KIRLOSKAR SHS Programming manual

INSTRUCTIONS ON INSTALLATION,
OPERATION AND MAINTENANCE
FOR
KIRLOSKAR PUMPS
TYPE
SHS
Grease Lubricated a d Water Lubricated
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 warra t that the pump supplied from us is free from defective
material a d faulty workma ship. This warra ty holds good for a
period of 12 mo ths from the date of commissio i g the equipme t or
18 mo ths from the date of dispatch from our factory, whichever is
earlier. Our liability i respect of a y complai t is limited to replaci g
part/parts free of charge ex-works or repairs of the defective
part/parts o ly to the exte t that such replaceme t/repairs are
attributable or arise solely from faulty workma ship or defective
material.
This warra ty holds good o ly for the products ma ufactured by us.
KIRLOSKAR BROTHERS LIMITED

INDEX
SR.NO. CONTENTS PAGE NO.
1 INTRODUCTION 1
2 SAFETY INSTRUCTIONS 2
3 PRE-REQUISITIES FOR SATISFACTORY OPERATION 5
4 PUMP HOUSING LAYOUT 5
5 FOUNDATION 7
6 TOOLS AND EQUIPMENT 8
7 EQUIPMENT SCHEDULE 10
8 EQUIPMENT OPERATION 11
9 PREPARATORY FOR ERECTION 12
10 ERECTION PROCEDURE OF THE PUMPS 15
11 OPERATION 21
12 MAINTENANCE 23
13 TECHNICAL SPECIFICATION 30
Please furnish complete nameplate details, name of parts, part nos. and material
construction while ordering spare parts for the pump.
Note: A copy of Ge eral i structio s for mai te a ce, operatio &
mai te a ce of ‘Kirloskar pumps’ is attached at the end of this manual.

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1.0 INTRODUCTION
Purpose of this ma ual
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 Description: -
SHS type sump pumps are manufactured to the close tolerances and rigid specifications.
Hence proper erection and maintenance is equally important to ensure trouble free service.
This booklet covers important guidelines and instructions on erection, operation and
maintenance for the following sizes of SHS pumps.
STANDARD SHS PUMP MODELS
*UNIT-7 *UNIT-9 UNIT-11 UNIT 13
SHS 50/26 N, NB, Q
SHS 50/32 N
SHS 100/26 N, Q SHS 150/26 N, NB, Q SHS 200/32 N, Q
SHS 0/26 N, Q SHS 100/32 N, Q SHS 150/32 N, Q SHS 150/40N, Q
SHS 65/32 N, NB, Q SHS 0/40 N, NM, Q SHS 100/40 N, Q SHS 200/40 N
** SHS-E pump models
UNIT-7 UNIT-9
SHS 50/26 NE, NBE, QE SHS 100/26 NE, QE
SHS 0/26 NE, QE
SHS
195/32 NE, QE
SHS 65/32 NE, NBE, QE
SHS 0/40 N, QE
**up to 3500 mm column length only. SHS-E pump models are obsolete.
The above models can be offered with following impellers:
P-Single vane enclosed impeller.
N-Two vanes enclosed impeller.
Q-Three vanes semi-open impeller.
R-Eight vanes free flow impeller.
These instructions should be followed carefully failing which it may result in the
unsatisfactory performance/damage to the pump.

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Only mechanical aspects are dealt in this manual. Civil and electrical engineering details are
to be finalized at customer end only.
The special problems arising at the site should be referred to the supplier. The name plate
details should be mentioned while making correspondence with supplier/manufacturer.
2.0 SAFETY INSTRUCTIONS:
2.1. Ge eral I formatio :
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 using 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
always the responsibility of the user of the equipment for maintaining safe working
practices.
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
with pressurized systems and hazardous substances. Other personal protection
equipment must be worn where local rules apply.
2.1.5 DO NOT wears 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.

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Hazard.
- This symbol refers to electrical safety.
2.2 E viro me tal safety:
Always keep the station clean to avoid and/or discover emissions.
Waste a d emissio s regulatio s:
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 i stallatio
For electrical installation recycling requirements, consult your local electric utility.
Recycli g guideli es
Always follow local laws and regulations regarding recycling.
2.3 Storage & ha dli g
2.3.1 O receivi g the material –
The SHS, SHS-E pump having column lengths up-to 2 metres are dispatched in
completely assembled condition. The pumps with more than 2 metres column
length are dispatched in partially assembled form.
i. Check that all the packages are intact and that open parts are not damaged in
transit.
ii. Open the packings and check contents of each packings against delivery notes.
iii. Check specifically line shafts by using V blocks or on lathe by dial gauge and verify
that these are not bent and are in good conditions (when the shafts are supplied in
separate package). The runout of shafts should be maximum 0.050 mm.
iv. Report immediately discrepa cies, if a y, to the supplier.
v. Unless the pump is to be installed immediately, repack the material in respective
cases after the contents have been verified against delivery note.
2.3.2 Storage:
i. Storing place should be free from dust, heat, moisture, etc. Storeroom should have
enough space for easy movement and stacking of material. The floor of the
storeroom should be hard and plain.
ii. Do not place the packages one over the other inconveniently. Keep the parts on
wooden logs and properly levelled.

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iii. Keep the parts in proper sequence so that during erection they can be taken out in
an orderly fashion.
2.3.2.1 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.
2.3.2.2 Lo g storage i structio s above 6 mo ths & up 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.
2.3.3 Ha dli g:
i. All machined parts are coated with special anti-rust coat. If any part is found
exposed, clean it and apply a thick coating of grease or anti-rust compound and
then wrap it with paper to prevent further rusting.
ii. Never try to drag any component part or packages of parts for any reason. Dragging
sets in intrinsic vibration which distorts the accuracies, parallelism, etc. of machined
surfaces. Distortion of accuracies might cause serious functional and operational
troubles.
iii. Over hanging should be avoided as far as possible. While lifting the parts by the
ropes, they should be properly balanced.
iv. Transportations should be free from jerks. Long parts should not be handled without
due supports.
v. Open parts must be transported on soft and well supported bedding.
2.3.4 Cautio :
CARE MUST BE EXERCISED IN HANDLING OF ALL PARTS PARTICULARLY THE
SHAFTS. THEY ARE MACHINED TO CLOSE TOLERANCES AND CAREFULLY
INSPECTED AT FACTORY AND IF BENT, CAN CAUSE TROUBLE. A BENT SHAFT
SHOULD NEVER BE INSTALLED.

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3.0 PRE-REQUISITIES FOR SATISFACTORY OPERATION
For satisfactory operation, the pump must work under specific conditions given
below:
3.1 The pump handles the liquid as specified in the O/A.
3.2 The pump operates as the duty point as specified in the O/A.
3.3 Minimum submergence is kept as shown in the outline dimension drawing
supplied.
3.4 Operating and maintenance instructions are followed as given in this manual.
3.5 Load of delivery pipe and other accessories such as sluice valve, reflux valve
is not coming directly on pump column.
3.6 The erection must be done by the experienced/skilled personnel. Prior
confirmation must be taken from the manufacturer/supplier, if the pump is to
be used for the conditions other than specified in the O/A.
4.0 PUMP HOUSE LAYOUT
The sump should be so designed as to provide.
4.1 E ough storage capacity to avoid:
4.1.1 Sudden fluctuations in liquid levels.
4.1.2 Kinematic disturbances at the bell mouth such as turbulence, eddies, vortices,
etc.
4.1.3 Air entrainment.
4.2 Low velocity:
The maximum liquid velocity in sump should not exceed one metre per second in
any case. Velocity can be reduced by providing suitable baffles in the flow
passage.
4.3 I dividual flow patter :
Where one sump houses more than one pumping set, every pump should have its
individual flow pattern undisturbed by the other. While locating the pump in the
sump, minimum distance from walls, floor and adjacent pipes as recommended by
manufacturer should be maintained.
4.4 Screen at inlet of the sump to avoid entry of large size solid (size more than
specified for the pump).
4.5 Pump submerge ce:
The lowest liquid level in the sump should be 300 mm above the centre line of the
pump as indicated in the outline drawing supplied. Highest liquid level should be
below the breather hole provided on top suspension pipe.
The level in the sump should be controlled by liquid level controller/float switch.

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4.6 Stre gth of the buildi g:
The building should be strong and sturdy to withstand the water thrust and weight
of the pump etc. The floor should be designed to take weight of the machine
including that of the water column in the rising pipes, axial thrust of the impeller,
water hammer, etc.
4.7 E ough floor area for worki g/overhauli g:
The following factors should be considered;
4.7.1 Proper spacing of the pumps to avoid transmission of vibration from one
machine to another.
4.7.2 Easy and safe access to electrical switch gear.
4.7.3 Space for dismantling the pump parts during overhauling.
4.7.4 Space for tools and equipment of the operator.
4.7.5 Enough head room for erection. Provision for overhead travelling crane or
chain pulley.
4.8 Block:
4. .1 Pump house should provide adequate height between the foundation and
upper most position of the crane hook to facilitate smooth and easy erection.
4. .2 The pump house should provide enough cross travel of trolley so that the
pump subassemblies can be moved without any hindrances of receiving any
undue stress during movement.
4.9 Ventilation for cooling of the motor.
4.10 Provision for storeroom.

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5.0 FOUNDATION
The foundation layout should be considered from the following aspects:
5.1 Dime sio al requireme ts
5.1.1 The location of foundation bolts should be marked as per the outline drawing
supplied in advance. The bolt holes should come on beam center or on
supporting frame centre.
5.1.2 If necessary, the machined pads should be welded to the beams to provide
enough depth to foundation bolts and to provide uniform and machined
surface for levelling.
5.1.3 The position of girders/supporting structure should be arranged in such a
fashion that there is no hindrance while lowering the pump in the sump.
5.2 Stre gth
5.2.1 The total load is borne by the motor stool and support plate in turn by the
beam on which they are resting. In order to take all this load including safety
factor for vibration, the girders/beams should be firmly embedded in the
walls.
5.2.2 The girders or supporting frames should be of adequate strength to take the
load of complete set, weight of the liquid column, axial thrust, etc. Below are
the schematic views of foundation types.
5.3 Levelli g
5.3.1 It is essential to check the level of the girders/beams individual and in
combination before mounting the motor stool. It is to be borne in mind that
motor stool must be levelled perfectly to the accuracy of 0.05 mm per
metre. For smooth working of the pump, it is necessary that the motor stool
keeps up its horizontal level perfectly after mounting and that rotating unit
keeps its vertical position. The rotating unit should be aligned with its
vertical axis.
5.3.2 If the girders are not in one level, then they should be brought in one level by
suitably grinding, filling, etc. or by welding machined pads. It is to be
ensured that there should be no point contact after mounting of the motor
stool on the girders.

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5.4 Disturba ces to the leveli g
After mounting the motor stool and support plate on the girders, delivery
branch flange above support plate should perfectly match with the flange of the
delivery pipe. In case, the matching is imperfect with respect to the parallelism
centre axis, bolt holes, etc. of the delivery branch it is bound to disturb the
alignment. Clearance between the flanges should be such that it does not give
rise to any displacement of the pumping unit, during tightening them together
alongwith the intermediate packing. Due care should be taken to see that load
of the delivery piping and accessories such as sluice valve, reflux valve, etc.
should not come on the motor stool and support plate. Separate firm supports
should be given to the delivery pipe and its accessories.
6.0 TOOLS AND EQUIPMENT
6.1 The equipment and tools which are essential for erection of the pump.
6.1.1 The crane/chain pulley block:
The crane/chain pulley block should be of ample capacity to take the load of
the complete unit. The pulley block should have the lift of about 3 metres and
the hand chains provided should be long enough to operate it conveniently
from the floor. The chain pulley block of 3 tons capacity is most suitable.
6.1.2 Chains, shackles, etc.
6.1.3 Jut ropes, crow bars and small pipes for leverage, wire rope.
6.1.4 Light but accurate straight edge.
6.1.5 Spirit level having the accuracy of 0.02 mm/m.
6.1.6 Kerosene or thinner for cleaning for parts.
6.1.7 Small wire brush for cleaning threads of shafts and couplings.
6.1. Threading compound for shaft and pipe threads.
6.1.9 Feeler gauge and shims of brass and steel for adjustment of level.
6.1.10‘V’ blocks, dial gauge with magnetic stand to check the runout of the shafts.
6.1.11Two sturdy wooden logs or MS girders to rest the clamps during erection
process.
6.2 Special spa ers a d clamps supplied alo gwith the pumps are as u der:
6.2.1 2 pairs of clamps for suspension pipe (for column length 2 m and above).
6.2.2 2 pairs of clamps for rising pipe (for column length 2 m and above).
6.2.3 1 set of clamps for line shaft.

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6.2.4 Hex. Socket head cap screw key.
6.2.5 2 spanners for screwed coupling and bearing nuts.
6.2.6 1 spanner for transmission shaft.
6.2.7 1 spanner for coupling pins.
6.2. 4 eye bolts for lifting the motor stool.
6.2.9 1 spanner for pipe nut.
6.3 Besides above, the erector must have followi g sta dard tools a d equipme t
for smooth erectio :
6.3.1 Files-Triangular half, round and flat of different cuts and sizes.
6.3.2 Triangular scraper.
6.3.3 2 sets of standard or ring spanners, set of box spanners, set of Allen keys.
6.3.4 Set of pipe wrenches and chain tang.
6.3.5 Adjustable spanner, screw drivers of 150 mm (6”) and 300 mm (12”).
6.3.6 Steel rule and steel tape.
6.3.7 Set of taps and dies up to 25 mm (1”).
6.3. Chisel, machinist’s hammer (1kg), hack saw, vice, etc.
6.3.9 Emery paper, grease gun, thin rolled sheets of 0.03 mm to 0.05 mm thickness
for cutting shims.
6.3.10Cotton waste and clean pieces of cloth for cleaning bearings.

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CORRECT
STEEL STRAIGHT EDGE
INCORRECT PARALLEL
MISALIGNMENT
STEEL STRAIGHT EDGE
STEEL STRAIGHT EDGE
INCORRECT ANGULAR
MISALIGNMENT
7.0 EQUIPMENT SCHEDULE:
7.1 I stallatio :
7.1.1 For location, preparing foundation, installation, alignment, general maintenance,
trouble shooting, etc., the instructions given in our publication - ’GENERAL
INSTRUCTIONS FOR INSTALLATION, OPERATION AND MAINTENANCE OF
KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed along this booklet must
be followed very carefully. If the pump is drawing liquid from the vessel under
vacuum, then vacuum equalizing connection piping must be made as per instruction
given in above publication. The external sealing connection to the pump, if
applicable, must be made after installing and before commissioning the pump.
7.2 MOUNTING AND ALIGNMENT
A flexible coupling is used to connect pump shaft to the driver.
7.2.1 ALIGNMENT
ALWAYS REMEMBER “A FLEXIBLE COUPLING IS NOT A UNIVERSAL 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.
Alternatively, it can be checked by any other suitable device like laser.
7.2.1.1 Before commissioning the pump set, please ensure:
A) The pipe connections are flushed and tightened properly.
B) Alignment is proper.

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8.0 EQUIPMENT OPERATION:
.1 Before starting the pump check the following:
1) The pump rotates freely by hand.
2) The cooling water connections are properly tightened and adjusted.
3) The direction of rotation of driver. It should correspond to the direction of
rotation of pump.
4) Valve on delivery side is closed.
5) The cock for pressure gauge connection is closed.
.2 Starting the pump
1) Start the pump.
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.
.3 During running the pump check the following things and regulate if needed -
1) The pump is running smooth.
2) The flow of cooling water is uninterrupted.
3) The bearings are not getting abnormally hot.
4) Head and capacity developed by the pump is as specified.
5) Power consumption is within limit.
6) Ensure that there is no mechanical friction in the pipe.
7) 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 During stopping the pump
1) Close the valve on the delivery line.
2) Stop the motor.
3) Close the cooling water liquid connections.
4) It has always recommended that use of NRV (Non return valve) in delivery pipe
to avoid back flow during stopping the pump.

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9.0 PREPARATORY FOR ERECTION
During transit and storage of equipment after it has reached at site considerable
dust and foreign material may have lodged on the various parts of the pumps. All
parts/assembled unit must be cleaned and checked with great care before
commencing the erection. It is necessary to remove the antirust coat given on the
machined surface before starting the erection.
9.1 Complete assembled pump-
9.1.1 Remove the antirust coat applied to the machined open surfaces of motor
stool, coupling etc. with the help of thinner and kerosene. In case of pump
supplied with water lubricated, rubber bearings should be flushed with
clear cold water only.
9.1.2 Rotate the flexible coupling by hand. It should rotate freely.
9.1.3 Check all the bolts and nuts for their tightness as there is a possibility of
loosening of nuts during transit and handling.
9.2 Pumps with colum le gth of more tha 2 metres:
In this case, only pump unit is dispatched in assembled form and
transmission unit, driving unit, rising pipes are sent in dismantled condition.
9.2.1 Pump u it: Rotate the pump shaft by hand or by using pipe wrench to see
that the impeller is free (rotating properly). Remove the antirust coat from the
machined portions of the transmission bearing and threaded portions with the
help of thinner and kerosene. Clean the threaded portion with the help of
wire brush or old toothbrush.
9.2.2 Tra smissio u it:
I termediate shafts-
The intermediate shafts are dispatched in wooden packings. Unpack
the shafts and clean them thoroughly with thinner and kerosene. The
screwed couplings are also to be cleaned with above solvent. The threads of
the coupling and shaft to be cleaned by using wire brush or toothbrush.
Ensure that threaded portions are completely free from dust, rust, etc.
Tra smissio beari gs-
Clean the spring of oil seals fixed in the bearing spider with
thinner/kerosene. It should be free from sharp edges and burr. Clean the
bearing bush. The grooves of bearing bush must be free from dust and burr.
Check the spring of oil seals fixed in the bearing cover are not
damaged. In the case pump supplied with water lubrication the rubber
bearing is used as transmission bearings. These should not meet oil, grease,
paint, etc. These bearings should be cleaned with clear cold water only.

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Colum pipe-
Clean the flanges and guide faces thoroughly with thinner and
kerosene. Ensure that corresponding portions of bearing spiders are fitting
properly. If they do not, scrape them suitably. Clean the column pipes from
inside.
9.2.3 Drivi g u it:
Clean the motor stool, thrust bearing carrier, bush bearing perfectly. Antirust
coat from the machined surfaces should be removed by using
thinner/kerosene. Check the grooves on the bronze bearing bush are clear
from dust and burr. Ensure that grease passes smoothly when forced from
the grease nipple. Clean the thrust bearing in the kerosene. Check the
springs of the oil seals fixed in the bearing covers are not damaged. Thrust
bearing and bush bearing should be free from dust particles, hence these are
to be covered suitably till they are used in the assembly.
9.2.4 Head shaft a d flexible coupli g:
Clean the head shaft and coupling with the help of thinner and kerosene.
Remove the sharp edges or burr if any, form the keyway and make sure that
coupling key fits properly. Coupling bushes should not meet grease, oil,
paint, etc.
9.2.5 Risi g pipes:
Clean the sockets and threaded surfaces of rising pipes.
9.2.6 Pipes for lubrication: When the pumps are supplied with grease lubrication
pipes to be filled with fresh grease. For pumps with water lubrication, pipe
nipples should be flushed with water. Also check the joints for its leakage.
9.3 Checki g:
Though all parts are inspected and duly packed while dispatching from
works, there is every possibility of bending of shaft, damage to the machined
portions during transit. Hence following checks should be made before
commencing the installation.
-Threaded portions of the shaft, screwed couplings, etc. are not damaged.
-Screwed coupling fits properly on the shaft. It should not be too tight or too
loose on the shaft.
-All the mating surfaces fit properly.
-The shafts are not bent during transit. Check them with the help of ‘V’
blocks and dial gauge or on centre lathe. The shaft run outs should not
exceed 0.05 mm.

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9.4 Do’s a d Do ’ts while assembly:
9.4.1 While assembling do not apply undue force.
9.4.2 Avoid use of hammer.
9.4.3 Ensure perfect matching of contact surfaces.
9.4.4 Each and every part should be free from high points.
9.4.5 Take care that no part is left out through oversight. Every single item,
however small has an importance in the proper functioning of pump.
9.4.6 Take care that no foreign substance is dropped or left inside. They will get
stuck up and cause jamming.
9.4.7 All tools and equipment are kept ready on hand before starting the erection.
Cross sectional drawing and erection instructions should be referred during
erection.
9.4. Erection should be done by specialized and experienced personnel.

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10.0 ERECTION PROCEDURE OF THE PUMPS
10.1 Erectio procedure for grease lubricated pumps with colum le gth
more tha 2 m.
10.1.1 Pump unit is sent from works in duly assembled conditions. It includes pump
casing (10700), impeller (15100/15300), impeller shaft (1 600), bell mouth
(21100), casing cover (22000), bottom column pipe (13302), first bearing
spider (24500), etc.
10.1.2 Fix adapter piece (55900), to the casing cover (22000) and connect copper
tube (56202) to this adapter. Temporarily tie the copper tube to the column
pipe till it is connected to the motor stool.
10.1.3 Connect bend (2 000) and first rising pipe (14201) to the delivery nozzle.
Insert packing between flanges before connecting them. Take care while
fitting the bend that rising pipe fitted on it will be parallel to the column pipe.
In any case rising should not be under tension while passing it through the
support plate (3 300).
10.1.4 Fix the clamp to the suspension pipe. Also fix the clamp to the rising pipe.
Arrange the clamps in such a way that both the clamps are at the same
height. This facilitate smooth erection (erection can be carried out with single
clamp for column pipe when the rising pipes are light and small).
10.1.5 Lift the unit vertically with the help of ropes/chains and chain pulley block.
While lifting take care that bell mouth is not dragged against the floor.
Suspend the unit vertically.
10.1.6 Put two girders or strong wooden logs across the foundation to rest the
clamps while erection. Lower the unit in the sump till the clamps rest on
girders.
10.1.7 Apply the thread compound liberally inside the screwed coupling and
impeller, shaft. Fit the screwed coupling (39500) to the impeller shaft
(1 600) after inserting brg. Spider (24500).
10.1. Column pipe (13301) and intermediate shaft (1 400) should be suspended
by the separate clamps. These are to be suspended in such a way that
intermediate shaft protrudes out of the column pipe. Fix again brg. Spider
(24500).
10.1.9 Connect the intermediate shaft to the screwed coupling. Make sure that ends
of the shafts are butted properly.
10.1.10 Lower the column pipe and fix it to the bottom column pipe (13302). Tighten
the diametrically opposite bolts evenly.
10.1.11 Similarly lower the rising pipe by fixing the clamp to it and couple it to the
bottom rising pipe with the help of coupler. Chain spanners to be used for
tightening. Apply thread compound liberally to the threaded portion before
connecting the pipes (flanged rising pipes are supplied in case of heavier
pipes).

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10.1.12 Fix the adapter (56900) to the bearing spider (24500). Connect the copper
tube (56206) to this adapter. Temporarily tie copper tube to the column pipe
till it is connected to the motor stool.
10.1.13 Lift the complete unit slightly. Remove the clamp fixed to the bottom column
pipe and bottom rising pipe. Lower the complete unit till the clamps fixed to
the column pipe and rising pipe rest on the girders.
10.1.14 Smear grease to the transmission bearing bush. Fit the bearing spider
(24500) with its covers and oil seals (27 00 & 60003) on the column pipe.
10.1.15 Repeat the same procedure till head shaft (1 500) top column pipe (13200)
complete rising pipes and other copper lubrication pipes are assembled. Let
the whole unit rest on the clamp fixed to the top column pipe (13200) and
top rising pipe (14202).
10.1.16 Fit pipe nut for rising pipe (33 00) with the help of spanner to it and fix the
motor stool to the top column pipe (13200). Tighten the diametrically
opposite bolts evenly. While fixing the motor stool, make sure that holes on
the motor stool and foundation will match properly.
10.1.17 Fit the adapter (55900) to the motor stool. Connect the Nylon tubes (56202,
56204, and 56206) to the corresponding adapters.
10.1.1 Lift the unit slightly and remove the clamps fixed to the column pipe and
rising pipe. Remove the girders used for erection and lower whole unit till
motor stool rests on the supporting structure foundation. With hanging
supports to motor stool, adjust the holes of the motor stool with that of
foundation holes.
10.1.19 Fix support plate (3 300) on the foundation. Just fix the foundation bolts
and do not tighten them. Adjust the pipe nut (33 00) from the bottom till it
touches the plate. Fit another pipe nut from top.
10.1.20 Tighten the foundation bolts of the motor stool. Check the level on the
machined surface of the motor stool. It should be leveled accurately to the
limit of 0.05 mm to 0.075 mm/metre.
10.1.21 Fix the cover for bearing bush along with oil seal and cover sheet (27002)
(50002) and to the thrust bearing carrier (24700). Smear the grease to the
bearing bush (35200). Fit the thrust bearing carrier (24700) to the motor
stool.
10.1.22 Fit the thrust bearing (26200) in the thrust bearing carrier. Fill the grease
(only about 50% of the volume to be filled).
10.1.23 Put the thrust bearing adapter (27200) on the head shaft till it touches the
thrust bearing.
10.1.24 Now the rotating unit to be lifted to ensure correct clearance between
impeller and wear plate (only for SHS-Q pumps).
The adjustment is done as under:
Put the bearing nuts (33500) & (33600) on the head shaft till it easily
touches the bearing adapter (27200). Do not tighten it further. Put the pump

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coupling (39000) along with the key on head shaft. Mount the magnetic
stand of the dial indicator on the motor stool & prop of the dial gauge on the
face of the coupling. Hold the coupling to prevent its rotation. Adjust the
zero of the dial gauges. Tighten the bearing nut (33500). Such that rotating
unit is fitted by 0.5 mm. Rotate the coupling so that it should rotate freely.
Tighten the lock nut (33600) for locking the bearing nut (33500).
10.1.25 Remove the flexible coupling and coupling key.
10.1.26 Fit the bearing cover (27001) along with the oil seal (50001) and cover
sheet.
10.1.27 Fix the coupling key (32100) and fit the flexible coupling pump half (39000)
on the head shaft (1 500).
10.1.2 Tighten the foundation bolts of the support plate. Make the further
connection of valves and delivery pipe. Ensure the complete weight of the
delivery pipe and accessories is not coming on the support plate. Connect
tubes (56201, 56203, 56205 & 56207) to adapter piece (55900) and nipple
of the grease lubricator.
10.1.29 Mount grease lubricator (if applicable) on support plate (3 300). Refer
instructions on grease lubricator supplied with SHS pumps.
10.1.30 Once again check the level on the surface of the motor stool. It should be
leveled accurately while tightening the bolts with the use of shims, if
necessary.
10.1.31 Fix the flexible coupling motor side on the motor. Make the motor
connections and check the direction of rotation before fitting on the motor
stool. The directio of rotatio should be clockwise whe viewed from top.
10.1.32 Mount the motor on the motor stool. There should be a gap of 6 mm
between two coupling faces. Check the parallel and angular alignment of the
coupling. Fix the coupling pins, coupling bushes.
10.2 Pumps with colum le gth of less tha two metre:
Complete pump is sent from Works in assembled condition. Only rising pipe
connections is to be made. Other instructions follow as per above points
10.1.2 to 10.1.32. Motor stool is to be levelled perfectly with the use of
shims, if necessary, to limit of 0.05 to 0.075 mm/metre.
10.3 Erectio Procedure for Pump with Water Lubricatio :
Pump with column length more than 2 metres:
10.3.1 Pump unit is sent from Works in duly assembled condition. It includes pump
casing (10700), impeller (15100/15300), impeller shaft (1 600), bell mouth
(21100), casing cover (22000), column pipe (13302), bearing spider
(24500), etc.
10.3.2 Connect the pipe nipple (53504) with half part of the union joint (54502) to
the casing cover (only for external water lubricated pump).