KIRLOSKAR UP 50/30A Programming manual

INSTRUCTION ON
INSTALLTION,
OPERATION &
MAINTENANCE
FOR KIRLOSKAR PUMP
TYPE UP METRIC
KIRLOSKAR BROTHERS LIMITED
“Yamuna”S.No.98/3 to 7, Baner, Pune 411045

CONTENTS
1. GENERAL
2. SAFETY INSTRUCTIONS
3. INSTALLATION
4. OPERATION
5. TECHNICAL DATA
6. MAINTENANCE
7. O ERHAULING
8. GENERAL OUTLINE DIMENSIONS
9. SPARE PART LIST AND CROSS-SECTIONAL DRAWINGS
10. EXPLODED IEW.
Please ensure these instru tions are read fully before installation and operation of the
pump.
Please furnish omplete name plate details, part des ription, part nos, material onstru tion
and quantity while ordering spare parts.

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1. GENERAL
1.1 The booklet covers instructions for following types of UP (M) pumps.
UP 50/30A UP 125/24 UP 150/38BC
UP 50/30B UP 125/30A UP 150/45
UP 65/24 UP 125/30B UP 150/45 BC
UP 65/24A UP 100/35 UP 200/30
UP 80/24 UP 100/38 UP 200/38
UP 65/38 UP 125/35 UP 250/30
UP 65/38M UP 150/26N UP 250/38
UP 80/30 UP 150/30 UP 150/53A
UP 80/38 UP 150/30A(N) UP 150/53F
UP 100/24 UP 150/38A UP 200/42
UP 100/29 UP 150/38B
1.2 These are horizontal split asing type pumps with su tion and dis harge nozzles and
their supporting feet integrally ast in the lower half asing. This onstru tion
enables to remove the rotating unit for inspe tion and repairs by just removing upper
half asing, and without disturbing alignment, pipe onne tion or prime mover.
1.3 Pumps when properly installed and given due are in operation and maintenan e
should operate satisfa torily for a long period.
1.4 When the pump is re eived, sometime before the a tual use of pump, it should be
inspe ted and lo ated in dry pla e. The oupling should be rotated periodi ally (on e
in a month) to prevent pitting of bearing surfa es.
1.5 Generally all the UP pumps mentioned above are similar in onstru tion with minor
hanges of some parts.
1.6 Pump Identifi ation: All pumps are designated by serial number, model number, size
and type. This information is stamped on an identifi ation plate whi h is fixed on the
pump.

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1.7 Nomenclature of the pump
Nomen lature for pump is as given below.
UP 100/35
UP- Basi pump type
100- Nominal Delivery size in mm
/ - Always slash
35- Nominal Impeller diameter in m.
PUMP DESCRIPTION
Casing - The asing is of axially-split volute design with su tion and dis harge flanges and
mounting feet ast integral with the lower half asing. Tapped and plugged holes are
provided for priming, vent, drain and gauge onne tions. Upper half asing is
removable without disturbing su tion or dis harge piping.
Su tion and Dis harge is on a ommon enterline in both the horizontal and verti al
planes.
Impeller - The impeller is of the en losed double-su tion (ex ept UP 150/56 pump),
stati ally and hydrauli ally balan ed. The impeller is keyed to the shaft and
positioned axially by the shaft sleeves. Hub shall have suffi ient metal thi kness to
allow ma hining for installation of asing wear rings.
Shaft - The shaft shall be of ample size to operate under load with of minimum defle tion.
Shaft Sleeves - The shaft sleeves should prote t the shaft from wear and from onta t
with the pumped liquid. An O-ring shall be furnished under sleeve to prevent
leakage.
Insert (Stuffing Box) - The insert is onsisting of at least six pa king rings and a split
type gland to permit removal and a ess to pa king. Ample spa e is provided for
repa king the insert.
Bearings - The bearings are grease lubri ated or oil lubri ated. The inboard or oupling
end bearing is a single row ball bearing. The outboard bearing is a double row
ylindri al roller bearing whi h is retained by bearing lo knut and lo k washer.

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Bearing Housings - The bearing housings are bolted to the end of the lower half asing
and assure positive alignment of the rotating element. The housings provides a fit for
the inboard bearing that allows freedom for thermal expansion while the outboard
bearing is lamped in pla e to take all thrust loads and keep the rotating element in
its proper axial lo ation.
Base plate - The base plate is suffi iently rigid to support the pump and driver and shall
be provided with a drip pan beneath the pump. The drip pan ontains a tapped drain
onne tion.
Coupling - Coupling an be supplied – Snap-wrap / Pin-Bush / Spa er type
Coupling Guard - The oupling guard an be in MS / AL / Bronze.
Rotation - Pump an have lo kwise or ounter lo kwise rotation when viewed from its
driving end

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2. SAFETY INSTRUCTIONS:
2.1: General Information
Before performing any a tions detailed within this instru tion, the Site Health and
Safety instru tions must read and fully understood. The instru tions in this
do ument also must be read and fully understood.
Whenever the equipment is operated, maintained or used in any way, the pro edures
detailed within the Health and Safety Dossier (DHS) and any pro edures detailed
within these instru tions shall be followed. The pump supplied by Kirloskar Brothers
Limited (KBL) has been designed with safety in mind, where hazards annot be
eliminated; the risk has been minimized by the use of guards and other design
features. Some hazards annot be guarded against and the instru tions below MUST
BE COMPLIED WITH for safe operation. These instru tions annot over all
ir umstan es. It is the responsibility of the user of the equipment for maintaining
safe working pra ti es at all times.
2.1.1 KBL produ ts are designed for installation in designated areas, whi h are to be kept
lean and free of obstru tions that may restri t safe a ess to the ontrols and
maintenan e a ess points.
2.1.2 Pump nameplate is fitted to ea h unit and must not be removed. Loss of this plate
ould make identifi ation impossible. This in turn ould affe t safety and ause
diffi ulty in obtaining spare parts. Should a idental loss or damage o ur, onta t
KBL immediately.
2.1.3 A ess to the equipment should be restri ted to the personnel responsible for
installation, operation and maintenan e and they must be trained, adequately
qualified and supplied with the appropriate tools for their respe tive tasks.
2.1.4 KBL firmly insists that all personnel responsible for installation, operation and
maintenan e of the equipment must read safety instru tions mentioned in the
manual before any work is done.

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2.1.5 Ear defenders should be worn where the spe ified equipment noise level ex eeds
lo ally defined safe levels. Safety glasses or goggles should be worn where working
with pressurized systems and hazardous substan es. Other personal prote tion
equipment must be worn where lo al rules apply.
2.2 DO NOT wear loose or frayed lothing or jewellery, whi h ould at h on the
ontrols or be omes trapped in the equipment.
2.3 Operation of the equipment for the appli ation other than for whi h it is supplied an
in rease the risk from hazards. Please onsult KBL before making su h hange in
the appli ation of the equipment.
2.4 Improper installation, operation and maintenan e of the produ t supplied by KBL
ould result in injury or death.
2.5 Within the manual, safety instru tions are marked with safety symbols.
Hazard
This symbol refers to general me hani al aspe ts of safety.
Hazard
This symbol refers to ele tri al safety.
2.6: Transport handling and storage instructions:
2.6.1: Transport
Pumps are dispat hed in duly assembled ondition. Pumps are prote ted against
orrosion and pa ked for transport by normal road, rail and sea arriers.
2.6.2: Handling
Crushing hazard
When lifting the pump or pump set, use lifting equipment having a safe working load
rating suitable for the weight spe ified. Use suitable slings for lifting any pump not
provided with lifting points.

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The use of suitable forklift tru k and four hain rane sling equipment is
re ommended but lo ally approved equipment rating may be used.
Pump should be slung as shown.
PU M P LIFTIN G A RRA N G EM EN T
Pump set must be lifted from the lifting holes provided on the pump by using
suitable four hain lifting equipment.
90°
Max.
PUMP SET LIFTING ARRANGEMENT

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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 arefully in a
horizontal position, in a sheltered, dry lo ation. Additional rust preventive should be
applied to all unpainted arbon steel or ast iron parts, and should not be removed
until final installation.
2.6.3.2: Long Term Storage.
If the pump is not to be installed and operated soon after arrival, store it in a
lean, dry pla e, having slow, moderate hanges in ambient temperature. Step
should be taken to prote t the pump from moisture, dust, dirt, and foreign bodies. It
is re ommended that the following pro edure is taken:-
a) Ensure that the bearings are pa ked with the re ommended grease, to prevent
moisture from entering around the shaft.
b) Remove the glands, pa kings and lantern rings from the stuffing box if the pump
is equipped in this manner. If the pump is equipped with me hani al seal, dismantle
and oat the seal with light oil.
) Ensure that su tion and dis harge bran hes of the pump and all other openings
are overed with ardboard, wood or masking tape to prevent foreign obje ts
entering the pump.
d) If the pump is to be stored where there is no prote tive overing, it is advisable to
over the unit with a tarpaulin or other suitable overing.
e) The shaft should be manually rotated periodi ally to prevent pitting of the bearing
surfa es by moisture.
Shearing Hazard.
Do NOT pla e fingers or hands et . into the su tion or dis harge pipe outlets and do
NOT tou h the impeller, if rotated this may ause severe injury. To prevent ingress
of any obje ts, retain the prote tion overs or pa kaging in pla e until removal is

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ne essary for installation. If the pa kaging or su tion and dis harge overs are
removed for inspe tion purposes, repla e afterwards to prote t the pump and
maintain the safety.
Fill the bearing housing with re ommended grease to ensure that the shaft and
bearings remain rust free.
2.6.3.3: Exposed or Extreme Conditions Storage.
For exposed storage or extreme variants in atmospheri or environmental onditions,
please refer to KBL for spe ial storage instru tions to suit the onditions a eptable.
3 INSTALLATIONS
3.1 Receiving pump
Upon re eipt of the pump, a visual he k should be made to determine if any
damage o urred during transit or handling. The main items to look for are:-
a) Broken or ra ked equipment, in luding base, motor or pump feet and flanges.
b) Bent shaft
) Broken motor end bells, bent eyebolts or damaged boxes of motor
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. DO
NOTLIFT ONLY THE DRIVER OR PUMP.

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3.2 Preparation
Before installing the pump, lean the su tion and dis harge flanges thoroughly.
Remove the prote tive oating from the pump shaft.
If the pump has been in storage and prepared for storage in the manner outlined
previously, remove all the grease from the bearings. The bearings should then be
flushed with arbon tetra hloride or kerosene and relubri ated.
3.3 Location
The pump should be installed as near the su tion supply as possible, with the
shortest and most dire t su tion pipe pra ti al. The total dynami su tion lift (stati lift
plus fri tion losses in su tion line) should not ex eed the limits for whi h the pump was
sold.
The pump must be primed before starting. Whenever possible, the pump should be
lo ated below the fluid level to fa ilitate priming and assure a steady flow of liquid. This
ondition provides a positive su tion head on the pump. It is also possible to prime the
pump by pressurizing the su tion vessel.
Pumps must be fully primed at all times during operation.
When installing the pump, onsider its lo ation in relation to the system to assure that
suffi ient Net Positive Su tion Head (NPSHA) is available at the pump inlet onne tion.
Available NPSH must always equal or ex eed the required NPSH (NPSHR) of the pump.
The pump should be installed with suffi ient a essibility for inspe tion and
maintenan e. A lear spa e with ample head room should be allowed for the use of an
overhead rane or hoist suffi iently strong to lift the unit.
NOTE: Allow sufficient space to be able to dismantle pump without disturbing the
pump inlet and discharge piping.

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Sele t a dry pla e above the floor level wherever possible. Take are to prevent
pump from freezing during old weather when not in operation. If the possibility of
freezing exists during a shut-down period, the pump should be ompletely drained, and
all passages and po kets where liquid might olle t should be blown out with
ompressed air.
Make sure there is a suitable power sour e available for the pump driver. If motor
driven, the ele tri al hara teristi s of the power sour e should be identi al to those
shown on motor data plate.
3.4 Foundation
The foundation should be strong enough to redu e vibrations and rigid enough to avoid
any twisting or misalignment.
The foundation should be poured without interruptions to within 20 to 40 mm of the
finished height. The top surfa e of the foundation should be well s ored and glued
before the on rete sets. This provides a bonding surfa e for the grout. Foundation
bolts should be set in on rete as shown in Fig. 1. Allow enough bolt length for
grout,shims, lower base plate flange, nuts and washers. The foundation should be
allowed to ure for several days before the base plate is shimmed and grouted.
3.5 Baseplate setting
Use blo ks and shims under base for support at foundation bolts and midway
between bolts, to position base approximately 25 mm above the on rete
foundation with studs extending through hole in the baseplate.
By adding or removing shims under the base, level the pump shaft and flanges. The
baseplate does not have to be leveled. Draw foundation bolt nuts tight against
baseplate and observe pump and motor shafts or oupling hubs for alignment.
Che k to make sure the piping an be aligned to pump flanges without pla ing pipe
strain on either flange.

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Grout baseplate in ompletely and allow grout to dry thoroughly before atta hing
piping to pump (24 hours is suffi ient time with approved grouting pro edure).
3.6 Grouting procedure
Grout ompensates for uneven foundation, distributes weight of unit and prevents
shifting. Use an approved, non-shrinking grout as follows, after setting and leveling
unit See Fig. 2.
a) Build strong form around foundation to ontent grout.
b) Soak top of on rete foundation thoroughly, then remove surfa e water.
) Baseplate should be ompletely filled with grout and, if ne essary, drill vent holes
to remove trapped air.
d) After grout has thoroughly hardened, he k the foundation bolts and tighten if
ne essary.
e) Che k the alignment after the foundation bolts are tightened.
f) Approximately 14 days after the grout has been poured or when the Grout has
thoroughly dried, apply an oil base paint to the exposed edges of the grout to
prevent air and moisture from oming in onta t with the grout.
3.7 Alignment procedure
The pump driver, if supplied, is orre tly aligned on its base plate at the fa tory. A
ertain amount of deformation of the base plate is possible during transit and it is
therefore essential to he k alignment, prior to final grouting.
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.
Coupling alignment an be he ked with dial gauge Indi ator also. Alignment should
be performed after the base plate has been properly set and grout has dried

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thoroughly a ording to instru tions. Final alignment should be made by shimming
driver only.
Alignment should be made at operating temperatures.
After final alignment, it is ne essary to dowel pump and driver feet to the baseplate.
FACTORS THAT MAY DISTURB ALIGNMENT
The unit should be periodi ally he ked for alignment. If the unit does not stay in
line after being properly installed, the following are possible reasons:
a) Setting, Seasoning of the foundation.
b) Pipe strains, distorting or shifting of the ma hines.
) Wear of the bearings.

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3.8 Suction and Discharge Piping
When installing the pump piping, make sure to observe the following pre autions:-
Piping should always run to the pump. Do not move pump to pipe. This ould make
final alignment impossible.
Both suction and discharge piping should be supported independently and close to
pump so that no strain is transmitted to the pump when the flange bolts are
tightened.
Use pipe hangers or other supports at necessary intervals to provide support. When
expansion joints are used in the piping system, they must be installed beyond the
piping supports close to the pump.
It is advisable to in rease the size of both su tion and dis harge pipes at the pump
onne tion to de rease the loss of head from fri tion.
Install piping as straight as possible, avoiding unne essary bends. Where ne essary,
use 45 degree or long sweep 90 degree fitting to de rease fri tion losses.
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.
The suction pipe should be as short & direct as possible. Where suction lift is not
very high, it is advisable to use a foot valve. Horizontal suction line must have a
gradual rise to the pump.
The dis harge pipe is usually pre eded by a non-return valve or he k valve and a
dis harge gate valve (See Fig. 5). The he k valve is to prote t the pump from
ex essive ba k pressure and reverse rotation of the unit and to prevent ba k flow
into the pump in ase of stoppage or failure of the driver. The dis harge valve is
used in priming, starting and when shutting down the pump.

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4 OPERATION
4.1 Before Starting
Before initial starting of the pump, make the following inspe tion:
4.1.1 The unit baseplate is grouted and bolted to the foundation.
4.1.2 Alignment between pump and motor.
4.1.3 Motor is orre tly wired to starting devi e, he k voltage, phase and frequen y on
motor nameplate with line ir uit. Ensure orre t dire tion of rotation prior to
oupling to pump. Che k by starting motor and swit hing off immediately. Observe
rotation is the same as the arrow dire tion on the pump asing.
4.1.4 Bearing lubri ation is provided (see lubri ation se tion), also he k driver lubri ation.
4.1.5 Me hani al seal has been fitted or stuffing box has been pa ked.
4.1.6 All rotating parts are found to be free when turned by hand.
4.1.7Pump is primed. Never run the unit dry. The liquid in the pump serves as a lubri ant
for lose running fits within the pump and the pump may be damaged if operated
dry. The pump may be primed by using an eje tor, exhauster or va uum pump. If a
foot valve is used in the su tion line, the pump may be primed by venting and filling
the asing with liquid.
4.2 Starting
4.2.1 Close valve in dis harge line.
4.2.2 Open fully all valves in the su tion line.
4.2.3 Turn on seal water to the stuffing box where external pipe supplied.
4.2.4 Prime the pump.
4.2.5 Start the pump driver.
4.2.6 When the pump is operating at full speed, open the dis harge valve slowly.
Do not operate pump for prolonged periods with losed dis harge valve, so as to avoid
overheating.
The pump should be shut down at on e and the trouble orre ted if the pump is running at
its rated speed and found to have any of the following defe ts:
a) No liquid delivered.

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b) Not enough liquid delivered.
) Not enough pressure.
d) Loss of liquid after starting.
e) Ex ess vibration.
f) Motor runs hot.
g) Pump bearing overheating.
4.3 Running
While the pump is running, a periodi inspe tion should be made of:
a) Stuffing box (soft pa ked pumps only). Ensure there is suffi ient leakage to
lubri ate the pa king.
b) Bearings. Che k the bearings for temperature, whi h should not ex eed pumped
liquid temperature or 80 Deg. C whi hever is the lower.
) With me hani al seal fitted pumps, he k that there is no leakage from the
stuffing box.
d) Su tion and dis harge gauge readings.
4.4 Stopping
a) Slowly lose delivery valve and shut down driving unit in a ordan e with
manufa turer’s instru tions.
b) Shut off external sealing liquid supply, if supplied, to relieve stuffing box pressure.
) Su essful operation of the pump depends on a urate alignment. It is
re ommended to re- he k the alignment after preliminary run.

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