Related Manuals for KIRLOSKAR RKB
Summary of Contents for KIRLOSKAR RKB
- Page 1 INSTRUCTIONS ON INSTALLATION, OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE RKB KIRLOSKAR BROTHERS LIMITED YAMUNA’ Survey No. 98/ 3 to 7, Baner, Pune – 411045, India.
- Page 2 This warranty holds good only for the products manufactured by us. KIRLOSKAR BROTHERS LIMITED...
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Page 3: Table Of Contents
CONSTRUCTION AND OTHER NAME PLATE DETAILS WHILE ORDERING SPARE PARTS FOR THE PUMP. General instructions for installation, operation & maintenance Note: A copy of of ‘Kirloskar pumps’ is attached at the end of this manual. IOM/RKB/OCT 19/00 Page 1 of 56... -
Page 4: General
1. GENERAL: The booklet covers instructions for cold model of RKB pumps. Cold Models pumps (without stuffing box cooling arrangement) are supplied for liquid having temperature up to 90°C. Pumps when properly installed & given due care in operation & maintenance should operate satisfactorily for a long period of time. - Page 5 This symbol refers to general mechanical aspects of safety. Hazard. This symbol refers to electrical safety. This symbol used introduce safety instructions, non- Observance for which may lead to damage to the machine and its functions IOM/RKB/ OCT 19/00 Page 3 of 56 Issue date :23/10/2019 Revision: 00...
- Page 6 Pump should be slung as shown. Pump set must be lifted from the lifting holes provided using suitable four chain lifting equipment. IOM/RKB/ OCT 19/00 Page 4 of 56 Issue date :23/10/2019 Revision: 00...
- Page 7 2.6.3.3 Exposed or Extreme Conditions Storage. For exposed storage or extreme variants in atmospheric or environmental conditions, please refer to KBL for special storage instructions to suit the conditions acceptable. IOM/RKB/ OCT 19/00 Page 5 of 56 Issue date :23/10/2019 Revision: 00...
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Page 8: Equipment Schedule
’GENERAL INSTRUCTIONS INSTALLATION, OPERATION MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed along with this booklet must be followed very carefully. 3.1.3 MOUNTING AND ALIGNMENT A jaw-flex type coupling is used to connect pump shaft to the driver. Follow the instructions as shown below. -
Page 9: Operation
Head and capacity developed by the pump is as specified. Power consumption is within limit. Ensure that there is no mechanical friction in the pump. IOM/RKB/ OCT 19/00 Page 7 of 56 Issue date :23/10/2019 Revision: 00... -
Page 10: Technical Data
TECHNICAL DATA: 5.1 Models: 5.1.1 ‘RKB’ types of pumps are available in models as given in table below. SR NO. PUMP TYPE MAX. STAGES RKB –... - Page 11 5.1.2 RKB pumps are suitable for clear liquids having temp -30 to +90 deg C. 5.2 Direction of rotation: The direction of rotation is clockwise when viewed from driving end. Against specific requirement pump suitable to anticlockwise rotation shall be supplied.
- Page 12 ALVANIA GREASE-3 ALVANIA GREASE-2 PETROLEUM INTERNATIONAL NLGI-3 NLGI-2 GRADE OIL QUANTITY APPLICABLE ONLY FOR RKB 250/46: Oil capacity for DE Bearing 0.30 litre Oil capacity for NDE Bearing 3.00 litre IOM/RKB/ OCT 19/00 Page 10 of 56 Issue date :23/10/2019...
- Page 13 Please refer to the following chart for stuffing box packing size and position of lantern ring. Pump Type Packing Arrangement Packing Size RKB – 32/9E 1+L+4 10 mm x 10 mm RKB – 32/14H 1+L+2 8 mm x 8 mm RKB –...
- Page 14 RKB – 125/30 1+L+4 14 mm x 14 mm RKB – 150/34 1+L+4 14mm x 14 mm RKB – 200/37 1+L+4 16 mm x 16 mm RKB – 250/46 2+L+3 20 mm x 20 mm ‘O’-ring & key specification: Material of O-ring shall be Nitrile rubber.
- Page 15 5.10 KEY SIZES FOR ‘RKB’ PUMPS Location Key for Coupling Key for First Key for Stage Key for Last impeller impeller impeller Part Code No. 32100 32000 32001 32002 Pump Type RKB – 32/9E 8 X 7 X 54L 6 X 4 X 25L...
- Page 16 5.13 Specification for Oil Seals. Oil seals at DE & NDE are identical. PUMP TYPE OIL SEAL SIZE RKB – 32/9E 40 X 52 X 7 Thick RKB – 32/14H Not Required RKB – 40/12L 45 X 60 X 8 Thick RKB –...
- Page 17 5 to 11 RKB – 50/15E 2 to 4 RKB – 50/15L 5 to 7 RKB – 50/16H 8 to 11 RKB – 50/17 2 to 3 3 to 5 RKB – 50/26 4 to 7 RKB – 65/19E 2 to 4 RKB –...
- Page 18 5.15 DIMENSIONS OF WASHER FOR RKB PUMPS. Pump Type d D9 Thickness Theoretical of washer Thickness RKB – 32/9E RKB – 32/14H Not applicable RKB – 40/12L RKB – 40/14H RKB – 50/15E RKB – 50/15L RKB – 50/16H RKB – 50/26 RKB –...
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Page 19: Preventive Maintenance
The washer shall have to be machined to required thickness at the time of assembly of the individual pump considering the axial movement of pump shaft on either side. For RKB 32/14H Pump adjustable washer is not used. 6. PREVENTIVE MAINTENANCE Preventive maintenance schedule is the periodical checks and precautions by which possibilities of failures and breakdowns are minimized. -
Page 20: Overhauling
Do not use hammer to remove brg. / brg. housing. 7.2.14 Remove adjustable washer (20901), liquid deflector (23600), distance sleeve (31700), gland (22300), ‘O’ ring (52200), shaft sleeve (31100). IOM/RKB/ OCT 19/00 Page 18 of 56 Issue date :23/10/2019 Revision: 00... - Page 21 Use bearing two jaw puller as shown in Figure 1. For this, two holes of 10mm dia. are provided on distance sleeve (31700). Use induction heater for localized heating of inner race and remove it after sufficient heating. (Please refer Fig. 1). IOM/RKB/ OCT 19/00 Page 19 of 56 Issue date :23/10/2019 Revision: 00...
- Page 22 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. Caution: IOM/RKB/ OCT 19/00 Page 20 of 56 Issue date :23/10/2019 Revision: 00...
- Page 23 Adopt one of the following methods for mounting the inner race- Heat inner race by induction heating or heating in an oil bath at a temperature of about 80 C and then mount. IOM/RKB/ OCT 19/00 Page 21 of 56 Issue date :23/10/2019 Revision: 00...
- Page 24 (35800) if pump is with renewable wear parts. If they are removed, please note that the case wear rings and inter stage bush should be fitted such that it flushes the surface ‘B’ of the stage IOM/RKB/ OCT 19/00 Page 22 of 56 Issue date :23/10/2019...
- Page 25 (12400) and inter stage bush flushes the surface ‘A’ of the diffuser with guide vanes (12900) and diffuser (12800). STAGE CASING IOM/RKB/ OCT 19/00 Page 23 of 56 Issue date :23/10/2019 Revision: 00...
- Page 26 7.3.10 Gland Packed pump: Mount shaft sleeve (31100), ‘O’ ring (52200), distance sleeve (31700). Insert gland (22300) and liquid deflector (23600) on delivery side. IOM/RKB/ OCT 19/00 Page 24 of 56 Issue date :23/10/2019 Revision: 00...
- Page 27 IOM/RKB/ OCT 19/00 Page 25 of 56 Issue date :23/10/2019 Revision: 00...
- Page 28 SUCTION IMPELLER SUPPORT FOR SUC. CASING SUPPORT FOOT SHAFT Fig. 3 IOM/RKB/ OCT 19/00 Page 26 of 56 Issue date :23/10/2019 Revision: 00...
- Page 29 Use of dummy piece is recommended to avoid cumbersome operation of fitting and removal of actual bearing. Actual bearing may alternatively be used in case dummy piece is not available. IOM/RKB/ OCT 19/00 Page 27 of 56 Issue date :23/10/2019...
- Page 30 FIG.NO.-4 FIG.NO.-5 IOM/RKB/ OCT 19/00 Page 28 of 56 Issue date :23/10/2019 Revision: 00...
- Page 31 IOM/RKB/ OCT 19/00 Page 29 of 56 Issue date :23/10/2019 Revision: 00...
- Page 32 IOM/RKB/ OCT 19/00 Page 30 of 56 Issue date :23/10/2019 Revision: 00...
- Page 33 IOM/RKB/ OCT 19/00 Page 31 of 56 Issue date :23/10/2019 Revision: 00...
- Page 34 We discuss below a typical case. Please refer to Fig. 6 & Fig. 7. Follow below steps- IOM/RKB/ OCT 19/00 Page 32 of 56 Issue date :23/10/2019 Revision: 00...
- Page 35 Insert lock washer and tighten lock nut (33600). Lock the lock washer. Similarly insert lock washer and tighten lock nut at NDE. Tighten the lock nut with half the torque specified under the clause 5.14. Lock the lock washer. IOM/RKB/ OCT 19/00 Page 33 of 56 Issue date :23/10/2019 Revision: 00...
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Page 36: Spare Parts List And Cross-Sectional Drawing
SPECIFICATION LIST FOR RKB PUMPS: PART PART DESCRIPTION CODE 11000 Delivery casing 11300 Suction casing 12400 Stage casing (N-1) 12400 Stage casing with diffuser (For RKB 32/14H only) (N-1) 12800* Diffuser 12900* Diffuser with guide vanes (N-1) 15100* Enclosed impeller 18000* Pump shaft 20900... - Page 37 24000 Bearing housing (DE) 24001 Bearing housing (NDE) 26000 Deep groove ball bearing (Only for RKB 32/9E) 26000 Deep groove ball bearing (For RKB 32/14H) 26300* Angular contact ball bearing 26400* Roller bearing (DE) 27000 Bearing cover (DE) 27100 Bearing cover (NDE)
- Page 38 * Recommended spares N-No. of stages **Up to RKB 65/19 models Qty=4 and above RKB 65/19 Qty=8 IOM/RKB/ OCT 19/00 Page 36 of 56 Issue date :23/10/2019 Revision: 00...
- Page 39 IOM/RKB/ OCT 19/00 Page 37 of 56 Issue date :23/10/2019 Revision: 00...
- Page 40 Delivery Side IV. Cooling Necessary when Feeding of cooling arrangement temperature of water at 7 bars Suction Side and water pumped is maximum pressure Delivery Side more than 105 IOM/RKB/ OCT 19/00 Page 38 of 56 Issue date :23/10/2019 Revision: 00...
- Page 41 Delivery side application Necessary when V. Cooling Feeding of cooling temperature of arrangement Suction water at 7 bars water pumped side and Delivery maximum is more than side pressure IOM/RKB/ OCT 19/00 Page 39 of 56 Issue date :23/10/2019 Revision: 00...
- Page 42 IOM/RKB/ OCT 19/00 Page 40 of 56 Issue date :23/10/2019 Revision: 00...
- Page 43 K IR LO S K A R B R O T H E R S LIM ITE D . KIR LO SK AR W A D I D IST.- SAN G LI (IN D IA) Drawing No: TP12788003-0 IOM/RKB/ OCT 19/00 Page 41 of 56 Issue date :23/10/2019...
- Page 44 IOM/RKB/ OCT 19/00 Page 42 of 56 Issue date :23/10/2019 Revision: 00...
- Page 45 GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION & MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS CO RRE CT IOM/RKB/ OCT 19/00 Page 43 of 56 Issue date :23/10/2019 Revision: 00...
- Page 46 A flexible coupling will not compensate for the misalignment of the pump and driver shafts. The purpose of the flexible coupling is to compensate for temperature changes and to permit the movement of the shafts without interference with each IOM/RKB/ OCT 19/00 Page 44 of 56 Issue date :23/10/2019...
- Page 47 Setting, seasoning of the foundation. b) Pipe strains distorting or shifting the machines. c) Wear of the bearing. IOM/RKB/ OCT 19/00 Page 45 of 56 Issue date :23/10/2019 Revision: 00...
- Page 48 Apply sealing liquid (external sealing) to the shaft seal cage to prevent entry of air in the case of the pumps with packed stuffing box. It is convenient to tap the sealing liquid from the delivery line above the non-return valve. FOOT-VALVE IOM/RKB/ OCT 19/00 Page 46 of 56 Issue date :23/10/2019 Revision: 00...
- Page 49 When there is liquid under some pressure in the discharge pipe, priming can be effected by bypassing the pressured liquid around the check and gate valve. Of course, the initial priming must be effected from some outside source. IOM/RKB/ OCT 19/00 Page 47 of 56 Issue date :23/10/2019 Revision: 00...
- Page 50 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 51 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 CHECK POINTS IOM/RKB/ OCT 19/00 Page 49 of 56 Issue date :23/10/2019 Revision: 00...
- Page 52 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). IOM/RKB/ OCT 19/00 Page 50 of 56 Issue date :23/10/2019 Revision: 00...
- Page 53 Some hazards cannot be guarded against and the instructions below MUST BE COMPLIED WITH for safe operation. These instructions cannot cover circumstances. Installation, operation maintenance personnel must use safe working practices at all the times. IOM/RKB/ OCT 19/00 Page 51 of 56 Issue date :23/10/2019 Revision: 00...
- Page 54 Note the “Limits of product application permissible use” specified in the manual. Operation of the equipment beyond these limits will increase the risk from hazards noted below and may lead to premature and hazardous pump failure. IOM/RKB/ OCT 19/00 Page 52 of 56 Issue date :23/10/2019...
- Page 55 PROPERTY DAMAGE. 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 also be ensured that the product will not be damaged or made unsafe by the operation, lubrication and maintenance or repair procedures you choose.
- Page 56 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 IOM/RKB/ OCT 19/00 Page 54 of 56 Issue date :23/10/2019...
- Page 57 Store all oily rags or other flammable material in a protective container in a safe place. Do not weld or flame cut on pipes/tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before IOM/RKB/ OCT 19/00 Page 55 of 56 Issue date :23/10/2019...
- Page 58 Adequacy of suitable crane should be checked before lifting the pump/pump components. Also condition of pulleys, chain and lifting shackles should be checked before use. IOM/RKB/ OCT 19/00 Page 56 of 56 Issue date :23/10/2019 Revision: 00...