KIRLOSKAR GK 10 Instruction On Installation, Operation And Maintenance Download Page 47 | Manualshive

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IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015
Page 47 LAST REV. DATE: 01.08.2019

4. Typical Cross section drawing of GK(P)CLM

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Summary of Contents for GK 10

Page 1: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 1 LAST REV DATE 01 08 2019 INSTRUCTIONS ON INSTALLATION OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE GK P...

Page 2: ...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 pa...

Page 3: ...TIONS 3 EQUIPMENT SCHEDULE 3 1 INSTALLATION 3 2 MOUNTING AND ALIGNMENT 4 OPERATION 4 1 EQUIPMENT DESCRIPTION 4 2 EQUIPMENT OPERATION 5 MAINTENANCE MANUAL 5 1 MAINTENANCE EHS INSTRUCTIONS 5 2 GENERAL M...

Page 4: ...or fitter error LIMITATIONS OF USE KBL products are designed to provide performance generally as shown in accompanying literature associated with the individual models or series All performance Figure...

Page 5: ...r personal protection This particularly applies when the pump is being operated or maintained If the product being processed is hazardous then provision must be made by the user to deal with this prob...

Page 6: ...alified to carry out the work involved If the personnel in question do not already possess the necessary knowledge and skill appropriate training and instruction must be provided If required the opera...

Page 7: ...MPERATURE CLASS IS SUITABLE FOR THE HAZARD ZONE A 5 1 Pump liquid temperature Pumps have a temperature class as stated in the ATEX Ex rating on the name plate These are based on a maximum ambient of 4...

Page 8: ...nt generating a spark the earth stud on the pump casing or foot must be connected Avoid electrostatic charge Do not rub non metallic surfaces with a dry cloth for cleaning etc ensure the cloth is damp...

Page 9: ...p and any external metalwork is at ground potential D Where a counter or count and stop device is fitted it is for indicating the number of cycles run only and not to use as a means of process flow co...

Page 10: ...40 32 16A 80 26 125 40N 50 16A 100 16 150 32 100 20 150 32N 150 40 Description of GK P pumps GK P GK P pumps with enclosed impeller GK P J GK P pumps with jacketed delivery casing and casing cover or...

Page 11: ...e of generic nature and applicable to various company products irrespective of its specific application use Additional instructions if any shall be specified on individual project drawings documents f...

Page 12: ...as which are to be kept clean and free of obstructions that may restrict safe access to the controls and maintenance access points Pump name plate is fitted to each unit and must not be removed Loss o...

Page 13: ...ety shoes while operating GK P CLM pumps meant for High temperatures 2 6 Transport handling and storage instructions 2 6 1 Transport Pumps are dispatched in duly assembled condition Lubricating oil in...

Page 14: ...dry place having slow moderate changes in ambient temperature Step should be taken to protect the pump from moisture dust dirt and foreign bodies It is recommended that the following precautions to b...

Page 15: ...paring foundation installation alignment piping general maintenance trouble shooting etc the instructions given in our publication GENERAL INSTRUCTIONS FOR INSTALLATION OPERATION AND MAINTENANCE OF KI...

Page 16: ...pump should be installed with sufficient accessibility for inspection and maintenance Ample space and head room should be allowed for the use of an overhead crane or hoist sufficiently strong to lift...

Page 17: ...y Check the alignment after the foundation bolts are tightened 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...

Page 18: ...arting and when shutting down the pump 3 2 MOUNTING AND ALIGNMENT A spacer type flexible coupling is used to connect pump shaft to the driver By using spacer type of coupling the complete rotating uni...

Page 19: ...al gauge Indicator Alignment should be performed after the base plate has been properly set and grout has dried thoroughly according to instructions Final alignment should be made by shimming under dr...

Page 20: ...ooling water inlet On bearing housing right G2 Bearing housing cooling water outlet On bearing housing right H Air breather cap On bearing housing top J1 St box jacket heating steam inlet Casing cover...

Page 21: ...and piping 1 2 13 BE Bulls eye indicator 1 2 BSP Notes All tappings are in inches and location of connections are specified looking from arrow X This special provision on request application requirem...

Page 22: ...d bar with inch BSP tapping at one end and a spirit level See Figure if the level is incorrect and oiler tilts downward oil will not flow from oiler into the reservoir see Figure given below Hence it...

Page 23: ...his is attached to an end suction volute casing fitted with wear rings The bearing housing shaft and impeller assembly can be withdrawn from the volute for maintenance without disconnection of pipe wo...

Page 24: ...ssary provide sight glass in the piping 3 The bearings are not getting abnormally hot 4 There is no leakage through mechanical seal 5 Head and capacity developed by the pump is as specified 6 Power co...

Page 25: ...has been handling any form of hazardous liquid ensure that the unit is safe to work on The pump must be flushed thoroughly with suitable cleanser to purge away any of the product left in the pump comp...

Page 26: ...le steps to dismantle the pump 5 2 1 1 1 Isolate power supply to motor 5 2 1 1 2 Shut off the valves controlling flow to and from the pump 5 2 1 1 3 Drain the liquid from pump by removing the drain pl...

Page 27: ...foot 5 2 1 1 9 Remove back pull out assembly use lifting eye bolt provided for higher weight pump models 5 2 1 1 10 In case of casing cover sandwiched between casing and bearing housing remove the he...

Page 28: ...ng cover 22000 to pump casing 10500 Removal of back pull out assembly casing cover is not sandwiched 5 2 1 1 12 Screw the release bolts provided in casing cover Turn bolts evenly through a quarter tur...

Page 29: ...shaft sleeve 51500 Removal of impeller 5 2 1 1 18 Removal of Cartridge mechanical seals from stuffing box For this following steps should be taken which are applicable for standard Cartridge Single D...

Page 30: ...val of mechanical seal f Remove Cartridge seal assembly from shaft g Loosen grub screw holding the liquid deflector 23600 Take out liquid deflector h 5 2 1 1 19 Remove impeller key 32000 5 2 1 1 20 Ta...

Page 31: ...ure 5 2 1 1 23 Take out the gasket 51400 Removal of NDE bearing cover gasket oil seal Removal of DE bearing cover gasket oil seal 5 2 1 1 24 Force shaft 18001 18002 carefully in the direction of drivi...

Page 32: ...found damaged 5 2 1 1 31 Casing ring suction side 19000 casing ring delivery side 19100 are to be removed only if they are worn out and need replacement For pumps with bearing housing cooling arrangem...

Page 33: ...fitted If hot oil bath is not available then ARBOUR PRESS must be used Use gloves while fitting bearings from hot oil bath b Slide inboard bearing on shaft by hand make sure that it is square with sh...

Page 34: ...ls Refer mechanical seal drawing a Mount deflector 23600 on shaft 18002 b Mount impeller key 32000 on the shaft c Take the complete cartridge from its package Do not disassemble or alter the unit Gent...

Page 35: ...oper position 5 2 1 2 16 Push impeller 15100 on shaft till it touches the shaft sleeve 5 2 1 2 17 Fix the impeller nut 33000 along with helicoil insert 47900 with gasket in between impeller hub and im...

Page 36: ...ll in advance to actual start of the pump Pump should be started only after ensuring that the liquid inside the casing and suction line is in liquid form Check free rotation of pump shaft prior to sta...

Page 37: ...ing failure choking of impeller or casing and such other operating troubles The pump performance should therefore be checked for noise and vibrations 5 3 2 Periodical checks 5 3 2 1 The temperature of...

Page 38: ...leakage the preventive maintenance is not advocated If leakage occurs a thorough check up is needed While fitting the mechanical seals in the pump initially by KBL due care is taken for its proper fit...

Page 39: ...ly 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 cent...

Page 40: ...ta 55 mm Bearing isolator NDE AES LabTecta 35 mm AES LabTecta 35 mm AES LabTecta 50 mm AES LabTecta 60 mm Against order 6 3 Bearings a Bearings of SKF make or equivalent and with C3 clearance are used...

Page 41: ...emperature is ISO VG 68 6 5 Cooling of stuffing box bearing housing and pump pads Clean non corrosive fresh water is normally used as the cooling medium Corrosion resistant material would be selected...

Page 42: ...1800 C Pump with centre line mounted delivery casing is optional Quantity of cooling water to pad 0 2 to 0 3 m3 hr Maximum permissible cooling water pressure 6 0 kg cm2 6 8 Steam or hot water circula...

Page 43: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 43 LAST REV DATE 01 08 2019 PART NUMBER AND DESCRIPTION Recommended Spares...

Page 44: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 44 LAST REV DATE 01 08 2019 1 Cross section drawing of GK P unit 7...

Page 45: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 45 LAST REV DATE 01 08 2019 2 Cross section drawing of GK P unit 7A 10 12 with back vanes...

Page 46: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 46 LAST REV DATE 01 08 2019 3 Cross section drawing of GK P unit 7A 10 12 with Back wear ring...

Page 47: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 47 LAST REV DATE 01 08 2019 4 Typical Cross section drawing of GK P CLM...

Page 48: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 48 LAST REV DATE 01 08 2019 5 Typical Cross section drawing of GK P with bearing isolator...

Page 49: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 49 LAST REV DATE 01 08 2019 GK P Standard End view GK P CLM End view Casing drain piping...

Page 50: ...e 50 LAST REV DATE 01 08 2019 GK P J Options available as per application customer requirement a Casing cover jacketed b Casing Jacketed c Casing Casing cover Both Jacketed Bearing cooling arrangement...

Page 51: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 51 LAST REV DATE 01 08 2019 Exploded view of Standard GK P Foot mounted pump...

Page 52: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 52 LAST REV DATE 01 08 2019 Exploded view of Standard GK P CLM pump...

Page 53: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 53 LAST REV DATE 01 08 2019 Note These are tentative dimensions Critical dimensions may change against order...

Page 54: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 54 LAST REV DATE 01 08 2019 Note These are tentative dimensions Critical dimensions may change against order...

Page 55: ...t 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 occurs contact KBL imme...

Page 56: ...othing or jewellery which could catch on the controls or become trapped in the equipment 1 7 Read the instruction manual before installation operation or maintenance of the equipment Check and confirm...

Page 57: ...is not provided with lifting points The use of forklift truck and chain crane sling equipment is recommended but locally approved equipment of suitable rating may be used While lifting the equipment...

Page 58: ...n 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 wat...

Page 59: ...afe 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...

Page 60: ...iner in a safe place Do not weld or flame cut on pipes tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting on them Use solvent chemical...

Page 61: ...IOM GK P CONICAL ISSUE DATE 10 11 2015 Page 61 LAST REV DATE 01 08 2019 CORRECT INCORRECT GENERAL INSTRUCTIONS FOR INSTALLATION OPERATION MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS...

Page 62: ...sable Foundation bolts of the proper size should be embedded in the concrete located by a drawing or template A pipe sleeve of two and one half diameter larger than the bolt should be used to allow mo...

Page 63: ...ING ALIGNMENT The two halves of the coupling should be at least 3 mm apart so that they cannot touch each other when the driver shaft is rotated Necessary tools for approximately checking are straight...

Page 64: ...submerged to avoid whirlpools and ingress of air but must be kept clear of any deposits of mud silt grit etc The pipe must be away from any side of the wall by 450 mm The end of the strainer must be p...

Page 65: ...sionally changed BALL BEARINGS Correct maintenance of ball bearings is essential The bearing manufacturers give the following as a guide to re lubrication periods under normal condition for Grease lub...

Page 66: ...ttention while running Lubrication at 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...

Page 67: ...N CAUSE CHECK POINTS In case of breakdown we recommend the location of the fault by using the following table BREAKDOWN CHECK POINTS Pump does not deliver 1 7 8 9 10 11 12 14 15 17 18 19 23 26 56 57 5...

Page 68: ...tuffing box etc 11 Suction lift too high 12 Suction head too low difference between pressure at suction connection and vapor pressure too low 13 Delivery liquid contains too much gas and or air 14 Del...

Page 69: ...e stuffing box cooling 43 Alignment of coupling faulty or coupling loose 44 Elastic element of coupling worn 45 Pump casing under stress 46 Pipeline under stress 47 Shaft runs untrue 48 Shaft bent 49...

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