KIRLOSKAR KPDS Programming manual

INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE - KPDS - KPDSQF
KIRLOSKAR BROTHERS LIMITED
REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002
GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 9 /(3-7), BANER, PUNE 411 045

KIRLOSKAR BROTHERS LIMITED
REGISTERED OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002
GLOBAL HEADQUARTERS, YAMUNA, SURVEY NO. 9 /(3-7), BANER, PUNE 411 045
WARRANTY
We warrant that the um su lied from us is free from defective material
and faulty workmanshi . This warranty holds good for a eriod of 12
months from the date of commissioning the equi ment or 18 months from
the date of dis atch from our factory, whichever is earlier. Our liability in
res ect of any com laint is limited to re lacing art/ arts free of charge ex-
works or re airs of the defective art/ arts only to the extent that such
re lacement/re airs are attributable or arise solely from faulty workmanshi
or defective material.
This warranty holds good only for the roducts manufactured by us.
KIRLOSKAR BROTHERS LIMITED

CONTENTS:
PAGE NO.
1. INTRODUCTION 1
2. SAFETY INSTRUCTIONS 2
3. PRE-REQUISITES FOR SATISFACTORY OPERATION 6
4. PUMP HOUSE / TANK LAYOUT 6
5. PUMP HOUSE REQUIREMENTS 8
6. FOUNDATION 8
7. TOOLS AND EQUIPMENTS 9
8. EQUIPMENT SCHEDULE 10
9. EQUIPMENT OPERATION 10
10. ERECTION/ASSEMBLING PROCEDURE 11
11. OPERATION 17
12. MAINTENANCE 18
13. TECHNICAL DATA 22
14. CROSS SECTIONAL ASSEMBLY DRAWINGS & SPECIFICATIONS LIST 30
15. EXPLODED VIEW 38
Note: A copy of General instructions for maintenance, o eration &
maintenance of ‘Kirloskar pumps’ is attached at the end of this
manual.

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1. INTRODUCTION:
Pur ose of this manual
The purpose of this manual is to provide necessary information for:
• Installation
• Operation
• Maintenance
CAUTION:
• Read this manual carefully before installing and using the product. Improper
use of the product can cause personal injury and damage to property, and
may void the warranty.
NOTICE:
• Save this manual for future reference, and keep it readily available at the
location of the unit.
Product Descri tion: -
1.1 ‘KIRLOSKAR’ make KPDS - KPDSQF pumps are used for handling various types of
chemical liquids like acids, alkalis, hazardous liquids, hydrocarbons and water.
These pumps are manufactured to close tolerance and are of rigid construction,
However, proper installation, operation and maintenance are equally important to
ensure trouble free service. This booklet covers important guidelines and
instructions for installation, operation and maintenance. These instructions should
be followed carefully for satisfactory performance of the pumping unit. Only
mechanical aspects are dealt within this booklet.
1.2 This booklet covers instructions for following types of KPDS and KPDSQF series.
Unit 80C25 Unit 100C25 Unit 150C38 Unit 150C45
(1450RPM only)
20/13QF 25/16QF 25/26A# 65/32*
20/16QF 32/13* 32/26* 0/32*
20/20QF 32/16* 40/26* 0/40*/ 0/40N#
32/16A# 40/32* 100/26#
32/20* 50/26* 100/32*
32/20A# 50/32* 100/40*
40/13* 65/16* 125/26*
40/16* 65/20* 125/32*
40/20*,40/20A# 65/26* 125/40#,125/45#
50/13* 65/26N# 125/40N#
50/16* 0/16* 150/32*,150/32N#
50/16A# 0/20* 150/40#
50/20* 0/26* 65/43#
65/13* 100/20*
NOTES:
a) *Marked pumps are also supplied with semi-open (QF) type impeller as an
option.

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b) # Marked pumps are supplied with “Enclosed” type impeller only.
c) KPDS40/32QF & 50/32QF supplied in 1450 RPM only.
1.3 Description of KPDS pumps.
KPDS - KPDS pumps with enclosed impeller
KPDS-QF - KPDS pumps with semi open impeller.
KPDS - KIRLOSKAR PROCESS DEVELOPMENT SUMP
KPDS 32/13
32 INDICATES DELIVERY SIZE OF PUMP IN mm
13 INDICATES NOMINAL IMPELLER DIAMETER IN cm
Maximum column length & pump will be supplied in assembled condition up to 6.0
meters.
1.4 The complete range of ‘KPDS’ pump is covered by four driving units thereby reducing
inventory and achieving interchangeability.
1.5 Pumps when properly installed & given due care in operation & maintenance should
operate satisfactorily for a long period.
1.6 When the pump is received, sometime before the actual use of pump, it should be
inspected & located in dry place. The coupling should be rotated once in a month to
prevent pitting of bearing surfaces.
2. SAFETY INSTRUCTIONS:
2.1. General Information:
Before performing any actions detailed within 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 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
safe 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.
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.
2.1.2 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 with the appropriate tools for their respective tasks.
2.1.3 KBL firmly insists that all personnel responsible for installation, operation and
maintenance of the equipment must read the manual before any work is done.
2.1.4 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

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with pressurized systems and hazardous substances. Other personal protection
equipment must be worn where local rules apply.
2.1.5 DO NOT wear loose or frayed clothing or jewelry, which could catch on the controls
or becomes trapped in the equipment.
2.1.6 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.
2.1.7 Improper installation, operation and maintenance of the product supplied by KBL
could result in injury or death.
2.1. 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.
2.2 Environmental safety:
Always keep the station clean to avoid and/or discover emissions.
Waste and emissions regulations:
Observe these safety regulations regarding waste and emissions:
• Appropriately dispose of all waste.
• Handle and dispose of the processed liquid in compliance with applicable
environmental regulations.
• Clean up all spills in accordance with safety and environmental procedures.
• Report all environmental emissions to the appropriate authorities.
Electrical installation
For electrical installation recycling requirements, consult your local electric utility.
Recycling guidelines
Always follow local laws and regulations regarding recycling.
2.3 Trans ort handling and storage instructions:
2.3.1 Trans ort-
Pumps are dispatched in duly assembled condition. Pumps are protected against
corrosion and packed for transport by normal road, rail and sea carriers.

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2.3.2 Handling-
WARNING:
• Make sure that the pump cannot roll or fall over and injure people or damage
property.
• These pumps might use carbon or ceramic silicon carbide components. Do
not drop the pump or subject it to shock loads as this can damage the
internal ceramic components.
NOTICE:
Use a forklift truck or an overhead crane with sufficient capacity to move the
pallet with the pump unit on top. Failure to do so can result in equipment
damage.
2.3.3 Lifting methods-
WARNING:
• Assembled units and their components are heavy. Failure to properly lift and
support this equipment can result in serious physical injury and/or equipment
damage. Lift equipment only at the specifically identified lifting points. Lifting
devices such as eyebolts, slings, and spreaders must be rated, selected, and
used for the entire load being lifted.
• Crush hazard. The unit and the components can be heavy. Use proper lifting
methods and wear steel-toed shoes at all times.
• Do not attach sling ropes to shaft ends.
Use the supplied lifting lugs and suitable slings in order to lift the entire pump to a vertical
position and lower the unit into the sump. Then use the lifting lugs on the motor and a
suitable sling in order to hoist the motor into position. Use a tag line attached to the casing
end in order to prevent the pump from swinging. Refer Figure 1.
Pump set must be lifted from the lifting eye bolts provided on the support plate by using
suitable four chain lifting equipment.

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LIFTING ARRANGEMENT
A) With Rectangular Su ort late B) With Round Su ort late
Figure 1
NOTE: It is recommended to dismantle the motor from um along with electrical
connections and then lift the um assembly. This is recommended to avoid damage to the
motor, ro er alignment and levelling while commissioning the um .

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2.3.4 Storage.
2.3.4.1 Tem orary storage for u to six weeks-
If the pump unit is not to be used immediately it should be stored carefully in a
horizontal 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.
2.3.4.2 Long storage instructions above 6 months & u to 2 Years-
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. Care should be taken to
protect the pump from moisture, dust, dirt and foreign bodies. It is recommended that
following has to be followed-
a) Ensure that the bearings are packed with the recommended grease, to
prevent moisture entry.
b) 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.
c) 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.
d) The shaft should be manually rotated periodically preferably once in a
month to prevent pitting of the bearing surfaces by moisture.
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. PRE-REQUISITES FOR SATISFACTORY OPERATION:
For satisfactory working of the pump insure that the following preliminary conditions are
maintained.
a) Pump handles the liquid as specified in the order.
b) The liquid is free of solid particles since the P.T.F.E (Teflon) bearing life is
greatly affected by solids in the liquid.
c) Minimum submergence is kept as shown in the outline dimension drawing
supplied against the order.
d) Operation & maintenance instructions are followed as given in this
booklet.
e) Load of delivery pipe & other accessories such as sluice valve, reflux
valve, etc. is not coming directly on support plate.
Prior confirmation must be taken from the manufacturer/supplier, if the pump is to be used
for the conditions other than those specified in the order.
4. PUMP HOUSE / TANK LAYOUT:
The layout should be done after considering following-
4.1 Liquid inlet to the tank:
The liquid should enter in the tank such that turbulence, high velocity and air
entrainment are avoided at the suction of the pump.
4.2 Suction tank:
The tank should be designed to be so as to provide-

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4.2.1 Enough storage capacity to avoid sudden fluctuations in the liquid level,
kinematics disturbances at the suction of the pump such as turbulences,
eddies, vortices, air entrainment.
4.2.2 Low velocity:
Maximum liquid velocity of the liquid entering the tank should not exceed 1
m/sec.
4.2.3 Individual flow pattern:
Where one tank houses more than one pumping sets, care must be taken to
provide appropriate distances from walls, floor & adjacent pipes. It is advised
that such layouts should be referred to pump manufacturer. This is
necessary to ensure individual flow pattern of each pump undisturbed by
other pumps.
4.2.4 Pump Submergence:
The lowest liquid level should be as recommended in the outline drawing
supplied against the order. Highest liquid level also be below specified level
on the same drawing. The liquid level in the tank should be positively
controlled by liquid level controller/ float switch.
Below is the reference from HI pump intake design.
Dimension
Variable
Descri tion Recommended value
C Distance between the inlet bell & floor C = 0.3 D to 0.5 D
D Inlet bell design outside diameter Suction size of pump
H Minimum liquid depth H = S + C
S Minimum pump inlet bell submergence S = D(1.0+2.3F D )
w Constricted bay width near pump inlet bell w = 2D
Where, F D = Froude Number = V / √(gD)
V = Velocity at inlet face = Flow /Area