Kirloskar SHM - 001 PDF

INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE SHM
KIRLOSKAR BROTHERS LIMITED

“Yamuna” Survey No. 98 (3-7) Baner, Pune-411045 (INDIA).
IOM/SHM/SEPT19/01 Issue Date: 05/09/2019

Revision: 01
1
WARRANTY
We warrant that the pump supplied from us is free from defective

material and faulty workmanship. This warranty holds good for a
period of 12 months from the date of commissioning the
equipment or 18 months from the date of dispatch from our
factory, whichever is earlier. Our liability in respect of any
complaint is limited to replacing part/parts free of charge ex-works
or repairs of the defective part/parts only to the extent that such
replacement/repairs are attributable or arise solely from faulty
workmanship or defective material.
This warranty holds good only for the products manufactured by

us.
KIRLOSKAR BROTHERS LIMITED
2
CONTENTS
1. GENERAL 4
2. SAFETY INSTRUCTIONS 4
3. INSTALLATION 6
4. OPERATION 9
5. TECHNICAL DATA 9
6. PREVENTIVE MAINTENANCE 15
7. OVERHAULING 16
8. SPARE PARTS LIST AND CROSS-SECTIONAL

DRAWINGS 19
PLEASE FURNISH COMPLETE NAMEPLATE DETAILS, NAME OF PARTS,

PART NOS. AND MATERIAL OF CONSTRUCTION WHILE ORDERING
SPARE PARTS FOR THE PUMP.
Note: A copy of General instructions for Installation, Operation &

Maintenance of ‘Kirloskar pumps’ is attached at the end of
this manual.
3
N, NB, NM- 2 vanes enclosed impeller.
1. GENERAL: Q- 3 vanes semi open impeller.
1.1 “SHM” is a non-clog solid handling R- 8 vanes free-flow impeller.
pump. SHM series of pumps are designed QP- 3 vanes semi open impeller (for paper
to withstand arduous duty conditions stock application only).
which normally every solid handling pump
has to face on sites. 1.3 Pumps when properly installed and
given due care in operation and
SHM pumps are horizontal, single stage, maintenance should satisfactorily perform
centrifugal, end suction, vertical delivery for a long period.
pump with specially designed volute
casings and impellers. 1.4 When the pump is received, it
should be inspected before installation. If
The complete series of SHM pumps with it is not installed immediately, it is to be
delivery size ranging from 50 mm to 200 located in dry place. When not in actual
mm covers a wide performance range. use, the pump shaft should be rotated
once in a month to prevent pitting of
1.2 This booklet covers instructions for bearing surfaces.
following types of SHM pump models with
impeller types. 2. Safety Instructions:
UNIT MODEL IMPELLER TYPE
Enclosed Three Free 2.1 General Information
Vane Flow
Semi
Before performing any actions
Two Vane Single
Vane Open detailed within this instruction, the Health
SHM- 50/26 N NB -- P Q -- R and Safety instructions shall be read and
7
50/32 N -- -- -- -- -- -- fully understood. The instructions in this
65/32 N NB -- P Q -- R
80/26 N -- -- P Q -- R
document shall also be read and fully
SHM- 80/40 N -- NM P Q -- -- understood.
9
100/26 N -- -- P Q -- R
100/32 N -- -- P Q QP R Whenever the equipment is
150/26 - NB -- -- -- -- --
NB operated, maintained or used in any way,
SHM- 100/40 N -- -- P Q QP R the procedures detailed within the Health
11
150/26 N -- NM P Q -- R and Safety Dossier and any procedures
150/32 N -- -- P Q -- R
detailed within these instructions shall be
150/34 N -- -- -- -- -- --
150/40 N -- -- -- Q -- R followed. Some hazards cannot be
200/32 N -- -- P Q -- R guarded against and the instructions
SHM- 150/50 N -- -- P Q -- --
13 below MUST BE COMPLIED WITH for safe
200/40 N -- -- -- Q -- R
operation. These instructions cannot cover
all circumstances. It is the responsibility of
Note: - Pumps with horizontal delivery are
the user of the equipment for maintaining
also available upon request.
safe working practices at all times.
Note: - A) the complete range of SHM
2.1.1 Kirloskar Brothers Limited (KBL)
pumps is covered by four driving units,
products are designed for installation in
thereby reducing inventory and achieving
designated areas, which are to be kept
interchangeability of parts.
clean and free of obstructions that may
B) The above models can be offered with
restrict safe access to the controls and
following impellers.
maintenance access points.
P- Single vane enclosed impeller
4
Pump nameplate is fitted to each by KBL could result in bodily injury or
unit and must not be removed. Loss of property damage.
this plate could make identification
impossible. This in turn could affect safety 2.5 Within the manual, safety
and cause difficulty in obtaining spare instructions are marked with safety
parts. Such accidental loss of nameplate symbols.
or damage if occurs, contact KBL
immediately. Hazard.
2.1.2 Access to the equipment should
be restricted to the personnel responsible This symbol refers to
for installation, operation and maintenance general mechanical aspects of safety.
and they must be qualified, trained
adequately and supplied with the
appropriate tools for their respective tasks. Hazard.
2.1.3 KBL firmly insists that all

personnel responsible for installation, This symbol refers to
operation and maintenance of the electrical safety.
equipment must read the manual before
any work is done. 2.6 Transport, Handling and Storage
Instructions:
2.1.4 Ear defenders should be worn 2.6.1 Transport.
where the specified equipment noise level Pumps are dispatched in duly
exceeds locally defined safe levels. Safety assembled condition. Lubricating oil in the
glasses or goggles should be worn where bearing housing is drained prior to
working with pressurized systems and dispatch of pump if the pump is oil
hazardous substances. Other personal lubricated. Pumps are protected against
protection equipment must be worn, corrosion and packed for transport by
where local rules apply. normal road, rail and sea carriers.
2.6.2 Handling
2.2 DO NOT wear loose or frayed
clothing or jewellery, which could catch
on the controls or becomes trapped in the Crushing Hazard.
equipment. When lifting the pump or pump set, use
lifting equipment having a safe working
2.3 Operation of the equipment for the load rating suitable for the weight
application other than for which it is specified. Use suitable slings for lifting any
supplied can increase the risk from pump, not provided with lifting points. The
hazards. Please consult KBL before making use of suitable forklift truck and four chain
such change in the application of the crane sling equipment is recommended but
equipment. locally approved equipment rating may be
used. Pump should be slung as shown.
2.4 Improper installation, operation
and maintenance of the product supplied
5
Shearing Hazard.
Do NOT place fingers or hands, etc.,
into the suction or discharge pipe outlets
and do NOT touch the impeller, if rotated
this may cause severe injury.
Fill the bearing housing with recommended

grease to ensure that the shaft and
bearings remain rust free.
Fig. 1
Pump set must be lifted from the lifting 2.6.3.3 Exposed or Extreme Conditions
holes provided using suitable four chain Storage.
lifting equipment. For exposed storage or extreme variants in
atmospheric or environmental conditions,
please refer to KBL for special storage
instructions to suit the conditions
acceptable.
3. INSTALLATION:
3.1 For location, preparing foundation,

installation, alignment, piping, general
maintenance, trouble shooting, etc., the
instructions given in our publication -
Fig. 2 ’GENERAL INSTRUCTIONS FOR
INSTALLATION OPERATION AND
2.6.3 Storage. MAINTENANCE OF KIRLOSKAR
2.6.3.1 Temporary Storage for up to six CENTRIFUGAL PUMPS’ which is also
weeks. printed along with this booklet must be
If the pump unit is not to be used followed very carefully.
immediately it should be stored carefully in
a horizontal position, in a sheltered, dry 3.2 MOUNTING AND ALIGNMENT
location. Additional rust preventive should A spacer type flexible coupling is used to
be applied to all unpainted carbon steel or connect pump shaft to the driver. By using
cast-iron parts and should not be removed spacer type of coupling, the complete
until final installation. rotating unit can be removed from the
volute without removing pump casing or
2.6.3.2 Long Term Storage. rotor and without disconnecting piping
Do not remove protection covers or connections. This also avoids any
packaging until removal is necessary for realignment of pump and motor after re-
installation. If the packaging or suction or assembly of rotating unit.
suction and discharge covers are removed
for inspection purposes, cover it by proper 3.3 ALIGNMENT
means to protect the pump and maintain ALWAYS REMEMBER “A FLEXIBLE
the safety. COUPLING IS NOT A UNIVERSAL JOINT”.
6
Correct alignment is essential for the SHM Pumps Tapping Connection Chart.
smooth operation of the pump. There are
two types of misalignment between the Code Description Size Location of connection
pump shaft and the drive shaft, which are: CL-1 Stuffing box 3/8 ˝ On stuffing box housing
cooling Water- BSP bottom left, viewed from
1) Angular misalignment – Shaft with Inlet for hot DE.
axis concentric, but not parallel. model only.
CL-2 Stuffing box 3/8˝ On stuffing box housing
2) Parallel misalignment – Shaft with cooling water- BSP top right, viewed from
axis parallel, but not concentric. outlet for hot DE.
model only.
STEEL STRAIGHT STEEL STRAIGHT INCORRECT ANGULAR
EDGE EDGE MISALIGNMENT D1 Delivery casing ½˝ On delivery casing
drain BSP bottom side towards
suction.
D2* Drip pan (against ½˝ On bearing housing
CORRECT INCORRECT PARALLEL
STEEL STRAIGHT EDGE
order only) drain. BSP bottom.
MISALIGNMENT
Fig. 3 D3* Circulation line 1/4˝ On pump discharge

connection from BSP nozzle on driving side.
This misalignment is checked by casing.
using a straight edge or any other device D4* Bearing housing 1/4˝ On bearing housing
as shown in figure given above. oil drain for oil BSP bottom.
lubrication only.
F1 Wear ring 1/4˝ On suction neck right
3.4 Before commissioning the flushing. BSP viewed from suction
pumpset, please ensure: side.
G1* Gauge 3/8 ˝ On suction neck left
1) The pipe connections are flushed connection- BSP viewed from suction
and tightened properly. suction side. side.
G2* Gauge 3/8 ˝ On pump discharge
2) Alignment is proper. connection- BSP nozzle on suction side.
discharge side.
H* Oil breathing cap On bearing housing top.
for oil lubrication 20mm
3.5 Please refer to diagram given below only. Drill.
for plugs and piping connections in SHM K* Constant level 1/4˝ On bearing housing left,
pumps. oiler for oil. BSP viewed from DE. For oil
lubrication only.
SL- Stuffing box 1/4˝ On stuffing box housing
1$ sealing inlet. BSP bottom right viewed
D3 G2 from DE.
H SL- Stuffing box 1/4˝ On stuffing box housing
2# sealing outlet. BSP top left viewed from DE.
G1 F1
D2
D1
D4 VIEW FROM SUC.SIDE
(SUCTION FLANGE)
* -This special provision is on request
ELEVATION
only (against order).
SL2 CL2 # -Plugged in case of grease stuffing
SL2
box sealing.
$- Grease nipple in case of grease
K SL1 stuffing box sealing.
SL1 CL1
3.6 SHM pumps are grease lubricated
VIEW FROM DRIVING END
VIEW FROM DRIVING END (ST. BOX COOLING as standard supply. Grease nipples are
(ST. BOX WITHOUT COOLING
ARRANGEMENT) ARRANGEMENT) provided on bearing cover and bearing
cartridge.
Fig. 4 3.7 Optional supply of oil lubrication is
available. The pump is provided with
constant level oiler.
7
3.8 CONSTANT LEVEL OILER
Fix the constant level oiler and fill the oil.
Procedure for fitting the constant level
oiler and the method of filling oil is given
below.
Constant level oiler has plastic container

in Aluminum body as a standard supply.
Connection stem is ¼ inch BSP tapped
INCORRECT METHOD
and its capacity is 70 ml approximately. If
the constant level oiler is properly fitted
and oil is filled as per instructions given,
practically no attention is required as far
as lubrication of bearing is concerned ALWAYS FILL OIL HERE
other than to replenish the visible reserve
NEVER FILL OIL HERE
supply of the oil in the container. Refer
figure given below.
METHOD OF FITTING
Screw constant level oiler stem into the
tapped hole of the bearing housing Fig. 5
reservoir. Before fitting oiler, check the
level of the tapped hole with the help of a
turned bar with ¼ inch BSP tapping at METHOD OF FILLING THE OIL
one end and a spirit level. See figure, if Tilt the container and fill it with oil
the level is incorrect and oiler tilts through stem of the oiler. Replace the
downward, oil will not flow from oiler into container and allow oil to flow into
the reservoir (see fig. given below). Hence reservoir. The oil in the container shall
it is necessary to check the level before flow into the bearing housing reservoir
fitting in the constant level oiler. and shall become empty. Repeat above
procedure till the level in the reservoir is
equal to the level of which the oiler is
adjusted. When the desired level is
attained, the oil in the container shall
SPIRIT LEVEL remain steady at a position. Visible level
of the oil in the container indicates that
bearing housing is filled up to mark.
CAUTION: -
CORRECT METHOD
In no case oil should be filled directly in
to the bearing housing reservoir, through
breather cap.
8
Replenish the visible reserve supply of oil Check the following things and regulate
in the container as oil is used up. Please if needed –
ensure that air ‘GROOVE’ provided on 1) The pump is running smooth.
Aluminum body on which plastic 2) The flow of sealing liquid and
container rests is not clogged with dust / cooling water is uninterrupted. If
fiber, oil film, etc. This groove allows necessary, provide sight glass in the
atmospheric air to enter inside the body, piping.
to maintain oil level in bearing housing. 3) The bearings are not getting
abnormally hot.
4. OPERATION: 4) The gland is properly tightened to
give leakage of approximate 60-80
4.1 Before starting the pump check the drops per minute through stuffing box.
following: 5) Head and capacity developed by
the pump is as specified.
1) The pump rotates freely by hand.
6) Power consumption is within limit.
2) Fill the grease/oil for the bearings, if
7) Ensure that there is no mechanical
not done earlier. The bearings are packed
friction in the pump.
with grease in the factory for grease
8) Stop the pump immediately, if any,
lubricated pumps.
defects are detected. Do not start the
3) However, if the pump is stored for a
longer time it is necessary to refill the pump unless the defects are rectified.
Report immediately to the supplier, if it
grease in the bearings. Check the level of
is not possible to rectify the defects.
oil in the constant level oiler when oil
lubricated.
4.4 During stopping the pump
4) The sealing liquid and cooling water
connections are properly tightened and 1) Close the valve on the delivery line.
adjusted. 2) Stop the motor.
5) The direction of rotation of driver. It 3) Close the cooling water and sealing
should correspond to the direction of liquid connections.
rotation of pump. 4) If the pump is not required to be
6) The pump casing and the suction operated for a long time, drain the
pipeline is fully primed with the liquid. casing completely. If the pump is
7) Valve on delivery side is closed. required to be stored for a long time, the
8) The cock for pressure gauge bearing housing should be dried
connection is closed. internally with hot air and should be
9) The stuffing box packing is properly flushed with moisture free protective
tightened. such as light oil or kerosene.
4.2 Starting the pump

1) Start the pump. Let the prime mover
5. TECHNICAL DATA:
pick up its full speed.
2) Open the valve on delivery line
5.1 Direction of rotation:
gradually.
3) Regulate the required flow by The direction of rotation is clockwise
adjusting the delivery valve. when viewed from driving end.
4) Open the cock for pressure gauge 5.2 Specification of bearings, oil seals,
connection. bearing lock nuts, ‘O’ rings, etc.
4.3 During running the pump
9
Note:- Bearings, bearing lock
nut/washers of SKF make or equivalents
are used.
Part Description Unit No.
Code SHM-7 SHM-9 SHM-11 SHM-13
26001 Ball Bearing SKF-6307 SKF-6309 SKF-6411 SKF-6413
DE
26002 Ball Bearing SKF-6307 SKF-6309 SKF-6411 SKF-6413
NDE
26400 Cylindrical SKF-NU307 SKF-NU309 SKF-NU411 SKF-NU413
Roller
Bearing NDE
for Heavy
Duty
arrangement
50001 Oil seal DE 32x45x7T 42x72x10T 50x78x13T 60x85x13T
50002 Oil seal NDE 35x52x10T 45x62x10T 55x80x13T 60x85x13T
33600 Bearing lock M35x1.5RH M45x1.5RH M55x2RH M65x2RH
nut DE SKF-KM-7 SKF-KM-9 SKF-KM-11 SKF-KM-13
41500 Bearing lock M35 M-35 M-55 M-65
washer SKF-MB 7 SKF-MB 9 SKF-MB 11 SKF-MB 13
52300 ‘O’ ring for 102 IDx3 123 IDx3 160 IDx3 182 IDx3
Cartridge DE THICK THICK THICK THICK
48500 Internal circlip B80x2.5 B100x3 B140x4 B160x4
for Roller THICK THICK THICK THICK
Bearing NDE
48501 Internal circlip B80x2.5 B100x3 B140x4 B160x4
for Ball THICK THICK THICK THICK
Bearing DE
44300 Constant level 70 ml A1 with plastic container
oiler ¼” BSP
44100 Grease Nipple ¼” BSP ¼” BSP ¼” BSP ¼” BSP
47900 Helicoil Screw SL-C16 SL-C24 SL-C24 ------
lock insert CNx16 CNx24 CNx36
5.3 Lubrication:
Grease replenishment quantity- The
5.3.1 Grease lubricated bearings are
bearings are grease packed in the factory.
standard supply and can be identified by
At site the following quantity of fresh
grease nipples.
grease should be added at regular intervals.
The specifications of grease are given
below. It should conform to the following
SHM-7 20 grams approx.
grades or their equivalent available in the
market.
INDIAN OIL - SERVOGEM-3
HINDUSTAN - NATRA-3 or LITHON-3
PETROLEUM 5.3.2 When oil lubricated the lubricating
CALTEX - STARFAX-3
CASTROL - SPHEEROL AP3 oil should conform to following grades of
INTERNATIONAL GRADE - NLGI-3 oil available in the market.
10
INDIAN OIL -SERVOSYSTEM-100
be filled in with the help of constant level
HINDUSTAN PETROLEUM -ENKLO-57 oiler. For filling and operation
INTERNATIONAL GRADE -ISO VG-68 instructions, please refer to 3.8.
Quantity of oil 5.3.3 Bearing temperature

in the bearing housing
SHM-7 0.7 lit approx. a) Maximum allowable bearing
temperature is 80° C.
SHM-9 0.8 lit approx.
.
SHM-11 1.0 lit approx. b) In case of new bearings, renew
grease/oil after about 2000 hrs. and then
SHM-13 1.2 lit approx. about once in a year, if the bearing
temperature is always below 50° C. If
The oil used should be a highly refined the bearing temperature is up to 80° C,
straight mineral product of high then grease/oil should be renewed after
demulsibility, free from running and acid about every 2 months.
forming tendencies. Detergent oil may
cause foaming and emulsion difficulties
and should not be used. The oil should
5.4 Specifications of stuffing box packing, gasket packing, etc.

Part Description Unit No.
Code SHM-7 SHM-9 SHM-11 SHM-13
Packing ring arrangement 2+L+3 2+L+3 2+L+3 2+L+3
with lantern ring
43001 Gland packing size 10x10x1080 10x10x1260 12.5x12.5x1330 12.5x12.5x1620
for 5 rings mm mm mm mm
(Champion style
3116)
68200 Gasket for 32x50x1 38.5x56x1 52x64x1 58x75x1
impeller mm mm mm 38.5x56x1
nut/screw mm
(FERROLITE NAM for lock nut
37) (IDxODxThick)
51500 Gasket for shaft 48x55x1 38x62x1 72.5x80x1 82.5x90x1
sleeve mm mm mm mm
(FERROLITE NAM
37) IDxODxThick
51100 Gasket for casing 265x285x1 265x258x1 265x258x1 420x440x1
cover and pump 330x350x1 330x350x1 330x350x1 515x535x1
casing mm 405x425x1 405x425x1 mm
(FERROLITE NAM mm mm
37) IDxODxThick
52300 ‘O’ ring for 80x3 mm 100x3 mm 123x3 mm 132x3 mm
cooling
chamber(IDxThick)
5.5 Cooling of stuffing box pumping liquid should not exceed
5.5.1 Cool the packed gland stuffing 140°C.
box when pumping liquid temperature
is above 90°C. However, with stuffing
box cooling, the temperature of
11
5.5.2 Quantity of stuffing box cooling 5.6 Interchangeability:
water with reference to temperature Parts standardization is optimized
and nominal impeller diameter in cms. utilizing interchangeable components to
cover a very wide performance. This
Full nominal Cooling water quantity unique feature enables the customer to
impeller (m3/hr) at various have very low spare parts inventory
diameter. pumping liquid
even though he may have many sizes
temperatures.
of these pumps. Interchangeability
110°C 140°C
26 chart is given in following chart.
0.21 0.24
32 0.23 0.28
40 0.26 0.31
Max. temperature of cooling water at

outlet- 50° C.
Max. permissible cooling water
pressure- 2 kg/cm2.
12
Interchangeability of parts
IMPELLER TYPE
100 / 32QP
150 / 26NB
100 / 26
100 / 32
150 / 26
150 / 32
50 / 26
80 / 26
65 / 32
80 / 40
50/32
PART DESCRIPTION
SHM 7 SHM 9
N, P, NB 1 2 3 4 5 6 - 7 8 8 9 1
NM - - - - - - - 16 - 8 -
PUMP CASING
Q, R 17 - 18 19 20 21 - 22 - 23 24 2
QP - - - - - - 30 - - - -
INSPECTION HOLE COVER 1 1 1 1 2 2 2 1 3 3 3 3
N 1 2 3 4 5 6 - 7 - 8 9 1
P 16 - 17 18 19 20 - 21 - 22 23 2
NB 27 - - 28 - - - - 29 - -
IMPELLER NM - - - - - - - 30 - 31 -
Q 32 - 33 34 35 36 - 37 - 38 39 4
R 45 - 46 47 48 49 - - - 50 51 5
QP - - - - - - 56 - - - -
CASING RING N, P, NB, NM 1 2 2 3 4 4 - 2 5 5 5 6
COOLING CHAMBERS 1 1 1 1 2 2 2 2 2 3 3 3
GLAND 1 1 1 1 2 2 2 2 2 3 3 3
LANTERN RING 1 1 1 1 2 2 2 2 2 3 3 3
GLAND PACKING SIZE 1 1 1 1 2 2 2 2 2 3 3 3
SHAFT 1 1 1 1 2 2 3 2 2 4 4 4
SHAFT SLEEVE 1 1 1 1 2 2 2 2 2 3 3 3
LIQUID DEFLECTOR P.S. 1 1 1 1 2 2 2 2 2 3 3 3
IMPELLER KEY 1 1 1 1 2 2 2 2 2 3 3 3
COUPLING KEY 1 1 1 1 2 2 2 2 2 3 3 3
13
IMPELLER TYPE
100 / 32QP
100 / 40QP
150 / 26NB
100 / 26
100 / 32
150 / 26
150 / 32
200 / 32
100 / 40
150 / 40
200 / 40
150 / 50
50 / 26
80 / 26
65 / 32
80 / 40
150/34
50/32
PART DESCRIPTION
SHM 7 SHM 9 SHM 11 SHM 13

CARTRIDGE 1 1 1 1 2 2 3 2 2 4 4 4 4 4 5 4 6 6
IMPELLER SCREW / NUT 1 1 1 1 2 2 3 2 2 4 4 4 4 4 3 4 5 5
BEARING HOUSING 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
SPACER FOR CARTRIDGE 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
DRIP PAN 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
BEARING P.S. 1 1 1 1 2 2 3 2 2 4 4 4 4 4 5 4 6 6
BEARING D.S. 1 1 1 1 2 2 3 2 2 4 4 4 4 4 5 4 6 6
LOCK NUT 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
LOCK WASHER 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
STUFFING BOX BUSH 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
INTERNAL CIRCLIP 1 1 1 1 2 2 3 1 2 4 4 4 4 4 5 4 6 6
OIL SEAL D.S. 1 1 1 1 2 2 2 2 2 3 3 3 3 3 3 3 4 4
OIL SEAL P.S. 1 1 1 1 2 2 2 2 3 3 3 3 3 3 4 4
ALLEN KEY FOR IMP. SCREW 1 1 1 1 - - - - - - - - - - - - - -
Q 1 - 2 3 4 5 - 6 - 7 8 9 - 10 - 11 12 13
WEAR PLATE FOR IMPELLER R 14 - 15 16 17 18 - - - 19 20 21 - 22 - 23 24 -
QP - - - - - - 25 - - - - - - - 26 - - -
SMALL 'O' RING FOR WEAR PLATE 1 - 2 3 4 4 4 2 - 5 5 6 - 4 4 5 7 5
LARGE 'O' RING FOR WEAR PLATE 1 - 1 2 1 2 2 3 - 1 2 2 - 4 4 4 4 5
IDENTICAL FIGURES IN LINE INDICATE IDENTICAL PARTS
14
worn out or shaft sleeve might have
6. PREVENTIVE MAINTENANCE: worn out or lantern ring is displaced. In
Preventive maintenance schedule is case the packings are worn out all the
the periodical checks and precautions packing rings should be replaced. If the
by which possibilities of failures and pumps are fitted with mechanical seal,
breakdowns are minimized. there should not be any product
leakage from stuffing box.
6.1 Daily Checks:
6.2.4 The alignment of the pump unit
6.1.1 Hourly record of suction and should be checked. Due to operational
delivery pressure, discharge quantity, vibrations, atmospheric temperature or
input to the pump driver should be stress induced by the weight of the
maintained. piping, the alignment may get
disturbed.
6.1.2 Bearing temperature, oil level,
stuffing box leakage / stuffing box 6.2.5 Sufficient quantity of suitable
temperature, cooling water inlet and type of lubricant should be ready for
outlet temperature should be checked. daily and emergency use.
This gives an idea of mechanical
performance of the pump. 6.2.6 Calibrate the measuring
instrument.
6.1.3 Noise and vibrations are the
first signs of impending troubles like 6.3 Annual Checks:
cavitation, air lock, bearing failure,
choking of impeller or casing and such 6.3.1 The pump should be overhauled
other operating troubles. The pump completely to check the clearance and
performance should therefore be to replace worn-out parts. Clearances
checked for noise and vibrations. between impeller and casing rings,
shaft sleeves and throat bush, lantern
6.2 Periodical Checks: ring and shaft sleeve, etc., are very
important. The bearings should be
6.2.1 The temperature of the bearing cleaned thoroughly and lubricated.
should be measured by thermometer or
any other device. Safe maximum 6.3.2 The effects of liquid handled on
working temperature of the bearing is pump components should be checked.
80°C. If abnormal corrosion, erosion is
observed, the component should be
6.2.2 The lubricants of the bearing replaced with that of suitable material.
should be checked. The lubricant might
get contaminated with foreign material 6.3.3 The auxiliary pipelines and
or get blackened due to overheating. In functioning of the auxiliary system
such cases, bearings should be flushed should be checked. The main pipe also
and charged with fresh lubricants. should be checked for scaling, leakage,
etc.
6.2.3 Check for the stuffing box
leakage. Normal leakage of 60-80 6.3.4 The measuring instruments,
drops per minute is recommended for gauges, etc., should be recalibrated.
safe operation. If the leakage is more 6.3.5 Full running test may be carried
the stuffing box packing might have out to check whether there is any fault
15
in the performance, in comparison with 7.2.6 Remove the bolts from pump
original performance. feet and base.
7.2.7 Remove the pump from bed
6.3.6 Piping supports should be and take it on to a table for stripping.
checked so that the pipes do not 7.2.8 Unscrew and remove the nuts
induce unwanted stresses on the of the studs holding the casing with
pump. casing cover and/or with bearing
housing.
7. OVERHAULING: 7.2.9 Lift the rotating unit
subassembly by eyebolt (30000)
With normal daily operation, the pump provided on bearing housing (24000)
will be due for overhaul after about one and remove it from delivery casing
year. This work is to be done by skilled (10500).
personnel. Complete pump is to be 7.2.10 Hold the pump coupling and
taken out from bed. unscrew the impeller nut (33002)
/screw by using box spanner.
7.1 Procedure for Dismantling and 7.2.11 Remove the impeller
Re-assembling (15100/15300/16600) from shaft by
While dismantling and re-assembling, using a puller.
the cross-sectional assembly drawing 7.2.12 Remove the casing cover sub-
and specification parts list should be assembly along with gland packed
referred. stuffing box, if casing cover is sand-
witched type.
7.2 Dismantling: If casing cover is held by studs
Follow the following simple steps to and nuts on to the bearing housing,
dismantle the pump. remove these nuts and take out casing
cover sub-assembly.
7.2.1 Isolate power supply to motor. 7.2.13 Remove the sleeve (31100)
7.2.2 Shut off valves controlling flow from pump shaft. If necessary, use a
to and from the pump. puller.
7.2.3 Drain the liquid from pump by 7.2.14 Remove the liquid deflector
removing the drain plug (60100) or (23600).
open the pump casing (10500) drain 7.2.15 Unscrew the grub screw
cock. holding the coupling and take out
7.2.4 Remove all auxiliary tubing and coupling from shaft. Make use of
piping. puller.
Drain the lubricating oil from the 7.2.16 Remove the screws holding the
bearing housing (24000) if oil bearing cover (27100) and cartridge
lubricated and remove constant level (24100) to the bearing housing
oiler (44300). (24000). Remove bearing cover
7.2.5 In case of pumps with spacer (27100) NDE.
type flexible coupling disconnect 7.2.17 Remove the shaft (18000)
coupling (pump half and motor half) along with bearings and DE cartridge
from the coupling spacer and remove (24100) from the bearing housing
coupling spacer. Coupling spacer shall (24000).
fall down. In case of ordinary flexible 7.2.18 Remove the circlips (48500)
couplings, remove motor from the from the cartridge by circlip puller and
base. remove the cartridge (24100) by slight
hammering.
16
7.2.19 Hold the shaft (18000) and
remove the bearing nut. Take out the c) Do not use hammer to fit the
lock washer. bearings. Do not damage the shaft
7.2.20 Remove the bearings surface especially where it is in
(26001 & 26002) from the shaft by contact with oil seal.
use of bearing puller.
7.2.21 Remove the oil seals (50001) 7.3.2 Tighten bearing lock nut (33600)
from cartridge and bearing cover using after inserting lock washer (41500) for
the holes provided in the oil seal cover. bearing locking in proper position. Fold
7.2.22 Remove the nuts holding the one lip of lock washer in slot of bearing
split gland (22900). lock nut to lock it.
7.2.23 Take out the clamping plate
and remove gland halves. 7.3.3 Put oil seal (50001) in the
7.2.24 Remove the gland packings bearing cartridge DE (24100). Insert DE
(43000) and lantern ring (22700). bearing along with shaft in bearing
cartridge.
7.3 Re-assembly: Put ‘O’ ring on the cartridge in
This procedure covers re-assembly of case of oil lubrication only. Insert
pump after complete dismantling of the internal circlip (48500) in the inner
pump. Before re-assembly, all the parts groove of the cartridge. Put a spacer
should be thoroughly cleaned in on bearing cartridge, in case of SHM-N,
kerosene, petrol or benzene to remove SHM-R and SHM-P pumps and shims in
the dust, rust, etc. After cleaning the case of SHM-Q pumps. Insert the
worn-out parts should be replaced with bearing cartridge from DE of the pump
new. shaft.
7.3.4 Insert the shaft along with ball
7.3.1 Mount drive side (26001) and bearings at DE and NDE and bearing
pump side (26002) deep groove ball cartridge at DE into the bearing housing
bearings on the shaft (18000). (24000) from driving end.
Caution: 7.3.5 Tighten the bearing cartridge on
the bearing housing with the help of
a) Use arbour press while fitting hexagonal screws.
the bearings. However, it is 7.3.6 Replace oil seal (50002) in
recommended that bearings should bearing cover NDE (27100). Tighten
be heated in oil bath at temperature the bearing cover NDE on bearing
70 to 800C and then fitted. (If hot housing with the help of hexagonal
oil bath is not available then screws.
ARBOUR PRESS must be used). 7.3.7 Slide the liquid deflector (23600)
from NDE of shaft. Tighten the
deflector on shaft by using grub screw.
Use gloves while fitting
7.3.8 Slide the clamping plate (22400)
bearings from hot oil bath.
from NDE of shaft.
b) Slide inboard ball bearing on
7.3.9 Push the shaft sleeve (31100)
shaft by hand, make sure that it is
into the shaft till it touches the collar
square with shaft. Press evenly the
on the shaft.
inner race of the bearing until
7.3.10 Fit the stuffing box neck
bearing is seated firmly against the
bush (35000) into the casing cover
shaft shoulder.
(22000).
17
7.3.11 Put the gasket (51500) on For 9 & 11 units insert the Helicoil
the impeller hub in proper position. screw lock insert (47900) in impeller
7.3.12 Fit the impeller key (32000) nut (33002) and tighten it on the shaft
on the shaft. It should enter partly in at NDE.
the shaft sleeve.
7.3.13 Put the casing cover (22000) For 13 unit nut/lock nut arrangement is
on the bearing housing. Tighten it by used for impeller locking.
studs and nuts to the bearing housing. a) Tighten impeller nut
7.3.14 Push the impeller (33002) fully.
(15100/15300/16600) on the shaft till b) Tighten impeller lock nut
it touches the shaft sleeve. (33001) fully.
7.3.15 Fix the coupling key (32100) c) Hold impeller lock nut
on shaft at DE. Put the spacer coupling firmly in position and slightly
half pump side on the shaft and tighten loosen impeller nut. This will
the grub screw to fix the coupling. ensure positive locking of impeller.
7.3.16 Insert the Helicoil screw lock
insert (47900) at NDE of shaft for 7-
unit and tighten impeller screw (66900)
in shaft by holding the
coupling.
Fig. 7
7.3.17 Slide this complete back

pullout assembly into pump casing
(10500). Insert studs in the pump
casing (10500) and casing cover
(22000). Tighten all nuts on the stud
firmly and evenly.
7.3.18 In case of pumps with gland
packings only, insert the gland packing
(43001) and lantern ring in two halves
(22700) in the order of 2+L+3.
7.3.19 Put the split gland in two
halves (22900) with clamping plate
(22400) and tighten the gland stud
nuts.
7.3.20 Rotate the shaft by hand and
ensure free rotation.
7.3.21 Fit all the accessories such as
sealing water, flushing water, cooling
water connections as per order.
7.3.22 Make suction and delivery
Fig. 6 piping connections properly.
18
8. SPARE PARTS LIST AND CROSS-SECTIONAL DRAWINGS:
PARTS LIST FOR SHM-N, NB, NM & P (UNIT-7) PUMPS
PART CODE PART DESCRIPTION

10500 Pump casing
*15100 Impeller enclosed
*18000 Pump shaft
*19000 Casing wear ring
20900 Spacer for cartridge
22000 Casing cover
22100 Cooling chamber (for hot model only)
22400 Clamping plate
22700 Lantern ring
22900 Split gland
23600 Liquid deflector
24000 Bearing housing
24100 Bearing cartridge
25100 Support foot
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
30000 Lifting eye bolt
*31100 Shaft sleeve
*32000 Key for impeller
*32100 Key for coupling
33600 Round lock nut
*35000 Stuffing box bush
*41500 Lock washer for bearing nut
*43000 Gland packing
44101 Grease nipple for bearing cover
44102 Grease nipple for bearing cartridge
44103 Grease nipple for grease sealing
44300 Constant level oiler
44400 Oil feeding plug
*47900 Helicoil screw lock insert
*48500 Internal circlip for bearing cartridge.
*50001 Oil seal driving side
*50002 Oil seal non-driving side
*51100 Gasket for casing cover
*51201 Gasket for cooling chamber inside (for hot model only)
*51202 Gasket for cooling chamber outside (for hot model only)
*51401 Gasket for bearing cover
*51500 Gasket for impeller and shaft sleeve
*51600 Gasket for inspection hole cover
*52300 ‘O’ ring for bearing cartridge
*52500 ‘O’ ring for casing cover and cooling chamber (for hot
model only)
53001 Pipe nipple for casing cover sealing inlet
53002 Pipe nipple for casing cover sealing outlet
19
53101 Pipe nipple for cooling chamber inlet (for hot model only)
53102 Pipe nipple for cooling chamber outlet (for hot model only)
54001 Socket for sealing pipe nipple
58100 Hexagonal nut for casing stud
58201 Hexagonal nut for stud of casing cover/bearing holder
58202 Hexagonal nut for stud of gland
59000 Stud for casing
59101 Stud for casing cover/bearing holder
59102 Stud for gland
59600 Stud for inspection hole cover
60001 Pipe plug for suction gauge connection
60002 Pipe plug for delivery gauge connection
60100 Pipe plug for casing drain
60200 Pipe plug for sealing pipe nipple outlet
60500 Pipe plug for bearing housing drain
60900 Pipe plug for flushing
61000 Cylindrical pin for casing cover
63001 Hexagonal screw for casing cover release
63002 Hexagonal screw for bearing cartridge
63100 Hexagonal screw for bearing cover
63200 Hexagonal screw for support foot
*65000 Hexagonal socket grub screw for casing wear ring
65400 Hexagonal socket grub screw for liquid deflector
66600 Cap screw for stuffing box bush
*66900 Screw for impeller
67101 Cooling nameplate inlet
67102 Cooling nameplate outlet
67601 Sealing nameplate inlet
67602 Sealing nameplate outlet
*68200 Gasket for impeller/impeller screw
*Recommended spares for two years normal working.
20
CROSS SECTIONAL ASSEMBLY OF
(SHM-N,NB,NM & P PUMPS (UNIT 7)
47000
51600 53001
60200 54001
ST. BOX SEALING OUTLET ST. BOX SEALING INLET DELIVERY
PLUGED 1/4" BSP 30000 31100
44103 22900 22700
18000 10500
32100 24000
44102 32000
26001 27100 44101 47900
66900
68200
21
51500
60900
50001 19000
33600 15100
60100
41500 35000
48500 60500 50002 22400
43000
24100 20900 25100 26002 23600 51100
60500 22000
PARTS LIST FOR SHM-Q (UNIT-7) PUMPS

10500 Pump casing
*15300 Impeller semiopen
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
25100 Support foot
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
33701 Acorn nut for wear plate
33702 Hexagonal nut for inspection
*46000 Wear plate
47000 Inspection hole cover for pump casing
47102 Protection cover-suction side.
*51400 Metallic gasket for cartridge
*52201 ‘O’ ring for wear plate
22
model only)
59400 Stud for wear plate
62600 Washer for acorn nut of wear plate
*68400 Gasket for acorn nut of wear plate
23
47000 CROSS SECTIONAL ASSEMBLY OF
51600 53001 SHM-Q PUMPS (UNIT 7)
60200 54001
ST. BOX SEALING OUTLET ST. BOX SEALING INLET
PLUGED 1/4" BSP
DELIVERY
44103
44102 18000 27100 44101 31100 10500 32000

22700 68400
33701
32100 26001 24000 30000 22900 47900
66900
24
52201
68200
SUCTION
51500
50001
46000
33600 15300
60100
41500 52202
51400 25100 26002 23600 22000 35000
22400 51100
24100 48500 60500 50002 43000
PARTS LIST FOR SHM-R (UNIT-7) PUMPS

10500 Pump casing
13000 Pump casing spacer
*16600 Impeller free flow
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
25100 Support foot
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*46000 Wear plate
47102 Protection cover-suction side
*48500 Internal circlip for bearing cartridge
25
model only)
26
47000
51600
53001 SHM-R PUMPS (UNIT 7)
60200 54001

PLUGED 1/4" BSP
DELIVERY
44103
VIEW FROM DRIVING END 44102 18000 24000 30000 31100 13000 10500 32000
22900 16600
68400
32100 26001 27100 44101 22700 47900
33701
66900
27
52201
68200
SUCTION
51500
50001
46000
33600
60100
41500
48500 60500 50002 22400 35000
51100
24100 20900 25100 26002 23600 22000 43000 52202

PARTS LIST FOR SHM-N, NB, NM & P (UNIT-9 & 11) PUMPS

10500 Pump casing
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*33002 Impeller nut
model only)
28
*68200 Gasket for impeller/impeller nut
29
51600 53001 SHM-N,NB,NM & P PUMPS (UNIT 9 & 11)
60200 54001
PLUGED 1/4" BSP
44103
VIEW FROM DRIVING END DELIVERY
32100 18000 30000 31100
44102 24000 22900 22700 10500
32000
26001 27100 44101
479
47900
30
33002
68200
SUCTION
51500
60900
50001 19000
33600 15100
60100
41500 35000
60500 50002 22400
43000
24100 20900 48500 26002 23600 22000 51100
PARTS LIST FOR SHM-Q, QP (UNIT-9 & 11) PUMPS

10500 Pump casing
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*33002 Impeller nut
*46000 Wear plate
31
model only)
32
51600 53001 SHM-Q, QP PUMPS (UNIT 9 & 11)
60200 54001
DELIVERY
PLUGED 1/4" BSP
44103 30000 31100

24000 22900 22700 10500 32000

18000 68400
44102
32100 33701
26001 27100 44101
47900
33002
33
52201
68200
SUCTION
51500
50001
46000
33600 15300
60100
41500 52202
48500 60500 50002 22400 51100 35000
24100 26002
51400 23600 22000 43000
PARTS LIST FOR SHM-R (UNIT-9 & 11) PUMPS

10500 Pump casing
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*33002 Impeller nut
*46000 Wear plate
34
model only)
35
530001
51600 SHM-R PUMPS (UNIT 9 & 11)
60200 540001

PLUGED 1/4" BSP
44103 DELIVERY
44102 22900 31100 13000
1800024000 30000 10500 32000
16600
32001 26002 22700 68400
27100 44101 47900
33700
33001
52201
36
68200
SUCTION
51500
50002
46000
33600
60100
41500
48500 50001 22000 51101 35000
60500 22400 51102
24100 20900 26001 23600 43000 52202
PARTS LIST FOR SHM-N & P (UNIT-13) PUMPS

10500 Pump casing
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*33001 Impeller lock nut
*33002 Impeller nut
model only)
37
*68201 Gasket for impeller lock nut
38
47000
51600 53001
60200 54001 SHM-N, P (UNIT-13) PUMPS
PLUGED 1/4" BSP
44103 DELIVERY
32100 18000 30000 31100
44102 24000 22900 22700 10500
32000
26001 27100 44101
33002
68201
39
33001
68200
SUCTION
51500
60900
50001 19000
33600 15100
60100
41500 35000
60500 50002 22400
43000
24100 48500 26002 23600 22000
20900 51100
PARTS LIST FOR SHM-Q (UNIT-13) PUMPS

10500 Pump casing
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*33002 Impeller nut
*46000 Wear plate
40
model only)
*68201 Gasket for Impeller lock nut
41
42
PARTS LIST FOR SHM-R (UNIT-13) PUMPS

10500 Pump casing
*18000 Pump shaft
22000 Casing cover
22700 Lantern ring
22900 Split gland
*26001 Bearing DE
*26002 Bearing NDE
27100 Bearing cover
*31100 Shaft sleeve
*33002 Impeller nut
*46000 Wear plate
43
model only)
*68201 Gasket for Impeller lock nut
44
53001
SHM-R PUMPS (UNIT 13)
51600
60200 54001

PLUGED 1/4" BSP DELIVERY
44103
32100 26001 24000 22900 13000 10500 32000

30000 22700 16600
68400
44102 18000 44101 31100
33701
33002
45
33001
52201
68201
SUCTION
68200
51500
50001
46000
33600
60100
41500 52202
48500 50002 22400 51100
35000
24100 20900 60500 26002 23600 22000 51100 43000
MECHANICAL SEAL ARRANGEMENT
26002
44102 24000 44400

18000 24000 30000 32100 18000
30000
32001 44300
27100 44101 26002
27100
52300
50001 50002
33600 33600
41500 41500
48500 50002 48500 50001 22400
23600
24100 26001 24100 51400 60500 26001 23600
BEARING HOUSING (GREASE LUBRICATED)

BEARING HOUSING (OIL LUBRICATED)
(AGAINST ORDER)
46
53102
51202
51201
43000
52500
53101
22100
22000
COO LING CHA M BER ARRA NGEM ENT

(FO R H OT M O DEL O NLY)
47
48
49
GENERAL INSTRUCTIONS
FOR INSTALLATION, OPERATION
& MAINTENANCE OF
KIRLOSKAR CENTRIFUGAL PUMPS
INCORRECT CORRECT
50
GENERAL INSTRUCTIONS ALIGNMENT
Pumps and the drivers supplied by the
FOR INSTALLATION, manufacturers, mounted on a common
OPERATION & base plate are accurately aligned before
MAINTENANCE OF dispatch. However, as the alignments
are likely to be disturbed during transit
KIRLOSKAR CENTRIFUGAL to some extent and hence must not be
PUMPS relied upon to maintain the factory
alignment. Re-alignment is necessary
WARNING after the complete unit is been leveled
The equipment supplied is designed for on the foundation and again after the
specific capacity, speed pressure and grout has been set and foundation
temperature. Do not use the equipment bolts have been tightened. The
beyond the capacities for which it is alignment must be checked after the
manufactured. The equipment unit is piped up and re-checked
manufactured is also shop tested for periodically.
satisfactory performance and if it is
operated in excess of the conditions for FLEXIBLE COUPLING
which it is manufactured, the
equipment is subjected to excessive A flexible coupling will not compensate
stresses and strains. for the misalignment of the pump and
driver shafts. The purpose of the
LOCATION flexible coupling is to compensate for
The pump should be located as near temperature changes and to permit the
the liquid source as possible. This will movement of the shafts without
minimize suction lift and pump will give interference with each other while
better performance. transmitting power from the driver to
Ample space should be provided on all the pump. There are two types of
the sides so that the pump can be misalignments.
inspected while in operation and can be
serviced whenever required. 1) Angular misalignment – Shaft with
axis concentric, but not parallel.
FOUNDATION
The foundation should be sufficiently 2) Parallel misalignment – Shaft with
substantial to sustain any vibrations axis parallel, but not concentric.
and to form a permanent rigid support STEEL STRAIGHT STEEL STRAIGHT INCORRECT ANGULAR
EDGE EDGE MISALIGNMENT
for the base plate. This is important in
maintaining the alignment of a directly
connected unit. A concrete foundation INCORRECT PARALLEL
CORRECT
on a solid base is advisable. Foundation MISALIGNMENT STEEL STRAIGHT EDGE
bolts of the proper size should be

embedded in the concrete located by a
drawing or template. A pipe sleeve of LEVELING THE UNIT
two and half diameter larger than the When the unit is received with the
bolt should be used to allow movement pump and driver mounted on the base
for the final position of the foundation plate, it should be placed on the
bolts. foundation and the coupling halves
disconnected. The coupling should not
51
be reconnected until all misalignment b) Pipe strains distorting or shifting the
operations have been completed. The machines.
base plate must be supported evenly c) Wear of the bearing.
on wedges inserted under the four
corners so that it will not be distorted PIPING
or sprung by the uneven distribution of Both suction and delivery pipes and
the weight. Adjust the wedges until the accessories should be independently
shafts of the pump and the driver are in supported near the pump, so that when
level. Check the coupling faces, suction the flanges, bolts are tightened no
and discharge flanges for the horizontal strains will be transmitted to the pump
and vertical position by means of spirit casing. It is usually advisable to
level. increase the size of both the suction
and delivery pipe at the pump nozzles
FLEXIBLE COUPLING ALIGNMENT in order to decrease the loss of head
The two halves of the coupling should due to friction and for the same reason
be at least 3 mm apart so that they piping should be arranged with
cannot touch each other when the minimum possible bends as possible, or
driver shaft is rotated. Necessary tools it should be made with long radius
for approximately checking are straight wherever possible. The pipe lines
edge or an outside caliper. A check for should be free from scales, welding
parallel misalignment is made by residuals, etc., and have to be mounted
placing a straight edge across both in such a way that they can be
coupling periphery at the top, bottom connected to suction and delivery
and both the sides. The unit will be in flanges without any stress on the
parallel alignment when the straight pump. It can be achieved by supporting
edge rests evenly on the coupling the pipelines at appropriate locations.
periphery at all the positions. Care
must be taken that the straight edge SUCTION PIPE
must be parallel to the axis of the The suction pipe should be as short as
shaft. possible. This can be achieved by
placing the pump near the liquid to be
GROUTING pumped. The suction pipe must be kept
When the alignment is correct, the free from air leakages. This is
foundation bolts should be tightened particularly important when the suction
evenly but not too firmly. The unit can lift is high. A horizontal suction line
then be grouted by working soft must have a gradual rise to the pump.
concrete under the edges. Foundation Any high point in the pipe will be filled
bolts should not be fully tightened until with air and thus prevent proper
the grout is hardened, usually 48 hours operation of the pocket in the top of
after pouring. the reducer and the pipe. Use an
eccentric piece instead.
FACTORS THAT MAY DISTURB The end of the suction pipe must be
ALIGNMENT well submerged to avoid whirlpools and
The unit should be periodically checked ingress of air but must be kept clear of
for alignment. If the unit does not stay any deposits of mud, silt, grit, etc. The
in line after being properly installed, the pipe must be away from any side of
following are possible causes: the wall by 450 mm. the end of the
a) Setting, seasoning of the foundation. strainer must be provided with a
strainer of sufficient open area.
52
(only for gland packed pump)
DELIVERY PIPE Stuffing boxes should be carefully
A check (non-return) valve and a gate cleaned and packing placed in them. Be
or sluice valve (regulating valve) should sure that sufficient packing is placed at
be installed in the discharge line. The the back of the water seal cage. If the
check valve placed between the pump water to be pumped is dirty or gritty,
and the gate valve is to protect the sealing water should be piped to the
pump from excessive pressure and to stuffing boxes from clean outside
prevent water running back through the source of supply in order to prevent
pump in case of failure of the driving damage to the packing and shaft. In
machine. placing the packing, each packing ring
Discharge piping should be provided should be cut to the proper length so
with a sluice valve adjacent to the that ends come together but do not
delivery flange to control the discharge overlap. The succeeding rings of
if required. packing should not be pressed too
tight, as it may result in burning the
VACUUM EQUALIZING LINE (AND packing and cutting the shaft. If the
LIQUID LINE) stuffing box is not properly packed,
If the pump draws from a system under friction in stuffing box prevents turning
vacuum an equalizing pipe must be the rotor by hand. On starting the
carried from the highest point of the pump, it is well to have the packing
suction line, however as close to the slightly loose without causing an air
suction flange of the pump as possible, leak, and if it seems to leak, instead of
to the top of the feed tank to keep gas putting too much pressure on the
bubbles that might have been gland, put some heavy oil in the
entrapped in the flow from entering the stuffing box until the pump works
pump. The line should be fitted with an properly and then gradually tighten up
isolating valve which should be closed the gland. The packing should be
only for maintenance work on the occasionally changed.
pumpset.
Apply sealing liquid (external sealing) to BALL BEARINGS
the shaft seal cage to prevent entry of Correct maintenance of ball bearings is
air in the case of the pumps with essential. The bearing manufacturers
packed stuffing box. It is convenient to give the following as a guide to re-
tap the sealing liquid from the delivery lubrication periods under normal
line above the non-return valve. condition.
Three monthly when on continuous
duty.
FOOT-VALVE Six monthly when on eight hour per
It is advisable to install a foot-valve to day duty.
facilitate priming. The foot-valve should The bearings and housings should be
have sufficient clear passage for water. completely cleaned and recharged with
Care must be taken to prevent foreign fresh grease after 2500 hrs. or the
matter from being drawn in to the nearest pump overhaul time.
pump or choking the foot-valve and for
this purpose an efficient strainer should PRIMING
be provided. No pumping action occurs unless the
pump casing is filled with the liquid.
STUFFING BOXES AND PACKING Pump casing and suction pipe must
53
therefore be completely filled with practically no attention while running.
liquid and thus all air removed before Lubrication at the bearings and
the pump is started. Several different manipulation of the glands are the only
priming methods can be used things that need attention from the
depending on the kind of installation operator.
and service involved.
1) Liquid level above pump level. STOPPING
Pump is set below liquid level of source Before stopping the pump; close the
of supply, so that liquid always flows gate valve. This will prevent water
to pump under positive head. hammer on the check valve.
2) Priming with foot-valve. STUFFING BOXES (only for gland
a. When pump is installed on packed pump)
suction lift with foot valve at the end Do not tighten the glands excessively.
of suction line, fill pump with water A slight dripping of water from the
from some outside source till all air is stuffing boxes when pump is running
expelled and water flows through the keeps packing in good condition.
air vent.
b. When there is liquid under some CASING RINGS
pressure in the discharge pipe, priming Casing rings are fitted in the casing to
can be effected by bypassing the reduce the quantity of water leaking
pressured liquid around the check and back from the high-pressure side to the
gate valve. Of course, the initial suction side. These casing rings are
priming must be effected from some fitted to maintain a small clearance and
outside source. depend on the water in the pump for
Note: In this case, the foot-valve must lubrication. When the rings are worn
be capable of withstanding pump out, the clearance becomes greater and
pressure and possible surge. more water passes back into the
3) Priming by ejector. suction side. The rings must be
An ejector operated by steam, replaced from time to time to restore
compressed air or water under pressure the pump efficiency to its normal value.
and connected to air vent at the top of
casing can be used to remove air from SPARE PARTS
pump and prime the pump on suction A set of ball bearings, a set of casing
lift installations. rings and a set of gland packing rings /
4) Priming by dry vacuum pump. mechanical seal must always be kept
A hand or power pump sucks in all the at hand to ensure uninterrupted service
air from the casing and the suction from the pump. While ordering for
pipe, and thus primes the system. spare parts, always give type, size and
serial number of the pump as stamped
STARTING on the nameplate.
The pump must not be started without
being primed. Be sure that the driver PUMP TROUBLE
rotates in the proper direction as When investigating trouble with
indicated by a direction arrow on the Kirloskar pumps, always remember that
pump casing. pumps have been tested at the factory
and are mechanically correct when sent
RUNNING out. Discounting the possibility of
On account of its simple construction, damage during transit, most of the
the centrifugal pump requires
54
trouble in the field is due to faulty
installation. Investigation shows that Motor gets hot or 14 22 27 28 40 43 50 55
burns out 56 57 58 59 60 61
the majority of troubles with centrifugal
pumps result from faulty conditions on Motor is difficult 14 22 27 28 45 46 50 58
the suction side. to start 59 60
BREAK DOWN-CAUSE-CHECK POINTS
In case of breakdown we recommend
the location of the fault by using the CHECK POINTS
following table. 1. Suction pipe, foot valve choked.
2. Nominal diameter of suction line
BREAKDOWN CHECK POINTS too small.
3. Suction pipe not sufficiently
Pump does not 1 7 8 9 10 11 12 14 15 submerged.
deliver 17 18 19 23 25 26 56 57 4. Too many bends in the suction
58
line.
Pump delivers at 1 2 3 4 5 6 7 8 9 10 11
reduced capacity 12 13 14 15 17 18 19 20
5. Clearance around suction inlet
21 22 56 57 58 not sufficient.
Delivery 1 3 7 9 10 11 12 13 14 6. Shut off valve in the suction line in
performance 19 20 21 22 23 24 53 57 unfavorable position.
deteriorates 62 7. Incorrect layout of suction line
Pump delivers too 16 56 57 58
(formation of air pockets).
much 8. Valve in the suction line not fully
open.
Delivery is 1 3 6 7 8 9 10 11 12 13 9. Joints in the suction line not
interrupted 14 15 16 19 22 23 25 26 leak-proof.
56 57 58 62
10. Air leaking through the suction
After stopping 52
pump runs in line and stuffing box, etc.
reverse direction 11. Suction lift too high.
12. Suction head too low (difference
Very noisy 1 2 5 6 7 8 11 12 13 15 between pressure at suction
19 20 22 54 55 56 57 62 connection and vapor pressure too
Unsteady running 19 20 22 31 32 33 35 36
of pump 37 38 39 40 43 44 47 48
low).
49 50 51 54 55 58 13. Delivery liquid contains too much
Stuffing box leaks 24 27 28 29 30 31 47 48 gas and/or air.
excessively 49 53 14. Delivery liquid too viscous.
15. Insufficient venting.
Fumes from 22 23 24 25 26 27 28 29
16. Number of revolutions too high.
stuffing box 30 41 42 43
17. Number of revolutions too low.
Pump rotor 22 45 46 50 18. Incorrect direction of rotation
locked in (electric motor incorrectly connected,
standstill position leads of phases on the terminal block
interchanged).
Pump is heating 23 24 25 26 27 28 29 30
up and seizing 40 41 42 45 47 48 49 50
19. Impeller clogged.
54 20. Impeller damaged.
Bearing 19 20 21 22 31 32 33 34 21. Casing rings worn out.
temperature 35 36 37 38 39 40 41 42 22. Separation of crystals from the
increases 43 44 45 46 47 48 49 51 flow of pumping liquid (falling below
54 55 58
Motor will not 14 22 60
the temperature limit/equilibrium temp).
start 23. Sealing liquid line obstructed.
55
24. Sealing liquid contaminated. 42. Sediment in the cooling water
25. Lantern ring in the stuffing box is chamber of the stuffing box cooling.
not positioned below the sealing liquid 43. Alignment of coupling faulty or
Inlet. coupling loose.
26. Sealing liquid omitted. 44. Elastic element of coupling worn.
27. Packing incorrectly fitted. 45. Pump casing under stress.
28. Gland tightened too 46. Pipeline under stress.
much/slanted. 47. Shaft runs untrue.
29. Packing not suitable for 48. Shaft bent.
operating conditions. 49. Rotor parts insufficiently
30. Shaft sleeve worn in the region balanced.
of the packing. 50. Rotor parts touching the casing.
31. Bearing worn out. 51. Vibration of pipe work.
32. Specified oil level not 52. Non-return valve gets caught.
maintained. 53. Contaminated delivery liquid.
33. Insufficient lubrication of 54. Obstruction in delivery line.
bearings. 55. Delivery flow too great.
34. Ball bearings over-lubricated. 56. Pump unsuitable for parallel
35. Oil/Grease quality unsuitable. operation.
36. Ball bearing incorrectly fitted. 57. Type of pump unsuitable.
37. Axial stress on ball bearings (no 58. Incorrect choice of pump for
axial clearance for rotor). existing operating conditions.
38. Bearings dirty. 59. Voltage too low/power supply
39. Bearings rusty (corroded). overloaded.
40. Axial thrust too great because of 60. Short circuit in the motor.
worn casing rings, relief holes 61. Setting of starter of motor too
obstructed. high.
41. Insufficient cooling water supply 62. Temperature of delivery liquid
to stuffing box cooling. too high.
56
GENERAL INFORMATION & KBL requires that, all personnel who are
responsible for installation, operation or
SAFETY INSTRUCTIONS maintenance of the equipment, have
access to and study the product
The products supplied by KBL have been instruction manual BEFORE any work is
designed with safety in mind. Where done and that they will comply with all
hazards cannot be eliminated, the risk local and industry based safety
has been minimized by the use of guards instructions and regulations.
and other design features. Some hazards
cannot be guarded against and the Ear defenders should be worn where the
instructions below MUST BE COMPLIED specified equipment noise level exceeds
WITH for safe operation. These locally defined safe levels. Safety glasses
instructions cannot cover all or goggles or face shield should be worn
circumstances. Installation, operation and where working with pressurized systems
maintenance personnel must use safe and hazardous substances. Other
working practices at all the times. personal protection equipment must be
worn where local rules apply. Wear
KBL products are designed for installation safety shoes, helmets and cotton overall
in designated areas, which are to be kept [Apron] when you enter pump house.
clean and free of obstructions that may Noise level should not exceed 90 dbA
restrict safe access to the controls and and 110 dbA for motor driven and engine
maintenance access points. driven pumps, respectively.
A pump duty nameplate is fitted to each Do not wear loose clothing or jewellery,
unit and must not be removed. Loss of which could catch on the controls or
this plate could make identification become trapped in the equipment.
impossible. This in turn could affect Read the instruction manual before
safety and cause difficulty in obtaining installation, operation or maintenance of
spare parts. If accidental loss or damage the equipment. Check and confirm that
occur, contact KBL immediately. you are referring relevant copy of the
manual by comparing pump type on the
Access to the equipment should be nameplate and with that on the manual.
restricted to the personnel responsible for Note the “Limits of product application
installation, operation and maintenance permissible use” specified in the manual.
and they must be trained, adequately Operation of the equipment beyond these
qualified and supplied with appropriate limits will increase the risk from hazards
tools for their respective tasks. noted below and may lead to premature
Most accidents involving product and hazardous pump failure.
operation, maintenance and repair are
caused by failure to observe safety rules Clear and easy access to all controls,
or precautions. An accident can often be gauge stand, dials, etc., must be
avoided by recognizing potential maintained at all times. Hazardous or
situations before an accident occurs. A flammable materials must not be stored
person must be aware of potential hazard in pump rooms unless safe areas or
associated in activities of installation, racking and suitable container have been
operation and maintenance of provided.
equipments. Use suitable earthing and tripping devices
for electrical equipments.
57
IMPROPER INSTALLATION, OPERATION, may have disturbed the pump or motor
MAINTENANCE, LUBRICATION, REPAIR mounting positions. If hot liquids [above
OF THIS KBL PRODUCT COULD RESULT 80°C] are being pumped, alignment
IN INJURY OR PROPERTY DAMAGE. should be checked and reset with the
pump and motor at their normal operating
If any tool, procedure, work method and temperature. If this is not possible, KBL
operation technique is not recommended can supply estimated initial offset figures
by KIRLOSKAR BROTHERS LIMITED is to suit extreme operating temperatures.
used or followed, it should be ensured Failure to support suction and delivery
that it is safe for personnel around and pipework may result in distortion of the
others. It should also be ensured that the pump casing, with the possibility of early
product will not be damaged or made pump failure.
unsafe by the operation, lubrication and
maintenance or repair procedures you SAFETY INSTRUCTIONS WHILE
choose. COMMISSIONING AND OPERATION
Never attempt adjustments while the
SAFETY INSTRUCTIONS WHILE pump is running, unless otherwise
HANDLING AND STORAGE specified in the operation, maintenance
When lifting the pump, use the lifting manual.
points specified on general arrangement
drawing, if provided. Use lifting Do not touch any moving or rotating
equipment having a safe working load parts. Guards are provided to prevent
rating suitable for the weight specified. access to these parts, where they have
Use suitable slings for lifting pump, been removed for maintenance they must
which is not provided, with lifting points. be replaced before operating the
The use of forklift truck and chain crane equipment.
sling equipment is recommended but
locally approved equipment of suitable Check that pump is primed. Pump should
rating may be used. While lifting, the never be run dry as the pumped liquid
equipment adjusts the centre of gravity, acts as lubricant for the close running fits
so that it is balanced properly. surrounding impeller and damage will be
incurred.
Do not place fingers or hands, etc., into
the suction or discharge pipe outlets and Failure to supply the stuffing box or
do not touch the impeller, if rotated this mechanical seal with cooling of flush
may cause severe injury. To prevent water may result in damage and
ingress of any objects, retain the premature failure of the pump.
protection covers or packaging in place
until removal is necessary for installation. Do not touch surfaces, which during
If the packaging or suction and discharge normal running will be sufficiently hot to
covers are removed for inspection cause injury. Note that these surfaces
purposes, replace afterwards to protect remain hot after the pump has stopped,
the pump and maintain safety. allow sufficient time for cooling before
maintenance. Be cautious and note that
SAFETY INSTRUCTIONS WHILE other parts of the pump may become hot
ASSEMBLY AND INSTALLATION if a fault is developing.
Shaft alignment must be checked again
after the final positioning of the pump Do not operate water pumps in
unit and connection to pipework as this temperatures below freezing point,
58
without first checking that the pumped Isolate the equipment before any
fluid is not frozen and the pump is free to maintenance work is done. Switch off
rotate. Pumps in these environments the main supply, remove fuses, apply
should be drained down during inactivity lockouts where applicable and affix
and re-primed before starting. suitable isolation warning signs to
prevent inadvertent reconnection. In
In addition to local or site regulations for order to avoid the possibility of
noise protection, KBL recommend the use maintenance personnel inhaling
of personal ear protection equipment in dangerous fumes or vapours, it is
all enclosed pump rooms and particularly recommended that maintenance work be
those containing diesel engines. Care carried out away from the pump location
must be taken to ensure that any audible by removal of the rotating unit assembly
alarm or warning signal can be heard to a suitable maintenance area.
with ear defenders worn.
Check and ensure that the pump
Be aware of the hazards relating to the operates at below the maximum working
pump fluid, especially the danger from pressure specified in the manual or on
inhalation of noxious and toxic gases, the pump nameplate and before
skin and eye contact or penetration. maintenance, ensure that the pump is
Obtain and understand the hazardous drained down.
substance data sheets relating to the
pumped fluid and note the recommended Wear a suitable mask or respirator when
emergency and first aid procedures. working with packing and gasket
containing fibrous material, as these can
SAFETY INSTRUCTIONS WHILE be hazardous when the fibrous dust is
MAINTENANCE AND SERVICING inhaled. Be cautious, if other supplier’s
Do not attempt repairs of the pump or its components have been substituted for
accessories which you do not know. Use genuine KBL parts, these may then
proper tools. contain hazardous materials.
Before attempting any maintenance on a Store all oily rags or other flammable
pump particularly if it has been handling material in a protective container in a
any form of hazardous liquid, it should be safe place. Do not weld or flame cut on
ensured that the unit is safe to work on. pipes/tubes that contain flammable
The pump must be flushed thoroughly fluids. Clean them thoroughly with
with suitable cleaner to purge away any nonflammable solvent before welding or
of the product left in the pump flame cutting on them. Use
components. solvent/chemical resistant gloves for
hand protection.
This should be carried out by the plant
operator and a certificate of cleanliness Dispose of all wastes like gaskets, gland
obtained before starting work. To avoid packing, oil, batteries, packing material,
any risk to health it is also advisable to etc., in accordance with local regulation.
wear protective clothing as
recommended by the site safety officer Adequacy of suitable crane should be
especially when removing old packing, checked before lifting the pump/pump
which may be contaminated. components. Also condition of pulleys,
chain and lifting shackles should be
checked before use.
59
60

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INSTRUCTIONS ON

KIRLOSKAR BROTHERS LIMITED

IOM/SHM/SEPT19/01 Issue Date: 05/09/2019

We warrant that the pump supplied from us is free from defective

This warranty holds good only for the products manufactured by

KIRLOSKAR BROTHERS LIMITED

8. SPARE PARTS LIST AND CROSS-SECTIONAL

PLEASE FURNISH COMPLETE NAMEPLATE DETAILS, NAME OF PARTS,

Note: A copy of General instructions for Installation, Operation &

2.1.3 KBL firmly insists that all

Fill the bearing housing with recommended

3.1 For location, preparing foundation,

Fig. 3 D3* Circulation line 1/4˝ On pump discharge

Constant level oiler has plastic container

4.2 Starting the pump

4.3 During running the pump

Quantity of oil 5.3.3 Bearing temperature

5.4 Specifications of stuffing box packing, gasket packing, etc.

Max. temperature of cooling water at

SHM 7 SHM 9 SHM 11 SHM 13

IDENTICAL FIGURES IN LINE INDICATE IDENTICAL PARTS

7.3.17 Slide this complete back

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

44102 18000 27100 44101 31100 10500 32000

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

ST. BOX SEALING OUTLET ST. BOX SEALING INLET

24100 20900 25100 26002 23600 22000 43000 52202

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

44102 24000 22900 22700 10500

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

44103 30000 31100

24000 22900 22700 10500 32000

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

ST. BOX SEALING OUTLET ST. BOX SEALING INLET

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

44102 24000 22900 22700 10500

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

PART CODE PART DESCRIPTION

*Recommended spares for two years normal working.

ST. BOX SEALING OUTLET ST. BOX SEALING INLET

32100 26001 24000 22900 13000 10500 32000

44102 24000 44400

24100 26001 24100 51400 60500 26001 23600

BEARING HOUSING (GREASE LUBRICATED)

COO LING CHA M BER ARRA NGEM ENT

bolts of the proper size should be

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