KIRLOSKAR 8 UP 200/38, Instruction On Installation, Operation And Maintenance

Page 1: ...INSTRUCTION ON INSTALLTION OPERATION MAINTENANCE FOR KIRLOSKAR PUMP TYPE UP METRIC KIRLOSKAR BROTHERS LIMITED Yamuna S No 98 3 to 7 Baner Pune 411045...

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Page 3: ...GENERAL OUTLINE DIMENSIONS 9 SPARE PART LIST AND CROSS SECTIONAL DRAWINGS 10 EXPLODED VIEW Please ensure these instructions are read fully before installation and operation of the pump Please furnish...

Page 4: ...half casing This construction enables to remove the rotating unit for inspection and repairs by just removing upper half casing and without disturbing alignment pipe connection or prime mover 1 3 Pum...

Page 5: ...xcept UP 150 56 pump statically and hydraulically balanced The impeller is keyed to the shaft and positioned axially by the shaft sleeves Hub shall have sufficient metal thickness to allow machining f...

Page 6: ...utboard bearing is clamped in place to take all thrust loads and keep the rotating element in its proper axial location Base plate The base plate is sufficiently rigid to support the pump and driver a...

Page 7: ...instructions cannot cover all circumstances It is the responsibility of the user of the equipment for maintaining safe working practices at all times 2 1 1 KBL products are designed for installation i...

Page 8: ...consult KBL before making such change in the application of the equipment 2 4 Improper installation operation and maintenance of the product supplied by KBL could result in injury or death 2 5 Within...

Page 9: ...and four chain crane sling equipment is recommended but locally approved equipment rating may be used Pump should be slung as shown PUM P LIFTING ARRANGEM ENT Pump set must be lifted from the lifting...

Page 10: ...h the recommended grease to prevent moisture from entering around the shaft b Remove the glands packings and lantern rings from the stuffing box if the pump is equipped in this manner If the pump is e...

Page 11: ...e conditions acceptable 3 INSTALLATIONS 3 1 Receiving pump Upon receipt of the pump a visual check should be made to determine if any damage occurred during transit or handling The main items to look...

Page 12: ...t be primed before starting Whenever possible the pump should be located below the fluid level to facilitate priming and assure a steady flow of liquid This condition provides a positive suction head...

Page 13: ...o within 20 to 40 mm of the finished height The top surface of the foundation should be well scored and glued before the concrete sets This provides a bonding surface for the grout Foundation bolts sh...

Page 14: ...the alignment after the foundation bolts are tightened f Approximately 14 days after the grout has been poured or when the Grout has thoroughly dried apply an oil base paint to the exposed edges of th...

Page 15: ...g temperatures After final alignment it is necessary to dowel pump and driver feet to the baseplate FACTORS THAT MAY DISTURB ALIGNMENT The unit should be periodically checked for alignment If the unit...

Page 16: ...IOM UP_METRIC Issue Date 31 12 2007 Page 16 of 66 Last Revision 12 06 2012...

Page 17: ...sary bends Where necessary use 45 degree or long sweep 90 degree fitting to decrease friction losses Make sure that all piping joints are air tight Provide pipe expansions bellows when hot fluids are...

Page 18: ...arts are found to be free when turned by hand 4 1 7Pump is primed Never run the unit dry The liquid in the pump serves as a lubricant for close running fits within the pump and the pump may be damaged...

Page 19: ...g b Bearings Check the bearings for temperature which should not exceed pumped liquid temperature or 80 Deg C whichever is the lower c With mechanical seal fitted pumps check that there is no leakage...

Page 20: ...IOM UP_METRIC Issue Date 31 12 2007 Page 20 of 66 Last Revision 12 06 2012...

Page 21: ...under SR NO PUMP TYPE Bearing model no Ball bearing reference no SKF or equivalent 1 UP 50 30A MODULE 0 6305 FOR DE NDE 2 UP 50 30B 3 UP 65 24 4 UP 65 24A 5 UP 80 24 6 UP 65 38 MODULE I 6306 FOR DE ND...

Page 22: ...bearings should not be dismantled Clean bearings thoroughly with an approved fluid Dry the bearings by spinning with dry compressed air or by hand Do not spin a clean dry bearing Inspect the bearing...

Page 23: ...ctions Recommended Grease specifications Manufacturer Trade name IOCL SERVOGEM 3 OR EQ IOCL SERVOGEM 2 OR EQ SHELL ALVANIA EP 2 EXXON POLYREX CHEVRON SRI GREASE NLGI 2 CHEVRON BLACK PEARL NLGI 2 TEXAC...

Page 24: ...e that cannot be compensated for Correction of this defect is very important Packing should be checked frequently and replaced as service indicates Six months might be a reasonable expected life depen...

Page 25: ...n products and should be treated with care Use special care when handling seals Clean oil and clean parts are essential to prevent scratching the finely lapped sealing faces Even light scratches on th...

Page 26: ...71 75 175 179 UP80 24 71 75 175 179 UP65 38 I 35 77 81 191 195 UP65 38M 77 81 191 195 UP80 30 77 81 191 195 UP80 38 77 81 191 195 UP100 24 77 81 191 195 UP100 29 77 81 191 195 UP125 24 77 81 236 5 240...

Page 27: ...e best efficiency point flow rate 5 10 NPSHA Net Positive Suction Head Available and NPSHR Net Positive Suction Head Required NPSHA should be at least greater than 0 5m than NPSHR for satisfactory ope...

Page 28: ...flanges NOZZLE SIZE mm Forces kg Moment kg m Fx Fy Fz Fx Fy Fz 150 200 250 300 350 400 450 500 600 133 178 210 226 241 256 270 286 317 334 445 525 566 603 641 680 717 792 267 356 420 453 483 513 540...

Page 29: ...80 38 100 80 10 UP 100 24 150 100 11 UP 100 29 150 100 12 UP 100 35 150 100 13 UP 100 38 150 100 14 UP 125 24 150 125 15 UP 125 30A 150 125 16 UP 125 30B 150 125 17 UP 125 35 150 125 18 UP 150 26 N 2...

Page 30: ...930 10 UP 100 24 14 1450 2000 11 UP 100 29 14 5 1450 2000 12 UP 100 35 20 5 1450 1500 13 UP 100 38 25 2 1450 2200 14 UP 125 24 25 2 1450 2000 15 UP 125 30A 24 5 1450 1760 16 UP 125 30B 24 5 1450 1760...

Page 31: ...starting up with open isolating or regulating valve on delivery side CASE 2 starting up with closed isolating or regulating valve with opening the valve when nominal speed is attained CASE 3 starting...

Page 32: ...8 9292 10 UP 100 24 158 2092 11 UP 100 29 137 3572 12 UP 125 24 180 2816 13 UP 125 30A 182 4656 14 UP 125 30B 182 4656 15 UP 100 35 177 4948 16 UP 100 38 240 6976 17 UP 125 35 282 7450 18 UP 150 26N 2...

Page 33: ...IOM UP_METRIC Issue Date 31 12 2007 Page 33 of 66 Last Revision 12 06 2012 5 18 Interchangeability of Components...

Page 34: ...us 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 procedure...

Page 35: ...t Preventive maintenance schedule is a periodical checks and precautions by which possibilities of failure and breakdown will be rare EVERY WEEK Visually check for leaks Check for vibration Adjust gla...

Page 36: ...half casing 7 1 1 3 Remove all insert joint nuts at both ends 58002 7 1 1 4 Insert a screw driver or peg bar into the slot between the two halves and separate two halves lifting off the upper half cas...

Page 37: ...NDE side shaft sleeve and slide it off the shaft from NDE side 7 1 1 15 For clockwise CW direction of rotation of pump viewed from driving end follow steps i ii then go to point no 7 1 1 16 i Unscrew...

Page 38: ...r correct direction of rotation Slide the impeller on the shaft Check that keyway provided on shaft extends equally outside the hub of impeller on both sides iii Slide DE side adjusting sleeve in the...

Page 39: ...ng oil bath NOTE DO NOT EXCEED 120 C 250 F 7 2 1 13 Use hand gloves while handling heated bearings Slide the heated bearing on to the shaft to about shoulder ring 19900 at non driving end Place lockin...

Page 40: ...O rings 7 2 1 23 Lift upper half casing 12200 and place it on lower half casing and engage casing joint nuts loosely NOTE When installing casing half upper make sure that the O rings 52201 are not cut...

Page 41: ...ue Date 31 12 2007 Page 41 of 66 Last Revision 12 06 2012 Note UP150 56 UP200 56 UP200 64M UP250 33 UP250 66 UP300 34 UP300 39 pumps are fitted with bare mechanical seal only This completes the reasse...

Page 42: ...IOM UP_METRIC Issue Date 31 12 2007 Page 42 of 66 Last Revision 12 06 2012...

Page 43: ...nce stated in Fig STUD SIZE TIGHTENING TORQUES M12 M16 M20 M24 250Kg CM 650Kg CM 1270Kg CM 2200Kg CM 2 Tightening sequence 2 1 Tighten the four corner stud marked X 1 2 3 and 4 2 2 Work outward along...

Page 44: ...connection allowing for movement of the ring deeper in to the box as the packing is compressed 4 When the correct number of rings have been inserted the last packing ring should not protrude past the...

Page 45: ...evenly by one sixth of a full turn until leakage is reduced to an acceptable level There should be leakage of 60 to 80 drops per minute CAUTION Excessive gland pressure will cause damage by cutting o...

Page 46: ...IOM UP_METRIC Issue Date 31 12 2007 Page 46 of 66 Last Revision 12 06 2012 8 0 GENERAL OUTLINE DIMENSIONS...

Page 47: ...CASING HALF LOWER IMPELLER WEARING RING SHOULDER RING BEARING HOUSING DE BEARING HOUSING NDE BALL BEARING BEARING COVER DE BEARING COVER NDE BEARING COVER DE NDE KEY IMPELLER KEY COUPLING LOCK NUT BEA...

Page 48: ...SOFT PACKED INSERT NDE SOFT PACKED Common for Mechanical Seal Gland Pack a Internal Flushing Components 55902 56002 STUD COUPLING TUBE FLUSHING b External Flushing Components 60200 SEALING PLUG CASING...

Page 49: ...IOM UP_METRIC Issue Date 31 12 2007 Page 49 of 66 Last Revision 12 06 2012 CROSS SECTIONALDRAWING FOR UP 50 30A UP 50 30B UP 65 38 UP 65 38M AND UP 80 38 SOFT PACKED...

Page 50: ...IOM UP_METRIC Issue Date 31 12 2007 Page 50 of 66 Last Revision 12 06 2012 CROSS SECTIONAL DRAWINGOF UP50 30A UP 50 30B UP 65 38 UP65 38M AND UP80 38 MECHANICAL SEAL...

Page 51: ...IOM UP_METRIC Issue Date 31 12 2007 Page 51 of 66 Last Revision 12 06 2012 CROSS SECTIONAL DRAWING FOR SOFT PACKED PUMP...

Page 52: ...IOM UP_METRIC Issue Date 31 12 2007 Page 52 of 66 Last Revision 12 06 2012 CROSS SECTIONAL DRAWING FOR MECHANICAL SEAL PUMP...

Page 53: ...IOM UP_METRIC Issue Date 31 12 2007 Page 53 of 66 Last Revision 12 06 2012 10 0 EXPLODED VIEW...

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Page 59: ...IOM UP_METRIC Issue Date 31 12 2007 Page 59 of 66 Last Revision 12 06 2012...

Page 60: ...done and that they will comply with all local and industry based safety instructions and regulations 1 5 Ear defenders should be worn where the specified equipment noise level exceeds locally defined...

Page 61: ...INSTRUCTIONS WHILE COMMISSIONING OPERATION Never attempt adjustments while the pump is running unless otherwise specified in the operation maintenance manual Do not touch any moving or rotating parts...

Page 62: ...ossibility of maintenance personnel inhaling dangerous fumes or vapours locations by removal of bearing housing and shaft assembly to a suitable maintenance area Check and ensure that the pump operate...

Page 63: ...Tel 91 044 28157769 28156546 7 8 Fax 044 28156549 EMAIL ID chennai kbl co in JAIPUR B 8 Durga Das Colony Behind Neelkanth Tower Bias Godam Circle Bhawani Singh Road Jaipur 302001 Rajasthan Tel 91 0141...

Page 64: ...1 0712 2234275 2234276 Fax 91 0712 2234276 EMAIL ID nagpur kbl co in PUNE Udyog Bhavan Tilak Road Pune 411 002 India Fax 33 0 1 34 66 07 33 EMAIL ID pune kbl co in Tel 91 020 2444 0770 SECUNDERABAD P...

Page 65: ...dustrial Area Benoni Gauteng Republic of South Africa Tel 27 0 11 421 5903 27 0 11 421 5904 Fax 27 0 11 421 6793 ajeet braybar co za braybar global co za Website www braybar edx co za Ajeet Kulkarni S...

Page 66: ...us press club building 59A Ly thai To Hoan Kiem Dist Hanoi Tel 84 902206662 tamil s kirloskarthailand com Tamil Selevan SPP PUMPS LIMITED UK HEADQUARTERS Theale Cross Pincents Lane Calcot Reading Berk...