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KIRLOSKAR GK 10, Инструкция по установке, эксплуатации и обслуживанию

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IOM/GK(P)/CONICAL                                                                                  ISSUE DATE: 10.11.2015  
Page 39                                                                                               LAST REV. DATE: 01.08.2019

 

 

 

 

 

 

5.4

 

   CORRECTIVE MAINTENANCE: 

 

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 referring 
the table for ‘Break Down Check Points’ given at the end of this manual. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Содержание GK 10

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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