~~~~~~~~~~~~~~~-~l

OPERATI N !

&
l.VIAINTEN ANCE MANUAL

/ ! LUBE OIL SYSTEM

Client:

M/s. FL Smidth Minerals Pvt Ltd

Project:

BHEL -NLC BARSINGSAR POWER PROJECT

Reference:
P.O No: BHEL-LSHS/16725 Dt :09.05.08.
FLSMfB/16725-0 Version:2 (Amended)
Our Job Ref.: ES-296

MANUFACTURED BY:
PS I ENGINEERING SYSTEMS (P) LTD.,
CHENNAI-41
 CONTENTS

~ OPERATION & MAINTENANCR MANUAL

~ PUMPS

~ MOTOR

• FLOW SWITCH

• LEVEL SWITCH

• PRESSURE SWITCH

• PRESSURE GAUGE

\..._ .~ GA DRAWING FOR LUBE OIL SYSTEM

(

OPERATION & MAINTENANCE MANUAL

 !NSTtUL.ATION
UNPACKING

Open the packing cases carefully after receipt from the carrier. Make sure there is no
external damage. The accessory items are packed in separate boxes. Examine & check
against packing slip. Make sure all items are undamaged.

MOUNTING
The system is supplied in assembled condition. The loose-supplied items have to be
mounted on the base skid, as shown in the GA Drawing. Mating flanges will have match
marks.

Support the system on a level foundation, with the base above floor level to protect the
( system from wash-downs. Anchor bolts are provided for fixing to the foundation. These

• have to be grouted into suitable holes in foundation. Make sure system is perfectly level,
after mounting/fixing base bolts.

PUMPS
The pump model fitted on Lube Oil Circulation module is mode11P-3090 rotary gear pump
(make: Dowty - 2 nos. pump). The pump model fitted on Lube Oil Pre-Jacking module is
modeIIRCE-3A-30 radial piston pump (make: Polyhydron - 2 nos. pump).

PIPING
The system will have to provided with external piping to termination paints as indicated in
the P&l drawing / GA drawing of this system. These external piping will have to be
connected to the mating flanges provided on the relevant system termination points.
Piping should preferably be of the same material and size as the system piping. All piping
should be well supported, and there should be no stress at the system termination point. .

c All system termination points are supplied with mating flangeslbolts-nuts-washers/gaskets ..

Additional gaskets for flanges, as well as companion flanges with bolts/nuts/washers, for

• all termination points, are supplied with the system initially.

FIXING COMPONENTS NOT IN OUR SCOPE

Certain components are not in PSI scope of supply. These items are supplied by others,
for fixing on the skid. Please refer the GA drawing enclosed for specific details of the
location/mounting of the system instruments. In all cases, it will only be necessary to
mount these on to the relevant nozzles/flanges, if supplied loose. Please follow instruction
manual of relevant equipment for fixing.

FIXING INSTRUMENTATION

Please refer the P&l drawing / GA drawing, for specific details of the location/mounting of
the system instruments. In all cases, it will only be necessary to mount these on to the.
relevant nozzles/flanges, if supplied loose.

Page 3
 POWER SUPPLY

The electric motor, for pump, will have to be connected to power supply through your
control panel. Check nameplate details of motors and give power supply accordingly. The
motors are rated for 3-Ph 415V 50 Hz. Ensure that earth connection is given to earthing
terminal provided on motors. Ensure that direction of rotation is as per the arrows shown
on the pumps. Incorrect rotation must be avoided at all costs. Always decouple pumps
before checking rotation direction.

OPERATION
( ?RINCIPLE OF OPERATION

• This system contains two positive displacement rotary gear pump. These two pumps are
for circulation of the lube oil through mill bearing. There are two radial piston pumps also
fitted on same sump, for pre-jacking oil supply. Oil stored in the sump is fed to the pumps
through the strainer. The sump has a capacity of 250 litres, and is fitted with level
indicators and an electric heater to maintain the oil temperature in the evnt of low ambient
temperatures.

In the lube oil circulation system, oil is pumped to thelube oil cooler. The delivery side of
the pump is fitted with a pressure relief valve, to prevent overpressure building up if the
pump delivery line is closed accidentally; the relief valve will, in that case, bypass the
liquid harmlessly back to the sump. After cooler the oil passes through a duplex filter, with
changeover valve. After the filter, a flow switch, followed by a flow divider, is fitted. The oil
flow is divided into two delivery lines, leading to the main user equipment.

c rhe Pre-Jacking Oil System, the radial piston pumps deliver the oil under high pressure to

• a flow divider. The oil flow is divided into two delivery lines, leading to the main user
equipment.

PRE-OPERATIONAL INSPECTION
After system is installed, please check the following, prior to start-up:

1 . All bolts/nuts/foundation bolts etc are tight.

2. Piping is installed properly and all flanges are tight.
3. Relief valve is fitted and the setting is not tampered with.
4. All isolating valves are opened, (except drain valves).
5. All drain valves are kept closed.
6. Pressure gauge/Snubber are fitted and working.
7. Electrical controls are connected properly and motors are running in proper direction.

Page 4
 Before starting, please do the following:

1. Clean & flush all lines thoroughly to remove dust, dirt, etc. It is necessary to blank off
suction & delivery ports of pump, before flushing, to prevent entry of dust into pump.

2. Ensure proper rotation of motors; incorrect rotation could cause severe damage to the
pump.

3. Start motors only after decoupling from pump, to check rotation. Never run the motor
with pump connected, for direction checking, even for a few seconds.

4. Follow the instruction given for pumps, under section 'installation' of enclosed O&M
manual of pumps. Ensure perfect alignment of motor shaft.

• 5. Check operation of all valves, by passing compressed air. Ensure that there is no
foreign material blocking valve seats/ports.

6. Clean all strainer meshes.

STARTUP:

Start the main operating pump and allow oil to enter, observe the working for any
abnormalities, for a few minutes. Observe for any leaks or abnormal operation. Check that
components are operating normally. Thereafter, if all p"rametersare normal, keep the oil
inlet valves fully open, and continue normal operation. Thereafter, start the other pump in
same procedure, after shutting down first pump.

Setting of the pressure-relief valves should not be changed at site. Please refer to the
pump manufacturers manual attached.
c
• NORMAL OPERATION:

Once the system startup is successfully established, there is little manual operation
thereafter. It is only necessary to monitor pressures and flows occasionally. In normal
operation, the flow & pressure should be closely monitored, as any abnormal variation is
sign of pump malfunction.

Please refer to pump 0 & M Manuals for standard operating precautions. Ensure always
that the following DO's and Don'ts are followed without deviation. We recommend that
spares for pump/motor/accessories be procured and kept ready always, to avoid
maintenance downtime.

Page 5
 RUNNiNG PRECAUTIONS

The following precautions should be always observed, while running:

DO's:

1. Always ensure to clean the strainers regularly, especially when pressure drop exceeds
rated figures (normally about 0.20 kg/cm2 ).

2. Ensure perfect alignment between pump & motor shafts, at coupling; misalignment will
c :esult in rapid damage to pump external bearing .

• 3. Observe the pressure gauges carefully for any pressure variations. Sudden changes
may be symptom of malfunctioning (see below).

4. Always ensure that the inlet pressure & temperature to system is maintained, as per
specification, otherwise there are chances of pump cavitation taking place. Adequate
NPSH is essentialJor proper operation of pumps.

5. Care should be taken when oil is admitted into system, when system is cold, at startup.

DONT's:

1. Do not run pumps dry.

2. Do not run motors in wrong direction.
3. Do not tamper with pump pressure relief valve setting.
c 4. Do not close pump delivery line suddenly when pump is running.

• 5. Do not continuously start the pump against full system pressure .

6. Do not dummy (blank off) pressure relief valves under any circumstances.
7. Do not operate system/pumps with oil of different characteristics.

WARNING:

1. Pump should never be run dry, even for a few seconds, as this will cause rapid
wear of the pump parts.

2. Incorrect rotation will severely damage the grar pumps. Do not run the pumps dry,
even for a few seconds, to check the rotation. (This should be done only with the
pump decoupled). This is essential.

3. Cavitation may occur if:

Page 6
 a. If the suction filters are getting choked frequently. If the filters are having
pressure drop greater than 0.20 to 0.40 kg/cm 2 very frequently, then it is possible
that the pump may be getting starved of oil.
b. If the oil inlet viscosity differs from that specified (may be due to different oil
quality or lower temperatures),
c. If there is inadequate NPSH at suction point of pumps (pressure gauge fitted at
pump suction should have positive reading always).

In such a case, there will be rapid abnormal crackling or popping noise from the
pump, accompanied by severe vibration. Suction pressure gauge 8. Delivery
pressure gauge will fluctuate violently. This is a very serious condition, which will
damage the pumps & system severely. To rectify, ensure that filters are always
clean and pressure drop across them is small. It is most essential to ensure that
there is adequate NPSH available at inlet of pumps.

Note: The purpose of the suction filters is only to protect the pump, and not
primarily to strain the liquid; it is assumed that the lube oil is already relatively
clean. If oil is very dirty, or if filters are clogging frequently, some additional
pre-filtration would be necessary.

MAINTENANCE

The system is designed to be as maintenance-free as possible. The following routine

maintenance needs to be done periodically. The maintenance periods noted are for
guidance only, they could be changed depending on operating results.

TO BE DONE WEEKLY
1. Strainer mesh elements should be cleaned / replaced (if needed)
c
• TO BE DONE MONTHLY
1. Strainer mesh elements should be cleaned / replaced
2.Check flanges for any leaks & tighten if needed.
3.Check alignment of pump & motor & correct if required.

SPARE PARTS

Please contact us for the spares requirements for this system. Please indicate full details
of parts, and pump serial no., when ordering spares from us. We recommend that spares
for pump/motor/accessories be procured and kept ready always, to avoid maintenance
downtime. Please quote relevant part numbers while ordering.

TROUBLE-SHOOTING

Page 7
 ,
"""'-!C,'''''''''',,;,,"

Most of the common problems relate to pump operation, and occasionally filter related
problems.

Filter choking will be indicated by (whenever pressure drop across filter exceeds limits) by
irregular flow, drop in delivery pressure, etc, signifying pump starvation. The filters should
be cleaned by taking out the filter element. It is only necessary to clean it with kerosene or
other solvent, and replace it after cleaning, compressed air can be used to blow-dry if
needed. (Not applicable for paper elements). Paper elements should be replaced
periodically.

Operation manual of the pumps is enclosed for trouble-shooting & maintenance details.
Refer parts list as shown on part section drawings, for ordering of spares.

(. ":>Iease refer to 0 & M Manuals of components supplied by others, for standard

maintenance instructions for these items.

Page 8
 PUMPS

(
 GROUP 2P ~ P3000 SERIES
PERFORMANCE DATA
Pressures quoted are relief valve maximum by-pass
Performance with SAE 20W oil at 50G C

..... .................•
....•.......... \
.
. : -. -S·pe:£id:-at- M:a~i~~m
I· Maximinir:-C_6nffri'u"QQ$
.-.-- ,- --.'-.'-":."
COiItjilliuus
PUMI' TYPE pi'es$u.reJ'- . .... Pre$Slii~e~P-

.,
I .
' ".
..
.

(- cc/rev Ipm psi bar max min

\
3050 15.13 22.70 3000 207 3000 550
3070 21.33 32.00 3000 207 3000 550
3090 27.33 41.00 3000 207 3000 650

3105 31.80 47.70 3000 207 3000 600

3120 36.33 54.50 3000 207 3000 650
3146 44.33 66.50 2525 174 2500 650
3158 47.87 71.80 2525 174 2500 650
3220 66.67 100.00 2000 138 2500 650

TYPICAL PERFORMANCE
TYPICAL PUMP DELIVERY TYPICAL INPUT HORSEPOWER
Flow at Max. Pressure. Fluid SAE 20W
Fluid Temperature 500 C

c 200

• .s
E
140

3120
180

160

140 .

120 .
a:
w
S
0
"-
100 3105 ill
Ul
50 0:
100 0
3090
s
o 3070 80 40
I
I-
IT! 60 6"
60· 30 ~
3050
40
40 20

20
Q
tj'!nl~lE~;;J
i !
,
I
5
3
10
' 2
§ .8 §
N N ~
SPEED rev I m in PRESSURE

@2003. DynamatiC Technologies Limited I 37

 2P SERIES
INSTALLATION DiMENSIONS

..
(

..
(

i-----------i------------·-T----------:
i 2p·3220 ! 81.7 1 167.8
r~---~---~,----------· ~-~--------;
i
; 2P-3200 i 728 J 150.0 !
I----------·--l---------t---------!
2P-3180 i 69.7 [ 143.8 [
l--------r-------j
2P-3158 I 74.3 I 153.0 I
. : --------t---------i
: 2P-3146 i 72.8 ! 150.0 [

r;;;;~-~=~~.-=~=~.-,=~~~-=I
j 2p·3105 i 67.9 ! 14{).O I
i-~-·--~-·-·-i ----------1---·----·-·· .~
'I 2P-3090 I 59.1 . I 122.6 i
---.--~-~--~.-.---~-+-..---~-.-.-;
, I I i
!; 2P-3070
,I
.! 56.7 ! ._ _
,
:2!!._~
!
~2'p:3050_-----l-. __54.3 ____ ~- 2.13.:ll..___ i
L...!'UMPTYPE. __L DIM:X__.J.. __f!!~~~._J
38 I
©2003. DynamaticTechno!ogl-es LimitGd
 STAN DAm) ..
.. . .... .

NAS ISO· .........

1688 4406 .....
CONT. LEVEL 5 to 15 15 to 25 25 to 50 50 to 100 > 100

00 8/5 125 22 4 1

0 9/6 250 44 8 2

1 10/7 500 88 16 3 1

2 11/8 1000 178 32 6 1

3 12/9 2000 356 63 11 2

4 13/10 4000 712 126 22 4

5 14/11 8000 . 1425 253 45 8

6 15/12 16000 2800 506 90 16

7 16/13 32000 5700 1012 180 32

8 17/14 64000 11400 2000 360 64

9 18/15 128000 22800 4100 720 128

c 10 19/16 256000 45600 8100 1440 256

• 11

12
20/17

21/18
512000

1000000
91200

182000
16200

32400
2800

5800 1024
512

Dynamatid' recommends, the oil should be filtered during top-up and continuously during operation,
to achieve and maintain a minimum cleanliness level of ISO 17/14.

© 2003. Dynamatic Technologies Limited I 9

 Pumps equipped with splioad 2. indirect Drives
or serrated shafts and
Generally, with any indirect
occasionally parallel-keyed
side drive, the gear, sprocket or
shafts, invite mis-application by
plugging the pump. shaft pulley diameter should be as
large as possible and installed
directly into the rigidly
as close as possible to the
supported mating shaft of a
pump mounting flange to
prime mover.
minimize the side loads
This practice should be avoided imposed on the pump shaft and
as far as possible since very bearings.
high side loads can be imposed
on the pump by the mating Chain, toothed, belt, V Belt or
( gear drives can be
splines acting as an internal!
external gear unless the accommodated but allowance
concentricity of the driving and must be made for the extra
driven shafts, when under load, load these drives apply to the
is of a very high order. pump bearings.
'V' belt drives require static belt
As a general recommendation
provided the concentricity of tension, which produces poor
bearing alignment. The static
the female drive spline or
tension which is dependent
serration is within 0.005 ins
upon maximum pump pressure
(0.13 mm) T.I.R. of the female
location spigot, the plug in and speed, and can generally
only be set approximately,
drive arrangement will be
cause the drive shaft to be tilted
acceptable. Where plug in
across the running clearance of
drives are to be used detail
the front and rear bearings
drawings ofthe components in
when operating at low
the drive train should be
pressures. The shaft will only
submitted to our Technical
run with correct alignment
Sales Department for approval,

c before use. when the moments due to the

hydraulic loads are greater than

• those due to the belt tension .

With all indirect drives, whether
gear, chain Or belt, their
suitability can be established by
calculation of the loads
imposed on the drive shaft.
Other variables such as pump
size, operating pressure and
drive attitude have an influence
on bearing loads therefore in all
cases where these types of
drives are contemplated please
consult our Technical Sales
Department giving full
application details, before use.

All dimensions are in mm, unless otherwise specified.

8 i@2003. Dynamatic Technologies Limltad

 now (of course, the volume for
rams and actuators must be
allowed for by providing
adequate air space and
breathing).
The pump suction line should
draw oil from a point not less
than 100 mm above the tank
bottom to avoid sludge
deposits from entering the
pump. The return line should
c be submerged to limit frothing
•
of oil. The suction and return
connections should be
positioned as far apart as
possible and separated by
baffles, so that oil circulation is
promoted within the tank to
assist convection cooling and
allow air entrained in the oil to
dissipate.
Filtration
The fluid should be filtered
during top-up and continuously
during operation, to achieve
and maintain a cleanliness level
of ISO 17/14.
This recommendation should
be considered a minimum.
(
•
Better cleanliness levels will
significantly increase
component life.
Fluids
Most premium grade mineral
oil based hydraulic fluids are
suitable for use with
DyriamatiC'Gear Pumps. A
primary consideration in the
selection of Hydraulic Fluid is
expected oil temperature
extremes that will be
experienced in service. When
choosing the hydraulic fluid,
these tem peratu re extremes
must be considered 10 obtain
the most suitable temperature-
viscosity characteristics. For
optimum performance, the
viscosity should be maintained
in the 97 - 456 SUS (20 - 100
CST) range. Limiting viscosities
of 4545 SUS (1000 CST)
maximum and 52 SUS (8cST)
minimum should not be
exceeded. It m ay be possible in
some applications to run on
other types of special fluids
contact DynamatiC" for more
details, before use.
Operating Temperature
Range
The pumps are designed to
operate between 0 deg and 80
deg C. intermittent
temperatures may vary
between -20 deg to 100 deg C if
the fluid being pumped is
suitable for such operations.
For higher temperature
applications, contact
DynamatiC' for more details,
before use.
© 2003. Dynamatic Technologies Limited
Pump Drives
1. Direct Drives
Drive to the pump shaft must
be arranged so that the shaft is
relieved of all side and end
loads.
A flexible coupling should be
seleCted to allow a minimum of
0.010' (0.25 mm) radial
displacement and should
impose little or no end load on
the pump shaft. (Not all
, flexible' couplings, especially
of the bonded rubber types,
allow complete radial or axial
freedom and should only be
used if alignment is good). The
table below gives the approved
types of drive.
Approved Drives (basic
pumps):
> UCC coupling (Crowned
100th gear couplings)
> Renold Chain Coupling
> Quill shaft ( The spline must
allow sufficient radial
movement)
> Turboflex & Hardy Spicer
(Must use two couplings to
provide radial alignments)
Note: Both Hardy Spicer joints
must be fitted such that the
pump shaft rotates uniformly
and large angles should be
avoided on the connecting
shaft.
Hardy Spicer type drives often
incorporates splined
connections to accommodate
plunge motions. Under torque
these splines tend to lock up
and many transmit intermittent
end loads on the pump shaft if
the prime mover can move
relative to the pump.
I 7
 . APPUCATIOI\J DATA
DRIVES
Use of flexible coupling is
recommended to
accommodate any slight
misalignment of shaft and to
dampen vibration.
The user should work closely
with the coupling manufacturer
( in selecting and ap·plying a
suitable coupling. Drives
should be arranged so that the
shaft is protected from all axial
and radial loads. The coupling
should allow a minimum of
0.25mm radial movement and
should impose little or no end
load. Splines must allow
sufficient radial movement.
A large angle between the drive
and connecting shafts should
be avoided (10' max.). Splined
shaft units may be plugged
directly into a rigidly supported
mating part, only if the
concentricity between the
female spline and pilot
c diameter is better than 0.12 mm
•
T.LR. In case where
manufacturing tolerances
exceed this figure, the
application should be referred
. to our Technical Sales
Department. When flexible
couplings, gears, Vee or
toothed timing belts are to be
used, the coupling half, gear or
pulley, should be secured to the
drive shaft.
If this is not possible,
continuous lubrication to the
shaft must be provided to
maintain maximum life. This
can be done by flooded
lubrication, oil mist lubrication
6 I © 2003. DYnamatic Technologies Limited
or by applying a molybdenum
disulfide based grease during
initial assembly.
Side loads by indirect drives
can be accommodated, but
allowances must be made for
the extra side load that these
drives impose on the pump
bearings. In general largerthe
gear, sprocket, or pulley
diameter and the closer this is
to the pump-mounting flange,
lesser the load on the bearings.
However, the loading must be
carefully calculated and should
be referred to our Technical
sales Department.
Both parallel and taper shaft
units are supplied with a shaft
key. The parallel shaft keys
must be hand-fitted when the
coupling is assembled. On no
account must the key or
coupling be fitted, or removed
by hammering or levering. This
will damage the pump
intemally.
Mounting
The pump may be mounted in
any position. The units are
supplied with a wide variety of
mounting flanges, having a
spigot for location. The fixture
that receives the mounting
flange spigot should have 1mm
x 45' chamfer to ensure proper
installation. To minimize
vibration, which can be
transmitted to the pump bV
rigid pipe runs, it is good
practice to use flexible hose
immediately connected to the
unit ports.
Rotation
Shaft rotation is denoted in the
unit coding. Inlet and Rotation
arrows are stamped on the unit
body. Direction of rotation is as
viewed from the drive shaft end
(see coding chart).
Pump Suction Line
The suction line must be as
large as possible and should be
free from sharp bends to
prevent excessive suction head,
which should in no case exceed
190 mm of mercury (0.24 bar)
below atmospheric pressures.
The system should be designed
to prevent entry of air and a
positive head of oil should be
maintained wherever possible.
Lower pressures during cold
start- up conditions are
permissible for short periods.
As a general guide, fluid
velocity in the pump suction
line should not exceed 2 m/sec
for pipe lengths upto 2 meters.
If longer suction runs or higher
velocities are contemplated,
contact Dynamatic®before use.
Oil Reservoir
As a general rule of thumb, the
reservoir capacity for industrial
applications should be three to
five times the open loop flow
per minute being drawn from
the reservoir. For mobile
applications, the reservoir
should be sized for not less
than 0.75 times the open loop
 PERFORMANCE THROUGH RFVOlUTION
Dynamatid' has a complete
range of gear pumps for both
mobile and industrial market
segments. Dynamatic@
developed these pumps in
technical collaboration with
achieved by pressure loading offluid, independent of
precise areas of the bush rear operating conditions.
face ""ith fluid at working
pressure. Special features are
incorporated in the bush
Durability
sealing face to compensate for High tensile aluminum alloy

.,
DOWTY Hydraulic units operating variables such as bodies are used throughout the
Limited, U.K. pressure, speed and range to ensure uniformity'in

c Complete Range
DynamatiC" gear pumps are
available in four frame sizes
giving displacements from 0.80
cc / rev. to 151.33 ccl rev.
Pumps are also available in
Tandem Configurations and the
company specializes in
supplying units to special order
instructions (subject to
quantity) including multiple
section pumps.
High Efficiency
High volumetric efficiency
produced by DynamatiC"
c pumps are achieved in part by
temperature. The DynamatiC"
pressure balancing system
ensures a minimum net load on
the bush bearings for high
mechanical efficiency, while at
the same time varying the
pressure distribution across the
bush faces with the change in
system pressure, thus
contributing to high volumetric
performance.
Performance
DU lined I bimetal bearings are
used to sustain high journal
loads when operating at 210
Kglcm' and speed upto 3500
RPM. Dynamatic® has
developed special journal
surface finishes and treatment,
material properties and
maximum fatigue strength .
Through - body bores enable
precise alignment of the
bearings and hence maximum
bearing load capacity. Careful
attention to machining details
and surface finishes, holds
wear rates to a minimum and
promotes an extended
operating life.
DynamatiC" Pumps have been
designed to perform with a
wide range of fluids and can be
supplied with either Nitrile or
Viton seals as standard.

•
careful attention to the control
of gear tip leakage. The body to
gear geometry is arranged such
that during the running-in test
cycle, to which every unit is
subjected, the gears cut
perceptible tracks in the body.
These results in virtually zero
clearance between the gear tips
and body producing a near
perfect tip seal under running
conditions.
Floating composite bushes are
used in DynamatiC" pumps,
which house the bearing liners
and provide a face seal to the
gears. This efficient seal is
to obtain maximum benefits
from these bearing
configurations.
Lo"" pressure bearing
lubrication is a feature of all
DynamatiC" Pumps. This is
achieved by utilising the
expression generated when the
gear teeth separate to draw
lubricating fluid from the inlet
port and along each bearing
journal by way of passage in
th'e composite bush. This
proven system ensures efficient
cooling and lubrication of the
bearings with a constant supply

© 2003. Dynamatic Technologies Limited I 5

 ENGINEERING 1
RADIAL PISTON PUMP
1RC Ref. No. 1"0<1892
Release 07/2004

Description

Radial piston arrangement, with 3, 5 or 7 pumping

elements. Oil immersed or external mounting type.

Face mounting, Valve controlled, Fixed delivery.

Si-directional rotation of shaft. Available with extension shaft

for through drive.

With extension bracket assembly for coupling a

low pressure pump having standard flange.

Section

Hydraulic Symbol

P S
Delivery Suction

Unit Dimensions
Dimensions in mm.

149 -

Air Bleeding Port

G3/8

ITF 1
~' ,
rT"
t-l
7310 _
r-
60~

Casing Plug
Bleeding Air
( 1OAlF) '"fU r
N
0
0

0
45 +
'"
'" -
f-
'"
j ~~
I- e- - -
! I
f-

~
M8x 1.25 tap, l '~+i
'
Tightening torqL.!e
12 deep. f 5 kg-m
on PCD 80 Suction Port
G1/2
Phone +91-(0)831-2411001
Polyhydron Pvt. Ltd. Fax +91-(0)831-2411002
78-80, Machhe Industrial Estate, Machhe E·mail polyhydron@vsnl.com
Belgaum - 590 014. INDIA. Website www.polyhydron.com
P04892
 I' p[dqhlljdf'~lrl
'_._-" -....,."
:rl.' 'lj:l

RADIAL PISTON PUMP

ENGINEERIN~--:;-

'~H"l"'~~i'lr@r-,;:,--,~t!tw' . 1RC Ref. No. 1"04892

Technical Specifications

Designation .................................................... 1RC basic radial piston pump group

Design ............................... , ........................... Radial piston, valve controlled
No. of pistons ................................................. 3,5 or 7 ; depending upon the flow requirement
Mounting ........................................................ Face mounting
Direction 01 rotation ............. 1RC .................. Can be run in either direction
1RCE .............. Depends upon the direction of rotation 01 pump attached.
Connection ............... Suction ......................... G 1/2 female. Suction head - The oil level can be max. 300 mm
below the suction port 01 the pump. Suction
pipe size - 16 o. d. x 3 th. (as far as possible use straight pipe)
Delivery ........................ G 3/8 female.
Suction pressure ............................................. 0.02 to 3 bar positive.
Speed range .................................................. 300 to 2000 rpm.
( eYdraUlic medium .......................................... Mineral oil
iscosity range ............................................. 10 to 100 eSt
Temperature range ......................................... -10 'C to +80 'C .
(Do not exceed viscosity limits at extreme temperatures
for efficient running ofthe pump)
Fluid cleanliness requirement ...... , ................. ,. As per ISO Code 16/13
Performance .................................................. RelerTable No. 1
Mass ............................................................ 14 kg .
Table No. 1
Code Geometrical Rated ouIput Cperating Input fXl- requirerrenl(@l450rpm)
No. displacement a! 1450 rpm. pressure 50 bar
100 "'"" 150 "'"" 200 bar 250 bar 300 bar 350 bar 400 bar 450 bar 5OOba- 550 bar
CC/REIl (11 mnl bar K-N Hp K-N !-4J K-N !-4J K-N Hp K-N Hp K-N Ii> K-N Ii> K-N Hp K-N Ii> K-N Ii> K-N Ii>
3A 1.21 1.5 550 0.17 0.23 0.3 0.5 0.5 0.7 0.7 0.9 0.9 1.2 1 1.4 1.2 1.6 1.4 1.8 1.6 21 1.7 2.3 1.9 2.5
SA 201 26 550 0.29 0.38 0.6 0.8 0.9 1.2 1.2 1.5 1.4 1.9 1.7 23 2 27 23 3.1 2.6 3.5 2.9 3.8 3.2 4.2
7A 281 3.7 550 0.4 0.54 0.8 1.1 1.2 1.6 1.6 22 2 2.7 24 3.2 2.8 3.8 3.2 4.3 3.6 4.8 4 5.4 4.4 5.9
38 1.88 2.5 450 0.Z7 0.38 0.5 0.7 0.8 1.1 1.1 1.4 1.3 1.8 1.6 2.2 1.9 25 21 29 2.4 3.2
58 3.14 4.2 450 0.45 0.6 0.9 1.2 1.3 1.8 1.8 2.4 2.2 3 2.7 3.6 3.1 4.2 3.6 4.8 4 5.4

.78 <lA 5.8 450 0.63 0.84 1.3 1.7 1.9 2.5 2.5 3.4 3.1 4.2 3.8 5 4.4 5.9 5 6.7 5.6 7.5
3e 271 3.7 350 0.38 0.52 0.8 1 1.2 1.6 1.5 2.1 1.9 26 2.3 3.1 2.7 3.6
se 4.52 6.2 ·350 0.84 0.00 1.3 1.7 1.9 2.6 2.6 3.5 3.2 4.3 3.9 5.2 4.5 6
7C 6.33 8.6 350 0.9 1.21 1.8 2.4 2.7 3.6 3.6 4.8 4.5 6 5.4 7.2 6.3 85
3D 3.19 4.3 300 0.45 0.61 0.9 1.2 1.4 1.8 1.8 2.4 2.3 3 2.7 3.6
50 5.31 7.2 300 0.76 1.01 1.5 2 2.3 3 3 4.1 3.8 5.1 4.5 6.1
70 7.43 10 300 1.06 f42 21 2.8 3.2 4.3 4.2 5.7 5.3 7.1 6.3 8.5
3E 3.69 5 250 0.63 0.7 1 1.4 1.6 2.1 2.1 2.8 26 3.5
SE 6.16 8.4 250 0.88 1.17 1.8 2.4 26 3.5 3.5 4.7 4.4 5.9
7E 862 11.7 250 1.23 1.84 2.5 3.3 3.7 4.9 4.9 6.6 6.1 8.2
3F 4.24 5.8 200 0.6 0.81 1.2 1.6 1.8 2.4 2.4 3.2
SF un 9.7 200 1 . 1.35 2 2.7 3 4 4 5.4
7F 9.9 13.6 200 1.11 1.89 2.8 3.8 4.2 5.7 5.6 7.5

Note: The first digit in the code No. indicates No. of pumping elements in the pump. The second letter indicates flow and pressure
rating of the pumping elements.

Code No. 7D for example, indicates a pump with 7 pumping elements having rated flow of 10 1/ min and operating pressure
upto 300 bar.
I
P04892
 ENGINEERING 3
RADIAL PISTON PUMP
iRe Ref. No. 1"04892

Accessories
Extension shaft (for through drive)
Dimensions

08.5 drill, 20 deep,

," H<t,
' M10x1.5tap, 17 deep,
2 nos.
o

N
00
Q

c
• L
.~-I-~
' ~

S9 - - " ' - - - - - 156 clc - - - - '

Note: Torque limitation - The sum of torque used for the piston pump and torque
used at extended shaft end should not exceed 75 Nm (11 kw at 1450 r.p.m.)

Ordering Code

liRe I El 5 I B :·28

30 For 3 Element pump.

Radial piston pump, Fixed delivery,
Closed Execution,With casing
With Extension Shaft
Omit if not required
28 . For 5 & 7 Elements Pump.
-
Design code subject to change.
lE InstalIation dimensions remain same
for design code 28 thru 39

Flow &pr rating of

i No.of pumping elements I pumping elements
7 I
3 I 5 I ( Ref: Table No. 1)

Note: For Bell housing refer sheet no. P09035.

For Extension bracket sheet no. P09090.

P04S92
 ENGINEERING 4
RADIAL PISTON PUMP
1[:;(C Ref. No. P!l4892

Priming Requirements for closed Execution PUMP

A] When the Casing Pump is mounted Horizontally

Case 1 : When the pump suction port height exceeds 300 mm above oil level.

During assembly 1installation provide a check valve with low or almost nil cracking pressure on the suction pipe and
fill up the casing with oil (UseAltemateSuction port- G1/2" BSP) before starting the pump. To be on safer side, keep
the Air bleeding port open till you get full luninterrupted flow. As soon as you get the uninterrupted flow, switch off the
moior & plug the Air Bleeding port. While bleeding connect Hose pipe (Plastic pipe) of Minimum 12 mm. 1.0.

Case 2 : When the pump suction port height is less than 300 mm above oHleve!.

The pump need not have a check valve as mentioned above. During commissioning the Air bleeding port should be
kept open till you get full 1uninterrupted ftow. Priming is not required to be done every time you start the pump after
short durations (a day or two) of non-operation .

• When the Casing Pump is mounted Vertically

Case 1: When the casing pump is immersed in oil.

. Remove the altemate suction port plug (G1/2" BSP).

Bel! Let the oil to enter Aluminium casing. Now loosen
the casing air bleeding plug, by rotating it 3 to 4
times. Wait for a while so that the complete air
Casing air
bleeding plug Oil level goes out through casing air bleeding plug.

c=;"rn-----.+--r~- L
(10 AIF
- Now, tighten the casing air bleeding plug and also
plug the alternate suction port. Now start the motor
& you will get an uninterrupted flow.

suction port
( G1/2")

.Aase 2 : When the oil level is below the suction port (Le up to a distance of 300mm. Maximum).
.. OilfiHing
pla!e.
port plug In this case, put a check valve of negligible crack-
Fill the oil
from here ing pressure at the bottom of the suction pipe.

Nowfill the pump casing with oil. This can be done

Bel!
by providing a pipe connection to alternate suction
port and bringing the other end at the top of the
Casing air Tank Top Plate.
I
Now loosen the casing air bleeding plug & keep on
filling the casing till you see the oil comming out of
~lrF~r-l----"~~I=~_IDelivery
~I Port
casing air bleeding plug.
( P)
After this tighten the casing air bleeding plug. Also,
plug the oil filling port & check it to be air tight. Now
-~;h..--Che.ck valve start the motor & you will get an uninterrupted flow.
suction port
( G1/2")
Suction
strainer
I

P04S92
 '_~~7XSF j,_~ _~, SERVICE :;

Fu:~!~h~dn~n RADIAL PISTON PUMP

'\r@O"'''''fWx-'Yw:::J- iRe Ref. No. P()4S92

Sectional view and Part list

3
/'
20

Hydraulic symbol

17

27

_ - Fori RCE

Suction Port
G1/2
( Alternate )
23

Delivery Port
G 318

Suction Port
G1/2

Air Bleeding Port

G 318

P04892
.~'Pi~~;:;k~n
'
RADIAL PISTON PUMP
SERVICE
I 6
l
\Sil:i~'Gf~1Z-r~~~~7 "iRe Ref. 1110. 1'04892

J
1RC3 i1RCE3 1RC517 1RCE 5!7
SLNo. Description Part No. Size Qty. Part No. Size I Qty
1 Valve plate 11204 1 11209[11212 11209[11212 1
2 Cover plate 11224 1 11228[11230 11228[11230 1
3 Shaft 11242 I 11243 1 11242 11243 1
4 Balancing Plate 11251 2 11252 2
5 Casing Ring 11232 1 11232 1
6 Bottom Bearing 11261 KOYO 6404 1 11264 6404 1
7 Centre Bearing. 11262 NUP 2206 1 11265 NUP 2206 1
8 Top Bearing. ! 11266 NJ 304 ECP 1 11266 NJ 304 ECP 1

- I ---
9 End cap I 11255 062 I 1 11256 I --- 062 I 1
10 Cap screw i 11271 Ml0x55 L 6 11271 Ml0x55 L 10114
11 Circlip 11285
047_~ype B)-++ 11285 047 (Type S) 1
12 I Circlip --- 11286 062 (Type S) 1
13 Shaft Key 11293 I 6x6x36 1 11293 6x6x36 1
14 Shaft Key --- J 11294 6x6x36 1 --- 11294 6x6x22 1
15 Label ( Caution) 11282 11282 1
16 0' Ring 11287 I --- 54x4
+...t.-+
1 11288 --- 54x4 1
17 O'Ring 11290 189x3 2 11290 189x3 2
, 18 Rotary Shaft Seal 11278 Dou. Lip 47 1 11278 Dou. Lip 47 1
, 19 Rotary Shaft Seal --- I 11278 Dou. Lip 47 1 --- 11279 Dou. Lip 62 1
20 Plastic cap 11283 1R 1 11283 1R 1
21 Plastic cap --- I 11284 1R 1 --- 11284 1RE(Shaft) 1
22 Elastomenc Plug 00203 G 3[8 1 00203 G 318 1
23 Elastomeric Plug 00204 G 1[2 1 00204 G 1[2 1
24 Bonded Seal 00160 G 1[8 6 00160 G 118 10[14
25 Rivet 00001 02,4.5 L 2 00001 02,4.5 L 2

• 26
27
28
29
30
Rubber Port Plug
Rubber Port Plug
Hex Plug
Copper washer
External Circlip
·00012
00013
11299
11297
00065
G 318 Plug Cap
G 1[2 Plug Cap
M6x16
06.5x09.5x1
Dia.4 Nom.
1
1
1
1
1
00012
00013
11299
11297
00065
G 3[8 Plug Cap
G 1[2 Plug Cap
M6x16
06.5x09·5x1
Dia. 4 Nom.
1
1
1
1
1
I I

SLNo.

31
DeSCription

Pump element assly.

(Refer Data Sheet
No. 011100)
T I
~ R-A-01 [
Product

1R-B-01 [ tR-C-01
1R-D-01 [ 1R-E-01 [ 1R-F-01
i'
1 RC*3
Qty.
1 RC'SI7

5[7

All rights reserved.

Subject to revision.

P04892
 MOTOR

(
 INSTRUCTIONS FOR
INSTALLATION
AND
MAINTENANCE OF
ELECTRIC MOTOR
(

(
 CUSTOMSR S~FeT'f'r~NSTRLI_1JIONI&
lNSl'Al.tA10·ION···CHSe·RUST

CAUTION.
All operations must be carried out by appropriately trained
personnel. For fufl Installation and maintenance instructions
referthls book thoroughly or consult the supplier, jf in doubt.

·UFT.NG:
1. Use all lifting facilities provided - Both lifting points if fitted
or single lifting point if fitted. Do not use any other part of
the motor for lifting,
Note: Maximum handlift is 20 Kg below shoulder, but
above ground level.
2. Vertica/llfting - prevent uncontrolled rotation of the motor.
3. Do not lift other equipments with motor lifting pOints only.

MAXIMUM WEIGHTS: (Unpacked)

c
ill ill ~ g
Weights
in KG ~ ~ ffi
Frame size
IEC 63 71 80 90 100 112 132
NEMA 56 145 184 215

/2~O\ /5~O\ /1~0\ /1~OO\ /2;00\ /3;00\

. Weights
in KG
Frame 160 180 200 250 315 355
size IEC 225 280
Frame 256 286 326 405
size NEMA 365
INSPBCTIONONRE.CEIPT:
1. Makesuretherlghtmotor is receIved.
2. Check for transit damage.
3. If necessary, please open packing case in presence of
an authorised Insurance Agent.
4. Please report damages to us giving complete
Nameplate details.

STORAGE:
1. Ensure motors are stored in a place with an ambient
range of -20°C to + 45 ° C
2. store motors under shade and not in open.
3. Ensure that the stored motor does not receive any
harmful vibration.
4. Ensure no water drips on motor and no water logging under
the motor.
5. Energise heaters if fitted.
6. Ensure all plugs originally provided are in place (e.g.
Cable entry hole plugs, drain plugs & fan cover greasing
hole plug for TEFC motors.)

PERIODIC Every Rotate shaft

REQUIREMENTS 1 Week

Every Check insulation

3 Months resistance.
If less than
10 M.Ohm, dry out.
 PRE..INSTALlAT10N CHECKS:
Ensure TICK WHEN CHECKED
1. Motor not corroded excessively. D
2. Fancover not damaged Of touching fan. o
3. Foot not broken or cracked. o
4. Shaft not damaged/bend. o
5. All fasteners are tight o
6. Check all the name plate details. o
7. Check free running by hand. o
8. Check grease condition if motor is idle for
more than 6 months. If bad
o
replenish with fresh grease.
9. Add LUbricating Oil in the oil seal o
(If provided).

INSTALLATION - MECHANICAL:
1. Level mounting surface. Clean mounting D
foot/flange & shaft of the motor.
(, 2. Check mounting plane, Add shims if 0
necessary (Maxm. change of indicator
reading - 0.075 mm with mounting bolts
loose & tight - while checking mounting
surface w.r.t. motor foot/flange.
3. Check for any misalignment in motor & 0
drive shaft. (Approx. TIR - 0.050 mJ
4. While mounting use appropriate fasteners 0
& tightening torques.
5. Check all the gaskets, sealants & guards 0
are correctly fitted.
6. verify belt tension. 0
1. Ensure power supply system is grounded. [1.
2. Ensure proper earthing. D
3. Check insulation resistance of all windings D
with 500V de megger. If < 10 MOhm, dry
out following proper procedure.
4. Ensure the equipment is fused and D
isolated correctlv.
5. Ensure all the covers are fitted and D
interior of terminal box is clean & free of
cable residues.
6. Seal unused cable entries. D

CONNECTIONS:
1. Check connection diagram and ensure D
correct terminal arrangement.
2. Ensure all the connections are tight and clean. D
3. Ensure air clearance between live & live to D
earth> 10 mm. '\;

4. Check driven equipment is free. D

5. Check rotation, uncoupled. D
6. Ensure rating of fuse, setting of protecting D
devices are correct.
Recommended protections:
Overload, Single Phasing, Under voltage,
Earth Fault.
7. Ensure space heater (if provided) is off D
while starting the motor.
 ···tt> Lt>AD:
aUa$;;p~t "'an1eo.late;& o
·w1~)~r1~~k~~~L
by ·deratin~ faytor·flrom,·thegrapn.
1.0"-·-r-..".-,,--.,.--r----,-.,.--,-....-.,.~~
(
0.9 I-+-+-+--+-"k-t-+-+-+--t----l

0.8 1-+-+-+-+-i-+-+-4>.+--I---i

0.7 '---'---'--'---'-L-L--'----'--'--.L...-I
o 1 2 3 4 5
% VOLTAGE UNBALANCE

2. Check three phase currents at No Load D

(Free Shaft>.
Note: The currents will be more if the voltage
is more. They will be less if the voltage is less.
c. The increase & decrease will not be in linear
proportion with voltage.
3. No abnormal nOise. (Use a screwdriver as a D
medium to hear.)
4. Bearing not heating up abnormaliy. o
5. Check direction of rotation. If specific. o
6. Check vibration. Nibration level on the
mounting structure immediately below the
o
motor should be within 30% of horizontal
vibration level at the bearing housing)
RW~~ING ON LO:AD
1. Ensure rated voltage at the motor D
terminal durlngstartup and Che.ckstarting
time within deSigneCflimit.{Any normal
applicatIon, the time reClulrecfWill Hotoe
more than 5 sec.atooL For high inertia
load the starting time is longer but$peOial
deSi~n is required to cater this. For star/delta
& reduced vOltage starter the time will be
longer than that in DOLL
2. Ensure Full Load Currents are balance in all D
phases (Maxm. unbalance 8% corresponding
to 1 % unbalance of voltage) and the value is
within Nameplate Data, In case of pulsating
load we recommend the maximum current to
be within Nameplate value.
3. No abnormal vibration. (If change in
vibration level is observed, check alignment
o ,:

···
.

again preferably in hot conditionJ I··.··

4. No abnormal noise.
5. Check maxm. air inlet temperature =
Ambient temperature mentioned on Nameplate
D
o \
6. No abnormal heating up.
Total permissible temperature including
o
ambient for Class B rated motors are
approximately as fOllows:
By Thermometer : At Eyebolt : 90°C
At Bearing Cover: 80 C
On Slipring Surface: 90°
Check the temperature after 4-5 hours of
operation, when it is stabilised. D
7. Check no sparking is appearing on the
 PROBLEMS:
NoiSY
Vibrating
Tripping Refer to supplier with Machine no.
Overheating
Not starting
(
MAINTENANCE:
While carrying out maintenance
1. Ensure that the motor is isolated.
2. Referto supplier, if in doubt.

SPARE PARTS:
While ordering Spare parts, always quote Machine Number
and Reference number which will befound on the Nameplate.
Please use only genuine spares.

HAZARDOUS AREAS:
If motor is marked with "EX" symbol, special conditions apply
Refer appropriate installation manual and relevant standards.A
operations are to be carried out by appropriately traine(
personnel.
This Motor. h.a$IQa~rt
hig h stafjd~lrd (j.r:~X@i
standardS as menti;
The motorrs SO~Jl'1Id~!n !lel;i.~flatt(1if:OPI~$til'1l(~~I1$tn
glvesatiSfactcJp/setVlce with COI'I~e(~t
routine maintenance.

SITE
Check for proper ventilation. TEFC Motors should be
provided with at least 2" gap between fan coverand
nearest barrier.
Install DP Motors at a clean dry place.
Check for ambient conditions, if special treatmenton
motor is provided for adverse ambient.
Ensure passages in-between ribs in TEFC Motors are properly
cleaned.

FOUNDATION
The foundation of the motor should be preferably of
concrete, or structural steel, and must be sufficiently rigid to
minimize vibrations and to maintain alignment between the
motor and the load. Normally a mixture of four parts of stone
and two parts of sand and one part of cement by volume is
suitable.
 , .

~afam~~C! {with halfKeVfPully /

balanoed wIth haff

FUF {htrrlrh'ifl"moqnt belt nearest to motor bearings.

se~'llHEav dlan'teter and coupling I pulley bore as

ronows:
PULLEY DIMENSIONS (mm)

TOLERANCE ON BORE DlA-OF

PULEY & COUPLING (H-7)

FRAME MIN MAX FACE

IEC NEMA DIA WIDTH NOMINAL TOLERANCE
63 75 30 18 to 30 +0.0
71 75 40 +0.021
80 75 50 30 to 50 +0.0
C
I<)
90 145 75 63 +0.025
100 75 80 50 to 80 +0.0
112 184 100 100 0.030
132 215 120 125 80 to 120 +0.0
160 256 150 177 0.035
180 286 180 203
200 326 187 280
225 365 197 330
250 405 228 380
280 375 380
315 400 380
355 500 400
STARTING
squirrel cage Motors are suitable for DOL, Star/Delta or Auto
Transformer starting.
Slipring motors Should be started by statorl rotor starter with
suitable external resistance in rotor circuit which should be
cut off grad ually when motor pi cks up speed.
In case of star/delta starter, put to 'Delta' when the motor
picks up fully In 'STAR' position.
While operating on load & the motor is hot, the motor is
suitable for 2 starts in one hour, unless it is designed for
higher number of starts.
In case of Slipring starters, ensure the current and voltage of
the starter are same as specified on the motor name plate
(RV & RA)

PREVENTIVE MAINTENANCE:
Motor should be kept clean and free from oil, dust and mOisture.
Care should be taken to see that ventilation passages are not
blocked. The earthing conductor should be regularly inspected
and checked for continuity. The insulation reSistance of stator
and rotor windings should be checked regularly between
respective terminals and the frame.
In case of slipring motors, carbon dust should be blown out
regularly from sliprings and brushes. The pressure on brushes
and wear out should be checked.
, '.

Tl11ielt1eaI'in~Jsmarl<ed'ZZ' Or '2RS' are sealed for life and

·reqUJreno lubrIcation .
.- ::-. .-

. ···Forgreased bearings: .
1. Check relubrication interval on name plate. The
regreaslng interval should be shortened for high ambient
temperature, presence of corrosive vapours or extreme
level of contamination.
(
2. For replenishing fresh grease in the bearing:
. Quantity of grease to be filled in bearing
(in gmsJ= Bearing bore dia.
o Fill1/3rd of bearing cover cavities with grease.

Recommended grease is lithium based grade - 2. MIXING OF

DIFFERENT GREASE SHOU LD BE AVOIDED.
While removing the bearings from the shaft, use properly
designed draw-off tackle or puller to hold the bearing
preferably at inner race. While pulling out the bearing, rotate
the bearing to avoid damages if the bearing is intended to be
used again.
Bearing should be re-fitted on shaft after heating upto
approximately 90°C and by slipping on to the shaft.
 l-e

AI Fe

T'(p

63
Bolt dla

MS
Nm

6·7
Lbf.ft

4-5
Bolt dla Nm LbUt r
i
i
71 MS 6'7 4-5
80 Mstap;tlte 24-25 111-19 . I
90 M8~p.tlte 24-25 18'19
100 MBCOrflex 52'$5 24,2£ M1Q ;.52 38.
112 M8cOrfl~x 32-35 24-2£ M1.0
.'
.52 38
132 MScor.flex 3%f55 24':26 1\112 90 66
160 M1.Q &&72 S0.53 M1. $ 220 162
180 M10 6&72 50.53 ·Mte 220 .162

I
ENDSHIElD FIXING i;'-

AI Fe

T'(p Bolt dla Nm Lbf.ft Bolt dla Nm Lbf.ft

63 M4 1-5 1.1
71 M4 'H 1.1
80 MS 5 3.7 MS 5. 5.7
90 MS 5 3.7 MS 5 5;7
100 M6 taptfte 1>-10 &7 M6 6 4
112 MS taptlte 8-10 6-7 M6 S 4
132 M6tapttte 8-10 6·/ M8 16 12
160 Mstaptlte 29 21 M8 16 12
180 Mi0 taptlte 52 38 MiD 31 22
 DATASHEET FOR AC DRIVE MOTOR

> PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM

CLIENT P.O NO. : BHEL-LSHS/16725 DATASHEET REF : ES-296!LOS/ACM
PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 01 of 02

SI. NO. ITEM

A. GENERAL
to Tag No 321-LOA-1A, 321-LOA-1 B, 321-LQA-l C & 321-LQA-1O R-1
2.0 Quantity 4 Nos

! 3.0
4.0
Make
Type
Crompton Greaves Lld
3ph, Sq TEFC Induction Motor
5.0 Type of Starting DOL
6.0 Rated Output i<JN I HP 3.7 i<JN I 5 HP /
bI' APPROVED
I APPROVED SUBJF..CT TO COMMFlJ1S PROCEED
B. Design and Performance Data o WITH MANtJFACTURE BASED ON CO~~MENT3
REVISE: ArID RE$UBM1T.
1.0 Frame size &type designation E112M NOT .t.PPRovED. DOCUMENT DOES Nor CO~f.l,RM
o
2.0 Type of duty Sl
BASIC REGUj~MENTS HEViSr: ..:>NO R~;SU!l"ilT FOR
APPROVAL. \ 'll •
n/

\S!g.._;~;~~;~;~;~~~ !NDI;; ~'::T·:~~~;f.~~;··Q·

A .

, 3.0 Rated Voltage 415V±10%

4.0 Penmissib!e variation for I APPROVl".l. ACCIJHlJEO BY THE- ?UROIASER IS liMITED- ONLY :>00 THE
COMPAnS!lITY WitH THE LAYOUT. IT DOES NOT AUTOMATICAllY ABSOlve THE
CONTRACTOR Cf HIS RESPONSIBILITY FOR THE CORRECTNESS Of DESIGN
4.1 Voltage 415V±10% oETM., MANUFACTURE ANO SATISFACTOR'i PERfORMI~••"CE Ot= THE EQUIPMENT
... - -
, 4.2 Frequency 50Hz± 5 %
4. 3 Combined voltage &Frequency ±10%

, 5. 0 Design ambient temperature 45deg C

6. 0 Temperature Rise (R) 70deg C [" 'OooM"".,~, '" "~
7.0 Synchronous speed & Rated slip 1440 rpm
8.0 DOL of Starting Current 600%FLC lfu",_~~;e>l'. t"t, tt·o~r
9.0 Starting Torque 200% FLT ,~~Sf?:N8~~~_~~:~~:~~f~~~~~~~~:' LTD.!
pJ6<c)£ .j,(.th 'If 6;'A dwrr foy rYt f./i "J1} y~
,,
-
SUBMtTIE:!JTO- :·f'tSMtDTItMtNE:RAtSPI;lTtTD-----------·----··--·- .•.....•... _-_...._...... _.._... _.- .•.- ._... --- - .. ..--.-...--'...

SUPPLIED BY : PSI ENGINEERING SYSTEMS PVr LIMITED .

CLIENT : FLSMIDTH MINERALS PVT LTD. .'

. .........1 ..... - . . J.t,lt-2008.• ... ---.. - . .,. _ITEM£EORAPflROVALS. ... .. .. -...... - ... ..... R..G . ........ - ., - .. .... R-M_ ..._.
REV DATE DESCRIPITION PREPARED BY CHECKED BY
I
 DATASHEET FOR AC DRIVE MOTOR

I
PSI JOB NO I! : ES-296 EQUIPMENT : LUBE OIL SYSTEM
CLIENT PO NO : BHEL -LSHSf16725 DATASHEET REF : ES-296fLOSfACM
PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 02 of 02
SI.NO. ITEM

10..0 Noise level a 1.0 m (dB) As per IS 12065

11.0 Amplitude of vibration As per normal class of IS 12075
12. 0 Efficiency & P.F. at rated voltage &
frequency
a) At 100"1<0 load 84%0 081
b) At 75%load 83% 0.76
cl At 50% Load 81% 0.69
C. Constructional Features
1.0 Applicable standard IS 325-1996
2.0 DOP of Enclosure TEFC
i 3.0 Method of cooling Fan cooled
4. 0 Class of Insulation 'F'
5.0 Main Terminal box
5.1.0 a} Type lP-55
5.2.0 b) Power cable details (Conductor, Size, 4Cx 10mm2
Armour f Unarmour)
5. 3.0 Cable Gland & lugs details (Size, type Compression type, Nickel plated Brass
&material)
6. 0 Kind of Bearings 6306ZZ I 6306ZZ
7,0 Direction of rotation when viewed from NDE Bi- Directional
8.0 Paint shade & type Gray-631
9,0 Net weight of Motor 42 Kg

SUBMITTED TO : FLSMIDTH MINERALS PVT LTD,

_...._- .. _-- ...•.. - ....•.._-- .. _-_." --_..__......... - .. -.---- ..•-.. ...• _•.... ........................
_ -- ...--...... . .. _..•.. ...• _.. .. - -- .
SUPPLIED BY : PSI ENGINEERING SYSTEMS PVT LIMITED.,
CLIENT : fLSMIOTH MINERALS PYT LTO,

1 11-11-2008, ITEMS FOR APPROVALS R.,G RM

REV
- .. ..__ •..... _--
DATE
•..-_.
... -........ --- -.-"" .. -. -.-_._,- -
DESCRIPITION
_
.---".---,-- .. .. - ....__ .. .•.••......_•... _._ ...•..•. _._. __ ...... .... - .. - PREPARED BY
. - . _.....•.....•....•.•.....•• .. - ...
" -.-.-~.- .. _QtIl;qq:;RJlY __ , .
(

FLOW SWITCH
 iKROHNEj

Installation ami
iopefating insi:rm::tio!'ls

Stmulard, higll·temperature,
tropical alld ATEX lIersiol'ls

flow switches

~~~tr0f!lilgnetic ilmvme:.~!3._. __.______ ._____ .. _." ______ ~ __

I!ariable arefl ffowrneters
~\18SS fio',vrneters
Ultrasonic flQwmeters
Vortex riowmeters
Flow controllers
-----------
Level rfleasuring instrwnem?___________________ _
Pressure and temperatu,e
Heat IPetering
Communications tecl1ooiogy
Switches, counters, displays and rec2.rder~ _____ _

Engineering systems & solution~ _________ _

 I able of contents

General advice on safety ... . .. ..4

Standards I Approvals ........ . . .... 4

Ex safety instructions .. . ............................................... 4

Handling .................................. . . ............................................................... 4

Product liability and warranty .............................................................. . . ...... 5

Items included with supply ................................................................................ 5

Documentation supplied.......................................................................... .5

Official approvals and certificates ... , .......... . . ...... 5

Principle components .. ..6

Equipment labels ...... . . ...... 7

Type code ........................................................................ . .8

1 Mechanical Installation.................................. ............................. 9

1.1 Positioning the flow switch.. . ... 9
1.2 Installation in hazardous areas (Ex applications).. . ....... 9
1.3 Connecting the DW 18 to the pipe.. . ................... : ....... 9
1.4 Flow direction... . ..... ", 9

2 Electrical Connections...................... ....................................................... 10

3 Commissioning .......................................................................................... 11
3.1 General notes.. . ..... 11
3.2 Adjusting the limit switches - standard and EEx ia flow switch versions.. . ..... 11
3.2.1 Type G indicator... . ... 11
3.2.2 Type A indicator.. . ......... ' ...... 12
( 3.3 Adjusting the limit switches - EEx d fiow switch version....... . ...... 12
3.3.1 MS 12/BRX switch ...... 12

4 Display ...................................................................................................... 13
4.1 Local Flow indication.. . ..... 13
4.2 Limit Switches.. .. 13
4.3 EEx d version.. 14
4.4 High-temperature version (KROHNE temperature class H3, non-EEx).. ' .... 15
4.5 Tropical version (non-EEx). _ 15

2 InstallatIon and operating instructions DW 181 - 184

 5 Service ..... . ..... 16
5.1 Maintenance 16
52 Exploded view of instruments.. 16
5.3 Spare parts.. 18
5.4 Inspection procedure.. . .. 21
5.4.1 Inspection procedure: measuring assembly. . .. 21
5.4.2 Inspection procedure: housing (DW181 & DW182 models) ..... 21
5.5 Basic servicing procedures.. . .22
5.5.1 Changing the position of the dial on the type A indicator... . . 22
5.5.2 Removing the display assembly: operating faults in the housing DW18x Std IEExia flow
controllers equipped with type G or A indicators... . ... 23
5.5.3 Cleaning the springs or changing the measuring system sub-assemb!y... . .... 24
5.5.4 Changing gaskets in DW 183 flow controllers.. . .. 24

6 Technical Data ........................................................................................ 25

6.1 Flow range table by fiow range code.. .. . 28
6.2 Instrument version materials.. . ..... 30

7 Dimensions and Weights ............ . . ................................................... 31

8 Measuring Principle ..................................... , ........................ . .......... 36

8.1 Measuring systems .. ... 36
8.2 DW 183 .. ... 36

Appendix A: Declaration of conformity: CE ........................................................ 37

Appendix S: If you need to return a device for testing or repair to KROHNE...... .. ... 38

IKRDHNEI Installation and operating instructions DW 181 - 134 3

 Type code

Refer to the standard device label, item 2 on the prevIous page.

DW /
2 3 4 5 6 7 8

Type code element Code Code definition

1 Type series 181 For horizontal or vertical pipes, screw
connection G% ... G2, measuring system C or
E'
182 For horizontal or vertical pipes, flange
connection DN15 ... 65 and ;;''' .. 2''·150 Ibs,
measuring system C or E*
183 For horizontal or vertical pipes, flange
connections DN65 ... 200 and 3" ... 8"·150 Ibs,
measuring system P*
( 1 1 84 For horizontal pipes (ON 2:250 or 10", mounting
flange DN150 PN16 or 6"·150 Ibs, measuring
I system P'
2 Measuring system C Measuring disc in tapered tube
E Nozzl~ with baffle·
P Baffle in constant diameter pipe
3 Code number 011 ·204 See section 7.1: Flow range table for the
characteristics of each code number.
4 Material of construction B Bronze
~ see also section 7.2 RR Stainless steel (SS) 316 L
R SS 316L measuring tube, steel connection
N Steel
5 Indicator system G Linear scale marks
A Dial with flow units
6 Limit switches K1 1 NC or 1 NO switch"
K2 1 NC and 1 NO switch"
KV1 Amplifier relay: 1 change·over switch"
KV2 Amplifier relay: 2 change·over switches"
7 Application field N Normal locations
Ex d Hazardous locations
Ex ia Intrinsically-safe applications

c 8 Connection G Y< ... G2

DN15 ... 200
(;;''' ... 8'') i
Pipe thread
Flange connection

, Refer to section 9.1

** Bistable.
NO is a "normally open" switch during operation (closed switch when flow is decreasing)
NC is a "normally closed" switch during operation (closed switch when fiow is increasing).

8 Installation and operating instructions DW 181 - 184 jKROHNEi

 1 Mechanical Installation
----

1.1 Positioning the flow switch

No obstacles along the pipe within five diameters (0) upstream and two diameters downstream of
the instrument.

,
c 1.2
Direction of flow

Installation in hazardous areas (Ex applications)

Read all instructions referring to flow switches in hazardous locations before installation.

Check that the fiange, gasket and other materials in contact with the product are compatible. Refer
to the information given on the converter nameplate l the flange markings and specifications given
in the ATEX approval certificate.

1.3 Connecting the DW 18 to the pipe

• Before installation, clean the piping to remove any dust or weld debris.

& Fit the instrument on the pipe with the arrow on the housing pointing in the direction of flow .

• Flange connections: ensure that the gaskets are in place, flange facings are aligned and parallel
and that the bolts have been tightened with the amount of torque specified in European or local (if
outside the EU.) standards.

c 1.4 Flow direction

The DW 183 and DW 184 can be installed in any position on the piping. However, the position of
installation and the flow direction must be indicated in the customer order (Le. up, down, left to right
and right to left) as the weight of the baffle disc is taken into account when calibrating the
instrument. Flow direction must be indicated for DW 181 and DW 182 instruments equipped with
type A indicators.

The DW 184 is used for high-velocity or turbulent fiows in pipes with diameters greater than
DN250. A special device, called a stilling well, is immersed in the liquid fiow and channels the fluid
through a tube in which the disc moves, secured to the end of a rigid support. This reinforced pivot
enables the flow switch to be used in difficult condjtions.

These instruments are only supplied with an index display (indicator type "G") and SWitches. They
are not equipped with a graduated dial. The heights of the connection piece indicated for the
production of the mating fiange must be respected.
iKROHNEi Installation and operating instructions DW 181 - 184 9
 2 Electrical Connections
~-------------------------------------------

Disconnect the power supply before opening the housing

'* The electrical connection Number Switch 10'-0'-'..:.1,..:,0..:.f..:.t..:.he..:.·..:.ra..:.n..:.g"i~

..:.0..:.%=--________
conforms to the standard of types
EN61010-1, protection switches Limit switch adjustable over entire range
class 1 (for aluminium
housing) or class 2 (for
PVC housing), voltage
category Ill, and
interference degree 2.
Type
K1 L
--~I -----;=cI.bTI2~13':T14':T1c=r51'561---- B
Type
~ The DW range conforms K1
bi ack ------<Y""'D--
~ -----{)"'"0------- NO
to EMC directives NF EN
( 50081.1 (Emission) and
NF EN 50 082.2
(Immunity). Type
K2
• It is obligatory to have a
switching or circuit
breaking device, following Type
1~121*1*1 D

present regulations. The K2 ~ ~~

K1 black --cro-- ~o------- NO
devices should completely ----0'"0 - ~ Ne
2 K2 black
isolate the unit and be
E
easily accessible, dose to
Type 1*1*1*1
the unit. K2
K1green~o-
9K;l 9K"2l
~NC
• Both the.live (L) and
neutral (N) wires should F
be protected by a fuse Type 1*1*1*1
(4 ... 6.3 A Time Lag). K2 I'Ki1 ~
K1 black-----<J'"'""D- ~O-NO
During the wiring
procedure the ground wire K2 green.......--.-o-o- -----0""0- NO

should always be
connected first (relevant Type

c only for aluminium

housing).
KV1

r--------+--------.-~-
'* EEx ia versions must be Type
used with a certified KV2
intrinsically-safe power
supply.

N.B. Use of the unit

outside the specifications K1 Change
detailed in this manual can + over
compromise the safety K2 (SPDT)
measures designed into the
unit. Always disconnect the
power supply before
accessing the terminals.

10 Installatron and operatmg mstructlons DW 181 ~ 184

 3 Commissionin~____ ,.

3.1 General notes

The flow switch is delivered pre-calibrated and ready for use. Open the valves slowly when starting
operation.

3.2 Adjusting the limit switches - standard and EEx ia flow switch versions

The limit switches can be adjusted individually over the entire measuring range. To adjust, remove
the locking pin securing the cap and remove the cap.

3.2.1 Type G indicator

The limit switch adjustment is indicated by a green strip (normally closed switch) or a black strip
(normally open switch) in a graduated window. For flow switches manufactured before September 1,
1991, the strips are red (normally closed switch) or orange (normally open switch).
Each graduation corresponds to 1/10 of the total measuring range, i.e. 35 Ifh for a flow range of
50 .. .400 I/h. This system enables the limit switch to be adjusted without having to circulate fluid in
the pipe. It is only necessary to adjust the micrometer screw (item 2) in order to move the switch
support (item 3) which has the coloured strip on its upper section.
"G" linear index indicator assembly
T ____
I Index

3
~""'~
. !}
f'-
!-+ '1
2 Micrometer screw

"1 3 Switch support

4
c.. 1?r 1-: I
III ,
6
4

5
Switch

Control magnet
5 I
'-jJ
I: 6 Following magnet

IKRDHNEj Installation and operating instructions DW 181 -184 11

 3.2.2 Type A indicator
The switch is adjusted by unlocking the adjustment screw (Item 7) and repositioning the switch
support arm (item 8).
"A" graduated dial indicator assembly
1
,
JI Pointer
2 /

~
f f'\ 5
2 Dial
::Jl
IL ,L -,l. 3 Following magnet
3 6
~ 4 Control magnet

fBi~
l:l 7
p 5 Mechanism
;rlJ.i 8 6 Switch
'L ') I t-
~
.~

~
7 Adjustment screw
( i :-,-
I : j
l I
i i
J 8 Switch support

3.3 Adjusting the limit switches - EEx d flow switch version

3.3.1 MS 12/BRX switch

The switch is adjusted by unscrewing the limit switch adjustment screw M8x1 0 (2) on top of the
pressure housing with a 4mm hexagon key. The switch (in its metal sheath) may then be
repositioned as required before retightening the screw. The original position is etched onto the
sheath.
MS 12/BRX switch assembly

MS 12/BRX switch
2

- -
. ~ Ic-
-----_._- -- ----- ---++~-~~---~~
3
2 Limit switch adjustment
screw
......... '==0;
3 Switch sheath
_-..4
c 5 4 Switch magnet

5 Pressure housing

12 Installation and operating instructions DW 181 - 184 [KROHNEi

 5 Service

5.1 Maintenance

In norma! operation no maintenance is requIred. However, the flow switch must be cleaned if
particles in suspension in the liquid build up on the measuring mechanism.

Caution
Check that the cleaning product used will not chemically react with (Le.
corrode) the component materials.

5.2 Exploded view of instruments

DW 183 Std I EEx ia DW 184 Std I EEx ia

,-
\

528 Pressure resistant housing 628 Pressure resistant housing

52b PTFE ring 62b PTFE ring
52c Washer 62c Washer
52d Tube 62d Tube
52e O-ring 62e O-ring
C 53
54
Magnet lever with measuring disc
Measuring spring
63a
63b
Measuring disc
Magnet lever
55 Nut 64 Measuring spring
56 Spring washer 65 Nut
57 Tubular body with collar and flanges 66 Spring washer
58 PTFE gasket 67 Flange with stilJing well
68 PTFE gasket

The parts listed above are not supplied separately. Please refer to section 5.3: Spare parts for
a list of available spare parts.

16 Instaifation and operating instructions DW 181 -184 [KROHNEI

 DW 182 (181) Std I EEx ia with indication G DW 182 (181) Std I EEx ia with indication A

Cap Cap
Q·nng
3 Housing
,.
2 O-flng
Hous!ng
4 Locking pill
4 Locking pin
Gasket 5 Gasket
II COy€-! 6 Cover
7 Snap nng
Sn"p flll~.J
8 G-ring 8 O-rlng
9 Pressure housmg
9 Pressure housmg
lOO-ring
10 Q..ring
11 Magne:1 lelier
11 Magnet lever - :;~
12 Measunng spring,
12 Measuring spring,
complete complete
13 PTFE ring
1:3 PTFE ring
14 Measuring disc
141,.r1easurlng disc (type C)
(type C)
15 Tubular boeJy (OW 182
15 Tubufarbody
with nanged connection)
(DW 182 with
17 Spring washer
flanged connection)
la Screw 17 Spring washer
34 R-eed contact G/Kl
18 Screw
36 8aseplate 19 Dial
37 SC<lle 20 Countersunk screw
6
38 ;1.djusting "crhJ for 21 Pornter
indicator 22 Dial mvunt
39 POinl"J 23 Countersunk screw
40 Tooth i(lCk Hasher 24 Searing plate
41 Strirup 25 Revolving body witn
42 ';,jjusting screw for magnet
contBcl G 26 Pinion
43 Rivets 27 Spacer pin
44 RevolvIng body for 28 Baseplate
indicator 29 Pin
45 Nul 30 Clamp plate
46 Spring W$SI1€( 31 Washer
47 Snap washel 32 Adjusting screw
69 BOnded seal 32a Nut
70 Nut 33 Reed contact AlKl
69 Bonded seal
7QNut

DW 182 H31K1 High-temperature version (Std)

c 9
10
11
Pressure resistant housing
O-ring
Magnet.lever
12 Measuring spring complete
13 PTFE-ring
14 Measuring disc
15 Tubular body
17 Snap ring
18 Screw
48 Reed switch H3/K1
49 Mount
50 Nut
51 Hexagon socket head screw

The parts listed above are not supplied

separately. Please refer to section 5.3: Spare
parts for a list of available spare parts.

iKROHNEi Installation and operating instructions DW 181 ¥ 184 17

 5.3 Spare parts
Measuring spring DW 181 1182 "C"
Magnet lever (Tag 11)1 PTFE Ring (Tag 13)1 Measuring spring (Tag 12)1 Measuring disc (Tag 14)
DN W Code DN IW Code
DN15 C011 XF71 01 01 00 DN40 C041 XF71010800
C012 XF71010200 I C042 XF71010900
C013 XF71010300 C043 XF71 011 000
C014 XF71010400 DN50 C051 XF71011100
ON 25 C021 XF71010500 C052 - XF71011200
C022 XF71010600 C053 XF71011300
C023 XF71010700 C054 XF71011400
Measuring spring OW 181 1182 " E "
Magnet lever (Tag 11)/ PTFE Ring (Tag 13)/ Measuring spring (Tag 12)/ Measuring disc (Tag 14)
ON W Code DN IW Code
DN15 E015 XF71011500 DN40 I E045 XF71012300
.. _ . _ - - -
E016 XF71011600 I E046 XF71012400
E017 XF71011700 DN50 I E055 XF71012500
( E018 XF71011S00 I E056 I
XF7101?600
E019 XF71011900 j i
DN 25 E025 XF71012000 I I
I
E026 XF71012100 i I

E027 XF71012200
:
: I
Measuring spring DW 183 (2 springs supplied - Tag 54)
Meter code nO Flow Direction
B t -!-
P081 XF71012700 XF71012800 XF71012900
P082 XF71013000 XF71013100 XF71 013200
P083 ' XF71013300 XF71013400 XF71 013500
P084 XF71013600 XF71013700 XF71013800
POS5 XF71013900 XF71014000 XF71014100
P086 XF71014200 XF71014300 XF71014400
P087 XF71014500 XF71014600 XF71014700
P088 XF71014800 XF71014900 XF71015000
P089 XF71015100 XF71015200 XF71015300
P101 XF71015400 XF71015500 XF71015600
P102 XF71015700 XF71015800 XF71015900
P103 I XF71 016000 XF71016100 I XF71016200
P104 ~ XF71016300 XF71016400 I XF71 016400
P105 XF71016500 XF71016600 ,._-
P106 XF71016700 XF71016800 XF71016900
P107 XF71017000 XF71017100 XF71017200
P10S XF71017300 XF71017400 I XF71 017500
P109 I XF71017600 XF71017700 i XF71 017800
P121 ! XF71017900 XF71018000
I
I
P122 XF71018100 XF71018200 XF71018300
P123 XF71018400 XF71018500 i
P124 XF71018600 XF71018700 XF71018800
P125 XF71018900 I
P126 I XF71019000 I XF71019100
P127 XF71019200 XF71019300 I
P128 XF71019400 XF71019500 i XF71 019600
P129 XF71019700 XF71019800 I

18 Installation and operating instructions DW 181 -184

 Measuring spring DW 183 (2 springs supplied ~ Tag 54) continued from last page
Meter code n° I Hit ~I
P151 i XF71019900 i XF71020000 I XF71020100

P152 • Xi71020200 TXF71 020300 : XF71 020400

P153 I XF71020500 I XF71 020600 I XF71020700
P154 i XF71020800 i
XF71020900 i
Xf-71021000
P155 ,'XF71021100 ,

P156 I XF71021200 XF71021300 I XF71021400

P157 XF71021500 XF71021600 I XF71 021700
P158 XF71021800 XF71021900 XF71022000
P159 : XF71022100 XF71022200 XF71022300
-
P201 XF71022400 XF71 022500 XF71 022600
P202 XF71022700 XF71 022800 XF71 022900
P203 XF71023000 XF71023100
P204 XF71023200 XF71023300 XF71023400
P205 XF71023500 XF71023600 XF71023700
P206 XF71023800 XF71 023900 XF71 024000

Kit gasket DW 181/182

Tag I Description Silicon code Viton code Perbunan code
2 I O-rinq D 88,49 X 3,53 I
8 I
O-ring 74 X 3 X 80 XF71030100 XF71030200 XF71030300
10 : O-ring D 36,17 X 2,62
13 I PTFE rinq

Kit gasket DW 181 .. .4 (ring for pressure resistant housing)

for special applications usin DW 181 .. .4 HT/H3 version
Description Code Description Code
PTFE XF71030400 Klingerit _ _ _ _--"'X"F-'7-'10."'30"'5"'0"'0_ _ __

Pressure housing DW 181/182

Tag Description I Standard code I HT version code Ex version code
9 ! pressure housing !
18 screw A2 70 CHC,
M6-20 DIN 912
I XF71040100 IXF71040200 XF71040300

16 nutA2 70 HM6
17 spring washer A4 W6 i
( Reed
Tag
switch "A" DW 181/182/183
Description NO** code NC* code Changeover code
33 reed switch
32a nut A2 70H,M3
31 sprinq washer A2 M3 plate XF71050900 XF71051000 I, XF71051100
32 screw A2 70 H3-10 DIN933
30 clamp plate I
Reed switch "G" DW 181 1182 1183
Tag Description NO** code I NC' code Changeovercode
34 reed switch G/K 1
46 sprinq washer D5X9 XF71051200 XF710105300 XF71051400
47 snap ring AC E005 REF A
7555 I
• NC. sWitch that IS " normally closed " dUring operation (closed SWitch when flow IS Increasing)
" NO: switch that is "normally open" during operation (closed switch when flow is decreasing)
IKROHNEI Installation and operating instructions DW 181 - 184 19
 Complete plastic housing for ...
Code I Description Code I Description
XF71060100 i DW18/AK1'-'-g'--r-e-en----- XF71062900 I DW18/GKV1 24VAC
XF71060200 i DW18/AK1 black -cX~F~7~1"'06"'3;-;:0700;C-+C1D::cW~18~/~G"'K"'V-:-1-=;4~8V'+A~C;c----
XF71060300 : DW18/AK1 "INV" XF71063100 I DW18/GKV1 110VA·"C;cc----
! XF71063200 I DW18/GKV1 220VAC
XF71060400 i DW18/AK2 green/green I

XF71060500 I DW18/AK2 black/black XF71063300 iDW18/GKV1 24VDC

XF71060600 I DW18/AK2 green/black XF71063400 I DW18/GKV1 48VDC
XF71060700 I DW18/AK2 black/green XF71063500 I
DW18/GKV1110VDC ____

XF71060800 DW18/AKV124VAC XF71063600 i DW18/GKV2 NC 24VAC

XF71060900 DW18/AKV148VAC XF71063700 I DW18/GKV2 NC 48VAC
XF71061000 IDW18/AKV1110VAC XF71063800 I DW18/GKV2 NC 110VAC
~~="":-;c---fI~D"W~1"8:"c/A~K·V1
XF71 0611 00 220VAC XF71063900 I DW18/GKV2 NC 220VAC
XF71061200 : DW18/AKV1 24VDC
,.r
\ XF71061300 I DW18/AKV1 48VDC XF71 064000 i DW18/GKV2 NC 24VDC
cc
XF71061400 I DW18/AKV1 110V;;c;D';c;C--- XF710641oo :O-----
I DW18/GKV2 NC 48VD C
XF71064200 I DW18/GKV2 NC 110VDC
XF71061500 I DW18/AKV2 24VAC
XF71061600 i
DW18/AKV2 48VAC XF71064300 DW18/KV1/BRX NC 220V AC
XF71 061700 DW18/AKV2110VAC XF710644oo DW18/KV1/BRX NC 110VAC
XF71061800 I
DW18/AKV2 220VAC ,X"Foc;7c;-10""6~4",5,,,00;c_h'D~W~18;;';I"'KVc;1:;';/"'B"'RX;_;_;N-;:';__C1-1
oV_D_C_
===~--t-;IDW18/AKV2 24VDC
XF71061900 XF71064600 DW18/KV1/BRX NC 48V AC
XF71 062000 I
DW18/AKV2 48VDC XF71064700 DW18/KV1/BRX NC 48V DC
XF710612100 I DW18/AKV2 11 OVDC XF71064800 DW18/KV1/BRX NC 24V AC
XF7106490o I DW18/KV1/BRX NC 24V DC
XF71062200 DW18/GK1 green
XF71062300 DW18/GK1 black XF71065000 DW18/KV1/BRX NO 220V AC
XF71062400 DW18/GK1 INV.yellow XF71065100 DW18/KV1/BRX NO 100V AC
DW18/KV1/BRX NO 110V DC
- XF71 065200
XF71062500 I DW18/GK2 green/green XF71065300 DW18/KV1/BRX NO 48V AC
XF71062600 DW18/GK2 black/black XF710654oo DW18/KV1/BRX NO 48V DC
XF71 062700 DW18/GK2 green/black XF71065500 DW18/KV1/BRX NO 24V AC
XF71062800 DW18/GK2 black/green XF71 065600 DW18/KV1/BRX NO 24V DC

c NC: sWitch that IS "normally closed" dUllng operation (closed sWitch when flow IS Increasrng)
NO: switch that is "normally open" during operation (closed switch when flow is decreasing)

Kit indicator type A Kit indicator type G

Tags Description Code Tags Description Code
22 .. 29 Indicator sub- XF71065900 36 . ..47 Indicator sub- I XF71066000
assembly (A) assembl (A)

Kitcap/cover DW 181/182/183
Tag DescripUon Code
1 cap --
2 O-ring Perb 0 88,49 X 3,53 XF7107o1oo
4 lockinQ pin 316L for cover
5+6 I gasket + cover + nut I

20 Installation and operating instructions DW 181 -184 IKROHNEI

 Kit measu ng system Reed switch for EXD or HT versions
Tags Description i Code ! ag Description Code
528.e, OW 183 XF71 0801 00
J 48 IVIS 14/HT NC XF 71051500
53 .. 56,57 IRR ! IIVIS 14/HT NC i
XF 7101600
OW 183 i XF71080400
/ RR I HT
- - - -+""Oc;W-"1-:-;8~3c--jxF71 080300
I RR I EXO !

5.4 Inspection procedure

5.4.1 Inspection procedure: measuring assembly

Check the condition of the measuring system, cone~disc or nozzle-disc. Check the condition of the
spring. In the event of leaks between the body and the cap, tighten the four bolts securing the cap.
Change the O-ring if necessary. Carefully follow the maintenance procedures in section 5.5.

5.4.2 Inspection procedure: housing (DW181 & DW182 models)

Check switch operation using an ohmmeter. Check the operation of the indicating mechanism. By
removing the lock ring (Tag no. 7, section 5.2) holding the housing onto the assembly, it is possible
to remove the housing from the measuring body without removing the flow switch from the pipe, or
stopping the flow. Carefully follow the maintenance procedures in section 5.5.

IKRDHNEI Installation and operating instructions DW 181 - 184 21

 5.5 Basic servicing procedures

DIN 181 . .4 servicing by the customer is limited by warranty to:

a Changing the position of the dial on the type A indicator
• Removing the display assembly
.. Removing the spring-loaded probe assembly
• Changing gaskets in DW 183 flow controllers
Other repairs must be done by KROHNE-authorized service staff
Read all servicing instructions carefully.

5.5.1 Changing the position of the dial on the type A indicator

Warning:
Do not remove the 4 bolts holding the pressure housing onto the measuring
tube.

( For the "A" indication version, it may be necessary to mOdify the position of the dial when flow
direction has been reversed, in order to read the flow rate correctly. Follow the steps 1 to 6.

Step 1
Remove the locking pin and remove the cap.

- - - - -1 Dial

2 Screwdriver

2
Step 2
Extract the pointer using an extractor or the flats of two screwdrivers placed at either side of the
( pointer.
3
3 Pointer

4 Screwdriver

5 Dial

5
Step 3
Unscrew the dial.

22 Installation and operating instructions DW 181 -184 IKROHNEI

 Step 4
Reposition the dial as required: attachment holes are provided to reposition the dial in 90° steps. Fit
screws.
~,~/_6
6 Dial
C I c'

\~ L __-------l
7 Screwdriver

Step 5
Hold the pivoting arm and fit the pointer aligned with zero.
Step 6
Reinstall the cap and locking pin.
8 Interference fit between pOinter shaft and
hole in dial

9 Pointer

10 Dial

11 Pivoting arm

5.5.2 Removing the display assembly: operating faults in the housing DW18x Std IEExia
flow controllers equipped with type G or A indicators

Warning:
Do not remove the 4 bolts holding the pressure housing onto the measuring
tube.

If the fault lies inside the housing, return the display assembly to the factory for standard
replacement. The display may be removed under flow conditions .
• Remove the whole display assembly from the pressure housing by extracting the snap-ring
underneath the display. See section 5.2 for the exploded views of the OW,S Std/EExia devices to
locate this component (Tag no. 7).

IKRDHNE! Installation and operating instructions DW 181 - 184 23

 5.5.3 Cleaning the springs or changing the measuring system sub-assembly

Warning:
Remember to shut off the flO\.II/ before
performing this operation

Step 1
UNSCREW the 4 nuts and washers dia. M12 (1).
Step 2
SEPARATE the two components (2) and (3) using a
screwdriver.
Step 3
REMOVE the pressure housing (2) in the direction of
the arrow F.
Either Step 4A. ..
I CLEAN the springs (4)

*-
'
--0_ ...1>00--
....
I
-+--
... or Step 4B
CHANGE the measuring system sub-assembly
Step 5
REASSEMBLE by following instructions 1, 2, 3 and 4 in
reverse order. Take care to orient the measuring disc
(A) so that it is facing upstream.

5.5.4 Changing gaskets in DW 183 flow controllers

Warning:
Remember to shut off the flow before
performing this operation

Step 1
UNSCREW4 nuts and washers dia. M12 (1).
Step 2
SEPARATE the two components (2) and (3) using a
screwdriver.
Step 3
( REMOVE the pressure housing (2) in the direction of
the arrow F.
Step 4
REMOVE the gaskets from their recess (4).
Step 5
CHANGE the gaskets and reassemble by following
Bill .,. -+--- _.- - instructions 1, 2, 3 and 4 in reverse order. Take care to
orient the measuring disc (A) so that it is facing
upstream.

24 Installation and operating instructions DW 181 -184 IKROHNEI

 --~.---~---

7 Dimensions and Weights

Type connectio1n ' Dimension h Dimension L Weight
DIN ASME mm inches mm inches kg Ib
DW 181 G I,' 115 4.53 135 5.31 1.7 3.75
Std/EEx ia G1" 120 4.72 160 6.30 1.8 3.97
G1 ' /,' 130 5.12 180 7.09 22 4.85
G2" 135 5.31 190 7.48 2.6 5.73

DW 182 15 I,' 115 4.53 200 7.87 3.0 6.61

Std/EEx ia 25 1" 120 4.72 200 7.87 4.0 8.82
40 1112" 130 5.12 200 7.87 55 12.13
50 2" 135 5.31 200 7.87 7.2 15.87
65 21H' 135 5.31 200 7.87 9.3 20.50

DW 183 65 2 I,' 185 7.28 200 7.87 11.5 25.35

Std/EEx la 80 3" 185 7.28 200 7.87 12.5 27.56

I~::
100 195 7 68 1200 7.87 14.0 30.86
( 125 210 1 8.27
. 300 11.81 18.0
1
3968
150 6" 220 8.66 300 11.81 23.0 5071
200 18 " 250 9 84 300 11.81 35.0 77.16
1 .
I 1

DW 184 150 6" 13.5 29.76

Std/EEx la
I
DW 181 Std I EEx ia
o,,! 00(3.9~)

c
Dimensions in mm (inches)

IKRDHNEI Installation and operating instructions DW 181 -184 31

 8 Measuring Principle _______ ~____________

8.1 Measuring systems

Measuring system c:
A hinged measuring disc moves freely in the axis of a tapered tube (OW 181, OW 182 only). Ai
flowing conditions, the system adjusts so that the force acting on the disc is in equilibrium with the
spring force. Each flow rate thus corresponds to a particular position of the indicator and
simultaneously actuates the limit switches.

Measuring system E:
Instead of being located in a tapered tube. this system incorporates a nozzle (OW 181. OW 182
only) to increase the flow velodty. This version is partlcularly suitable for liquids with solids
content.

Measuring system P
(OW 183 and 184 flow switches only)
( This is used for large nominal pipe diameters (Dv'\) 183, DW 184). It is similar to system E but
does not require a nozzle.

Measuring system C Measuring system E (P)

c·
3.2 DW 183

The model OW 183 is recommended for pipe diameters from ON65 ... 200, which can be installed in
any position in the piping. The diameter of the measuring tube depends on the flow to be measured
and the connection is adapted to that of the piping.
The maximum flow rate is 4 m/sec. The OW 183 is available in the "N" (carbon steel) "R" (stainless
steel-coated carbon steel) or "RR" (stainless steel) versions. The indicator and the switches are the
same as those used in the standard model.
For instruments without flow indication, the scale ratio between min. and max. range valUes is
1:2.5. A scale ratio of 1:4 is possible if required by the two limit switches. For instruments with flow
indication, the scale ratio is 1:4.
For vertical installation, the position of the installation and the flow direction should have been
indicated in the order for calibratjon in order to take the weight of the disc into account.

36 lnstallation and operating instructions DW 181 - 184 IKROHNEi

'~--'
 DATASHEET FOR FLOW SWITCH

i PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM

• CLIENT P.O NO. : BHEL-LSHS/16725 DATASHEET REF : ES-296ILOS/FS

i PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 01 of 01

ITEM
APFRoV£'l> Wl"fH C.OH'.!£AH$~
A. GENERAL O Wrm MANUFAcruR.E. uONf"~
~E..Y1Se AtJj) RE.. &2,-,m ~ii
1.0 Tag No FSL-1305 o 1<01 APf1'.ov"D
OMlc...
2.0 Model No 0'1'1182 A-FP !2O'ftl-
3.0 Make. Krohne Marshall i);1----;~,~_::;;~~~.....!laI<,.... J:f.~.jh,AIl&
1--~~'"
4.0 Quantity 1 No
B. TECHNICAL
1.0 Switch Rating 1 NC and 1 NO cont<icli,""24V DC--
2.0 Set Point 36LPM
3.0 Max. Flow 65 LPM for ISO VG 320
4.0 Max. Working Pressure 30 bar

6.0 Enclosure Weatherproof IP: 55

7.0 Mounting On-line Mounting
8.0 Process Connection 40 NB ANSI #300 Flanged Ends
9.0 Repeatability +/-3%
10.0 Differential Fixed R-2
11.0 Electrical Connection Y."ET R-2
12.0 Body Disc S8-316 R-2

Rw:o~. (0'(2. .08

!j!sm1DiH F!..SM!DTH MINERALS PVT. LTD.
MIN'=FtAt§ CHENNAI, IND!A.

SUBMITTED TO : FLSMIDTH MINERALS PVT LTD.

SUPPLIED BY : PSI ENGINEERING SYSTEMS PVT LIMITED.

CLIENT : FLSMIDTH MINERALS PVT LTD.

2 9-12-08 ITEMS FOR APPROVALS RG RM

~
lEV
__ ~b-
DATE
__ ~~~ ____ DESCRIPITION
~~~~ __ ~ __ ~~~
PREPARED
__ BY
~~~~
CHECKED
______ BY ~

_NlJr-e. /. 'JW>h.~ ~k41... ;h..U k ve4':' -k

tMkt. w'tlt--. ~ff£,( .spec. \;0/<:[[8. 3..b 9.ckOYt - '])12.
 LEVEL SWITCH

(
 Installation, Operation and Maintenanc Manua! for
levcon Float Operated level Switch; MlS Series
Genral:
"Levcon" MLS Series External Cage Float Operation Level Switchs are suitable for side mounting externally on
vessels. Depending on application, various models are avaliable. and Fig. 'I given the model decoding procedure.

~~~~~~~~cp
MLS

Enclosure Type of Pressuere Material of No. of Material of No. & Type No. & Type Special
Class of Design Class Flange / Floats Float of Switch of Switch Features if
Switch Box Cage Carriage Carriage any

3.Weather- 4.6" NB Cage 1. Nominal 4. SS304. 9. One Float 4. SS304. 1. One Std. 1. One 3"/4"/5"/S"
proof Weld type Pressure Type. Micro- Cages,
Side & 4.10/15 kg/ 6. SS316. O. Two Float 6. SS316, Switch Rubber
Bottom 2. Two Std.
Conn. cm' S. Carbon 9. Others. Type. 2. Two Lined
( 5.Weather- Steel Micro- Cage,
proof & 5.6" NB Cage 5.20/30 kg/ 4. One-2 . Interface
Magnet SWitches Application,
Flame- Weld type cm' 9. Others.
Proof Side & Side 6.50/60 kg/ Type. 5. One Sliding
(I,IIA,IIB) Conn. cm' Mercury Sleeve Etc.
5. Two-2 Switch etc.
6.6" NB Cage 7. SOI11 0 Magnet
r 7.weather Bolted type kg/ cm' Type. 6. Two
-proof & Side & Mercury
7. One-3
Flame- Bottom 8. High Pr. Switches
Magnet
Proof Conn. Type Type. 8. Air Break
( IIC)
7.6" NB Cage 8. Two-3 Type
Bolted type Magnet (1No + 1
Side & Type. Ne
Bottom 9. Three-3
Conn. Magnet
Type.
S.Horizontal
Cage O. Four or
(Welded more 3-
type) Magnet
Type.
9.Side
Mbunted
without
Cage,

O. Top Mounted
without
Cage. (Float
Operated)
Note:
1.4,5,6,7 undr pressure class are basically 150,300,600,900 ANSI rated and hence rnax. pressure may be higher than the
Figures indicated.
2. Special materials belonging to same category will be deSignated by same number (for example SS304LL will be '4' low
temp Carbon Steel Will be '8' etc. followed by'S')

MLS Series Level Switch has a Float moving up and down with liquid level inside the Cage, Whn the Float rises
with liquid level, a Magnetic Sleev (See Fig, 2) attachd to Float by <tn Extension Rod moves up inside the Sleeve
Pipe. The Sleeve atracts a Magnet located outside the Sleeve Pipe. When the Magnet moves in, iltilts the switch
'rnechanism on it. When liquid level goes down again the sleeve. goes down with the Float and the Magnet, operated
by return spring" goes back to original position thereby re-operating the Switches. The normal differential in liquid
1
level between 'make' and 'break' of the Switch is 12 mm approx.

Instead of standard Single Magnet Spring return switch Mechanism shown in Fig, 2, Two magnetic type Switch
as per Fig, 3 can be provided. Two Magnet type Switch is more suitable under conditions of vibration and the
differential between 'make' and 'break' of Switch can be adjusted externally by shifting the positions of the magnets
along the slots provided.

By providing 2 Switch Carriages (2 Magnet type) it is possible to have switch operation at two different levels. The
operating levels can also be adjusted to some extent by moving the Switch Carriages up and down along the
Sleeve Pipe. For other types, please See pub. MLS/2

Depending upon the application, the Float and Extension Rod can be in Stainless Steel (AISI 304 or 316). The
sleeve is normally of Magnetic Stainless Steel (AISI 410) but can also be of Mild Steel jacketed by Stainless Steel
AISI 316). PI. also See pub. MLS/2 for other materials.

Magnet

,
'I 1
I ' I
,I 1.L-.--r1l
__
I h-..r.
BAKELITE ~ F,r.-=t
TER1\'UNAL T 1'1 1L--'---till Sloat for
I I~ !
;~ 1 Magnet
Adjustment

Micro
Switch

Sleeve Pipe

Fig. 2: Standard Switch Mechanism with Micro Switch

showing Principle of operation

TWO MAGNETIC TYPE

SWITCH MECHANISM

Fig. 3: Two Magnetic Type Switch Mechanism

The cage which can be Welded or Bolted type, can be of Mild Steel, Carbon Steel or Stainless Steel (AISI 304 or
AISI 316). The Switch Housing and Cover (weatherproof or flameproof) are of Aluminium. Electrical cable Entry
is W' / %" NPT or as required. The connections to vessel can be top side and bottom. (See Fig, 4), top side and
bottom side having plugged drain connections at bottom (See Fig. 5) or top side & bottom side (See Fig. 6) the
end connection can be socket weld type-standard 1" NB (See Fig.4) or screwed-standard 1" NPT (See Fig.5)
or flanged-Standard 1" NB to suit appropriate flange table (See Fig. 6)

2
 1 or 2 Mercury or Micro Switches are mounted on each carriage (each SPDT type) and are wired to Bakelite
Terminal Blocks (See Fig. 7). Current rating for Mercury Switch is 5 Amp at 230 AC or 0.3 Amp at 220V DC. In
case Micro Switch, current rating is 5 Amp at 230V AC or 0.25 Amp. At 220V DC.

!!2"N_P_T••

Fig. 5: Bolted Type cage 1" NPT(F) top side

Fig. 4: Welded Type Cage with 1" S.W. Side and bottom side connection.
And Bottom Connections. (Flameproof Cover)

j
i1 •.

,
.
C-
I
~
I ~~
)7/ li~c~iI II~C~H
I!~ L ~Ii Ii~ l~!I
Fig. 6:Bolted Type Cage with flanged top
Fig. 7:Terminals of Level Switch
side and bottom side connections.

Instead of Standard or 2-Magnet type Switches, 3-Magnet type switches can also be provided which is described

c in Fig. 8. In this case, instead of a Magnetic Sleeve, a Cylindrical Magnet (Primary Magnet) is provided at the end
of Float Extension Rod inside Sleeve Pipe (Magnet Tube). When the float goes down with liquid Level it operates
the Secondery Magnet (by attraction),which in turn operates Tertiary Magnet by repulsion.The Tertiary Magnet
makes terminals 1,2 (Air break type contacts) & breaks terminal 3,4. In the likewise fashion, terminal 1,2 break &
3,4 make when liquid level rises. The advantage of the3-magnet type mechanism is that even if Primary Magnet
has moved considerably away from the field of action (due to further rise or fall of liquid level), the Secondary and
Tertiary magnets remain in position due to mutual repulsion, thereby keeping contacts .firmly operated. Further,
with facility to have the Switches on left side & right side enable switch operating distance between adjacent
switches to be reduced considerably. These advantages and compact size of the assembly enable providing more
than one switch (two/three/four etc.) in a Single Switch Box (some on lefl side some on right side) for Signalisation
at different Levels (very low, Low, High, Very High etc.).

The Switch positions can be adjusted by looseing the screw holding the Switch Assembly and retightening after
bringing the same to new desired position. The complete Switch Assembly can be removed (after disconnecting
wire connections) after removing the Cross Bars at the top between the Sleeve Pipe (Magnet Tube) and Switch
fixing Rods.

Actual wiring arrangement is shown in Fig. 9. Wires from 1.2,3,4 Terminals of the Switch Assemblies are terminated
"to Terminals 1,2,3,4 at the Terminal Blocks (Loop Wires used to ensure that there is no stress onthewires when
the positions of the Switch Assemblies are shifted). While setting the Switches for high or low levle Signalisation,
it should be borne in mind that in-herent differential between make & break of switch is 17 mm approx. For Pump
Control with (adjustable) differential more than 17 mm, two switches have to be used, one for starting the pump
3
 and the other for stopping the same.

In case of 3-magnet type switches the Switch Housing size & Design are different from standard type (Weatherproof
only-not flameproof). Cover is normally fixed to Switch Box base with the help of 4 mm bolts and nuts.

SECONDARY MAGNET

PRIMARY MAGNET.
(CYLINDRICAL)

MAGNET TUBE

TERTIARY MAGNET

VIEW-P

TERMINALS 1.2 MAKE & 3, 4 BREAK

p WHEN LEVEL IS LOW AND TERIVIINALS
1,2 BREAK & 3, 4 MAKE WHEN LEVEL
THREE MAGNET TYPE SWITCH ASSEMBLY IS HIGH
(SECTIONAL PLAN) FIGURE-8

WIRTNG ARRANGEMENT
FIGURE-9

In case of Standard Switch Assy. (Switch opeating level is fixed and present at particular level) upper & lower end
stops are provided to prevent overtravel & under travels of float. During rise of Level, the float should not rise
more than 10/15 mm after Switch Operation (to avoid Switch reoperation).This is normally achieved by having
proper length of Extension Rod (float cannot move up further once the Extension Rod end comesup upto the end
of Sieve Pipe). Lower end Stop is in the form ofa Disc which is fixed in proper position o.n Extension Rod with
the help of Lock nuts. As opening at top of Dish End or fianged is less, the Disc cannot go down beyond Dish End
or Flange. This Limits downware movement of float (float should not be allowed to set at bottom, three by closing
the bottom port).

Double Floats (With two switch assemblies) in case is provided in case of singles at two independent Levels where
(a) Level Switch is regd. Flameproof (Single float operating two switches at two Levels will need large switch box
which is wather proof only) & (b) when distance between two levels is too high to have a very long switch housing.
The Extension Rod of Lower float passes through annular opening through upper float & its hollow stem (extension
pipe). In this case upper float assy. only will have lower side end stop.

Larger differential between make & break of switch can be achieved by providing sliding sleeve. Depending upon
the differential reqd (to the extent more than normal differential), the Locknuts for sleeve are shifted upwards (&

4
 lockd at higher place) for which longer extension rod & longer sleeve pipe is povided. During rise of float, the
sleeve is at bottom most position (resting on lower locknut) but during fall of level the float lowers but not the sleeve
until ittouches the upper locknut and further lowering of float only will cause sleeve become down-resu!ting in
switch.

For diffrent Pressurerremperature classes please see Model Decoding Procedure as given above. For temp. higher
than 250 0 / 300° C or below 0° C calling / radiating fins are normally provided.

Installation:

Unpack the Level Switch carefully. In case of Welded type Cage, remove any device (if provided) restricting
the movement of Float during transit and ensure that Float with Extension Rod and Sleeve is moving freely
inside the Cage and sleeve Pipe. In case of Bolted type Cage remove the bolts and top portion of the Cage, take
out any transit packing material from inside the Cage and refit the top portion of the Cage after ensuring free
Float movement. Mount the Level Switch rigidly outside the main vessel at the appropriate Level and connect
up by, suitable pipings to the vessel. The operating level markings when provided on the outside of the Cage can
be used as guideline for installing the Level Switch at correct height. While connecting up the upper side and lower
side pipes to the vessel, please ensure that the pipe lengths are as short as possible, sharp bends are
avoided and any valves provided in the pipes should be full bore type. Ensure that the Cage has been
mounted vertically (up to 3° slant from vertical is allowed). If necessary, provide additional support for the
Cage to ensure that the installation is rigid.The cage and connecting pipes are to be left unlagged. Keep the
top and bottom Isolating Valves closed.

Before insallation ensure that service cOl)ditions are suitable for the equipment supplied.

Electrical Connection:

The Switch Head of MLS Srises Level Swich is rotatable. 1/2 Cable entries are provided with '12" /3/4" NPT
threading. After removing the Cover and loosening the screws, rotate the Switch Head to the desired direction so
as to make the Cable laying work most convenient. Where conduit is to be connected lay the same upto the Cable
Entry preferably using Flexible Conduit at the Level Switch end. While laying the conduit, ensure that there is no
chance of accumulated condensate flowing inside the Level Switch. use Condensate/Moisture Trap if required.
Now pass the Cable/Cables having desired number of cores through the Conduit and bring the cable ends inside
the switch Head. Do the corrections as per circuit diagram. While conneting please note that in case of one Switch
Assembly, if one SPOT Mercury/Micro Switch is provided, left side terminals H,C and L are wired (see Fig. 7).
Terminals l.C make when liquid level falls and H,C make when liquid level rises, C being the common terminal.
When two Switches are provided right side terminals H, C & L are similarly wired.

Alternatively provide suitable Cable Gland at the level Switch Cable Entry and use Armoured Cable (without
conduit) and directly wire the same to the Level Switch Terminals. Remove any restrictions provided to stop
the movement of Switches during transit. Fit back cover. In case of Non-flameproof type, tighten the blank nut
provided at the top of the Cover (tighten 4 cover bolt & nuts in case of 3- magnet type). Wher weatherproof cover
c is provided, ensure that the Sealing Ring is properly pOSitioned. Cover for Flameproof type Level Switch is to be
screwed on the Switch Housing Base. For tightening, use the Special Spanner provided,

Commissioning

To commission the Level Switch, first open the top Isolating Valve and then open the bottom Isolating Valve slowly.
Switch on the electrical circuitry. Following adjustments can be done, if required:-

a) If the tilting of Switch is not proper, the same can be adjusted with the help of spring locaded screw provided
for the purpose.

b) If cage installation is correct but switch operation is still not desired level the switch carriages can be
repositioned to some extent on the sleeve pipe. To do this,

c) Loosen the two screws on opposite sides holding the Switch Assembly and tighten

d) the screws after repositioning the same.

e) If required, the sleeve can be also be moved up or down on the extension rod. T<> do this, remove Cable
Conduit and Cable. Remove Switch Box Cover and Switches. Slide out the complete Switch Box Base after
loosening the screws holding it on Sleeve Pipe exposing the Float Extension Rod and Sleeve. Fit back in
the reverse sequence after readjusting the sleeve.

f) In case of 2-magnet type the differential between make & break can be changed by re-positioning the
5
 magnets on the slots provided (sliding outwards will increase the differential & vice versa).

g) Note on Replacement of 3-magnet type Switch Assembly and Magnet: While replacing, please keep in
mind that (a) Primary Magnet must have North Pole (painted Red) facing upwards and (b) Switch Assembly
Marked L with Secondary Magnet end Marked N is to be fitted at the left hand side of the Switch Box (as
seen fromTerminallock side) and Switch AssY: Marked R with Secondary Magnet end Marked S is to be
fitted at the Right Hand Side of the Switch Box.

h) In case of double float type, ensure that extension Rod of lower float does not bend too much (when end
of extension rod is touching Sleeve Pipe top stopping its further movement and float is still trying to rise
due further increase of level) causing it to affect smooth movement of upper float assy.

i) In case of sliding sleeve type, if differential is to be changed, the position of upper lock nuts can be changed
but lower locknuts should not be disturbed,

Maintenance:

"LEVCON" MLS Series Level Switches hardly need any maintenance. The Cages (Chambers) should be cleaned
from time to time by purging.

In case of bolted type Cage, the inside including the Float Assembly should be thoroughly cleaned during shut-
down.

Replace Switch Assemblies, individual switchs and other parts as and when required. Complete Switch Assemblies
can be removed by loosening the two screws holding the same on the sleeve pipe. Individual Mercury Switches
can be pulled out (after disconnecting wires) and replaced by pushing the same between the spring clamps. While
refitting Mercury Switch, please ensure that weight of the same is equally distributed. Micro-Switch can be removed
by taking out the screws holding the same. After re-fitting the Micro-Switch, ensure that Switch is operating properly.
To achieve this it may be necessary to properly position the Micoswitch before tightening the screws holding the
same.

In Case of Flameproof Level Switch, Supply to switch head is to be cut off first before opening the Cover.

Since improvements are made from time to time, the design/specifications are liable to change without
notice.

ADDRESS

Kolkata (Office)
Kolkata (Factory)
"RAJKAMAL" 6'h Floor 138-G. Picnic Garden Road,
Kolkata-700 039
13, Camac Street
Phones:2343-8528/4325, 2344-1019/2680
Kolkata - 700 017
Fax No: 23442680
INDIA
Email:levconw@vsnl.net
Phones: 2283-2764/30225767/9831826885
Fax No.: 91 3322809645/22832719
E-Mail- levconh@vsnl.net
Website: www.levcongroup.com

Mumbai Branch
301,P cotoprima Chambers.1. Suren Road.
Andheri East.Mumbai-400 093.
Phones :(022) 26832127/26833015
Cable: CONLEV. MUMBAIS
Fax :(022) 26833015

Ref No. Ll/IM/MLS(2)/17/12/2002

6
 I~~ DATASHEET FOR LEVEL SWITCH ,

I
.,
PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM ,

,
CLIENT PO NO" : BHEL-LSHS!16725 DATASHEET REF : E8-296!LOSILS !
,

rPROJECT
I
: BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 01 of 01
! SLNO. ITEM DESCRIPTIC ~APPROVED i
APPROVED SUBJECT TO COMMENTS PROCEED
0 WITH MANUFACTURE BASED ON COMMENTS
REVISE AND RESUBMiT.
NOT .4PPROVEO. DOCUMENT OOfS NOT CONFORM
1.0 Tag No LSL-1311 0
2,0 Model No
IlASlC REOUIRMENTS, REVlSE AND RESUBMIT FOR
E~
MLS 3544-9~\w..".... _...",.," •. , "":,~,,,,....._,,,,,,,,.,.,,,,o.t.,,,,,,B:,1.,,gl..!,1 , ~
APPROV>l, IJ
3.0
4.0
5.0
Make
Type
Location
LEVCON ~SMillrH MlllEAAlS INDIA ( i') Ll'i), cHeNNAI

Floa! pera!
Side!Side
o I ar.; ='
APPROVAL AC~O£D ElY me PURCHASER 1$ LIMITED ONlY tOR THE
IT OOES NOT AUTOMATIC"-LY ABSOlVE 1ll,
IC!mTPJ..GIOR Of HI RE_ .SIt!J!.~Jrt fOR. W,f CORP.ECTlfESS Of OES1G.'i
DEr"'"t,"""UFAcro!!O£""OSAnSl'AClCru'~()frne_"T
.... .. --_. --."
1
6.0 Quantity 1 No
70 Cage Material 8S-304 FLSM DOCUMENT No.: b <;"\ t 04- 'T
8,,0 Switch Housing & Cover Cast Aluminum
Max,Working Temp,. 65 deg, C
~\j"\-
•. "
t+ !loo \\ ,I
g"O
tH1?:~~~!~1 --:,~ FLSMJOTH M!NERAlS PVT. LTD_!
10,0 Max. Working Pressure 5 Kg!cm2 L.~.~:~::::~~.~,"_",,_,~,_._ cH~:':~~:!.i~~. __ ;

11.0 Electrical Cable Entry WNPT(F)

i
12.0 Type of Switch Micro Switch
13.0 Enclosure Weather Proof IP: 66
14.0 Noo! Contracts Per Carriage 2-SPDT
-
15.0 Current Rating 24VDC R-t
16.0 Process Connection 25 NB #150 SORF R-1
17.0 Float Material 8S316 R-1
18.0 Differential 12 +!-2mm R·1
19. 0 Isolation Valves Required R-1
,
--
}.rote
'j;,..,hct.,"l{£,} JJJ ecti'tl" bLH .~ 'y£2i1
f do..f./J, J'uL, f IF"Xrb9-fh(j In iW:</c.f... §; Ht/..
SUBMJTTED TO
__ ••• n • • • • • • • • _ • •_ ••• ___ •••
: FLSMIDTH MINERALS PVT LTD..
. . . .. - ...-... _-_ .•.... _- ._._•......__ .. . - .. .. \roL 71'f',_ £,J-.,_ ... s<,dJJilf,l,<"' -C
9 .. ,-, . . .....

SUPPLIED BY : PSI ENGINEERING 8YSTEMS PVT LIMITED

CLIENT : FLSMIDTH MINERALS PVT LTD.

1 11-11-2008. ITEMS FOR APPROVALS R.G ·R.M

.. --REV ... ·_·DA'fE· ... ..........•.. __ .. ··_-··_··DESCRIPI'fION .. -.. ................. ................ PREPARED-BY -CHECKEElBY·
(

PRESSURE SWITCH

c
 CLASSIC SERiES
PRESSURE I DIFFERENTIAL PRESSURE SWITCHES

SWITZER Pressure or Differentia! Pressure Switch is a spring, and in turn moves a balancing arm to effect a
simple electro mechanical device operating on basic minimal movement required to actuate a
principles of Levers and opposing forces. Three microswitch (es).
essential elements, various combinations of which form
the basics for presenting hundreds of variants to suit a Refer table below for sensing element type and material.
variety of industrial applications. They are:
I ",,1nl ITent On·off
1. sensing element either of bellows or diaphragm Senso r & Male 1i31
Model Dillerential
(metallic or elastomeric)
2. a stable spring to determine the range setpoint Bellows
and 201 Ph:)sph)r Bt'onze l Fc{ed
.J16L SS./ Mone!
3. a snap~acting microswltch available in a wide
variety. Bellows
203- Ph).::o.pf·or Brunze j ,6,dJu::o.table
.316L 33 f f',l}onel
( Mounting I Connections I Precautions I
I
1. Position gaskets correctly while covers are fixed. 281 Bellows
(Dual Ph:;.spn.';-r Bronze i Fi:-:ed
Cover mounting screws must be tight.
Setpoint) 316L SS J Monel
2. Properly seal the electrical entries and cables with
correct cable gland, weatherproof or flameproof 204
Metallic Diaphragm
as required. If in doubt, consult factory, (High Stale Fixed
316 SS f t\llonel f Ha.st'1 C
Pre.2$ure)
3, Process pressure should not exceed stated --
,
maximum working pressure, Metallic Diaphragm
200 Fixed

~
.316 S8 f Monel}' Ha.,:;!'1 G
4. Connected electrical load should not exceed
declared maximum electrical capacity BOTH in 200
amperes and volts. (F.:::od 0 rad e j Metallic Diaphragm
Fixed
Hygenic 316L 8S
5, Do not establish pressure connections by rotating 8er'Jice)
the housing. Hold hexagon of the sensor
pressure connector with suitable spanner and 021
Elaslomer Diaphragm
tighten. (Draft &
Nitrile I EPDt'Jj /Viton l Fixed
Compound
6, Mount the instrument firmly and rigidly either directly Silicone
Ranges)
on the pressure piping or on a vibration free wall,
panel or pipe stanchion, on Elastomer Diaphrao]nl

c 7. If outdoor installation is envisaged provide sufficient

protection against aggressiveness of air, dust, very
low or very high temperature, solar radiation, water
(Or'aft &
Compound
R;s,nge.s)
Nitrile/EPDt'Jl fViton l
Silicr.:>ne
Adju:ttable

penetration etc, This is essential even for

weatherproof instruments.'
8, If process temperature is higher than the permissible
maximum temperature, it can be brought down at
the instrument end by employing a longer pressure
piping. Ask factory for piping nomogram.
9. A condensate coil or Pig tail should be used
invariably for steam service.
10. Ensure that suitable dampener I snubber is used
in rapidly fluctuating pressure lines.
OPERATION
Pressure Switch: Models 201, 203, 281, 204, 208,
209 and 021 & 023
Process pressure when applied to the senSing element
creates a force which overcomes that of a pre-tensioned
Differential Pressure Switch: Models 301, 303, 381,
304,384,306, 386, 310, 313, GN 310
When pressures from two different sources in a process
are connected across the sensing diaphragm, metallic
or eiastomeric, the pressure difference creates a force
which when overcomes that of a pre-tensioned spring,
moves a balancing arm to effect t,he minima! movement
required to actuate a microswitch(es).
High and low pressures are applied on either side of
the specially contoured diaphragm and this design
feature straight away eliminates the errors due to the
difference in area, a common problem present in twin
element pressure differential switches.
In models 301/4, 303, 381/4, 306, 386 and ON 310, a
unique motion transfer assembly is used, which is
sensitive to minute movements of the diaphragm but
 immune to the application of very high static pressure Now proceed with the setting of the switching points
except in 310, 313 & ON 310. as below:

In models 310 & 313, the task of transferring the resultant Fixed ON-OFF Differential Models
movement of the diaphragm is achieved by employing
an additional sealing diaphragm above the low pressure a) Rotate the range adjustment screw clockwise to
chamber. increase the switching point. Rotating anti-clockwise
will decrease the switching paint.
Refer table below for sensing element type and materia1.
b) After setting, re-fix the locking device back in position
r----Instrumn nt --------.--- --~~'--r--O-n--~f- to prevent unauthorised adjustment of the setpoint.
1 Model Sen;:xli" & MaIenal Dift8renHaI c) The center screw and the striker screw are precisely

lH~1----+-1-'I~;~~,~"it-:r,-"~;- --_-F-c-:e-••~-i--
adjusted and factory-set using Loctite. Alteration
of centre screw height wi!! disturb the contact
established between the sensor and the balance
beam. Disturbance of stricker screw wil! result in
I! !ID3
Metal!k:. Oiaphr:agm
3161.. SS
P.djLj.S"Jable microswitch not acting or set-point shift. Ref. Fig 1.
1------- -.---------------j------
I 3(j4
Dlaphragm ~ Range Adjuster
! (1-':lIgh ;:it;:.tiG Fixed si: ~-- .~ ",~,

l
I
F're-3.s-u re)

331
.316L SS

Diaphragm
FEx-ed
11F-- r-~ Microswitch
I~!,'-L''I.ale. t '.,
08 p>::)-it"fl;} ·31 i3L SS ~. I r Center Screw

! ~ I I !,- Stricker Screw

( 334
(Dual So::tpoint,
~
="= ~~I~' ,~r,
1-
Fv.ed
High St:dc
F're.:o..:sure)
316L SS
--=--
ber /'(i) I I~
C0'j
. I I
Diaphragm
Nltnle
Fv.ed ~\\
\
t,n' , , .....)
1 PI
I 386
(DI.Jol 8etpoint, Diaphragm
'
Ecorr.)m:l i\litn!e
Fc..:ecl t
Ve.rsi::;.n) Force from Process Pressure

Diaphragm Fig.1 : Fixed On-Off Differential Model

31U,GN 3'10
N,;:":"prene / EPDM / Fi:.:ed
I (Low Rang es)
~3i!):;0ne
Models 281 & 381/4 provide an independently adjustable
I Diaphragm high and low setpoint facility. A single sensing element
I 313 hle,::>pfene / EPDM i actuates two different balance arms through a floating
arm. See Fig.2. Two sets of range springs, range scales,
I
balance arms and micro switches are independently
operated.

SETTING OF SWITCHING POINTS

Set-up

A pressure source and a master gauge of accuracy

better than 0.5% is required to set the actuating point
In the case of Differentia! Pressure switches connect
the pressure source to the high pressure port and leave
the low pressure port vented to atmosphere.

Switching point should preferably He in the mid 50% of

the adjustable range span.

Markings provided on the range scale are for- guidance

only. To set switching points precisely use a master
Pressure Gauge.

The switching point can be set, either for fall in pressure

or rise in pressure by rotating the Range Adjusting
screw.

Remove the instrument cover. Unscrew and remove

Force from Process
the lock plate, which prevents the movement of the
Range screw. Fig.2: Operating Principle of Dual Setpoint Version
 Both the range springs are clearly marked for high and
low functions. First set the low range spring and adjust
the desired value for the actuation of the microswitch.
The high range spring should then be adjusted similarly
to the desired high setpoint. Ensure that the correct
microswitch is monitored while settings are done. Refer
Fig.3.
Precaution
The switch actuating screw on the balancing arm is
critically adjusted, Disturbance of this would result in
not achieving the desired result while ON-OFF differential
adjustments are made. If accidentally disturbed, to
reset the microswitch for correct operation adjust the
height of the striker screw such that the balancing arm
is not in contact with the auxiliary spring seat at the
time of switch de-actuation. Refer Fig.5. This alone will
ensure unloaded condition of the auxiliary spring during
de-actuation. For actuation of the microswitch, the
balance beam has to lift the aux, spring seat which is
pre-Ioaded with the desired value of wide band On-Point.
Refer Fig.6.

Microswitch

Fig.3
l Force from Process
Side-view of Mechanical Frame \'\\
___ - -

~
fft
t!------ '--'~ff!.
_~ ;- Aux. Spring
Spring Seat
r 0.5/0.8 mm Gap
S.A. of Dual Setpoint Version ~' 1:--;

Adjustable ON-OFF Differential Models

':::-l?C==rrll
. ,; .
( On-Off differential value can be adjusted for a wider
Fig.5: Switch at 'OFF' Position-
value from about 10 to 15% of the span to a maximum Aux Spring load not acting
of 60% as specified against each range. The minimum
value will vary with different switch combinations. This i Microswitch
facility is achieved by an auxiliary spring brought into ......-' .-..L. r Aux. Spring
action when the switch actuating plate moves up before
it operates the microswitch. Adjustment of the tension
ti l '!:tJir Diffl. Spring Seat
of the spring decides the pressure difference between ,\ ~ ;flj I.
\\ :~:t,fh
the on paint and off paint. Refer Fig. 4 .

. bk~- .m._, __ '. Range Adjuster

'" . M OiL·
~---~----~---"
1;------'----
,~--
r= Microswitch Fig.6: Switch at 'ON' Position-
Aux Spring load acting

r
Center Screw
Stric: Screw Notes

1) In the instrurnents with 2 SPDT switches for DPDT

~&ITIiJ Nyloc Nut
action, the synchronization of actuation is achieved
)'-:::¥=~it:_t:_=__ =.1=:7~~ Dlff!. Adjuster within practical limits. The switches are

i ~~(L:kr:J\~
::j_

synchronized as per customer preference either

on falling or on rising pressure. If no preference
Aux. Spring is indicated, synchronization is done on fall in

\\."JVL'--'"
ilts:==r:- ~I''Trl
Dlff!. Spring
Seat 2)
pressure at factory.

Do not exceed the rated maximum working

=-'='==-~
FigA : Wideband Adj. Differential Mechanism
a) In adjustable differential mode! set the lower switching
point first Release the aux, spring to be free by
lifting up the nyloc nut and the diff!. Adjuster. Using
the range adjuster set the lower switching point.
Then load the aux. spring by turning in the Diff!.
Adjuster to set the upper switching point.
b) Adjusting the differential adjuster will shift only
the upper switching point Le. the switching pressure
difference (on-off differential) alone changes. A
clockwise rotation will increase upper switching
point and anti-clockwise rotation wil! decrease it.
c) The upper switching point should not exceed the
maximum range value.
d) After setting the differential, tighten the Nyloc nut
to lock the differential adjuster to prevent loosening
during operation.
pressure. Over pressure beyond the specified value
will permanently damage the sensing element
leading to replacement.
MAINTENANCE
instruments are so designed with rugged components
that they seldom require maintenance. Occasional
cleaning of the moving parts, checking of the
microswitch(s) and ensuring firm electrical contacts at
the terminals will provide a long trouble-free
performance.
In the caSe of diaphragm operated instruments, do not
attempt dismantling the sensing diaphragm as it would
permanently disturb the factory settings. Special jigs
are needed for reassembly and hence replacement is
not recommended at the user end. However, cleaning
of the diaphragm chamber can be perforrned by flushing
with a cleaning fluid, which is compatible with the
diaphragm and its housing material,
 -
~T DATASHEET FOR PRESSURE SWITCH 11

I
PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM I I

CLIENT P.O NO. : BHEL-LSHS/16725 DATASHEET REF : ES-296ILOS/PS ,I

il
i PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 01 of 01 I

SI.NO. ITEM DESCRIPTION

,

1.0 Make SiNitzer

2.0 Welted parts SS316
I

I 3.0
4.0
Contact firm & Rating
No. Of Se! Pain!
2 x SPDT, 4A @ 24V DC
One
t LSM DOCUMENT No.: b SI b€) t
R-1

'2, I
5.0 Protection IP:66
6.0 Max. Working Temperature 170deg C
R..v.o~ to .12.·08'
7.0 Process Connection Yi' NPT (F) msJnllHH FLSMIDTH MINERALS PVT. LTO.
Mii\l .. ;:;lAI.:g CHENNAt, INDIA.
8.0 Electrical Connection %" ET (F)
g.O Housing Enclosure Die Cast Aluminum R-1
10.0 Isolation Valves Required (3 way valve Manifold) R-1

Pr. Range Set Pr. MWP. Repeatabuity. Actuation

Model No QTY Tag No. Differential
Type
. bar bar bar %FSR
GM-203-02-B3K-33-Z 1 PSL-1307 15-75 bar 50 bar 80 bar ±D.5 Adjustable Falling
GM-S24-0G-W7-55-Z 1 PSL-1308 50-400 bar 250 bar 1000 bar ±1 Fixed Falling
GM-203-02-A8K-33-Z 2 PSL-1301 1.6-16 bar 8 bar 25 bar ±D.S AdjuStable Falling
(LOOSE SUPPLy) PSL-1302
GM-S24-0G-W7-55-Z 1 PSH-1309 50-400 bar 350 bar 1000 bar ±1 FIXed Rising
NOTES: 1.0' APPROVED
APPROVED SUBJECT TO COM!.i£NTS PROCEED
0 WITH IAANUFACTURE BASED ON COMMENTS

SUBMITIED TO : FLSMIDTH MINERALS PVT LTD. o NOT APPROVED. OOCtJMENT DOES NOT CONFORM
BASIC REQUIRJm;NTS. ,no
SUPPLIED BY : PSI ENGINEERING SYSTEMS PVT LlMITE Q., APPROVA~~ ,~
n... t&fl'1- og--
CLIENT : FLSMIDTH MINERALS PVT LTD. For FLSMlOm MINERALS INDIA ( P) LTD. CHENNAI
IfIt'nwvAL ACWKOE~~:\V:: ~:S;~.,.JS LIMITED ONLY FOR THE
CONTRACTOR Of RES~FORTHC i!,;,,,c~M.:srGN
ITEMS FOR APPROVAL~
.
2 9-12-2008. OE1AlL. -'WMACTU EAAO !'Woo CEOF ENT

REV DATE DESCRIPITION . PREPARED BY- CHECKED BY

f..~{e ;- J;.),hw'\>.,;..J. .r:Je C(.,'010\. j)~,-"U lk V..vJU( : ~/::ow}b1~7 10

Mo-I-d, ':tHE/" r Sr~(" \01~ 1L B. U- 5Qc ~"of'1-. -]).3,
l
\.

PRESSURE GAUGE
( \'

~r
I
~ iNSTRUMENTS CONSORTIUM
INSTRUCTIONS
for mounting, use and maintenance of pressure gauge
Gauges with different possible mounting positions:
WE A WE S lYP£ ~ WE D lYPE E lYP£ F

~SACK ~SACK ~FRONT

0 [1 FlMGE FlMGE FlMGE

&,SRACKEf

LOCAL BOTIOI.! LOCAL SACK LOCAL SURFACE PANEL FLUSH PANEL FLUSH PANEL
I.KlUNTING MOUNTING MOUNTING MOUNTING MOUNTING IIDUNTlNG

NO

~
MOUNTlNG

1) MOUNTING:
Mount always vertical, for any other position kindly specify angle and direction.
Gauge is normally calibrated in a dial vertical position.The pointer may be out
of zero if instrument is in horizontal,particularly for low pressure ronges.

2) Threaded connections:
Standard threads are : parollel BSP(gos) or NPT
a) Parall.1 threads: Fix gasket between the YES NO YES
the end of thread and around spigot.
b) Taper threads: Tightness achieved metal
on metal without gasket.Use of a teflon tape

around the threads provides better tightness

and makes the tightening easier.

Gasket NPT threading
3) Bourdon tube: BSP threading BSPT threading
The Bourdon tube is supplied as per customer requirement Parallel threading
in material SS 316 Ti ,bronze ,monel , brass

4) Oxygen service:
The oxygen service, ail-free wetted parts are required.
Specify clearly when ordering.

5) Steam service/ Hot service

~ is essential to prevent entl)' of steam or hot fluid entering the bourdon tube.
This is to be effected by interposing a syphon between the gauge & process pipe.
The syphon should be filled with water before the gauge is put in ta service.
Steam / Hot fluid
 I INSTRUCTIONS
for mounting. use and maintenance of pressure gauges
/
INSTRUCTIONS: NO YES
Installations:
Never install the gauge by turning the case,
but mount it with 0 spanner by meons of the flats
provided for tightening on the socket.

NO YES
Isolating cocks:
A pressure gauge should always be mounted with on iscloting cock.

COCK
Vibrations:
( Vibrations of pressure gauge must be avoided to
,
[0
YES
prevent excessive wear of movement mechanism.
It woold be b..-tter to set the gauge on a riqid support
NO Oil filled gauge

. on which vibrations of the pipe have no influence.

~ rigid moonting not possible, choose a oil filled gauge.

Pressure pUlsations:
In case of pressure measurement· of pulsoting fluids 0 snubber NO
(dampener) should be fitted' between pressure gauge and pipe.
Adjustment of snubber to be carried on line, where gauge
YES
is used, according to the pressure pulsations.

A flexible capillary of Small diameler can be installed

between gouge and 0 diaphgram sealed unit.
A flexible capillary (impulse tube) may be occasionally
used os pulsations dampener along with gouge cock.
o -Snubber

Corrosion:
If stainless steel or monel do not provide suffide..t guorantee YES
against corrosion, it is advised to use of 0 diaphragm seal unit
between gauge and process pipe.
Ports of diaphragm seal in contoct with fluid (wetted ports)

ore mode of 0 molerial withstanding corrosive fluids:

o
:~~~'~~~chem~icol seal
stainless steel, nickel, hestalloy-c, tantalum, titanium, silver etc ...
corrosive fluid
or eooted with co~n proof material P1FE
 """

l~
; P81JOBNO : ES-296
DATASHEET FOR PRESSURE GAUGE

EQUIPMENT : LUBE OIL SYSTEM

l 11

CLIENT P.O NO. : BHEL-LSHSf16725 DATASHEET REF : ES-296fL08/PG I

,
I PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 01 of 02

~
I
. SI.NO. ITEM DESCRIPTION
FLSM DOCUMENT No.: ~. '" I b0 4-1.
A. GENERAL
I
1.0 Make GIC \kJ,) : Dol· tCl' \2· 0<6
FLSM!DTH MINERALS PVT. LTD. 1
,
I 2.0 Type Bourdon Type t!smlD'fH
MiNta!<fALS CHENNAI. INOlk

3.0 Model No. BSPG·P

I

4.0 Fluid Handled Lube Oil (Grade:ISO VG 320)

B. MATERIAL OF CONSTRUCTION
1.0 Sensing Element 88316
2.0 Movement SS 304
3.0 Casing Die Cast Aluminum with epoxy coating R-1
4.0 Shrank/Socket Malerial SS-316 R-1
v. I ",crmtC:AL
1.0 Case White Background + Black
2.0 Dial Size 150 mm as per IS: 3624 R-2
3.0 Accuracy ±0.5%FSD R-1
4.0 Enclosure IP: 67
5.0 Mounting Panel Mounting
6.0 Process End Connection 'h' NPT (M)
7.0 Bezel ring SS-304 (Screwed Type) R-1
8.0 Blow Out Protection Required R-1
9.0 Zero Adjustment Micro Meter Pointer (Internal) R-1
10.0 Over Range Protaction 150% FSD R-1
11.0 3-Way Manifold Provided R-2

SUBMITIED TO : FLSMIDTH MINERALS PVT LTO.

SUPPLIED BY : PSI ENGINEERING SYSTEMS PVT LIMITED.

CLIENT : FLSMIDTH MINERALS PVT LTD.

2 9-12-2008. . ITEMS FOR APPROVALS . R.G RM

REV DATE DESCRIPITION PREPARED BY CHECKED BY
 -~--- -
,
il
ili DATASHEET FOR PRESSURE GAUGE !
11
~
I, PSI JOB NO

I CLIENT P.O NO.

: ES-296
: BHEL-LSHSl16725
EQUIPMENT
DATASHEET REF
1: LUBE OIL SYSTEM
: ES-296ILOSIPG
I
1
PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 02 of 02 Ir
I
l
,
!
OPERATING !
,i
REV QUANTITY TAG NOS RANGE SERVICE' REMARKS
PRESSURE
I
2 1 PG-1310 0-40 bar 20 bar Lube oil !
! t
2 1 PG-1309 0-400 bar 310 bar Lube Oil 1
2 1 PG-1303 0-16 bar -- Lube Oil Loose Supply , I
}
2 1 PG-1304 0-16 bar - Lube Oil Loose Supply i
!
Notes: I
I
,
;
I
I! j
,;
r
NcJ ~t i- \
t
--== -
k ~f ;tIfo~pen.1/)rwfr/ly i

!)Q.le.ch'oVL ,~kc<il
J)

'[/v,fncw.J- ,!
Yol-lIB. fk.b- Se.ckO(l ":']);t •. j

NfU- ::e pe-('. I

~ MDJ-J.. N'l-Il
.. /
I!
, Jr1tPP~o ,
IlrrROVEO SUBJECT TO COMMENTS PROCEEO !
[l \'IiTH MANUfACTURE BASEO ON COMMENTS

,0
REVISEANO RESUeMlT.
NOT AJ'AAOIIEO, DOCUMENT DOES NOT CONFORM
SA$1C REOUIRMENTS. REVlSE AND RESUBMIT FOR
i, ~

s,,,. ._:::. .~. . . _Da!e......lb..)..Jl.::l9. t !

i
ForFLSMIOTH MINERALS INDIA (P) LTD. CHEHNAI
,
APPROVAL ACCORDED BY THE PURCHASER 1$ LIMITED ONLY FOR THE i
COMPAT1S1LllY 'Mm THE LAYOUT. 11 roes NOT AUTOMATiCAlL'f ABSClVE T"'~ [
CONTRACTOR OF HIS RESPONSl8U.lTY FOR THE CQRRECmESS OF m~" "
DETAIl., MANUFACTURE AND SATISFACTORY P£P,FCRMANCE OF THE EOI.!lP'.ll. .',. i
..
1

SUBMITTED TO : FLSMIDTH MINERALS PVT LTD. !I

SUPPLIED BY :·PSI ENGINEERING SYSTEMS PVT LIMITED. !
~

CLIENT : FLSMIDTH MINERALS PVT LTD. I

!
i
2
REV
9-12-2008.
DATE
ITEMS FOR APPROVALS
DESCRIPITION
R.G
PREPARED BY
R.M
CHECKED BY
I
t
I
 ,

1Gtl!) I
DATASHEET FOR DIFERENTlAL PRESSURE INDICATING SWITCH

PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM

, CLIENT P.O NO. : BHEL-LSHS!16725 DATASHEET REF : ES-296JLOSIDPIS

PROJECT : BHEL-NlC,BARSINGSAR POWER PROJECT PAGE : 01 of 01

SI.NO. ITEM DESCRIPTION

1.0
2.0
Tag No
Model No
DPSH-1306
120-6-1-P-4 tl. SM DOCIJMENT No.: (" '" ( ; D 4- 8' I
3.0 Make SWITZER
I 4.0 Quantity 01 No.
fuw.ca, (" .\2.0:>-/
ijt):ml01f.t FLSMfDTH M1NERAlS PVT LTO
M1N"'~At:~ CHENNAJ, INDIA. • .
i 5.0 DPRange 0-1.6 bar
!
, 6.0 Sensor Type & Material SS 316, Piston
7.0 No. Of Set Point One ,
I
8.0 Contact form & Rating 28VDC 6A R-1
9.0 Process Connection 114" NPT (F)
10.0 Housing Material & Rating SS 316 & 200 kglcmA2
II.V Ulel "Ize IOU nun

12.0 Scale Type Non-linear

13.0 Movement Magneticatly coupled
14.0 Protection Weatherproof to IP 66
15.0 Max. Workng Temperature 120 Deg.C.
'6.0 Cap Seal Nitrile
17.0 Repeatability +1-2% FSD /'"
IT
18.0 Over Range protection 150% ofFSD A!'PROVED SUBJECT TO COI.li!ENTs PROCEED R-2
o WITH IMNUFAC111RE BASED OIlCOllMaas
19.0 Differential Fixed REVlSEANJ) R-2
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2 9-12-2008. ITEMS FOR APPROVALS R.G R.M

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 DATASHEET FOR TEMPERATURE GAUGE WITH THERMOWELL

PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM

CLIENT P.O NO. : BHEL-LSHS/16725 DATASHEET REF : ES-296!LOSITG

! PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE....--' :01 of 01

SI.NO. ITEM
A. GENERAL
1.0 Make
2.0 Type
3.0 Model No.
4.0 Fluid Handled
B. TECHNICAL
1.0 Case Die Cast Aluminum with epoxy painted
2.0 Stem 12 mm OD in SS 316, Length 150 mm
3.0 \ Dial Size 150mm
4.0 Range 0-100 deg C
O.U "~"UI Q"Y :!:17. r;:,u
6.0 Over Range 150% FSD R-t
7.0 Zero Reset Micro Pointer (Internal)
8.0 Connection y," NPT (M) adjustable compression fitting in SS 316
9.0 Mounting On-line Mounting
10.0 Bezel Ring SS-304 (Screwed Type) R-1
11.0 Response Time 2 10 4 sec with thermowell R-2

FlSM IT NO.: 6· <)lbo4/

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SUBMITTED TO : FLSMIDTH MINERALS PVT LTD. I='-" , INDIA.

SUPPLIED BY : PSI ENGINEERING SYSTEMS PVT LIMITED.

CLIENT : FLSMIDTH MINERALS PVT LTD.

2 9-12-2008. . ITEMS FOR APPROVALS R.G R.M

REV DATE DESCRIPITION PREPARED BY CHECKED BY
 DATASHEET FOR TEMPERATURE GAUGE WITH THERMOWEI.I.

PSI JOB NO : ES-296 EQUIPMENT : LUBE OIL SYSTEM

CLIENT P.O NO. : BHEL-LSHS/16725 DATASHEET REF : ES-296/LOSITG

PROJECT : BHEL-NLC-BARSINGSAR POWER PROJECT PAGE : 01 of 01

SI.NO_ ITEM DESCRIPTION

C. THERMOWELL DETAILS (Designs will conform to ASTM PTC 19.3)
1.0 Type Threaded Type
2.0 Thermowell Material SS316
3.0 Bore 13mm R-2
4.0 Imm. Length (U) U=150mm
5.0 Hot end OD 16mm tapering from 21mm
6.0 Instrument Connection W NPT(F)
7.0 Process Connection Threaded End Connection
R-2

2 1 TG-1312 0-100 deg C

2 1 TG-1313 0-100 deg C 32 deg C LubeOil

2 1 TG-1314 0-100 deg C 36 deg C Lube Oil

2 1 TG-1315 0-100deg C 65 deg C Lube Oil

SUBMITTED TO : FLSMIDTH MINERALS PVT LTD.

SUPPLIED BY : PSI ENGINEERING SYSTEMS PVT LIMITED.

CLIENT : FLSMIDTH MINERALS PVT LTD.

2 9-12-2008. ITEMS FOR APPROVALS RG RM

REV DATE DESCRIPITION PREPARED BY CHECKED BY

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