INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE RKBV
Page 1: ...INSTRUCTIONS ON INSTALLATION OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE RKBV...
Page 2: ...hichever 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...
Page 3: ...REVENTIVE MAINTENANCE 7 OVERHAULING 8 SPARE PARTS LIST AND CROSS SECTIONAL DRAWINGS PLEASE FURNISH PUMP TYPE NAME OF THE PART PART NUMBER MATERIAL CONSTRUCTION AND OTHER NAMEPLATE DETAILS WHILE ORDERI...
Page 4: ...n dry place The shaft should be rotated once in a month to prevent pitting of bearing surfaces 2 Safety Instructions 2 1 General Information Please read the manual thoroughly prior to installation of...
Page 5: ...or their respective tasks 2 1 3 KBL firmly insists that all personnel responsible for installation operation and maintenance of the equipment must read the manual before any work is done 2 1 4 Ear def...
Page 6: ...ousing is drained prior to dispatch of pump Pumps are protected against corrosion and packed for transport by normal road rail and sea carriers 2 6 2 Handling Crushing Hazard When lifting the pump or...
Page 7: ...ainted carbon steel or cast iron parts and should not be removed until final installation 2 6 3 2 Long Term Storage Shearing Hazard Do NOT place fingers or hands etc into the suction or discharge pipe...
Page 8: ...h this booklet must be followed very carefully 3 1 3 Flushing Quenching of Mechanical Seal Whenever pump is supplied with mechanical seal the flushing plan as per recommended in O A shall have to be f...
Page 9: ...pump Refer Fig No 5 5 The direction of rotation it should be anticlockwise when viewed from driving end 6 The sealing liquid and cooling water connections are properly tightened and adjusted 7 The dir...
Page 10: ...g the pump 1 Close the valve on the delivery pipe line 2 Stop the motor 3 Close the cooling water and sealing liquid connections 4 If the pump is not required to be operated for a long time drain the...
Page 11: ...l bearing at driving end and bush bearing at non driving end The bearing specifications are given below The designations of bearings are as per SKF catalogue However equivalent bearing in type capacit...
Page 12: ...EED 2900 RPM INDIAN OIL SERVOGEM 3 SERVOGEM 2 HINDUSTAN PETROLEUM ALVANIA GREASE 3 ALVANIA GREASE 2 INTERNATIONAL GRADE NLGI 3 NLGI 2 5 6 Flushing of bearing bush at non driving side For this please r...
Page 13: ...Packed Part No 52200 RKBV 32 9E 148 82 ID X 3 53 T 81 0 ID X 3 T 31 6 ID X 2 4 T RKBV 40 12L 190 1 ID X 3 53 T 99 5 ID X 3 53 T 36 5 ID X 3 T RKBV 40 14H 190 1 ID X 3 53 T 99 5 ID X 3 53 T 36 5 ID X...
Page 14: ...ng End PUMP TYPE OIL SEAL SIZE RKBV 32 9E 40 ID X 52 OD X 7 Thick RKBV 40 12L 45 ID X 60 OD X 8 Thick RKBV 40 14H 45 ID X 60 OD X 8 Thick RKBV 50 15E L 52 ID X 68 OD X 8 Thick RKBV 50 16H 52 ID X 68 O...
Page 15: ...with steel spring 5 14 TORQUE FOR TIE BAR NUTS Sr No Pump Type Number of Stages Torque in kg m 1 RKBV 32 9E 2 to 6 7 to 10 8 9 2 RKBV 40 12L RKBV 40 14H 2 and 3 4 to 7 8 to 9 16 18 20 3 RKBV 50 15E L...
Page 16: ...0 6 3 3 RKBV 50 16H RKBV 65 19E L 58 45 6 4 RKBV 100 23E 62 50 6 4 RKBV 125 27 72 55 8 5 5 RKBV 125 30 80 60 8 5 8 RKBV 150 34 90 65 10 7 RKBV 200 37 90 70 10 7 NOTE Initially washer is to be manufact...
Page 17: ...ngs should be flushed and charged with fresh lubricants 6 2 3 Check for the stuffing box leakage 6 2 4 The alignment of the pump unit should be checked Due to operational vibrations atmospheric temper...
Page 18: ...ry flexible couplings remove the motor from the base 7 2 7 Remove the delivery and suction pipe connections 7 2 8 Take out sealing water pressure relaxation piping if applicable and other connections...
Page 19: ...p is substantial 7 2 28 All the damaged parts should be replaced by new one 7 2 29 Inspect all the O rings carefully Replace the damaged ones It is advisable to use NEW O RINGS instead of used ones 7...
Page 20: ...screw on the shaft 7 3 2 Mount the shaft sleeve 31000 suction side on the shaft from DE 7 3 3 Insert the shaft so far assembled inside the suction casing 113 bore Please ensure that bush bearing is f...
Page 21: ...provided on diffuser engages properly with the rib provided inside the delivery casing 7 3 12 Insert the delivery casing 10100 into the main assembly Please ensure that the stuffing box cavity is fill...
Page 22: ...the bearing housing 7 3 20 Insert adjustable washer 20901 Adjustable washer plays very important role in locating the rotating unit of the pump with respect to stationary unit The adjustable washer t...
Page 23: ...should be as given below O D 1 0 mm 0 5 mm I D 0 5 mm 0 1 mm Thickness 0 1 mm Note Use of dummy piece is recommended to avoid cumbersome operation of fitting and removal of actual bearing Actual beari...
Page 24: ...IOM RKBV OCT 19 00 Page 21 of 47 Issue date 23 10 2019 Revision 00 Fig A FIG NO 4 FIG NO 5...
Page 25: ...ld be within 0 05 mm to that of calculated thickness h Insert the adjustable washer on the shaft 7 3 21 Gland Packed Pump Mount antifriction bearing at DE on the shaft Insert lock washer 41500 and tig...
Page 26: ...or 1 24000 Bearing housing DE 1 26300 Angular contact ball bearing 2 26000 Deep groove ball bearing Only for RKB 32 9E 1 26000 Deep groove ball bearing For RKB 32 14H 2 26300 Angular contact ball bear...
Page 27: ...65 19 Qty 8 Mechanical Seal Pump Mount the dummy piece on the shaft Tighten the lock nut 33600 with half the torque indicated under clause 5 14 Note that so far we have assembled the pump without mech...
Page 28: ...t forget to mount O rings 52205 before fitting the mechanical seal covers 7 3 16 Insert O ring 52200 and mount distance sleeve 31700 7 3 17 Mount bearing housing 24001 and insert adjustable washer 209...
Page 29: ...9 Revision 00 FLUSHING OF MECHANICAL SEALS FOR VERTICAL PUMPS FIG 1 ARRANGEMENT SCHEMATIC PLAN SUPPLY CONDITION ADDITIONAL DETAILS I Internal flushing Delivery side Standard II External flushing Deliv...
Page 30: ...IOM RKBV OCT 19 00 Page 27 of 47 Issue date 23 10 2019 Revision 00 Cross Section assembly drawing of RKBV pump with Gland packing FIG 2...
Page 31: ...IOM RKBV OCT 19 00 Page 28 of 47 Issue date 23 10 2019 Revision 00 Cross Section assembly drawing of RKBV pump with Mechanical Seal FIG 3...
Page 32: ...IOM RKBV OCT 19 00 Page 29 of 47 Issue date 23 10 2019 Revision 00 Leak off pressure water piping for RKBV pumps FIG 4...
Page 33: ...hing of Bearing Bush Vertical Pumps FIG 5 A Internal Flushing suction Side This is our standard supply condition In this condition port A will be open and port B will be closed Feeding of clear water...
Page 34: ...019 Revision 00 B External Flushing Suction Side FIG 6 This is our optional supply condition In this condition port B will be open and port A will be closed Feeding of clear water should be having pre...
Page 35: ...IOM RKBV OCT 19 00 Page 32 of 47 Issue date 23 10 2019 Revision 00 RKB Vertical Pump Assembly Process FIG 7...
Page 36: ...and reassembling Toolbox containing a general set of tools such as different size ring spanners torque wrenches open ended spanners light ball peen hammer wooden mallet various sizes Allen keys etc s...
Page 37: ...IOM RKBV OCT 19 00 Page 34 of 47 Issue date 23 10 2019 Revision 00 GENERAL INSTRUCTIONS FOR INSTALLATION OPERATION MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS C ORRECT INC OR RECT...
Page 38: ...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 of two and one half diameter lar...
Page 39: ...ide caliper A check for parallel misalignment 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 str...
Page 40: ...rainer of sufficient open area DELIVERY PIPE A check non return valve and a gate or sluice valve regulating valve should be installed in the discharge line The check valve placed between the pump and...
Page 41: ...when on continuous duty Six monthly when on eight hour per day duty The bearings and housings should be completely cleaned and recharged with fresh grease after 2500 hrs or the nearest pump overhaul...
Page 42: ...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 the rings are worn out the clearance become...
Page 43: ...35 36 37 38 39 40 43 44 47 48 49 50 51 54 55 58 Stuffing box leaks excessively 24 27 28 29 30 31 47 48 49 53 Fumes from stuffing box 22 23 24 25 26 27 28 29 30 41 42 43 Pump rotor locked in standstill...
Page 44: ...paration of crystals from the flow of pumping liquid falling below the temperature limit equilibrium temperature 23 Sealing liquid line obstructed 24 Sealing liquid contaminated 25 Sealing liquid omit...
Page 45: ...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 circumsta...
Page 46: ...should not exceed 90 dbA and 110 dbA for motor driven and engine driven pumps respectively Do not wear loose clothing or jewellery which could catch on the controls or become trapped in the equipment...
Page 47: ...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 SA...
Page 48: ...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...
Page 49: ...ximum working pressure specified in tSShe 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 g...
