INSTRUCTIONS ON INSTALLATION OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE SHVT

KIRLOSKAR BROTHERS LIMITED

UDYOG BHAVAN, TILAK ROAD, PUNE - 411 002

Udyog Bhavan, Tilak Road, Pune 411 002 (India)

KIRLOSKAR BROTHERS LIMITED

WARRANTY
We warrant that the pump supplied by us is free from defective material and faulty workmanship. This warranty holds good for a period of 12 months from the date of commissioning of the equipment or 18 months from the date of despatch 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 to or arise solely from faulty workmanship or defective material. The warranty holds good only for the products manufactured by us.

KIRLOSKAR BROTHERS LIMITED

CONTENTS INTRODUCTION FOUNDATION PROCEDURE FOR DISMANTLING AND REASSEMBLY MAINTENANCE TRANSMISSION SHAFT UNIT/DRIVING UNIT ASSEMBLY OPERATION TECHNICAL DATA PLEASE FURNISH COMPLETE NAMEPLATE DETAILS, NAME OF PARTS, PART NOS. AND MATERIAL OF CONSTRUCTION WHILE ORDERING SPARE PARTS FOR THE PUMPS. CAUTION: THIS INSTRUCTION MANUAL COVERS THE GENERAL REQUIREMENT OF INSTALLATION, OPERATION AND MAINTENANCE. HOWEVER THE END USER SHOULD ALSO REFER TO THE DRAWINGS AND DOCUMENTS IF SUPPLIED AGAINST SPECIFIC ORDERS.

1. 2. 3. 4. 5. 6. 7.

1.

INTRODUCTION This booklet covers instructions for following type of SHVT pumps. SHVT 50/26 SHVT 65/32 SHVT 80/26 SHVT 100/26 SHVT 150/32 SHVT 80/40 7 Unit SHVT SHVT SHVT SHVT SHVT 150/26 150/32 100/40 200/32 150/40

11 Unit

9 Unit

SHVT 200/40 SHVT 150/50

13 Unit

It is very essential that these instructions be followed in every detail during installation operation and maintenance. Ensure that these instructions are made available to all persons responsible for installation, operation and maintenance of the pumps. Failure to follow these instructions may lead to unsatisfactory working or damage to the pump. Any special problem arising at site should be referred to the supplier. Full name plate details should be furnished while exchanging correspondence in connection with these pumps. 2. FOUNDATION The following factors should be considered while designing the foundation. 2.1 2.2 2.3 2.4 2.1 Dimensional requirements. Strength of the foundation. Leveling the foundation. Rechecking of the levels. Dimensional requirements: The location of the foundation bolts should be as per the general arrangement drawing supplied in advance. 2.2 Strength of foundation: The foundation should be suitable to take load of pump, motor etc. to absorb any vibration and to form permanent rigid support. The total load is borne by sole plates/base plates. In order to take this load (including safety factor for vibration) the sole plate should be firmly grouted in the concrete. If possible, sole plates should be welded to the reinforcement of the concrete. Sole plates should not get loose or form pockets with the foundation even with vibration. For the pumps mounted on girders the sole plates should be properly welded on girders/ beams. In turn girders should be firmly embedded in the walls of the pump house. The foundation and grouting should be done by the experienced civil engineering personnel. 2.3 Leveling the foundation: The guidelines for grouting and leveling of the sole plates are as under: a. It is essential to check the level of the sole plates individually and in combination.

b.

The top surfaces of the sole plates be leveled to the accuracy of 0.05 mm/m. First of all one sole plate should be adjusted for height and leveled by putting shims below them. Then other sole plate should be leveled with respect to this sole plate with the help of straight edge and spirit level. Before allowing the concrete to set check the level of sole plates individually and in combination as there is a possibility of distortion while pouring concrete. After setting of the concrete, recheck the levels on surfaces of sole plates. Bring the sole plates in levels to the accuracy of 0.05 mm/m by grinding or filling if distortion has taken place due to setting. If the sole plates are produced by the client directly at their end, then ensure that the sole plates are machined to close tolerance and polished.

c.

d.

e. 2.4

Checking of the level: Check the level of the sole plates frequently whenever the pump is dismantled for overhauling.

3. 3.1

PROCEDURE FOR DISMANTLING AND RE-ASSEMBLY OverhaulingWith normal daily operation the pump will be due for overhaul after about one year. This work is to be done by skilled personnel. Complete pump is to be taken out from support plate.

3.2 3.2.1 3.2.2

Dismantling: Remove the delivery and suction piping holding down bolts and nuts. Remove all external piping connections such as: a. Sealing b. Cooling water connections (if applicable) c. Flushing etc. Remove shafting by adopting procedure given in section 4.1, 4.2 of this booklet. Remove the nuts from the support plate and pump casing. Remove the pump from support plate and take it on to a table for stripping. Unscrew and remove the nuts holding the casing with casing cover and/or with bearing housing. Lifting the rotating unit sub-assembly by the hook provided on bearing housing and remove it from delivery casing (10500). Hold the pump coupling and unscrew the impeller nut (33001) for SHVT 9 & 11 unit pumps. For SHVT 7 unit pumps remove impeller screw (66900) and for SHVT 13 unit pumps unscrew lock nut (33002) as well as impeller nut. Remove impeller from shaft by using a puller. The plate of puller is to be fixed to impeller wearing ring boss and screw to be held in shaft end.

3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8

3.2.9

3.2.10

Remove the casing cover sub-assembly along with gland packed stuffing box, if casing cover is sandwiched type. If casing cover is held by studs and nuts on to the bearing housing, remove these nuts and take out casing cover sub-assembly. Remove the sleeve (31100) from pump shaft. If necessary use a puller. Remove the liquid deflector (23600). Unscrew the grub screw holding the pump coupling hub and take out coupling from shaft. Make use of puller. Remove the screws holding the bearing cover (27100) and cartridge (24100) to the bearing housing. Remove the shaft (18000) along with bearings and DS cartridge from the bearing housing (24000). Remove the circlip from the cartridge by circlip puller and remove the cartridge by slight hammering. Hold the shaft and remove the bearing nut (33600). Take out the lock washer (41500). Remove the bearings from the shaft by use of puller. Remove the oil seals (50001 and 50002) from cartridge and bearing cover using holes provided in the oil seal cover. Remove the nuts holding the split gland (22900). Take out the clamping plate (22400) and remove gland half. Remove the gland packings/lantern ring (22700). Re-assembly Before re-assembly all the parts should be thoroughly cleaned with Kerosene, petrol or Benzene to remove the dust, rust etc. Mount driver side (26001) and pump side (26002) deep groove ball bearings on the shaft. CAUTION: a. Use arbor press while fitting the bearings. However, it is recommended that bearings should be heated in oil bath at temperature 70 to 80 C and then fitted. Slide in ball bearing on shaft by hand and make sure that it is square with shaft. Press evenly the inner race of the bearing until bearing is seated firmly against the shaft shoulder. Do not use hammer to fit the bearings. Do not mark the shaft, especially where it is in contact with the oil seal.

3.2.11 3.2.12 3.2.13 3.2.14 3.2.15 3.2.16 3.2.17 3.2.18 3.2.19 3.2.20 3.2.21 3.2.22 3.3 3.3.1 3.3.2

b.

c. 3.3.3

Tighten lock nut after inserting the lock washer (41500) in proper position on driver ball bearings. Fold one lip of lock washer in the slot of bearing lock nut to lock it.

3.3.4

Put oil seal in the bearing cartridge DE. Insert internal circlip (485) in the inner groove of the cartridge. Put a spacer on bearing cartridge in case of SHM-N, SHM-R and SHM-P pumps and shims in case of SHM-Q pumps. Insert the bearing cartridge from DE of the pump shaft. Insert the shaft alongwith ball bearings at DE and NDE and bearing cartridge at DE into the bearing housing from driving end. Tighten the bearing cartridge on the bearing housing with the help of hexagonal screws. Fit the oil seal in bearing cover PS. Tighten the bearing cover PS on bearing housing with the help of hexagonal screws. Slide the liquid deflector from NDE of shaft. Tighten the deflector on shaft by using grub screws. Push the shaft sleeve (31100) into the shaft till it touches the collar on the shaft. Fit the stuffing box neck bush (35000) into the casing cover if worn out. Put the gasket (51500) on the impeller hub in proper position. Fit the impeller key (32000) on the shaft. It should enter partly in the shaft sleeve. Put the casing cover (22000) on the bearing housing. Tighten it by studs and nuts to the bearing housing. Push the impeller (15100) on the shaft till it touches the shaft sleeve. Fix the coupling key on shaft at D.E. Put the pump side coupling half on the shaft and tighten the grub screw to fix the coupling. Insert the helicoil lock insert (47900) in the impeller nut for 9 &11 units and in the shaft for 7 unit, put gasket (68200) on it and tighten it in the shaft by holding the pump coupling hub. For unit-13 pumps tighten impeller nut & lock nut to tighten the impeller without helicoil insert. Slide this complete backpullout assembly into pump casing duly fitted with studs. Tighten all nuts on the stud firmly and evenly. 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. Put the split gland in two halves (22900) with clamping plate (22400) and tighten the gland stud nuts. Rotate the shaft by hand and ensure free rotation. Fit all accessories such as sealing water, flushing water, cooling water connections as per order. Make suction and delivery piping connections properly. MAINTENANCE Preventive maintenance schedule is the periodical checks and precautions by which possibilities of failure and breakdowns are minimised.

3.3.5 3.3.6 3.3.7 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12 3.3.13 3.3.14 3.3.15 3.3.16

3.3.17 3.3.18 3.3.19 3.3.20 3.3.21 3.3.22 4.

4.1 4.1.1 4.1.2

Daily Checks: An hourly record of suction and discharge pressure, discharge quantity, input to the pump driver should be maintained. Bearing temperature, oil level, stuffing box leakage, stuffing box temperature, cooling water inlet and outlet and outlet temperature should be checked. This gives an idea of mechanical performance of the pump. Noise and the vibrations are first signs of impending troubles like cavitation, air lock, bearing failure, choking of impeller or casing and such other operating troubles. The pump performance should therefore be checked for noise and vibration. Periodical checks: The temperature of the bearing should be measured by a thermometer. Safe maximum temperature a bearing can attain is 80C. The lubricants of the bearings should be checked. The lubricant might get contaminated with foreign material or get blackened due to overheating. In such cases, bearings should be flushed and charged with fresh lubricants. Check stuffing box leakage. Normal leakage of approx. 60 drops per minute is recommended for safe operation. If the leakage is more the stuffing box packing might have worn out or lantern ring is displaced. In case the packings are worn out all the packing rings should be replaced. Replacement of one or two rings or addition of rings should never be done. The alignment of the pumping unit should be checked. Due to operational vibrations, atmospheric temperature or stress induced by the weight of the piping the alignment may get disturbed. Sufficient quantity of suitable type of lubricant and stuffing box packing should be kept for daily and emergency use. Calibrate the measuring instruments. Annual checks The pump should be overhauled completely to check the clearance and to replace worn out parts. Clearances between impeller and casing ring, shaft sleeve and stuffing box bush, lantern ring and the shaft sleeve etc. are very important. The bearing should be cleaned thoroughly and lubricated properly. The stuffing box should be repacked by correctly located the lantern ring. The effects of liquid handled on pump components should be checked. If abnormal corrosion/erosion is observed, the component should be replaced with that of suitable material. The auxiliary pipe lines and functioning of the auxiliaries should be checked. The main pipe also should be checked for scaling, leakage etc. The measuring instruments, gauges etc. should be recalibrated. Full running test may be carried out to check whether there is any fault in the performance, in comparison with original performance. Piping supports should be checked so that the pipe do not induce unwanted stresses on the pump.

4.1.3

4.2 4.2.1 4.2.2

4.2.3

4.2.4

4.2.5 4.3 4.3.1

4.3.2 4.3.3

4.3.4 4.3.5 4.3.6 4.3.7

5. 5.1 5.1.1 5.1.2 5.1.3 5.2 5.2.1 5.2.2

TRANSMISSION SHAFT UNIT/ DRIVING UNIT ASSEMBLY Transmission shaft assembly includes major components like motor stool (29000) and metaflex flexible drive shaft (18500). Assemble the motor on motor stool. The motor shaft should align with pump shaft within 0.05 mm. Assemble the metaflex flexible drive shaft to motor shaft coupling and pump shaft coupling with the help of soc. Head bolts. Make the electrical connections and check for correct direction of rotation. Dismantling Disconnect metaflex flexible drive shaft from motor and pump coupling hubs by loosening soc. Head bolts. Switch off the power supply and remove the motor terminal connections. Disconnect the motor from motor stool (290) and remove the same along with hub. Lift the metaflex flexible drive shaft and keep the same on motor stool floor in horizontal position. Disconnect the motor stool. Re-assembly Place the motor stool on the foundation. Take the metaflex flexible drive shaft and clean it properly. For further assembly please refer 5.1.1 to 5.1.3.

5.2.3 5.3 5.3.1

6. 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.2 6.2.1 6.2.2

OPERATION Before starting the pump, check the following: The pump rotates freely by hand. The sealing liquid and cooling water connections are properly tightened and adjusted. The direction of rotation of driver. It should correspond to the direction of the rotation of the pump. The pump casing and suction pipe is fully primed with the liquid. Valve on delivery side is closed. The cock for pressure gauge connection is closed. The stuffing box packing is properly tightened. Starting the pump: Start the pump. Let the prime mover pick up its full speed. Open the valve on delivery line slowly to reduce the starting load on the motor.

6.2.3 6.2.4 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6 6.3.7 6.3.8

Regulate the required flow by adjusting the delivery valve. Open the cock for pressure gauge connection. During running the pump, check the following things and regulate, if necessary: The pump is running smoothly. The flow of sealing liquid is uninterrupted. If necessary provide a sight glass in between the piping. The bearings are not getting abnormally hot. The gland is properly tightened to given leakage of approx. 60 drops per minute through stuffing box. Head and capacity developed by the pump is as specified. Power consumption is within the limit. Ensure that there is no mechanical friction in the pump. Stop the pump immediately, if any defects are detected. Do not start the pump unless the defects are rectified. Report immediately to the supplier if it is not possible to rectify the defects. During stopping the pump: Close the valve on delivery side. Stop the motor. Close the sealing liquid connections. If the pump is not required to be operated for a long time, drain the casing completely. If the pump is required to be stored for a long time, the bearing housing should be dried internally with hot air and should be flushed with moisture free protective, such as light oil or kerosene. TECHNICAL DATA Direction of rotation: The direction of rotation is clockwise when viewed from driving end.

6.4 6.4.1 6.4.2 6.4.3 6.4.4

7. 7.1

7.2

Specification of bearings, oil seal and quantity of oil fill and O rings etc.

Part Code 26001 26002 26400 50001 50002 33600 41500 48500 48501 44101 44102 &

Description SHM-7 Ball Bearing DS Ball Bearing PS Cylindrical roller bearing PS for heavy duty arrangement Oil seal DS Oil seal PS Bearing lock nut DS Bearing lock washer Internal circlip for rolle brg. PS Internal circlip for Ball brg. DS Grease nipple SKF-6307 SKF-6307 SKF-NU307 32 x 45 x 7 35 x 52 x 10 M35x1.5RH SKF-KM-7 M-35 SKF-MB7 B80 x 2.5 thick B80 x 2.5 thick BSP SHM-9

UNIT NO. SHM-11 SKF-6411 SKF-6411 SKF-NU411 50 x 78 x 13 55 x 80 x 13 M55x2 RH SKF-KM-11 M-55 SKF-MB11 B 140 x 4 thick B140 x 4 thick BSP BSP B160 x 4 thick SHM-13 SKF-6413 SKF-6413 SKF-NU413 60 x 85 x 13T 65 x 85 x 13T M65x 2RH SKF-KM-13 M-65 SKF-MB13 B160 x 4 thick SKF-6309 SKF-6309 SKF-NU309 42 x 72 x 10 45 x 62 x 10 M45x1.5RH SKF-KM-9 M-35 SKF-MB9 B100 x 3 thick B100 x 3 thick BSP

7.3 7.3.1

Lubrication Grease lubricated bearings are standard supply. The specifications of grease are given below. It should conform to the following grades or their equivalents available in the market. INDIAN OIL HINDUSTAN PETROLEUM SERVOGEM - 3 NETRA-3 OR LITHON-3

7.4 Part Code

Specification of stuffing box packing, gasket packing etc. Description Packing ring arrangement with lantern ring SHM-7 2 + L +3 10 x 1080 mm 32x50x1 mm 48x55x1 mm UNIT NO. SHM-9 SHM-11 2 + L +3 2 + L +3 10 x 1260 mm 38.5x56x1 mm 62x70x1 mm 12.5 x 1330 mm 52x64x1 mm 72.5x80x1 mm 405x425x1 mm

SHM-13 2 + L +3 12.5x1620 mm 58x75x1mm & 38.5x56x1 (for lock nut) 82.5x90x1.5 mm 420x440x1 mm

43000 Gland packing size for 5 ring 68200 Gasket for impeller Nut/ Screw mm 51500 Gasket for shaft sleeve (ID x OD x Thick) 51100 Gasket for casing cover & pump casing (permanite) (ID x OD x Thick) 52300 O ring for cooling chamber (ID x Thick)

265x285x1 330x350x1 mm mm

80 x 3

100 x 3

123 x 3

132 x 3

10

7.5 7.5.1 7.5.2 7.5.3

Cooling of stuffing box Cool the packed gland stuffing box when pumping liquid temperature is above 90C. Cool the mechanical seal, stuffing box when pumping liquid temperature is above 140C. this limit is subject to change as per seat manufacturers recommendation. Quantity of stuffing box cooling water with reference to temperature and nominal impeller diameter in cms. Full nominal impeller dia. in cms. 110C 26 32 40 0.21 0.23 0.26 COOLING WATER QUANTITY AT VARIOUS PUMPING LIQUID TEMPERATURES 150C 0.24 0.28 0.31 200C 0.30 0.37 0.43 250C 0.40 0.48 0.55 300C 0.54 0.63 0.71

Cooling quantities mentioned are in m3/hr. Maximum temperature of cooling water at outlet - 50C Maximum permissible cooling water pressure 6 kg/cm2

11

SPARE PARTS LIST OF SHVT PUMP SR. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 PART CODE 10500 * 15100 * 18000 * 19000 20900 22000 22400 * 22700 * 22900 * 23600 * 31100 * 32000 * 35000 * 43000 24000 24100 * 26001 * 26002 27100 30000 * 32100 * 33600 * 41500 44101 44102 48500 * 50001 * 50002 * 51100 * 51500 * 68200 60500 29000 47900 33001 46700 38100 18500 DESCRIPTION PUMP CASING ENCLOSED IMPELLER PUMP SHAFT CASING WEAR RING SPACER FOR BRG. CARTRIDGE CASING COVER CLAMPING PLATE LANTERN RING SPLIT GLAND LIQUID DEFLECTOR SHAFT SLEEVE KEY FOR IMPELLER STUFFING BOX BUSH GLAND PACKING BEARING HOUSING BEARING CARTRIDGE BALL BEARING BALL BEARING BEARING COVER PS LIFTING EYEBOLT KEY FOR COUPLING BEARING LOCK NUT LOCK WASHER GREASE NIPPLE GREASE NIPPLE INTERNAL CIRCLIP OIL SEAL (D.S.) OIL SEAL (P.S.) GASKET FOR PUMP CASING GASKET FOR SHAFT SLEEVE GASKET FOR IMPELLER NUT PIPE PLUG FOR BRG. HSG. DRAIN MOTOR STOOL HELICOIL INSERT IMPELLER NUT SUPPORT PLATE SOLE PLATE METAFLEX FLEXIBLE DRIVE SHAFT

* RECOMMENDED SPARES.

12

13

GENERAL INFORMATION & SAFETY REQUIREMENTS

1.0 The products supplied by KBL have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimised by the use of guards and other design features. Some hazards cannot be guarded against and the instructions below MUST BE COMPLIED WITH for safe operation. These instructions cannot cover all circumstances; YOU are responsible for using safe working practices at all times. KBL products are designed for installation in designated area, which are to be kept clean and free of obstructions that may restrict safe access to the controls and maintenance access points. A Pump Duty Nameplate is fitted to each unit and must not be removed. Loss of this plate could make identification impossible. This in turn could affect safety and cause difficulty in obtaining spare parts. If accidental loss or damage occur, contact KBL immediately. 1.2 Access to the equipment should be restricted to the personnel responsible for installation, operation and maintenance and they must be trained, adequately qualified and supplied with appropriate tools for their respective tasks. KBL requires that, all personnel that are responsible for installation, operation or maintenance of the equipment, have access to and study the product instruction manual BEFORE any work is done and that they will comply with all local and industry based safety instructions and regulations. Ear defenders should be worn where the specified equipment noise level exceeds locally defined safe levels. Safety glasses or goggles should be worn where working with pressurised systems and hazardous substances. Other personnel protection equipment must be worn where local rules apply. Do not wear loose clothing or jewellery which could catch on the controls or become trapped in the equipment. Read the instruction manual before installation, operation and maintenance of the equipment. Check and confirm that the manual is relevant copy by comparing pump type on the nameplate and with that on the manual. Note the Limits of product application permissible use specified in the manual. Operation of the equipment beyond these limits will increase the risk from hazards noted below and may lead to premature and hazardous pump failure. Clear and easy access to all controls, gauges and dials etc. must be maintained at all times. Hazardous or flammable materials must not be stored in pump rooms unless safe areas or racking and suitable containers have been provided. IMPROPER INSTALLATION, OPERATION OR MAINTENANCE OF THIS KBL PRODUCT COULD RESULT IN INJURY OR DEATH. SAFETY INSTRUCTIONS WHILE HANDLING AND STORAGE When lifting the pump, use the lifting points specified on general arrangement drawing. Use lifting equipment having a safe working load rating suitable for the weight specified. Use suitable slings for lifting pump which is not provided with lifting points. The use of fork-lift truck and chain crane sling equipment is recommended but locally approved equipment of suitable rating may be used. -i-

1.1

1.3

1.4

1.5 1.6

1.7

1.8

1.9 2.0

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. To prevent ingress of any objects, retain the protection covers or packaging in place until removal is necessary for installation. If the packaging or suction and discharge covers are removed for inspection purposes, replace afterwards to protect the pump and maintain safety. 3.0 SAFETY INSTRUCTIONS WHILE ASSEMBLY & INSTALLATION 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. To prevent ingress of any objects, retain the protection covers or packaging in place until removal is necessary for installation. Do not touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they must be replaced before operating the equipment. Shaft alignment must be checked again after the final positioning of the pump unit and connection to pipework as this may have disturbed the pump or motor mounting positions. If hot liquids (above 80C) are being pumped, alignment should be checked and reset with the pump and motor at their normal operating temperature. If this is not possible, KBL can supply estimated initial offset figures to suit extreme operating temperatures. Failure to support suction and delivery pipework may result in distortion of the pump casing, with the possibility of early pump failure. 4.0 SAFETY INSTRUCTIONS WHILE COMMISSIONING & OPERATION. Do not touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they must be replaced before operating the equipment. Check that the pump is primed. Pump should never be run dry as the pumped liquid acts, as lubricant for the close running fits surrounding impeller and damage will be incurred. Failure to supply the stuffing box or mechanical seal with cooling of flush water may result in damage and premature failure of the pump. Do not touch surfaces which during normal running will be sufficiently hot to cause injury. Note that these surfaces will remain hot after the pump has stopped, allow sufficient time for cooling before maintenance. Be cautious and note that other parts of the pump may become hot if a fault is developing. Do not operate water pumps in temperatures below freezing point, without first checking that the pumped fluid is not frozen and the pump is free to turn. Pumps in these environments should be drained down during inactivity and re-primed before starting. In addition to local or site regulations for noise protection, KBL recommend the use of personal ear protection equipment in all enclosed pump rooms and particularly those containing diesel engines. Care must be taken to ensure that any audible alarm or warning signal can be heard with ear defenders worn. Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance data sheets relating to the pumped fluid and note the recommended emergency and first aid procedures. -ii-

5.0

SAFETY INSTRUCTIONS WHILE MAINTENANCE & SERVICING Before attempting any maintenance on a pump particularly if it has been handling any form of hazardous liquid, it should be ensured that the unit is safe to work on. The pump must be flushed thoroughly with suitable cleaner to purge away any of the product left in the pump components. This should be carried out by the plant operator and a certificate of cleanliness obtained before starting work. To avoid any risk to health it is also advisable to wear protective clothing as recommended by the site safety officer especially when removing old packing which may be contaminated. Check and ensure that the pump operates at below the maximum working pressure specified in the manual or on the pump nameplate and before maintenance, ensure that the pump is drained down. Wear a suitable mask or respirator when working with packing and gasket components which contain fibrous material, as these can be hazardous when the fibrous dust is inhaled. Be cautious, if other suppliers components have been substituted for genuine KBL parts, these may then contain hazardous materials. Be aware of the hazards relating to the pumped fluid, especially the danger from inhalation of noxious and toxic gases, skin and eye contact or penetration. Obtain and understand the hazardous substance data sheets relating to the pumped fluid and note the recommended emergency and first aid procedures. Isolate the equipment before any maintenance work is done. Switch off the mains supply, remove fuses, apply lock-outs where applicable and affix suitable isolation warning signs to prevent inadvertent reconnection. In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapours, it is recommended that the maintenance work be carried out away from the pump locations by removal of bearing housing and shaft assembly to a suitable to a suitable maintenance area.

_____________ Ref: Proposed draft standard prEN 800: Pumps and pump units for liquids; General safety requirements

-iii-

INCORRECT

CORRECT

INCORRECT LAYOUT OF SUCTION PIPE

CORRECT LAYOUT OF SUCTION PIPE

FOR RECOMMENDATIONS OF SUITABLE SUCTION AND DELIVERY PIPE SIZE PLEASE CONTACT OUR AUTHORISED DEALER OR NEAREST REGIONAL OFFICE

CONCENTRIC TAPER PIECE

ECCENTRIC TAPER PIECE

GENERAL INSTRUCTIONS FOR INSTALLATION OPERATION & MAINTENANCE OF

REDUCED SUCTION PIPE

INCREASED SUCTION PIPE

KIRLOSKAR CENTRIFUGAL PUMPS

SHORT BEND

LONG BEND

INSUFFICIENT
D

D SPACE AROUND

FOOT VALVE
D

SUFFICIENT SPACE AROUND FOOT VALVE

Registered users Kirloskar Brothers Ltd.

GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION & MAINTENANCE OF

WARNING The equipment supplied is designed for specific capacity, speed, pressure and temperature. Do not use the equipment beyond the capacities for which it is manufactured. The equipment manufactured is also shop tested for the satisfactory performance and if it is operated is excess of the conditions for which it is manufactured, the equipment will be subject to excessive stresses and strains. LOCATION The pump should be located as near the liquid source as possible. This will minimise the suction lift and pump will give better performance. Ample space should be provided on all sides so that the pump can be inspected while in operation and can be serviced conveniently whenever required. FOUNDATION The foundation should be sufficiently substantial to absorb any vibration and to form a permanent rigid support for the base plate. This is important in maintaining the alignment of a direct connected unit. A concrete foundation on a solid base is advisable. Foundation bolts of the proper size should be embedded in the concrete located by a drawing or template. A pipe sleeve about two and one-half diameter larger that the bolt should be used to allow movement for the final position of the foundation bolts. ALIGNMENT Pumps and drivers that are supplied by the manufacturers, mounted on a common base plate are accurately aligned before despatch. However as the alignments are likely to be disturbed during transit to some extent and therefore must not be relied upon to maintain the factory alignment. Re-alignment is necessary after the complete unit has been levelled on the foundation and again after the grout has been set and foundation bolts have been tightened. The alignment must be checked after the unit is piped up and re-checked periodically. FLEXIBLE COUPLING A flexible coupling will not compensate for misalignment of the pump and driver shafts. The purpose of the flexible coupling is to compensate for temperature changes and to permit the movement of the shafts without interference with each other while transmitting power from the driver to the pump. TYPE OF MISALIGNMENT (SEE FIGURE 1) There are two types of misalignment between the pump shaft and the driver shaft. (a) Angular misalignment : Shafts with axis concentric but not parallel. (b) Parallel misalignment : Shafts with axis Parallel but not concentric.
ANGULAR MISALIGNMENT PARALLEL MISALIGNMENT

KIRLOSKAR CENTRIFUGAL PUMPS

Figure 1

LEVELLING THE UNIT When the unit is received with the pump and driver mounted on the base plate, it should be placed on the foundation and the coupling halves disconnected. The coupling should not be reconnected until all alignment operations have been completed. The base plate must be supported evenly on wedges inserted under the four corners so that it will not be distorted or sprung by the uneven distribution of the weight. Adjust the wedges until the shafts of the pump and driver are in level. Check the coupling faces, suction and discharge flanges for the horizontal or vertical position by means of spirit level. FLEXIBLE COUPLING ALIGNMENT (SEE FIGURE2) The two halves of the coupling should be at least 4 mm apart so that they cannot touch each other when the driver shaft is rotated. Necessary tools for approximately checking are straight-edge and on an outside caliper.

MEASURING WEDGE

1 2 3 4

Tank under Vacuum Vacuum equalizing line Valve Line supplying the seeling liquid 5 Valve 6 Connecting line 7 Valve

3 4 5 7 6
STRAIGHT EDGE

Figure 2

A check for parallel alignment is made by placing a straight-edge across both coupling periphery at the top, bottom and both the sides. The unit will be in parallel alignment when the straight-edge rests evenly on the coupling periphery at all positions. Care must be taken to have the straight-edge parallel to the axis of the shafts. A check for angular alignment is made by using an outside caliper across the width of the coupling faces at various points. Coupling alignment can be checked with dial gauge indicator as shown in Fig. 2. GROUTING When the alignment is correct, the foundation bolts should be tightened evenly but not too firmly. The unit can then be grouted by working soft concrete under the edges. Foundation bolts should not be fully tightened until the grout is hardened, usually 48 hours after poring. FACTORS THAT MAY DISTURB ALIGNMENT The unit should be periodically checked for alignment. If the unit does not stay in line after being properly installed, the following are possible causes: (a) Setting, seasoning of the foundation (b) Pipe strains distorting of shifting the machines (c) Wear of the bearings PIPING Both suction and delivery pipes and accessories should be independently supported near the pump so that when the flanges bolts are tightened no strain will be transmitted to the pump casing. It is usually advisable to increase the size of both suction and delivery pipes at the pump nozzles in order to decrease the loss of head from friction and for the same reason piping should be arranged with as minimum bends as possible, as these should be made with along radius wherever possible. The pipe lines should be free from scales, welding residuals etc., and have to be mounted in such a way that they can be connected to suction and delivery flanges without any stress on the pump. Adequate supports should be given to pipe lines to that weight of the pipe lines does not fall on the pump. The use of minimum number of the bends and other fittings will minimise the frictional losses. SUCTION PIPE The suction pipe should be as short as possible. This can be achieved by placing the pump near the liquid to be pumped. The suction pipe must be kept free from air leaks. This is particularly important when the suction lift is high. A horizontal suction line must have a gradual rise to the pump. Any high point in the pipe will be filled with air and thus prevent proper operation of the pump. A concentric taper piece should not be used in a horizontal suction line as it forms an air pocket in the top of the reducer and the pipe. Use an eccentric piece instead. The end of the suction pipe must be well submerged to avoid whirlpools and ingress of air but must be kept clear of nay deposits of mud, silt, grit etc. The pipe must be clear from any side of wall by at least 450 mm. The end of the suction pipe should be provided with a strainer of sufficient open area. DELIVERY PIPE A check (non-return) valve and a gate of sluice valve (regulating valve) should be installed in the discharge line. The check valve placed between the pump and the gate valve is to protect the pump from excessive pressure and to prevent water running back through the pump in case of failure of the driving machine. Discharge piping should be provided with a sluice valve adjacent to the delivery flange to control the discharge, if required. VACUUM EQUALISING LINE (AND LIQUID LINE) (SEE FIGURE 3) If the pump draws from a system under vacuum an equalising pipe must be carried from the highest point of the suction line, however, as close to the suction flange of the pump as possible, to the top of the feed tank to keep gas bubbles that might have been entrapped in the flow from entering the pump. The line should be fitted with an isolating valve which should be closed only for maintenance work on the pumpset. Apply sealing liquid (external sealing) to the shaft seal cage to prevent entry of air in the case of pumps with packed stuffing box. It is convenient to tap the sealing liquid from the delivery line above the non-return valve.

FOOT VALVE It is advisable to install a foot valve to facilitate priming. The foot valve should have sufficient clear passage for water. Care must be taken to prevent foreign matter from being drawn into the pump or choking the foot valve and for this purpose an efficient strainer should be provided. STUFFING BOXES AND PACKING Stuffing boxes should be carefully cleaned and the packing placed in them. Be sure that sufficient packing is placed at the back of the water seal cage. If the water to be pumped is dirty or gritty, sealing water should be piped to the stuffing boxes from clean outside source of supply in order to prevent damage to the packing and shaft. In placing the packing, each packing ring should be cut to the proper length so that ends come together but do not overlap. The succeeding rings of packing should not be pressed too tight as it may result in burning the packing and cutting the shaft. If stuffing box is not properly packed, friction in stuffing box prevents turning the rotor by hand. On starting the pump it is well to have the packing slightly loose without causing an air leak, and if it seems to leak, instead of putting too much pressure on the gland, put some heavy oil in the stuffing box until the pump works properly and then gradually tighten up the gland. The packing should be occasionally changed. BALL BEARINGS Correct maintenance of ball bearings is essential. The bearing manufacturers give the following as a guide to relubrication periods under normal conditions. Three monthly when on continuous duty. Six monthly when on eight-hour per duty. The bearings and housings should be completely cleaned and recharged with fresh grease after 2500 hours or the nearest pump overhaul time. PRIMING No pumping action occurs unless the pump casing is filled with liquid. Pump casing and suction pipe must therefore be completely filled with the liquid and thus all air removed before the pump is started. Several different priming methods can be used depending on the kind of installation and service involved. (1) Liquid level above pump level Pump is set below liquid level of source of supply so that liquid always flows to pump under positive head. (2) Priming with foot valve (a) When pump is installed on suction lift with foot valve at the end of suction line, fill pump with water from some outside source till all air is expelled and water flows through air vent. (b) When there is liquid under some pressure in the discharge pipe, priming can be effected by byepassing the pressure liquid around the check and gate valve. Of course, the initial priming must be effected from some outside source. NOTE: in this case, the foot valve must be capable of withstanding pump pressure and possible surge. (3) Priming by ejector: An ejector operated by steam, compressed air or water under pressure and connected to air vent on top of casing can be used to remove air from and prime the pump on suction lift installations. (4) Priming by dry vacuum pump : a hand or power pump sucks in all the air from the casing and the suction pipe, and thus primes the system. STARTING The pump must not be started without being primed. Be sure that the driver rotates in the proper direction as indicated by a direction arrow on the pump casing. RUNNING On account of its simple construction, the centrifugal pump requires practically no attention while running. Lubrication of the bearings and manipulation of the glands are the only things that need attention from the operator. STOPPING Before stopping the pump, close the gate valve. This will prevent water hammer on check valve. STUFFING BOXES Do not tighten the glands excessively. A slight dripping of water from the stuffing boxes when pump is running keeps packing in good condition. CASING RINGS Casing rings are fitted in the casing to reduce the quantity of water leaking back from the high pressure side to the suction side. These casing rings are fitted to maintain a small clearance and depend on the water in the pump for lubrication. When they are worn out, the clearance becomes greater and more water passes back into the suction. They must be replaced from time to time to restore the pump efficiency to its normal value.

SPARE PARTS A set of ball bearings, a set of casing rings, and a set of gland packing rings must always be kept at hand to ensure uninterrupted service from the pump. While ordering for spare parts, always give type, size and serial number of the pumps as stamped on the name plate. PUMP TROUBLE When investigating trouble with Kirloskar pumps, always remember that pumps have been tested at the factory and are mechanically correct when sent out. Discounting the possibility of damage during transit, most of the trouble in the field is due to faulty installation. Investigation shows that the majority of troubles with centrifugal pumps result from faulty conditions on the suction side. BREAK DOWN-CAUSE-CHECK POINTS In case of breakdown we recommend the location of the fault by using the following table. BREAKDOWN Pump does not deliver CHECK POINTS 1 18 1 11 22 1 20 16 1 14 58 52 1 19 19 39 55 24 22 42 22 23 42 19 37 47 14 14 58 14 2 20 20 40 58 27 23 43 45 24 45 20 38 48 22 22 59 22 5 22 22 43 28 24 46 25 47 21 39 49 60 27 60 27 28 61 28 40 45 43 46 50 50 55 58 56 59 57 60 6 54 31 44 29 25 50 26 48 22 40 51 27 49 31 41 54 28 50 32 42 55 29 54 33 43 58 30 34 44 40 35 45 41 36 46 7 55 32 47 30 26 8 56 33 48 31 27 11 57 35 49 47 28 12 62 36 50 48 29 13 37 51 49 30 15 38 54 53 41 7 19 2 12 56 3 21 56 3 15 62 8 23 3 13 57 7 22 57 6 16 9 25 4 14 58 9 23 58 7 19 8 22 9 23 10 25 11 26 12 56 13 57 10 26 5 15 10 24 11 56 6 17 11 53 12 57 7 18 12 57 14 58 8 19 13 62 15 9 20 14 17 10 21 19

Pump delivers at reduced capacity Delivery performance deteriorates Pump delivers too much Delivery is interrupted After stopping pump runs in reverse direction Very noisy Unsteady running of pump Stuffing box leaks excessively Fumes from stuffing box Pump rotor locked in standstill position Pump is heating up and seizing Bearing temperature increases Motor will not start Motor gets hot or burns out Motor is difficult to start

CHECK POINTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Suction pipe, foot valve choked. Nominal diameter of suction line too small. Suction pipe not sufficiently submerged. Too many bends in the suction line. Clearance around suction inlet not sufficient. Shut off valve in the suction line in unfavourable position. Incorrect layout of suction line (formation of air pockets). Valve in the suction line not fully open. Joints in the suction line not leak-proof. Air leaking through the suction line and stuffing box etc. Suction lift too high. Suction head too low (difference between pressure at suction connection and vapour pressure too low). Delivery liquid contains too much gas and/or air. Delivery liquid too viscous. Insufficient venting. Number of revolutions too high. Number of revolutions too low. Incorrect direction of rotation (electric motor incorrectly connected, leads of phases on the terminal block interchanged). Impeller clogged. Impeller damaged. Casing rings worn out. Separation of crystals from the flow of pumping liquid (falling below the temperature limit/equilibrium temp). Sealing liquid line obstructed. Sealing liquid contaminated. Lantern ring in the stuffing box is not positioned below the sealing liquid inlet. Sealing liquid omitted. Packing incorrectly fitted. Gland tightened too much/slanted. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. Packing not suitable for operating conditions. Shaft sleeve worn in the region of the packing. Bearing worn out. Specified oil level not maintained. Insufficient lubrication of bearings. Ball bearings over-lubricated. Oil/Grease quality unsuitable. Ball bearing incorrectly fitted. Axial stress on ball bearings (no axial clearance for rotor). Bearings dirty. Bearings rusty (corroded). Axial thrust too great because of worn casing rings, relief holes obstructed. Insufficient cooling water supply to stuffing box cooling. Sediment in the cooling water chamber of the stuffing box cooling. Alignment of coupling faulty or coupling loose. Elastic element of coupling worn. Pump casing under stress. Pipeline under stress. Shaft runs untrue. Shaft bent. Rotor parts insufficiently balanced. Rotor parts touching the casing. Vibration of pipe work. Non-return valve gets caught. Contaminated delivery liquid. Obstruction in delivery line. Delivery flow too great. Pump unsuitable for parallel operation. Type of pump unsuitable. Incorrect choice of pump for existing operating conditions. Voltage too low/power supply overloaded. Short circuit in the motor. Setting of starter of motor too high. Temperature delivery liquid too high.