials Parts in contact with the product Other Steel parts Gaskets in contact with the product Surface finish AISI 316L (1.4404) AISI 304L (1.4306) EPDM (standard) FPM (other materials available upon request) Polished Ra ≤ 0,8 µm Mechanical seal Type Material of rotating part Material of stationary part Gasket material Internal single, cooled seal or double seal Graphite(C) (standard) Silicon carbide (SiC) (standard) EPDM (standard) Water consumption (quench mec. seal) Pressure (quench mech. seal) 0,25 to 0,6 l/min from atmospheric to 100 kPa (1 bar) If the single mechanical seal is working in dry conditions, its maximum operating temperature may be exceeded. This is why a simple mechanical seal must not operate under any circumstances in dry conditions. - Regularly check that the single mechanical seal is functioning correctly. Check that the hydraulic part of the pump is always free of liquid during operation. Avoid pumping fluids that contain large amounts of gas. The client must use a flow meter, flow detector or any other safety device, to ensure that there is a constant flow to the pump and prevent it from operating in dry conditions. Another option is to fit a temperature probe in the mechanical seal. a. Double mechanical seal option (only available on bareshaft pump models). Must be protected by controlling the washing liquid. - Check the level of supply reserve. - Check the temperature of the washing liquid - Check the pressure ¡Caution! The washing liquid must always be under pressure when the pump is operating. - Check the condition of the washing liquid: Change the washing liquid if it has been contaminated by another liquid. Contamination of the liquid means that the pump is not functioning properly and it must be inspected. For example, the sealing system may have leaks in the middle or be open due to insufficient backpressure of the washing liquid. b. Optional cooled mechanical seal. This must be protected by controlling the washing fluid. 14 7. Technical Specifications (C) 2022/11 NOTAS INOXPA, S.A. BANYOLES Tel. +34 972 575 200 [email protected] DELEGACIÓN NORDESTE BARCELONA Tel. +34 937 297 280 [email protected] IMPROVED SOLUTIONS PORTUGAL LDA VALE DE CAMBRA Tel. +351 256 472 138 [email protected] INOXPA SKANDINAVIEN A/S DENMARK Tel. +45 76286900 [email protected] INOXPA USA, INC CALIFORNIA Tel. +1 707 585 3900 [email protected] INOXPA AUSTRALIA PTY, LTD MORNINGTON Tel. +61 (3) 5976 8881 [email protected] DELEGACIÓN CENTRO MADRID Tel. +34 918 716 084 [email protected] SWEDEN Tel. 031-336 05 60 [email protected] INOXPA SOUTH AFRICA GAUTENG Tel. +27 (0)11 794-5223 [email protected] DELEGACIÓN LEVANTE VALENCIA Tel. +34 963 170 101 [email protected] INOXPA ITALIA, S.R.L. VENEZIA Tel. +39 041 - 411236 [email protected] INOXPA ALGERIE S.A.R.L. ALGER Tel. +213 (0) 23 833 320 [email protected] DELEGACIÓN SUR CADIZ Tel. +34 956 140 193 [email protected] INOXPA UK LTD KENT Tel. 01737 378060 [email protected] INOXPA EGYPT CAIRO Tel: +2 0111 489 8989 [email protected] SUMINISTROS TECNICOS ALIMENTARIOS, S.L. VIZCAYA Tel. +34 944 572 058 [email protected] INOXPA Solutions Moldova CHISINAU Tel. +373 (69)102 624 [email protected] INOXPA SPECIAL PROCESSING EQUIPMENT (JIAXING), CO., LTD. JIAXING, CHINA Tel.: 00 86 573 83570035 [email protected] DELEGACIÓN VALLADOLID Tel. +34 983 403 197 [email protected] INOXRUS САНКТ-ПЕТЕРБУРГ Teл. +7 812 622 16 26 [email protected] DELEGACIÓN GALICIA, ASTURIAS y LEÓN Tel. +34 638 334 359 [email protected] INOXPA SOLUTIONS FRANCE SAS LYON Tel. +33 474627100 [email protected] PARIS Tel. +33 130289100 [email protected] S.T.A. PORTUGUESA LDA ALGERIZ Tel. +351 256472722 [email protected] МОСКВА Тел. +7 495 120 26 17 [email protected] STARINOX МOСКВА Тел. + 7 495 215 02 42 [email protected] INOXPA INDIA PRIVATE LIMITED MAHARASHTRA Tel. +91 020-64705492 [email protected] INOXPA MIDDLE EAST DUBAI, UAE Tel. +971 4 333 5388 [email protected] INOXPA UKRAINE КИЕВ Тел. +38 044 536 09 57 [email protected] INOXPA COLOMBIA SAS BOGOTÁ Pbx 57-1-7427577 [email protected] In addition to our branches, INOXPA has a network of independent distributors in over 50 countries worldwide. For further information, visit our website www.inoxpa.com ">
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