KIRLOSKAR DSM Series Programmierhandbuch

INSTRUCTIONS ON

INSTALLATION

OPERATION AND

MAINTENANCE FOR

KIRLOSKAR PUMP

TYPE DSM (STANDARD)

KIRLOSKAR BROTHERS LIMITED

UDYOG BHAVAN, TILAK ROAD, PUNE - 411 002

IOM/DB/005/01 Issue Date: 25/09/2000

Page: 1/12 Last revision date:

KIRLOSKAR BROTHERS LIMITED

Udyog Bhavan, Tilak Road, Pune 411 002 (India)

WARRANTY

We warrant that the pump supplied by us is free from defective

material and faulty workmanship. This warranty holds good for a

period of 12 months from the date of commissioning of the

equipment or 18 months from the date of despatch 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 to or arise solely from faulty

workmanship or defective material.

The warranty holds good only for the products manufactured by us.

KIRLOSKAR BROTHERS LIMITED

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CONTENTS

1. GENERAL

2. INSTALLATION

3. OPERATION

4. TECHNICAL DATA

5. MAINTENANCE

6. OVERHAULING

7. SPARE PARTS LIST AND CROSS-SECTIONAL DRAWINGS

PLEASE FURNISH COMPLETE NAMEPLATE DETAILS, NAME OF THE PARTS, PART

NOS. AND MATERIAL OF CONSTRUCTION WHILE ORDERING SPARE PARTS FOR

THE PUMPS.

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1. GENERAL:

1.1 The booklet covers instructions for following models of DSM pumps.

Type of pump:

DSM-1E

DSM-2E

65-DSM, 315M

DSM-3

DSM-3ME

DSM-4RM, RSM-4RN, DSM-4RR

DSM-5B

DSM6-15°, DSM6-30°

DSM-150-45

1.2 These are Horizontal split Casing type, two stage pumps.This

construction enables to remove the rotating unit without disturbing pipe

connections and alignment.

1.3 Pumps when properly installed and given due attention in operation and

maintenance should operate satisfactorily for a long period.

1.4 When the pump is received, sometime before the actual use of pump, it

should be inspected and stored in dry place. The coupling should be

rotated once in a month to prevent pitting of bearing surfaces.

2INSTALLATION :

For location, preparing foundation, installation, alignment, general maintenance,

trouble shooting etc., the instructionsgiven in our publication “General Instructions

for Installation, Operation & Maintenance of Kirloskar Centrifugal Pumps.” which is

also printed alongwith this booklet must be followed carefully.

2.1 The sealing connection piping to the pump stuffing box must be made

after installing and before commissioning the pump.This piping is supplied

only for 65DSM 315M, DSM-4RM, DSM-4RN, DSM-4RR, DSM-5B, DSM-

6 and DSM 150-45 pumps. For other pumps, sealing connection is

integral.

2.2 Put gland packing and lantern ring, if it is sent separately along with the

pump.For DSM-3, 65 DSM 315M also DSM 1E, DSM 2E, DSM 3ME and

DSM-4RM, DSM-4RN, DSM-4RR pumps, stuffing boxes are packed with

packing before despatch. For balance pumps gland packings and lantern

rings are sent separately along with the pumps.

3. OPERATION:

3.1 Before starting the pump. Check the following:

3.1.1. The pump rotates freely by hand.

3.1.2. Sealing connection provided is properly tightened and adjusted.

3.1.3. Fill in the grease for bearings, if not done earlier.

3.1.4. The direction of rotation of motor corresponds to the direction of rotation

of the pump.

3.1.5. The pump and the suction pipe is fully primed with the liquid.

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3.1.6. Valve on the delivery side is closed.

3.1.7. Stuffing box packing is properly tightened.

3.1.8. The cock for the pressure gauge connection is closed.

3.2 Starting the pump

3.2.1 Start the pump. Let the prime mover pick up its full speed.

3.2.2 Open the valve on delivery side slowly.

3.2.3 Open the cock for pressure gauge connection.

3.3 During running the pump

3.3.1 The pump is running smooth.

3.3.2 The flow of sealing liquid water is uninterrupted.

3.3.3 Leakage through stuffing box is normal. There should be leakage is 60 to

80 drops/min.

3.3.4 The bearings are not getting heated up excessively.

3.3.5 Head and capacity developed by the pump is as specified.

3.3.6 Power consumption is within the limit.

3.3.7 Ensure that there is no mechanical friction in the pump.

3.3.8 Stop the pump immediately, if any defects are noticed. Do not start the

pump unless the defects are rectified. Report immediately to the supplier if

it is not possible to rectify the defects.

3.4 During stopping the pump:

3.4.1 Close the valve on delivery side.

3.4.2 Stop the motor.

3.4.3 If the pump is not required to be operated for a long time, then drain the

casing completely.

4. TECHNICAL DATA:

4.1 Direction of rotation

The standard direction of rotation is anticlockwise when viewed from

driving end. The pump suitable for clockwise rotation can also be supplied

against specific requirements.

4.2 Rotational speed

Normally the pumps are supplied suitable for speed of 1450 rpm. Please

contact supplier if the pump is to be used for higher speeds.

4.3Bearings

The shaft is supplied with antifriction ball bearings at driving end and non-

driving end. The details of the bearings are given in the technical data

chart. The designationsof bearings are as per SKF catalogue. However,

equivalent bearings in type, capacity and dimensions are also used.

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4.4Lubrication

4.4.1 Type of lubricant –The bearings are grease lubricated.

4.4.2 Quantity of grease –Please refer to Technical Data chart.

4.4.3 Refilling period –After 1000 hours of running.

4.4.4 Bearing temperature –The permissible bearing temperature rise is 40°C

above ambient temperature.

4.4.5 Grades of recommended grease

Following grades of grease of their equivalents available in the market are

suitable for bearing lubrication.

INDIAN OIL -SERVOGEM -3

CALTEX -STARFAK -3

HINDUSTAN PETROLEUM NATRA-3 OR LITHON -3

4.5Stuffing box

4.5.1 Stuffing box –The stuffing boxes are extra deep to reduce the leakage.

4.5.2 Stuffing box sealing –Lantern ring provided for sealing purpose is used

only in first stage stuffing box. Normally clear cold self liquid only is used

for sealing. Grease Sealing/ External sealing can be provided against

specific request.

4.5.3 Stuffing box packing

Champion Style–3316–Graphited Cotton Greasepacking is used in the

pump as a standard supply. However, stuffing box packing suitable for

liquid handled is supplied against specific requirements.

For DSM-3, 65 DSM-315 M, DSM 1E, DSM 2E, DSM 3ME, DSM-4RM,

DSM-4RN, DSM-4RR pumps the stuffing box packing is sent duly packed

in the pump. For other pumps the packing and lantern ring are sent

separately alongwith the pump.

4.5.4 Stuffing box packing size –Please refer Technical Data Chart.

4.5.5 Flexible couplings –The pumps are supplied with LOVE-JOY type & pin

bush type flexible couplings. Details (of rubber bushes) are given in

Technical Data Chart.

4.5.6 Packing between upper and lower half casing-

Dalmia Duplex board packing paper to be used of following thickness.

Pump Type Packing thickness

in mm

DSM-1

DSM-1E

DSM-2

DSM-2E

DSM-3

DSM-3M

DSM-3ME

65 DSM-315M

DSM-4RM, DSM-4RN, DSM-4RR

DSM-5

DSM-5B

DSM6-15°, DSM6-30°

DSM 150-45

0.8 mm

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4.5.7 TECHNICAL DATA CHART

Ball bearing No.

SKF or equiv.

St. box packing

Size in mm No. of

Packing

Rings

Pump

type Flange Size

In mm

Del. X Suc.

Driving

end Non

driving

End

Qty. of

Grease

Per Brg.

Gms.

Size x length

Position of

Lantern ring

(L) from

Impeller side

(NDE side) DE NDE

Coupling

Type

DSM-1E

DSM-2E

65 DSM

315M

DSM-3

DSM-3ME

DSM-4RM

DSM-4RN

DSM-4RR

DSM-5B

DSM-6, DSM6-15

DSM6-30°

DSM150-45

50 X 65

65 X 80

80 X 100

”

100 X 125

125 X 150

150 X 200

150 X 175

6305

6306

6307

”

6309

”

21309cc

6315

N310

6305

6306

6307

”

3309

”

6413

2 x 7310

100

”

150

6 Sq. x 1525

10 Sq. x 2135

10 Sq. x 2300

10 Sq. x 1650

” ”

12 Sq. x 2290

” ”

12 Sq. x 3180

16 Sq. x 6250

12 Sq. x 2820

3+L+2

4+L+2

3+L+2

”

2+L+3

”

3+L+3

4+L+4

2+L+3

”

Love-Joy Type –SW -110

Love-Joy Type –SW -190

Love-Joy Type –CW-226

”

Pin Bush Type –CW-226

”

Love-Joy Type –CW -276

Pin Bush Type –360φ

Pin Bush Type –310φ

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5. MAINTENANCE:

Preventive maintenance schedule is the periodical checks and precautions by which

possibilities of failure and breakdown are made very remote.

5.1 Daily Checks

5.1.1 Pressure gauge reading.

5.1.2 Bearing temperature.

5.1.3 Leakage through stuffing box.

5.1.4 Noise and vibration.

5.1.5 Voltage and current.

5.2 Periodical Maintenance

5.2.1 Replenish the grease.

5.2.2 Check the stuffing box packing.

5.2.3 Check the alignment of the pumpset.

5.2.4 Calibrate the measuring instruments.

5.2.5 Check the sealing and cooling connections for leakage etc.

6. OVERHAULING:

With normal daily operating spell, the pump will be due for overhaul after about

5000 working hours. This work should be done by skilled personnel.

6.1 Dismantling and Assembling procedure

All DSMpumps are similar in construction except some minor changes in

the parts. The important changes are:

6.1.1 Shaft sleeves (310,311) are not provided in DSM-3 and DSM-1E, 2E, 3ME

pumps.

6.1.2 Stuffing box bushes (350) are not provided in DSM-1E, 2E, 65 DSM-

315M, DSM-4RM, DSM-4RN, DSM-4RR and DSM-150-45 pumps.

6.1.3 Separate lantern ring (227) is not provided in DSM-3, DSM-3ME pump

since the same is made integral with Stuffing Box Bush.

6.1.4 Threaded shaft sleeves (310, 311) are used in DSM-4RM, DSM-4RN,

DSM-4RR pump where as other sleeves are keyed ones.

6.1.5 Coupling spacer (195) is not provided in DSM-4RM & DSM-150-45 pumps

6.1.6 Coupling nut (332) is not provided in DSM-4RM, DSM-6 and DSM-150-45

pumps.

6.1.7 Allen bolts are provided for top & bottom casing of DSM 150-45 pump

where as other pumps have standard bolt nuts and studs with nuts.

Please refer to the cross sectional drawings and spare parts list given in

this booklet while dismantling and reassembling.

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6.2 Dismantling

6.2.1 Uncouple the pump from the prime mover by removing coupling bolts,

nuts and rubber bushes.

6.2.2 Remove –

-Sealing Connections

-Priming funnel, air vent

-Grease cup/ nipples and other fittings.

6.2.3 Remove all the bolts and nuts (572, 581) holding the upper half casing &

lower half casing. Take out upper half casing (122) slowly by tightening

the release bolts and after removing taper pins.

Upper half casing should be removed slowly so that impellers and other

parts are not damaged. By removing upper half casing, the complete

rotating unit is exposed for inspection and repairs.

6.2.4 Loosen the bolts and nuts (573) holding the bearing cap to the lower half

casing (122). Remove the bearing caps.

6.2.5 Lift the rotating unit slowly after slinging it in correct fashion so that none

of the parts are damaged. Keep the rotating unit in clean dry place for

further dismantling.

6.2.6 Now start dismantling from driving end side. Loosen the coupling nut

(332) if provided.

6.2.7 Take out flexible coupling, pump half (390) with help of a puller. Remove

the coupling key (321).

6.2.8 Take out coupling spacer (195) if provided.

6.2.9 Loosen the bolts (631) holding bearing cover (270) to the bearing

cartridge (241).

6.2.10 Remove the bearing cartridge driving end (241) pull out the bearing driving

end (260.1) with the help of puller.

6.2.11 Remove bearing cover (270) and water deflector (236).

6.2.12 Take out gland (223). Remove the st. box packing.

6.2.13 Remove the st. box bush (350) if provided. Also take out casing ring

(190).

6.2.14 Take out the shaft sleeve DE (317.1) (only for 65 DSM-315 M, DSM-5,

DSM-6 and DSM 150-45 pumps). Remove the ‘O’ ring (522).

6.2.15 Remove the shaft sleeve under st. box (310).

6.3 Start dismantling from non-driving end

6.3.1 Remove the bearing cartridge (253) NDE.

6.3.2 Loosen the bearing lock nut (336) bearing nut (335).

6.3.3 Remove bolts (631) for bearing cover (271) and take out the ver.

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6.3.4 Remove the casing ring NDE (191). Water deflector (236), Glands (229)

and lantern ring (227).

6.3.5 Take out open shaft sleeve (317.2) and ‘O’ ring in case of 65 DSM 315M,

DSM-5, DSM-6 & DSM 150-45 unscrew or remove the shaft sleeve NDE

side (311).

6.3.6 Take out impellers (157) and (158). Before removing the impellers put the

mark of first stage and second stage impellers so that while re-assembling

the impellers may not be interchanged.

6.3.7 Remove the impeller key (320). Take out the interstage rin (204). In case

of (DSM-5B, DSM-6 & DSM 150-45, remove interstage diaphragm (462)

alongwith interstage bush).

6.4 Reassembling

Before reassembling, all parts are to be cleaned including upper half &

lower half casings. Bearings are to be cleaned with Kerosene. Change

packing and ‘O’ rings, if any.

6.4.1 Put the impeller key (320) in the keyways provided on the shaft. Fix the

impellers on the shaft with interstage ring (204/462) in between them.

First stage impeller should come towards non-driving end.

6.4.2 Put the shaft sleeves (310, 311) and (317.1 & 317.2) with ‘O’ rings for

65 DSM-315M, DSM-5B, DSM-6 and DSM 150-45.

6.4.3 Start the reassembly for non-driving end.

Insert the casing ring, NDE (191).

Insert the gland NDE (223) if non-split type (in case of DSM-4RM).

Put the water deflector, NDE (236).

Insert the bearing cover, NDE (271).

Press the NDE bearing on the shaft.

Tighten the bearing nuts. Put appropriate quantity of grease to the

bearings.

Fix the cartridge NDE (Except DSM 150-45). The bearing should touch

the shoulder provided on the cartridge.

Fix the bearing cover to the cartridge by tightening the screws (631).

6.4.4 Now start assembling from driving end.

Insert the casing ring DE (190).

Insert the gland DE (223) if non-split type (DSM-4RM)

Fit the water deflector (236).

Insert the bearing cover (270).

Press fit the DE bearing on the shaft.

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