KIRLOSKAR i-HT Programming manual

INSTRUCTIONS
ON
INSTALLATION OPERATION
AND
MAINTENANCE
FOR
KIRLOSKAR PUMP
TYPE – i-HT

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

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1. GENERAL
1.1 The booklet covers instructions for following types of i-HT pumps.
Single Stage
i-HT06B i-HT12B i-HT12E
i-HT08B i-HT12BD i-HT15B
i-HT08BD i-HT12BE i-HT15BE
i-HT08BE i-HT12BF i-HT15D
i-HT10B i-HT12C i-HT15DF
i-HT10BD i-HT12CF i-HT15DF
i-HT10BE i-HT12CG i-HT20DD
i-HT10DE i-HT12D i-HT20DE
i-HT10ED i-HT12DF i-HT20ED
Double Stage
i-HT05 i-HT06 i-HT12XD
i-HT15XE i-HT15XF
1.2 These are horizontal split casing type pumps with suction and discharge nozzles and
their supporting feet integrally cast in the lower half casing. This construction enables to
remove the rotating unit for inspection and repairs by just removing upper half casing,
and without disturbing alignment, pipe connection or prime mover.
1.3 Pumps when properly installed and given due care in operation and maintenance
should operate satisfactorily for a long period.
1.4 When the pump is received, sometime before the actual use of pump, it should be
inspected and located in dry place. The coupling should be rotated periodically (once in a
month) to prevent pitting of bearing surfaces.
1.5 Generally all the i-HT pumps mentioned above are similar in construction with minor
changes of some parts.
1.6 Pump identification: ll pumps are designated by serial number, model number, size
and type. This information is stamped on an identification plate which is fixed on the
pump.

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2. SAFETY INSTRUCTIONS:
2.1: General Information
Before performing any actions detailed within this instruction, the Site Health and Safety
instructions must read and fully understood. The instructions in this document also must
be read and fully understood.
Whenever the equipment is operated, maintained or used in any way, the procedures
detailed within the Health and Safety Dossier (DHS) and any procedures detailed within
these instructions shall be followed. The pump supplied by Kirloskar Brothers Limited
(KBL) has been designed with safety in mind, where hazards cannot be eliminated; the
risk has been minimized 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. These instructions cannot cover all circumstances. It is the responsibility
of the user of the equipment for maintaining s
afe working practices at all times.
2.1.1 KBL products are designed for installation in designated areas, which are to be
kept clean and free of obstructions that may restrict safe access to the controls and
maintenance access points.
2.1.2 Pump nameplate is fitted to each unit and must not be removed. Loss of this plate
could make identification impossible. This in turn could affect safety and cause difficulty
in obtaining spare parts. Should accidental loss or damage occur, contact KBL
immediately.
2.1.3 ccess to the equipment should be restricted to the personnel responsible for
installation, operation and maintenance and they must be trained, adequately qualified
and supplied with the appropriate tools for their respective tasks.
2.1.4 KBL firmly insists that all personnel responsible for installation, operation and
maintenance of the equipment must read safety instructions mentioned in the manual
before any work is done.
2.1.5 Ear defenders should be worn where the specified equipment noise level exceeds
locally defined safe levels. Safety glasses or goggles should be worn where working with

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pressurized systems and hazardous substances. Other personal protection equipment
must be worn where local rules apply.
2.2 DO NOT wear loose or frayed clothing or jewellery, which could catch on the
controls or becomes trapped in the equipment.
2.3 Operation of the equipment for the application other than for which it is supplied
can increase the risk from hazards. Please consult KBL before making such change in the
application of the equipment.
2.4 Improper installation, operation and maintenance of the product supplied by KBL
could result in injury or death.
2.5 Within the manual, safety instructions are marked with safety symbols.
Hazard
This symbol refers to general mechanical aspects of safety.
Hazard
This symbol refers to electrical safety.
2.6: Transport handling and storage instructions:
2.6.1: Transport.
Pumps are dispatched in duly assembled condition. Pumps are protected against
corrosion and packed for transport by normal road, rail and sea carriers.
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 specified. Use suitable slings for lifting any pump not
provided with lifting points.
The use of suitable forklift truck and four chain crane sling equipment is recommended
but locally approved equipment rating may be used.
Pump should be slung as shown.

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Pump set must be lifted from the lifting holes provided on the pump by using suitable
four chain lifting equipment.
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 carefully in a horizontal
position, in a sheltered, dry location. dditional rust preventive should be applied to all
unpainted carbon steel or cast 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 clean,
dry place, having slow, moderate changes in ambient temperature. Step should be taken
to protect the pump from moisture, dust, dirt, and foreign bodies. It is recommended that
the following procedure is taken:-
a) Ensure that the bearings are packed with the recommended grease, to prevent
moisture from entering around the shaft.

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b) Remove the glands, packings and lantern rings from the stuffing box if the pump is
equipped in this manner. If the pump is equipped with mechanical seal, dismantle and
coat the seal with light oil.
c) Ensure that suction and discharge branches of the pump and all other openings are
covered with cardboard, wood or masking tape to prevent foreign objects entering the
pump.
d) If the pump is to be stored where there is no protective covering, it is advisable to
cover the unit with a tarpaulin or other suitable covering.
e) The shaft should be manually rotated periodically to prevent pitting of the bearing
surfaces by moisture.
Shearing Hazard.
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. If the packaging or suction and discharge covers are removed for inspection
purposes, replace afterwards to protect the pump and maintain the safety.
Fill the bearing housing with recommended 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 atmospheric or environmental conditions,
please refer to KBL for special storage instructions to suit the conditions acceptable.
3 INSTALLATIONS
3.1 Receiving pump
Upon receipt of the pump, a visual check should be made to determine if any damage
occurred during transit or handling. The main items to look for are:-
a) Broken or cracked equipment, including base, motor or pump feet and flanges.
b) Bent shaft
c) Broken motor end bells, bent eyebolts or damaged boxes of motor

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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 NOT
LIFT ONLY THE DRIVER OR PUMP.
3.2 Preparation
Before installing the pump, clean the suction and discharge flanges thoroughly.
Remove the protective coating 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 carbon tetrachloride or kerosene and relubricated.
3.3 Location
The pump should be installed as near the liquid source as possible, with the shortest and
most direct suction pipe practically.
The pump should be installed with sufficient accessibility for inspection and maintenance.
mple space and head room should be allowed for the use of an overhead crane or hoist
sufficiently strong to lift the unit.
Make sure there is a suitable power source available for the pump driver. If motor driven,
electrical characteristics should be identical to those shown on motor data/ name plate.
3.4 Foundation
The foundation should be strong enough to reduce 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 surface of the foundation should be well scored and glued before
the concrete sets. This provides a bonding surface for the grout. Foundation bolts should
be set in concrete as shown in Fig. 1. llow enough bolt length for grout, shims, lower

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base plate flange, nuts and washers. The foundation should be allowed to cure for
several days before the base plate is shimmed and grouted.
3.5 Base plate setting
Use blocks and shims under base for support at foundation bolts and midway between
bolts, to position base approximately 25 mm above the concrete 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 coupling hubs for alignment.
Check to make sure the piping can be aligned to pump flanges without placing pipe strain
on either flange.
Grout baseplate in completely and allow grout to dry thoroughly before attaching piping
to pump (24 hours is sufficient time with approved grouting procedure).
3.6 Grouting procedure
Grout compensates 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 content grout.
b) Soak top of concrete foundation thoroughly, then remove surface water.
c) Baseplate should be completely filled with grout and, if necessary, drill vent holes to
remove trapped air.
d) fter grout has thoroughly hardened, check the foundation bolts and tighten if
necessary.
e) Check the alignment after the foundation bolts are tightened.
f) pproximately 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 coming in contact with the grout.
3.7 Alignment procedure
The pump driver, if supplied, is correctly aligned on its base plate at the factory.
certain amount of deformation of the base plate is possible during transit and it is
therefore essential to check alignment, prior to final grouting.

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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 can be checked with dial gauge Indicator also. lignment should be
performed after the base plate has been properly set and grout has dried thoroughly
according to instructions. Final alignment should be made by shimming driver only.
lignment should be made at operating temperatures.
fter final alignment, it is necessary to dowel pump and driver feet to the baseplate.
FACTORS THAT MAY DISTURB ALIGNMENT
The unit should be periodically checked 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 machines.
c) Wear of the bearings.
3.8 Suction and Discharge Piping
When installing the pump piping, make sure to observe the following precautions:-
Piping should always run to the pump. Do not move pump to pipe. This could 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 increase the size of both suction and discharge pipes at the pump
connection to decrease the loss of head from friction.
Install piping as straight as possible, avoiding unnecessary bends. Where necessary, use
45 degree or long sweep 90 degree fitting to decrease friction 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).

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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 discharge pipe is usually preceded by a non-return valve or check valve and a
discharge gate valve (See Fig. 5). The check valve is to protect the pump from excessive
back pressure and reverse rotation of the unit and to prevent back flow into the pump in
case of stoppage or failure of the driver. The discharge valve is used in priming, starting
and when shutting down the pump.
4 OPERATION
4.1 Before Starting
Before initial starting of the pump, make the following inspection:
4.1.1 The unit baseplate is grouted and bolted to the foundation.
4.1.2 lignment between pump and motor.
4.1.3 Motor is correctly wired to starting device, check voltage, phase and frequency on
motor nameplate with line circuit.
Ensure correct direction of rotation prior to coupling to pump. Check by starting motor
and switching off immediately. Observe rotation is the same as the arrow direction on
the pump casing.
4.1.4 Bearing lubrication is provided (see lubrication section), also check driver
lubrication.
4.1.5 Mechanical seal has been fitted or stuffing box has been packed.
4.1.6 ll rotating parts are found to be free when turned by hand.

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4.1.7 Pump is primed. Never run the unit dry. The liquid in the pump serves as a lubricant
for close running fits within the pump and the pump may be damaged if operated dry.
The pump may be primed by using an ejector, exhauster or vacuum pump. If a foot valve
is used in the suction line, the pump may be primed by venting and filling the casing with
liquid.
4.2 Starting
4.2.1 Close valve in discharge line.
4.2.2 Open fully all valves in the suction 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 discharge valve slowly.
Do not operate pump for prolonged periods with closed discharge valve, so as to avoid
overheating.
The pump should be shut down at once and the trouble corrected if the pump is running
at its rated speed and found to have any of the following defects:
a) No liquid delivered.
b) Not enough liquid delivered.
c) Not enough pressure.
d) Loss of liquid after starting.
e) Excess vibration.
f) Motor runs hot.
g) Pump bearing overheating.
4.3 Running
While the pump is running, a periodic inspection should be made of:
a) Stuffing box (soft packed pumps only). Ensure there is sufficient leakage to lubricate
the packing.
b) Bearings. Check the bearings for temperature, which should not exceed pumped liquid
temperature or 80 Deg. C whichever is the lower.

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c) With mechanical seal fitted pumps, check that there is no leakage from the stuffing
box.
d) Suction and discharge gauge readings.
4.4 Stopping
a) Slowly close delivery valve and shut down driving unit in accordance with
manufacturer’s instructions.
b) Shut off external sealing liquid supply, if supplied, to relieve stuffing box pressure.
c) Successful operation of the pump depends on accurate alignment. It is recommended
to re-check the alignment after preliminary run.

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5 TECHNICAL DATA
5.1 Direction of Rotation
Pumps are supplied with clockwise direction of rotation when viewed from coupling end.
The direction of rotation can be reversed easily without changing any part
5.2 BEARING DETAILS:
Pump Model Bearing Module
Bearing DE
Deep Groove Ball
Bearing
Bearing NDE
ngular Contact
Paired Bearing
(Face to Face)
i
-
HT 06 B
1 6306 7306(BECB)
i
-
HT 08 B
i
-
HT 12 C
i
-
HT 08 BD
i
-
HT 08 BE
i
-
HT 10 DE
i
-
HT 12 CF
i
-
HT 12 CG
i
-
HT 12 D
2 6309 7309(BECB)
i
-
HT 12 B
i
-
HT 15 B
i
-
HT 12 E
i
-
HT 15 D
i
-
HT 10 B
i
-
HT 10 BD
i
-
HT 10 BE
i
-
HT 12 BD
i
-
HT 12 BE
i
-
HT 12 BF
i
-
HT 12 DF
i
-
HT 15 BE
i
-
HT 15 DF
i
-
HT 10 ED
i
-
HT
20
DD
3 6312 7312(BECB)
i
-
HT 20 DE
i
-
HT 20 ED
Note: Thrust bearing is at non driving end and radial bearing is at driving end.
Two Stage

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5.3 Special care for Bearings
These instructions do not supersede any information issued by the bearing
manufacturers, to whom application should be made for more comprehensive literature
by personnel responsible for bearing care, who with it to make a detailed study.
Care and maintenance of bearings is a matter of ensuring that they are:
a) Correctly lubricated at intervals as laid down in routine maintenance chart.
b) Removed, cleaned and refitted with care.
c) Tools used and work areas should be cleaned.
To remove a bearing, use correctly suited withdrawal equipment.
C UTION: Damage can be caused by exerting force against the outer ring of a ball
bearing.
Ball bearings should not be dismantled.
Clean bearings thoroughly with an approved fluid.
Dry the bearings by spinning with dry compressed air or by hand. Do not spin a clean dry
bearing.
Inspect the bearing for wear, fractures, cracks, corrosion or other damage which may
necessitate bearing replacement.
Pack both sides of bearing with grease.
Check that the bearing, shaft and housing are cleaned and undamaged.
Recharge with grease to a maximum of two thirds full.
Refit the bearing onto the shaft and press for tap into position.
Pump Model Bearing Module
Bearing DE
Deep Groove
Ball Bearing
Bearing NDE
i-HT 12 XD
3T 6411 6411
i-HT 15 XE
i-HT 15 XF
i-HT 05 1T 6307 6307
i-HT 06 2T 6309 6408

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5.4 Lubrication Details
Initially bearings are lubricated during assembly. In the regreasing period these bearings
should be repacked with a high quality, lithium soap base, ball and roller bearing grease
free from resin and acid, not liable to harden or crumble and possessing rust preventive
properties. Re-greasing interval depends upon the operating speed of the unit.
Operating speed Regressing Interval
1450 RPM 4000 hours
2900 RPM 3000 hours
To recharge the bearings with fresh grease, use a grease gun and feed through the two
grease nipples provided.
DO NOT APPLY LUBRICANT WHEN PUMP IS RUNNING.
fter 10,000 hours or two years whichever is earlier remove bearings from pumps,
degrease, thoroughly clean, recharge with fresh grease and refit in accordance with
reassembly instructions.
Recommended Grease specifications
Speed Lubricant recommended
1450 rpm. IOCL SERVOGEM-3 or equivalent.
2900 rpm. IOCL SERVOGEM-2 or equivalent.
Drop point: 180° C min
5.5 Wearing ring Details
Pumps are supplied with casing wear rings. The Diametrical clearances between
Impeller and casing rings should be minimum 0.18 mm and maximum 0.6 mm depending
up on pump model.

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Pump
Type
Fig.
No.
D1 Tol.H7.
Min. Max
D2 Tol.c9.
Min. Max
DiametralClearances
Min Max
i-HT06B 1 115.000 115.035 114.733
114.820 0.180 0.302
i-HT08B 1 115.000 115.035 114.733
114.820 0.180 0.302
i-HT08BD 1 120.000 120.035 119.733
119.820 0.180 0.302
i-HT08BE 1120.000 120.035 119.733
119.820 0.180 0.302
i-HT10B 1 150.000 150.040 149.690
149.790 0.210 0.350
i-HT10BD 1150.000 150.040 149.690
149.790 0.210 0.350
i-HT10BE 1150.000 150.040 149.690
149.790 0.210 0.350
i-HT10DE 1145.000 145.040 144.690
144.790 0.210 0.350
i-HT10ED 1150.000 150.040 149.690
149.790 0.210 0.350
i-HT12B 1 175.000 175.040 174.670
174.770 0.230 0.370
i-HT12BD 1175.000 175.040 174.670
174.770 0.230 0.370
i-HT12BE 1175.000 175.040 174.670
174.770 0.230 0.370
i-HT12BF 1175.000 175.040 174.670
174.770 0.230 0.370
i-HT12C 1 145.000 145.040 144.690
144.790 0.210 0.350
i-HT12CF 1145.000 145.040 144.690
144.790 0.210 0.350
i-HT12CG 1145.000 145.040 144.690
144.790 0.210 0.350
i-HT12D 1 175.000 175.040 174.670
174.770 0.230 0.370
i-HT12DF 1175.000 175.040 174.670
174.770 0.230 0.370
i-HT12E 1 185.000 185.046 184.645
184.760 0.240 0.401
i-HT15B 1 175.000 175.040 174.670
174.770 0.230 0.370
i-HT15BE 1180.000 180.040 179.670
179.770 0.230 0.370
i-HT15D 1 185.000 185.046 184.645
184.760 0.240 0.401
i-HT15DF 1185.000 185.046 184.645
184.760 0.240 0.401
i-HT20DD 1224.000 224.046 223.625
223.740 0.260 0.421
i-HT20DE 1224.000 224.046 223.625
223.740 0.260 0.421
i-HT20ED 1245.000 245.046 244.605
244.720 0.280 0.441
TWO ST GE
i-HT12XD 2 240.000 240.072 239.465
239.580 0.420 0.607
i-HT15XE 2 240.000 240.072 239.465
239.580 0.420 0.607
i-HT15XF 2 240.000 240.072 239.465
239.580 0.420 0.607
i-HT05 2 115.035 115.000 114.630
114.543 0.492 0.370
i-HT06 2 150.040 150.000 149.605
149.505 0.535 0.395
•For HT12XD, HT15XE, HT15XF Tolerance is H8b9

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5.6 Impeller Details
Sr.
No.
Pump Type
Full. Impeller
Dia. In mm.
Min. Impeller
Dia. In mm.
Impeller Type
1 i-HT06B 240 180 Double Entry
2 i-HT08B 235 175 Double Entry
3 i-HT08BD 235 190 Double Entry
4 i-HT08BE 210 160 Double Entry
5 i-HT10B 245 190 Double Entry
6 i-HT10BD 245 210 Double Entry
7 i-HT10BE 210 184 Double Entry
8 i-HT10DE 303 225 Double Entry
9 i-HT10ED 370 270 Double Entry
10 i-HT12B 245 185 Double Entry
11 i-HT12BD 245 210 Double Entry
12 i-HT12BE 210 180 Double Entry
13 i-HT12BF 245 205 Double Entry
14 i-HT12C 286 210 Double Entry
15 i-HT12CF 286 210 Double Entry
16 i-HT12CG 286 255 Double Entry
17 i-HT12D 303 230 Double Entry
18 i-HT12DF 308 230 Double Entry
19 i-HT12E 348 280 Double Entry
20 i-HT15B 252 205 Double Entry
21 i-HT15BE 252 215 Double Entry
22 i-HT15D 325 240 Double Entry
23 i-HT15DF 325 240 Double Entry
24 i-HT20DD 340 240 Double Entry
25 i-HT20DE 340 240 Double Entry
26 i-HT20ED 378 320 Double Entry
TWO STAGE
27 i-HT12XD 310 275 Single Entry
28 i-HT15XE 326 295 Single Entry
29 i-HT15XF 326 295 Single Entry
30 i-HT05 220 195 Single Entry
31 i-HT06 240 180 Single Entry
ll models have double entry impellers.