DEWATERING & DREDGE PUMPSET

DnD 150

MANUFACTURER DATA REPORT

PT. KSB Indonesia

Head Office – Factory
Jalan Timor Blok D2-1 Kawasan Industri MM2100
Cibitung, Jawa Barat 17520
Phone : +62 21 – 89983570 (Hunting)
Fax : +62 21 – 89983571
 DEWATERING & DREDGE PUMPSET

DnD 150

COSTUMER :
ADDRESS :

CONTACT PERSON :
PHONE :
COSTUMER PO NO. :
KSB JOB NO. :
PUMP SERIAL NO. :

Prepare By:

PT. KSB INDONESIA

 Table Of Contents

1 General 1

2 Safety 1

2.1 Marking on Instructions in the Manual 1

2.2 Personnel Qualification and Training 1

2.3 Non-compliance with Safety Instructions 1

2.4 Safety Awareness 1

2.5 Safety Instructions for Operator/User 1

2.6 Safety Instructions for Maintenance, Inspection and Installation 1

2.7 Unauthorized Modification and Manufacture of Spare parts 2

2.8 Unauthorized Modes of Operation 2

3 Transport and Interim Storage 2

3.1 Transport 2

3.2 Short Time storage 2

4 Description of the Product and Accessories 2

4.1 Technical Specification 2

4.2 Designation 2

4.3 Design Detail 3

4.3.1 Pump 4

4.3.2 Engine 4

4.3.3 Vacuum Pump 4

4.3.4 Electrical Control Panel and Level Sensor 4

5 Installing Pump Unit 4

5.1 Safety Regulations 4

5.2 Foundation 4
5.3 Installing Pump Unit 4

5.3.1 Pontoon Leveling 4

5.3.2 Aligning the Pump Set 4

5.3.3 Accessories Installation 5

6 Commissioning, Start Up and Shut Down 5

6.1 Commissioning 5

6.2 Start up Preparation 5

6.3 Start up / Shut down Procedure 6

6.3.1 Start Up (Automatic Mode) 6

6.3.2 Start up (Manual Mode) - For Self test only 7

6.3.3 Shutdown 7

7 Trouble Shooting 7

7.1 Low Flow Rate 7

7.2 Pump Fail to Prime 7

8 Diagrams and Drawings 8

8.1 General Priming Diagram 8

8.2 Electrical System for Priming Wiring Diagrams 9

8.3 Engine Volvo TAD1343VE Wiring Diagram 14

8.4 Engine Volvo TAD1643VE Wiring Diagram 16

8.5 Display Control Unit (DCU) Wiring Diagram 18

8.6 GA and Part List Drawing 19

9 Short Cut Operational Procedure 20

9.1 6.6 Start Up Procedure 20

9.2 6.7 Inspection After Start Up 20

9.3 6.8 Unit Shut Down 20

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1. General 2.2 Personnel Qualification and Training

All personnel involved in the operation, maintenance,

Caution This manual contains important inspection and installation of the machine must be
information for reliable, proper and efficient operation. fully qualified to carry out the work involved.
Compliance with the operating instructions is of vital
importance to ensure reliability and long service life of Personnel responsibilities, competence and supervision
the pump, and to avoid any risks. must be clearly defined by the operator. If the
personnel in question are not already in possession f
These operating instructions do not take into account the requisite know-how, appropriate training and
local regulations; the operator must ensure that such instruction must be provided. If required, the operator
regulations are strictly observed by all, including the may commission the manufacturer/supplier to provide
personnel called in for installation. such training. In addition, the operator is responsible
for ensuring that the contents of the operating
instructions are fully understood by the responsible
! This pump unit must not be operate beyond personnel.
the limit values in the technical documentation for
medium handled, speed, density, PH, pressure, 2.3 Non-compliance with Safety Instructions
temperature, Ampere & voltage of panel, magnetic
clutch, vacuum pump and engine rating. Non-compliance with safety instructions can jeopardize
the safety of personnel, the environment and the
The nameplate indicates the type of series/size, main machine itself. Non-compliance with these safety
operating data, serial number and engine type. instructions will also lead to forfeiture of any and all
rights to claims for damages.
If you need any additional information or instruction
exceeding the scope of this manual or any case 2.4 Safety Awareness
damage please contact PT. KSB Indonesia head office
/ KSB representative. It is imperative to comply with the safety instructions
contained in this manual, the relevant national and
local health and safety regulations and the operator's
2. Safety own internal work, operation and safety regulations.

These operating instructions contain fundamental that 2.5 Safety Instructions for Operator/User
must be complied with during operation and
maintenance. Therefore this operating manual must  Any hot or cold components that could pose a
be read very carefully before you start the pump unit hazard must be equipped with the guard by the
or do any maintenance and service. operator.
 Guards that are fitted to prevent accidental
Not only must the general safety instruction given in contact with moving parts (e.g. coupling) must
this chapter of “safety” be complied with, but also the not be removed while the machine is operating.
safety instruction outlined under specific headings.  Leakages (e.g. at the shaft seal) of hazardous
media handled (e.g. explosive, toxic, hot) must be
For detail information in index enclose of manual contained so as to avoid any danger to persons
operation of each product. and environment. Pertinent legal provisions must
be adhered to.
2.1 Marking on Instructions in the Manual  Electrical hazards must be eliminated. (Refer to
the relevant safety regulations applicable to
The safety instructions contained in this manual whose different countries and/or the local energy supply
non-observance might cause hazards to persons are companies.)
specially marked with the general hazard sign, namely
2.6 Safety Instructions for Maintenance, Inspection
! and Installation
Safety sign accordance with DIN 4844-W9 The
electrical danger warning is The operator is responsible for ensuring that all
maintenance, inspection and installation work is
performed by authorized and qualified personnel who
Safety sign accordance with DIN 4844-W8 The word are thoroughly familiar with the manual.
Caution Work on the machine must be carried out only during
is to introduce safety instructions whose non standstill. The shutdown procedure described in the
observance may lead to damage to the machine and
its functions. manual for taking the machine out of service must be
adhered to without fail.
Instruction attached directly to the machine, such as:
 Arrow indicating the direction of rotation Pump units handling media injurious to health must be
 Marking for fluid connections decontaminated.
Must always be complied with and be kept in legible
conditions at all times.

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Immediately following completion of the work, all Option:

safety/protective devices must be re-installed and/or
reactivated.

Please observe all instructions set out in the chapter

on "Commissioning" before returning the machine to
service.

2.7 Unauthorized Modification and Manufacture of

Spare parts

Modifications or alterations of the machine are only

permitted after consolation with the manufacturer.
! Total weight for pump unit vary from 4.5 - 5
Original spare parts and accessories authorized by the
manufacturer ensure safety. The use of other parts tons
can invalidate any liability of the manufacturer for
damage or warranty. 3.2 Short Time storage

2.8 Unauthorized Modes of Operation The pump unit should be stored in a dry room where
the atmospheric humidity is as constant as possible.
Any warranty of the operating reliability and safety of
the pump/unit supplied is only valid if the machine is If stored outdoors, the unit must be covered by
operated in accordance with its designated use as waterproof material to avoid any contact with
described in the following sections. The limits stated in humidity.
the data sheet must not be exceeded under any
circumstances. All openings of the assembled pump/unit components
are closed and must be opened when required during
3. Transport and Interim Storage installation.

3.1 Transport Caution

Protect all stored goods against
Proper lifting and safety practice must be observed at humidity, dirt, vermin and unauthorized access!
all times. Lifting the pump unit requires extreme care,
since the center of gravity is not located in the
physical center of the unit. 4. Description of the Product and Accessories

Please lift by a single point and do not use the 4.1 Technical Specification
pump/motor shaft as lift point. Eyebolt locations on
the bearing assembly and motor are intended for DnD Pumps unit have been designed and
lifting those items only and must not be used to lift the manufactured to provide a better and more reliable
pump unit. alternative to efficiently pump clean the open pit coal
mining pits at the time. “, pump set capable of
Always make sure that pump unit remains in the pumping not only water against high head conditions
horizontal position during transport and con not slip and handle coarse or fine particles from solids-laden
out the transport suspension arrangement. waste water to aggressive slurries of an abrasive or
corrosive nature , but also large quantities of slurry.

! If the pump/unit slips out of the suspension 4.2 Designation

arrangement, it may cause personal injury and
damage to property.

Figure below give suggested lifting method. Actual

safe lifting method will vary with pump configuration
and type of lifting equipment. Ensure secure
attachment and test lifting method for stability before
moving pump unit.

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Discharge Nozzle DN (in mm) 4.3 Design Detail

DnD pump is open pit entered pump unit for coal

mining industry, driven with various range of diesel
Hydraulic type engine and equipped by electric PLC vacuum system
M Metal for self priming.
H Extra-Heavy Construction
R Rubber

MUFFLER
CHAIN HOLE

CHAIN STROBE LAMP WORKING LAMP

PULLEY
ROOF

PANEL

ENGINE

SACKLE

VACUUM PUMP

BOOM

WINCH
DRAIN VALVE

GATE VALVE
WIRE ROPE
NON-RETURN
VALVE
SUCTION HOSE
CLAMP VACUUM TANK
WATER SEPARATOR
TANK

PUMP

SKID
SUCTION HOSE

STRAINER

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4.3.1 Pump  Make sure Pontoon dimension is bigger than

pump base frame. Recommendation min 50 cm
Horizontal, end suction, modified volute casing pump wider.
with threevane impeller for large solids passage.
Available in interchangeable Eastover, metal and extra
heavy designs.

4.3.2 Engine

Volvo Penta Engine is directly injected, 6-cylinder

industrial diesel engines. The engine is equipped with
turbocharger, charge air cooler, thermostatically
controlled cooling systems and speed control.

4.3.3 Vacuum Pump

Ingersoll-Rand 3/4 Horsepower (.5KW) through 20

Horsepower (14.9 KW) units is two-stage, single
acting, air – cooled vacuum pumps that do not require
installation on a special foundation. It can be furnished  Mark the pontoon match with base frame
as a compact, self- contained, receiver –mounted dimension. It will make lifting/maintenance
units, automatically regulated and driven by an operation easier in the future.
electrical motor. Double piston vacuum pump coupled
by 12/24 Volt DC magnetic clutch which working when
priming is needed.

4.3.4 Electrical Control Panel and Level Sensor

The brain of dewatering pump set is PLC. It acts to

control system for vacuum priming pump and
automatic shutdown to prevent pump from dry
running. Level sensors are installed to sense water
level in vacuum tank. The pump will automatically shut
down in 3 (three) minutes if water level sensor
detected minimum reading.
 Make sure the pontoon is free of leakage.
5. Installation at Site
Caution Check the pontoon for leakage
5.1 Safety Regulations before installing the pump !

5.3 Installing Pump Unit

Electrical equipment operated in hazardous
locations must comply with the applicable explosion 5.3.1 Pontoon Leveling
protection regulations. This is indicated on the motor
rating plate. If the equipment is installed in hazardous Place the skid above the wedge. The mounting surface
locations, the applicable local explosion protection of pontoon must be flat and level before pump set
regulations and the regulations of the test certificate installation.
supplied with the equipment and issued by the
responsible approval authorities must be observed and
complied with. The test certificate must be kept close
to the location for easy access (e.g. foreman's office).

5.2 Foundation

All structural work required must have been prepared

in accordance with the dimension state in installation 5.3.2 Aligning the Pump Set
plan. The pontoon shall have sufficient strength for the
pump unit and be completely fix before installation. After placing pump set on the pontoon surface, it must
be leveled by shimming. Shims should be fitted
between the pump base frame and foundation it self;
they should always be inserted to the left and right of
the foundation bolts in close proximity to these bolts.
Anchor bolts must be located according to the
installation plan.

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After placing the skid to pontoon, it must be welded to

plate skid and bolt plate must be tighten. After
attaching the unit to the foundation and connecting
the piping, the pump and drive train must be
thoroughly checked and if necessary realigned. All
components must be level during operation.

! Improper alignment of the unit can cause

damage to both coupling and the unit itself.
Do not overfill the bearing assembly. The capacities
5.3.3 Accessories Installation listed above are approximate. When filling the bearing
housing the oil level must be at the centerline of the
a. Install all working lamps and strobe lamp. oil level sight glass when then is not turning.
b. Connect the engine exhaust pipe to muffler on
the roof. Engine preparation:
c. Connect the suction hose to vacuum tank, and  Tightening all bolts of diesel engine
the strainer to suction hose.  Check coolant for diesel engine radiator.
d. Tightening the suction hose clamp. Composition of coolant is 40% coolant and 60%
e. Install the Boom to skid. fresh water.
f. Tightening both sackles at the boom  Check the diesel engine oil. Oil should be filled in
g. Connect the chains from sackles at the boom to the diesel engine as recommended by diesel
chain hole at roof’s front pillars. engine manufacturer (see on diesel engine
h. Setting the boom angle by arrange chain’s length. operating manual). Check level oil with dipstick on
i. Stretching the wire rope from winch. Pass it to engine oil bath. Make sure level oil to OPERATION
the pulley at the boom, then connect it to suction level on dipstick.
hose clamp.

6. Commissioning, Start Up and Shut Down

Caution Compliance with the following

requirement is of paramount importance. Damage
resulting from non-compliance shall not be covered by
warranty.

6.1 Commissioning

Before starting up the pump unit make sure that

following requirement are checked and fulfilled. The
operating data, the oil level, the direction of rotation
must be checked and pump should be primed. Pump Unit Preparation:
 Check connection cable to battery. Make sure that
6.2 Start up Preparation the cable condition is good.
 Check tightening bolts for piping system, vacuum
Pump preparation: tank, separator tank, vacuum pump, hose, boom.
 Tightening all bolts on pump foot  Check instrument on control panel. Make sure the
 Check oil level on bearing bracket. Make sure that instrument is working.
the pump position and floor are in a horizontally  Check fuel engine hose inlet/outlet. Make sure no
level and oil level should on recommendation level leakage on hose.
as showed in the figure below.  Check the tightening bolts on roof.

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 Check condition of boom and winch. Turn the c. Press ON button in Engine Management System
handle at winch to up and down the boom. (EMS) panel LCC Lamp will blinking on (A)
 Check coupling alignment by remove coupling
guard from skid, loosen the bolts at coupling and
remove the rubber coupling. Make sure alignment
coupling ± 0,10 mm.
 Re-assemble the coupling installation after check
the alignment and make sure tightening bolts
coupling is correct.
 Drain “water separator tank.”
d. Start the engine. Pump indicator will be turned on
(X). Low level indicator will turned on (Z).
6.3 Start up / Shut down Procedure Vacuum pump will work, vacuum pump indicator
will turned on (Y).
Make sure these conditions below are fulfilled before After ± 40 seconds low level turned off (Z) it
starting up the pump for both automatic and manual indicates fluid has already enter the pump,
mode. vacuum pump will off, indicator (Y) will turn off.
a. Make sure strainer of suction hose is immersed Let the engine runs idle for several (5) minutes.
under water. Minimum depth is 6 x hose
diameter.
e. Press to increase engine speed and

to decrease engine speed in EMS.

b. Check that the oil level of engine is between Max

d c
and Min marks.
c. Check the coolant level of the engine and the
radiator.
d. Check that no leakage of oil, fuel, coolant occurs.

Note The ON & OFF of vacuum lamp

Indicate priming process. Maximum priming time is 3
minutes. If priming process failed after 3 minutes, the
engine will be automatically shut down to prevent
pump from running in dry condition.
e. Drain remain slurry and fluid from water
separator tank. Caution
If the AUTO mode is not working, the
6.3.1 Start Up (Automatic Mode) engine still can be operated in Manual mode by
switching the selector from AUTO to MANUAL setting
a. Rotate the switch battery clockwise from but this mode is :
horizontal position to vertical. The key can’t be
released when switch is on. “NOT RECOMMENDED".
b. Set the selector in control panel to Auto

X Y Z Any damage due to manual operation

will not covered under warranty.

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6.3.2 Start up (Manual Mode) - For Self test only

Note Pump set can also turned off by lift
a. Rotate the switch battery clockwise from up strainer /suction hose. Pump/engine will
horizontal position to vertical. The key can’t be automatically shut off after three minute.
released when switch is on.
b. Set the selector in control panel to Manual.
c. Press ON button in Engine Management System 7. Trouble Shooting
(EMS) panel LCC Lamp will blinking on (A)
d. Turn on Vacuum Pump by pressing Vacuum pump 7.1 Low Flow Rate
press button on Control Panel. Indicator lamp will
turn on, indicates the vacuum pump is active (Y). a. Verify that the pump is correct for the system
e. Repeat step from d to e from automatic mode parameters in terms of flow and head. The pump
operation manual. curve can be used to determine the output,
f. Turn off Vacuum Pump by pressing Vacuum pump power and speed.
press button on Control Panel. Indicator lamp will b. Depending on the operating time and service of
turn off, indicates the vacuum pump is not active. the pump, parts could be worn sufficiently and
Turn off vacuum pump immediately after fluid reduce performance.
enter the pump. c. Verify that the pump is running at the correct
speed.
Y d. Verify that suction side has adequate NPSH as
outlined in the pump specification.
e. Check the suction pipe for air pocked, leaks;
partially closed valves or other restriction.
f. Be certain that the suction inlet and impeller are
not clogged.

7.2 Pump Fail to Prime

b d
a. Check Vacuum pump, whether it is running or
not.
b. If the vacuum pump was not working, check
electric current that power up magnetic clutch.
c. If the vacuum pump is running well then check
strainer for solid slurry, dirt that might obstruct
liquid from entering the suction hose.

d. Check connection of suction line from leakage.

! In Manual mode, automatic start/stop e. Clean up magnetic clutch from dirt, slurry, dust if
vacuum pump will not function. Any late to shut off you find it run on slip.
Vacuum pump will let the water come inside the f. Check part inside check valve, wear part may
vacuum pump and will cause fatal damage on the unit. cause leakage and reduce vacuum condition.
Vacuum pump will stack and magnetic clutch will get
burned out.

6.3.3 Shutdown

a. Reduce the speed by pressing . Let the

engine run for a one minutes in idle condition.
b. Press the STOP button.
c. Turn MCB panel off on control panel
d. After the engine in complete off, open drain valve
on vacuum tank to avoid slurry/ dirty contact with
the level sensor.
e. Open drain valve on water separator tank.
f. Open drain valve on discharge pipe.

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8. Diagrams and Drawings

8.1 General Priming Diagram

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8.2 Electrical System for Priming Wiring Diagrams

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8.3 Engine Volvo TAD1343VE Wiring Diagram

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8.4 Engine Volvo TAD1643VE Wiring Diagram

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8.5 Display Control Unit (DCU) Wiring Diagram

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8.6 GA and Part List Drawing

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9. Short Cut Operational Procedure

9.1 Start Up Procedure

a. Check pump and engine oil/grease, radiator, and

diesel fuel level.

b. Drain water separator tank.

c. Start the engine, let it operate at idle position

until priming process is finished.

d. Once priming completed, raise the engine speed

(RPM) to duty point

9.2 Inspection After Start Up

a. Check bearing oil temperature and gland packing

for leakage. Adjust gland packing tightness when
there is too much leakage.

b. Always check engine panel. Do the trouble

shooting when there is “WARNING” sign.

9.3 Unit Shut Down

a. Reduce engine speed (RPM) to idle position. Let it

run for one minute.

b. Stop the engine.

c. Close the gate valve then open the drain valve at

both discharge pipe and water separator tank

Emergency Stop button is only used in emergency

situation.

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