KIRLOSKAR SHM Instruction On Installation, Operation And Maintenance

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INSTRUCTIONS ON

INSTALLATION

OPERATION AND

MAINTENANCE FOR

KIRLOSKAR PUMP

TYPE SHM

KIRLOSKAR BROTHERS LIMITED

UDYOG BHAVAN, TILAK ROAD, PUNE - 411 002

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Page 1 INSTRUCTIONS ON INSTALLATION OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE SHM KIRLOSKAR BROTHERS LIMITED UDYOG BHAVAN, TILAK ROAD, PUNE - 411 002...
Page 2: Warranty
KIRLOSKAR BROTHERS LIMITED Udyog Bhavan, Tilak Road, Pune 411 002 (India) WARRANTY We warrant that the pump supplied by us is free from defective material and faulty workmanship. This warranty holds good for a period of 12 months from the date of commissioning of the equipment or 18 months from the date of despatch from our factory, whichever is earlier.
Page 3: Table Of Contents
CONTENTS GENERAL INSTALLATION OPERATION TECHNICAL DATA MAINTENANCE OVERHAULING SPECIFICATION LIST AND CROSS-SECTIONAL DRAWING PLEASE FURNISH COMPLETE NAMEPLATE DETAILS, NAME OF PARTS, PART NOS. & MATERIAL CONSTRUCTION WHILE ORDERING SPARE PARTS FOR THE PUMP.
Page 4: General
150/34 150/40 200/32 Note: A) The complete range of SHM pumps is covered by four driving units, thereby reducing inventory and achieving interchangeability of parts. B) The above models can be offered with following impellers. P- Single vane enclosed impeller...
Page 5 Before Commissioning the pumpset, please ensure: 2.3.1 The pipe connections are flushed and tightened properly. 2.3.2 Alignment is proper. 2.3.3 Please refer to Fig.2 for plugs and piping connections in SHM pumps. ELEVATION VIEW FROM VIEW FROM DRIVING END VIEW FROM DRIVING END SUC.SIDE (ST.
Page 6 # Plugged in case of grease stuffing box sealing $ Grease nipple in case of grease stuffing box sealing. 2.3.4 ‘SHM’ pumps are grease lubricated as standard supply. Grease nipples are provided on bearing cover and bearing cartridge. 2.3.5 Optional supply of oil lubrication is available. The pump is provided with constant level oiler.
Page 7: Operation
S P I R I T L E V E L Fig. 3.1 C O R R E C T M E T H O D Fig. 3.2 I N C O R R E C T M E T H O D A L W A Y S F I L L O I L H E R E N E V E R F I L L O I L H E R E Fig 3.3...
Page 8: Technical Data
3.1.6 Valve on delivery side is closed. 3.1.7 The cock for pressure gauge connection is closed. 3.1.8 The stuffing box packing is properly tightened. Starting the pump: 3.2.1 Start the pump. Let the prime mover pick up its full speed. 3.2.2 Open the valve on delivery line slowly to reduce the starting load on the motor.
Page 9 Part Description UNIT NO. Code SHM-7 SHM-9 SHM-11 SHM-13 26001 Ball Bearing DS SKF-6307 SKF-6309 SKF-6411 SKF-6413 26002 Ball Bearing PS SKF-6307 SKF-6309 SKF-6411 SKF-6413 26400 Cylindrical roller bearing PS for heavy duty SKF-NU307 SKF-NU309 SKF-NU411 SKF-NU413 arrangement 50001 Oil seal DS...
Page 10 80°C then grease/oil should be renewed after about every 6 months. Specification of stuffing box packing, gasket packings etc. Part Description UNIT NO. Code SHM-7 SHM-9 SHM-11 SHM-13 Packing ring arrangement with 2 + L +3 2 + L +3...
Page 12: Maintenance
Interchangeability: Parts standardisation is optimised utilising interchangeable components to cover a very wide performance. This unique feature enable the customer to have very low spare parts inventory even though he may have many sizes of these pumps. Interchangeability chart is given in 4.6.1 MAINTENANCE Preventive maintenance schedule is the periodical checks and precautions by which...
Page 13: Overhauling
5.3.6 Piping supports should be checked so that the pipe do not induce unwanted stresses on the pump. PROCEDURE FOR DISMANTLING AND RE-ASSEMBLING. Overhauling- With normal daily operation, the pump will be due for overhaul after about one year. This work is to be done by skilled personnel.
Page 14 Put ‘O’ ring on the cartridge in case of oil lubrication only. Insert internal circlip (48500) in the inner groove of the cartridge. Put a spacer on bearing cartridge, in case of SHMN, SHMR and SHMP pumps and shims in case of SHM-Q pumps. Insert the bearing cartridge from DE of the pump shaft.
Page 15 6.3.11 Put the gasket (51500) on the impeller hub in proper position. 6.3.12 Fit the impeller key (32000) on the shaft. It should enter partly in the shaft sleeve. 6.3.13 Put the casing cover (22000) on the bearing housing. Tighten it by studs and nuts to the bearing housing.
Page 16 6.3.16 Insert the helicoil lock insert (47900) at NDE of shaft fro 7 unit and tighten impeller screw (66900) in shaft by holding the coupling. For 9 & 11- unit insert the helicoil screwlock insert (47900) in impeller nut (33200) and tighten it on the shaft at NDE.
Page 17 PART LIST FOR SHM PUMPS PART CODE PART DESCRIPTION 10500 Pump casing 13000 Pump casing spacer *15100 Impeller enclosed *15300 Impeller semi open *16600 Impeller free flow *18000 Pump shaft *19000 Casing wear ring 20900 Spacer for cartridge 22000 Casing cover...
Page 18 PART CODE PART DESCRIPTION *51202 Gasket for cooling chamber outside *51400 Metallic gasket for cartridge *51401 Gasket for bearing cover *51500 Gasket for impeller and shaft sleeve *51600 Gasket for inspection hole cover *52201 ‘O’ ring for wear plate *52202 ‘O’...
Page 22 GENERAL INFORMATION & SAFETY REQUIREMENTS The products supplied by KBL have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimised 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 23 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. To prevent ingress of any objects, retain the protection covers or packaging in place until removal is necessary for installation.
Page 24 SAFETY INSTRUCTIONS WHILE MAINTENANCE & SERVICING Before attempting any maintenance on a pump particularly if it has been handling any form of hazardous liquid, it should be ensured that the unit is safe to work on. The pump must be flushed thoroughly with suitable cleaner to purge away any of the product left in the pump components.
Page 25 CONCENTRIC TAPER PIECE ECCENTRIC TAPER PIECE INSTRUCTIONS INSTALLATION OPERATION & MAINTENANCE OF KIRLOSKAR CENTRIFUGAL REDUCED SUCTION PIPE INCREASED SUCTION PIPE PUMPS SHORT BEND LONG BEND INSUFFICIENT SUFFICIENT SPACE AROUND SPACE AROUND FOOT VALVE FOOT VALVE ® Registered users – Kirloskar Brothers Ltd.
Page 26 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 the satisfactory performance and if it is operated is excess of the conditions for which it is manufactured, the equipment will be subject to excessive stresses and strains.
Page 27: Factors That May Disturb Alignment
MEASURING 1 Tank under Vacuum WEDGE 2 Vacuum equalizing line 3 Valve 4 Line supplying the seeling liquid 5 Valve 6 Connecting line 7 Valve STRAIGHT EDGE Figure 2 A check for parallel alignment is made by placing a straight-edge across both coupling periphery at the top, bottom and both the sides.
Page 28 FOOT VALVE It is advisable to install a foot valve to facilitate priming. The foot valve should have sufficient clear passage for water. Care must be taken to prevent foreign matter from being drawn into the pump or choking the foot valve and for this purpose an efficient strainer should be provided. STUFFING BOXES AND PACKING Stuffing boxes should be carefully cleaned and the packing placed in them.
Page 29: Spare Parts
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 30 CHECK POINTS 1. Suction pipe, foot valve choked. 29. Packing not suitable for operating conditions. 2. Nominal diameter of suction line too small. 30. Shaft sleeve worn in the region of the packing. 3. Suction pipe not sufficiently submerged. 31. Bearing worn out. 4.
Page 31 INSTRUCTIONS ON INSTALLATION OPERATION AND MAINTENANCE FOR KIRLOSKAR PUMP TYPE SHVT KIRLOSKAR BROTHERS LIMITED UDYOG BHAVAN, TILAK ROAD, PUNE - 411 002...
Page 32 KIRLOSKAR BROTHERS LIMITED Udyog Bhavan, Tilak Road, Pune 411 002 (India) WARRANTY We warrant that the pump supplied by us is free from defective material and faulty workmanship. This warranty holds good for a period of 12 months from the date of commissioning of the equipment or 18 months from the date of despatch from our factory, whichever is earlier.
Page 33 CONTENTS INTRODUCTION FOUNDATION PROCEDURE FOR DISMANTLING AND REASSEMBLY MAINTENANCE TRANSMISSION SHAFT UNIT/DRIVING UNIT ASSEMBLY OPERATION TECHNICAL DATA PLEASE FURNISH COMPLETE NAMEPLATE DETAILS, NAME OF PARTS, PART NOS. AND MATERIAL OF CONSTRUCTION WHILE ORDERING SPARE PARTS FOR THE PUMPS. CAUTION: THIS INSTRUCTION MANUAL COVERS...
Page 34: Introduction
INTRODUCTION This booklet covers instructions for following type of SHVT pumps. SHVT 50/26 SHVT 150/26 SHVT 65/32 7 Unit SHVT 150/32 SHVT 80/26 SHVT 100/40 11 Unit SHVT 200/32 SHVT 100/26 SHVT 150/40 SHVT 150/32 9 Unit SHVT 80/40 SHVT 200/40 13 Unit SHVT 150/50 It is very essential that these instructions be followed in every detail during...
Page 35: Procedure For Dismantling And Reassembly
The top surfaces of the sole plates be leveled to the accuracy of 0.05 mm/m. First of all one sole plate should be adjusted for height and leveled by putting shims below them. Then other sole plate should be leveled with respect to this sole plate with the help of straight edge and spirit level.
Page 36 3.2.10 Remove the casing cover sub-assembly along with gland packed stuffing box, if casing cover is sandwiched type. If casing cover is held by studs and nuts on to the bearing housing, remove these nuts and take out casing cover sub-assembly. 3.2.11 Remove the sleeve (31100) from pump shaft.
Page 37: Maintenance
3.3.4 Put oil seal in the bearing cartridge DE. Insert internal circlip (485) in the inner groove of the cartridge. Put a spacer on bearing cartridge in case of SHM-N, SHM-R and SHM-P pumps and shims in case of SHM-Q pumps. Insert the bearing cartridge from DE of the pump shaft.
Page 38 Daily Checks: 4.1.1 An hourly record of suction and discharge pressure, discharge quantity, input to the pump driver should be maintained. 4.1.2 Bearing temperature, oil level, stuffing box leakage, stuffing box temperature, cooling water inlet and outlet and outlet temperature should be checked. This gives an idea of mechanical performance of the pump.
Page 39: Transmission Shaft Unit/Driving Unit Assembly
TRANSMISSION SHAFT UNIT/ DRIVING UNIT ASSEMBLY Transmission shaft assembly includes major components like motor stool (29000) and metaflex flexible drive shaft (18500). 5.1.1 Assemble the motor on motor stool. The motor shaft should align with pump shaft within 0.05 mm. 5.1.2 Assemble the metaflex flexible drive shaft to motor shaft coupling and pump shaft coupling with the help of soc.
Page 40: Technical Data
6.2.3 Regulate the required flow by adjusting the delivery valve. 6.2.4 Open the cock for pressure gauge connection. During running the pump, check the following things and regulate, if necessary: 6.3.1 The pump is running smoothly. 6.3.2 The flow of sealing liquid is uninterrupted. If necessary provide a sight glass in between the piping.
Page 41 Part Code Description UNIT NO. SHM-7 SHM-9 SHM-11 SHM-13 26001 Ball Bearing DS SKF-6307 SKF-6309 SKF-6411 SKF-6413 26002 Ball Bearing PS SKF-6307 SKF-6309 SKF-6411 SKF-6413 26400 Cylindrical roller bearing PS for SKF-NU307 SKF-NU309 SKF-NU411 SKF-NU413 heavy duty arrangement 50001 Oil seal DS...
Page 42 Cooling of stuffing box 7.5.1 Cool the packed gland stuffing box when pumping liquid temperature is above 90°C. 7.5.2 Cool the mechanical seal, stuffing box when pumping liquid temperature is above 140°C. this limit is subject to change as per seat manufacturers recommendation. 7.5.3 Quantity of stuffing box cooling water with reference to temperature and nominal impeller diameter in cms.
Page 43 SPARE PARTS LIST OF SHVT PUMP PART CODE DESCRIPTION 10500 PUMP CASING * 15100 ENCLOSED IMPELLER * 18000 PUMP SHAFT * 19000 CASING WEAR RING 20900 SPACER FOR BRG. CARTRIDGE 22000 CASING COVER 22400 CLAMPING PLATE * 22700 LANTERN RING * 22900 SPLIT GLAND * 23600...
Page 45 GENERAL INFORMATION & SAFETY REQUIREMENTS The products supplied by KBL have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimised 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 46 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. To prevent ingress of any objects, retain the protection covers or packaging in place until removal is necessary for installation.
Page 47 SAFETY INSTRUCTIONS WHILE MAINTENANCE & SERVICING Before attempting any maintenance on a pump particularly if it has been handling any form of hazardous liquid, it should be ensured that the unit is safe to work on. The pump must be flushed thoroughly with suitable cleaner to purge away any of the product left in the pump components.
Page 48 CONCENTRIC TAPER PIECE ECCENTRIC TAPER PIECE INSTRUCTIONS INSTALLATION OPERATION & MAINTENANCE OF KIRLOSKAR CENTRIFUGAL REDUCED SUCTION PIPE INCREASED SUCTION PIPE PUMPS SHORT BEND LONG BEND INSUFFICIENT SUFFICIENT SPACE AROUND SPACE AROUND FOOT VALVE FOOT VALVE ® Registered users – Kirloskar Brothers Ltd.
Page 49 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 the satisfactory performance and if it is operated is excess of the conditions for which it is manufactured, the equipment will be subject to excessive stresses and strains.
Page 50 MEASURING 1 Tank under Vacuum WEDGE 2 Vacuum equalizing line 3 Valve 4 Line supplying the seeling liquid 5 Valve 6 Connecting line 7 Valve STRAIGHT EDGE Figure 2 A check for parallel alignment is made by placing a straight-edge across both coupling periphery at the top, bottom and both the sides.
Page 51 FOOT VALVE It is advisable to install a foot valve to facilitate priming. The foot valve should have sufficient clear passage for water. Care must be taken to prevent foreign matter from being drawn into the pump or choking the foot valve and for this purpose an efficient strainer should be provided. STUFFING BOXES AND PACKING Stuffing boxes should be carefully cleaned and the packing placed in them.
Page 52 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 53 CHECK POINTS 1. Suction pipe, foot valve choked. 29. Packing not suitable for operating conditions. 2. Nominal diameter of suction line too small. 30. Shaft sleeve worn in the region of the packing. 3. Suction pipe not sufficiently submerged. 31. Bearing worn out. 4.

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