KIRLOSKAR SHS Instruction On Installation, Operation And Maintenance
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KIRLOSKAR SHS Instruction On Installation, Operation And Maintenance

KIRLOSKAR SHS Instruction On Installation, Operation And Maintenance

Grease lubricated and water lubricated
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INSTRUCTIONS ON INSTALLATION,
OPERATION AND MAINTENANCE
FOR
KIRLOSKAR PUMPS
TYPE
SHS
Grease Lubricated and Water Lubricated
KIRLOSKAR BROTHERS LIMITED
REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002
GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 98/(3-7), BANER, PUNE 411 045

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  • Page 1 INSTRUCTIONS ON INSTALLATION, OPERATION AND MAINTENANCE KIRLOSKAR PUMPS TYPE Grease Lubricated and Water Lubricated KIRLOSKAR BROTHERS LIMITED REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002 GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 98/(3-7), BANER, PUNE 411 045...

  • Page 2: Warranty

    KIRLOSKAR BROTHERS LIMITED REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002 GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 98/(3-7), BANER, PUNE 411 045 WARRANTY We warrant that the pump supplied from us is free from defective material and faulty workmanship. This warranty holds good for a...
  • Page 3 Please furnish complete nameplate details, name of parts, part nos. and material construction while ordering spare parts for the pump. General instructions for maintenance, operation & Note: A copy of maintenance of ‘Kirloskar pumps’ is attached at the end of this manual.
  • Page 4 Product Description: -  SHS type sump pumps are manufactured to the close tolerances and rigid specifications. Hence proper erection and maintenance is equally important to ensure trouble free service. This booklet covers important guidelines and instructions on erection, operation and maintenance for the following sizes of SHS pumps.

  • Page 5: Safety Instructions

    Whenever the equipment is operated, maintained or used in any way, the procedures detailed within the Health and Safety Dossier (DHS) and any procedures detailed within these instructions shall be followed. The pump supplied by Kirloskar Brothers Limited (KBL) has been designed with safety in mind, where hazards cannot be eliminated;...
  • Page 6 Storage & handling 2.3.1 On receiving the material – The SHS, SHS-E pump having column lengths up-to 2 metres are dispatched in completely assembled condition. The pumps with more than 2 metres column length are dispatched in partially assembled form.
  • Page 7 SHAFTS. THEY ARE MACHINED TO CLOSE TOLERANCES AND CAREFULLY INSPECTED AT FACTORY AND IF BENT, CAN CAUSE TROUBLE. A BENT SHAFT SHOULD NEVER BE INSTALLED. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 4 4 4 4 of 56 56 56...
  • Page 8 Highest liquid level should be below the breather hole provided on top suspension pipe. The level in the sump should be controlled by liquid level controller/float switch. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 5 5 5 5 of 56...
  • Page 9 4.9 Ventilation for cooling of the motor. 4.10 Provision for storeroom. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 6 6 6 6 of 56 56 56...
  • Page 10 It is to be ensured that there should be no point contact after mounting of the motor stool on the girders. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 7 7 7 7 of 56...

  • Page 11: Tools And Equipment

    6.2.1 2 pairs of clamps for suspension pipe (for column length 2 m and above). 6.2.2 2 pairs of clamps for rising pipe (for column length 2 m and above). 6.2.3 1 set of clamps for line shaft. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 8 8 8 8 of 56...
  • Page 12 6.3.9 Emery paper, grease gun, thin rolled sheets of 0.03 mm to 0.05 mm thickness for cutting shims. 6.3.10 Cotton waste and clean pieces of cloth for cleaning bearings. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 9 9 9 9 of 56...

  • Page 13: Equipment Schedule

    - ’GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION AND MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed along 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 14: Equipment Operation

    3) Close the cooling water liquid connections. 4) It has always recommended that use of NRV (Non return valve) in delivery pipe to avoid back flow during stopping the pump. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 11 11 of 56...
  • Page 15 In the case pump supplied with water lubrication the rubber bearing is used as transmission bearings. These should not meet oil, grease, paint, etc. These bearings should be cleaned with clear cold water only. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 12...
  • Page 16 The shafts are not bent during transit. Check them with the help of ‘V’ blocks and dial gauge or on centre lathe. The shaft run outs should not exceed 0.05 mm. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 13 13 of 56...
  • Page 17 9.4.7 All tools and equipment are kept ready on hand before starting the erection. Cross sectional drawing and erection instructions should be referred during erection. 9.4.8 Erection should be done by specialized and experienced personnel. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 14 14 of 56...
  • Page 18 Chain spanners to be used for tightening. Apply thread compound liberally to the threaded portion before connecting the pipes (flanged rising pipes are supplied in case of heavier pipes). IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 15 15 of 56...
  • Page 19 10.1.24 Now the rotating unit to be lifted to ensure correct clearance between impeller and wear plate (only for SHS-Q pumps). The adjustment is done as under: Put the bearing nuts (33500) & (33600) on the head shaft till it easily touches the bearing adapter (27200).
  • Page 20 10.1.29 Mount grease lubricator (if applicable) on support plate (38300). Refer instructions on grease lubricator supplied with SHS pumps. 10.1.30 Once again check the level on the surface of the motor stool. It should be leveled accurately while tightening the bolts with the use of shims, if necessary.
  • Page 21 Make the lubrication pipe connection upto bearing spider. 10.3.15 Repeat the same procedure till head shaft (18500), top column pipe (13202), top rising pipe (14201) and water lubrication popes are assembled. (let the IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 18...
  • Page 22 10.3.25 Now the rotating unit is to be lifted to ensure correct clearance between impeller and wear plates (Only for SHS-Q pumps). The adjustment is done following: Entire procedure is as outlined in 10.1.24 given in the manual.
  • Page 23 It should rotate freely. If it does not adjust the bearing lock nuts (33500/33600) suitably to make it free. The method for pumps with column length more than 2 M as per 10.3.25. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 20...

  • Page 24: Operation

    11.3.4 Head and capacity developed by the pump is as specified on the name plate of the pump. 11.3.5 Pump and motor bearings are not getting hot excessively. 11.3.6 Check the grease flow through tubes, removing acorn nut on three-way piece. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 21 21 of 56...
  • Page 25 11.4.1 Pump should be switched off only after closing the delivery side sluice valve. 11.4.2 In case of external water lubrication, it is to be stopped, only after pump comes to standstill. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 22...

  • Page 26: Maintenance

    12.3.2 After dismantling, parts are to be cleaned and checked thoroughly for wear and tear. Following parts are to be checked for clearance and replaced of it exceeds those given below: i. Impeller & wear plate (only for SHS-Q pumps): 1 mm ii. Shaft & bush bearing.: 0.55 mm IOM/SHS/NOV 19/00...
  • Page 27 12.4.1.16 After removal of the last bearing spider (24500) take out the remaining unit out of the sump. 12.4.1.17 Disconnect the bend (28000) along with the rising pipe (14201). Disconnect copper tube (56202). IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 24 24 of 56...
  • Page 28 (13301) and rising pipe (14201). Let the unit rest on the clamps fixed to the column pipe and rising pipe. 12.4.2.12 Unscrew the bolts and take out the top column pipe (13200). IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 25...
  • Page 29 Put the impeller shaft sleeve (31100) on pump shaft (18000)/impeller shaft (18600). 12.5.1.2 Slide impeller on shaft & tighten the impeller screw (66900) with its gasket (68200) by using Allen key. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 26 26 of 56 Revision: 00...
  • Page 30 Put the impeller shaft sleeve (31100) on pump shaft (18000)/impeller shaft (18600). 12.5.2.2 Slide impeller on shaft & tighten the impeller screw (66900) with its gasket (68200) by using Allen key. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 27 27 of 56 Revision: 00...
  • Page 31 Follow the procedure from 10.3.17. 12.6 Maintenance manual: MAINTENANCE ENVIRONMENTAL HEALTH AND SAFETY INSTRUCTIONS Following hazards may arise during maintenance work. Fluid Pressure Jet Hazards IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 28 28 of 56 Revision: 00...
  • Page 32 In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapors, it is recommended that maintenance work be carried out away from the pump location by removal of the rotating unit assembly to a suitable maintenance area. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 29...

  • Page 33: Technical Specification

    The permissible bearing temperature rise is 40°C above ambient temperature. 13.5 Bearing Details: The bearing is Single direction thrust ball bearings SKF or Equivalent. This bearing is grease lubricated and the bearing sizes are as under. IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 30 30 of 56...
  • Page 34 PART NO. DESCRIPTION SIZE (in mm) 51100 Gasket for pump casing and casing cover SHS 50/26N, SHS 80/26N, SHS 100/26N, 265DX285DX1T SHS 150/26N, SHS 50/26NB, SHS 50/26Q, SHS 80/26Q, SHS 100/26Q, SHS 150/26Q, SHS 150/26NB SHS 80/40N, SHS 100/40N, SHS...
  • Page 35 1 For rising pipe size same as delivery size of pump casing. 2 For rising pipe size one size higher than delivery size of pump casing. SHS 50/26N, SHS 50/26NB, SHS 50/26Q, 1) 50DX165DX1T SHS 50/26M, SHS 50/32N 2) 65X185X1T...
  • Page 36 2) 40DX52DX7T 150/26N, SHS 150/32N, SHS 50/26NB, SHS 80/40N, SHS 100/40N, SHS 150/40N, SHS 200/32N, SHS 200/40N, SHS 50/26Q, SHS 80/26Q, SHS 50/32N, SHS 100/26Q, SHS 65/32NB, SHS 65/32Q,SHS 100/32Q, SHS 150/26Q,SHS 150/26NB, SHS 150/32Q, SHS 80/40NM, SHS 80/40Q, SHS 100/40Q, SHS...

  • Page 37: Spare Parts List

    15300** Impeller Semi Open (SHS/Q Pumps) 16600 Impeller Free Flow (for SHS/R Pumps) 18000** Pump shaft 18400** Intermediate shaft 18500** Head shaft 18600** Impeller shaft 19000** Casing Ring (for SHS/N & SHS/P Pumps) 19400** Sealing ring 21100 Bell mouth 21600 Strainer (optional) 22000...
  • Page 38 38300 Support plate for rising pipe 39000** Coupling 39500 Screwed Coupling 44100 Grease Nipple 46000** Wear Plate (for SHS/Q & SHS/R Pumps) 47000 Inspection Cover 47900 Helicoil Lock Insert 49000** Flanges 50001** Oil seal D.S. 50002** Oil seal Pump side...

  • Page 39: Cross Sectional Drawings

    15.0 CROSS SECTIONAL DRAWINGS: IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 36 36 of 56 Revision: 00...
  • Page 40 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 37 37 of 56 Revision: 00...
  • Page 41 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 38 38 of 56 Revision: 00...
  • Page 42 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 39 39 of 56 Revision: 00...
  • Page 43 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 40 40 of 56 Revision: 00...
  • Page 44 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 41 41 of 56 Revision: 00...
  • Page 45 Where on time is a parameter for running the lubricator while off time is idle. (This is a not a standard Scope of Supply). IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 42 42 of 56...
  • Page 46 These lubricators are good for any grease upto NLGI-II k) Grease specification: Indian Oil : Servorex L0/L1 Hindustan Petroleum : Limaplex IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 43 43 of 56 Revision: 00...
  • Page 47 Automatic Grease lubrication system IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 44 44 of 56 Revision: 00...
  • Page 48 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 45 45 of 56 Revision: 00...
  • Page 49 IOM/SHS/NOV 19/00 Issue Date : 22/11/2019 Page 46 46 of 56 46 46 56 56 Revision: 00...
  • Page 50 IOM/SHS/JUN19/01...
  • Page 51 IOM/SHS/JUN19/01...
  • Page 52 IOM/SHS/JUN19/01...
  • Page 53 IOM/SHS/JUN19/01...
  • Page 54 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 a safe for personnel around and others.
  • Page 55 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. IOM/SHS/JUN19/01...
  • Page 56 CUSTOMERS ARE ADVISED TO DISPOSE OF ALL UNUSABLE WASTE LIKE GASKETS, GLAND PACKING, OIL, BATTERIES, PACKING MATERIAL, ETC. THROUGH APPROPRIATE DISPOSAL AGENCIES AND IN ACCORDANCE WITH LOCAL REGULATION AVOID HARMFUL IMPACT ANY) ENVIRONMENT. IOM/SHS/JUN19/01...

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