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.