KIRLOSKAR RKB Programmierhandbuch

IOM/RKB MSMO/SEPT19/00 P a g e 1 | 47 Issue Date: 29/09/19

Revision: 00

INSTRUCTIONS ON

INSTALLATION,

OPERATION AND

MAINTENANCE FOR

KIRLOSKAR PUMP

TYPE RKB (MULTIOUTLET)

KIRLOSKAR BROTHERS LIMITED

‘YAMUNA’ Survey No. 98/ 3 to 7, Baner, Pune –411045, India.

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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 3 to 4

2. SAFETY INSTRUCTIONS 4 to 7

3. EQUIPMENT SCHEDULE 7 to 8

4. OPERATION 8 to 9

5. TECHNICAL DATA 9 to 15

6. PREVENTIVE MAINTENANCE 15 to 16

7. OVERHAULING 16 to 30

8. SPARE PARTS LIST AND CROSS-SECTIONAL DRAWING. 31 to 47

PLEASE FURNISH PUMP TYPE, NAME OF THE PART, PART NUMBER, MATERIAL

OF CONSTRUCTION AND OTHER NAMEPLATE DETAILS WHILE 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.

1. GENERAL:

1.1 The booklet covers instructions for cold model of multioutlet pumps.

RKB 40/12L

RKB 40/14H

RKB 65/19

RKB 100/23E

RKB 125/27

RKB 125/30

RKB 150/34

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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 and given due care in operation and

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 and 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 COMPLIED 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 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. Such accidental

loss or damage if occur, contact KBL 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 KBL firmly insists that all personnel responsible for installation, operation and

maintenance of the equipment must read the manual before any work is done.

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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 KBL before making

such change in the application of the equipment.

2.4 Improper installation, operation and maintenance of the product supplied by KBL

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.

2.6 Transport Handling and Storage Instructions:

2.6.1 Transport.

Pumps are dispatched in duly assembled condition. Lubricating 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.

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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.

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 object, 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.

2.6.3.2 Exposed or Extreme Conditions Storage.

For exposed storage or extreme variants in atmospheric or environmental

conditions, please refer to KBL for special storage instructions to suit the

conditions acceptable.

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 –

’GENERAL INSTRUCTIONS FOR INSTALLATION OPERATION AND

MAINTENANCE OF KIRLOSKAR CENTRIFUGAL PUMPS’ which is also printed

along 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

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:

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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. Correct as STEEL STRAIGHT EDGE in above sketch.

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.

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. Let the prime mover pickup 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.

CORRECT

STEEL STRAIGHT STRAIGHT EDGE

INCORRECT PARALLEL

MISALIGNMENT

STEEL STRAIGHT STRAIGHT EDGE

INCORRECT ANGULAR

MISALIGNMENT

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Revision: 00

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.

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.

For Multistage Multi-outlet pump it is always recommended to operate

only one outlet at a time and keep other pump outlets closed. This is important for

getting expected pump performance at respective outlet.

5. TECHNICAL DATA:

5.1 Models:

5.1.1 ‘RKB (MULTIOUTLET)’ type of pumps are available in models as given in table

below.

SR NO.

PUMP TYPE

MAX.

STAGES@1450

MAX.

STAGES@2900

RKB –40/12L

RKB –40/14H

RKB –65/19

RKB –100/23E

RKB –125/27

RKB –125/30

RKB –150/34

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5.1.2 RKB pumps are suitable for clear liquids having temperature -30°C to +900C.

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 DE

Bearing at NDE

RKB –40/12L

NU 307

2 X 7307BG

RKB –40/14H

RKB –65/19

NU 309

2 X 7309BG

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

NOTE:

1. Above bearing details at DE and 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°C.

5.5 Lubrication of Bearing:

Bearings are grease lubricated. Bearings are lubricated during assembly of pump

at our factory. The 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 APPLY LUBRICANT WHEN PUMP IS RUNNING.

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