KIRLOSKAR IN 40/160 IL Programming manual

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INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE MANUAL
KIRLOSKAR PUMP
TYPE – IN-IL
KIRLOSKAR BROTHERS LIMITED
REGD. AND HEAD OFFICE:
UDYOG BHAVAN, TILAK ROAD, PUNE 411002 (INDIA)

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KIRLOSKAR BROTHERS LIMITED
REGD. AND HEAD OFFICE UDYOG BHAVAN, TILAK ROAD, PUNE-411002
WARRANTY
We arrant that the pump supplied from us is free from defective
material and faulty orkmanship. This arranty holds good for a
period of 12 months from the date of commissioning the equipment
or 18 months from the date of dispatch from our factory, hichever
is earlier. Our liability in respect of any complaint is limited to
replacing part/parts free of charge ex- orks or repairs of the
defective part/parts only to the extent that such replacement/repairs
are attributable or arise solely from faulty orkmanship or defective
material.
This arranty holds good only for the products manufactured by us.
KIRLOSKAR BROTHERS LIMITED

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Table of contents
1. Introduction Page No
1.1 Preface 05
1.2 Safety 05
1.3 Service and support 07
1.3.1 Ordering spare parts 07
1.3.2 Pump serial number 07
1.3.3 Contact Information 07
1.4 Inspection of delivered items 07
1.5 Lifting 08
1.6 Storage
2. Genera
2.1 Pump Description 10
2.2 Explanation of Designations 10
2.3 Applications
2.3.1 Application guidelines 11
2.3.2 Field of application 12
2.4 Construction
2.4.1 Pump casing 12
2.4.2 Impeller 12
2.4.3 Stuffing Box Cover 12
2.4.4 Bearing Assembly 13
2.4.5 Hydraulic performance 13
2.5 Re-use 13
2.6 Scrapping 13
3. Insta ation
3.1 Safety 14
3.2 Environment 14
3.3 Mounting 14
3.3.1 Installation of set 14
3.3.2 Dismantling procedure 14
3.3.3 After dismantling 15
3.3.4 Reassembly 15
4. Commissioning
4.1 Electrical open and closed-loop control elements 16
4.2 Direction of rotation of drive/driven shafts 17
4.3 Filling 17
4.4 Start-up 17
4.5 Pressure limitation/Pressure control 17
4.6 Preparation for lubrication 17

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Page no
5. Maintenance
5.1 Routine Inspections 18
5.2 Mechanical Seal 18
5.3 Noise 18
6. Cause of fai ures
7. Technica data
7.1 Recommended greases 21
7.2 Tightening moments 21
7.3 Tools 22
8. Sectiona Drawings and Parts-List
8.1 Cross-Sectional Dra ing 23
8.2 Parts list-Sectional Dra ing 24
8.3 Exploded vie - Pump unit assembly 25
8.4 Exploded vie - Hydraulic parts assembly 26
8.5 Exploded vie - Drive assembly 27
8.6 Exploded vie - Shaft end assembly 28
9. Dimensiona GA drawing 29
9.1 Out ine dimensions of INIL Pump 29-30

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1. INTRODUCTION
1.1 Preface:
This manual contains important and useful information for the proper functioning and
Maintenance of this pump. It also contains important instructions to prevent possible
accidents and serious damage and to ensure the safe and smooth functioning of this pump.
Read this manual carefully before commissioning the pump. Familiarize yourself ith the
operation of the pump and strictly obey the instructions!
The data published here comply ith the most recent information at the time of going to
press. Ho ever, they may be subject to later modifications.
Kirloskar Brothers Limited reserves the right to change the construction and design of the
product at any time ithout being obliged to change earlier deliveries accordingly.
1.2 Safety:
The manual contains instructions for the safe operation of the pump. Operators and
maintenance staff shall be familiarized ith these instructions.
This manual has been compiled by Kirloskar Brothers Limited ith the utmost care. Kirloskar
Brothers Limited cannot guarantee the completeness of this information and therefore
assumes no liability for possible deficiencies in this manual. The buyer/user shall at all times
be responsible for testing the information and for taking possible additional and or deviating
safety measures. Kirloskar Brothers Limited reserves the right to change the safety
instructions at any time.
Safety Instructions:
1.2.1 Genera Information:
Before performing any actions detailed ithin this instruction, the Site Health and
Safety instructions shall be read and fully understood. The instructions in this
document shall also be read and fully understood.
Whenever the equipment is operated, maintained or used in any ay, the
procedures detailed ithin the Health and Safety Dossier (DHS) and any procedures
detailed ithin these instructions shall be follo ed. The pump supplied by Kirloskar
Brothers Limited (KBL) has been designed ith safety in mind; here 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
belo 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 safe orking practices at all times. The pumps are supplied ith
stickers for hazard, caution and safety herever these are applicable.
1.2.2 Within the manual, safety instructions are marked ith safety symbols.
Hazard.
This symbol refers to general mechanical aspects of safety.

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Hazard
This symbol refers to electrical safety.
This symbol is used to introduce safety instructions hose non-
observance may lead to damage to the machine and its functions.
This symbol refers to magnetic field safety.
This symbol refers to restrict person ith having heart pacemaker to
avoid contact ith magnetic components hile pump is in running
condition or hile carrying out maintenance ork of pump .
KBL products are designed for installation in designated areas, hich are to be kept
clean and free of obstructions that may restrict safe access to the controls and
maintenance access points.
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.
1.2.3 Access to the equipment should be restricted to the personnel responsible for
installation, operation and maintenance and they must be trained, adequately
qualified and supplied ith the appropriate tools for their respective tasks.
1.2.4 KBL firmly insists that all personnel responsible for installation, operation and
maintenance of the equipment must read the manual before any ork is done.
1.2.5 Ear defenders should be orn here the specified equipment noise level exceeds
locally defined safe levels. Safety glasses or goggles should be orn here orking
ith pressurized systems and hazardous substances. Other personal protection
equipment must be orn here local rules apply.
1.2.6 DO NOT ear loose or frayed clothing or je ellery, hich could
catch on the controls or becomes trapped in the equipment.
1.2.7 Operation of the equipment for the application other than for hich it is supplied
can increase the risk from hazards. Please consult KBL before making such change
in the application of the equipment.
1.2.8 Improper installation, operation and maintenance of the product supplied by KBL
could result in injury or death.

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1.3 Service and support:
This manual is intended for technicians and maintenance staff and for those ho are in
charge of ordering spare parts.
1.3.1 Ordering spare parts:
This manual contains the spare - and replacement parts as recommended by
Kirloskar Brothers Limited.
1.3.2 Pump serial number:
The pump serial number is stated on the pump nameplate. Please refer to this serial
number and the other data mentioned on the nameplate hen corresponding for
ordering spare parts ith Kirloskar Brothers Limited.
1.3.3 Contact Information:
KIRLOSKAR BROTHERS LIMITED
REGD. OFF:
UDYOG BHAVAN, TILAK ROAD,
PUNE-411002 (INDIA)
CORPORATE OFFICE: “YAMUNA”,
SURVEY NO-98/3-7,
PUNE-MUMBAI HIGHWAY,
BANER, PUNE-411 045 (INDIA)
WORKS:
KIRLOSKARWADI,
416308,
DIST.: SANGLI (INDIA)
TEL: [phone]
FAX: [phone]
TEL: [phone]
FAX: [phone]
TEL: [phone]
FAX: [phone]
Note: The information in this document may sometimes be of generic nature
and applicable to various company products irrespective of its specific
application and use. Additional instructions if any shall be specified on
individual project dra ings and documents furnished to the buyer against
specific order.
Where a conflict exists bet een the contents herein and the actual
equipment supplied, the user must make an engineering judgment, else
contact KBL.
Kirloskar Brothers Ltd reserves the right to change the construction and
design of the products at any time ithout being obliged to change
products already supplied earlier.
1.4 Inspection of de ivered items:
•Check the consignment immediately on arrival for conformity ith the packing note.
•Check for damage and/or missing parts if any.
•In case of damage and/or missing parts, have a report dra n up by the
carrier/receiver at once and inform to the concerned people immediately.

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1.5 Lifting:
If a pump or a complete pump unit should be lifted, the slings should be fixed as sho n in
Figure 1.
Figure 1. Lifting instruction
NOTE: Proper care shou d be taken to protect pump and/or prime mover and/or paint at
contact area of s ing or rope at the time of ifting.

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1.6 Storage:
In case the pump is not immediately being used, the pump shaft must be rotated manually
once in a month to prevent pitting on bearing surfaces.
1.6.1 Temporary Storage for up to six weeks:
If the pump unit is not to be used immediately it should be stored carefully in a
horizontal/vertical position, in a sheltered, dry location.
Additional rust preventive should be applied to all unpainted carbon steel or
cast-iron parts and should not be removed until final installation.
1.6.2 Long Term Storage:
If the pump is not to be installed and operated soon after arrival, store it in a clean, dry
place, having slo , 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
follo ing precautions to be taken:
a) Ensure that the bearings are packed ith the recommended grease, to prevent moisture
from entering around the shaft.
b) Ensure that suction and discharge branches of the pump and all other openings are
covered ith cardboard, ood or masking tape to prevent foreign objects entering the
pump.
c) If the pump is to be stored here there is no protective covering, it is advisable to cover
the unit ith a tarpaulin or other suitable covering.
d) The pump shaft should be manually rotated periodically (once in 2 eeks) to prevent
pitting of the bearing surfaces due to 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 after ards to protect the pump and maintain the safety.
Fill the bearing housing ith recommended oil to ensure that the shaft and bearings remain
rust free.
1.6.3 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.

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2. Genera
2.1 Pump Description:
Kirloskar IN-IL pump is of vertical execution, back pullout design hich enables to remove
the rotating unit of pump for inspection and repair ithout disturbing the pipe connections
and motor.
Pumps hen properly installed and given due care in operation and maintenance should
satisfactorily perform for long period of time.
Follo ing are the pump models available:
1. IN 40/160 IL
2. IN 50/160 IL
3. IN 65/160 IL
4. IN 65/200 IL
5. IN 65/320 IL
6. IN 80/260 IL
7. IN 100/160 IL
8. IN 100/260 IL
9. IN 125/260 IL
10. IN 150/320 IL
11. IN 200/320 IL
2.2 Exp anation of Designations:
Example : IN 40/160 IL
Pump family: IN - INDIAN NAVY / IL – INLINE
Pump size : 40/160 (diameter of discharge connection [mm]/nominal impeller diameter
[mm]

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Material construction
Part
Description
↓
MOC Code
→01 02 03 04
Pump Casing NiAlBr GM GM Cast Iron
Impeller NiAlBr GM Al. Br Cast Iron
Pump Shaft SS 431 SS 431 SS 431 SS 316
Casing Ring NiAlBr GM GM Cast Iron
Impeller Ring NiAlBr GM GM Cast Iron
Casing Cover NiAlBr GM GM Cast Iron
Liquid Deflector SS 316 SS 316 SS 316 SS 316
Bearing Housing GM GM GM Cast Iron
Impeller Nut NiAlBr GM GM SS 316
Stuffing Box NiAlBr GM GM MS
Motor Stool MS MS MS MS
2.3 App ications:
2.3.1 App ication guide ines:
Please do not use the pump for the applications other than those for hich it is designed
ithout consulting ith the manufacturer/supplier.
Using a pump in a system or under system conditions (liquid, orking pressure,
temperature, etc.) for hich it has not been designed may be hazard to the user!
App ication Area:
The application area globally looks as follo s:
Suction/Delivery Size : up to 200 mm
Capacity : up to 500 m³/hr (500 TPH)
Head : up to 150 meter
Speed : 1450 and 2900 rpm (50 Hz)
1750 and 3500 rpm (60 Hz)

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2.3.2 Fie d of app ication:
Ballast and Bilge.
Air conditioning chilled ater.
Main fire-fighting.
Bilge transfer.
Waste ater recycling.
Portable ater supply.
Distilling plant feed systems.
Main and auxiliary engine cooling.
Main boiler feed and condensate.
2.4 Construction:
2.4.1 Pump casing:
The casing is of single volute design ith suction and discharge connections situated "in-
line".
The In-line design offers advantages, viz:
•a lo resistance (NPSHR).
•increases efficiency.
• The velocity of the liquid is uniform hen entering the impeller eye; baffles prevent
vortex formation at the impeller eye .
2.4.2 Impe er:
Impeller of INIL pumps are of enclosed type. The hydraulic axial thrust in enclosed impellers
is either balanced by back vanes or by drilling balancing holes depending upon magnitude of
axial thrust.
Dynamic balancing of impeller is done at reduced speed to Grade 6.3 of ISO 1940.
Impeller is positively locked on the pump shaft by means of an impeller nut.
A radial running clearance has been set up on the suction side bet een impeller and
casing.
2.4.3 Stuffing Box Cover:
Stuffing Box Cover - Efficient cooling of the packing/mechanical seal is achieved by
formation of a cooling chamber in the stuffing box portion ensuring thereby long life of
packing/mechanical seal. Mechanical seal is supplied in “cartridge” construction exclusively
and is to be fitted from impeller end.
The flushing of the mechanical seal ill be by the pumped liquid, for most pumps by
an internal channel.

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2.4.4 Bearing Assemb y:
Inline pump is available ith Bearings of SKF or Equivalent make. Smaller models of these
pumps are provided ith a specially designed journal bearing at NDE side to make it ideally
suitable for pumping sea ater hile large models are provided ith high capacity
antifriction ball bearings on DE and NDE side.
The bearing arrangements mentioned above are suitable for suction pressure less than 5
kg/cm
2
. For applications involving suction pressure above 5 kg/cm
2
please refer to
Marketing Division or Engineering Department.
C3 clearance bearings are used.
Axial running clearance shall be less than 0.45 mm for all above bearing
arrangements. Maximum allo able temperature of bearing shall be 80 degrees Celsius.
Bearings are grease lubricated.
2.4.5 Hydrau ic performance:
The performance curve sho s the hydraulic performance for each pump type at
several impeller diameters and standard speeds.
A) Performance as per curves shall be applicable for the liquids satisfying follo ing
conditions.
a. Viscosity not greater than 2 centistokes.
b. Consistency of liquid not greater than 2%.
c. Specific gravity equal to 1.
d. Total solid contents not greater than 3000 PPM.
B) Performance testing can be offered as per any of the follo ing standards.
a. IS 5120, 1520 and 9137.
b. ISO 3555 Class B.
c. ISO 9906 Gr. 2B.
d. As per approved type test procedure.
C) Pumps can be offered for type tests and NPSH tests at extra cost.
D) Performance curves (IM) indicate NPSH requirements of pumps on the basis of a 3%
drop in total head.
2.5 Re-use:
The pump may only be used for other applications after prior consultation ith Kirloskar
Brothers Ltd or your supplier. Since the lastly pumped medium is not al ays kno n, the
follo ing instructions should be observed:
Flush the pump properly.
Make sure the flushing liquid is discharged safely (environment).
Take adequate precautions and use the appropriate personal protection means
(rubber gloves, spectacles).
2.6 Scrapping:
If it has been decided to scrap a pump, the same procedure as for Re-use (2.5) should be
follo ed.

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3. Installation
3.1 Safety:
These instructions should be read carefully before installing the pump.
•This pump is designed for circulation of sea ater or other suitable HVAC media. It
is not suitable for hazardous, corrosive or flammable liquids.
•Pump must not be started until all electrical connections are in place.
•Pump must not be operated ithout installing the safety guards.
•The piping should be adequately supported to reduce thermal and mechanical
stresses.
•Refer to motor installation instructions to determine proper terminal connections to
obtain correct pump rotation.
•Good installation practice recommends the system must be cleaned and flushed off
all foreign materials and sediments prior to pump installation.
3.2 Environment:
•A too high ambient temperature and air humidity, as ell as a dusty environment
may have a negative effect on the functioning of the electric motor.
•Ensure adequate space is left above and around the pump for operation,
maintenance, service and inspection of parts.
•In open system locate the pump as possible as close to the liquid being pumped so
that suction line is short and direct.
•Head room must be provided to use hoist or tackle as necessary.
3.3 Mounting:
3.3.1 Insta ation of set:
•Pump set is delivered as a complete set ith pump and motor on center mounting
assembled together.
•The alignment is done at KOV orks.
•Ensure the direction of the suction and discharge pipeline before placing the pump on
the foundation.
•For permanent arrangement, place the complete set on the foundation. Check the
level ith the help of level bottle and if required put the shims under AVM of the
pump. Tighten all the bolts carefully. Recheck the pump and motor alignment.
•While dismantling and reassembling, the cross-sectional assembly dra ing and
specification list should be referred.
3.3.2 Dismant ing procedure:
•Isolate the po er supply to motor.
•Shut off the valves controlling flo to and from the pump.
•Drain the liquid from the pump by removing the drain plug (60100).
•Remove safety guard (38800). Remove flushing pipe from mechanical seal cover.
•Remove scre s of the coupling cover.
•Remove motor from motor stool (29000) if standard coupling is used.

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•For spacer coupling no need to remove the motor stool. only remove the spacer
coupling.
•Remove the hex. nut from casing studs holding the bearing housing (24000) to pump
casing (11800).
•Slightly pull out the driving unit till impeller (15100) clears the pump casing (11800).
•Take out this assembly through the indo provided in motor stool (29000).
•Place this rotating unit on a table or clear place for further dismantling.
•Remove gasket (51100) from pump casing.
•Unscre the impeller nut (33000). Remove the gasket (68200) bet een impeller and
impeller nut.
•Take out the impeller (15100) from pump shaft (18000). Remove the gasket
bet een impeller and shaft sleeve (51500). Remove key for impeller (32000).
•Remove Casing cover (22000) along ith Cartridge mechanical seal assembly by
slightly tapping.
•Removal of stuffing box bush (35000) from mechanical seal (23000).
•For pumps ith mechanical seal arrangement, lock mechanical seal assembly by
tightening t o Allen scre s of the cartridge mechanical seal. Unscre the nuts of
mechanical seal cover studs (4 nos.) and remove cartridge mechanical seal assembly
along ith shaft sleeve from casing cover (22000).
•Remove pump half coupling (39700) after unscre ing grub scre .
•Take out coupling key (32100).
•Loosen the hex. socket scre holding driving end bearing cover (27000). Remove
carefully bearing cover along ith oil seal (50000) or Felt ring (50200).
•Force shaft (18000) carefully in the direction of the driving end. Shaft ill come out
along ith the bearings.
•Unlock the lock asher (41500) and remove lock nut (33600).
•Take out driving end bearing (26200) ith the help of puller.
•Radial roller bearing (26400) fitted in casing cover (22000) should be removed only if
it is orn out. Or Thordon bush (for IN 50/160 IL and IN 100/160 IL pumps only).
•Take out Radial roller bearing at non-driving end (26400) ith the help of suitable
sleeve.
•Casing ring suction side (19000) to be removed only if it is orn out and need
replacement.
CAUTION:
Coupling half should be removed ith the help of suitable extraction device. To
avoid damage to the bearings, the coupling half should not be knocked off the
shaft.
3.3.3 After dismant ing:
1. All parts must be carefully cleaned and checked for ear. Recondition or
replace the parts herever necessary.
2. Wear rings clearances should be checked and ear rings are replaced if
excessive ear has taken place.
3.3.4 Reassemb y:
•This procedure covers reassembly of pump after complete dismantling of the pump.
Before reassembly, all the parts should be thoroughly cleaned in Kerosene, Petrol or
Benzene to remove the dust, rust, etc. After cleaning the necessary parts should be
replaced.
•Follo ing clearances are to be checked before reassembly of pump.
a. Clearance bet een ear rings: max 0.50 mm diametrically.
b. Clearance bet een Radial bearing and shaft sleeve: 0.05 mm.

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•Mount the pair of angular contact ball bearings. Please refer to any standard
bearing catalogue for back to back arrangement.
Caution: Use arbor press hile fitting the bearings. Ho ever, it is recommended
that bearings should be heated in oil bath at temperature 70-80° C and then
fitted. Slide inboard ball bearing on shaft by hand and make sure that it is square
ith shaft. Press the inner race of the bearing until bearing is seated firmly
against the shaft shoulder.
•Tighten the bearing lock nut (33600) after inserting lock asher for bearing in proper
position. Fold one lip of lock asher in slot of bearing lock nut to lock it.
•Insert shaft along ith bearings (26300) (i.e. angular contact ball bearings at driving
end) in to the bearing housing from driving end.
•Tighten bearing cover DE (27000) ith the help of hexagonal headed scre s.
•Push Radial roller bearing (26400) at non-driving end into casing cover (22000) if it is
removed.
•Fit mechanical seal cover along ith cartridge seal assembly and tighten the nuts on
studs of casing cover evenly.
•Slide pump shaft fitted in bearing housing in to casing cover assembly.
•Fit clamping plate by tightening 4 nos. cap scre s.
•Fit impeller key (32000). Fit gasket (51500) on impeller. Fit impeller (15100) on
shaft.
•Fit gasket (68200) in to impeller nut. Tighten impeller nut (33000).
•Fit pump half coupling (39700).
•Rotate shaft by hand and ensure free rotation.
•Fit gasket (51100) of the pump casing.
•Fit entire assembled unit along ith the impeller into pump casing (11800).
•Tighten scre s of pump casing (11800) and bearing housing (24000) evenly.
•Fit motor along ith the motor half coupling. Align the coupling halves.
•Fit scre s of the coupling guard (38800).
•Loosen the t o scre s of seal cover by allen key and unlock the cartridge
mechanical seal (23000).
•Fit the drain plug (60100) of the pump casing.
4. Commissioning
Purpose of Commissioning:
1. Minimize the life-cycle maintenance costs of the pumps.
2. Demonstrate that the provided equipment is fit for purpose and fully covered under
manufacturer’s arranty.
3. Set the pump to the requested flo rate.
4. Reduce the risk of noise and vibration problems ith the pumps.
5. Reduce the risk of pump damage, particularly mechanical seals failing
during flushing.
4.1 E ectrica open and c osed- oop contro e ements:
– Observe voltage and current values.

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4.2 Direction of rotation of drive/driven shafts:
Observe directional arro .
Testing of a unit filled ith hydraulic fluid:
S itching the unit briefly on and off prevents damage in the case of the rong
direction of rotation.
If the direction of rotation is not correct, change connecting ire of motor to match
ith the rotation of pump.
4.3 Fi ing:
For Pump types self-priming, the pump casing need not to be filled. For all other
pumps, verify hether the pump casing must be filled.
4.4 Start-up:
Observe specific component instructions.
Set all valves, especially on the suction and supply side, to the free-flo
position.
S itch the motor briefly on and off several times in order to facilitate bleeding. Only
operate the pump under full load hen it operates properly and smoothly.
During initial start-up, bleed the pressure line to allo complete filling of the pump.
Exceptions to this are pumps ith automatic bleed valve.
The pump should never run dry.
When the system starts up, the fluid level in the tank must not fall belo the
minimum suction level.
As soon as the pump develops the pressure, slo ly open the delivery valve until the
orking pressure is attained.
Make sure that hen the pump is running, rotating parts are al ays properly guarded
by the safety guard/cover.
4.5 Pressure imitation / pressure contro :
Al ays select the lo est settings for commissioning.
Carefully increase the pressure to the required values, but do not set to
unnecessarily high values.
If required, secure settings against un anted adjustment.
4.6 Preparation for ubrication:
The bearings of pump are provided ith grease lubricated bearings. They are filled
ith grease at the time of delivery from factory.

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5. Maintenance
5.1 Routine Inspections:
Routine inspections should be made on a regular basis. Inspections made hile pump is
running should reveal potential failures.
A) Inspect motor bearings for any sign of temperature rise. Temperature should not exceed
160°F. Temperature rise may indicate the early stages of bearing problems.
B) Listen for any unusual noise.
a. Air trapped in pump.
b. Hydraulic noise.
c. Mechanical noise in motor and/or pump.
C) Check suction gauge reading and confirm that it is normal.
D) Check discharge gauge reading and confirm that it is normal. If gauge readings are
abnormal find out hy.
Note: Suction and discharge gauges shou d read the same with pump stopped.
5.2 Mechanica Sea :
A mechanical seal generally not require any maintenance. Ho ever, it should never be
allo ed to run dry. If there is no problem, it is not advisable to dismantle the mechanical
seal. As the sealing faces are running on one another, dismantling al ays means damage
and/or replacement of partial or complete mechanical seal. When the shaft sealing area is
found leaking, part or complete mechanical seal needs to be replaced based on results of
investigation.
5.3 Noise:
If after some time, the pumps start making noise this may indicate that something is rong
ith the pump unit. For instance, a crackling noise can indicate cavitation or an excessively
noise motor can indicate deterioration of the bearings.

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6. Cause of fai ures
A. Fai ure: - No Discharge
Causes: -
•Air leakage in suction line.
•Suction lift higher than pump is designed.
•Suction pipe block.
•Pump not primed.
•NPSH available too lo .
•Incorrect direction of rotation.
•Wrong pump selection.
•Obstructions in impeller and in pump casing
•Damaged impeller.
•Speed too lo .
B. Fai ure: - Insufficient discharge flo
Causes: -
•Air leak in suction line.
•Speed too lo .
•System head higher than anticipated.
•Insufficient NPSH. Suction lift too high. Check gauges.
•Also check for clogged suction line.
•Impeller partially plugged.
•Mechanical defects.
- Worn out ear rings.
- Impeller damaged.
- Incorrect direction of rotation.
C. Fai ure: - Insufficient discharge pressure
Causes: -
•Speed too lo .
•System head less than anticipated.
•Air in system.
•Mechanical defects.
- Worn out ear rings.
- Impeller damaged.
- Impeller diameter too small.
- Incorrect direction of rotation.
•Gas or air coming from the liquid.
D. Fai ure: - Loss of Suction
Causes: -
•Leak in suction line.
•Suction lift too high.
•Insufficient NPSH.
•Air in system.

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•Casing gasket defective.
E. Fai ure: - Excessive po er consumption
Causes: -
•Speed too high.
•System head lo er than rating.
•Specific gravity of liquid too high.
•Mechanical defects.
- Shaft bent.
- Rotating part running out of concentricity.
- Worn out ear ring.
F. Fai ure: - Minimum Po er consumption
Causes: -
•Speed too lo .
•Wrong direction of rotation.
•Pump doesn’t ork at the right duty point.
•Liquid density differs from the calculated liquid density.
•Liquid viscosity differs from the calculated liquid viscosity.
•Pump orks hen the liquid flo is too lo .
G. Fai ure: - Vibration / Noise
Causes: -
•Air in system.
•Foundation not rigid.
•Rotating part running out of concentricity.
•Obstruction in impeller or Pump casing
•Imbalance in rotating parts e.g. impeller, pump shaft, coupling.
•Mechanical defects.
- Damaged impeller.
- Motor bearings orn out.
- Rotor out of balance.
- Shaft bent.
H. Fai ure: - Motor runs hot
Causes: -
•Speed too high.
•Specific gravity of liquid too high.
•Mechanical defects.
- Shaft bent.
- Rotating elements bent.
- Defective motor.
- Voltage lo er than rating.