KDP Series - Md-kinney

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Kinney Dry-Screw Vacuum PumpManual 1854 Rev B p/n 001854 0000WARNING: Do Not Operate Before Reading ManualKDP SeriesOPERATOR’S MANUALOperator’s Manual: Dry-Screw Vacuum PumpModelsKDP-150KDP-330KDP-400KDP-800800.825.6937 www.kinneyvacuum.comOriginal Instructions

Disclaimer Statement:All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intendedas representative reference views only. Products are under a continuous improvement policy.Thus, information, illustrations and/or specifications to explain and or exemplify a product,service or maintenance improvement may be changed at any time without notice.Rights Reserved Statement:No part of this publication may be reproduced or used in any form by any means - graphic,electronic or mechanical, including photocopying, recording, taping or information storageand retrieval systems - without the written permission of Kinney .Product information and specifications subject to change.

Table of ContentsTable of ContentsIntroduction. 1Description. 1Construction. 1Rotor Shaft. 1Timing Gear. 1Bearings. 1Oil Level Sight Gauges. 1Shaft Seal. 2Cooling Purge. 2Specifications. 2Safety. 3Graphic Conventions Used in this Manual. 3Safety Instruction Tags. 3Safety Precautions for Dry Vacuum Pumps. 4Installation. 5Installation Location . 5Foundation. 5Pump Installation. 5Manifold Installation – Main Piping. 5Cooling Water Piping. 6Drive Assembly. 6V-Belt Drive. 6Manual 1854 Rev B p/n 001854 0000i

Table of ContentsBelt Tension. 7Coupling Drive. 7Operation. 8Prestart Checks. 8Piping Inspection. 8Piping Final Assembly. 8Oil Level. 8Cooling Water. 8Starting the Pump. 8Trial Run. 9Stopping the Pump. 9Suction Shutoff . 9Corrosive Gas Purging. 9Motor Shutoff . 9Steam Flushing. 9Lubrication. 9Maintenance and Inspection.11Overheating. 11Abnormalities. 11Interference. 11Freezing. 11Inspection Schedule. 11Daily Inspection . 11Monthly Inspection. 12Every-3-Month Inspection. 12Bi-annual Inspection. 12Yearly Inspection. 12Maintenance and Inspection Schedule. 12Disassembly. 13iiManual 1854 Rev B p/n 001854 0000

Table of ContentsReassembly. 15Screw Clearances. 18Troubleshooting. 19Exploded Views and Parts Lists. 21KDP-150 Exploded View Drawing. 21KDP-150 Parts List. 22KDP-330 Exploded View Drawing. 23KDP-330 Parts List. 24KDP-400 Exploded View Drawing. 25KDP-400 Parts List. 26KDP-800 Exploded View Drawing. 27KDP-800 Parts List. 28Warranty – Vacuum Products. 29Operating Data Form / Product Registration. 30Manual 1854 Rev B p/n 001854 0000iii

01INTRODUCTIONCONGRATULATIONS on the purchase of a newKinney KDP Dry-Screw Vacuum Pum. Pleaseexamine the pump for shipping damage, and ifany damage is found, report it immediately to thecarrier. If the pump is to be installed at a later date,make sure it is stored in a clean, dry location androtated regularly. Make sure covers are kept on allopenings. If pump is stored outdoors, be sure toprotect it from weather and corrosion.This manual provides instructions for handling andmaintaining the Kinney KDP Dry-Screw VacuumPump. Read this manual carefully before installing,operating, or servicing the pump.DESCRIPTIONThe KDP Dry-Screw Vacuum Pump dischargesgas under pressure by the counterrotation of screwrotors. Power is transmitted to the main rotor shaftthrough a V-belt or direct-drive coupling and thenfurther transmitted to the driven rotor shaft throughtiming gears.The screw rotors have a specially selected profileformed by Archimedean, Quimby, and arc curves.The counterrotation of these rotors creates anaxial flow through the pumping chamber. Due tothe special profile of the screw rotors, the inlet gasis smoothly pressurized, in a single stage, againstthe pressurized gas on the discharge side. Thetwo screw rotors operate freely in the pumpingchamber, with a clearance maintained between therotors and between the rotors and the casing wall.Because there is no oil in the pumping chamber, oilcannot mix with the discharge gases.Manual 1854 Rev B p/n 001854 0000CONSTRUCTIONRotor ShaftThe rotor shaft is made of high-grade spheroidalgraphite cast steel. The shaft rotors have beenprecision-machined to numerical tolerances.After being machined, the shaft rotors have beenperfectly dynamic-balanced and coated withoptional materials.Timing GearThe helical timing gear pair is the most importantpart of the Dry-Screw Vacuum Pump. It isnecessary for turning the rotors so that they arekept apart at a precision tolerance. The gear toothsurfaces have been heat cured and then polishedwith a high-precision polishing machine to lowernoise and reduce gear wear.BearingsThe bearings on the fixed side are double-row,angular-contact ball bearings. The bearings on theexpansion side are roller bearings with heavy loadcapacity. These bearings have been designed towithstand high-speed, heavy-load service and topreserve the clearances between gears and rotors.Oil Level Sight GaugesThe pump has an oil level sight gauge on eachside of the front-end cover. Check both sightgauges. The two readings should be equal,indicating that the pump is mounted level. Duringoperation, oil is splashed over the bearings andmechanical seals by revolution of the gears.1

01IntroductionShaft SealCooling PurgeThe shaft seals consist of a bellows-type mechanicalseal assembly on the discharge side and double-lipseals on the suction side. These seals prevent oilfrom the front end plate and grease from the rear endplate from migrating into the casing. The motor side ofthe front-end cover/drive rotor shaft is sealed by an oilseal or optional mechanical seal.If the pump has the After Cooler option, the coolingwater inlet should be located on the cooler side. Ifatmosphere intake is impractical, cool the dischargeair and recycle Capacity (60 Hz)90 CFM(150 m3/hr)195 CFM(330 m3/hr)235 CFM(400 m3/hr)460 CFM(800 m3/hr)Ultimate pressure0.1 Torr(0.13 mbar)0.1 Torr(0.13 mbar)0.1 Torr(0.13 mbar)0.05 Torr(0.067 mbar)7.5 HP15 HP20 HP30 HPMotorPower50 Hz60Hz3.7 kW5.5 kW7.5 kW11.5 kW11.5 kW15 kW19 kW22 kWRotational speed50 Hz60 Hz2,900 RPM3,500 RPM2,900 RPM3,500 RPM2,900 RPM3,500 RPM2,900 RPM3,500 RPM1.4 qt(1.3 L)1.7 qt(1.6 L)2.1 qt(2.0 L)3.8 qt(3.6 L)0.5 GPM(1.9 LPM)1.0 GPM(3.8 LPM)2.0 GPM(7.6 LPM)2.6 GPM(9.8 LPM)Suction port size1.5 in.(40 mm)2.0 in.(50 mm)2.5 in.(65 mm)4.0 in.(100 mm)Discharge port size1.5 in.(40 mm)1.5 in.(40 mm)2.0 in.(50 mm)2.5 in.(65 mm)Silencer port size1.5 in.(40 mm)1.5 in.(40 mm)2.0 in.(50 mm)2.5 in.(65 mm)Weight (pump only)484 lb(220 kg)698 lb(317 kg)887 lb(402 kg)1,320 lb(600 kg)Gear oilCooling water @ 75 F (24 C)Table 1-12Manual 1854 Rev B p/n 001854 0000

02SAFETYGRAPHIC CONVENTIONS USED INTHIS MANUALThe following hazard levels are referenced withinthis manual:! DANGERIndicates a hazardous situation that, if notavoided, will result in death or serious injury.NOTE: Indicates a procedure, practice, orcondition that should be followed inorder for the equipment to function in themanner intended.SAFETY INSTRUCTION TAGS! WARNINGDo not operate without beltguard.! WARNINGIndicates a hazardous situation that, if notavoided, could result in death or seriousinjury.! CAUTIONIndicates a hazardous situation that, if notavoided, could result in minor or moderateinjury.Indicates a situation that can cause damageto the engine, personal property, and/orthe environment or cause the equipment tooperate improperly.Manual 1854 Rev B p/n 001854 0000! CAUTIONDo not valve or restrict pump dischargeopening.Use oil mist eliminator when operating pump,ensure adequate ventilation when dischargingindoors.Refer to manual safety instructions.The above safety instruction tags werepermanently affixed to your pump prior toshipment. Do not remove, paint over orobscure in any manner.Failure to heed these warnings could result inserious bodily injury to the personnel operatingand maintaining this equipment.3

02SafetySAFETY PRECAUTIONS FOR DRYVACUUM PUMPSPlease read the following safety information beforeoperating the vacuum pump. Do not operate the pump without the belt guardproperly attached. Disconnect the pump motorfrom the electrical supply at the main disconnectbefore removing the belt guard. Replace the beltguard before reconnecting the power supply tothe pump motor. Operating the pump without thebelt guard properly installed exposes personnelin the vicinity of the pump to risk from rotatingdrive components. Do not operate the pump with oxygen-enrichedgas (greater than 21% by volume) in the suctionline, unless the pump has been prepared withan inert fluid suitable for the application andequipped with seal and start/stop purge system.! WARNINGPumping oxygen-enriched gases with mineraloil or other non-inert fluids and withoutproper purges can cause fire or explosionin the pump, resulting in damage or seriousbodily injury. Do not restrict the pump discharge in any way orplace valves in the discharge line. The vacuumpump is a compressor and will generate highpressures without stalling the motor whenoperated at low suction pressures. Excessivepressure could cause damage or serious bodilyinjury. Disconnect the pump motor from the electricalsupply at the main disconnect beforedisassembling or servicing the pump. Make surethat the pump is completely reassembled, thebelt guard is properly installed, and all fill anddrain valves are installed and closed beforereconnecting the power supply. Accidentalstarting or operation of the pump whilemaintenance is in progress could cause damageor serious bodily injury. Lift pump only by the lifting lugs supplied withthe pump. Never lift equipment attached to thepump by the pump lifting lugs. Do not touch hot surfaces on the pump. Innormal operation at low pressures, surfacetemperatures will not normally exceed 180 F(82 C). Prolonged operation at 200 Torr(267 mbar) may cause surface temperatures ashigh as 220 F (104 C). Take precautions to avoid prolonged orexcessive exposure to oil mist or processmaterials emanating from the discharge of thepump. Do not allow the pump to discharge into aclosed or inadequately ventilated room. Whereprocess vapor contains environmentallyunfriendly chemical vapor, pump discharge mustbe connected to the properly sized scrubbersystem to neutralize the harmful chemicalsprior to the discharge to the atmosphere. Lawsand ordinances may pertain to your local arearegarding discharge of oil mist, oil vapor, orchemical vapor to atmosphere. Check local lawsand ordinances prior to operation of the pumpwith discharge to outside atmosphere.4Manual 1854 Rev B p/n 001854 0000

03INSTALLATIONINSTALLATION LOCATION4. Use a level to check that the pump assemblyis level.Mount the pump on a clean, flat, and level rigidsurface. If the pump will be installed outdoors,check the motor, V-belt, and other parts for outdoorservice suitability.5. Grout the cement mortar in the space underthe bed and in the anchor boltholes, and let itset. Once the mortar is hardened, tighten thenuts for the anchor bolts.Allow enough space surrounding the pump foraccess during maintenance such as disassembly,re-assembly, and periodic inspections.NOTE: Be sure to tighten the nuts evenly.FOUNDATIONMake sure the concrete foundation has anadequate pressure-bearing area to counteract theweight of the pump. Anchor the pump securely tothe foundation.PUMP INSTALLATION1. Position the pump and center it for installation.2. Set the pump on the foundation, and supportthe base plate evenly by inserting a choke linerbetween the pump and the foundation surface.Make sure that the bed is level and thatthere is space for grouting the cement mortarbetween the foundation surface and the bed.3. Place anchor bolts in position on the bedtemporarily, set the nuts on the full head of thebolts, and leave them in the boltholes. Chokeliners will help provide proper support.Manual 1854 Rev B p/n 001854 0000MANIFOLD INSTALLATION – MAINPIPINGClean the interior of the suction and discharge pipeto remove any rust, dust, or foreign matter.Kinney recommends installing an expansion jointon the suction side as well as the discharge sideof the pump. Properly support the piping to protectthe pump from absorbing excessive load. If asilencer is provided on the discharge side, install itas closely as possible to the discharge port of thepump.Kinney recommends installing a non-return valve(inlet check valve supplied) on the suction ordischarge port so that the pump will not rotatein reverse upon shutdown. If it is not possible toinstall the recommended non-return valve, installa gate valve instead and be sure to shut the valvebefore stopping the pump.5

03InstallationSuctionDRIVE ASSEMBLY* The After Cooler is optionalCooling Water InletDRY PUMP SHELLV-Belt DriveCooling Water OutletSILENCERAFTER COOLER*The belt and bearing life depends greatly on thebelt tension.DischargeCooling Water OutletCooling Water Inlet If the belt tension is too loose, the transmissionefficiency can be reduced due to belt slippage.Fatigue and heating on the belt will also occur.This can shorten the belt life considerably anddamage the bearings.Figure 3-1 – Standard PipingCOOLING WATER PIPING If the belt is too tight, too much tension will beapplied and the strength will be decreased. Thebelt life will also be reduced, and excessive loadwill cause severe heat or wear of the bearing.For the KDP Series pumps, cooling water pipingis required to cool the front-end cover, front endplate, casing, rear end plate, and water-jacketedexhaust silencer or separator. The water inlet tothe pump is from the bottom on the drive end. Thewater outlet from the pump is from the top on thesuction end. The water inlet and outlet are labeledon the pump.To maintain proper belt tension, adjust the belttension as shown in Figure 3-2.LOAD ON BELT TENSION, W (kg)LNOTE: In addition to the water outlet, the pumpalso has water drains for fully draining thepump casing, front-end cover, front endplate, rear end plate, and water jackets.Water drains are not water outlets. Usethe water drains only to drain the pumpbefore moving or disassembling it.Figure 3-2 – V-Belt TensionBelt TensionApply the load vertically at the center of “L” (seeFigure 3-2). The belt sag at this time should bed 0.0016 x L (mm).TYPEABCD3V5V8VNew .03.710.427.6Table 3-16Manual 1854 Rev B p/n 001854 0000

03InstallationCLASS OF MOTORON SIDE OF COUPLINGCLASS OF MOTORAT END OF COUPLINGM180L (ML5-180L) andunderLess than 0.00197 in.(0.05 mm)M132M (ML5-132M) andunderLess than 0.00394 in.(0.10 mm)M200M (M15-200M) andaboveLess than 0.00315 in.(0.08 mm)M160M (ML5-160M) andaboveLess than 0.00709 in.(0.18 mm)Table 3-2Coupling DriveUse a dial gauge to align the coupling (see Figure3-3 for proper concentricity).Figure 3-3 – Coupling AlignmentManual 1854 Rev B p/n 001854 00007

04OPERATIONPRESTART CHECKSPiping InspectionMake sure all piping is clean and free from dirt anddebris. Remove all welding slags and chips fromthe interior of the process piping.Piping Final AssemblyCheck that all suction and discharge connectionsare properly tightened and all piping is supported.Repeat for all cooling water piping.Oil LevelBe sure to turn off the pump before adding oil.Never add oil with the pump running.1. With the pump shut off, fill the oil case to thetop of the red dot on the oil sight gauge.2. Start up the pump.3. Check the oil level. With the pump running, theoil level should be between the top and middleof the red dot on the gauge.NOTE: The oil level on a pump that is not runningwill drop once the pump is started. Besure to check and establish the level withthe pump running.Keep the oil level with the pump runningbetween the top and middle of the red dotat all times. If the oil level is too low, thegears, bearings, and mechanical seals willbe damaged. If the oil level is too high, theequipment will overheat.Cooling WaterMake sure that the cooling water, as specified inFigure 3-1, is fully circulating through the pump.STARTING THE PUMP1. Check the pump rotational direction by joggingthe pump briefly, with the process inlet isolationvalve open, while checking the rotationaldirection of the motor fan. The pump rotationdirection should be CW (Clock Wise), viewedfrom the motor.If the motor rotates CCW (Counter ClockWise), correct the power cable connectionsand check the rotational direction again tomake sure the pump rotates in the correct CWdirection.2. With the process inlet isolation valve still open,operate the pump for 20 – 30 minutes.3. Check all pump operating parameters for anytrouble, such as excessive vibration, highoil/grease temperatures, high cooling liquiddischarge temperature, high process discharge8Manual 1854 Rev B p/n 001854 0000

04Operationtemperature noise, and over-current draw.If any abnormal condition appears, stop thepump to investigate and correct the cause.NOTE: Typical causes of an abnormal conditionare improper lubrication or installation ofthe pump.Corrosive Gas PurgingIf any corrosive gas gets drawn into the piping orpump, purge the pump and piping by flushing thesystem with a cleansing gas. To make sure that thepump is thoroughly cleaned, flush the system for20 – 30 minutes before stopping the pump.4. Operate the pump for 2 – 3 hours undernormal process load conditions.Motor Shutoff5. Check the pump operating parameters again.To stop the pump, turn off the motor.6. If any abnormal condition arises during initialoperation with normal process load, shutdown the pump immediately and correct theabnormal condition before restarting the pump.STEAM FLUSHINGTrial Run1. Operate the pump under no load condition for20 – 30 minutes to check for any abnormalvibration or heat. If any abnormality arises,stop operation and see Troubleshooting onpage 19 or call Kinney.2. Operate the pump for 2 – 3 hours undernormal load conditions, and check thetemperature and motor current.! WARNINGDuring the operation, monitor the bearingtemperature, lubricant temperature, andmotor current plus the cooling water flow.Maintain the pump operation within thedesignated specifications.STOPPING THE PUMPSuction ShutoffTo shut off the suction, close the isolation valve onthe suction line.Manual 1854 Rev B p/n 001854 0000If any process materials have been ingested intothe pump and caused resistance, do not attemptto rotate the pump with force. Flush steam insidethe pump and screws according to the followingprocedure:1. Close the inlet (suction) valve. Open thedischarge valve and drain valve from theexhaust silencer or separator.2. Inject steam for 1 – 10 minutes through oneof the purge or instrumentation ports on theinlet manifold. Steam pressure should beapproximately 1 kg/cm2G.3. Make sure power to the motor is disconnected,and then try to rotate the drive shaft via pulleyor coupling by hand.4. If necessary, repeat the above steps 2 or 3times.LUBRICATIONAny lubricants used must be high-grade petroleumproducts that contain oxidation inhibitors, rustpreventatives, extreme-pressure additives, etc.NOTE: Do not use any lubricant that containsany elements of water, sulfate resin, or tarturbine oil (ISO VG 68).9

04OperationRecommended lubricants: Kinney Type AX BP Energol THHT 68 BP Energol THB 68 Shell Turbo 68 Mobil DTE Heavy MediumRecommended grease: Dow Corning 3451 BearingGrease10Manual 1854 Rev B p/n 001854 0000

05MAINTENANCE AND INSPECTIONOVERHEATINGFREEZINGDuring pump operation, the temperature will risecorresponding to the compression ratio due to heatof compression. However, if the temperature rise islocal and the exterior coating becomes scorched,there is an abnormality. There may be interferencebetween the rotors and casing, or the pump mayhave drawn in some foreign material.In cold weather, the water jackets could bedamaged if cooling water freezes. Drain the coolingwater after the pump is shut down.INSPECTION SCHEDULEDaily Inspection! CAUTIONStop the operation immediately and check forabnormalities.ABNORMALITIESCarefully check bearing temperatures, vibration,and noise. Note any abnormalities as they arise.INTERFERENCETo check for interference between rotors orbetween a rotor and casing, place a stethoscopeagainst the casing to listen for any abnormalsounds.Manual 1854 Rev B p/n 001854 00001. Oil Level Gauge – Make sure the level isbetween the high and low level specified inOil Level on page 8. Low or excessivelyhigh levels of lubricant can damage gears,bearings, and seals.2. Cooling Water – Make sure that the coolingwater is fully circulating through the pump atthe proper flow rate.3. Suction and Discharge Pressure – Check thesuction and discharge pressures.4. Temperature – Use a surface thermometer andinspect the surface of the grease cover andgear case.5. Motor Amperage – Check for any increase ofamperage in the motor, which can be used todetermine an abnormal operating conditionthat can cause early pump failure or loss ofefficiency.11

05Maintenance and InspectionMonthly InspectionBi-annual Inspection1. Check the V-belt tension.Check the piping for scale or dirt build-up.2. Check the lubricant color. If the color is dark,replace the lubricant.Yearly Inspection3. Check the oil level. If the oil level decreasesdrastically, check the mechanical seals.Every-3-Month InspectionInspect the non-drive end bearings, and lubricateas needed.1. Check the mechanical seals.2. Disassemble the piping on the suction sideto check the inner surface of the rotors andcasings.3. Remove the gear case to check the gear.4. Replace the lubricant in the gear case.MAINTENANCE AND INSPECTION SCHEDULEITEMCHECK POINTDAILYMONTHLY3 MOS.6 MOS.YEARLYMotor amperageAny change? Amperage as specified?XRotationIs the rotation smooth and direction correct?XSuction and discharge pressureIs the pressure as specified?XNoise and vibrationAny abnormal sound or vibration?XTemperatureAny excessive oil or water temperature?XOil level gaugeIs oil at proper level?XWater contamination on free end coverWhat is the color? Has it changed to reddish brown?XCooling water pressureIs the pressure as specified or too high?XOil leaksAny signs of oil leaks?XReverse cooling filter (cooler)Any heat on suction pipe?XChamber purge (clean)Close suction line, and run for 20 – 30 minutes whilepurging with nitrogen or air.XBelt tensionCheck V-belt tension.XLubricant colorCheck color. If dark, replace lubricant.XOil levelIf oil level drops drastically, check mechanical seal.XNon-drive end bearingsInspect every 3 months and lubricate as needed.Suction and discharge pipingIs there any accumulated scale or dirt?Mechanical seal, oil seal, bearing,O-ring, V-belt, and packingInspect for damage and replace as needed.XRotors and casingsInspect interior for rust and any damage or flaw.XGear case lubricantReplace.XGearInspect for damage.X12XXManual 1854 Rev B p/n 001854 0000

06DISASSEMBLY! CAUTION11. Remove bearing holder A and bearing holder Bfrom the front end plate. Place matching marks on all connectionsand fitted parts.12. Press out the ball bearings from bearing holderA and bearing holder B. Keep disassembled parts away from dustand dirt, especially the bearings.13. Remove the spacers A from the drive shaft anddriven shaft. Do not sand blast parts that are coated(SHAFTS, PLATE GUIDES and the ends andinside of the CASING).NOTE: Label the spacers as drive side or nondrive side.1. Open the drain valves. Drain the cooling waterfrom the pump.2. Remove the oil drain plug from the front endcover. Drain the oil.3. Remove the oil level gauges, valves, and allaccessories from the pump.14. Remove the mechanical seal assembly fromthe drive shaft and driven shaft.15. Remove the grease covers from the bearingholders.16. Remove the lock nuts, lock washers, andbearing push sleeves.17. Remove the bearing holders.4. Remove the seal adapter housing from thefront end cover.18. Press out the roller bearings and lip seals fromthe bearing holders.5. Remove the oil seal from the seal adapterhousing.19. Remove the slip sleeves and spacers B.6. Remove the front end cover.7. Remove the ball bearing from the front endcover.8. Loosen the power locks. Remove timing gear Aand timing gear B.9. Remove bearing stopper A and bearingstopper B.10. Remove the lock nuts and lock washers.Manual 1854 Rev B p/n 001854 000020. Remove the front end plate.21. If needed, remove plate guide A and plateguide B from the front end plate.22. Remove the rear end plate from the casing.23. If needed, remove plate guide B from the rearend plate.24. Carefully remove the drive shaft and drivenshaft from the casing.13

06Disassembly25. Remove the blind plates and gaskets for thewater jacket at the casing and end plates.NOTE: Clean all parts with a suitable grade ofclean solvent, and replace any worn ordamaged parts with factory-approvedparts. Install new bearings, seals, gaskets,and O-rings at each assembly.14Manual 1854 Rev B p/n 001854 0000

07REASSEMBLY! CAUTION Check all parts for wear or damage duringdisassembly. Damaged joints or fittings will impairproper operation of the pump after i

This manual provides instructions for handling and maintaining the Kinney KDP Dry-Screw Vacuum Pump. Read this manual carefully before installing, operating, or servicing the pump. DESCRIPTION The KDP Dry-Screw Vacuum Pump discharges gas under pressure by the counterrotation of s

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