KIRLOSKAR GK Series Instruction On Installation, Operation And Maintenance
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KIRLOSKAR GK Series Instruction On Installation, Operation And Maintenance

KIRLOSKAR GK Series Instruction On Installation, Operation And Maintenance

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INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE GK(P)
IOM/GK(P)/CONICAL
Page 1
ISSUE DATE: 10.11.2015
LAST REV. DATE: 01.08.2019

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  • Page 1 INSTRUCTIONS ON INSTALLATION, OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE GK(P) IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 1 LAST REV. DATE: 01.08.2019...
  • Page 2 KIRLOSKAR BROTHERS LIMITED REGD. OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002 WARRANTY We warrant that the pump supplied from us is free from defective material and faulty workmanship. This warranty holds good for a period of 12 months from the date of commissioning the equipment or 18 months from the date of dispatch from our factory, whichever is earlier.

  • Page 3: Table Of Contents

    CONTENTS PART A: ATEX SAFETY MANUAL PART B: INSTRUCTIONS ON INSTALLATION, OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE GK(P) 1. GENERAL 2. SAFETY INSTRUCTIONS 3. EQUIPMENT SCHEDULE 3.1 INSTALLATION 3.2 MOUNTING AND ALIGNMENT 4. OPERATION 4.1 EQUIPMENT DESCRIPTION 4.2 EQUIPMENT OPERATION 5.

  • Page 4: Part A: Atex Safety Manual

    PART A: ATEX SAFETY MANUAL TRAINING It is recommended and a part of the CE regulations that users personnel who will be involved in the installation, operation and/or maintenance of KBL products should have the opportunity of an initial training period, which can be carried out either at KBL works or customers premises by arrangement.
  • Page 5 ESSENTIAL SAFETY REQUIREMENTS (ESR) ATEX DIRECTIVE 2014/34/EU (EXPLOSION HAZARD SAFETY) All KBL products that are certified to comply with the Directive also carry a specific ATEX Safety Manual (Section 5) which must be referred to in conjunction with this manual. It is the responsibility of the user to ensure that the equipment is correctly rated for the environment in which it is to be used.
  • Page 6 CE marking & ATEX marking certification, additional safety instructions & directives etc., as applicable. Kirloskar pumps GK(P) range of pumps are certified to comply with the ATEX directives 2014/34/EU & user is to ensure compliance with the European Directive 2014/34/EU.
  • Page 7 Pumps have a temperature class as stated in the ATEX Ex rating on the name plate. These are based on a maximum ambient of 40ºC (104ºF). Refer to KIRLOSKAR BROTHERS LTD. for higher ambient temperatures. The surface temperature of the pump may be influenced by the temperature of the liquid handled.
  • Page 8 Where there is any risk of the pump being run for prolonged periods against a closed or partially closed valve generating high liquid and casing external surface temperatures, it is recommended that users fit an external surface temperature protection device. A.5.2 Additional requirements for self-priming conditions Where the system operation does not ensure control of priming, and the maximum permitted surface temperature of the T3 Class could be exceeded, it is...

  • Page 9: Part B: Instructions On Installation, Operation And Maintenance For Kirloskar Pump Type Gk(P)

    PART B: INSTRUCTIONS ON INSTALLATION, OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE GK(P) GENERAL: ‘KIRLOSKAR’ make GK(P) pumps are used for handling various types of chemical liquids. These pumps are manufactured to close tolerance and are rigid construction.
  • Page 10 Nomenclature: GK(P)32/13 GK(P) - Global Kirloskar (Process) Pump. 32 - Delivery size in mm. 13 - Impeller diameter in cm. This booklet covers instructions for following types GK(P), GK(P)J, GK(P) CLM of GK(P) series. GK(P) GK(P) GK(P) UNIT GK(P) UNIT UNIT –...

  • Page 11: Safety Instructions

    Where a conflict exists between the contents herein and the actual equipment supplied, the user must make an engineering judgment, else contact KBL. Kirloskar Brothers reserves the right to change the construction & design of the products at any time without being obliged to change products already supplied earlier.
  • Page 12 Kirloskar Brothers Limited (KBL) has been designed with safety in mind; where hazards cannot be eliminated, the risk has been minimized 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.
  • Page 13 Operation of the equipment for the application other than for which it is supplied can increase the risk from hazards. Please consult KBL before making such change in the application of the equipment. Improper installation, operation and maintenance of the product supplied by KBL could result in injury or death.
  • Page 14 Pump set must be lifted from the lifting holes provided using suitable four chain lifting equipment. Lifting of Pump set 2.6.3 Storage. 2.6.3.1 Temporary storage for up to six weeks. If the pump unit is not to be used immediately it should be stored carefully in a horizontal position, in a sheltered, dry location.

  • Page 15: Equipment Schedule

    INSTRUCTIONS INSTALLATION, OPERATION MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed along with this booklet must be followed very carefully. If the pump is drawing liquid from the vessel under vacuum, then vacuum equalizing connection piping must be made as per instruction given in above publication.
  • Page 16 KBL representative, KBL Dealer and the transport company who delivered the pump. When unloading pump units, lift equally at four or more points from the base. DO NOT LIFT ONLY THE DRIVER OR PUMP. 3.1.3 Preparation Before installing the pump, clean the suction and discharge flanges •...
  • Page 17 • By adding or removing shims under the base, level the pump shaft and flanges. The base plate does not have to be leveled. Draw foundation bolt nuts tight against base plate and observe pump and motor shafts or coupling hubs for alignment. Check to make sure the piping can be aligned to pump flanges without •...

  • Page 18: Mounting And Alignment

    eccentric reducers are to be fitted in suction lines and straight taper reducers in discharge and vertical lines. Misuse of reducers may cause the formation of air pockets in the pipe • and thus preventing the correct operation of the pump. The suction pipe should be as short &...
  • Page 19 ALWAYS REMEMBER “A FLEXIBLE COUPLING IS NOT A UNIVERSAL JOINT” Correct alignment is essential for the smooth operation of the pump. There are two types of misalignment between the pump shaft and the drive shaft, which are: 1) Angular misalignment – shaft with axis concentric, but not parallel. Maximum allowable misalignment is 1°.
  • Page 20 GK(P) PUMPS – TAPPINGS CONNECTIONS CHART Code Description Location of connection when viewed from driving end Gauge connection discharge side. On pump discharge flange. Gauge connection suction side. On suction flange right. Flushing line connection. On casing top left. Pump casing drain. On pump casing bottom side towards suction.
  • Page 21 Tapping size details for GK(P) pump: CODE DESCRIPTION SIZE OF PIPE CONNECTION CONN Gauge connection discharge side. Suction Gauge / Vacuum equalising connection. Flushing/Sealing conn. from pump casing. Pump casing drain. Bearing housing cooling water inlet. Bearing housing cooling water outlet. Air breather cap.
  • Page 22 is 70 ml approximately. If the constant level oiler is properly fitted and oil is filled as per instructions given, practically no attention is required as far as lubrication of bearing is concerned other than to replenish the visible reserve supply of the oil in the container refer Figure given below. 3.2.1.3 METHOD OF FITTING Screw constant level oiler stem into the tapped hole of the bearing...

  • Page 23: Operation

    in the container shall remain steady at a position. Visible level of the oil in the container indicates that bearing housing is filled up to mark. Caution 1) In no case oil should be filled directly in to the bearing housing reservoir, through breather cap.
  • Page 24 4) The direction of rotation of driver should correspond to the direction of rotation of pump. 5) The pump casing and the suction pipeline is fully primed with the liquid. 6) Valve on delivery side is closed. 7) The cock for pressure gauge connection is closed. 8) For GK(P)J pumps before each start up of pump, circulate steam/hot water to pump casing and/or casing cover jacket for a period of about ½...

  • Page 25: Maintenance Manual

    MAINTENANCE MANUAL: MAINTENANCE EHS INSTRUCTIONS: Following hazards may arise during maintenance work. Fluid Pressure Jet Hazards Check and ensure that the pump operates at below the maximum Working Pressure specified. Hazardous Materials: Wear a suitable mask or respirator when working with chemical material handling.

  • Page 26: General Maintenance Documents

    5.2 GENERAL MAINTENANCE DOCUMENTS: 1) Maintenance documents: Pump Sectional assembly drawing with part list Pump Outline dimension drawing iii) Mechanical seal assembly drawing Foundation plan drawing Pump datasheet 2) Specific maintenance data: 5.2.1 Overhauling: Procedure for dismantling and re-assembly While dismantling and re-assembling, the cross-sectional assembly drawing and specification part list should be referred.
  • Page 27 5.2.1.1.8 Remove the support foot (25100) hold down bolts. Removal of support 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 hexagonal nuts from casing stud holding the bearing housing (24000) to pump casing (10500).
  • Page 28 5.2.1.1.11 In case of casing cover is tightened directly to casing (i.e. casing cover is not sandwiched between casing and bearing housing), remove the hexagonal nuts from casing stud holding the casing 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.
  • Page 29 5.2.1.1.16 Unscrew the impeller nut (33000 / 33001). Remove the gasket between impeller and impeller nut (68201). Removal of impeller nut and gasket 5.2.1.1.17 Take out the impeller (15100) from pump shaft (18002). Remove the gasket between impeller and shaft sleeve (51500). Removal of impeller 5.2.1.1.18 Removal of Cartridge mechanical seals from stuffing box:...
  • Page 30 GROOVE ON DRIVE COLLAR FIRMLY. Remove grub screw of driving collar which is engaged on Shaft / Shaft sleeve. c) Remove Impeller from rotating unit. d) Remove hex. nuts from casing cover (22000) studs holding the cover of mechanical seal. e) Then remove casing cover (22000) from rotating unit.
  • Page 31 5.2.1.1.22 Take out coupling key (32100). 5.2.1.1.22.1 Loosen the bolts holding bearing cover (27000/27100). Remove carefully bearing cover along with the oil seal (50001/50002) or bearing isolator if applicable. In Labyrinth type sealing arrangement at DE side first remove labyrinth type liquid deflector from shaft & then follow above procedure.
  • Page 32 Dismantling the bearings from bearing housing 1) Push the sleeve on arbour press with uniform pressure. 2) Steps 5.2.1.1.25 to 5.2.1.1.28 are to be followed only if bearings are damaged and to be replaced. 5.2.1.1.29 Oil seals / bearing isolators in the DE & NDE bearing cover (50001/50002) should be removed if the oil seal lips / bearing isolators are worn out or spring has lost tension.
  • Page 33 5.2.1.2 RE-ASSEMBLY: This procedure covers re-assembly of pump after complete dismantling of the pump. Before re-assembly, all the parts should be thoroughly cleaned in kerosene, petrol or benzene to remove the dust, rust, etc. After cleaning the necessary parts should be replaced.
  • Page 34 5.2.1.2.5 Insert circlips at driving end (48500) in the grooves of the bearing housing (24000 / 24200). Check returning duct holes in bearing housing and bearing cover at driving end are clean. 5.2.1.2.6 Insert shaft (18001 / 18002) along with bearings (viz. angular contact bearings at driving end and inner race of roller bearing at non-driving end) in to the bearing housing from driving end.
  • Page 35 For reassembly of the bearing housing cooling arrangement follow steps given below. 5.2.1.2.12 Fit the oil well cover (if applicable) for bearing housing cooling arrangement (36700) along with cooling tube coil (37000) with Gasket (685) in between and tighten screws. 5.2.1.2.13 Place ‘O’...
  • Page 36 5.2.1.2.23 Fit coupling spacer between pump half and motor half coupling in case of spacer type flexible couplings. 5.2.1.2.24 Mount motor on the base in case of standard flexible coupling and align the unit. 5.2.1.2.25 Fit coupling guard. SPECIAL IMPORTANT INSTRUCTIONS 1) The instructions given in this book are of general nature.

  • Page 37: Preventive Maintenance

    • Maintenance tools required: No special tools are required for dismantling and reassembling. Toolbox containing a general set of tools such as different sizes of ring spanners, torque wrenches, open ended spanners, light ball peen hammer, wooden mallet, various sizes of Allen keys, etc., serves the purpose. It is important to ensure that the suitable lifting equipment is available and that the work is carried out in clean area.
  • Page 38 5.3.3.2 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. 5.3.3.3 The auxiliary pipelines and functioning of the auxiliary system should be checked.

  • Page 39: Corrective Maintenance

    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.

  • Page 40: Technical Data

    6.0 TECHNICAL DATA: Direction of rotation: The direction of rotation is clockwise when viewed from driving end. Specification of oil seal, bearing isolator, quantity of oil, Bearing: Description Unit No. 7 Unit No. 7A Unit No. 10 Unit No. 12 Oil seal DS 32x45x7 32x45x7...
  • Page 41 Notes: 1. The bearing arrangements mentioned above are suitable for suction pressure less than 5 kg/cm . For applications involving suction pressure above 5 kg/cm , please refer to RO/Marketing. 2. Axial running clearance shall be less than 0.45 mm for all above bearing arrangements.
  • Page 42 Cooling to pump pads: Centre line mounted pumps are supported on pads through which cooling water should be circulated. Centre line mounted pumps are recommended for pumping liquids of temperature above 180 C. Pump with centre line mounted delivery casing is optional. Quantity of cooling water to pad –...
  • Page 43 PART NUMBER AND DESCRIPTION * Recommended Spares IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 43 LAST REV. DATE: 01.08.2019...
  • Page 44 1. Cross section drawing of GK(P) unit 7 IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 44 LAST REV. DATE: 01.08.2019...
  • Page 45 2. Cross section drawing of GK(P) unit 7A, 10, 12 with back vanes IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 45 LAST REV. DATE: 01.08.2019...
  • Page 46 3. Cross section drawing of GK(P) unit 7A, 10, 12 with Back wear ring IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 46 LAST REV. DATE: 01.08.2019...
  • Page 47 4. Typical Cross section drawing of GK(P)CLM IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 47 LAST REV. DATE: 01.08.2019...
  • Page 48 5. Typical Cross section drawing of GK(P) with bearing isolator IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 48 LAST REV. DATE: 01.08.2019...
  • Page 49 GK(P) Standard End view GK(P) CLM End view Casing drain piping IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 49 LAST REV. DATE: 01.08.2019...
  • Page 50 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 60510 25200 51760 37000 68500 36700 60530 IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 50 LAST REV.
  • Page 51 Exploded view of Standard GK(P) Foot mounted pump IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 51 LAST REV. DATE: 01.08.2019...
  • Page 52 Exploded view of Standard GK(P)CLM pump IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 52 LAST REV. DATE: 01.08.2019...
  • Page 53 Note – These are tentative dimensions. Critical dimensions may change against order. IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 53 LAST REV. DATE: 01.08.2019...
  • Page 54 Note – These are tentative dimensions. Critical dimensions may change against order. IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 54 LAST REV. DATE: 01.08.2019...
  • Page 55 GENERAL INFORMATION & SAFETY INSTRUCTIONS The products supplied by KBL have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimized 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.
  • Page 56 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 or face shield should be worn where working with pressurized systems and hazardous substances.
  • Page 57 REPAIR OF THIS KBL PRODUCT COULD RESULT IN INJURY OR DEATH. If any tool, procedure, work method and operation technique is not recommended by KIRLOSKAR BROTHERS LIMITED is used or followed, it should be ensured that it is safe for personnel around and others. It should...
  • Page 58 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. SAFETY INSTRUCTIONS WHILE COMMISSIONING &...
  • Page 59 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 pump 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.
  • Page 60 Wear a suitable mask or respirator when working with packing and gasket containing fibrous material, as these can be hazardous when the fibrous dust is inhaled. Be cautious, if other supplier’s components have been substituted for genuine KBL parts, these may then contain hazardous materials. Store all oily rags or other flammable material in a protective container in a safe place.

  • Page 61: General Instructions For Installation, Operation

    GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION & MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS CORRECT INCORRECT IOM/GK(P)/CONICAL ISSUE DATE: 10.11.2015 Page 61 LAST REV. DATE: 01.08.2019...
  • Page 62 GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION & MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS 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 satisfactory performance and if it is operated in excess of the conditions for which it is manufactured, the equipment is subjected to excessive stresses and strains.
  • Page 63 INCORRECT ANGULAR STEEL STRAIGHT EDGE STEEL STRAIGHT EDGE MISALIGNMENT STEEL STRAIGHT EDGE CORRECT INCORRECT PARALLEL MISALIGNMENT 2) Parallel misalignment – Shaft with axis parallel, but not concentric. Maximum allowable misalignment is 0.1 mm. LEVELING 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.
  • Page 64 PIPING Both suction and delivery pipes and accessories should be independently supported near the pump, so that when the flanges, bolts are tightened no strains will be transmitted to the pump casing. It is usually advisable to increase the size of both the suction and delivery pipe at the pump nozzles in order to decrease the loss of head due to friction and for the same reason piping should be arranged with minimum possible bends as possible, or it should be made with long radius...
  • Page 65 from being drawn in to the pump or choking the foot-valve and for this purpose an efficient strainer should be provided. STUFFING BOXES AND PACKING (only for gland packed pump) Stuffing boxes should be carefully cleaned and packing placed in them. Be sure that sufficient packing is placed at the back of the water seal cage.
  • Page 66 3) Priming by ejector. An ejector operated by steam, compressed air or water under pressure and connected to air vent at the top of casing can be used to remove air from pump and prime the pump on suction lift installations. 4) Priming by dry vacuum pump.
  • Page 67 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.
  • Page 68 Bearing temperature increases 19 20 21 22 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 51 54 55 58 Motor will not start 14 22 60 Motor gets hot or burns out 14 22 27 28 40 43 50 55 56 57 58 59 60 61 Motor is difficult to start 14 22 27 28 45 46 50 58 59 60...
  • Page 69 33. Insufficient lubrication of bearings. 34. Ball bearings over-lubricated. 35. Oil/Grease quality unsuitable. 36. Ball bearing incorrectly fitted. 37. Axial stress on ball bearings (no axial clearance for rotor). 38. Bearings dirty. 39. Bearings rusty (corroded). 40. Axial thrust too great because of worn casing rings, relief holes obstructed.

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