KIRLOSKAR GK Series Programmierhandbuch

1 IOM/GK/SEP19/00

INSTRUCTIONS ON

INSTALLATION,

OPERATION AND

MAINTENANCE FOR

KIRLOSKAR PUMP

TYPE ‘GK’

KIRLOSKAR BROTHERS LIMITED

REGD. AND HEAD OFFICE UDYOG BHAVAN, TILAK ROAD PUNE-411002

2 IOM/GK/SEP19/00

WARRANTY

We warrant t at t e pump supplied from us is free from

defective material and faulty workmans ip. T is warranty olds

good for a period of 12 mont s from t e date of commissioning

t e equipment or 18 mont s from t e date of dispatc from our

factory, w ic ever is earlier. Our liability in respect of any

complaint is limited to replacing part/parts free of c arge ex-

works or repairs of t e defective part/parts only to t e extent

t at suc replacement/repairs are attributable or arise solely from

faulty workmans ip or defective material.

T is warranty olds good only for t e products manufactured by us.

KIRLOSKAR BROTHERS LIMITED

3 IOM/GK/SEP19/00

Table f c ntents

Sr. No. Description

Page No.

1.0 General 04

2.0 Safety Instructi ns 05

3.0 Equipment Schedule 09

4.0 Operati n 12

5.0 Maintenance Manual 14

5.1 Maintenance EHS instructi ns 14

5.2 General maintenance d cuments 14

5.3 Overhauling 14

5.3.1 Dismantling 15

5.3.2 Reassembly 18

5.4 Maintenance T ls required 19

5.5 Preventive Maintenance 19

5.5.1 Daily Checks 19

5.5.2 Peri dical Checks 19

5.5.3 Annual Checks 20

5.5.4 Mechanical Seal in Pumps 20

5.6 C rrective Maintenance 21

6.0 Technical Data 21

6.1 Directi n f R tati n 21

6.2 Bearing Details 21

6.3 Bearing Lubricati n 21

6.4.1 Stuffing B x Sealing 22

6.4.2

Stuffing B x packing specificati n 22

6.4.3 Stuffing B x Packing & Lantern Ring 22

6.4.4 Gaskets, O-rings & Wear Ring details 23

6.4.5 Interchangeability Chart f C mp nents 26

6.4.6 Rec mmended Spare Parts 29

7.0 Part Descripti n and Secti nal

Drawings 30

8.0 Expl ded View 36

9.0 General Outline Dimensi ns 37

10.0 Cut secti n View 39

4 IOM/GK/SEP19/00

1.0 GENERAL

1.1 ‘KIRLOSKAR’ make GK series pumps are f back pull ut design which enables

t rem ve the r tating unit f pump f r inspecti n and repairs with ut

disturbing sucti n and delivery pipe c nnecti ns.

1.2 The b klet c vers instructi ns f r installati n, perati n & maintenance f

f ll wing m dels f GK Pumps:

UNIT – 30

UNIT – 40

UNIT – 50

GK32/13

GK40/26B

GK65/32B

GK32/13B

GK50/26A

GK80/32B

GK32/16

GK50/32A

GK80/40B

GK32/20A

GK65/16B

GK100/26B

GK32/20B

GK65/20B

GK100/32B

GK40/13

GK65/26A

GK100/40A

GK40/

GK65/26B

GK100/40B

GK40/20A

GK80/16A

GK12

5/26A

GK40/20B

80/20A

GK125/32A

GK50/13

GK80/26A

GK125/32B

GK50/16A

GK100/20A

GK50/20A

GK65/13A

Applicati ns:

GK pumps are mainly used f r clean and clear liquids which are free fr m

suspended s lids/particles. Few f the applicati ns are as bel w:

Water supply, Sprinkling, Air c nditi ning, Industrial water, Swimming p l water,

H t water, Fire fighting, Irrigati n, Drinking water/P table water, C ling water,

C ndensate, Clear juice.

1.3 Nameplate inf rmati n:

Every pump has the f ll wing nameplate fitted t bearing h using

(2400000) pr vided with necessary identificati n f the pump and its

specific hydraulic characteristics.

The nameplate must n t be rem ved.

L ss f this plate c uld make

identificati n imp ssible. This in turn c uld

affect safety and cause difficulty in btaining spare parts.

Such accidental

l ss r damage if ccur, c ntact KBL immediately.

5 IOM/GK/SEP19/00

1.4 Pumps when pr perly installed & given due care in perati n & maintenance

sh uld perate satisfact rily f r a l ng peri d.

1.5 When the pump is received, s metime bef re the actual use f pump, it sh uld

be inspected & l cated in dry place. The shaft sh uld be r tated nce in a

m nth t prevent pitting f bearing surfaces.

2.0

Safety Instructions:

2.1 General Information

Bef re perf rming any acti ns detailed within this instructi n, the site Health

and Safety instructi ns and the instructi ns in this d cument shall be read and

fully underst d.

Whenever the equipment is perated, maintained r used in any way,

the pr cedures detailed within these instructi ns shall be f ll wed. The

pump supplied by Kirl skar Br thers Limited (KBL) has been designed

with safety in mind; where hazards cann t be eliminated, the risk has

been minimized by the use f guards and ther design features. S me

hazards cann t be guarded against and the instructi ns bel w MUST BE

COMPLIED WITH f r safe perati n. These instructi ns cann t c ver all

circumstances. It is the resp nsibility f the user f the equipment f r

maintaining safe w rking practices at all times. The pumps are supplied with

stickers f r hazard, cauti n & safety wherever these are applicable.

2.2.1

Within the manual, safety instructi ns are marked with safety symb ls.

Hazard.

This symb l refers t general mechanical aspects f safety.

Hazard.

This symb l refers t electrical safety.

6 IOM/GK/SEP19/00

This symb l is used t intr duce safety instructi ns wh se

n n bservance may lead t damage t the machine and its

functi ns.

2.1.2

KBL pr ducts are designed f r installati n in designated areas, which are t be

kept clean and free f bstructi ns that may restrict safe access t the c ntr ls

and maintenance access p ints.

2.1.3

Access t the equipment sh uld be restricted t the pers nnel resp nsible f r

installati n, perati n and maintenance and they must be qualified, adequately

trained and supplied with the appr priate t ls f r their respective tasks.

2.1.4

This pr duct must be serviced by qualified pers nnel wh are familiar with

the design and perati n f this pr duct and the system with the

essential safety aspects inv lved.

2.1.5

KBL firmly insists that all pers nnel resp nsible f r installati n, perati n and

maintenance f the equipment must read the manual bef re any w rk is d ne.

2.1.6

Our guarantee

will be valid nly if the installati n, perati n,

maintenance and repairs f this pump are carried ut in acc rdance

with these

instructi ns. The plant perat r is t make sure that the c ntents f these

instructi ns are fully underst d by the perating

pers nnel. During

perati n, peri dic inspecti ns sh uld be made t assure safe perati n

under the prevailing c nditi ns.

2.1.7

Ear defenders sh uld be w rn where the specified equipment n ise level

exceeds l cally defined safe levels. Safety glasses r g ggles sh uld be

w rn where w rking with pressurized systems and hazard us substances.

Other pers nal pr tecti n equipment must be w rn where l cal rules apply.

2.1.8

Any m dificati n may be made t the pr duct nly after c nsultati n

with the manufacturer. Using spare parts and access ries auth rized by

the manufacturer is a relevant safety aspect. Only genuine spare parts

which are in acc rdance with the riginal delivery (in the parts list) are t

be used.

2.2

DO NOT

wear l se r frayed cl thing r jewellery, which

c uld catch n the c ntr ls r bec me trapped in the

equipment.

2.3

Operati n f the equipment f r the applicati n ther than f r which it is

supplied can increase the risk fr m hazards. Please c nsult KBL bef re making

such change in the applicati n f the equipment.

2.4

Impr per installati n, perati n and maintenance f the pr duct supplied by KBL

c uld result in injury r death.

2.5

Within the manual, safety instructi ns are marked with safety symb ls.

CAUTION

CACA

UTION

UTIONUTION

UTION

7 IOM/GK/SEP19/00

2.6

Transp rt Handling and St rage Instructi ns:

2.6.1

Transp rt

Pumps are dispatched in duly assembled c nditi n. Lubricating il in the

bearing h using is drained pri r t dispatch f pump. Pumps are pr tected

against c rr si n and packed f r transp rt by n rmal r ad, rail and sea

carriers.

2.6.2

Handling

Crushing Hazard.

When lifting the pump r pump set, use lifting equipment having a safe w rking l ad

rating suitable f r the weight specified. Use suitable slings f r lifting the pump which

is n t pr vided with lifting p ints.

The use f suitable f rklift truck and f ur chain crane sling equipment is rec mmended

but l cally appr ved equipment rating may be used.Pump sh uld be slung as sh wn.

Pump set must be lifted fr m the lifting h les pr vided using suitable f ur chain lifting

equipment.

8 IOM/GK/SEP19/00

2.6.3

St rage:

2.6.3.1Temp rary

St rage f r up t six weeks.

If the pump unit is n t t be used immediately it sh uld be st red carefully in a

h riz ntal p siti n, in a sheltered, dry l cati n. Additi nal rust preventive

sh uld be applied t all unpainted carb n steel r cast-ir n parts and sh uld n t

be rem ved until final installati n.

2.6.3.2

L ng Term

St rage

If the pump is n t t be installed and perated s n after arrival, st re it in a

clean, dry place, having sl w, m derate changes in ambient temperature.

Step sh uld be taken t pr tect the pump fr m m isture,

dust, dirt, and

f reign b dies. It is rec mmended that the f ll wing precauti ns t be

taken:

Ensure that the bearings are packed with the rec mmended grease, t

prevent m isture fr m entering ar und the shaft.

Rem ve the glands, packings and lantern rings fr m the stuffing b x

if the pump is equipped in this manner. If the pump is equipped with

mechanical seal, dismantle and c at the seal with light il.

Ensure that sucti n and discharge branches f the pump and all ther

penings are c vered with cardb ard, w d r masking tape t

prevent f reign bjects entering the pump.

If the pump is t be st red where there is n pr tective c vering, it

is advisable t c ver the unit with a tarpaulin r ther suitable

c vering.

The pump shaft sh uld be manually r tated peri dically t prevent

pitting f the bearing surfaces due t m isture.

S earing Hazard.

D NOT place fingers r hands, etc., int the sucti n r discharge pipe utlets

and d NOT t uch impeller, if r tated this may cause severe injury.

Fill the bearing h using with rec mmended grease t ensure that the shaft and

bearings remain rust free.

2.6.3.3

Exp sed r Extreme C nditi ns St rage.

F r exp sed st rage r extreme variants in atm spheric r envir nmental

c nditi ns, please refer t KBL f r special st rage instructi ns t suit the

c nditi ns acceptable.

2.7

Environmental safety

Always keep the stati n clean t av id and/ r disc ver emissi ns.

Waste and emissions regulations

Observe these safety regulati ns regarding waste and emissi ns:

•

Appr priately disp se f all waste.

9 IOM/GK/SEP19/00

•

Handle and disp se f the pr cessed liquid in c mpliance with applicable

envir nmental regulati ns.

•

Clean up all spills in acc rdance with safety and envir nmental pr cedures.

•

Rep rt all envir nmental emissi ns t the appr priate auth rities.

Electrical installation

F r electrical installati n recycling requirements, c nsult y ur l cal electric utility.

Recycling guidelines

Always f ll w l cal laws and regulati ns regarding recycling.

3.0

Equipment Sc edule:

3.1

Installati n:

3.1.1

F r l cati n, preparing f undati n, installati n, alignment, piping, general

maintenance, tr uble sh ting, etc., the instructi ns given in ur publicati n -

’GENERAL INSTRUCTIONS FOR INSTALLATION, OPERATION AND

MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is als printed

al ng this b klet must be f ll wed very carefully.

3.1.2

MOUNTING AND ALIGNMENT

A spacer type flexible c upling is used t c nnect pump shaft t the driver. By

using spacer type f c upling, the c mplete r tating unit can be rem ved fr m

the v lute with ut rem ving pump casing r r t r and with ut disc nnecting

piping c nnecti ns. This als av ids any realignment f pump and m t r after

re-assembly f r tating unit.

3.1.3

ALIGNMENT

ALWAYS REMEMBER “A FLEXIBLE COUPLING IS NOT A UNIVERSAL

JOINT”.

C rrect alignment is essential f r the sm th perati n f the pump. There

are tw types f misalignment between the pump shaft and the drive shaft,

which are:

Angular misalignment – Shaft with axis c ncentric, but n t parallel.

Maximum all wable misalignment is 1°.

Parallel misalignment – Shaft with axis parallel, but n t c ncentric.

10 IOM/GK/SEP19/00

This misalignment is checked by using a straight edge as sh wn in figure

given ab ve. Bef re c mmissi ning the pump set, please ensure:

The pipe c nnecti ns are flushed and tightened pr perly.

Alignment is pr per.

Auxiliary piping c nnecti ns such as sealing c nnecti ns, c ling

c nnecti ns, etc., are made. Details f sealing liquid are given in ur supply

rder.

FACTORS THAT MAY DISTURB ALIGNMENT

The unit sh uld be peri dically checked f r alignment. If the unit d es n t

stay in line after being pr perly installed, the f ll wing are p ssible reas ns:

Setting, Seas ning f the f undati n.

Pipe strains, dist rting r shifting f the machines.

Wear f the bearings.

3.1.4

Bef re c mmissi ning the pump set, please ensure:

A. The pipe c nnecti ns are flushed and tightened pr perly.

B. Alignment is pr per.

C. Auxiliary piping c nnecti ns such as sealing c nnecti ns, c ling c nnecti ns,

etc., are made.

D. External c nnecti n t the pump if applicable, must be made after installati n

and bef re c mmissi ning f pump.

Andere Handbücher für GK Series

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