KIRLOSKAR HSC LLC User manual

1
INSTRUCTIONS ON
INSTALLATION,
OPERATION & MAINTENANCE
FOR KIRLOSKAR PUMP TYPE
HORIZONTAL SPLIT CASE-
“HSC LLC”
KIRLOSKAR BROTHERS LIMITED
“Yamuna” S.No.98/3 to 7, Baner, Pune 411045

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CONTENTS
SR. NO. PAGE NO.
1. GENERAL 04
. SAFETY INSTRUCTIONS 07
3. INSTALLATIONS 1
4. OPERATION 19
5. TECHNICAL DATA 3
6. MAINTENANCE 35
7. OVERHAULING 38
8. GENERAL OUTLINE DIMENSIONS 57
9. CROSS-SECTIONAL DRAWINGS 59
10. CONTACT INFORMATION 63
Please ensure these instru tions are read fully before installation and operation of the
pump.
Please furnish omplete nameplate 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 HSC LLC pumps:
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 15
days) to prevent pitting of bearing surfa es.
Sr.
No. Pump Type
1 SCT150/38L
2 SCT200/38L
3 SCT250/38L
4 SCT150/48L
5 SCT200/48L
6 SCT250/30L
7 SCT250/40L
8 UP300/46L
9 UP400/48L
10 UP400/51L
11 UP 400/67L
12 UP 500/68L
13 SCT200/58L
14 SCT250/51L
15 SCT350/39L
16 SCT300/48L
17 SCT350/66L
18 SCT200/58-2L
19 UP300/39L

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1.5 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.
1.6 Nomenclature of the pump.
Nomen lature for single stage pump is as given below.
SCT 150/38L
SCT- Basi pump type
150- Nominal delivery size in mm
/ - Always slash
38- Nominal impeller diameter in m.
L - LLC
Nomen lature for two-stage pump is as given below.
SCT 00/58- L
SCT- Basi pump type
00- Nominal delivery size in mm
/ - Always slash
58- Nominal impeller diameter in m.
2 – number of stages
L - LLC
1.7 For any information or instru tion not given in this manual, pl onta t nearest KBL
offi e.
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.

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Su tion and Dis harge is on a ommon enter line in both the horizontal and verti al planes.
Impeller – For single stage pumps, impeller is of the en losed double-su tion stati ally and
hydrauli ally balan ed. For two-stage pumps, impellers are of the en losed single su tion
type. The impeller is keyed to the shaft and positioned axially by the impeller nuts.
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 minimum defle tion.
Insert (Stuffing Box) - The insert is onsisting of single artridge type me hani al seal.
Bearings - The bearings are grease lubri ated or oil lubri ated. The DE side or oupling end
bearing is a double row ball bearing. The NDE side bearing is a single row ball bearing. DE
side bearing is retained by bearing lo knut and lo k washer.
Bearing Housings - The bearing housings are bolted to the upper and lower half asing
and assure positive alignment of the rotating element. The housings provide a fit for the NDE
side bearing that allows freedom for thermal expansion while the DE side bearing is lamped
in pla e to take all thrust loads and keep the rotating element in its proper axial lo ation.
Baseplate - The baseplate 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 - Spa er Type.
Coupling Guard - The oupling guard MOC - AL.
Rotation - Pump an have lo kwise or ounter lo kwise rotation when viewed from its
driving end.

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. SAFETY INSTRUCTIONS:
.1 General Information.
Before performing any a tions detailed within this instru tion, the Site Health and
Safety instru tions must be 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 wor
king 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 jewelry, whi h ould at h on the ontrols
or be ome 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.
.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.

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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.
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 R R A 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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.6.3 Storage.
2.6.3.1 Temporary Storage up to Six Weeks.
If the pump unit is not to 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) For the pump 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 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.

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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.

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3. INSTALLATIONS:
3.1 Receiving the Pump.
Upon re eipt of the pump, a visual he k should be made to determine if any shortage or
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.
Pumps and drivers are normally shipped from the fa tory mounted on a baseplate. Couplings
may either be ompletely assembled or have the oupling hubs mounted on the shafts and
the onne ting members removed. When the onne ting members are removed, they will be
pa kaged in a separate ontainer and shipped with the pump or atta hed to the baseplate.
Parts or accessories are sometimes 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 NOT LIFT ONLY THE DRIVER OR PUMP.
3. 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. Then bearings should be flushed with arbon tetra hloride or kerosene and re-
lubri ated.

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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.
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.

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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
baseplate flange, nuts and washers. The foundation should be allowed to ure for several
days before the baseplate is shimmed and grouted.
Refer to General Arrangement and Foundation plan drawing of pump for dimensional
details and foundation enters. Ensure that po kets for foundation bolts are left in mother
on rete.
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 that piping an be aligned to pump flanges without pla ing pipe
strain on either flange.
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-Ref. Fig. 2.
a) Build strong form around foundation to ontent grout.

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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.
Note - The grouting pro edure des ribed here is for guideline. Final grouting is to be done as
per approved grouting pro edure at ustomer’s end.
3.7 Alignment Procedure.
The pump driver, if supplied, is orre tly aligned on its baseplate at the fa tory. A
ertain amount of deformation of the baseplate 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. In Angular and
parallel alignment all measurements show that all points of oupling fa es are within + 0.2
mm of ea h other. Alignment should be performed after the baseplate has been properly set
and grout has dried 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.

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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 move towards the pump. Do not move pump to pipe. This ould make
final alignment impossible.
Both su tion and dis harge piping should be supported independently and lose to
pump so that no strain is transmitted to the pump when the flange bolts are tightened.
Use pipe hangers or other supports at ne essary intervals to provide support. When
expansion joints are used in the piping system, they must be installed beyond the piping
supports lose 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.
For negative su tion, to avoid priming a tivity every time, valve should be pla ed in
su tion piping.
Install piping as straight as possible, avoiding unne essary bends. Where ne essary,
use 45 degrees or long sweep 90 degrees fitting to de rease fri tion losses.
Make sure that all piping joints are air-tight. Provide pipe expansion bellows when hot
fluids are to be pumped. Where redu ers are used, e entri redu ers are to be fitted in
su tion lines and straight taper redu ers in dis harge and verti al lines (Refer Fig. 5).
Misuse of redu ers may ause the formation of air po kets in the pipe and thus preventing
the smooth operation of the pump.
The su tion pipe should be as short and dire t as possible. Where su tion lift is not
very high, it is advisable to use a foot valve. Horizontal su tion 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 (Refer 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 useful for 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 (refer lubri ation se tion), also he k driver lubri ation.
4.1.5 Me hani al seal has been fitted.
4.1.6 All rotating parts are found to be free when turned by hand.
4.1.7 Pump 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.
4.1.8 Co k for pressure gauge onne tion is losed.
4. 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 Me hani al seal 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.
4.2.7 Open the o k for pressure gauge onne tion.

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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.
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 During running of the pump, check the following and regulate if necessary:
4.3.1 The pump is running smooth.
4.3.2 The flow of me hani al seal flushing liquid from dis harge of pump.
4.3.3 The bearings are not getting heated ex essively.
4.3.4 Head and apa ity developed by the pump are as spe ified.
4.3.5 Power onsumption is within the limit.
4.3.6 Ensure that there is no me hani al fri tion in the pump.
4.4 Operating.
While the pump is running, a periodi inspe tion should be made of:
a) Driver/Pump rotation. Ea h time the motor leads are dis onne ted ensure the driver
operates in the dire tion indi ated by the arrow on the pump asing.
b) Bearings. Che k the bearings for temperature, whi h should not ex eed 80
0
C.
) With me hani al seal fitted pumps, he k that there is no leakage from the seal.
d) Su tion and dis harge gauge readings.