technical manual for kirloskar end suction · pdf file1 technical manual for kirloskar end...

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TECHNICAL MANUAL

FOR

KIRLOSKAR

END SUCTION PUMPS

TYPE GK-(Water)

KIRLOSKAR BROTHERS LIMITED UDYOG BHAVAN, TILAK ROAD, PUNE 411 002.

CONTENTS

2

1. MODELS. 3

2. APPLICATIONS. 3

3. NOMENCLATURE. 3

4. CONSTRUCTIONAL FEATURES. 3

5. OPERATING DATA. 4

6. HYDROSTATIC TEST PRESSURE 4

7. CONSTRUCTION. 7

8. DRIVE. 12

9. COUPLINGS. 12

10. MATERIALS OF CONSTRUCTION. 12

11. ALLOWABLE MOMENTS & FORCES ON PUMP FLANGES. 14

12. RECOMMENDED SPARES. 16

13. DESIGN CRITERIA. 16

14. PAINTING DETAILS. 17

15. INTERCHANGEABILITY CHART. 18

16. SPECIFIC SPEED. 19

17. CRITICAL SPEED. 19

18. WEIGHTS OF PUMPS. 19

19. GD² VALUES 19

20. MAXIMUM ROTATIONAL SPEED. 19

21. GENERAL CROSS SECTIONAL DRAWING. 20

22. GENERAL OUTLINE DRAWING. 24

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TECHNICAL DATA FOR “GK “PUMP.

1. MODELS:

Following models are available in GK pump series.

Sr.

No

Pump

Model

SUC. SIZE

(mm)

DEL.SIZE

(mm)

Driving Unit

01 GK65/32B 100 65

Unit 50

02 GK80/32B 125 80

03 GK80/40B 125 80

04 GK 100/26B 125 100

05 GK 100/32B 125 100

06 GK 100/40A 125 100

07 GK 100/40B 125 100

08 GK 125/26A 150 125

09 GK 125/32A 150 125

10 GK 125/32B 150 125

2. APPLICATIONS:

GK pumps are mainly used for clean and clear liquids which are free from suspended

solids\particles. Few of the applications are as below:

1. Water supply.

2. Sprinkling.

3. Air conditioning.

4. Industrial water.

5. Swimming pool water.

6. Hot water.

7. Fire fighting.

8. Irrigation.

9. Drinking water/Potable water

10. Cooling water

11. Condensate

12. Clear juice.

3. NOMENCLATURE:

Following nomenclature is used.

Example: GK 65/32B

GK: Basic pump series

65: Nominal delivery size in millimeters ‘/’: Always slash

*32: Nominal impeller diameter in centimeters.

#B: Impeller Design

4. CONSTRUCTIONAL FEATURES:

GK Pumps are conforming to ISO: 5199 & dimensionally are fully conforming to ISO

2858 / EN: 22858. These pumps are horizontal back pullout design, radially split,

single stage, centrifugal end suction volute with top centerline delivery. Pump feet are

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integrally cast with delivery casing. Impeller is of an enclosed type. Bearing housing is

fitted with a support foot. Pump shaft is supported by grease lubricated anti friction

deep groove ball bearings as a standard scope of supply.

Owing to its back pull out design, complete driving unit can be withdrawn from

the driving end, without disturbing suction and delivery pipelines. The motor

too remains in the position, if spacer coupling is used. Pumps are suitable for

belt drive application with plummer block arrangement.

5. OPERATING DATA:

i) PERFORMANCE RANGE

a) At 1450 rpm

Rate of flow [Q] up to 450m^3/hr

Head [H] up to 60 m

Temperature up to 900C [maximum] without stuffing box cooling.

ii) NET POSITIVE SUCTION HEAD

Performance curve is drawn based on the values obtained on our test bed. A

safety margin of 0.5 meters minimum should be added for applying the same for

site conditions.

iii) MINIMUM SAFE FLOW RATE

Minimum safe flow for GK pumps is 10% of capacity at best efficiency point capacity

subjected to –

a) Temperature of liquid being pumped is less than 900C.

b) Available NPSH is greater than NPSHR value by 0.5 meter at minimum safe flow

discharge.

c) Vapour pressure of liquid is less than vapour pressure of water at all temperatures.

d) Thermal capacity of liquid is greater than thermal capacity of water.

Thermal capacity: The quantity of heat necessary to produce a unit change of

temperature in a unit mass of substance

Note: - Duration of running the pump at shut off (Delivery Valve fully closed) is maximum

1-minute.

iv) MAXIMUM PERIPHERAL PERMISSIBLE VELOCITES OF IMPELLERS.

Please refer chart no. CT1GK001 0

v) STARTING TORQUE-SPEED CURVE


6. HYDROSTATIC TEST PRESSURE:

Please refer note below chart no. CT1GK003 0

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7. CONSTRUCTION:

i) DELIVERY CASING

Delivery casing has axial suction and top centerline delivery. It is having integral

bottom feet. 3 mm extra corrosion allowance on casing wall thickness is provided.

Flanges are drilled as per BS EN 1092 (DIN 2533 ND16), plain face unstock finish as

a standard. However flange drillings ANSI B 16.1, CL-125 and ANSI B 16.5, CL-150

can be offered against order at extra cost.

The pumps are supplied with BSP tapping as a standard.

Notes:

1. Pump flange thickness and outer diameter may be more than specified by the

standard in case of unstock finish flanges.

2. Pump flange thickness may be more than specified by the standard.

TOP CENTRE LINE DISCHARGE AND FOOT MOUNTED VOLUTE CASING


FIGURE OF TAPPING CONNECTIONS ON THE PUMP


ii) IMPELLER

Impellers are enclosed type. The hydraulic axial thrust is balanced either by providing

back vanes or through balancing holes depending upon magnitude of axial thrust.

Pump size Method of balancing hydraulic axial thrust

65/32B, 80/32B, 100/32B,

80/ 40B, 100/40A, 100/40B,

125/32A,125/32B

With wearing rings on both sides of

impeller and with balancing holes.

100/26B,125/26A With back vanes

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KIRLOSKAR BROTHERS LIMITED TOP CENTRE DISCHARGE AND

FOOT MOUNTED VOLUTE CASING.

CT1GK004 0

Top Centre Line Discharge.

Liquid is cut at the highest point. So practically no chances to form air

pockets. Hence „GK‟ pumps have got greater ability to handle vaporized

liquids.

Residual pipe stresses are transferred to base by the shortest possible

route and thus the harmful influence on wear ring clearances, bearing,

shafts, shaft seal etc. is avoided.

Layout of plant becomes simpler. Allows interchange of pumps without

making costly piping changes.

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Dynamic balancing of impeller is done at reduced speed to the grade 6.3 of ISO

1940.

The impeller is locked on the pump shaft by means of impeller screw.

iii) BEARING DETAILS

Driving

Unit

Max.

Speed

(RPM)

Min.

Speed

(RPM)

Bearing Life

(Hrs) Deep groove Ball Bearing size

Driving End Non driving

End

50 2300 980 25000 6310(1nos.) 6310(1nos.)

Notes:

1. Bearings of SKF make or equivalent are used.

C3 clearance bearings are used.

2. Axial running clearance shall be less than 0.45 mm.

3. Maximum allowable temperature of bearing shall be 80° C considering 40° C above

ambient temperature.

4. The bearings are lubricated with grease as a standard supply.

iv) Details of Grease Lubrication:

MANUFACTURER SPEED

1500 RPM 3000 RPM

INDIAN OIL SERVOGEM 3 SERVOGEM 2

CALTEX STARFAX 3 STARFAX 2

HINDUSTAN NATRA 3 OR NATRA 2 OR

PETROLEUM LITON 3 LITON 2

Quantity of Grease :

DRIVING UNIT QUANTITY APPROX.(gm.)

50 35

Regressing intervals:

1) 1500RPM- After 5000Hrs

2) 3000RPM- After 4500Hrs

v) PUMP SHAFT

Pump shaft is supported between antifriction deep groove ball bearings. The critical speed

of the shaft is sufficiently above the operational speed. The shaft is critically machined &

ground to maintain concentricity. It is fully protected from the liquid being handled by

means of shaft sleeve & gasket between impeller & impeller screw.

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Shaft Dimensions.

Driving

Unit

Diameter

Under

Coupling

(mm)

Diameter

Under Shaft

Sleeve (mm)

Diameter

Under Impeller

(mm)

∅D (mm)

X1

(mm)

X2

(mm)

50 42 48 38 42 221 161

vi) STUFFING BOX

The gland packing arrangement in the stuffing box is 2+L+3

(i.e. 5packings and one lantern ring).Stuffing box cavity dimensions as per

ISO 3069 Standard.

Stuffing box details (Fig) please refer drawing no. CT1GK006 0

a) Gland Packing and Gasket Material:

As a standard scope pumps are supplied with following gasket and gland

packing in materials:

Gasket: Ferrolite NAM 37 or equivalent.

Gland packing: Champion 3116 or equivalent.

Note: Against requirement, gland packing and gasket in PTFE can be

supplied at extra cost.

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Wear ring details:

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Mechanical seals sizes:

The mechanical seal is optional feature and standard supply as cartridge type single seal.

vi) SHAFT SLEEVE

Hook type shaft sleeve is provided with one end free to expand with temperature

variation. Rubber deflector is mounted on the shaft sleeve.

8. DRIVE

Direct Drive: - The pump can be driven by electric motor or engine.

Belt Drive: - Pumps are suitable for belt drive applications with plummer block arrangement.

Direction of rotation: Direction of rotation is clockwise when viewed from the

Coupling end.

9. COUPLINGS:

In order to avail the benefit of back pullout feature of GK pumps, it is recommended that

these pumps should be used with Flexible jaw type spacer coupling. Only spacer type of

coupling will be supplied along with these pumps. Whenever ordered, we supply these

pump with flexible jaw type spacer coupling.

10. MATERIAL OF CONSTRUCTION:

“GK” pumps are provided in “ALL CI” material of construction as a standard.

Other optional materials of constructions are as mentioned below.

MATERIAL OF CONSTRUCTION CODES FOR GK PUMPS

CODE MATERIAL CONSTRUCTION CODE

01 STANDARD ALL CI

02 BRONZE FITTED

11 CF8M FITTED

94 CF8 FITTED + SS304

60 CF8M FITTED + SS316 SHAFT

96 ALL2.5%NiCi+BR IMP & BOTH WR + SS316 SHAFT

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MATERIAL CONSTRUCTION CHART FOR GK PUMPS

(MOC CODE 01 IS STANDARD, * MARK INDICATES MATERIAL SAME AS OF 01 CODE)

Sr.

No

Description of part

Part

code 01 02 11 60 94 96

1 PUMP CASING, 105, 012 * * * * 563

CASING COVER 220 012 * * * * 563

2 ENCLOSED IMPELLER 151 012 110 232 232 240 110

3 CASING RING (SUC) 190 012 110 232 232 240 110

CASING RING (DEL) 191 012 110 232 232 240 110

4 PUMP SHAFT 180 053 * * 251 250 251

5

SHAFT SLEEVE

(GLAND PACKED)

310

556 *

251

251

250 *

6

SHAFT SLEEVE

(MECH SEAL)

315 253 *

251

251

250 *

7 MECH SEAL COVER 231 253 * * * * *

8 LANTERN RING 227 364 * * * * *

9 GLAND 223 012 * * * * *

10 BEARING HOUSING 240 012 * * * * *

NOTE: The above list contains only material of construction of the main parts.

The materials for all other parts e.g. bolts, gaskets are selected according to the material of

construction of main parts and the application.

LIST OF MATERIALS FOR GK PUMPS

MATERIAL

CODE

MATERIAL DESCRIPTION EQUIVALENT ASTM STANDARD

012 CI IS 210-FG 260 ASTMA A48 CLASS 40

053 CS IS 1570 PART II 40C8 HOT ROLLED ASTMA-107 GR.1040

110 BRONZE IS 318 GR LTB2 ASTMA 584 – C90500

232 ST ST ASTMA351/351M-CF8M ST ST ASTMA351/351M-CF8M

240 ST ST ASTMA743/743M-CF8 ST ST ASTMA743/743M-CF8

250 ST ST ASTMA276-304 ANLD ST ST ASTMA276-304 ANLD

251 ST ST ASTM A276 TYPE 316 ANNEALED ASTMA 279 type 316

253 ST ST ASTM A276 TYPE 410 ANNEALED ASTMA 276 type 410

556 ST ST ASTM A276 TYPE 410 (250-280

BHN)

ASTMA 276 type 410

563 CI IS 210 FG 260 Ni2.5(MIN) -

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11. ALLOWABLE MOMENTS AND FORCES ON PUMP FLANGES

PUMP TYPE

ALLOWABLE FORCES (Kp) ALLOWABLE MOMENTS (mKp)

Px Py Pz Mx My Mz

65/32B 170 210 135 90 50 40

80/32B 200 260 170 110 70 50

80/40B

100/32B

255 325 210 135 90 70 100/40A

100/40B

125/32A 320 400 260 155 105 80

125/32B 320 400 260 155 105 80

100/26B 255 325 210 135 90 70

125/26A 320 400 260 155 105 80

Note: 1) Kp force in kilogram

2) mKp moment in Meter kilogram

3) Above moments and forces are applicable for Cast Iron casings.

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12. RECOMMENDED SPRES.

Item no Description No. / Unit No. / spares kit

1 year 2 years 3 years

180 Pump Shaft 1 - - 1

151 Impeller 1 - - 1

260 Ball bearing 2 - 1 set 2 sets

511 Gasket 1 1 2 5

515 Gasket 1 1 2 5

230 Mech seal 1 - 1 2

223 Gland 1 - - 1

227 Lantern ring 1 - - 1

430 Gland packing 5 1 set 4 sets 10 sets

190 Suc.Wear ring 1 - 1 2

191 Del. Wear ring 1 - 1 2

310 Shaft Sleeve 1 - 1 2

669 Impeller Screw 1 - 1 2

320 Key for impeller 1 - - 1

321 Key for coupling 1 - - 1

13 DESIGN CRITERIA

i) Viscosity:

GK pumps are primarily designed for handling water; hence, viscosity of liquids

shall be same as water.

ii) Reserve power margin:

In order to avoid continuous overloading of electric motor, the recommended

motor rating in kW should exceed the calculated power by following

percentage.

Duty point BkW Motor margin %

Up to 1.4 kW 30 %

1.5 kW to 3.6 kW 25 %

3.7 kW to 7.4 kW 20 %

7.5 kW to 18.4 kW 15 %

Above 18.5 kW 10 %

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iii) Hydraulic performance

1) Performance as per curves shall be applicable for liquids satisfying following

conditions.

a) Viscosity not greater than water.

b) Specific gravity equal to 1.

c) Total solid content not greater than 3000 ppm.

2) Guarantee verification as per any of the below mentioned performance

testing standard can be offered.

A) ISO 9906 –Grade-2B

B) IS 9137

3) Pumps can be offered for NPSH testing on closed circuit at extra cost.

4) Performance curves (IM) indicate NPSH requirements of pumps on the basis

of a 3% drop in total head.

14. Painting details:

Paint type: special synthetic enamel fast drying

Shade: violet blue RAL5000

Dry film thickness: 80 micron

15. Interchangeability chart: Please refer CT1GK007 0

16. Specific speeds: Please refer chart no CT1GK003 0

17. CRITICAL SPEED: Please refer chart no CT1GK003 0

18. WEIGHTS OF PUMPS: Please refer chart no. CT1GK003 0

19. GD² values: Please refer chart no. CT1GK003 0

20. Maximum rotational speed: Please refer chart no. CT1GK003 0

21. General cross sectional drawing: TC1GK00001-0 & TC1GK00002- 0

22. General outline drawing: TL1GK00001-0

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Chart no: CT1GK003 0

Sr. No.

Pump Type Specific

Speed

1st

Critical

Speed

(RPM)

Weight

of pump

(kg)

Water Fill

Capacity

(Liters)

Max.

Rotational

Speed, RPM

Gd2

Kg-m^2

1 GK65\32B 65 13777 143 7.3 2300 0.5

2 GK80\32B 82 12230 145 8.3 2300 0.69

3 GK100\32B 89 15302 152 9.6 2300 0.81

4 GK125\32A 115 12122 160 14 2300 0.82

5 GK125\32B 118 12122 161 14 2300 0.84

6 GK80\40B 58 11394 175 11 2300 0.71

7 GK100\40A 73 12714 197 13.8 2300 0.72

8 GK100\40B 82 12212 200 13.8 2300 0.83

9 GK100\26B 110 19056 135 8 2300 0.32

10 GK125\26A 54 15092 135 12 2300 0.41

Note:

1) Max. Allowable suction pressure is 12 kg/cm^2 subject to max. working pressure

is 16 kg/cm^2.

2) Hydro test pressure will be 24Kg/cm².

a) The above hydrostatic test pressures are irrespective of material of pump casing.

Duration of hydrostatic test pressure shall be 5 minutes unless otherwise

specified.

b) The above test pressures are applicable for pumps operating on suction

pressure up to 12Kg/cm² (considering max.working pressure is16 kg/cm^2).

c) For higher suction pressures than those specified in note b), hydrostatic test

Pressure should be calculated as given below.

d) Hydro test pressure in (Kg/cm²) = 1.5 × (max. working pressure experienced

by pump casing corresponding to duty point impeller diameter, Kg/cm²).

However, the hydrostatic test pressure for various pump casing materials

should not exceed the following limit.

Pump Casing Material

Max. Test Pressure

Cast Iron, Bronze

24.0 Kg/cm²

3) Specific speed Metric: = Ns = 3.65 N x √Q / H0.75

Where, N= Speed in rpm

Q= Capacity in m3/sec.

H= Head in meter.

technical manual for kirloskar end suction · pdf file1 technical manual for kirloskar end...

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