KIRLOSKAR BROTHERS LIMITED

1 CM-0501 SPMSPCM - 0503 KIRLOSKAR BROTHERS LIMITEDA KIRLOSKAR Group CompanyINSTALLATION, OPERATIONANDMAINTENANCE MANUALWORKSU jjain Road, Dewas - 455 001 ( ) Phone : +91 7272 227401/2/5/9 Fax : +91 7272 228747 Toll Free No. 1800 103 4443 CORPORATE OFFICE : YAMUNA , Survey No. 98 (3-7), Baner, Pune 411 045 (India)Phone : +91 20 27214444 E-mail : Visit us at : REGISTERED OFFICE :Udyog Bhavan, Tilak Road, Pune - 411 002 (India)Tel. : +91 20 24444444 Fax : +91 20 24444198E-mail : KIRLOSKAR BROTHERS LIMITEDA KIRLOSKAR Group CompanyA View of KBL Dewas Manufacturing Plant06010610DO NOT RUN THE PUMP DRY TO AVOID DAMAGE TO SEALOur products are meant for pumpingwater and they do not have any significant effecton environment during their use, if properlyselected and used as per instructionsgiven in this are advised to dispose unusablecomponents through appropriate disposal agencies toavoid the impact on work PROMPT SERVICE & SPARESR egister on our website.

2 Connections66 Connection Diagrams77 Operation98 Trouble Shooting119 Maintenance1510 Procedure for Dismantling & Reassembly1711 Cross sectional Drawing For SP (Bare Shaft) Pumps2112 Part List2213 Typical Cross Sectional Drawing For SP (Bare Shaft) Pumps2414 Part List2515 Cross Sectional Drawing For SP O M Pumps 3216 Part List3317 Cross Sectional Drawing For SP M Pumps3518 Part List3619 Product Range3820 Warranty Certificate39 Content SP type pumps are centrifugal pumps with an added feature of self primingmechanism. The pump is always ready for use, once the pump casing is filled initially with thepumping liquid after its installation. The design speciality of SP type pumps allows pumpingout certain amount of mud, dirt and suspended solids. These pumps are suitable for handlingwater and non corrosive liquids having temperature upto OF OPERATIONThe self priming action of the pump works on the diffusion principle.

3 Initially, the completepump casing is filled with the pumping liquid which is retained by its flap valve assembly. Whenthe pump is started, due to centrifugal action, flap assembly opens and the air from suctionbranch is mixed up with the liquid. Then mixture of air and liquid is transferred into large casingoutside the pumping chamber and air escapes through delivery branch. De-aired liquid againdiffuses with the pumping chamber and air escapes through delivery branch. No sooner all theair is eliminated, diffusion of the liquid stops and the pump works as a centrifugal pump with itsfull AND FEATURESA pplications :-Where self priming action is - Pumping water from docks, ports, - Pumping petroleum products, chemicals, effluents, ash-water construction - Dewatering foundations, trenches and Machinery - Cooling water for marine engines and utilities - Sewage pumping1=INSTALLATIONLOCATION : The pump should be located as near the water source as possible.

4 This will minimisethe suction lift and pump will give better performance. Amplespace should be provided on all sides for ease in inspection, operation and : After the installation is completed, the foundation bolts should betightened evenly and grouting may be completed. Allow about 48 hours for setting andseasoning of the foundation. For coupled pumpsets, base plates should be :vPipe size should be as per the flange size to get higher discharge. It is notrecommended to reduce the pipe size. If length of delivery pipe is more than 3 m., usehigher piping should be airtight. Any leakage in suction pipe may drastically affect theperformance of the suction pipe should be as short as possible for getting better of bends and other fittings should be as minimum as possible to reduce frictional : -=Withstand wide voltage fluctuations.

5 (For SP M pump only).Voltage range from :180V to 240V(Single Phase)300V to 440V(Three Phase)=Efficiency at par with internationally available flat efficiency curve; minimum variation in efficiency over the entire operating alignment due to monobloc construction. (For SP M pump only)=Long life : due to relpaceable wearing parts=Dynamically balanced rotating maintenance and spares lubricated deep groove ball automatic self priming for automatic air release during possible without disturbing the pipe connections (except SP O ).=Non - clogging impeller to handle suspended when fitted on for motor need for foot are with IP-44 protection (For SP M pump only). Also against order, models can besupplied with IP-55 protection (For galnd packed pumps).

6 VAdequate supports should be provided to pipes so that its dead weight does not fallon delivary casing horizontal length of the suction pipe should be straight to avoid air trapping in should not be inclined towards the delivery pressure more than 20 meters, it is recommended to install a check (non-return) valve in the discharge line. The check valve placed near the pump is to protect thepump from excessive back- pressure to prevent the water running back through the pump incase of sudden failure of prime CONNECTIONS (For SP M pumps) : Proper earthing connection should be made at the bolts provided for earthing. Proper size of cable should be used between supply and motor terminals to minimise voltagedrop and to carry full load current (FLC) marked on nameplate, cable should be large enough tocarry the starting current without excessive voltage drop.

7 The starting current for the direct on line (DOL) will be 6 to 7 times of FLC at rated voltage and3 to 4 times of FLC in star delta connection. Nuts at terminal should be tightened properly. No. of joints in cable should be as minimum as possible, preferably joints should be avoided. Wires and connections should be properly insulated. If not, it may lead to fatal shock. Proper backup protection (reputed make starter, main switch and fuse) should be DIAGRAM OF 1 PHASE MOTORSLEADS FROM MOTORPHASE NEUTRAL1 PHASE 50 HzSUPPLY7 CONNECTION DIAGRAM OF 3 PHASE DOL or Auto transformer with 3 leads or 6 of leads 3 Connectionstar or deltaFigureTo linesfor starTo linesfor deltaTo Star or delta startingNo. of leads 06 Connection deltaTo starterV1U1W1U2V2W2V1W1U2V2U1W2 UWVV1U2W1V2U1W28 OPERATION PROCEDURE : After the pumpset is installed, the following should be checked and done before starting thepump :=The shaft rotates freely by stuffing box (gland) is properly tightened.

8 (in case of gland packed pump.)=If there is any valve in delivery branch, it is pump casing is filled with clear water/pumping liquid through the priming plug providedonthe top of the body. Close the plug after the lantern ring grease cup 2 to 3 turns. This should be repeated weekly or as per not run the pump dry for too the pump is idle for sometime, it may get stuck or locked in place. This sticking is usuallydue to film of dust or dirt developed between the impeller and pump body. Give jerk at thefree end of the shaft to ensure free the pump is used to handle water containing solids and slit, it is necessary to wash out thesame with clean water, before restarting. Restarting of the pump should be done after fillingclean bearing should be lubricated once a Check following during running condition :=The direction of rotation is pump is running that the prime mover is not through stuffing box is normal, 50 to 60 drops per minute in gland ball bearings do not get excessively is no leakage from mechanical idle running on operation against closed discharge valve for a longer period of dirty water is handled by the pump of diesel engine set, do not use delivery sidewater for engine correct grade grease in grease cups.

9 We recommend servo Gem-2 Indian oil make correct grade grease in the bearings. We recommend servo Gem-2, Indian oil makeor equivalent. REASON FOR FAILUREW rong direction of rotationPump not primed or filled with liquidInlet or suction pipe insufficiently submergedNPSH available too lowPump not upto rated speedAir leaks in suction line or stuffing boxViscosity greater than rated10 TROUBLE SHOOTINGTYPE OF THEFAILURE Failure to Deliver waterPump Does not deliverrated dischargePump does not deliverrated headPump loses water afterSatrtPump overloads PrimemoverVibrationBearing overheatBearing wear rapidlyMotor heating upSeized pumpIrregular deliveryPump does not primeNoisy Pump Stuffing bore overheats REASON FOR FAILUREI mpeller damagedInternal leakage (gasket)

10 Priming air/vent valves openSpeed too highTotal head lower than recommendedViscosity and / or specific gravity higher than ratedStarved suctionWorn or loose bearingsRotor out of balance11 TROUBLE SHOOTING (Cont.)TYPE OF THEFAILUREF ailure to Deliver waterPump Does not deliverrated dischargePump does not deliverrated headPump loses water afterSatrtPump overloads PrimemoverVibrationBearing overheatBearing wear rapidlyMotor heating upSeized pumpIrregular deliveryPump does not primeNoisy Pump Stuffing bore overheatsREASON FOR FAILUREI mpeller blocked or damagedBent shaftFoundation not rigid or poor mixtureGland packing too tightGland packing not IubricatedWrong grade of gland packingInsufficient cooling waterStuffing box badly packedWrong grade of GreaseDirt in bearingsMoisture in IubricantFailure of lubricating systemBearings too tightExcessive thrust TROUBLE SHOOTING (Cont.)