PART A: PUMP

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 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 our arise solely from faulty workmanship or
defective material.

This warranty holds good only for the products manufactured

by us.

- KIRLOSKAR BROTHERS LIMITED -

 CONTENTS

1. INTRODUCTION.

2. PRE-REQUISITES FOR SATISFACTORY OPERATION.

3. PUMP HOUSE / TANK LAYOUT.

4. PUMP HOUSE REQUIREMENTS.

5. STORAGE AND HANDLING.

6. FOUNDATION.

7. TOOLS AND EQUIPMENTS.

8. ERECTION AND ASSEMBLING PROCEDURE.

9. OPERATION.

10. MAINTENANCE.

11. TECHNICAL DATA.

12. TROUBLE SHOOTING.

13. CROSS SECTIONAL DRAWING.

14. OUTLINE DRAWING.

CAUTION :

THIS INSTRUCTION MANUAL COVERS THE GENERAL

REQUIREMENTS OF INSTALLATION, OPERATION AND
MAINTENANCE. HOWEVER THE END USER SHOULD REFER TO
THE DRAWINGS AND DOCUMENTS IF SUPPLIED AGAINST
SPECIFIC ORDER.
 1. INTRODUCTION

KPDS-L pumps are specifically developed for handling of turbine oil. These
pumps shall be used as AOP (Auxiliary Oil Pump) or EOP (Emergency Oil
Pump) to lubricate the turbine bearings at the time of starting.

The pump types are designated as KPDS (delivery size in mm X nominal

full dia of impeller in cm) e.g. KPDS 80/26 L pump where 80 mm is
delivery nozzle size of pump casing and 26 cm is nominal full diameter
impeller. It should be noted that the rising pipe sizes are higher than the
delivery nozzle size of the pump casing in order to reduce the frictional
losses in the pipe and the bend.

This booklet covers important guidelines and instructions on

erection, operation and maintenance. These instructions should be
followed carefully and failing to this may result in unsatisfactory
performance and damage to the pump parts.

Only mechanical aspects in connection with erection and maintenance of

the pumps are covered in this booklet. Civil and electrical engineering
aspects are to be considered and taken care of at customers end only. The
customers are requested to report the problems arising at the site to the
supplier without fail. The name plate details should be mentioned while
making correspondence with supplier / manufacturer.

150C45 UNIT PUMP KPDS-80/32L

2. PRE-REQUISITES FOR SATISFACTORY OPERATION

For satisfactory working of the pump ensure that the following preliminary
conditions are maintained.

a. Pump handles the liquid as specified in the order.

b. Minimum submergence is kept as shown in the outline dimension

drawing supplied against the order.

c. Operation and maintenance instructions are followed as given in this

booklet.

d. Load of delivery pipe and other accessories such as sluice valve, reflux
valve etc. is not coming directly on support plate of the
pump.
 Prior confirmation must be taken from the manufacturer / supplier if the
pump is to be used for the conditions other than those specified in the
order.

3. PUMP HOUSE / TANK LAYOUT

The layout should be done after considering following -

3.1 Liquid inlet to the tank:

The liquid should enter in the tank such that turbulence, high velocity and
air entrainment is avoided at the suction of the pump.

3.2 Suction tank:

The tank should be designed so as to provide -

3.2.1 Enough storage capacity to avoid sudden fluctuations in liquid levels,

kinematics disturbance at the suction of the pump such as
turbulence, eddies, vortices, air entrainment etc.

3.2.2 Low velocity -

The maximum liquid velocity of the liquid entering in the tank
should not
Exceed 1 m/sec.

3.2.3 Individual flow pattern -

Where one tank houses more than one pumping sets, care must
be taken to provide appropriate distances from walls, floor and
adjacent pipes. It is advised that such layouts should be referred
to the pump manufacturer. This is necessary to ensure
individual flow pattern of each pump undisturbed by other pumps.

3.2.4 Pump submergence -

The lowest liquid level should be as recommended in the outline

drawing supplied against order. Highest liquid level also is below
specified level on the same drawing. The liquid level in the tank
should be positively controlled by liquid level controller / float
switch.
4. PUMP HOUSE REQUIREMENTS

These should cover mainly the following aspects.

4.1 The floor of tank should be sturdy enough to take total weight of the
machine including that of liquid column in the rising pipe/column pipe axial
thrust of impeller etc.

4.2 Sufficient floor area for working and overhauling. In this, the following
factors are to be considered.

4.2.1 Proper spacing of the pumps to avoid transmission of vibrations

from one machine to another.

4.2.2 Easy and safe accessibility to the electrical switch box.

4.2.3 Space for dismantled pump parts during overhauling.

4.3 Sufficient height of the room for erection. Provision for overhead
traveling crane or chain pulley block-

4.3.1 Pump house should provide adequate height of the room

between the foundation and the upper most position of the
crane hook. The minimum required height is shown on outline
drawing against order.

4.3.2 The pump house should provide sufficient cross travel of the
trolley so that the pump assembly can be moved without any
hindrance or receiving any undue stress during movement.
5. STORAGE AND HANDLING

5.1 KPDSL pumps upto 3 m suspension length are dispatched completely

assembled condition.

5.1.1 Check that all packages are intact and open parts are not
damaged in transit.

5.1.2 Open packages and check contents of each package against

delivery notes.

5.1.3 Report immediately discrepancies, if any to the supplier.

5.1.4 Unless the pump is to be installed immediately, repack the

material in respective cases after the contents have been
verified against delivery notes.

5.1.5 Do not open the packages again, unless site is completely ready
for erection.

5.2 Storage:

5.2.1 Storing place should be free from dust, heat, moisture etc. The
floor of the store room should be hard and plane.

5.2.2 Do not place packages one over the other inconveniently. Keep
the parts on wooden logs and properly leveled.
5.3 Handling:

5.3.1 All machined surfaces are coated with a special antirust

compound. If any surface is found exposed, clean it and apply a
thick coating of grease or antirust compound and wrap it with
paper to prevent further rusting.

5.3.2 Never drag any components or package of parts for any reason.
Dragging sets in intrinsic vibration which may distort the
accuracies, parallelism etc of machined surfaces. Distortion of
accuracies might cause serious functional and operational
troubles.

5.3.3 Over hanging should be avoided as far as possible. While lifting

the parts by ropes, they should be properly balanced.

5.3.4 Transportation should be free from jerks. Long parts should not
be handled without due supports.
 5.3.5 Open parts must be transported on soft and well supported
bending to prevent scratches.
5.4 Temporary storage for up to six weeks.

If the pump unit is not 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.

5.5 Long Storage Instructions above 6months & 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. Step should be taken to protect the pump from
moisture, dust, dirt, and foreign bodies. It is recommended that the
following procedure is taken:-

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
month to prevent pitting of the bearing surfaces by moisture.

CAUTION:

CARE MUST BE TAKEN IN HANDLING OF ALL PARTS ESPECIALLY THE

SHAFTS. THEY ARE MACHINED TO CLOSE TOLERANCES AND
CAREFULLY INSPECTED AT FACTORY AND IF BENT, THEY CAN CAUSE
A SERIOUS TROUBLE. A BENT SHAFT SHOULD NEVER BE USED RUNOUT
MORE THAN 0.05 MM IS NOT PERMISSIBLE).

6. FOUNDATION

6.1 The location of foundation bolts should be marked out as per the outline
drawing supplied in advance. The supporting frame should be strong
enough to take the load of complete unit, axial thrust, etc and should be
rigid enough not to vibrate.
6.2 Leveling:

For smooth working of the pumps it is necessary that the machined

surface of a support plate on which motor stool keeps up its vertical
position.
The rotating unit should be aligned with the vertical axis.

The whole foundation frame plane position on which the support plate is
to be mounted should be checked with straight edge and spirit level
(0.05 mm accuracy) for its horizontal level. The plane portion should
make horizontal by scraping operation, if necessary. Use gasket in
between support plate and foundation plane portion so that the joint
becomes leak tight for grease and air coming out of the tank. After
tightening the foundation bolts ensure that the top portion of motor stool is
exactly horizontal.

6.3 Ensure that the holes on flange of delivery pipe above support plate and
that of delivery pipe to be connected to it exactly match and there is
proper uniform clearance in between two pipe flanges and the clearance
will not give rise to any horizontal displacement of the pumping unit. Due
care should be taken to see that load of the delivery pipes and accessories
such as sluice valve; reflux valve etc should not come on support plate.
Separate firm supports should be given to the delivery pipe and its
accessories.

7. TOOLS AND EQUIPMENTS

Essential equipment required for erection are as follows.

7.1 The chain pulley block / crane should be of ample capacity to take the
load of the complete unit. The pulley block should have lift of 3 meter
minimum and the hand chains provided should be long enough to operate it
conveniently from the floor. The chain pulley block of 3 tons capacity is
most suitable.

7.2 Chain and lifting hook.

7.3 Jute ropes, crow bars and small pipes for leverage.

7.4 Light but accurate straight edge

7.5 Kerosene or thinner for cleaning of parts.

7.6 Spirit level having the accuracy of 0.02 mm/meter.

7.7 Small wire brush for cleaning threads at shafts.

7.8 Threading compounds for shafts and pipe threads.

7.9 "V" blocks, dial gauge with magnetic stand to check run out of shafts.

7.10 Two sturdy wooden logs or mild steel girders to rest the clamps during
erection process.

7.11 Besides above following standard tools and equipment should be

available for smooth erection.

7.11.1 Files-triangular, half round and flat of different cuts and sizes.

7.11.2 Triangular scraper, filler gauge.

7.11.3 Two sets of standard/ring spanners.

7.11.4 Set of pipe wrenches and chain tang.

7.11.5 Adjustable spanner, screw drivers of 12" and 6".

7.11.6 Allen keys.

7.11.7 Steel rule and steel tape.

7.11.8 Sets of taps and dies upto M16.

7.11.9 Chisel, hammer, hacksaw, vice etc.

7.11.10 Emery paper, cloth.

8. ERECTION / ASSEMBLING PROCEDURE

Follow the procedure given below in case of pumps to be erected for the
first time or pumps to be assembled after dismantling for overhauling.
Clean all the parts thoroughly in Kerosene, Petrol or Benzene to remove
dust, dirt etc. Replace the parts with a new one if found damaged. Use
new gaskets and "O" rings at the time of reassembly of pump.

8.1 Mount the double row ball bearing (26300) on the thrust bearing carrier
(24700).

8.2 Mount the ball bearing along with the carrier in the bearing holder
(25400). Clamp the bearing cover (27001) to the bearing holder.
8.3 Put oil retainer on shaft & place key on shaft. Pass the shaft through the
bearing holder & clamp the oil retainer to the bearing holder.

8.4 Fit the bearing nut (33500) and lock nut (33600) on the pump shaft. Do
not tighten the lock nut till the final stage of the assembly.

8.5 Clamp the top column pipe (13301) to the bottom column pipe with the
help of long studs and nuts .Pl. note that the bearing holder along with
rotating assembly is sandwiched between the column pipe and the top
column pipe.

8.6 Clamp the top column pipe (13200) to the support plate (46700).

8.7 Insert the shaft sleeve (31100) on the pump shaft with key (32000) in
proper position. Fit the journal bearing (37100) along with the cast shell
in the casing cover (22000) & fix the hex socketed cap screws (666000)

8.8 Insert the casing cover on the pump shaft with shaft sleeve and clamp
with column pipe. Press fit the impeller wear ring (19000) to the impeller
with the help of grub screws. Fit the helicoil lock insert (47900) in the
impeller nut (33000). Mount the Impeller (15100) on the pump shaft with
gasket (51500) in position and tighten the impeller nut with gasket
(68200) in between the impeller and the impeller nut.

8.9 Fit the casing ring (19200) to the pump casing (10700) with grub
screws. Insert the pump casing on the assembly so far completed with
permanite (oil) gasket (51100) in proper position. Clamp the pump casing
to the column pipe with the help of long studs and nuts. Pl. note that the
casing cover is sandwiched between the pump casing and column pipe.
Clamp the bell mouth (21100) to the pump casing.

8.10 Float adjustment – For semi open impeller - Loose both lock nuts (33500
& 33600) so that impeller will touch the wear plate. Lift the rotating unit
by 0.5-1.00 mm so that impeller rotates freely. Tighten the lock nut
(33600) to lock the bearing nut.
For enclosed impeller - loosen the shaft unit (along with impeller) so as
to rest at bottom portion. Mark the position on shaft threads with
respect to bearing cover top face. Now lift the shaft unit, till the
impeller touches top surface & ensure further lift not possible. Again
mark the position on shaft w.r.t.bearing cover top face. Find the mean
distance between these two readings & adjust the shaft at mean position.

8.11 Connect the discharge bend (bottom side) (28000) with the pump casing.
8.12 Fit the pipe nut (33801) with washer (62500) and gasket (68001) tightly
to the rising pipe. Pass the rising pipe through the hole in the support
plate and adjust in such a way that the holes of the flange for rising pipe
match with those of the bend.
8.13 Tighten the pipe nut along with the gasket loosely to the support plate.
Pass the other pipe nut (33801) along with the gasket (68002) from
upper side and tighten loosely to the support plate.

8.14 Fit the delivery flange above the support plate over the rising pipe and
tighten loosely over the pipe nut above support plate.

8.15 Adjust and tighten both the pipe nuts and the delivery flange in such a
way that the drilled holes of the flange are 45 deg. Off CRS.

8.16 Connect the discharge bend (top side) (28001) to the delivery flange if it
is in the scope of supply.

8.17 Connect and clamp the mating flange (49004) to the bend if it is in scope
of supply. Note that the side of the flange having the same size of the
taper hole as that of the top bend should be mounted on the bend side.

8.18 Connect the slipon companion flange to the mating flange if it is in the
scope of supply.

8.19 Fix the flushing pipe between the rising pipe and the bearing holder with
help of adapter and sealing nut in tapped hole.

CAUTION :

ENSURE THAT THE SHAFT ROTATES ABSOLUTELY FREE.

8.20 Mount the pump half coupling (39000) along with the key (32100) and
tighten the set screw. Put coupling star / coupling spacer in-between as
applicable.

8.21 Mount the motor half coupling (39100) on motor shaft along with the
key and tighten the set screw of the coupling. Fit the cushions in case
of ‘C’ type couplings. Check the angular alignment with the help of filler
gauge and the parallel alignment with the help of straight edge and filler
gauge. Alignment should be within 0.05 mm.

8.22 In case of LFG ( Gear Type coupling) – Two tapped holes are provided on
the coupling boss O.D. for grease filling. Please fill the grease from one
end till the grease comes out from the hole from other side. This is to be
done for both halves of the coupling (.i.e. pump side & motor side)
 Grade of grease – Indian Oil – Servogem-3
Caltex – Regal starfak No.3
Hindustan Petroleum – Lithon -3 or Natra -3
Refilling period – after 1000 hrs. of working.

8.23 Mount the pump on tank containing oil.

8.24 Mount the motor on support plate. Check the direction of rotation
before mounting the motor on the support plate. The direction of rotation
of motor should be clockwise when viewed from top i.e. non-driving
end of the motor.

8.25 Make all the connections of valves and delivery pipe above support
plate .

8.26 Once again check the level on the machined surface of the support plate.
If level is disturbed once again it should be reset up in the range of 0.05
mm.

8.27 Make the electric connections of the motor.

8.28 Ensure that liquid level controller is fitted and is working properly if used.

9. OPERATION

9.1 Prior to starting :

9.1.1 Rotate the coupling by hand. It should rotate freely.

9.1.2 Ensure that submergence is more than the recommended

minimum on outline drawing. Use of liquid level controller is
recommended.

9.1.3 Ensure direction of rotation by giving the driver a short run.

Incorrect rotation will quickly damage the pump.

9.2 Putting the pump in operation :

9.2.1 Start the pump. Let the motor pickup full speed.

9.2.2 Open the delivery sluice valve gradually till the current taken
by motor reaches the full load /current stated on the motor
name plate.
 9.2.3 See that motor is not getting over loaded.

9.3 Check during running :

9.3.1 The pump is running smooth. Check noise and

vibrations. Vibrations should be checked at the top of motor.
Stop the pump if abnormal noise or vibrations are
observed. Detect the reasons for vibrations and restart the
pump after eliminating the reasons for the same.

9.3.2 Head and capacity developed by the pump is as specified

in the name plate of the pump.

9.3.3 Motor bearings are not getting heated up excessively.

9.3.4 Check the oil temperature is not more than 80 deg. C.

9.4 Stopping the pump :

Pump should be switched off only after closing the delivery sluice valve.

10. MAINTENANCE :

10.1 Daily checks :

10.1.1 Pressure gauge reading.

10.1.2 Voltage and current.

10.2 Periodical checks :

10.2.1 Check the vibrations.

10.2.2 Check the liquid level controller for its functioning.

10.2.3 Calibration of measuring instruments.

10.2.4 Clean the tank, if there are chances of deposition of the

contents
of the liquid handled.
10.3 Overhauling :

10.3.1 With continuous daily operations spell, the pump will be

due for overhaul after 10,000 working hours. This work
should be carried out by specialized and experienced fitters.

10.3.2 While ordering spare parts, the details of the name plate
must be quoted in full. Particularly the name of the pump,
order number, name of the part and quantity required.

10.3.3 Keep the sufficient stock of spare parts in order to meet

the emergency requirement. The recommended parts are
shown with Asterisk(*) mark in the cross section drawing.

10.4 Follow the following procedure while dismantling the pump -

10.4.1 Disconnect the delivery pipe/flange/bend connections above

support plate (46700). Unscrew the fasteners holding
support plate on the flange of tank.

10.4.2 Unscrew the nuts of motor and take out the motor along with
the key and the motor half coupling (39100). Remove
coupling star/block/spacer as applicable.

10.4.3 Disconnect the motor power connections. Lift the pump

vertically upwards out of the tank and keep it horizontally.

10.4.4 Remove flushing pipe connection

10.4.5 . Remove the bottom bend (28002) by unscrewing the nuts.

. Remove the slipon companion flange (49003) if in the
scope of supply.

. Remove the mating flange (49004) if in the scope of supply.

. Remove the discharge bend (top side) (28001) if in the scope

of supply.

. Remove the delivery flange (49001) by unscrewing over the

rising pipe(14201).

. Remove the rising pipe from support plate after unscrewing

and removing the upper pipe nut (33801) along with the
bottom bend (28002).
 . Remove the other pipe nut from the rising pipe. Disconnect
the bottom bend from rising pipe.
In case of KPDS 80/32L, follow following procedure –
i) Remove flushing piping connections
ii) Remove the rising pipe & support plate assembly along with the
bottom bend.
iii) Disconnect the bottom bend from the rising pipe.

10.4.6 Unscrew the studs of the pump casing (10700) connecting it

to the column pipe and the studs connecting it with the
discharge bend (bottom side). Remove the pump casing and
the casing ring (19000) assembly.

10.4.7 Unscrew the impeller nut (33000) along with the helicoil lock
insert (47900) and remove the impeller (15100) along with
the key (32000), gasket (68200) and impeller ring (19200)
from the pump shaft (18000) with the help of suitable puller.

10.4.8 Unscrew the nuts connecting column pipe (13301) and

remove the casing cover (22000) along with the journal
bearing and the bearing shell (37100).

10.4.9 Remove the shaft sleeve (31100) .

10.4.10 Unscrew the nuts and remove the bottom column pipe
(13301).

10.4.11 Take out the pump half coupling (39000) after loosening the
set screw. Use suitable puller. Remove coupling key (32100).

10.4.12 Unscrew and remove the two bearing nuts (33500 and
33600) along with the spacer (19500).

10.4.13 Remove the bearing cover (27001). Remove the thrust

bearing carrier (24700) along with the bearing (26300) and
key (32400). Remove the oil retainer (68003).

10.4.14 Disconnect the top column pipe (Lower stool) (13200) from
support plate.

10.4.15 After dismantling the parts as indicated above, clean them

and inspect them for wear, tear and damage. Following
parts should be specifically inspected.

a. Angular contact ball bearings - Wear.

 b. Bearing bushes - For wear and surface condition.

c. Shaft for runout (within 0.05 mm).

d. Shaft sleeves - For wear and surface condition.

e. Casing and impeller wear rings for wear and surface

condition.

10.4.17 Replace all the damaged parts with new one.

11. TECHNICAL DATA:

11.1 Direction of rotation:

Direction of rotation shall be clockwise when viewed from motor top.

11.2 Details of antifriction bearings used :

Unit 150C45
Pump Type 80/32L

Bearing SKF 3311

Oil lubricated bearings can be operated upto 80°C.

11.3 Journal bearing :

Journal bearing (37100 ). This bearing is made out of babbit material.
Clearances between bearing and shaft sleeve are as follows.

Minimum clearance = 0.1 mm dia.

Maximum clearance = 0.6 mm dia.

11.4 Non asbestos gaskets :

SR. PART DESCRIPTION QTY.

NO. NOS.
1 51100 Gasket for Casing Cover. 1
2 51301 Gasket for Casing and Bend. 1
3 51302 Gasket for Bend and Rising Pipe. 1
4 51500 Gasket for Shaft Sleeve. 1
5 68001 Gasket for Pipe Nut 2
6 68002 Gasket for Oil Retainer 1
7 68200 Gasket for Impeller Nut. 1
 Sr. Pump SIZE OF GASKET IN MM (I.D. X O.D. X THK.)
No. Type PART NOS.
51100 51301 51302 51500
1 80/32 L 331 D X 80 D X 200 D X 44 D X
348D X 1T 200D X 1T 285D X 1T 50D X 1T

Sr. Pump SIZE OF GASKET IN MM (I.D. X O.D. X THK.)

No. Type PART NOS.
68001 68002 68200
1 80/32 L - 50 D X 80 D X 38 D X 48 D X
1T 1T

12. PUMP TROUBLE SHOOTING :-

When investigating trouble with Kirloskar pumps, always remember that pumps have been
tested at the factory and are mechanically correct when sent out. Discounting the possibility
of damage during transit, most of the trouble in the field is due to faulty installation.
Investigation shows that the majority of troubles with centrifugal pumps result from faulty
conditions on the suction side.

BREAK DOWN-CAUSE-CHECK POINTS

In case of breakdown we recommend the location of the fault by using the following table.

BREAKDOWN CHECK POINTS

Pump does not deliver 1 7 8 9 10 11 12 14 15 17 18 19 23 25 26 56

57 58
Pump delivers at reduced capacity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19
20 21 22 56 57 58
Delivery performance deteriorates 1 3 7 9 10 11 12 13 14 19 20 21 22 23 24 53
57 62
Pump delivers too much
16 56 57 58
Delivery is interrupted 1 3 6 7 8 9 10 11 12 13 14 15 16 19 22 23
25 26 56 57 58 62
After stopping pump runs in
reverse direction 52

Very noisy
Unsteady running of pump
Stuffing box leaks excessively
1 2 5 6 7 8 11 12 13 15 19 20 22 54 55 56
57 62
19 20 22 31 32 33 35 36 37 38 39 40 43 44
47 48 49 50 51 54 55 58
24 27 28 29 30 31 47 48 49 53
Fumes from stuffing box
22 23 24 25 26 27 28 29 30 41 42 43
Pump rotor locked in standstill
position 22 45 46 50

Pump is heating up and seizing 23 24 25 26 27 28 29 30 40 41 42 45 47 48

49 50 54
Bearing temperature increases 19 20 21 22 31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 51 54 55 58
Motor will not start
14 22 60
Motor gets hot or burns out
14 22 27 28 40 43 50 55 56 57 58 59 60 61
Motor is difficult to start
14 22 27 28 45 46 50 58 59 60

CHECK POINTS

1. Suction pipe, foot valve choked.

2. Nominal diameter of suction line too small.
3. Suction pipe not sufficiently submerged.
4. Too many bends in the suction line.
5. Clearance around suction inlet not sufficient.
6. Shut off valve in the suction line in unfavorable position.
7. Incorrect layout of suction line (formation of air pockets).
8. Valve in the suction line not fully open.
9. Joints in the suction line not leak-proof.
10. Air leaking through the suction line and stuffing box etc.
11. Suction lift too high.
12. Suction head too low (difference between pressure at suction connection and vapor
pressure too low).
13. Delivery liquid contains too much gas and/or air.
14. Delivery liquid too viscous.
15. Insufficient venting.
16. Number of revolutions too high.
17. Number of revolutions too low.
18. Incorrect direction of rotation (electric motor incorrectly connected, leads of phases
on the terminal block interchanged).
19. Impeller clogged.
20. Impeller damaged.
21. Casing rings worn out.
22. Separation of crystals from the flow of pumping liquid (falling below the
temperature limit/equilibrium temp).
23. Sealing liquid line obstructed.
24. Sealing liquid contaminated.
25. Lantern ring in the stuffing box is not positioned below the sealing liquid Inlet.
26. Sealing liquid omitted.
27. Packing incorrectly fitted.
28. Gland tightened too much/slanted.
29. Packing not suitable for operating conditions.
30. Shaft sleeve worn in the region of the packing.
31. Bearing worn out.
32. Specified oil level not maintained.
33. Insufficient lubrication of bearings.
34. Ball bearings over-lubricated.
35. Oil/Grease quality unsuitable.
36. Ball bearing incorrectly fitted.
37. Axial stress on ball bearings (no axial clearance for rotor).
38. Bearings dirty.
39. Bearings rusty (corroded).
40. Axial thrust too great because of worn casing rings, relief holes obstructed.
41. Insufficient cooling water supply to stuffing box cooling.
42. Sediment in the cooling water chamber of the stuffing box cooling.
43. Alignment of coupling faulty or coupling loose.
44. Elastic element of coupling worn.
45. Pump casing under stress.
46. Pipeline under stress.
47. Shaft runs untrue.
48. Shaft bent.
49. Rotor parts insufficiently balanced.
50. Rotor parts touching the casing.
51. Vibration of pipe work.
52. Non-return valve gets caught.
53. Contaminated delivery liquid.
54. Obstruction in delivery line.
55. Delivery flow too great.
56. Pump unsuitable for parallel operation.
57. Type of pump unsuitable.
58. Incorrect choice of pump for existing operating conditions.
59. Voltage too low/power supply overloaded.
60. Short circuit in the motor.
61. Setting of starter of motor too high.
62. Temperature of delivery liquid too high.
Specification List of KPDS L pump

Part code No. Description Qty.

10700 Pump casing 1
13200 Column Pipe (Top) 1
13301 Column Pipe 1
14201 Rising Pipe 1
15100 Enclosed Impeller 1
18000 Pump shaft 1
19000 Casing wear ring suc. side 1
19200 Impeller wear ring del. side 1
19500 Bearing spacer 1
21100 Bell mouth 1
22000 Casing cover 1
24700 Thrust bearing carrier 1
25400 Bearing holder 1
26300 Angular contact ball bearing 1
27001 Bearing cover 1
27700 Oil retainer 1
28001 Discharge bend (Top side) 1
28002 Discharge bend (Bottom side) 1
31100 Shaft sleeve (P.S.) 1
32000 Key for impeller 1
32100 Key for coupling 1
32400 Key for thrust bearing carrier 1
33000 Impeller nut 1
33500 Bearing nut 1
33600 Lock nut 1
33801 Pipe nut 2
37100 Bearing bush under impeller 1
39000 Flexible coupling pump side 1
39100 Flexible coupling motor side 1
40200 Coupling block 1
46700 Support plate 1
47900 Helicoil spring insert 1
49001 Delivery flange 1
49002 Flange for rising pipe 1
49003 Slip on flange (Companion ) 1
51100 Gasket for casing cover 1
51301 Gasket for bend 1
51302 Gasket for bend & rising pipe 1
51303 Gasket for bend / comp-flange 1
51500 Gasket for shaft sleeve (PS) 1
58005 Hex. Nut for support plate holding bolt 1
60000 Plug for pressure gauge 1
62500 Washer for pipe nut 1
66600 Hex socket cap screw ( bearing shell) 4
68001 Gasket-pipe nut 1
68002 Gasket pipe - nut 4
68003 Gasket for oil retainer 1
68200 Gasket for impeller & impeller nut 1
70600 Spring washer 4
81500 Support plate holding bolt 4

C:\pedin13\sab\Technical manual\KPDS-L-MANUAL.doc
 13 CHECK LIST BEFORE STARTING THE PUMPS
Before starting any AOP or EOP pump following points shall be attended

Sr. No. Check Point

1 Direction of Rotation: It should be clockwise viewed from motor fan end cover
2 Free Rotation:- Free rotation of shaft shall be ensured
3 Gear coupling: Both coupling halves shall be filled with the given grease
quantity. (As mentioned in the point D3-Coupling IOM)
4 Float Adjustment:- This is an important parameter to be carried out as
mentioned in point no. 8.10
5 Support plate leveling –same shall be checked at 4 locations length wise and
widthwise by spirit level. It should be 0.05 mm
6 Ensure blue matching of support plate and MOT top face within 60 to 70%
7 Avoid excessive pipe stresses- Ensure that there are no excessive stresses of
the system pipe line exerting on the pump delivery pipe.
8 Position of the delivery valve shall be closed before starting and after starting it
should be opened gradually and set at duty point
PART B : GEAR COUPLING
(TYPE LFG)
 COUPLING INSTALLATION INDEX

¾ Purpose of Installation / Alignments

¾ Conditions of Shaft Alignments
¾ How to Align Shafts?
¾ Installations of Couplings
– Gear Coupling
– Vertical Installations

Technical Presentation 1/11/2011 11:58 AM Turning Quality into a Revolution

 Installation / Alignment Instructions
Purpose –
The purpose of aligning equipment is to avoid transmission of
unwanted stresses to bearings, shafts, keys, couplings, seals, etc.
That is to increase life of bearings, couplings, seals, etc.
How -
By providing minimum angularity and offset (Parallel Misalignment)
at normal operating conditions.

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 Shaft Alignment Conditions
Align Shafts

Parallel Misaligned Shafts

Angular Misaligned Shafts

Combined Angular &

Parallel Misaligned Shafts

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 Forms of Displacement

Angular Ø

Parallel δ

End Float f

Torsion Flexibility ø

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 GEAR COUPLING

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 Exploded view of GEAR coupling

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 Installation
Motor Shaft

Sleeve ¾ Follow the assembly as

given sequence.
Hub
Plate 1
Bolt
Plate 1 & thrust button shall be towards pump side (bottom side)
Plate 3
Hub

Sleeve

Pump Shaft
7

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 Comparison of Vertical & Horizontal Assembly – Gear Coupling
Horizontal Assembly:

1. In this, both hubs are mounted horizontally on drive & driven shaft. Hence
sliding of hubs is not possible.
2. In case of longer spacer length only in metallic coupling, effect of weight of
spacer on gear teeth's is reduced by using bush/bearing support at both
end of spacer.

Vertical Assembly:

1. To prevent sliding down of top hub/flange is supported by bolting lock washer

to shaft as shown in fig.
2. And bottom hub/flange is either rested on stepped shaft or supported by
using shaft collar or distance piece as shown in fig.
3. Axial load on sleeve during running condition. This reduces flexibility and thus
reduces max. Misalignment capacity. To avoid this hub is supported on pivot
as shown in fig.
4. Effect of weight of sleeve/spacer on flexible element can be eliminated by
providing pivot at bottom side of spacer / hub as shown in fig.

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 Parallel Alignment

Parallel misalignment
using straight edge.

Parallel misalignment
using Dial Gauge

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 Angular Alignment

Angular misalignment
using straight edge /
Dial Gauge.

10

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 After completion of alignment insert the Gasket

Gasket

11

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 Bolt
Insert Coupling
Nut & Bolts

Lock Washer

Nut

12

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 Tighten the fasteners with
appropriate torque

13

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 Fill the required amount of
grease (Refer installation
manual for correct amount
of grease)

14

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9 Maintenance
Standstill precautions
Standstill precautions
Despite the use of water extractors,
many oil lubrication systems have small
quantities of free water, especially in
the forming and press section. Grease
lubricated bearings also may have free
water in the lubricant.
The highest risk of water ingress
probably occurs during high-pressure
cleaning of machine frames, wires and
felts. Free water in the lubricant, espe-
cially water mixed with cleaning chem-
icals, will rapidly start a corrosion pro-
cess on bearing surfaces when the
machine is at a standstill. There are
some different ways of avoiding such
corrosion:
• never direct the high pressure spray
nozzle towards the sealing gap
• keep the water outside the bearing
by more efficient seals
• with oil lubrication, remove the free
water by using more efficient water
extractors
• replace the contaminated lubricant
(grease or oil in a bath) by fresh and
clean lubricant
The last alternative is the one most
commonly used method for grease
lubricated bearings. Fresh grease is
SKF LHVI 1 injected just before closing down.
196
The most common method with oil
lubrication is to remove the water by
increasing extractor capacity before
closing down, e.g. using a portable
vacuum extractor. In some circulating
oil systems it is even possible to let the
oil continue to circulate during stand-
still, which is of course an advantage.
SKF LHVI 1 is a rust inhibiting agent
which creates a vapour that coats and
protects surfaces from corrosion. It
can be added to the oil to improve
corrosion protection in machines that
are stored for some time. Before the
machine restarts, the oil should be
drained. It is also suitable for use on
external components where a tacky
film is acceptable e.g. castings, pumps,
valves and compressors. The agent
should not be used in the oil for
machines that are in operation, since
it then can clog the filters
 SKF Reliability Maintenance Institute ©
Best Practices for Bearing Handling and Storage
As manufactured, bearings are supplied as precision machine components and should be respected as
such during transport, intermediate handling, storage and installation until the associated machinery is
brought into active service. Damage may occur at any point which could reduce the ultimate service of
the bearing.

Shipping: Standard packaging is

intended to protect the bearing during
normal transport and handling activities.
If the external packaging is significantly
damaged, return the bearing for
replacement. Inspect the inner wrapper.
If compromised, it’s likely the bearing has
been contaminated and should not be
installed.

Storage:
Bearings should be stored horizontally in
their original, unopened packages until
needed. (The objective is to maximize
the number of rolling elements in contact
with the raceways during storage.) The
storage area should be vibration free.
Subsonic vibration from railway spurs and/or truck movement is a common cause of bearing damage on
the shelf. Temperature and relative humidity should be reasonably constant. Use the oldest bearings
first.
Bearings supplied in housings (pillow blocks, flange units, etc.) should be stored flat on their bases, but
the bearing inner rings should be rotated as per the instructions for stationary equipment.
Shelf life of bearings varies with the type of packaging, preservative material, and storage environment.
Uncapped bearings can be stored in their original packages for many years, provided relative humidity in
the storeroom does not exceed 60 % and there are no great fluctuations in temperature. Check the
packaging: if unbroken and the preservative appears fresh, the bearing should be suitable for use.
Bearings pregreased or with closures should be used within five (5) years of the date of manufacture.
Long-term storage (over five years) of capped (sealed or shielded) bearings is not recommended.
Potential hazards include:
Grease separation in pregreased (double shielded or sealed bearings)
Grease settling to one side of the bearing
False brinelling damage
Corrosion

SKF ® is a registered trademark of SKF. All material contained herein © 2003 SKF.

Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage
whether direct, indirect or consequential arising out of use of the information contained herein.

Page 1 of 2
 SKF Reliability Maintenance Institute ©

Installation:
Proper installation practices are crucial to prevent damage during removal and installation. Don’t wash
new bearings prior to installation unless absolutely necessary for compatibility with in-service lubricants
or other process requirements (food grade service, for example.)

Post-Installation:
After the bearing is installed, wrap completed assemblies in plastic, waxed paper, or a clean, dry, lint-free
cloth to prevent contamination and corrosion to exposed components. Shafts should be strapped down
to prevent false brinelling damage during transportation. Assemblies not expected to be put into service
immediately should be lubricated and consideration given to the addition of a long-term corrosion
inhibitor. A properly constructed base for completed assemblies may mitigate transportation damage and
safety hazards.

Shafts of stored, ready-for-

installation assemblies, like
electric motors and bearings
in housings, should have
their shafts rotated several
turns on a quarterly basis to
reduce the potential for false
brinelling damage.

In-Service: Vibrations and

shock loads may brinell
bearing raceways and rolling
elements. Avoid operating
equipment in poor running
condition as damage to
bearings and other
components may result.

Temporary Shutdowns:
Rust preventatives, vapor phase corrosion inhibitors, desiccants, breathers and positive pressure
systems are available to protect equipment from corrosion and particle ingress during shutdown periods.
Consult a qualified supplier for assistance.

Bearings in standby equipment may be subject to damage from currently operating systems. As
operating equipment fails, unwanted vibrations and/or shock loads may be transmitted to standby
machinery. The common result is premature failure soon after the standby equipment is brought online.
Although removing the vibration source is the ideal solution, vibration isolators may also be effective in
preventing bearing damage.

SKF ® is a registered trademark of SKF. All material contained herein © 2003 SKF.

Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage
whether direct, indirect or consequential arising out of use of the information contained herein.

Page 2 of 2
 Guidelines for bearing short term storage before
installation (Before Assembly)
• Preservation and packaging are not the only factors to be considered in order to prevent
the bearings from corroding. Humidity and temperature must, as far as is feasible, be
controlled during storage, handling, packaging and transport at all stages, particularly in
tropical areas (temp. 38°C and Relative Humidity: 90 % ).

• Do not open the bearing from its packing unless and until the assembly needs to be done.
Do not wash the Rust preventive applied on the bearings even if it is open for some reasons
of quality inspections. In case the bearing is opened from the packing, please ensure that it
has the sufficient visible layer of rust preventive oil on it.

• Do not store the bearing in the area exposed directly to the atmosphere. Store the
bearing in a controlled humidity, temperature environment and clean place, free of dust and
dirt particles.

• It is strongly recommended that the temperature of the bearings in their packages should
be kept below 40°C. Peaks of more than 45°C should initiate corrective measures. The
temperature in excess of 40°C accelerates the degradation of the preservatives.
 Guidelines for bearing short term storage before
installation (Before Assembly)
• Warehouse temperature and humidity must be controlled. The great daily variations are
not permitted, but seasonal variations of gradual nature are acceptable. As a general rule,
the following conditions should be adhered to:
•Relative Humidity (RH): Not exceeding 60%.
•RH fluctuation: Peaks of more than 65% humidity should initiate corrective measures.
•Temperature: For Long term storage, the temperature below 30°C is recommended.
•Temperature fluctuation: Maximum 3°C / 48 hours.

• Rust or corrosion will not occur on a naked, clean steel surface if the relative humidity is
below 50% and the air is clean. With increasing relative humidity, corrosion will occur and
above 75% relative humidity the rate of corrosion is high. Sulphur dioxide, salt (NaCl) and
other impurities accelerated the corrosion process. The preservative will protect the surface
and if correctly applied it will protect against rust for a long time even at high relative
humidity.

• If there are signs of damage to the packaging, it must be opened and to be inspected for
the possible further damage to the bearing.

2010-02-04 ©SKF Slide 3 [Code]

SKF [Organisation]
 Guidelines for bearings in Idle machinery.

• For the bearing installed in the equipment, we also recommend to follow the similar
guidelines applicable for the storage of the bearings given in above slides.

• Equipment which is idle must be set in motion periodically to spread the lubricant over
all bearing surfaces. It is recommended to turn the Shaft bearing slowly (to carry out two
rotation of the Shaft once in a month) to have proper lubrication at all contact areas.

• Ensure that the bearing housing is not directly exposed to the extreme temperature,
wet and humid environment.

• If possible, arrange to keep the Shaft in locked position when standstill. Especially when
the surrounding has vibrations as loose shaft increases the probability of bearing damage
by false brinelling.

• Please check in the compatibility of the storage grease & the oil being used for
lubrication.

2010-02-04 ©SKF Slide 4 [Code]

SKF [Organisation]
 Guidelines for bearings in Idle machinery.

• If the equipment is standstill for more than 3 years, then it calls for checking the
condition of the bearing, housing and grease. There are chances that the bearing/housing
may be rusted / corroded and grease may be caked if stored in a humid/rainy or dusty
environment.

• For this, after 3 years dismantle the housing covers and related components from the
bearing and check the condition of the bearing, housing and grease. If required, take out
the housing body from the bearing and check the bearing Outer ring raceway. If the
bearing and housing condition is OK, then the bearing can be used.

• All lubricants have a tendency to deteriorate in the course of time, but at a greatly
different rate. Therefore, sooner or later, it will be necessary to replace the old lubricant
with new. Oils and greases should be removed in the early stages of deterioration so that
removal does not become unnecessarily troublesome. We recommend taking out the old
grease from the bearing and housing at this time and fill the new grease as per the
regreasing procedure.

2010-02-04 ©SKF Slide 5 [Code]

SKF [Organisation]