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INSTRUCTIONS ON
Operation AND
Maintenance FOR
KIRLOSKAR PUMP
TYPE - KPDS - KPDSQF
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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Summary of Contents for KIRLOSKAR KPDS
- Page 1 INSTRUCTIONS ON INSTALLATION, OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE - KPDS - KPDSQF 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 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 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 EQUIPMENT OPERATION ERECTION/ASSEMBLING PROCEDURE OPERATION MAINTENANCE TECHNICAL DATA CROSS SECTIONAL ASSEMBLY DRAWINGS & SPECIFICATIONS LIST 30 EXPLODED VIEW 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: - ‘KIRLOSKAR’ make KPDS - KPDSQF pumps are used for handling various types of chemical liquids like acids, alkalis, hazardous liquids, hydrocarbons and water. These pumps are manufactured to close tolerance and are of rigid construction, However, proper installation, operation and maintenance are equally important to ensure trouble free service.
- Page 5 Maximum column length & pump will be supplied in assembled condition up to 6.0 meters. The complete range of ‘KPDS’ pump is covered by four driving units thereby reducing inventory and achieving interchangeability. 1.5 Pumps when properly installed & given due care in operation & maintenance should operate satisfactorily for a long period.
- Page 6 2.3.1 Transport- Pumps are dispatched in duly assembled condition. Pumps are protected against corrosion and packed for transport by normal road, rail and sea carriers. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 3 3 3 3 of 50 Revision: 00...
- Page 7 Refer Figure 1. Pump set must be lifted from the lifting eye bolts provided on the support plate by using suitable four chain lifting equipment. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 4 4 4 4 of 50...
- Page 8 NOTE: It is recommended to dismantle the motor from pump along with electrical connections and then lift the pump assembly. This is recommended to avoid damage to the motor, proper alignment and levelling while commissioning the pump. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 5 5 5 5 of 50...
- Page 9 The liquid should enter in the tank such that turbulence, high velocity and air entrainment are avoided at the suction of the pump. 4.2 Suction tank: The tank should be designed to be so as to provide- IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 6 6 6 6 of 50 Revision: 00...
- Page 10 Constricted bay width near pump inlet bell w = 2D Where, F = Froude Number = V / √(gD) V = Velocity at inlet face = Flow /Area IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 7 7 7 7 of 50 Revision: 00...
- Page 11 Use gasket in between support plate & foundation plane portion so that the joints become leak tight for gases and air coming out of the IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 8 8 8 8 of 50...
- Page 12 7.11.7 Steel rule and steel tape. 7.11.8 Set of taps and dies up to M16. 7.11.9 Chisel, hammer, hacksaw, vice, etc. 7.11.10 Emery paper, cloth. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 9 9 9 9 of 50 Revision: 00...
- Page 13 INSTRUCTIONS INSTALLATION OPERATION MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed along with this booklet must be followed very carefully. The external sealing connection to the pump, if applicable, must be made after installing and before commissioning the pump. Pump on hot service must have final coupling alignment made with the unit at its operating temperature.
- Page 14 (47900) in the impeller nut (33000) by using special tool, tighten the impeller nut (33000) with gasket (68200) in between the impeller and Impeller nut. For KPDS 20/13, 20/16 and 20/20QF impeller nut is inbuilt in impeller. IOM/KPDS/NOV 19/00...
- Page 15 In short casing cover is sand-witched between pump casing and bottom column pipe. NOTE: For pumps with impeller diameters 32 & 40 cm (e.g. KPDS 40/32, 80/40, etc.) and KPDS 20/16QF casing cover is double flanged, hence first nuts on casing cover to...
- Page 16 10.5.1 Use of thread compound is a must to prevent rust seizing. 10.5.2 Half of the screwed coupling length should come on each shaft. 10.5.3 Ends of shafts should rest on each other perfectly. Ensure this by taking Colour seat. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 13 13 13...
- Page 17 10.14 Lift the column pipe (13302) with the help of another clamp. 10.15 Lower the standard column pipe (13302) and fix to the lower column pipe (13301) with the bearing spider in between. Tighten the diametrically opposite nuts one by one. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 14 14 14...
- Page 18 : USE SUITABLE GASKET IN BETWEEN TANK FLANGE AND SUPPORT PLATE (IF APPLICABLE) 10.27 With the hanging support to the support plate, adjust the holes of support plate with that of the tank holes. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 15 15 15...
- Page 19 Tighten the lock nut (33600) to lock the bearing nut. Fold one arm of the lock washer (41501) in the bearing cover slot and fold remaining arms on bearing nut (33500). IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 16...
- Page 20 11.1.3 Ensure direction of rotation of Motor is CLOCKWISE (when viewed from non-driving end) before connecting motor coupling to pump coupling. Incorrect rotation even for small duration will quickly damage the pump. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 17 17 17...
- Page 21 12.1.4 Vibration and Noise. 12.2 Periodical checks: 12.2.1 Replenishing of the grease to the pump bearing and motor bearing after proper intervals. 12.2.2 Check the vibrations. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 18 18 18 18 of 50 50 50...
- Page 22 (24700), bearings (26300). Also take out spacer for bearing (19801). Remove bearing cover with oil seal (50001). 12.4.8 Lift entire unit vertically upward with the help of crane having slings supported on eye bolts screwed on support plate. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 19 19 19...
- Page 23 (18400), last bearing spider (24500) and last screwed coupling (39500). 12.4.26 Disconnect the rising pipe (14201) at support plate while dismantling the column pipes if rising pipe is in two or more pieces. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 20 20 20...
- Page 24 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. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 21 21 21 21 of 50...
- Page 25 125/26,125/32,125/40,125/40N,125/45,150/32,150/32N,150/40,32/26QF,40 /26QF,50/26QF,65/16QF,65/20QF,65/26QF,80/16QF,80/20QF, 100/20QF,25/26A,65/26N,80/26QF SKF 7310B 40/32, 50/32, 40/32QF, 50/32QF SKF 7311BG 65/32QF,80/32QF,80/40QF,100/32QF,100/40QF,125/26QF,150/32QF, 125/32QF 13.3 Quantity and refilling of grease: For 1000 running hours. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 22 22 22 22 of 50 50 50 Revision: 00...
- Page 26 216D x 230D x 1T 80/20,100/20 32/26,40/26,50/26,65/26,80/26, 266D x 282D x 1T 100/26,125/26 40/32,50/32,65/32,80/32,100/32,125/32, 331D x 348D x 1T 150/32,150/32N 80/40,100/40,125/40,125/40N,150/40 411D x 432D x 1T IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 23 23 23 23 of 50 50 50 Revision: 00...
- Page 27 3 For rising pipe size two size higher than delivery size of pump casing. 1 20D x 120D x 1T KPDS 20/13QF, 20/16QF, 20/20QF 2 25D x 125D x 1T 1 25D x 125D x 1T KPDS 25/16QF...
- Page 28 3 For rising pipe size two size higher than delivery size of pump casing. PART NO. DESCRIPTION SIZE (in mm) KPDS 20/13 QF, 20/16 QF, 20/20 QF 1 26.5D x 38D x 1T 1 39D x 67D x 1T KPDS 25/16 QF 2 42D x 54D x 1T...
- Page 29 KPDS 20/13, 16, 20QF, 25/16QF, 32/13- 180D x 130D x 1T 20, 40/13-20, 50/13-20, 65/13 KPDS 32/26, 40/26-32, 50/26-32, 65/16- 171D x 270D x 1T 32, 80/16-40, 100/20-40, 125/26-45, 150/32 51200 Gasket for adapter plate. KPDS 20/13, 16, 20QF, 25/16QF, 32/13-...
- Page 30 Apply grease on O-ring area of sleeve. Also apply on the area for gasket. Put the gasket. Put the key on the shaft. Apply grease on shaft for easy movement of seal on shaft. IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 27 27 27...
- Page 31 Put the pump side hub of the coupling on pump shaft. Then assemble the motor stool along with motor on the support plate. FIGURE - A IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 28 28 28...
- Page 32 FIGURE – 1 FIGURE – 2 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 29 29 29 29 of 50 50 50 Revision: 00...
- Page 33 BEARING BUSH FOR IMPELLER SHAFT 35601 BEARING SHELL FOR BEARING BUSH 38800 COUPLING GUARD 39000 PUMP COUPLING 39100 MOTOR COUPLING 39500 SCREWED COUPLING IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 30 30 30 30 of 50 50 50 Revision: 00...
- Page 34 WASHER FOR RISING PIPE NUT SCREW FOR SHELL FOR BUSH UNDER BEARING. 66600 SPIDER 68001 GASKET FOR RISING PIPE NUT 68201 GASKET FOR IMPELLER AND IMPELLER NUT IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 31 31 31 31 of 50 50 50 Revision: 00...
- Page 35 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 32 32 32 32 of 50 50 50 Revision: 00...
- Page 36 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 33 33 33 33 of 50 50 50 Revision: 00...
- Page 37 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 34 34 34 34 of 50 50 50 Revision: 00...
- Page 38 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 35 35 35 35 of 50 50 50 Revision: 00...
- Page 39 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 36 36 36 36 of 50 50 50 Revision: 00...
- Page 40 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 37 37 37 37 of 50 50 50 Revision: 00...
- Page 41 15. EXPLODED VIEW: IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 38 38 38 38 of 50 50 50 Revision: 00...
- Page 42 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 39 39 39 39 of 50 50 50 Revision: 00...
- Page 43 IOM/KPDS/NOV 19/00 Issue Date : 22/11/2019 Page 40 40 of 50 40 40 50 50 Revision: 00...
- Page 44 Issue Date: 10/08/2007 IOM/KPDS Page 41 of 50 Last Revision:20/07/2017...
- Page 45 Issue Date: 10/08/2007 IOM/KPDS Page 42 of 50 Last Revision:20/07/2017...
- Page 46 Issue Date: 10/08/2007 IOM/KPDS Page 43 of 50 Last Revision:20/07/2017...
- Page 47 Issue Date: 10/08/2007 IOM/KPDS Page 44 of 50 Last Revision:20/07/2017...
- Page 48 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. It should also be ensured that the product...
- Page 49 Do not operate water pumps in temperatures below freezing point, without first checking that the pumped fluid is not frozen and the pump is free to turn. Pumps in these environments should be drained down during inactivity and re-primed before starting. Issue Date: 10/08/2007 IOM/KPDS Page 46 of 50 Last Revision:20/07/2017...
- Page 50 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 TO AVOID HARMFUL IMPACT (IF ANY) ON ENVIRONMENT. Issue Date: 10/08/2007 IOM/KPDS Page 47 of 50 Last Revision:20/07/2017...