KIRLOSKAR RKB Programming manual

INSTRUCTIONS ON
INSTALLATION,
OPERATION AND
MAINTENANCE FOR
KIRLOSKAR PUMP
TYPE RKB
KIRLOSKAR BROTHERS LIMITED
YAMUNA’ Survey No. 98/ 3 to 7, Baner, Pune – 411045, ndia.

WARRANTY
We warrant that the pump supplied from us is free from defective material and
faulty workmanship. This warranty 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, whichever is earlier. Our liability in respect of any complaint is limited
to replacing part/parts free of charge ex-works or repairs of the defective part/parts
only to the extent that such replacement/repairs are attributable or arise solely from
faulty workmanship or defective material.
This warranty holds good only for the products manufactured by us.
KIRLOSKAR BROTHERS LIMITED

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CONTENTS:
1. GENERAL
2. SAFETY INSTRUCTIONS
3. EQUIPMENT SCHEDULE
4. OPERATION
5. TECHNICAL DATA
6. PREVENTIVE MAINTENANCE
7. OVERHAULING
8. SPARE PARTS LIST AND CROSS-SECTIONAL DRAWING
P EASE FURNISH PUMP TYPE, NAME OF THE PART, PART NUMBER, MATERIA
CONSTRUCTION AND OTHER NAME P ATE DETAI S WHI E ORDERING SPARE
PARTS FOR THE PUMP.
Note: A copy of General instructions for installation, operation & maintenance
of ‘Kirloskar pumps’ is attached at the end of this manual.

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1. GENERAL:
1.1 The booklet covers instructions for cold model of RKB pumps.
1.2 Cold Models pumps (without stuffing box cooling arrangement) are supplied for
liquid having temperature up to 90°C.
1.3 Pumps when properly installed & given due care in operation & maintenance
should operate satisfactorily for a long period of time.
1.4 When the pump is received, sometime before the actual use of pump, it should
be inspected & located in dry place. The shaft should be rotated once in a
month to prevent pitting of bearing surfaces.
2. Safety Instructions:
2.1 General Information
Please read the manual thoroughly prior to installation of unit. The 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 this instructions manual 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 COMP IED 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 KB 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. oss of this plate could make identification impossible. This in turn

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could affect safety and cause difficulty in obtaining spare parts. Such accidental
loss or damage if occurs, contact KB immediately.
2.1.2 Access to the equipment should be restricted to the personnel responsible for
installation, operation and maintenance and they must be qualified, adequately
trained and supplied with the appropriate tools for their respective tasks.
2.1.3 KB 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 with 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 KB before making
such change in the application of the equipment.
2.4 Improper installation, operation and maintenance of the product supplied by KB
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.
This symbol is used to introduce safety instructions, non-
Observance for which may lead to damage to the machine and its
functions.

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2.6 Transport Handling and Storage Instructions:
2.6.1 Transport.
Pumps are dispatched in duly assembled condition. ubricating oil in the bearing
housing is drained prior to dispatch of pump. 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 fork lift truck and four chain crane sling equipment is
recommended but locally approved equipment rating may be used.
Pump should be slung as shown.
Pump set must be lifted from the lifting holes provided using
suitable four chain lifting equipment.

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2.6.3 Storage.
2.6.3.1 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 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.
2.6.3.2 Long Term Storage.
Shearing Hazard.
Do NOT place fingers or hands, etc., into the suction or discharge pipe outlets
and do NOT touch the impeller, if rotated, may cause severe injury. To prevent
ingress of any objects, retain the protection covers or packaging in place until
removal is necessary for installation.
Fill the bearing housing with recommended oil/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 KB for special storage instructions to suit the
conditions acceptable.

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3. Equipment Schedule:
3.1 Installation:
3.1.2 For location, preparing foundation, installation, alignment, piping, general
maintenance, trouble shooting, etc., the instructions given in our publication -
’GENERA INSTRUCTIONS FOR INSTA ATION, OPERATION AND
MAINTENANCE OF KIR OSKAR CENTRIFUGA PUMPS’ which is also printed
along with this booklet must be followed very carefully.
3.1.3 MOUNTING AND ALIGNMENT
A jaw-flex type coupling is used to connect pump shaft to the driver. Follow the
instructions as shown below.
3.1.4 ALIGNMENT
A WAYS REMEMBER “A F EXIB E COUP ING IS NOT A UNIVERSA JOINT”
Correct alignment is essential for the smooth operation of the pump. There are
two types of misalignment between the pump shaft and the drive shaft, which
are:
1) Angular misalignment – Shaft with axis concentric, but not parallel.
2) Parallel misalignment – Shaft with axis parallel, but not concentric.
This misalignment is checked by using a straight edge as shown in figure given
above.
3.1.5 Before commissioning the pump set, please ensure:
1) The pipe connections are flushed and tightened properly.
2) Alignment is proper.
3) Auxiliary piping connections such as sealing connections, cooling
connections, etc., are made. Details of sealing liquid are given in our
supply order.

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4. OPERATION:
4.1 Before starting the pump check the following:
1) The pump rotates freely by hand.
2) Fill the grease/oil for the bearings, if not done earlier. The bearings are packed with
grease in the factory for grease lubricated pumps.
3) However, if the pump is stored for a longer time it is necessary to refill the grease in
the bearings. Check the level of oil in the constant level oiler when pump is oil
lubricated.
4) The sealing liquid and cooling water connections are properly tightened and
adjusted.
5) The direction of rotation of driver. It should correspond to the direction of rotation of
pump.
6) The pump casing and the suction pipeline is fully primed with the liquid.
7) Valve on delivery side is closed.
8) The cock for pressure gauge connection is closed.
9) The stuffing box packing is properly tightened.
4.2 Starting the pump
1) Start the pump. et the prime mover pick up its full speed.
2) Open the valve on delivery line gradually.
3) Regulate the required flow by adjusting the delivery valve.
4) Open the cock for pressure gauge connection.
4.3 During running the pump
Check the following things and regulate if needed –
1) The pump is running smoothly.
2) The flow of sealing liquid and cooling water is uninterrupted. If necessary,
provide sight glass in the piping.
3) The bearings are not getting abnormally hot.
4) The gland is properly tightened to give leakage of approximate 60-80 drops per
minute through stuffing box.
5) Head and capacity developed by the pump is as specified.
6) Power consumption is within limit.
7) Ensure that there is no mechanical friction in the pump.

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8) Stop the pump immediately, if any defects are detected. Do not
start the pump unless the defects are rectified. Report immediately to the
supplier, if it is not possible to rectify the defects.
4.4 During stopping the pump
1) Close the valve on the delivery line.
2) Stop the motor.
3) Close the cooling water and sealing liquid connections.
4) If the pump is not required to be operated for a long time, drain the
casing completely. If the pump is required to be stored for a long time, the
bearing housing should be dried internally with hot air and should be flushed with
moisture free protective such as light oil or kerosene.
5. TECHNICAL DATA:
5.1 Models:
5.1.1 ‘RKB’ types of pumps are available in models as given in table below.
SR NO. PUMP TYPE MAX. STAGES
1 RKB – 32/9E 16
2 RKB – 32/14H 14
3 RKB – 40/12 14
4 RKB – 40/14H 12
5 RKB – 50/15E 14
6 RKB – 50/15 14
7 RKB – 50/16H 11
8 RKB – 50/26 8
9 RKB – 65/19E 12
10 RKB – 65/19 12
11 RKB – 65/19 M 12
12 RKB – 65/19H 12
13 RKB – 65/24 11
14 RKB – 100/23E 11
15 RKB – 125/27 11
16 RKB – 125/30 10
17 RKB – 150/34 9
18 RKB – 200/37 8
19 RKB – 250/46K 6
20 RKB – 250/46DK 5

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5.1.2 RKB pumps are suitable for clear liquids having temp -30 to +90 deg C.
5.2 Direction of rotation: The direction of rotation is clockwise when viewed from
driving end. Against specific requirement pump suitable to anticlockwise rotation
shall be supplied.
Please refer to the Arrow nameplate attached to pump for the
direction.
5.3 Bearings: The shaft is supported with antifriction roller bearing at driving end and
pair of angular contact ball bearing at non-driving end in face to face arrangement.
The bearing specifications are given below. The designations of bearings are as per
SKF catalogue. However, equivalent bearing in type, capacity and dimensions can
also be used.
Pump Size Bearing at D.E. Bearing at N.D.E.
RKB – 32/9E NU 306 6306
RKB – 32/14H 6305 6305
RKB – 40/12 NU 307 2 x 7307BG
RKB – 40/14H
RKB – 50/15E NU 308 2 x 7308BG
RKB – 50/15
RKB – 50/16H NU308 2 x 7308BG
RKB – 50/26 NU 308 2 x 7308BG
RKB – 65/19E
NU 309 2 x 7309BG
RKB – 65/19
RKB – 65/19 M
RKB – 65/19H
RKB – 65/24 NU 413 2 x 7314BG
RKB – 100/23E NU 310 2 x 7310BG
RKB – 125/27 NU 411 2 x 7311BG
RKB – 125/30 NU 412 2 x 7312BG
RKB – 150/34 NU 413 2 x 7313BG
RKB – 200/37 NU 414 2 x 7314BG
RKB – 250/46
NU 319
Spherical Roller Brg. SKF 22220E
Spherical Roller Thrust Brg. SKF
29422E

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NOTE:- 1) Above bearing details at DE & NDE applicable for clockwise pump operating
at 50 c/s only.
2) Bearing of SKF or equivalent make.
3) Pair of angular contact ball bearing are fitted in face to face condition
4) In case of anticlockwise direction pump, NDE becomes DE and DE becomes NDE.
5.4 Bearing temperature:
Maximum allowable temperature of bearings: 80
0
C.
5.5 ubrication of Bearing:
Bearings are grease lubricated. Bearings are lubricated during assembly of pump
at our factory. The re-greasing should be done after every 1000 hours of running.
To recharge the bearing with fresh grease, use a grease gun through the nipples
provided.
DO NOT APP Y UBRICANT WHEN PUMP IS RUNNING.
Following lubricant grades available in the market are suitable.
[A] GREASE:
NAME GREASE SPECIFICATION
SPEED 1450 RPM SPEED 2900 RPM
INDIAN OI SERVOGEM-3 SERVOGEM-2
HINDUSTAN
PETRO EUM A VANIA GREASE-3 A VANIA GREASE-2
INTERNATIONA
GRADE N GI-3 N GI-2
[B] OIL QUANTITY APPLICABLE ONLY FOR RKB 250/46:
Oil capacity for DE Bearing 0.30 litre
Oil capacity for NDE Bearing 3.00 litre

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5.6 Stuffing box: Stuffing box sealing arrangement-
5.6.1 Sealing to antern ring: One of the following methods fit to be employed. This is
applicable for horizontal pumps only with gland packing arrangement (For this
please refer to Drg. No. CT 127-82-001-0).
5.6.2 Self sealing: If order specifies sealing through liquid pumped, self sealing
arrangement shall be provided. For this lantern ring is connected to first stage
internally.
5.6.3 External sealing: If order specifies sealing through external compatible liquid,
supply liquid externally. Pressure recommended is one kg/cm
2
(g) more than
suction pressure and quantity required shall be 0.05 m
3
/hr. max.
5.6.4 Grease sealing: If order specifies grease sealing, pump is provided with a grease
nipple at the suction side stuffing box. Through this grease nipple, grease is
required to be pushed in with the help of grease gun.
NOTE- In the stuffing box of the delivery side, lantern ring is not provided as
sealing to stuffing box is not required on delivery side.
5.7 Stuffing box packing and lantern ring:
Please refer to the following chart for stuffing box packing size and position of
lantern ring.
Pump Type Packing Arrangement Packing Size
RKB – 32/9E 1+ +4 10 mm x 10 mm
RKB – 32/14H 1+ +2 8 mm x 8 mm
RKB – 40/12 1+ +4 10 mm x 10 mm
RKB – 40/14H 1+ +4 10 mm x 10 mm
RKB – 50/15E 1+ +4 10 mm x 10 mm
RKB – 50/15 1+ +4 10 mm x 10 mm
RKB – 50/16H 1+ +4 10 mm x 10 mm
RKB – 50/26 1+ +4 10 mm x 10 mm
RKB – 65/19E 1+ +4 12 mm x 12 mm
RKB – 65/19 1+ +4 12 mm x 12 mm
RKB – 65/19 M 1+ +4 12 mm x 12 mm
RKB – 65/19H 1+ +4 12 mm x 12 mm
RKB – 65/24 1+ +4 14 mm x 14 mm
RKB – 100/23E 1+ +4 12 mm x 12 mm
RKB – 100/23M 1+ +4 12 mm x 12 mm
RKB – 125/27 1+ +4 14 mm x 14 mm

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RKB – 125/30 1+ +4 14 mm x 14 mm
RKB – 150/34 1+ +4 14mm x 14 mm
RKB – 200/37 1+ +4 16 mm x 16 mm
RKB – 250/46 2+ +3 20 mm x 20 mm
5.8 ‘O’-ring & key specification:
Material of O-ring shall be Nitrile rubber.
5.9 ‘O’ RING SIZE SPECIFICATION
Pump
T
ype
Stage Part No.
52201/52203
Diffuser Part
No.52202
Shaft Sleeve
(Gland Packed
Part No. 52200
RKB – 32/9E 148.82 ID X 3.53 T 81.0 ID X 3 T 31.6 ID X 2.4 T
RKB – 32/14H 172 ID X 3 T ------ 23 ID X 3 T
RKB – 40/12 190.1 ID X 3.53 T 99.5 ID X 3.53 T 36.5 ID X 3 T
RKB – 40/14H 190.1 ID X 3.53 T 99.5 ID X 3.53 T 36.5 ID X 3 T
RKB – 50/15E 202.8 ID X 3.53 T 104.37 ID X 3.53 T 41.5 ID X 3 T
RKB – 50/15 202.8 ID X 3.53 T 104.37 ID X 3.53 T 41.5 ID X 3 T
RKB – 50/16H 202.8 ID X 3.53 T 104.37 ID X 3.53 T 41.5 ID X 3 T
RKB – 50/26 322 ID X 4 T 104.37 ID X 3.53 T 41.5 ID X 3 T
RKB – 65/19E 240.9 ID X 3.53 T 120.25 ID X 3.53 T 46.5 ID X 3 T
RKB – 65/19 240.9 ID X 3.53 T 120.25 ID X 3.53 T 46.5 ID X 3 T
RKB – 65/19 M 240.9 ID X 3.53 T 120.25 ID X 3.53 T 46.5 ID X 3 T
RKB – 65/19H 240.9 ID X 3.53 T 120.25 ID X 3.53 T 46.5 ID X 3 T
RKB – 65/24 297 ID X 4 T 170 ID X 4 T 75.57 ID X 5.33 T
RKB – 100/23E 278.99 ID X 3.53 T 129.27 ID X 3.53 T 49.5 ID X 3 T
RKB – 100/23M 278.99 ID X 3.53 T 129.27 ID X 3.53 T 49.5 ID X 3 T
RKB – 125/27 355.19 ID X 3.53 T 158.35 ID X 3.53 T 55.5 ID X 3 T
RKB – 125/30 385 ID X 3 T 174.3 ID X 5.7 T 60.33 ID X 3.53 T
RKB – 150/34 436 ID X 4 T 200 ID X 6.3 T 75.57 ID X 5.33 T
RKB – 200/37 468 ID X 6 T 215.27 ID X 6.99 T 69.22 ID X 5.53 T
RKB – 250/46 586 ID X 6 T 283 ID X 6 T 95 ID X 4 T

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5.10 KEY SIZES FOR ‘RKB’ PUMPS
5.11 Coupling: Coupling shall be supplied along with the pump only if specified so.
Coupling type used shall be preferably jaw flex type.
5.12 Pressure Relaxation Piping:
(Please refer Drg. No. TP 129-88-003-0).
To reduce stuffing box pressure on delivery side, pump is supplied with special
piping which connects the chamber just before the delivery side stuffing box to
lower pressure region. This piping is provided in order to reduce the pressure of
liquid acting on the stuffing box to minimize leakage through gland. The chart
Location Key for Coupling Key for First
impeller
Key for Stage
impeller
Key for Last
impeller
Part Code No.
Pump Type 32100 32000 32001 32002
RKB – 32/9E 8 X 7 X 54 6 X 4 X 25 6 X 4 X 14 6 X 4 X 44
RKB – 32/14H 8 X 7 X 54 6 X 4 X 25 6 X 4 X 20 6 X 4 X 44
RKB – 40/12 8 X 7 X 50 6 X 4 X 25 6 X 4 X 20 6 X 4 X 55
RKB – 40/14H 8 X 7 X 50 6 X 4 X 25 6 X 4 X 20 6 X 4 X 55
RKB – 50/15E 10 X 8 X 75 8 X 7 X 45 6 X 4 X 25 8 X 7 X 64
RKB – 50/15 10 X 8 X 75 8 X 7 X 45 6 X 4 X 25 8 X 7 X 64
RKB – 50/16H 10 X 8 X 75 8 X 7 X 45 6 X 4 X 25 8 X 7 X 64
RKB – 50/26 10 X 8 X 75 8 X 7 X 45 8 X 7 X 32 8 X 7 X 72
RKB – 65/19E 12 X 8 X 100 10 X 8 X 60 10 X 8 X 44 10 X 8 X 80
RKB – 65/19 12 X 8 X 100 10 X 8 X 60 10 X 8 X 44 10 X 8 X 80
RKB – 65/19 M 12 X 8 X 100 10 X 8 X 60 10 X 8 X 44 10 X 8 X 80
RKB– 65/19H 12 X 8 X 100 10 X 8 X 60 10 X 8 X 44 10 X 8 X 80
RKB – 65/24 18 X 11 X 80 12 X 8 X 75 12 X 8 X 50 12 X 8 X 75
RKB – 100/23E 14 X 9 X 100 10 X 8 X 60 10 X 8 X 50 10 X 8 X 100
RKB – 100/23M 14 X 9 X 100 10 X 8 X 60 10 X 8 X 50 10 X 8 X 100
RKB – 125/27 14 X 9 X 100 10 X 8 X 60 10 X 8 X 50 10 X 8 X 100
RKB – 125/30 16 X 10 X 100 12 X 8 X 60 12 X 8 X 44 12 X 8 X 110
RKB – 150/34 18 X 11 X 130 12 X 8 X 75 12 X 8 X 50 12 X 8 X 130
RKB – 200/37 18 X 11 X 130 12 X 8 X 75 12 X 8 X 50 12 X 8 X 130
RKB – 250/46 25 X 14 X 150 16X10X150 16X10X110 16X10X210

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enclosed indicates the stage to which the pipe is to be connected. The chart
holds well only if suction pressure is below 2 bars. Alternative arrangement shall
be recommended if suction pressure exceeds 2 bars.
5.13 Specification for Oil Seals.
Oil seals at DE & NDE are identical.
PUMP TYPE OIL SEAL SIZE
RKB – 32/9E 40 X 52 X 7 Thick
RKB – 32/14H Not Required
RKB – 40/12 45 X 60 X 8 Thick
RKB – 40/14H 45 X 60 X 8 Thick
RKB – 50/15E 52 X 68 X 8 Thick
RKB – 50/15 52 X 68 X 8 Thick
RKB – 50/16H 52 X 68 X 8 Thick
RKB – 50/26 52 X 68 X 8 Thick
RKB – 65/19E 52 X 68 X 8 Thick
RKB – 65/19 52 X 68 X 8 Thick
RKB – 65/19 M 52 X 68 X 8 Thick
RKB – 65/19H 52 X 68 X 8 Thick
RKB – 65/24 Not Required
RKB – 100/23E 65 X 85 X 10 Thick
RKB – 100/23M 65 X 85 X 10 Thick
RKB – 125/27 72 X 95 X 10 Thick
RKB – 125/30 80 X 110 X 13 Thick
RKB – 150/34 90 X 110 X 13 Thick
RKB – 200/37 100 X 125 X 12 Thick
RKB – 250/46 Not Required
Material of oil seal shall be Nitrile rubber with steel spring.
5.14 TORQUE FOR TIE BAR NUTS:
Sr. No. Pump Type Number of Stages Torque in (kg-m
1
RKB – 32/9E
RKB – 32/14H
2to 6
7 to 10
11 to 13
8
9
10
2
RKB – 40/12
RKB – 40/14H
2 and 3
3to 7
16
18

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5 to 11 20
3
RKB – 50/15E
RKB – 50/15
RKB – 50/16H
RKB – 50/17
2 to 4
5 to 7
8 to 11
25
29
35
4 RKB – 50/26
2 to 3
3to 5
4 to 7
8
15
24
34
40
5
RKB – 65/19E
RKB – 65/19
RKB – 65/19 M
RKB – 65/19H
2 to 4
5 to 7
8 to 9
60
70
80
6 RKB – 65/24
2 to 3
4 to 6
7 to 9
65
75
85
7 RKB – 100/23E
RKB – 100/23M
2 to 3
4 to 5
6 to 8
51
56
61
8 RKB – 125/27
2 to 4
5 to 7
8 to 10
11 to 13
14
40
45
50
55
57
9 RKB – 125/30
2 to 5
6 to 9
10 to 13
60
70
80
10 RKB – 150/34
2 to 4
5 to 8
9 to 12
35
70
95
11 RKB – 200/37
2 and 3
4 and 5
6 and 7
8 to 11
125
140
155
172

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5.15 DIMENSIONS OF WASHER FOR RKB PUMPS.
Pump Type D d D9 Thickness
of washer
(t
Theoretical
Thickness
(B
RKB – 32/9E 40 30 6 3.5
RKB – 32/14H Not applicable
RKB – 40/12 46 35
6 3.5
RKB – 40/14H
RKB – 50/15E
50 40 6 3.3
RKB – 50/15
RKB – 50/16H
RKB – 50/26
RKB – 65/19E
58 45 6 4
RKB – 65/19
RKB – 65/19 M
RKB – 65/19H
RKB – 65/24 90 70 10 6
RKB – 100/23E 62 50
6 4
RKB – 100/23M
RKB – 125/27 72 55 8 5.5
RKB – 125/30 80 60 8 4
RKB – 150/34 90 65 10 4
RKB – 200/37 90 70 10 4
RKB – 250/46 115 90 10 7.75

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NOTE: - Initially washer is to be manufactured with thickness ‘t’ as specified
above. The washer shall have to be machined to required thickness at the time of
assembly of the individual pump considering the axial movement of pump shaft
on either side.
For RKB 32/14H Pump adjustable washer is not used.
6. PREVENTIVE MAINTENANCE :
Preventive maintenance schedule is the periodical checks and precautions by
which possibilities of failures and breakdowns are minimized.
6.1 Daily checks:
6.1.1 Hourly record of suction and delivery pressure, discharge quantity, input to
the pump driver should be maintained.
6.1.2 Bearing temperature, stuffing box leakage / stuffing box temperature, this
gives an idea of mechanical performance of the pump.
6.1.3 Noise and vibrations are the first signs of impending troubles like cavitation,
air lock, bearing failure, choking of impeller or casing and such other operating
troubles. The pump performance should therefore be checked for noise and
vibrations.
6.2 Periodical checks:
6.2.1 The temperature of the bearing should be measured by thermometer. Safe
maximum working temperature of the bearing is 80°C.
6.2.2 The lubricants of the bearing should be checked. The lubricant might get
contaminated with foreign material or get blackened due to overheating. In
such cases, bearings should be flushed and charged with fresh lubricants.
6.2.3 Check for the stuffing box leakage.
6.2.4 The alignment of the pump unit should be checked. Due to operational
vibrations, atmospheric temperature or stress induced by the weight of the
piping, the alignment may get disturbed.
6.2.5 Sufficient quantity of suitable type of lubricant should be ready for daily and
emergency use.
6.2.6 Calibrate the measuring instrument.
6.3 Annual checks:
6.3.1 The pump should be overhauled completely to check the clearance and to
replace worn-out parts. Clearance between impeller and casing rings, shaft
sleeves and throat bush, lantern ring and shaft sleeve, etc., are very
important. The bearings should be cleaned thoroughly and lubricated.

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6.3.2 The effects of liquid handled on pump components should be checked. If
abnormal corrosion, erosion is observed, the component should be replaced
with that of suitable material.
6.3.3 The auxiliary pipelines and functioning of the auxiliary system should be
checked. The main pipe also should be checked for scaling, leakage, etc.
6.3.4 The measuring instruments, gauges, etc., should be recalibrated.
6.3.5 Full running test may be carried out to check whether there is any fault in the
performance, in comparison with original performance.
6.3.6 Piping supports should be checked so that the pipes do not induce unwanted
stresses on the pump.
7. OVERHAULING:
7.1 Procedure for dismantling and re-assembly.
While dismantling and re-assembling, the cross-sectional assembly drawing
and specification part list should be referred.
7.2 Dismantling:
Follow the following simple steps to dismantle the pump.
7.2.1 Isolate power supply to motor.
7.2.2 Shut off valves controlling flow to and from the pump.
7.2.3 Drain the liquid from pump by removing the drain plug or open the pump
casing drain cock.
7.2.4 Remove all auxiliary tubing and piping.
7.2.5 We recommend matching the punch mark of the coupling halves.
7.2.6 In case of the pumps with spacer type flexible couplings, disconnect coupling
(pump half and motor half) from the coupling spacer and remove coupling
spacer. In case of ordinary flexible couplings, remove the motor from the
base.
7.2.7 Remove the delivery and suction pipe connections.
7.2.8 Remove the pump from the base plate and place it on a plain table or
platform. Remove pump half coupling.
7.2.9 Drain the liquid from suction and delivery casing by removing the drain plugs.
7.2.10 oosen the gland (22300) at DE & NDE.
7.2.11 Take out bearing cover NDE (27100).
7.2.12 Unlock lock washer (41500) and unscrew the locknut (33600).
7.2.13 Take out bearing housing (24001) along with bearing/bearings. For this
purpose use two jaw puller. Do not use hammer to remove brg. / brg. housing.
7.2.14 Remove adjustable washer (20901), liquid deflector (23600), distance sleeve
(31700), gland (22300), ‘O’ ring (52200), shaft sleeve (31100).