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.

IOM/UP_METRIC Issue Date: 31/12/2007
Page 4 of 66 Last Revision: 12/06/2012
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.

IOM/UP_METRIC Issue Date: 31/12/2007
Page 5 of 66 Last Revision: 12/06/2012
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.

IOM/UP_METRIC Issue Date: 31/12/2007
Page 6 of 66 Last Revision: 12/06/2012
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

IOM/UP_METRIC Issue Date: 31/12/2007
Page 7 of 66 Last Revision: 12/06/2012
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.

IOM/UP_METRIC Issue Date: 31/12/2007
Page 8 of 66 Last Revision: 12/06/2012
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.

IOM/UP_METRIC Issue Date: 31/12/2007
Page 9 of 66 Last Revision: 12/06/2012
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

IOM/UP_METRIC Issue Date: 31/12/2007
Page 10 of 66 Last Revision: 12/06/2012
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