CW Pumps - BHM 150 - O&M Manual

Operators Instructions for Manual /Rev
CIRCULATING WATER PUMP BHM150 HINDUJA / R00
Operation and maintenance manual
BHM 150, SINGLE STAGE,

EXTERNAL WATER LUBRICATD PUMP
PROJECT
2 X 520 MW VIZAG THERMAL POWER PLANT

VISAKHAPATNAM
M/s KBL WORK ORDER NO: C09712A002
ERECTION, OPERATION &

MAINTENANCE MANUAL
KBL DOCUMENT NUMBER : KBL/IOM/BHM150/HINDUJA/C09712A002/ REV -00
KIRLOSKAR BROTHERS LIMITED

REGD & HEAD OFFICE: UDYOG BHAVEN, TILAK ROAD,
PUNE – 411002
TELPHONE: 020-444 0770
E-MAIL: [email protected]
1
O & M MANUAL FOR BHM 150
DESCRIPTION PAGE NO.
A- E GENERAL INFORMATION & SAFTEY INSTRUCTIONS 4-9
SECTION- 1 INTRODUCTION
1.1 GENERAL DESCRIPTION.
1.2 TECHNICAL DATA OF PUMP.
1.3 GENERNAL CONSTRUCTION OF PUMP. 10-21
1.4 BEARING & LUBRICATION ARRANGEMENT.
1.5 PIPE CONNECTIONS.
SECTION- 2 RECEIPT STORAGE & HANDLING.

2.1 PUMP ROOM REQURIEMENT DETAILS. 22-30
2.2 PROCEDURE FOR TRANSPORTATION
2.3 PROCEDURE FOR STORAGE & HANDLING
2.4 UNPACKING AND LIFTING
SECTION- 3 INSTALLATION INTRUCTIONS

3.1 FOUNDATION – GROUTING PROCEDURE.
3.2 STEPS PRIOR TO ERECTION (CLEANING OF PARTS)
3.3 PUMP ASSEMBLY PROCEDURE 31-45
3.4 LOCATION OF UNIT, EQUIPMENTS AND TOOLS
REQUIRED.
SECTION- 4 OPERATION INSTRUCTIONS

4.2 PRIOR TO STARTING.
4.3 STARING.
4.4 CHECK DURING RUNNING.
4.5 STOPPING OF PUMP.
4.6 PRE – REQUISITES FOR SATISFACTORY
OPERATION OF PUMP. 46-50
4.7 CHECKS / STEPS TO BE TAKEN FOR INITIAL
START - UP IS AFTER A LONG TIME.
4.8 CHECKS / STEPS TO BE MADE FOR PREPARING
PUMP FOR PROLONGED SHUT – DOWN.
2
SECTION- 5 INSTUCTION FOR MAINTENANCE

5.1 GENERAL INTRODUCTIONS
5.2 DAILY, WEEKLY, M O N T H L Y , H A L F Y E A R L Y ,
Y E A R L Y CHECKS. 51-62
5.3 OVERHAULING.
5.4 DISASSEMBLY OF PUMP
5.5 CHECKING OF COMPONENT AFTER DISASSEMBLY.
5.6 SPARE PARTS.
SECTION- 6 TROUBLE SHOOTING CHARTS

6.1 Fault Chart & Remedy
6.2 Installation & Maintenance Record 63-67
6.3 SPARES & SERVICE
SECTION- 7 DRAWINGS AND DOCUMENTS

7.1 ASSEMBLY SKTECHES
7.2 GENERAL ARRANGEMENT DRAWING
7.3 CROSS SECTIONAL DRAWING
7.4 PUMP PERFORMANCE CURVE
7.5 PUMP DATA SHEET
7.6 PIPING CONNECTION DRAWINGS
3
A) GENERAL INFORMATION & SAFETY INSTRUCTIONS
Before installing the pump, read this manual and examine all related drawings until they are
fully understood. If questions arise, contact KBL. Also, please carefully read the instruction
manual for the motor and become thoroughly familiar with it. The subject manual describes
standard procedures for installation work, of which details may be modified by the
responsibility of the supervisor authorized by KBL depending on actual site conditions
A-1) The products supplied by KBL have 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. Installation, operation& maintenance personnel must use safe working
practices at all the times.
A-2) 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.
A Pump Duty 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. If accidental loss or damage occurs, contact KBL
immediately.
A-3) Access to the equipment should be restricted to the person net responsible for
installation, operation and maintenance and they must be trained, adequately qualified
and supplied with appropriate tools for their respective tasks.
A-4) Most accidents involving product operation, maintenance and repair are caused by
failure to observe safety rules or precautions, An accident can often be aware of
potential hazard associated in activities of installation, operation & maintenance of
equipment’s
4
A-5) KBL requires that, all personnel that are responsible for installation, operation or
maintenance of the equipment, have access to and study the product instruction manual
BEFORE any work is done and that they will comply with all local and industry based
safety instructions and regulations.
A-6) Ear defenders should be worn where the specified Equipment noise level exceeds
locally defined safe levels. Safety glasses or goggles or face shield should be worn
where working with pressurized systems and hazardous substances. Other personal
protection equipment must be worn where local rules apply. Wear safety shoes,
helmets and cotton overalls (Apron) when you enter pump house. Noise level should
not exceed 85 dBA and 110 dBA for motor driven and engine driven pumps
respectively.
A-7) Do not wear loose clothing or jewelry, which could catch on the controls or
become trapped in the equipment.
A-8) Read the instruction manual before installation, operation or maintenance of the
equipment. Check and confirm that the manual is relevant copy by comparing pump
type on the nameplate and with that on the manual.
A-9) Note the ‘Limits of product application permissible use ‘specified in the manual.
Operation of the equipment beyond these limits will increase the risk from hazards
noted below and may lead to premature and hazardous pump failure.
A-10) Clear and easy access to all controls, gauges and dials etc. must not be
maintained at all times. Hazardous or flammable materials must not be stored in pump
rooms unless safe areas or rack and suitable container have been provided.
A-11) Use suitable earthlings and tripping and tripping devices for electrical
equipments.
5
IMPROPER INSTALLATION, OPERATION, MAINTENANCE, LUBRICATION, REPAIR OF

THIS KBL PRODUCT COULD RESULT IN INJURY OR DEATH.
If tool, procedure work method are operating technique not specifically recommended
by KIRLOSKAR BROTHERS LIMITED is used, it should be ensured that it is a safe for
personnel around and others. It should also be ensured that the product will not
be damaged or made unsafe by the operation, lubrication, and maintenance or
repair procedures you choose.
Within the manual, safety instructions are marked with safety symbols.
This symbol refers to general mechanical aspects of safety.
This symbol refers to electrical safety.
ATTENTION This symbol gives warning of hazard to the pump itself, this in turn, could
cause a risk to personal safety.
B) SAFETY INSTRUCTIONS WHILE HANDLING AND STORAGE

When lifting the pump, use the lifting points specified on general arrangement
drawing, if provided. Use lifting equipment having a safe working load rating
suitable for the weight specified. Use suitable slings for lifting pump, which is not
provided, with lifting points. The use of forklift truck and chain crane sling equipment
is recommended but locally approved equipment of suitable r ating may be used.
While lifting, the equipment adjusts the center of gravity, so that it is balanced
properly. Do not place fingers or hands etc. into the suction or discharge pipe
outlets and do not touch the impeller, if rotated this may cause severe injury. To
prevent ingress of any objects, retain the protection covers or packaging in place
until removal is necessary for installation. If the packaging or suction and discharge
covers are removed for inspection purposes, replace afterwards to protect the pump
and maintain safety.
6
C) SAFETY INSTRUCTIONS WHILE ASSEMBLY & INSTALLATION

Shaft alignment must be checked again after the final positioning of the pump unit and
connection to pipe work as this may have disturbed the pump or motor mounting
positions. If hot liquids (above 80° C) are being pumped, alignment should be checked
and reset with the pump and motor at their normal operating temperature. If this is not
possible, KBL can supply estimated initial offset figures to suit extreme operating
temperatures. Failure to support suction and delivery pipe work may result in distortion
of the pump casing, with the possibility of early pump failure.
D) SAFETY INSTRUCTIONS WHILE COMMISSIONING & OPERATION

Never attempt adjustments while the pump is running, unless otherwise specified in
the operation, maintenance manual. Do not touch any moving or rotating parts.
Guards are provided to prevent access to these parts, where they have been removed
for maintenance they must be replaced before operating the equipment.
Check that the pump is primed. Pump should never be run dry as the pumped
liquid acts, as lubricant for the close running fits surrounding impeller and damage
will be incurred.
Failure to supply the stuffing box or mechanical seal with cooling of flush water
may result in damage and premature failure of the pump.
Do not touch surface, which during normal running will be sufficiently hot to cause
injury. Note that the else surfaces remain hot after the pump has stopped; allow
sufficient time for cooling before maintenance. Be cautious and note that other parts
of the pump may become hot if a fault is developing.
Do not operate water pumps in temperatures below freezing point, without first
checking that the pumped fluid is not frozen and the pump is free to turn. Pumps in
these environments should be drained down during inactivity and re-primed before
starting.
7
In addition to local or site regulations for noise protection, KBL recommend the use of
personal ear protection equipment in all enclosed pump rooms and particularly those
containing diesel -engines. Care must be taken to ensure that any audible alarm or
warning signal can be heard with ear defenders worn.
Be aware of the hazards relating to the pumped fluid, especially the danger from
inhalation of noxious and toxic gases, skin and eye contact or penetration. Obtain and
understand the hazardous substance data sheets relating to the pumped fluid and note
the recommended emergency and first aid procedures.
E) SAFETY INSTRUCTION WHILE MAINTENANCE & SERVICING

Do not attempt repairs, you do not understand. Use proper tools. Before attempting any
maintenance on a pump particularly if it has been handling any form of hazardous
liquid, it should be ensured that the unit is safe to work on. The pump must be
flushed thoroughly with suitable cleaner to purge away any of the product left in the
pump components.
This should be carried out by the plant operator and a certificate of cleanliness obtained
before starting work. To avoid any risk to health.
It is also advisable to wear protective clothing as recommended by the site safety

officer especially when removing old packing, which may be contaminated, isolate the
equipment before any maintenance work is done. Switch off the main supply,
remove fuses, apply lockouts where applicable and affix suitable isolation warning
sings to prevent inadvertent reconnection. In order to avoid the possibility of
maintenance personnel inhaling dangerous fumes or vapors locations by removal of
bearing housing and shaft assembly to a suitable maintenance area.
Check and ensure that the pump operates at below the maximum working pressure
specified in the manual or on the pump nameplate and before maintenance, ensure
that the pump is drained down.
8
Wear a suitable mask or respirator when working with packing and gasket contain
fibrous material, as these can be hazardous when the fibrous dust is inhaled. Be
cautious, if other supplier’s components have been substituted for genuine KBL parts,
these may then contain hazardous materials.
Store all oily rags or other flammable material in a protective container in a safe
place. Does not weld or flame cut on pipes/tubes that contents flammable fluids.
Clean them thoroughly with nonflammable solvent before welding or flame cutting on
them. Use solvent/chemical resistant gloves for hand protection.
Dispose of all wastes like gaskets, gland packing, oil, batteries, packing material etc. in
accordance with local regulations. Normally this would involve incineration of liquid
waste and controlled landfill of polymerized material.
Adequacy of suitable crane should be checked before lifting the pump/pump

components. Also condition o f p u lleys , chain and lifting shackles should be
checked before use.
9
SECTION – 1
INTRODUCTION
1.1 : GENERAL DESCRIPTION
1.2 : TECHNICAL DATA OF PUMPS.
1.3 : GENERAL CONSTRUCTION.
1.4 : BEARING & LUBRICATION ARRANGEMENT
1.5 : PIPE CONNECTIONS
10
O & M MANUAL FOR BHM150
1.1) GENERAL DESCRIPTION
Pump specifications:
Pump model no. & type : BHM150, Single Stage, External water
lubricated pump.
Name of the Customer : Hinduja National Power Corporation
Limited
No. of pump sets : 04
Sr. No. of pump : Pump No.1 - 150N812001
Pump No.2 - 150N812002
Pump No.3 - 150N812003
Pump No.3 - 150N812004
KBL O/A No. & date : C09712A002 / 14.06.2011
Motor rating /Make/Frame Size : 4600 kW ,325 RPM (FLS)/
Hyosung/ 1250
Name of project : 2 X 520 MW Vizag Thermal Power
Plant , Visakhapatnam
Service of pump : Circulating Water Pump
Design points :
Capacity (Discharge at Duty : 45,500 m3/hr
point)
Rated pump development : 27 mtr
head at rated capacity
(Total Head)
Pump efficiency : 90 %
Speed : 325 RPM (FLS)
Pump input (At duty point) : 3828.84 kW
Sp. Gravity : 1.03
Shut – off heat at rated speed : 48 mtr
11
1.2 TECHNICAL DATA OF PUMP
1.0 General
a. Manufacture’s name : Kirloskar Brothers Ltd.

KIRLOSKARVADI – 416 308
b. KBL O/A No. & date : C09712A002 / 14.06.2011
c. Model No. : BHM150, Single Stage, EWL
d. No. of pumps supplied. : 04 (Four))
e. Pump casing type : Diffuser Type
f. Casing : Fabricated Bowl
g. No. of stages : 1 (One)
h.
Specific speed Ns : 356.05
As calculated from
Ns : 3.65 x N x Q1 / 2
------------------
H¾
N 325 RPM (FLS)

:
Q 12.638 m³/s (45500 m³/Hr)

:
H : 27
2.0 Guarantied performance data at rated Condition:
a. Capacity (m3/hr.) : 45,500 m³/Hr
b. Total Head : 27 m
c. NPSH required : 11 m
d. Rated pump speed : 325 RPM (FLS)
e. Pump input : 3828.84 kW
(At duty point)
f. Pump efficiency : 90 %
g. Shut – off head at rated : 48 m
speed
12
h. Time required accelerating : 10 Sec

the pump motor unit to
rated speed at 100 %
voltage.
i. Vibration level – Velocity in :
mm / sec at motor top. As per HIS
(RMS VALVE )
j. Minimum flow required for : 31850 m³/Hr
continuous operation
k. Maximum continuous flow : 59850 m³/Hr
l Range of pump operation : 70% to 130%
m. KW rating of motor : 4600 kW
provided.
3 Design, construction and technical data -

3.1 Pump casing (Pump Bowl) :
a. Casing type : Diffuser type.
b. Pump casing hydro test :
pressure (Pump Bowl) 7.5 Kg/cm2
3.2 Discharge nozzle

a. : Size in mm : Ø 2100
b. Flange rating drilling : AWWA C-207 ,CLASS-D
standard
C Max. Allowable force – N : Fx = 38888  Refer GA
Fy = 35047  dwg. for
Fz = 43273  Direction
d. Max. Allowable moment – : Mx = 52800  Refer GA
KG-m My = 57138  d w g. for
Mz = 43323  Direction
3.3 Shaft data

a.
Shaft diameter at : Ǿ 255(With sleeve OD)
stuffing box – mm
:
Impeller – mm Ǿ 210
:
Trans. Bearing – mm Ǿ 255 (With sleeve OD)
:
Thrust. Bearing – mm Ǿ 210 (At thrust collar)
13
b. Shaft length
Impeller shaft : 5640 mm.
Intermediate shaft : 3000 mm x 3 Nos
Head shaft : 4135 mm.
Total shaft length : 18775 mm
3.4 Impeller data :

a. Design : Mixed Flow
No. of vanes : 5 VANES
Type : Semi open Impeller.

b. impeller eye diameter. : Ǿ 1383 mm
impeller hub diameter. : Ǿ 325 mm
3.5 Rotor
a. Pump rotor wt. Kgs. : 11500 (Approx.)
b. GD. Sq. of pump rotor with : 1400 kg-m2
pump coupling
c. Method of fastening of : Key with Impeller nut. (Split
impellers to shaft ring arrangement)
d. Total permissible max. : As per ISO 1940 Gr- 6.3
unbalance limits
3.6 Line shaft bearing :

a. Nos. provided : Thirteen (13)
b. Type : NEO RBR LND BRG SS 316L

c. Lubrication arrangement : External water lubrication.
d. Bearing life expected. : 16000 Running hours.
3.7 Thrust bearing

a. Type / Make : Tilting Pad Type / Michell Pad
b. Bearing capacity : 75,000 Kg. (Appx)
d. Life expected (min.) : More than 40,000 Running
hours.
e. Lubrication arrangement : Oil bath/water cooled
14
3.8 Pump Coupling

a. Size : Ǿ800 OD x Ǿ205 Bore x 350L
b. Make : Kirloskar Brothers Ltd.
d. Type : Flexible pin bush type.
3.9 Shaft sealing details :

a. Type : Stuffing box
b. Gland plate : Split type
c. Leakage : 120 drops / min. (*Approx)
*Leakage should be sufficient to quench the heat generated in the stuffing
box assembly
4.0 Pump materials

a. Sole plate : CI IS210 FG260 Ni2(MIN)
b. Discharge Head : Outer skirt in MS IS 2062-Fe
410 W A EPXY & inner bend, in
ST ST ASTMA240 /240M -
UNS31803(PLATE) with flanges
in CD3MN - TYPE 4A GRADE)
c. Column pipe : ST ST ASTMA240/240M-UNS

31803(PLATE) with flanges in
CD3MN - TYPE 4A GRADE)
d. Impeller : STST ASTM-A890/890M
CD4MCuN-1B
e. Impeller Guide Piece : ST ST ASTMA890/890M-
CD3MN-TYPE 4A
e. Pump bowl : ST ST ASTMA240/240M-UNS

31803(PLATE) with INNER CORE
AND WELD NECK FLANGES are
in ST ST ASTMA890/890M-
CD3MN-TYPE 4A
f. shaft : ST ST ASTMA276-UNS
S31803(ANLD)
g. Motor Stool : MS IS 2062-Fe 410 W A EPXY
h. Thrust bearing -
Housing : SGI IS:1865-SG 500/7
(2-2.5% Ni)
CS ASTMA 216/216 M WCB
Ratchet Cover :
CS ASTMA 216/216 M WCB
Thrust Collar :
CS BS080M40FORG+WHITE
Journal Bearing : MET LNG(90%SnBASE)
i. Ratchet Pin Housing : CS ASTMA 216/216 M WCB
j. Rigid coupling : ST ST ASTMA276-UNS
S31803(ANLD)
15
k. Fasteners coming in ST ST ASTMA276-UNS

contact with Liquid : S31803(ANLD)
l. Main drive coupling
Coupling body : CS ASTMA-105 (FORGED)
Pin / bolt CS IS1570-40C8 HOT RLD

:
NAT RUB ASTMD2000-AA(70
Bushing (for flexible : SHORE/7MPa)
coupling)
m. Gaskets : NON ASB GASKET FERROLITE
NAM37
n. Shaft locking ( Bearing lock : CS IS1570-40C8 HOT RLD
nut)
o. Cooling coil : TITANIUM ASTM-B338 GR 2
(TUBE)
5.0 Cooling Water requirement

a. Cooling water required : 35 lit/min
b. Size of connection : 3/4” BSP
ADDITIONAL DATA FOR CW PUMP

Sr. no. Description
01 Length of column pipe (3 Nos) 3000 mm
02 Length of taper column pipe 1975 mm
03 Length of Discharge Head 3800 mm
04 Suspension Length 14800 mm
05 Height of Motor Stool 1265 mm
06 Maximum OD of pump 2800 mm (Bell Mouth)
07 Id of column pipe 2100 mm
08 Distance of pump discharge 1800 mm
centerline from ground level
9 Guide bearing in bowl NEO RBR LND BRG SS 316L
SHELL
10 Nos provided in bowl 3
11 Guide bearing in column pipe NEO RBR LND BRG SS 316L
SHELL
12 Nos provided in column pipes 8
13 Bearing span 3000 mm
14 Weight of Complete assembled 1,14,200 kgs
pump and motor with without
base plate
15 Motor weight 48,000 kgs
16 Total length (motor) 3570 (Approx)
17 Sole plate provided Yes.
19 Special tools and accessories Yes.
16
1.3 GENERAL CONSTRUCTION OF PUMP.
DESIGN FEATURES
1. Pump Casing/Diffuser (Pump Bowl):

A Pump bowl is fabricated with vane and inner core cast integrally.
2. Impeller:
The impeller is of semi open type, accurately machined, balanced and finished
smooth by hand to achieve less friction in water passage. The impellers are
secured to the shaft by impeller nut, keys and split ring arrangement.
3. Pump shaft:
The shaft is of high grade stainless steel and is accurately machined for
handling cooling water.
4. Transmission bearings:
The transmission bearings are of Rubber type with SS316L shell. They are
being lubricated by the external water.
5. Thrust bearing:
The axial thrust is taken by Tilting pad type Mitchell make bearing provided in the
thrust bearing housing. The bearing is lubricated by oil.
6. Coupling:
The coupling is of flexible pin bush type. This is provided for coupling the prime
mover t o the pump. Due to the rubber bushes provided the reduction of
shocks and absorption of the vibration energy within the coupling takes place.
Easy to assemble and disassemble.
CONSTRUCTIONAL FEATURES
Column unit:
The column unit connects the pump unit to the driving unit. The column
unit consists of column pipes, line shafts, rigid coupling and Rubber
bearings fitted within the inbuilt bearing spiders. Rigid couplings are used
to connect impeller shaft, intermediate shaft and head shaft. The column
17
pipe is of fabricated steel with weld neck flanges and is machined

accurately for the perfect alignment.
Driving unit:
The driving unit supports the suspended column unit, pump unit and the
driving motor at the floor level (operating level). It consists of the thrust
bearing housing, the stuffing box unit, driving shaft, the pump and motor
coupling etc. The motor is directly mounted on the motor stool.
Discharge branch:
The discharge head is provided for the pump with delivery above ground
level. The discharge head directs the flow of water from column unit to
the discharge piping.
Drives:
The pump unit is driven by an electric motor with vertical shaft.
1.4 BEARING AND LUBRICATION ARRANGEMENT
1.4.1 External water lubricated line shaft bearings:
Cutless rubber bearing have resilient property which can accommodate the
silt particles and further flushes out silt through the specially designed
vertical flutes. This bearing is consisting of cutless rubber molded into SS
316L shell. They offer ease of installation, lower maintenance cost as well
as extended shaft life and vibration damping qualities.
1.4.2 Oil lubricated Thrust bearing:

The Tilting pad type thrust bearing used to take the axial thrust and is
lubricated by oil. The oil is cooled by cold water circulated through the
cooling coils located in the thrust bearing housing. The oil temperature is
measured by temperature gauge and RTD provided in bearing assembly.
18
Thrust Bearing details ( Lubrication & Cooling)

Make/Type Michell make / Tilting pad type
Location In pump
Lubrication / cooling Oil Bath / water cooled
Normal operating temperature of pad. 80 – 85¼ C
Maximum limiting temperature of pad. 105¼ C alarm / 115¼ C trip
Normal operating temperature of oil 70 - 75¼ C
Maximum limiting temperature of oil. 85¼ C alarm / 90¼ C trip
Oil qty 90 Ltrs (Approx.)
After 1000 working hours for
Refilling period first 5000 working hours. Then
after each 5000 working hours.
1.4.3 Lubricating oil specification for thrust bearing.
Oil type Servosystem-68

Viscosity (Centi strokes) 68
Viscosity index 95
Density grams/cc at 60 0C 0.890
Flash point 210 0C
Pour point 0-5 0C
Different recommended grades of lubricating oil

Indian Oil Corporation Servosystem-57
Hindustan Petroleum ENKLO - 53
Caltex-Regal Oil B(R&O)
Shell – Tell US Oil 68
ESSO-NUTO H 68
Mobil – M0bil D TE 26
Texaco-Rando Oil HDC 68
Sunoco-Sunvis 831 WR
1.4.4 Cooling water details for thrust bearing

Cooling water for the thrust bearing housing is provided from pump discharge. However
in case of external supply use the following details.
Maximum Cooling Water pressure 1.5 kg/cm2
CW flow rate required 35 LPM
CW inlet temperature Ambient temp.
Maximum allowable Cooling Water temperature
rise 15-20 0C
(above ambient temperature )
19
1.4.5 External cooling water details for line shaft (transmission) bearings
Cooling water for the transmission bearing is provided from external source with the
following details -
Maximum CW pressure 6 Kg/cm2
Type of Liquid to be used for Lubrication External clear water
CW flow rate required 35 LPM
CW inlet temperature Ambient temp.
PUMPS WITH EXTENAL WATER LUBRICATION:
• The external water provided for transmission bearing lubrication must be clear &
cold. The pressure of the external water must be one atmosphere above the
maximum working pressure of the pump. This pressure should be checked where it
is introduced in the shaft protection pipes. The quantity of the water should be
about 35 lit/min.
• Before starting of main CW pump, the external water supply must be started before
30 minutes & ensure that all air to be vented from enclosing tube. Same Logic
should be incorporated in control panel.
• The main pump should not be started unless all air is vented out of protection pipes
by feeding external pressurized water. It is essential to expel the air from protection
pipe from time to time by operating the air vent, when the pump is in operation. The
bearing should never run dry.
20
1.5 PIPE CONNECTIONS
Column Pipe venting connection

♦ Refer General Arrangement drawing (HNPCL Doc. No.KSL/SYS-DE-POW/107/ME02/02)
for the provision made for venting of column pipe (4”BSP) two nos connection should
be operated manually.
Enclosing Tube venting connection
2” BSP connection is provided for venting of enclosing tubes
Stuffing box leakage drain
for showing the provision made for stuffing box drain 3/4” BSP. This connection is
made to remove the leakage water from stuffing box to drain.
Cooling water inlet and outlet connection for thrust bearing assembly
for showing the provision made for cooling water inlet (3/4”BSP) and cooling water
outlet connection 3/4” BSP. The cooling water from the external source is to be
provided for cooling of the thrust bearing. Quantity of cooling water required is 35
liters/minute from external source.
Oil feeding/Oil drain connection
♦ Provision made for oil feeding 3/4” BSP and for oil drains 1/2” BSP. The oil drain
connection is to remove the oil from the thrust bearing carrier. The oil feeding
connection is to refill the oil in the thrust bearing carrier.
Oil level indicator
♦ Oil level indicator (1/4” BSP) is provided to indicate the level of the oil in the thrust
bearing housing.
External Water lubrication and Shaft Enclosing Tube Venting
♦ External Water connection on stuffing box of size 1” BSP (Refer HNPCL Doc.
No.KSL/SYS-DE-POW/107/ME02/02) is provided to lubricate the transmission bearing
and to vent the air from Shaft Enclosing Tube
(Refer all piping connection drawings at the end of manual in section: 7)
21
SECTION 2
RECEIPT, STORAGE AND HANDLING
2.1 : PUMP ROOM REQUIREMENT
2.2 : PROCEDURE FOR TRANSPORTATION.
2.3 : PROCEDURE FOR STORAGE AND HANDLING
2.4 : UNPACKING AND LIFTING
22
2.1 PUMP ROOM REQUIREMENT
These cover mainly the following aspects.

1. The strength of the building.
2. Sufficient floor area for working and overhauling.
3. Sufficient head room for erection.
4. Provision for over head traveling crane.
5. Provision for external water lubrication arrangement.
6. Easy transportation of heavy parts so as to avoid dragging.
7. Ventilation for cooling of motor.
8. Provision of store room.
2.2 PROCEDURE FOR TRANSPORTATION
1. Transport
After Complete assembly of CW pump, it is tested prior dispatch and It is usually
disassembled for packing and transport, but by agreement with the customer, shorter
pumps may be dispatched as one unit. This will enable quicker and easier
installation, but the length and weight of the pump, and lifting equipment and
headroom must be suitable for installation of the pump as one unit. Pumps are
protected against corrosion and packed for transport by normal road, rail ,air and sea
carriers.
2. Removal from Transport
Off-loading from transportation should undertaken using lifting gear with suitable capacity,
the units being handled and slung as indicated on the packing of each item. Inspect and
check off all items against the delivery note and report any damage or shortage. Where
provided, the cases provide some protection during storage and therefore no equipment
should be left unpacked at site before erection is about to start.
2.3 PROCEDURE FOR STORAGE AND HANDLING

2.3.1 On receipt of material
1. Check that all packages are intact and that open parts are not damaged in transport.
2. Open the packing and check contents of each packing against delivery notes/packing list.
23
3. Check all shafts and verify that those are not bent and are in good condition. And no
dent or score marks are there.
4. Report discrepancies immediately if any.
5. Unless the pump is to be installed immediately, repack the material in their respective
cases.
6. Do not open the packages again unless ready for erection.
2.3.2 STORAGE
POST ERECTION STORAGE INSTRUCTION

Pumps may be stored in their original packing for a short time before installation, provided
that they are placed in a dry, covered location that is well ventilated with low humidity. For
extended storage periods or for exposed storage or in tropical or cold locations, refer to KBL
for recommendations.
Short term storage (up to 3 months)
- Store the pump components in a dry place, with suitable protection against dirt and
corrosion.
- The pump components should be stored at least SIX inches above the ground on anti termite
wooden beams, avoiding direct exposure to sun heat, rain, sand storms, and flood, etc.
- If in case due to unavoidable circumstance the pump components are stored in open
condition then it should be covered with plastic sheet of atleast 0.150 mm & ensure proper
ventilation from the underneath.
- Packing should not be removed until erection work begins.
- Ensure oil or grease in the bearing housing, to protect the bearing assembly against
corrosion
- In case of assembled pump, rotate the pump shaft manually every two weeks to prevent
damage to the shaft bearing assembly. Never leave the shaft in a previous position or in the
extreme raised or lowered lateral position making sure that the shaft rotates freely.
24
Long term storage (above 3 months)
- If the pump / components are to be stored for more than three months before erection work
begins, please observe the following storage instructions.
- Store the pump / components in a dry place, with suitable protection against dirt and
corrosion.
- The pump components should be stored at least six inches above the ground on anti termite
wooden beams, avoiding direct exposure to sun heat, rain, sand storms, etc.
- Open the wooden packing box, remove the VCI+XF bags or polythene bags / paper and
check the paint / rust preventive condition visually.
- Touch up if any damage found in painted portion & pump components.
- Drain any liquid from the pump.
- Apply Volvoline–Tectyl506 rust preventive oil or other corrosive resistant coating on all
machined surfaces as well as cover the components with bags / paper as received & keep all
components inside the shop (away from dirt, rain & direct sunlight)
- Replenish the moisture absorbent bags / silica gel every three months.
- Repeat this procedure after every three months
- For long storage take out the shafts from packing boxes & store vertically. In case vertical
storage is not possible open the boxes, rotate the shaft 90 Deg. Every month & repack as
above.
- Rubber components to be replaced considering its shelf life (18 months)
- In case of assembled pump stored for long duration, then before erection, the pumps to be
dismantled totally and to be assembled at site.
- Rotate the pump shaft manually every two weeks to prevent damage to the shaft bearing
assembly. (In case of assembled pump). Never leave the shaft in a previous position or in the
extreme raised or lowered lateral making sure that the shaft rotates freely.
25
- If a pump has been installed, but is not in regular operation for an extended period of time,
such as during a seasonal shutdown, operate it for at least 15 minutes every two weeks, if
possible.
- A full inspection is to be carried out at least every twelve months to check for exhaustion of
desiccant, condensation and any signs of rust or damage. Take the appropriate remedial
action as necessary.
- For short term and long term storage of motor please refer motor manufacturers installation,
operation and maintenance manual.
Component
Maintenance Action Maintenance Frequency
Description
Pump Component in Check fasteners are
Before Final assembly
assembled condition tightened to given Torque.
Check machined faces. 1 months & apply if

Pump Machined parts
Provide rust preventive. required.
Clean pump components /
Pump Check pump components
assembly weekly
Erosion / Corrosion of check Painted / coated
Pump
components. parts
Gland Packing Wearing of Gland Packing Regular
Long term storage (above 3 months) of pump assembly inside the pit after installation.
If pump is to be stored for longer duration in pit without operation following checks and
procedure to be followed strictly
- Check the oil level in the bearing housing up to mark on oil level indicator. Check the quality
of oil by taking out sample from oil drain connection on regular intervals of one month. If oil
found dirty or black then remove all oil from thrust bearing and refill fresh oil up to mark on
oil level indicator. If the quantity is less than required then refill it up to the mark on the oil
level indicator.
- Do not assemble, or remove the pump coupling pins and coupling bushes (rubber) from
motor and pump coupling and store in dry place in proper packed boxes.
26
- To protect the thrust bearing assembly against corrosion and line shaft bearings to avoid
sticking with shaft, rotate the pump shaft manually every two weeks. Never leave the shaft
in a previous position or in the extreme raised or lowered lateral position making sure that
the shaft rotates freely.
- The pump should never run dry. Dry running will result in seizing of bearings and other
mating surfaces.
- When the pump is in idle condition, clear and clean external water to be supplied for
lubrication of line bearings to avoid sticking of rubber bearings with shaft sleeves. External
water must be supplied at least twice in a week.
- If delivery nozzle is not connected with further pipe line then cover with card board as
applicable.
- Keep the assembled pump and surrounding area clean.
- Cover the equipment with vented or breathable material to prohibit build up the dust and
dirt.
- If all instruments and auxiliary pipe connections were installed on pump motor assembly,
then same should be covered with proper guards or packing to avoid damages.
- If a pump has been installed, but is not in regular operation for an extended period of time,
such as during a seasonal shutdown, operate it for at least 15 minutes every two weeks.
- A full inspection is to be carried out at least every twelve months to check for exhaustion of
desiccant, condensation and any signs of rust or damage. Take the appropriate remedial
action as necessary.
- Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump
and the cooling coils. Failure to do so can cause liquid to freeze and damage pumps.
- After storage, test the motor insulation resistance between phases and earth, and if
necessary dry out in accordance with manufacturer’s instruction
- A pump log book and data entry to be maintained for regular checks of preservation
procedure.
27
- Before starting the pumps during commissioning, please ensure twice, the pump is free in
rotation by hand. If the assembled pump found to be jammed condition or hard to rotate by
hand it is strongly recommended to dismantle the pump for inspection and re-assembly.
- For re–assembly, please refer the erection procedure from manual.
- For more information and any details please contact pump manufacturer.
Refer below sketches for information.
NOTE:
It should be noted that unless otherwise agreed to, full responsibility and costs associated with
the storage and inspection of this equipment rests with the customer.
Recommendations given herein are made with the strict understanding that Kirloskar will incur no
cost resulting from Long Term Storage Procedures. Kirloskar also relinquishes any responsibility
for any damage or malfunction incurred to the unit at the time of installation due to inadequate
preservation by the Customer.
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2.3.3 HANDLING
Crushing Hazard
When lifting the pump unit, use lifting equipment having a safe working load rating suitable
for the weight specified. Use suitable slings for lifting of items.
1. The use of suitable forklift truck and four-chain crane sling equipment is recommended
but locally approved equipment of suitable rating may be used.
2. All machined parts are coated with a special antirust coat. If any part is found exposed
clean it and apply a thick coating of grease or antirust compound and then wrap it in
wax paper to prevent further rusting.
3. Never drag any component parts or packages for any reason. Dragging sets in intrinsic
vibration which distort accuracies, parallelism etc of machined surfaces. Distortion of the
accuracies might cause serious functional and operation troubles.
4. Overhauling should be avoided as far as possible. While lifting the parts by ropes,
they should be properly balanced.
5. Transportation should be free from jerks. Long parts should not be handled without
adequate supports.
6. Open part must be transported on soft and well supported bedding to prevent
scratches.
7. The spares should be stored with tag numbers for identification.

Thrust bearing should not be kept open (without packing) to atmosphere.
8. The shafts can be kept in horizontal position, resting on wooden ‘V’ blocks with
proper supports. It is better to keep the shafts in vertical hanging position if possible.
CAUTION
Care must be exercised in handling all parts, particularly the shafts. They are
machined to close tolerances and carefully inspected at the factory and if bent, can
cause serious trouble. A bent shaft should never be installed.
29
2.4 UNPACKING AND LIFTING
1. Preservation Status
The equipment prior to shipment had been inhibited for transportation and short -term
storage. For prolonged storage of the unit, consult KBL for recommendations.
A full inspection is to be carried out at least every twelve months to check for
exhaustion of desiccants, condensation and any signs of rust or damage. Take the
appropriate remedial action as necessary.
For short term and long term storage of motor please refer motor manufacturers installation,
operation and maintenance manual.
2. Unpacking
Unpacking of all equipment should be undertaken with extreme care, notice should
be taken of any requirement for the reuse of all cases, bags and packaging
material.
3. Lifting
The headpiece has lifting points suitable for lifting the assembled pump complete.
The pump assembly when horizontal must be handled with care using pairs of slings
when lifting to spread the load.
WARNING
Eyebolts and lifting lugs on individual items that are mounted on the
headpiece (i.e. motor) are for lifting that item only and should not be used to lift
or assist the lifting of a larger assembly.
CAUTION
Slender parts or assemblies can be rendered inoperative by use of inappropriate

lifting techniques. Even slight distortions during handling can give rise to
assembly and running problems.
30
SECTION –3
INSTALLATION INSTRUCTIONS
3.1 : FOUNDATION–GROUTING PROCEDURE.
3.2 : STEPS PRIOR TO ERECTION (CLEANING OF PARTS)
3.3 : PUMP ASSEMBLY PROCEDURE AND HANDLING
3.4 : LOCATION OF UNIT EQUIPMENT AND TOOLS REQUIRED
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3.1 FOUNDATION:
The foundation should be sufficiently strong to absorb vibration and to form a permanent
rigid support for the sole plate. The pump foundation and installation works must be
performed to provide smooth pump operation and to prevent transmission or vibration and
impact caused by operation to other objects. The sole plates embedded in the concrete
should not get loosened or form pockets with parent foundation even with slight
vibration.
When the pumps are installed by other methods than as described in the manual, such
changes should be made only after consultation with KBL or supervisory personnel.
GROUTING PROCEDURE:
Fix the sole plate on foundation area along with foundation bolt. Level it with the help of
leveling screw, straight liners and taper wedges. The location of the foundation bolts
should be marked as per the General Arrangement Drawing (HNPCL Doc. No.KSL/SYS-
DE-POW/107/ME02/02).
Keep the discharge head on sole plate with the help of fasteners provided. Final master
level to be checked on the machined top surface of discharge head. Level on discharge
head top surface should be within 0.05 mm/meter. After that final grouting to be done.
Then first grout the 24 numbers foundation bolts size M42 in initial concrete. Recheck
the levels on the surfaces of sole plate before the final grout. Pour the final grout.
Blue matching of sole plate (Base plate) with discharge head should be done after finish
grouting. (For details refer standard Field Quality Plan)
3.2 STEPS PRIOR TO ERECTION.
3.2.1 CLEANING OF PARTS:

Due to long storage, components may get rusted and the rubber parts may swell and
stick. It is therefore recommended that prior to the commencement of the installation
the pump unit which is sent in an assembled condition from the factory, should be
stripped and all parts to be thoroughly cleaned by kerosene or acetone or petrol. Check the
clearance between line bearings & shaft before assembly or erecting at site. Clearances
between relative parts are given in Section – 5.3.4
32
3.3 INSTALATION INSTRUCTIONS AND PUMP ASSEMBLY PROCEDURE
ON RECEIPT OF PUMP ON SITE
1.0 Unpack all the pump items, check these against the packing note for completeness
and examine to ensure free from damage.
2.0 Do not remove any protective covers, plugs, wrappings or coatings until ready to
make connections.
3.0 Lay the pump on timbers that are thick enough to prevent debris from entering the
pump suction bowl when the pump is lifted into the vertical position.
4.0 Protect all parts, especially shafts, bearings etc. and avoid blockage of all openings,
from dirt, grit or any foreign material.
IMPORTANT
Avoid fouling of any material inside the sump while assembly and maintenance operation.
CAUTIONS FOR INSTALLATION
5.0 In hoisting heavy parts such as the pump casing, pay atmost attention to attaching
the wire rope so that the load will be centered and the wire rope will not slip.
6.0 When lifting heavy parts, used soft padding under the wire to protect the coated and
machined surface from the wire. And do not raise or lower the parts too rapidly with
the crane.
7.0 When mounting the parts on ground, use protecting blocks between the parts and
the ground. Also, when assembling the pump parts horizontally, use protecting
blocks under the pump casing to protect the coated surface and prevent rolling.
33
8.0 When assembling each part, check that there is no flash, protuberances or dust on
the flange surface and fitting surface.
9.0 Be careful not to drop tools and parts into the suction pit. If these are sucked into
the pump, the rotating element, casing and impeller will be damaged.
10.0 Dombell type Lock washers should be used for fastening bolts, screws and studs.
Bend the washers to the nut side to lock the nut against turning as shown in fig.
Sketch No.3.1 – Folding of Dombell Washer

11.0 When the shafts are set in rubber bearings, do not coat their inside surfaces with
grease or oil, using grease or oil makes rubber expand and shorten the bearing life.
So, glycerin or soapsuds should be used.
12.0 When assembling the shaft coupling, rigid coupling and coupling nut to the shaft and
tightening the fixing bolts, spray or coat anti-galling compound on the fitting surface
and thread surface to prevent seizing. Parts made of stainless steel are very sensitive
to seizing, therefore it is especially important that assembling and inserting work of
these parts should be performed carefully and slowly (gradually), confirming that
foreign matter should not adhere to the fitting surfaces and alignment of axes for
both parts should not miss. Also, when insertion is not smooth, do not insert
forcibly.
13.0 After assembly, repeatedly check to make sure that all bolts of each flange and other
parts are completely and evenly tightened.
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IMPORTANT
- Prior to assembly all parts must be cleaned and inspected for any signs of damage,
especially around the area of threads, bosses and recesses of mating parts.
- A light coating of oil or grease where appropriate can aid assembly. Check suitability
of oil or grease for water applications where applicable.
PUMP ASSEMBLY PROCEDURE
14.0 Keep two blocks approx 1.5 mtr heights on assembly floor. Keep sufficient distance
between blocks for assembly of split ring. Place rubber pads / wooden blocks on
upper surface of block. Take care to keep same level on both sides of blocks.
Ref. Sketch No.1
15.0 Place Impeller Guide piece (2120101) on rubber pads. Fit the ‘O’ ring (5220201) in
‘O’ ring groove of Impeller Guide piece (2120101). Ref.Sketch No.1
16.0 Take the impeller and clean it Ensure properly. With the help of eye bolts lift Impeller
(1560101) & place in Impeller Guide piece. Ref. Sketch No.1
17.0 Take the impeller shaft (1860101) assembled with 2 nos of Keys (3200101)
assembled with retaining screws on shaft, Impeller shaft sleeves (3170101,
3160101, 3160201, and 3160301) & Intermediate sleeves (3120101). Clean it
properly. Sleeves are assembled on shaft using cylindrical pin 6100101 and M8 x
35L hex. Soc. cap screw. Use supplied special tool & mount on Impeller shaft top
end. Lift the Impeller shaft vertically & pass through Impeller bore. Take care of
position of keys between Impeller & shaft. Confirm that “O” ring (5220301) is
already fitted on impeller shaft sleeve (3160101). Ref. Sketch No.1
18.0 Pass impeller shaft through Impeller bore such that guide for split ring (4050101) is
clear. Ref. Sketch No.2
35
19.0 Then place split rings (4050101) on Impeller shaft bottom. After fitting of split ring
lift the shaft until split ring face rest on impeller. Ref. Sketch No.2
20.0 Then assemble Impeller nut (3300101) along with Shim for impeller nut (6820101)
with Impeller. Ensure that there is no gap between Impeller & Impeller nut. Ref.
Sketch No.2
21.0 Take pump bowl (1200101) already fitted with bearing holder (2540101) fitted at
bowl bottom side & bearing holder (2540201) fitted at bowl top side & sealing ring
cover(4730101) along with sealing ring (1940101) and ‘O’ ring (5220401) at
bottom side. Confirm that total 2 nos. of Bowl bearing (3540101) is fitted into
bearing holders at bowl bottom side (2540101) and 1 nos of bowl bearing
(3540201) is fitted at bowl top side bearing holder (2540201). Check all these
bearings are in good condition & proceed for further assembly. (Ref.Fig.no.03 &
Fig.no.04 )
22.0 Mount studs on bowl, then lift pump bowl assembly & place pump bowl on impeller
guide piece. Then tighten joint such that ‘O’ ring (5220101) well sandwiched in
between. Ref. Sketch No.3 ,Sketch No.4 & Sketch No.5
23.0 Take taper column pipe (1410101) already fitted with bearing holder (2540301).
Ensure that 2 nos. of rubber bearing (3570101) is already fitted in bearing holder
(2540301). Check condition of rubber bearing & proceed for further assembly. Lift
taper column pipe & mount on pump bowl so that impeller shaft protrudes taper
column pipe. Tighten joint between taper pipe & upper bowl with ‘O’ ring (5220201
& 5220501) is sandwiched in between. Ref. Sketch No.6 & Sketch No.7
24.0 Place Bell mouth (2110101) near to assembly on leveled flat surface. Maintain level
at all sides. Ensure rubber bearing (3530101) is fitted on bell mouth. Fit the pipe
plug of 2” BSP at bell mouth bottom bearing holder. Attach lifting equipment to the
taper pipe using the lugs and suitable slings. Take the weight of the complete
assembly; raise the pump unit vertically & place this pump unit assembly on bell
36
mouth taking guide such that bottom bearing flush piping connection (1 “BSP) must
be match with taper pipe piping connection. Tighten the joint. Complete the flush
piping connection of 1” BSP by connecting end to end piping flanges. This completes
pump unit assembly. Ref. Sketch No.8 & Sketch No.9
25.0 Place “I” beams on foundation & tighten with provided tie rods. Adjust the distance
between two beams as per requirement. Now lift the entire assembly vertically. Then
lower through the foundation opening till the Taper column pipe supporting pads rest
on two “I” beams placed across the opening. Release the crane hooks now. Ref.
Sketch No.10 & Sketch No.11
26.0 Put the keys (3210101) on impeller shaft and then fit the rigid coupling (3940101)
on Impeller shaft (1860101). Tighten lock nut (3360201) on impeller shaft threads.
Fit the “O” ring (5240101) and “O” ring (5240201) on taper pipe(1410101). Ref.
Sketch No.12
27.0 Take intermediate shaft (1840101) fitted with intermediate shaft sleeve (3120101)
& keys (3210101). Intermediate sleeves should be assembled using cylindrical
(6100201) and Hex. Soc. Cap screw (M8 x 35L). Mount rigid coupling (3930101)
on intermediate shaft bottom side. Then tighten lock nut (3360201) on intermediate
shaft threads. Lift intermediate shaft with coupling using lifting tool & connect with
impeller shaft (1860101) with the help of coupling pins. Ref. Sketch No.13
28.0 Take Column pipe (1330101) fitted with bearing holder (2540301) is assembled
with column pipe. Ensure that 2 nos. of Rubber bearing (3570101) is already fitted
in bearing holder. Check condition of Rubber bearing. Lift the column pipe & rest on
taper column pipe by taking guide. Tighten joint between Column pipe & taper
column pipe with ‘O’ ring (5240101 & 5240201) is sandwiched in between. Ref.
Sketch No.14
37
29.0 Mount rigid coupling (3930101) on intermediate shaft top side. Then tighten lock
nut (3360201) on intermediate shaft threads. Fit the “O” ring (5240101) and “O”
ring (5240201) on column pipe (1330101). Ref. Sketch No.15
30.0 Lift the entire assembly, remove the “I” beams under column pipe and lower the
entire assembly down slowly. So that resting pad of column pipe rest on “I” Beam.
Mount rigid coupling (3930101) on intermediate shaft top side. Then tighten lock
nut (3360201) on intermediate shaft threads. Fit the “O” ring (5240101) and “O”
ring (5240201) on column pipe (1330101). Connect the shaft rigid coupling joint.
Repeat the assembly procedure till all the column pipes are assembled. This
completes Column unit assembly Ref. Sketch No.15, Sketch No.16, Sketch No.17 &
Sketch No.18.
31.0 Take the head shaft (1850101). Ensure shaft sleeve (310101 and 3170301 is
assembled on head shaft using cylindrical pin (6100301) and Hex. Soc. Cap screw
(M8 x 35L). Mount rigid coupling (3930101) on head shaft bottom side. Then
tighten lock nut (3360201) on head shaft threads. Lift head shaft with coupling at
lower end & connect with intermediate shaft (1840101) by taking guide & with the
help of coupling pins. Confirm that “O” ring (5240101) & “O” ring (5240201) is
already fitted in the groove of column pipe upper flange & head shaft enclosing tube
guide before assembly of rigid coupling. Ref. Sketch No.19.
32.0 Lift the discharge head (1170101) for assembly & lower such that the head shaft
protrudes from discharge head bore. Now on top of column pipe, place discharge
head bottom flange (1170101) supported by crane hook. Tighten joint between
Column pipe & discharge head with ‘O’ ring (5240101 & 5240201) is sandwiched in
between the joint. Ref. Sketch No.20.
33.0 Take the 4 nos of special lifting lugs provided to lift whole pump assembly. Fit these
lugs on discharge head top flange using hex screws provided. Lift the entire
assembly using lifting lugs provided and D-shackle of suitable capacity such that “I”
beams under column pipe can be removed. (Lifting devices such that slings, wire
38
ropes or D-shackle should of suitable capacity to hold complete total pump assembly
weight safely.) Then lower the entire assembly down slowly such that discharge
head bottom flange rests on sole plate. Remove the lifting lugs from discharge head.
Ref. Sketch No.21 & Sketch No.22
34.0 Once discharge head rests on sole plate release the crane hook. Check the discharge
head top flange level by means of precision spirit level on top machined surface.
Check the level in two directions at right angles to one another. Adjust the level by
means of leveling screws on foundation plate. Tighten the foundation bolts. The
level on pump discharge head it should be within 0.05 mm/meter.
35.0 Now take Stuffing box housing (2380101) which is already fitted with Rubber
bearing (3520101).Then tightens stuffing box on discharge head (1170101) with
the help of fasteners. Ensure that “O” ring (5250101) is fitted in between stuffing
box and discharge head. Fit the split gland (2290101) and clamping plate (2240101)
on stuffing box. Fit the liquid deflector (2360101) on head shaft at suitable position.
Sketch No.22 & Sketch No.23
36.0 The thrust-bearing carrier (2470101) is supplied in partially assembled condition.

Remove the Ratchet cover (4740101). Clean thrust bearing carrier thoroughly and fit
it with thrust housing plate (3890101) with the help of Stud, Nut & Washer.
Sketch No.24
37.0 Fit the thrust bearing pads with carrier ring (3610101) on thrust bearing housing
plate (3890101). Pour little quantity of oil till the segments are just submerged.
Ref. Sketch No.24
38.0 Fit the journal bearing along with white metal lining (3710101) on thrust bearing
carrier taking guide in the step provided on thrust bearing housing (2470101).Fit
thrust bearing assembly on discharge head. Ref. Sketch No. 24 & Sketch No. 25
39
39.0 Check the thrust collar (3630101) bottom surface, it should be clean & dust free.
Then put the thrust collar on thrust pad. Ensure that the key (3280101) is fitted on
head shaft. Take care while lowering the thrust collar, key (3280101) should pass
through the keyway on thrust collar & not damage the bore diameter of thrust collar
due to shaft ends. Fit the cover plate on journal bearing (9080101) Ref. Sketch 25
40.0 Put the ratchet cover (4740101) along with cooling coil (3700101) on thrust bearing
housing and fix on housing with the help of Stud, Nut & washer. Ensure that felt ring
is fitted in ratchet cover near shaft opening Pour more lubricating oil till its level
reaches the mark on oil level indicator.
IMPELLER ADJUSTMENT
41.0 Lifting of the rotating unit as per instruction given below is essential to ensure free
rotation of the pump. Fit the bearing nut (3360101) on the head shaft and rotate
bearing nut by hand (threads are anticlockwise, left hand threads) till it touches
firmly against the face of thrust collar (3630101). Do not tighten it further.
Measure the distance between the head shaft end and top surface of the bearing
nut (3360101). Now tighten the bearing nut against the thrust collar (3630101)
such that the rotating unit is lifted up by 6 to 8 mm. Tighten the lock nut. Ref.
Sketch No. 27
42.0 Insert key for pump half coupling (3210201) assembled with ratchet pin housing
on head shaft using grub screw provided. Fit the pump half coupling (3900101) on
head shaft (1850101) till it rests on the bearing nut (3360101).Check the free of
shaft rotation by means of handles provided. Ref. Sketch No. 28
43.0 Lift the motor stool with suitable lifting device and lower on discharge head. Fit the
motor stool with discharge head using fasteners. Ref. Sketch No. 29
40
44.0 Mounting of motor

1. If motor half coupling (3910101) is supplied loose then fit the coupling on
motor shaft such that its face matches with motor shaft end face. Ref. Sketch
No. 30
2. Lift the motor by using lifting locations provided on motor. (Refer motor
drawing for more details) and place it over motor stool, but with the weight still
on the hoist. In case of an electric motor, swing it around so the junction box is
in the desired orientation. Ref. Sketch No. 31 & Sketch No. 32
3. Align the mounting holes and start attaching screws by hand. Transfer the
weight gently from hoist to motor stool and secure the hex screw, tightening
them uniformly.
4. Please note that lifting lugs on the driver are for handling the driver only. Never
attempt to use these lugs to hoist the pump. The pump must be handled with
its own lifting lugs.
5. Check the gap between the two coupling faces it should be 8 to 12 mm. If
required lower the motor coupling downward to maintain gap between pump &
motor coupling.
6. Then align the motor and pump coupling radially within 0.1 mm (100 microns)
maximum & axially within 0.2 mm (200 microns) maximum. Although the
coupling probably will be within the required maximum limits, the unit should be
adjusted to correct any misalignment within practical limits.
X
Y
X= ±0.1 mm Y= ±0.2 mm
41
7. After alignment put the coupling pins. First tighten the coupling pins at opposite
ends to each other. Tighten the complete assembly. Rotate the pump and
check whether the pump is free for rotation.
8. Check the direction of motor separately. It should rotate clockwise when

viewed from top.
IMPORTANT: NEVER LIFT PUMP – MOTOR SET TOGETHER.
45.0 Insert the coupling pins (4040101) through motor half coupling along with coupling
bushes (4000101) and washers for coupling pins (4090101). Then tighten the
coupling nut (4080101).
46.0 DOWELLING (OPTIONAL) :

The motor flange may be (if required) dowelled to the motor stool flange, if
desired, to restore the alignment after dismantling.
Ensure that the coupling mates in accordance with the manufacturer’s instructions.
NOTE: Dowelling should only be done after final alignment has been completed.
Procedure of Dowelling:
a) Drill two holes, one in each mounting flanges, at the locations provided, using a
14 mm dia size drill. The holes should be drilled through both the motor & motor
stool mounting flanges. Clean the metal chips produced from the drilling and
reaming operations. Take care to clean all burrs and metal chips from the holes.
b) Ream the holes with a reamer to the proper fit with the taper dowel pins.
c) Fit taper pins firmly in holes with hardwood block or soft faced hammer.
CAUTION
Failure to remove the dowel pins prior to motor removal may result in mismatch
during re-assembly.
42
47.0 GLAND PACKING ASSEMBLY BEFORE STARTING OF PUMP

New Gland Packing Preparation
1. Put the supplied square size gland packing rings (4300101) with their ends staggered
into stuffing box chamber. If the gland packing is to be cut from a coil or long length the
size, follow the below mentioned procedure
2. Wrap the packing around a dummy shaft, of the same diameter as the sleeve. To assist
in cutting rings, two guide lines parallel to the shaft axis and separated by a distance
equal to the packing section may be drawn on the spiral. Refer sketch no.33
Sketch No. - 33
3. Cut each ring from the spiral at an angle of 45° diagonally across the guidelines. Ref.
sketch no.34
Sketch No. - 34
4. Remove split gland (2290101) and Insert the first ring and tap it to the bottom of the
stuffing box. Each following ring should be installed in the same manner and positioned
in the stuffing box so that the "split" is advanced 120°. When all the rings have been
inserted, the last packing ring should not protrude from the stuffing box face.
5. Slide the gland into the stuffing box and ensure that it sits squarely against the last
packing ring, then clamping plate downward & place on the split gland. Fit the gland
retaining nuts on the studs and tighten evenly to finger pressure.
6. Before starting the pump connect the auxiliary piping connections.
43
7. Conduct the no load test by running the motor for 3 to 6 hours.
ATTENTION
INCORRECT ROTATION OF THE SHAFT EVEN FOR VERY SHORT TIME MAY CAUSE SERIOUS DAMAGE
TO THE PUMP INTERNAL COMPONENTS.THEREFORE BEFORE CONNECTING THE MOTOR COUPLING
HALF TO THE PUMP COUPLING, IT IS IMPERATIVE TO CHECK AND VERIFY THAT THE MOTOR IS OR
WILL BE WIRED TO GIVE THE CORRECT DIRECTION OF ROTATION .
To check the motor rotation:
1. Temporarily position spacers of sufficient width between the motor flange & motor
stool, so that the coupling has no possibility of driving the pump.
2. Connect the electrical supply to the motor and momentarily switch on motor and
check direction of rotation. This should match the direction of rotation of the pump.
3. For three phase electric motors, if the direction of rotation is incorrect, disconnect the
supply and change over two of three supply wires.
DIRECION OF ROTATION OF MOTOR IS CLOCKWISE WHEN VIEW FROM TOP.
3.4 LOCATION OF THE UNIT, EQUIPMENT AND TOOLS REQURIED.
1. The pump should be so arranged as to allow periodic inspection. Both suction and
discharge piping should be independently supported near the pump and properly
aligned so that no stress is transmitted to the pump when the flange bolts are
tightening. Any misalignment in the pump assembly can cause vibration in the unit
and reduce the life of the bearings.
Following equipments are essential for erection of the pump.
2. The over head crane and chain pulley block -

The over head crane and chain pulley block should be of ample capacity to take
the load of the complete unit. There should be minimum clear height between
foundation and the pulley block/hook as indicated in the General arrangement drawing.
3. Chains and lifting hooks, shackles of suitable load capacity.
4. Ropes, crow bars and small pipes and leverages.
5. Accurate straight edge.

44
6. Spirit level / Master level having an accuracy of 0.02 mm per meter.
7. Kerosene and thinner for cleaning of parts.
8. Filler gauge and shims for adjustment of level.
9. “V” blocks and dial gauge with magnetic stand to check the run outs of the shafts.
10. Small wire brush for cleaning of threads of the shaft.
11. Lubricating oil for thrust bearing.
12. **The recommended special tools and accessories are as under.
Sr. No. Description Size Qty(Nos)

LIFTING EYE BOLT M30 x 45L 08
1 M12 x 22L 04
M24 x 55L 04
M36 x 55L 08
M16 x 28L 04
M20 x 30L 08
M42 x 65L 04
2 Tie Bar for Clamp M48 x 2800L 04
3 Clamp for column pipe “I” Beam Type 02
4 Clamp for Shaft M165x3 RH Threads 02
5 Clamp for Head shaft 01
6 Lifting Clamp 100 D hole size (To lift
complete pump assembly only) 04
3 Spanner for coupling Nut A/C FLAT 46 01

4 Plate for puller For motor and pump coupling 01
9 Puller for impeller Set 01
Besides the above the erector must have f o l l o w i n g standard tools and equipments for
smooth erection.
1. Files –triangular, half round and flat.

2. Triangular scrapper.
3. Two sets of standard or ring spanners.
4. Set of pipe wrenches.
5. Adjustable spanners screw drivers of 300mm (12”) and 150 mm (6”) length.
6. Steel rule, steel tape.
7. Set of taps and dies up to 25mm (1”) and hand drills.
8. Chisel, machinist’s hammer, hacksaw, vice etc.
9. Emery paper, thin rolled sheets of brass 0.03 mm to 0.05 mm thickness for
cutting shims.
45
SECTION – 4
OPERATING INSTRUCTIONS
4.1 : PRIOR TO STARTING.
4.2 : STARTING.
4.3 : CHECK DURING RUNNING
4.4 : STOPPING OF PUMP
4.5 : PRE-REQUISITES FOR SATISFACTORY

OPERATION OF PUMP.
4.6 : CHECKS / STEPS TO BE TAKEN IF INITIAL

START-UP IS AFTER A LONG TIME.
4.7 : CHECKS / STEPS TO BE MADE FOR PREPARING

PUMP FOR PROLONGED SHUT-DOWN.
46
4.1 PRIOR TO STARTING :
Before the pump is started initially, make the following inspection.
EXTERNAL WATER LUBRICATION FOR LINE SHAFT BEARINGS-
External water supply to be started before starting the pump as per instructions given
below-
A) SUPPLY WATER SHOULD BE WITH PRESSURE HEAD 10 M ABOVE THE SHUT OFF
HEAD OF PUMP
B) THE QUANTITY OF SUPPLY WATER SHOULD BE 35 LPM
C) PUMP SHOULD NOT BE STARTED UNLESS THE EXTERNAL LUBRICATION OF

SUPPLY IS STARTED AND ALL AIR IS VENTED OUT FROM SHAFT PROTECTION
TUBE
a) Cooling water for thrust bearing is flowing at the rate of minimum 35 liters per minute.
b) All air vents are open.
c) The oil filled in the thrust bearing is up to the indication mark on oil level indicator.
d) Inlet cock for thrust bearing cooling is open.
e) External water lubrication is made as per instruction given above.
f) Check all connections to motor and starting device with wiring diagram.
g) Ensure that the motor rotates in CLOCKWISE direction when looking from the top of the
motor.
h) Check discharge piping and pressure gauges for proper operation.
i) The stuffing box packing’s are inserted in such a way that their joints are staggered.
The gland should be tightened to given enough pressure on packing’s to prevent heavy
leakage. Sufficient leakage should be allowed to quench the gland.
j) Checking for free turning –
Before the pump is actually put in to operation ensure the free rotation by starting and
immediately stopping the pump or manually rotating the pump by hand.
47
4.2 STARTING:
Refer Operation philosophy for pump starting, operation and shutdown.

Following are the steps indicated to start the pump.
a) First start the external clear water to stuffing box inlet. Ensure venting valve of
enclosing tube vent line is open. Close the vent valve after air to be vented out clearly
from enclosing tube.
b) Close valve in discharge line.
c) Ensure the enclosing tube is pressurized with external water.
d) Then turn on power to pump driver.
e) Isolation valves for pressure and temperature gauges always kept open.
f) Cooling water inlet – outlet for pump thrust bearing to be kept open and cooling water
supply is started from external source at the rate of minimum 35 liters per minute.
g) When pump is operating at full speed, open discharge valve as per logic sequence.
h) Close the air vent line (of column pipe) after all the air is vented out from column pipes.
If auto air release valve is provided same may not be required.
4.3 CHECK DURING RUNNING :
Check the following points and regulate if necessary.

a) Pump is running smooth. Check vibration and noise. Vibration should not exceed
the limit as per given in HIS. Vibrations can be checked with a Vibrometer. Power
consumption is within the limits. Current reading should not exceed than the value given
on the name plate of the motor.
b) There is constant continuous flow of cooling water through cooling coil. The
temperature of oil & thrust pad is within limit of set points.
48
4.4 STOPPING OF PUMP :

While stopping the pump, close the delivery valve first immediately after closing the
valve switch off the driver. The pump, however, should not be run for a longer period
with discharge valve closed due to danger of increased temperature of lubricating oil in
thrust bearing.
4.5 PRE-REQUISITES FOR SATISFACTORY OPERATION OF PUMP:
It should be ensured that the pump works under specific conditions given below.
a) The pump handles the liquid as specified in the order.
b) The pump operates at the duty point specified in the order.
c) The minimum submergence available is not less than that indicated in the order.
d) Installation, operation and maintenance instructions given in this manual are adhered
strictly.
e) Loads due to pipes and accessories such as sluice and reflux valves do not come
directly on pump flanges.
f) The erection is carried out by experienced and skilled personnel.
g) Prior confirmation must be obtained, if the pump is to be utilized for conditions other
than those specified in the order.
4.6 CHECKS/STEPS TO BE TAKEN IF INITIAL START UP IS AFTER A LONG TIME:

a) Check external water (for line shaft bearing) is ON to stuffing box inlet as per
requirement. Check enclosing tube is pressurized with external water.
b) Check air is vented out from enclosing tube.
c) Check pump is rotating freely.
d) Check oil level in thrust bearing carrier.
e) Check all tapping connections and motor connections.
f) Check delivery valve position.
g) Check that all gauges are calibrated and are in working condition.
49
4.7 CHECKS TO BE MADE FOR PREPARING PUMP FOR PROLONGED SHUT-

DOWN:
a) Note down vibration level before shut down.
b) Note down alignment of pump.
c) In hoisting huge parts – such as the pump casing – pay utmost attention while attaching
the wire rope so that the load will be centered and wire rope will not slip. In short,
check crane and ropes available.
d) Check availability of sufficient space for disassembling pump components.
e) Check spare parts which are ordered are available.
f) Check accessories, special tools which are supplied are available.
g) Disassemble the pump in same method as described in this manual.
h) Tagging of parts, part numbers should be written on tags.
i) All the components of pump should be stored properly. Rust polish should be applied if
repaired. Parts can be kept loose by tagging part numbers on each tag.
50
SECTION – 5
INSTRUCTIONS FOR MAINTENANCE
5.1 : GENARAL INTRODUCTION
5.2 : DAILY, WEEKLY, MONTHLY, HALF YEARLY,

YEARLY CHECKS
5.3 : OVERHAULING.
5.4 : DISASSEMBLY OF PUMP.
5.5 : CHECKING OF COMPONENT AFTER

DISASSEMBLY.
5.6 : SPARE PARTS.
51
INSTRUCTIONS FOR MAINTENANCE:
5.1 GENERAL INTRODUCTION
KBL VT Series pumps will provide many years of trouble free service when
maintained in accordance with these instructions. In the event of failure of the
pump it is recommended that KBL Service Department is called to investigate and
carry out repairs. The following instructions are given to cover the main elements
of strip and rebuild b ut d o N O T include instructions for work that MUST be done
by a KBL Service Engineer.
The pump assembly requires limited routine maintenance. The pump line shaft bearings
are lubricated by External water. The thrust bearing is oil lubricated and is cooled by
water. The impeller running clearance can only be checked and reset at major
overhauls.
BEFORE ATTEMPTING ANY MAINTENANCE ON A PUMP, PARTICULARLY IF IT IS

HANDLING ANY FORM OF HAZARDOUS LIQUID, ENSURE THAT THE UNIT IS SAFE TO
WORK ON. THE P U M P M U S T B E FLUSHED THOROUGHLY WITH A SUITABLE
CLEANSER TO PURGE AWAY ANY OF THE PRODUCT LEFT I N THE PUMP
COMPONENTS. THIS SHOULD BE CARRIED OUT BY THE PLANT OPERATOR AND A
CERTIFICATE OF CLEANLINESS OBTAINED BEFORE STARTING WORK. IN ORDER TO AVOID
ANY HEALTH RISK, IT IS ALSO ADVISABLE TO WEAR PROTECTIVE CLOTHING AS
RECOMMENDED BY THE SITE SAFETY OFFICER, ESPECIALLY WHEN REMOVING OLD SEALS
OR GASKETS THAT MAY BE CONTAMINATED.
The following hazards may arise during maintenance work:
Fluid Pressure Jet Hazards:-
Check and ensure that the pump operates at below the Maximum Working Pressure
specified in the manual or on the pump nameplate and before maintenance, ensure
that the pump is drained down.
52
Hazardous Materials:-
Wear a suitable mask or respirator when working with packing or gasket
components that contain fibrous material, as these can be hazardous when the
fibrous dust is inhaled. Be cautious, if other supplier’s components h a v e b e e n
s u b s titu ted fo r g e n u i n e K B L parts, these may be then containing
hazardous materials.
Hazardous Gases, Mists, Sprays and Leaks:-

Aware of the hazards relating to the pumped fluid, especially the danger from
inhalation of noxious and toxic gases, skin and eye contact or penetration. Obtain
and understand the hazardous substance (COSHH) datasheets relating to the pumped
fluid and note the recommended emergency and first aid procedures.
Preparation for Maintenance:-
Electric Shock & Accidental Starting Hazard
ISOLATE the equipment before any maintenance work is done. Switch off the mains
supply, remove fuses, apply lock-outs where applicable and affix suitable isolation
warning signs to prevent inadvertent re-connection.
Special tools are required for dismantling and re-assembling these pumps. Suitable
lifting equipment must be available and it is recommended that maintenance requiring
disassembly of the pump unit is done in a clean area.
5.2 CHECKS –
Daily checks –
a. Discharge pressure gauge reading.
b. Voltage, current and power.
c. Pump and motor bearing temperature.
d. Oil level in the thrust bearing.
e. Uninterrupted flow of cooling water for the thrust bearing
53
f. Leakage through stuffing box.

g. Thrust bearing temperature [oil and metal].
h. External water connection for line shaft lubrication
Weekly checks –
a. Check the stuffing box packing.
b. Check the level of the discharge head / sole plate as there is possibility of
resetting of foundation in course of time or disturbance in delivery pipe line.
c. Check the cooling water and other pipe connection. Ensure that cooling water
lines are not choked.
d. Check auxiliary pipe connection.
Monthly check –
a. Coupling alignment.
b. Oil level.
c. Calibrate the measuring instruments.
Half yearly checks:
a. Oil change after 1000 hours or half yearly.
Yearly checks:
a. Calibration of measuring instruments.
b. Examination of coupling elements.
c. Check the silt deposition
d. Change the stuffing box packing
IMPORTANT:
♦ A pump should not be kept idle for long periods. It should run for a short period once in a
week to avoid shaft and impellers from stick to each other. The pump should never run
dry. Dry running will result in seizing of bearings and other mating surfaces.
♦ If a pump has been installed at site , but not in operation due to unavailability of power
supply ,then rotate the pump shaft manually every two weeks to prevent damage to the
shaft bearing assembly.
♦ If a pump has been installed, but is not in regular operation for an extended period of
time, such as a seasonal shutdown, operate it for at least 15 minutes every two weeks,
or rotate the pump shaft manually every two weeks to prevent damage to the shaft
54
bearing assembly. (In case of assembled pump). Never leave the shaft in a previous
position making sure that the shaft rotates freely.
♦ The pump should never run dry. Dry running will result in seizing of bearings and other
mating surfaces.
♦ Do not expose an idle pump to freezing conditions. Drain all liquid that is inside the pump
and the cooling coils. Failure to do so can cause liquid to freeze and damage pumps.
♦ For long term shutdown follow the indications as per paragraph 2.3 for storage
♦ To avoid the dry running of bearing and accumulation of slit or sticking of bearing with
sleeve in transmission the external water to be given as precautionary measure.
Stuffing Box leakage check:-
Normal leakage:
With the pump in operation, there should be some leaking at the stuffing box packing.
The correct leak is a rate which keeps the shaft & stuffing box cool. This rate is
approximately 120 drops per minutes.
*Leakage should be sufficient to quench the heat generated
Decreased leakage:
If the pumps runs hot and the leaks begin to decrease, stop the pump and allow it to
cool down. Loosen the packing gland in order to allow the packing to resume leaking &
restart the pump.
IMPORTANT:
Oil should be filled in the thrust bearing housing up to the mark on the oil level indicator with
the pump idle. Oil should not be replenished during operation. The oil should be removed
before it becomes black and the oil reservoir cleaned at the same time, this should be done every
two months.
There should be uninterrupted flow of cooling water and which must be checked
from the flow indicator.
There should be uninterrupted flow with required pressure for line shaft bearings at
stuffing box inlet.
55
5.3 OVER HAULING
5.3.1 Check the running clearances.
5.3.2 Check the level of pump base due to the possibility of foundation resetting in
course of time or disturbance in delivery pipe line.
5.3.3 With the normal operation of the pump will be due for overhaul after about
three years. This work should be carried out by specialized personnel.
5.3.4 All parts should be cleaned and checked thoroughly for wear after
dismantling. The following parts should be checked for clearance which if
exceed the worn out condition, to be replaced. Replace the gaskets and “O’
rings.
Location Designed Diametrical Diametrical Clearance at
Clearance value in mm Worn out condition after
(Max) running
Shaft and bearing in Bell mouth 0.6 1.2
Shaft sleeve and bearing in Bearing holder

0.8 1.6
of pump bowl
Shaft sleeve and bearing in taper pipe 0.8 1.6
Shaft sleeve and bearing in Column pipe 0.8 1.6
Shaft sleeve and bearing in Stuffing box 0.8 1.6
5.3.5 The rubber rings and rubber parts used for water lubricated pumps must not
come in contact with grease, oil, petrol, paint etc. These parts are to be
cleaned with clear cold water.
5.3.6 While ordering spare parts the details of the name plate must be quoted in
full. Name of the part and part number must be given.
5.3.7 Keep sufficient stock of spares in order to meet emergency.
56
5.4 DISASSEMBLY OF THE PUMP.
Introduction
The dismantling of the complete pump assembly is a major operation and is generally
undertaken for one of the following reasons:
a) The scheduled regular periodic inspection is due.
b) Significant fall-off in pump performance.
c) Excessive vibration or persistent noisy operation.
Dependant upon the reasons for dismantling the pump or the probable cause of failure, only
partial dismantling may be required i.e. to the stage where remedial action can be taken.
The tooling requirements for dismantling and removing the pump from site are those
required for installation, therefore reference should be made to section 3.4 - installation
equipment.
Electric Shock & Accidental Starting Hazard
ISOLATE the equipment before any maintenance work is done. Switch
off the mains supply, remove fuses, apply lock-outs where applicable and affix
suitable isolation warning signs to prevent inadvertent re-Connection.
Remove for protection any instruments, gauges & oil bottles that could be
vulnerable to damage during subsequent operations. All openings and flanges etc.
should be sealed for protection and to stop the ingress of foreign objects.
The dismantling procedure for the pump assembly is the reverse of the installation
procedure as previously described. Reference should be made to section 3.3
– Installation Instructions, taking note of all warnings and cautions given.
ATTENTION
Care must be taken not to impose any bending force on the shaft during this operation.
Further dismantling by pressing or drifting out of bearings or wear rings from their
respective housings should only be required when the bearings or the wear rings are to be
replaced.
Before disassembling the pump, tag number chit of each pump components should be
attached to the respective pump components.
57
DISASSEMBLY PROCEDURE:
1. The shut off valves in delivery lines should be closed and pump relieved to
atmospheric pressure. Then remove the auxiliary pipe connection.
2. Disassemble the flange bolts at delivery side and remove the pipe immediately
after delivery flange in the delivery piping.
3. After a delivery pipe is disconnected the next step is to drain off oil from the
bearing housing. Then remove all instruments like PGS.TGS and RTDS etc.
4. Remove fasteners between motor stool & motor. Remove the joint between motor
stool & discharge head. Then lift motor with motor stool & place at maintenance
bed.
CAUTION
Remove the dowel pins (In case of assembled) prior to motor removal.
5. Remove pump coupling with ratchet pin housing.
6. Remove thrust bearing assembly with individual components.
7. Remove the water deflector (2360101).
8. Remove the stuffing box (2380101) along with split gland (2290101) and gland
packing (4300101).
9. Remove the nuts for discharge head (1170101) from sole plate joint.
10. Place “I” beams on foundation & tighten with provided tie rods. Adjust the distance
between two beams as per requirement after resting of assembly on beams.
11. Fit the lifting lugs for discharge head. Now lift the entire assembly vertically. Then
58
lift through the foundation opening till the column pipe (1330101) supporting pads
rest on two “I” beams placed across the opening. Release the crane hooks now.
12. Remove the nuts from discharge head (1170101) & column pipe (1330101) joint
along with “O” ring provided in between. Now lift the discharge head & place it
away from foundation. Take Care that discharge head will not touch & affect to
head shaft.
13. Disassemble the rigid coupling joint (3930101 & 3940101) by loosening coupling
pins. Then remove the head shaft (1850101) from Intermediate shaft (1840101).
14. Now lift the entire assembly vertically. Then lift through the foundation opening till
the column pipe supporting pads rest on two “I” beams placed across the opening.
Release the crane hooks now.
15. Remove the nuts from column pipe joint along with “O” ring provided in between.
Lift the column pipe & keep aside at flat level surface. Then dismantle the
Intermediate shaft joint. Take Care that column pipe will not touch & affect to
intermediate shaft. Repeat the same procedure until all column pipes are removed.
16. Now lift the entire assembly vertically. Then lift through the foundation opening till
the taper column pipe (1410101) supporting pads rest on two “I” beams placed
across the opening. Release the crane hooks now.
17. Then dismantle the Intermediate shaft (1840101) from Impeller shaft (1860101).
18. Now lift all assembly along with taper column pipe from foundation opening & take it
outside on blocks
WARNING
Pump and components are heavy. Failure to properly lift and support equipment
could result in serious physical injury or damage to pumps.
59
19. Remove fasteners from taper column pipe & pump bowl joint with “O” ring provided
in between. Remove taper column pipe and keep aside.
20. Then remove the bowl assembly (1200101) from Impeller Guide piece (2120101).
21. Remove the Bell mouth (2110101) from guide piece (2120101) and keep remaining
assembly on block of 1.5 m height.
22. Remove Impeller Nut (3300101) from Impeller.
23. Then push the Impeller inside towards bowl side until split ring for impeller
(1560101) gets clearly visible / free from impeller. Then remove split ring (4050101)
from impeller shaft.
24. Remove Impeller from impeller shaft. (Use puller if required, which is supplied with
special tools).
25. Remove bearing holders from pump bowl
26. Take the impeller shaft and keep it properly.
27. Collect all “O” rings and fasteners provided for each joint for easy accessibility while
re assembling the pump.
28. All the keys and retaining screws to be kept properly to avoid problem in re
assembly.
29. All shafts to be kept properly to avoid damages and bending.
60
5.5 CHECKING THE COMPONENTS AFTER DISASSEMBLY
1. Wear and tear of shaft sleeves, impellers, thrust bearing pads and journal
bearings, scratches marks which are observed along the direction of
rotation should be inspected. Remove the scratch mark and burr by files
and scrappers.
2. Hard particles which may come in contact with the pump parts like impeller,
shaft sleeve and rubber bearings along with the liquid being handled can
damage them because of rubbing action. To avoid this check the liquid being
handled.
3. In absence of sufficient lubricating oil in the thrust bearing carrier, oil film is
not created between runner ring and thrust bearing pads. To avoid this check
the oil level and refill it at interval of 1000 working hours. To ensure the oil
level, please check the mark provided on oil level indicator.
4. While refilling the oil into the thrust bearing carrier care must be taken to
prevent foreign particles from entering along with oil. It may damage thrust
pads and runner ring.
5. Before assembling pump component check that all parts are not damaged in
transit. Check concentricity/run out of the shaft, shaft sleeve and wear ring
etc. If run out/ concentricity of above component is out of limit these parts
may wear at one side portion only.
6. For checking the run out and concentricity of the pump shaft pump shaft is
clamped between centers of lathe or on “V” blocks and measure it by dial
indicator.
7. Permissible shaft run out is 0.2 mm on grinding surface of the shaft sleeve or
shaft.
8. Check the impeller dynamically balanced.
61
5.6 SPARE PARTS:
How to order spare parts?

While disassembling pump component all parts are thoroughly checked. Parts
which are worn out or damaged see part code numbers KBL O/A No. and date on
CS drawing TC15011009) which is already supplied to you and place the order
against it to Head Office KBL Pune.
62
SECTION – 6
TROUBLESHOOTING
6.1 : FAULT CHART & REMEDY
6.2 : INSTALLATION & MAINTENANCE RECORD
6.3 : SPARES & SERVICE
63
6.0 TROUBLESHOOTING
6.1 Fault Chart & Remedy
SR.NO TROUBLE PROBABLE CAUSE REMEDY
A. Electrical Circuit open or

Check circuit & correct.
not completed
Check driver wiring for full voltage
B. Low voltage
supply.
Pump does not
1 check wiring diagram furnished with
start C. Incorrect connections
starter
D. Defective Motor, Faulty
Replace
control equipment
E. Faulty switch Repair or Replace
A. Discharge valve closed Open discharge Valve
Start & stop pump several times or use
B. Pump inlet plugged,
the line pressure if available to back
Impeller plugged, or pump in
flush. .Disassemble the pump & clean
mud or sand
the impeller
Check that the motor is correctly
connected and receiving the full supply
C. Speed too low
voltage also confirm that the supply
No liquid delivered frequency is correct.
2 and or Insufficient
Check for clockwise rotation when
liquid delivered D. Wrong rotation
viewed from top.
Check water level in sump as per GA
E. Lift too high for pump
drg. consult with KBL
F. Impeller loose on shaft Pull unit & repair
G. Broken or disconnected
Repair all damage component
shaft
Maintain minimum submergence by
H. Pump not submerged
adding fluid to system.
A. Lift too high for pump check performance curve
B. Motor not coming up to
Check voltage while pump is running.
speed
Start & stop pump several times or use
the line pressure if available to back
C. Impeller partly plugged
flush. Disassemble the pump & clean the
3 Reduced capacity impeller
D. Leaks anywhere in system Repair leaks
E. Excessive amounts of air or
correct conditions
gas
F. Impellers not properly
Adjust the lift
adjusted.
G. Impeller loose on shaft Pull unit & repair
64
A. Excessive power required Use higher rating motor, consult KBL.

B. Pumping higher viscosity or Test liquid for viscosity and specific
Pump stops
specific gravity than design gravity
4 frequently after
sometime C. Mechanical failure of parts Check bearings & impeller for damage
D. Misalignment Make alignment for pump & motor
A. Damaged impeller Inspect, replace if damaged.
B. Pump inlet plugged,
Remove object as required
Impeller plugged
C. Specific gravity higher than Test liquid for viscosity and specific
design gravity
Pumps Take too Line voltage too high or incorrect
D. Motor speed too high
much power and frequency.
5
/or Motor E. Operation at on point on
overloaded Check & correct the operating conditions
pump curve other than design
F. Faulty equipment used to
check & correct the equipment
check
G. Line voltage not correct. Check & correct.
Release gland pressure & retighten.
H. Gland Packing is too tight
Allow leakage flowing.
Insufficient NPSH available. lower down
A. Cavitation
the pump by adding column pipe
B. Available submergence
Check liquid levels.
insufficient
C. Pump not well fixed on the
Check the correct installation of the
foundation or is subject to
pump.
mechanical tensions
D. Pump & Motor coupling
Repair for misalignment
misalignment
Pump is too noisy Check air release valve. Consult KBL. It
6 & Vibrating may be possible to increase the pump
excessively E. Air or gas in liquid.
performance to provide adequate
pumping
F. Loose fasteners. check all bolts ,nuts etc.
G. Bearings are worn out Replace bearings.
H. Deformed shafting Replace shafting
I. Stress due to piping
Correct the misalignment.
misalignment
Check & correct by pump disassembly.
J. Resonance, impeller
For Complex problem consult with
unbalance, piping strains
factory
A. Defective packing Replace worn packing
Excessive gland Replace improper packing with correct
7 B. wrong type of packing
leakage grade.
C. Sleeves are worn out Replace sleeves.
65
A. Packing is too tight Release gland pressure & retighten.

B. Packing is not lubricated Allow leakage flowing.
Over heating of
8 Replace improper packing with correct
Stuffing box C. wrong grade of packing
grade and or consult factory
D. Improper gland packing Repack properly.
A. Impurities Analyze fluid
9 Corrosion
B. Corrosive Liquid Change to corrosion resistant materials
IMPORTANT: IF TROUBLE CANNOT BE LOCATED CALL FACTORY SERVICE ENGINEER.
6.2 Installation & Maintenance Record

Date Summary of maintenance & repairs done - replacement parts fitted etc:
Commissioning Engineer’s notes:
Installed & Commissioned Signed –

Commissioning Engineer
66
6.3 SPARES & SERVICE
KBL Pumps operate a comprehensive Spares and Service support network throughout the
world, and can be contact as follows.
SPARES & SERVICE Telephone: 020-27214347
For spare parts, supply only. ask for : Spares Dept.
For breakdowns, spare parts and on-site fitting, pump installation

And commissioning, and service contracts ask for: Service Dept.
For breakdowns outside office hours. Telephone: 020-27214347
Copies of this manual are available from KIRLOSKAR BROTHERS LTD the Spares &
Service Department by quoting the manual reference number and revision number.
PUMP SERIAL NUMBERS
Pump No.1 150N812001
Pump No.2 150N812002
Pump No.3 150N812003
Pump No.4 150N812004
KIRLOSKAR BROTHERS LIMITED

REGD. OFF. PROJECTS & WORKS
UDYOG BHAVAN, TILAK ROAD, CORPORATE OFF. KIRLOSKARWADI, 416308
PUNE- 411 02 (INDIA) “YAMUNA” DIST. SANGLI (INDIA)
Tel. +91(0)20 2440 0770 Survey No 98(3-7) Tel +91(0) 2346221255
Fax +91(0)20 2444 0156 Pune 411045 (INDIA) Fax +91(0) 23462223
Tel +91 (0)20 27214332
Fax +91 (0)20 27214436
67
SECTION – 7
DRAWINGS AND DOCUMENTS
7.1 : ASSEMBLY SKETCHES
7.2 : PIPING CONNECTIONS
68
APPROVED AS INDICATED BY BELOW
CATEGORY – I APPROVED
CATEGORY – II APPROVED;SUBJECT TO COMMENTS TO BE

INCORPORATED
CATEGORY – III NOT APPROVED, TO BE REVISED
CATEGORY – IV FOR INFORMATION ONLY
CATEGORY – IV-R FOR INFORMATION WITH COMMENTS
Contractor is responsible for Design, coordination, dimensions, quantities etc.

Approval does not relieve the contractor of his responsibility for design and
performance of the equipment / system / overall plant in accordance with the
contract document.
______________________________________________________________
MOTT MACDONALD PVT. LTD.
Job No. ……………………………………………………….
Samad
Checked by ………………. Date ………………………… 14.05.2013
CATEGORY – II APPROVED;SUBJECT TO COMMENTS TO BE

INCORPORATED
CATEGORY – IV FOR INFORMATION ONLY
Contractor is responsible for Design, coordination, dimensions, quantities etc.

Approval does not relieve the contractor of his responsibility for design and
performance of the equipment / system / overall plant in accordance with the
contract document.
______________________________________________________________
Job No. ……………………………………………………….
Checked by ………………. Date …………………………
KIRLOSKAR BROTHERS LTD
Kirloskarwadi, Dist: Sangli (INDIA)
PERFORMANCE CURVE FOR BHM150, Single Stage Pump

PUMP TYPE : BHM150 DISCHARGE 45500 M^3/Hr SP.GRAVITY 1.03
MOTOR RATING : 4600 KW TOTAL HEAD 27.0 M Column Size 2100 mm
MOTOR SPEED : 325 RPM (FLS) PUMP INPUT 3828.84 KW Delivery Size 2100 mm
PUMP SPEED : 325 RPM (FLS) PUMP EFFICIENCY 90.0 % NPSHR 11 mtr
60
48 mtr
50
Minimum Flow Maximum Flow
= 31850 m3/hr = 59850 m3/hr
Total Head in mtr
40 RANGE OF OPERATION
30 45500m3/hr, 27 mtr
20
10
59750m3/hr,14.6 mtr
0
0 10000 20000 30000 40000 50000 60000
4400
Pump Input, kW
4200
3920 kW 45500 m3/hr, 3828.84
4000
kW
3800
3600
3400
3200
0 10000 20000 30000 40000 50000 60000
100 √
19
90 CATEGORY – II APPROVED;SUBJECT TO COMMENTS TO BE 18

INCORPORATED
80 √ CATEGORY – IV FOR INFORMATION ONLY 45500m3/hr, 90% 17

Contractor is responsible for Design, coordination, dimensions, quantities

70 etc. Approval does not relieve the contractor of his responsibility for design 16
Pump Efficiency %
and performance of the equipment / system / overall plant in accordance with

the contract document.
______________________________________________________________
60 Job No. ………………………………………………………. 15
Samad
Checked by ………………. Date ………………………… 07.03.2012
50 14
40 13
30 45500m3/hr,11 mtr 12
NPSHR (M)
20 11
10 10
0 9
0 10000 20000 30000 40000 50000 60000
Discharge in m3/hr
CLIENT HINDUJA NATIONAL POWER CORPORATION LTD. CURVE NO HA15011013 2

SERVICE CW PUMPS CHECKED BY SJC / 29.08.2011
PROJECT 2 X 520 MW VIZAG THERMAL POWER PLANTVISAKHAPATNAM APPROVED BY CVD / 29.08.2011
DOCUMENT TITLE KSL/SYS/DE-POW/1107/ME02/04A
O/A NO. & DATE C09712A002
1040 MW Vizag Thermal Power Project
EPC Tender Specification No.: Tender/253292 b/Cooling Water/MECI Hinduja National Power Corporation Limited
Volume-IV, Schedule-6: Bidder's Data Sheet for Mechanical
Document No. – KSL/SYS-DE-POW-1107/ME02/01
1 Bidder’s Data Schedule for Sea Water Intake Pumps
S no. Particular Unit Bidder to Indicate

1 Equipment Data
2 Manufacturer Kirloskar Brothers Ltd.
3 No. required 04
4 Size (Model) BHM150
5 Operating Conditions
Liquid Sea Water
Pumping Temp.(PT) -
SP Gr. At PT 1.03
pH Range -
Viscosity at PT -
Duty flow M3/Hr 45500
TDH at duty flow M 27
NPSH Available M 14.10 (Ref. Annexure –I)
6 Performance Data
No. of Stages Single Stage
Pump speed rpm 325 (FLS)
Max Impeller diameter mm 1960
NPSH Required m 11.00
3
Rated Flow M /Hr 45500
Duty flow M3/Hr 45500
Min cont flow M3/Hr 31850
TDH at duty flow M 27
TDH at min cont flow M 31
Minimum submergence required mm 5300
above edge of suction bell
Shutt-off Head M 48
Pump Input power at shutt-off kW 3920
Pump Input power at Run out flow kW 3510
Reverse runaway speed ( % rated 130 %
speed)
Critical Speed of pump (1st) rpm 2810
Range of pump operation 70% to 130%
Maximum Flow 130% of rated flow.
Internal Head Loss in pump m 0.27
Noise Level at 1.0 m from edge 85 dBA
equipment
7 Construction Data
Horizontal/vertical Vertical
Design Non Pull out
Casing type Diffuser Type
Seal type Gland Packing
Coupling type Rigid Type
Impeller type Mixed Flow semi open
Axial thrust balance system Thrust Bearing arrangement on
Discharge Head
Discharge nozzle size mm 2100
Weight
pump kg 66200
motor kg 48000
base plate kg 2500
total kg 116700
8 Motor Details
Manufacturer Hyosung Corporation
Rated power kW 4600
Speed rpm 325 (FLS)
Frame size 1250F
Type VSTC
Insulation class ‘F’ Class
Enclosure type TE
Temperature rise (0C) 70 (at Full Load)
Volts/Phase/Cycle --/3/50 11000/3/50
9 Material of Construction
(ASTM Grade)
DUP ST ST ASTMA240/240M-UNS
31803(PLATE) with
Casing (Bowl)
ST.ST.ASTMA890/890M-CD3MN-TYPE 4A
Flange
DUP ST ST ASTMA240/240M-UNS
31803(PLATE) with
Bell Mouth
Flange
Impeller Guide Piece ST.ST.ASTMA890/890M-CD3MN-TYPE 4A
Impeller DUP ST ST ASTMA890/890M CD4MCUN-
1B
Column Pipe DUP ST ST ASTMA240/240M-UNS
31803(PLATE) with
Flange
Gland Packing PTFE
Shaft ST ST ASTMA 276-UNS31803 (ANLD)
Shaft sleeve ST ST ASTMA 276-UNS31803 (ANLD)
Discharge head Outer Skirt MS IS:2062 Fe-410 W A EPOXY
Discharge head Bend DUP ST ST ASTMA240/240M-UNS
31803(PLATE) with
Flange
Bolting (in contact with water) ST ST ASTMA 276-UNS31803 (ANLD)
Bolting (not in contact with water) ST ST ASTMA 276-316 L (ANLD)
Bowl bearing NEO RBR LND BRG SS 316L SHELL
Line shaft bearing NEO RBR LND BRG SS 316L SHELL
Thrust Bearing Mitchell Make (Tilting Pad type)
10 Shop Test
Performance Required
Witness Yes
NPSH Required
NA
Witness
Hydro test Required Yes
Witness One unit
11 Drawings Required
Data sheet No.
General arrangement and
TL15011009
dimensional drawing no
Sectional drawing no. TC15011009
Characteristic curve no. HA15011013

CW Pumps - BHM 150 - O&M Manual

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Operators Instructions for Manual /Rev

CIRCULATING WATER PUMP BHM150 HINDUJA / R00

Operation and maintenance manual

BHM 150, SINGLE STAGE,

2 X 520 MW VIZAG THERMAL POWER PLANT

M/s KBL WORK ORDER NO: C09712A002

ERECTION, OPERATION &

KBL DOCUMENT NUMBER : KBL/IOM/BHM150/HINDUJA/C09712A002/ REV -00

KIRLOSKAR BROTHERS LIMITED

Operation and maintenance manual

O & M MANUAL FOR BHM 150

DESCRIPTION PAGE NO.

A- E GENERAL INFORMATION & SAFTEY INSTRUCTIONS 4-9

SECTION- 2 RECEIPT STORAGE & HANDLING.

SECTION- 3 INSTALLATION INTRUCTIONS

SECTION- 4 OPERATION INSTRUCTIONS

Operation and maintenance manual

SECTION- 5 INSTUCTION FOR MAINTENANCE

SECTION- 6 TROUBLE SHOOTING CHARTS

SECTION- 7 DRAWINGS AND DOCUMENTS

Operation and maintenance manual

A) GENERAL INFORMATION & SAFETY INSTRUCTIONS

Operation and maintenance manual

Operation and maintenance manual

IMPROPER INSTALLATION, OPERATION, MAINTENANCE, LUBRICATION, REPAIR OF

This symbol refers to general mechanical aspects of safety.

This symbol refers to electrical safety.

B) SAFETY INSTRUCTIONS WHILE HANDLING AND STORAGE

Operation and maintenance manual

C) SAFETY INSTRUCTIONS WHILE ASSEMBLY & INSTALLATION

D) SAFETY INSTRUCTIONS WHILE COMMISSIONING & OPERATION

Operation and maintenance manual

E) SAFETY INSTRUCTION WHILE MAINTENANCE & SERVICING

It is also advisable to wear protective clothing as recommended by the site safety

Operation and maintenance manual

Adequacy of suitable crane should be checked before lifting the pump/pump

Operation and maintenance manual

1.1 : GENERAL DESCRIPTION

1.2 : TECHNICAL DATA OF PUMPS.

1.3 : GENERAL CONSTRUCTION.

1.4 : BEARING & LUBRICATION ARRANGEMENT

1.5 : PIPE CONNECTIONS

Operation and maintenance manual

O & M MANUAL FOR BHM150

1.1) GENERAL DESCRIPTION

Operation and maintenance manual

1.2 TECHNICAL DATA OF PUMP

a. Manufacture’s name : Kirloskar Brothers Ltd.

N 325 RPM (FLS)

Q 12.638 m³/s (45500 m³/Hr)

Operation and maintenance manual

h. Time required accelerating : 10 Sec

3 Design, construction and technical data -

3.2 Discharge nozzle