KIRLOSKAR i-HT Instruction On Installation, Operation And Maintenance
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KIRLOSKAR i-HT Instruction On Installation, Operation And Maintenance

KIRLOSKAR i-HT Instruction On Installation, Operation And Maintenance

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INSTRUCTIONS
ON
INSTALLATION OPERATION
AND
MAINTENANCE
FOR
KIRLOSKAR PUMP
TYPE – i-HT

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Summary of Contents for KIRLOSKAR i-HT

  • Page 1 INSTRUCTIONS INSTALLATION OPERATION MAINTENANCE KIRLOSKAR PUMP TYPE – i-HT...

  • Page 3: Table Of Contents

    CONTENTS GENERAL 2 SAFETY INSTRUCTIONS 3. INSTALLATION 4. OPERATION 5. TECHNICAL DATA 6. MAINTENANCE 7. OVERHAULING 8. SPARE PART LIST AND CROSS-SECTIONAL DRAWINGS 9. GENERAL OUTLINE DIMENSIONS Please ensure these instructions are read fully before installation and operation of the pump.

  • Page 4: General

    (once in a month) to prevent pitting of bearing surfaces. 1.5 Generally all the i-HT pumps mentioned above are similar in construction with minor changes of some parts. 1.6 Pump identification: All pumps are designated by serial number, model number, size and type.

  • 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; the risk has been minimized by the use of guards and other design features.
  • Page 6 pressurized systems and hazardous substances. Other personal protection equipment must be worn where local rules apply. DO NOT wear loose or frayed clothing or jewellery, which could catch on the controls or becomes trapped in the equipment. Operation of the equipment for the application other than for which it is supplied can increase the risk from hazards.

  • Page 7: Installation

    Pump set must be lifted from the lifting holes provided on the pump by using suitable four chain lifting equipment. 2.6.3: Storage. 2.6.3.1: Temporary storage for up to six weeks. If the pump unit is not be used immediately it should be stored carefully in a horizontal position, in a sheltered, dry location.
  • Page 8 b) Remove the glands, packings and lantern rings from the stuffing box if the pump is equipped in this manner. If the pump is equipped with mechanical seal, dismantle and coat the seal with light oil. c) Ensure that suction and discharge branches of the pump and all other openings are covered with cardboard, wood or masking tape to prevent foreign objects entering the pump.
  • Page 9 d) Missing parts. e) Pump shaft rotates freely. Parts or accessories are some times wrapped individually or fastened to the equipment. If any damage or losses have been incurred; promptly notify your 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.
  • Page 10 base plate flange, nuts and washers. The foundation should be allowed to cure for several days before the base plate is shimmed and grouted. 3.5 Base plate setting Use blocks and shims under base for support at foundation bolts and midway between bolts, to position base approximately 25 mm above the concrete foundation with studs extending through hole in the baseplate.
  • Page 11 A flexible coupling will only compensate for small amount of misalignment and should not be used to compensate for excessive misalignment of the pump and driver shafts. Inaccurate alignment results in vibration and excessive wear on the bearings, sleeve or shaft and wear rings.
  • Page 12 IOM/i_HT Issue Date: 26/06/2009 Page 12 of 50 Last Revision:26/10/2009...

  • Page 13: Operation

    Make sure that all piping joints are air tight. Provide pipe expansions bellows when hot fluids are to be pumped. Where reducers are used, eccentric reducers are to be fitted in suction lines and straight taper reducers in discharge and vertical lines (See Fig.5). Misuse of reducers may cause the formation of air pockets in the pipe and thus preventing the correct operation of the pump.
  • Page 14 4.1.7 Pump is primed. Never run the unit dry. The liquid in the pump serves as a lubricant for close running fits within the pump and the pump may be damaged if operated dry. The pump may be primed by using an ejector, exhauster or vacuum pump. If a foot valve is used in the suction line, the pump may be primed by venting and filling the casing with liquid.
  • Page 15 c) With mechanical seal fitted pumps, check that there is no leakage from the stuffing box. d) Suction and discharge gauge readings. 4.4 Stopping a) Slowly close delivery valve and shut down driving unit in accordance with manufacturer’s instructions. b) Shut off external sealing liquid supply, if supplied, to relieve stuffing box pressure. c) Successful operation of the pump depends on accurate alignment.

  • Page 16: Technical Data

    Groove Ball Angular Contact Pump Model Bearing Module Bearing Paired Bearing (Face to Face) i-HT 06 BA i-HT 08 BA i-HT 12 CA i-HT 08 BD 6306 7306(BECB) i-HT 08 BE i-HT 10 DE i-HT 12 CF i-HT 12 CG...
  • Page 17 Bearing DE Bearing NDE Pump Model Bearing Module Deep Groove Ball Bearing i-HT 12 XD 6411 6411 i-HT 15 XE i-HT 15 XF i-HT 05 AA 6307 6307 i-HT 06 AA 6309 6408 5.3 Special care for Bearings These instructions...
  • Page 18 5.4 Lubrication Details Initially bearings are lubricated during assembly. In the regreasing period these bearings should be repacked with a high quality, lithium soap base, ball and roller bearing grease free from resin and acid, not liable to harden or crumble and possessing rust preventive properties.
  • Page 19 Pump Fig. D1 Tol.H7. D2 Tol.c9. DiametralClearances Type Min. Min. 115.000 115.035 114.733 114.820 0.180 i-HT06BA 0.302 115.000 115.035 114.733 114.820 0.180 i-HT08BA 0.302 120.000 120.035 119.733 119.820 0.180 i-HT08BD 0.302 120.000 120.035 119.733 119.820 0.180 i-HT08BE 0.302 150.000 150.040 149.690 149.790 0.210 i-HT10BA...
  • Page 20 5.6 Impeller Details Full. Impeller Min. Impeller Pump Type Impeller Type Dia. In mm. Dia. In mm. i-HT06BA Double Entry i-HT08BA Double Entry i-HT08BD Double Entry i-HT08BE Double Entry i-HT10BA Double Entry i-HT10BD Double Entry i-HT10BE Double Entry i-HT10DE Double Entry i-HT10ED Double Entry i-HT12BA...
  • Page 21 5.7 Stuffing Box Details Mech Sr.No. i-HT Model seal i-HT06BA, i-HT08BA, i-HT12CA, i-HT08BD i-HT08BE, i-HT10DE, i-HT12CF, i-HT12CG i-HT12BA, i-HT12DA, i-HT15BA, i-HT12EA, i-HT15DA,i-HT10BA, i-HT10BD, i-HT10BE, i-HT12BD, i-HT12BE,i-HT12BF, i-HT12DF, i-HT15BE, i-HT15DF, i-HT10ED i-HT20DE, i-HT20DD, i-HT20ED IOM/i_HT Issue Date: 26/06/2009 Page 21 of 50...
  • Page 22 5.9 Interchangeability of Components Two Stage IOM/i_HT Issue Date: 26/06/2009 Page 22 of 50 Last Revision:26/10/2009...

  • Page 23: Maintenance

    6. MAINTENANCE. Maintenance EHS (Environmental Hazard Safety) 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. Hazardous Gases, Mists, Sprays and Leaks.

  • Page 24: Overhauling

    Isolate the equipment before any maintenance work is done. Switch off the mains supply, remove fuses, apply lockouts where applicable and affix suitable isolation warning signs to prevent inadvertent re-connection. In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapours, 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.
  • Page 25 2. Remove all casing main joint nuts (58001) and dowel pins (61100). Remove flushing piping. 3. Insert a screw driver or peg bar into the slots between the Upper and Lower half casing and separate the halves, lifting off the upper half casing. 4.
  • Page 26 ASSEMBLY PROCEDURE For clockwise rotation Wipe shaft [18000] with clean light oil. Screw impeller nut [33000] onto shaft at drive end as per dimension “A” given on page34. Place impeller key [32000] into key way and tap milled-down end right home under sleeve.
  • Page 27 Slide the heated bearing onto the shaft to about shoulder ring [19900] [coupling end]. Cool the bearing to room temperature and coat both sides with recommended grease. Coat the inside of the bearing housing [24001] with grease and slide into place over bearing.
  • Page 28 Check impeller for correct rotation page 31 and slide onto shaft from drive end. Screw second impeller locking nut [33000] or shaft sleeve onto shaft at drive end and using hook spanner, lock up tight against the impeller hub. From step 5 the assembly procedure is the same as for clockwise rotation pumps.
  • Page 29 7.5 Assembly Procedure 1. Check the “O” rings (522) for cut or flows, discard if faulty, lubricate and roll the “O” ring in groove. 2. Wipe over the shaft (180) with clean light oil. 3. Place the impeller key (320) into the keyway and interstage ring (204) along with interstage bush (313).
  • Page 30 Check whether both Impellers are centrally placed in volute. If it did not, adjust NDE sleeve. Place the cylindrical pins (used to locate the wear ring) in their respective holes. Install casing gasket (519) with a light coat grease on both gasket surfaces.
  • Page 31 IOM/i_HT Issue Date: 26/06/2009 Page 31 of 50 Last Revision:26/10/2009...
  • Page 32 JOINT FLANGE TIGHTENING TORQUES AND SEQUENCE Stud and Nut use in this main joint flange of SCT pumps should be tightened to the torques stated in table 1 and in the sequence stated in Fig. STUD SIZE TIGHTENING TORQUES 160 N.meters 360 N.meters 600 N.meters 2.
  • Page 33 IOM/i_HT Issue Date: 26/06/2009 Page 33 of 50 Last Revision:26/10/2009...
  • Page 34 Clockwise Pump CCW pump Pump Type “A” “Z” i-HT06BA i-HT08BA i-HT08BD i-HT08BE i-HT10BA i-HT10BD i-HT10BE i-HT10DE i-HT10ED i-HT12BA i-HT12BD i-HT12BE i-HT12BF i-HT12CA i-HT12CF i-HT12CG i-HT12DA i-HT12DF i-HT12EA i-HT15BA i-HT15BE i-HT15DA i-HT15DF i-HT20DD i-HT20DE i-HT20ED i-HT12XD i-HT15XE i-HT15XF i-HT05AA i-HT06AA IOM/i_HT Issue Date: 26/06/2009 Page 34 of 50 Last Revision:26/10/2009...

  • Page 35: Spare Part List And Cross-Sectional Drawings

    8.0 SPARE PART LIST AND CROSS SECTIONAL DRAWINGS * marked part code nos. are recommended spares. Part code no. Part description 12200 CASING HALF UPPER 12300 CASING HALF LOWER 15900* IMPELLER 19000* WEARING RING 19900 SHOULDER RING 24001 BEARINF HOUSING DE 24002 BEARING HOUSING NDE 26000*...
  • Page 36 IOM/i_HT Issue Date: 26/06/2009 Page 36 of 50 Last Revision:26/10/2009...
  • Page 37 IOM/i_HT Issue Date: 26/06/2009 Page 37 of 50 Last Revision:26/10/2009...
  • Page 38 IOM/i_HT Issue Date: 26/06/2009 Page 38 of 50 Last Revision:26/10/2009...

  • Page 39: General Outline Dimensions

    9. GENERAL OUTLINE DIMENSIONS IOM/i_HT Issue Date: 26/06/2009 Page 39 of 50 Last Revision:26/10/2009...
  • Page 40 IOM/i_HT Issue Date: 26/06/2009 Page 40 of 50 Last Revision:26/10/2009...
  • Page 41 IOM/i_HT Issue Date: 26/06/2009 Page 41 of 50 Last Revision:26/10/2009...
  • Page 42 IOM/i_HT Issue Date: 26/06/2009 Page 42 of 50 Last Revision:26/10/2009...
  • Page 43 IOM/i_HT Issue Date: 26/06/2009 Page 43 of 50 Last Revision:26/10/2009...
  • Page 44 IOM/i_HT Issue Date: 26/06/2009 Page 44 of 50 Last Revision:26/10/2009...
  • Page 45 IOM/i_HT Issue Date: 26/06/2009 Page 45 of 50 Last Revision:26/10/2009...
  • Page 46 IOM/i_HT Issue Date: 26/06/2009 Page 46 of 50 Last Revision:26/10/2009...
  • Page 47 IOM/i_HT Issue Date: 26/06/2009 Page 47 of 50 Last Revision:26/10/2009...
  • Page 48 LUBRICATION, 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 a safe for personnel around and others.
  • Page 49 equipment is recommended but locally approved equipment of suitable rating may be used. While lifting, the equipment adjusts the center of gravity, so that it is balanced properly. Do not place fingers or hands etc into the suction or discharge pipe outlets and do not touch the impeller, if rotated this may cause severe injury.
  • Page 50 Isolate the equipment before any maintenance work is done. Switch off the main supply, remove fuses, apply lockouts where applicable and affix suitable isolation warning signs to prevent inadvertent reconnection. In order to avoid the possibility of maintenance personnel inhaling dangerous fumes or vapours locations by removal of bearing housing and shaft assembly to a suitable maintenance area.

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