BFP BHEL Manual For 500MW

BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM :: HYDERABAD 502 032
OPERATING AND MAINTENANCE INSTRUCTIONS OF PUMPS
VOLUME-1
BOILER FEED BOOSTER PUMP, BOILER FEED PUMP & CONDENSATE EXTRACTION PUMP
MEJIA PHASE-II T.P.S - 2x500MW, UNIT-1&2
DAMODAR VALLEY CORPORATION
LIST OF CONTENTS
VOLUME 1
PART - 1 SAFETY STANDARDS
PART - 2
SYSTEM INFORMATION
PART 3
PRESERVATION & STORAGE
PART 4 A. B. C. PART 5 A. PART 6 A. B. C.
EQUIPMENT DETAILS BOILER FEED BOOSTER PUMP BOILER FEED PUMP CONDENSATE EXTRACTION PUMP SUB-DELIVERY ITEMS RECIRCULATION CONTROL VALVE DRAWINGS / DOCUMENTS BOILER FEED BOOSTER PUMP BOILER FEED PUMP CONDENSATE EXTRACTION PUMP
VOLUME 2
HYDRAULIC COUPLING
PART 1
SAFETY STANDARDS
SAFETY STANDARDS
Persons responsible for the equipment covered in this manual must ensure that it is property and safely installed and maintained, and operated at the specified conditions. Only appropriately qualified staff, applying acceptable standards of engineering practice and the recommendations contained in this manual, must be employed in these activities. Any similar instructions for the overall plant in which the equipment is to be incorporated, which have an influence on the equipment application, must be strictly followed. Statutory and local requirements concerning work practices, safety and/or health precautions must be observed. When appropriate, warnings, cautions and notes are included in the manual, and are defined as follows :-
WARNING : A WARNING CALLS ATTENTION TO INSTRUCTIONS WHICH MUST BE FOLLOWED TO AVOID DANGER TO PERSONNEL.
CAUTION : A caution calls attention to instructions which must be followed to avoid damaging the equipment or its surroundings.
NOTE : A note gives supplementary information where considered necessary.
OPERATING CONDITIONS If the equipment application or operating conditions differ from those for which equipment was supplied, the equipment and the operating recommendations contained in this manual may be inappropriate. In such circumstances verification of the suitability of the equipment and of the operating and maintenance manual must be obtained in writing from BHEL ltd.
PART 2
SYSTEM INFORMATION
PART 2
SYSTEM INFORMATION
LIST OF CONTENTS
CHAPTER 1 2 3
TITLE General System Description Equipment Schedule Sub-Vendor List for Bought-out Items
PART 2
SYSTEM INFORMATION
1.0 1.1
GENERAL SYSTEM DESCRIPTION Mejia Phase-II Thermal Power Station Unit-1&2, Damodar valley Corporation consists of Two generating unit of 500 MW capacity along with their auxiliaries. This manual contains the description, operation and maintenance instructions for Boiler Feed Booster Pumps, Boiler Feed Pumps and Condensate Extraction Pumps.
1.2
There are three Boiler Feed Pumps ( 2 Turbine Driven and 1 Motor Driven ) each of 50% capacity, which take suction from the deaerator and discharge the feed water to series of HP heaters, economizer and finally to Boiler Drum.
1.3
The Condensate Extraction Pumps (3 x 50%) capacity take suction from the respective hot wells and discharge to deaerator through gland steam condenser and LP Heaters.
2.0
EQUIPMENT SCHEDULE : Following equipments are covered in Volume1 and Volume-2. 1. Boiler Feed Booster Pump, type : FA1B75 2. Boiler Feed Pump, type : FK4E36 3. Condensate Extraction Pump, type : EN6J40/500 4. Recirculation Control Valve for BFP 5. Hydraulic Coupling of MDBFP, type : R18KGS
3.0
SUB VENDOR LIST FOR BOUGHT-OUT ITEMS
3.1
Mechanical Seals : BFP & CEP
(a)
M/s.Burgmann India Pvt. Ltd A.K. Industrial Estate Madina Manzil Compound S.V.Road, Goregaon (W) BOMBAY 400 062 Tel : 022-28741534, 1820, 1905 Fax : 022-28748820 M/s.Flowserve Sanmar Limited 147, Karapakkam Village CHENNAI 600 096 Tel : 044-2450 4140 Fax : 044-2450 2124 M/s.Eagle Seals&Systems India Ltd 212/2, Sholapur-Poona Road Hadapsar PUNE 411 028 Tel : 020-2650 8100 Fax : 020-2699 3921
(b)
BP
(c)
3.2
Journal Bearings :
(a)
M/s. Waukesha Bearings Argyle House, Joel Street Northwood Hills, Middlesex. Middlesex, United Kingdom, HA 6 1LN M/s.Michell Bearings Scotswood Road New Castle Upton Type N E 1 5 6LL, U.K. M/s.Michell Bearings India Pvt Ltd. 8D, Attibele Indl Area, Hosur Road, Bangalore 562 107 Tel : 080-2782 0202, 0303 Fax : 080-2782 0302 M/s.Colherne Ltd. Lodge Street, Newton Hyde Cheshire, SK 14 4LE United Kingdom Tel : 061-366 6603 Fax : 061-367 8239
(b)
(c)
(d)
3.3
Thrust Bearings : BP & CEP
(a)
M/s.Michell Bearings Scotswood Road New Castle Upton Type N E 1 5 6LL, U.K. M/s.Michell Bearings India Pvt Ltd. 8D, Attibele Indl Area, Hosur Road, Bangalore 562 107 Tel : 080-2782 0202, 0303 Fax : 080-2782 0302 M/s. Kingsbury Inc. 10385, Drummond Road Philadelphia., Pennsylvania, 19154 USA I/A : M/s.Arcum Engineering Pvt Ltd B-201, Matrusri Apartments Hyderguda, Hyderabad-500 029 Tel : 040-23211765 Fax : 040-23296197
(b)
BFP
(c)
3.4
Hydraulic Coupling
(a)
M/s. Voith Turbo GMBH & Co. P.B.No.1555 D-7180, Crailsheim GERMANY I/A: M/s.Voith India Pvt. Ltd. P.O. Industrial Estate Nacharam, HYDERABAD-500 076 Tel : 040-2717 3561, 3592 Fax : 040-2727 1141
3.5.
BFP RC Valve
(a)
M/s. Dresser Produits Industriels, France I.A. : M/s. Dresser Valves India Pvt Ltd. No.12, 2nd Floor, D-Block, Doshi Gardens 174, Arcot Road, Vadapalani Chennai 600 026 Tel : 040-52134056, 24802393 Fax : 040-52134057
(b)
M/s. Control Components Inc., 22591, Avenida Empresa Rancho Margarita California 92688 U.S.A
I.A. : M/s. Control Components India Flat no. 5-B, 377-A, Prince Anwar Shah Road Kolkata 700 068 Tel : 033-24833583 Fax : 033-24822052 3.6 Suction Strainers BP : Simplex Basket type BFP : Conical type CEP : Simplex Basket type (a) M/s. Gujarat Otofilt Plot no. 3712, Phase-IV GIDC Estate, P.B.No. 67 B/H New Nirma, Vatva Ahmedabad 382 445 Tel : 079-25841164, 25842719 Fax : 079-25842719 M/s. Otoklin Global Business Plot no.1, Shah Industrial Estate Veera Desai Road Andheri West Mumbai 400 053 Tel : 022-26732135, 226732123 e-mail : otoklin@vsnl.com M/s. Multitex Filteration Engineers (P) Ltd. 217, Hans Bhavan Bahadurshah Zafar Marg New Delhi 110 002 Tel : 011-23311275, 23316779 Fax : 011-2372 2221 M/s. Euroflex Transmissions India Pvt.Ltd Plot No.99, CIE Phase-II Gandhinagar, Balanagar HYDERABAD 500 037 Tel : 040-23079775, 23076970 Fax : 040-23079523, 27847149 M/s. Bibby Transmissions Limited. Cannon Way, Mill Street West Dewsbury, Yorkshire, WF 13 1EH, UK I/A : M/s.Rathi Transpower Pvt. Ltd. Rathi Chambers, 7-Deccan College Road PUNE 411 006 Tel : 020-26696820, 26694826 Fax : 020-26695655
(b)
(c)
3.7
Connecting couplings BP, BFP & CEP
(a)
(b)
(c)
M/s. Unique Transmissions (India) Pvt.Ltd. Mercantile Building, 10/1 D, Lalbazar Street 3rd Floor (Rear Block) KOLKATA 700 001 Tel : 033-2220 0366, 2248 0231 Fax : 033-2230 6593
3.8
Local Gauge Board Assy with Pre & Temp Instruments
(a)
M/s. Nagarjuna Fabricators Plot No. 44-B, Phase-1 IDA, Jeedimetla Hyderabad 500 855 Tel : 040-23096515 Fax : 040-23413977 M/s. Procon Instrumentation Pvt. Ltd. 1H, Sakthi Towers 766, Anna Salai Chennai 600 002 Tel : 044-28524942 Fax : 044-28522348 M/s. Panam Controls 12-11-1299/3, Raghavendra nagar Warasiguda Secunderabad 500 061 Tel : 040-27077546 Fax : 040-27070365 M/s. Instrumentation Limited KOTA 324 005 Tel : 0744-426309, 423381-85 Fax : 0744-426309
(b)
(c)
(d)
3.9
Local Instrument Rack for Transmitters, BFP&CEP
(a)
M/s. Instrumentation Limited KOTA 324 005 Tel : 0744-426309, 423381-85 Fax : 0744-426309
3.10
Reverse Rotation Monitoring System of TD &MD BFPs
(a)
M/s.Bently Nevada Corporation P.O.Box No.157 1617, Water Street Minden, Nevada, USA 89423 Through : M/s.Bently Nevada (Sales&Services) Ltd AIFACS Building, 1-Rafi Marg NEW DELHI 110 001 Tel : 011-23355899, extn. 505 Fax : 011-23737608
(b)
M/s. Shinkawa Electric Co. Ltd, Japan Through : M/s.Forbes Marshall A-34/35, MIDC Estate, H-Block Pimpri, Pune 411 018 Tel : 020-27442020, extn. 355 Fax : 020-27442040
NOTE :
- Indicates make of the equipment in original supply.
== ## ==
PART - 3
PRESERVATION & STORAGE
LIST OF CONTENTS
STD. NO. HY0490563 HY0490564
TITLE TRP Application on Ferrous components of different products Code of practice for storage of different products and their components
PLANT STANDARD
HYDERABAD
HY0490563
REV. NO: 04 PAGE 1 OF 12
TRP APPLICATION ON FERROUS COMPONENTS OF DIFFERENT PRODUCTS 1. 1.1 1.2 2. SCOPE: The standard covers the selection and applications of Temporary Rust Preventives (TRP) for different products & their components during production, before despatch and at site. This standard supersedes the old company standard and other Product Standards/ documents made on the subject. GENERAL: The effectiveness of TRP depends on the following aspects: 2.1 2.2 2.3 Selection of proper TRP. Proper preparation of the surface to be protected. Refer plant standard HY 067 41 66. Application of TRP Under normal atmospheric conditions, corrosion of machined surfaces starts as soon as they are accessible to moisture, air etc. Hence it is necessary to apply rust preventive immediately after the machining of surfaces. TRP Reference on manufacturing & erection instructions/drgs. wherever necessary by Engg. SELECTION OF TRPs: The list of rationalized TRPs, is given in Annexure - I. This covers various types, method of application, durability of protection, equivalent brands etc. 4. SURFACE PREPARATION: (For details refer plant std HY0674166) Before application of TRPs, it is necessary to ensure that the surfaces are free from rust, dust, dirt, grease, oil etc. The effectiveness of TRP depends on the cleanliness of the surface.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in any way detrimental to the interest of the company.
Copyright and Confidential
2.4 3.
Revisions: Cl. Nos. 1.2, 2.2 modified. Cl. No. 2.4 added. Cl. Nos. 4.1 to 4.4 deleted. Annexures I, II, & III modified. Rev.No. 04 Amd. No. Reaffirmed: Dt.FEB. 98 Dt. Year:
Issued : STANDARDS ENGINEERING DEPARTMENT Prepared: STDS. ENGG. Approved: SR.MANAGER STDS. ENGG. Date: MAY, 83
HY0490563
Rev. No.04 PAGE 2 OF 12 5. 5.1 5.2 6. 6.1 6.2 6.3 TRP APPLICATION:
PLANT STANDARD
HYDERABAD
The application of TRPs is classified in Annexure II keeping in view the finish and the extent of protection required. The details of components against each category of application are given productwise in the Annexure III.
PRECAUTIONS FOR APPLICATION: The TRP shall be stirred well in the original container so as to make a homogenous mixture of its constituents. The container, brush, cloth to be used for application of TRP shall be clean. The container and the brush shall be washed with white spirit, for the next operation.
Preservative shall be applied in closed premises not later than 3-5 hours after cleaning and degreasing. Application shall not be done in humid atmosphere and during sharp changes in temperature, which may cause sweating. Care shall be taken to see that the preservative coating is uniform and without overflow or gaps, bald spots, and flows in. Each subsequent layer shall be coated after the preceding one dries up completely. The quality of preservative layer shall be checked by visual inspection for uniform coat. Any defect observed shall be immediately rectified. DURABILITY OF PRESERVATION: The durability of preservation varies from 6 months to 1 year depending on the category of TRP application refer AnnexureI. After this period, it is necessary to inspect the preserved parts and if necessary carry out re-preservation after cleaning and making the surfaces free from corrosion, if any.
6.4
6.5 7.
8. 8.1 8.2
DETAILS OF REPRESERVATION TECHNIQUES: The earlier coating shall be removed by using white spirit. Rust if any shall be removed with fine emery paper. Care shall be taken to see that precision machined surfaces like Journal surfaces shall not be damaged during this operation. Surfaces prepared for re-preservation shall not be touched by hand. The duration of re-preservation shall be as per the durability of protection specified in Annexure I. After drying, re-preservation shall be carried out in accordance with clause 6
8.3 8.4
PLANT STANDARD
HYDERABAD
9. 9.1 9.2 9.3
HY0490563
REV. NO.04 PAGE 3 OF 12
DEPRESERVATION BEFORE ASSEMBLY / ERECTION: Depreservation of the various parts shall be done during Assembly/erection period as and when necessary. Depreservation of parts consists of removal of TRP coatings from all the machined surfaces with white spirit. Degreasing or cleaning of any forged components like rotors, blades, shafts etc., shall not be done with Chlorinated Solvents like Carbon Tetrachloride. Preservative Instruction to Site: 1. 2. This standard on preservation of different products and components shall be followed. As soon as the components are received at site, they should be examined for rupture of TRP film, VCI paper and development of rust, if any. Patch work wherever necessary should be done with the TRP system. The components should be stored in such a way that TRP film does not get damaged. The surface of TRP coated components shall be examined for damage and corrosion spots regularly. Represervation shall be followed as per the Tag attached to the component. Inspect coated and wrapped surfaces. If coating or wrapping appears to have been removed during shipping clean and re-wrap or coat as applicable. Inspect shafts for adequate preservative and add a heavy film of valvoline TECTYL 894 or Equivalent as necessary. Rotate the Rotors a few revolutions every month and ensure that the bearings are packed with grease.
3. 4. 5. 6. 7. 8.
HY0490563
Rev. No.04 PAGE 4 OF 12
PLANT STANDARD
HYDERABAD
RECOMMENDED TYPES OF TRPs (Clause 3) Type of TRP Hard Film Solvent deposited Description of TRP/SPEC. No. Rust Preventive Hard Film Black AA55154 Rust Preventive Hard Film Yellow AA55155 Rust preventive solution, clear (TRP) AA55152 Rust solution, Steam washable (TRP) AA55151 Temporary Corrosion Preservative Grease IS:958 Rust inhibitive oil (TRP) AA55153 Temporary corrosion Preventive Fluid IS:1153 Volatile Corrosive inhibitor (VCI) powder/tablet IS:5730 VCI paper IS:6263 Nitrogen Blanketing Silica-jel Method of Application Dipping, Spraying, Brushing Dipping, Spraying, Brushing -DoDurability of Protection 6 months 1 year 6 months 3 months Smearing Brushing Dipping, Rinsing, Spraying, Sprinklin 6 months 3 weeks 6 months 3 months
ANNEXURE-I Equivalent Brands HE 1710 (Bhopal) HE 1706 (Bhopal) HE 1709 (Bhopal)

Soft Film deposited Grease Oil
HE 1712 (Bhopal) IOC MultiPurpose Grease No.2 HE 1711 (Bhopal) ESSO: RUST BAN 394
Powder/ Tablet Paper Gas Crystal
Wrapping Filling Inserting
3 months 3 months 3 months
PLANT STANDARD
HYDERABAD
TRP APPLICATION CATEGORIES (Clause 5) TRP Application Category Application Details
HY0490563
REV. NO.04 PAGE 5 OF 12 ANNEXURE-II
Guide Lines for Selection
Apply 1 Coat of Rust Preventive Hard Film yellow (HE 1706) / AA55155 and 1 Coat of Rust Preventive Hard Film Black (AA55154)/HE1710. Wrap the surfaces with Volatile Corrosive inhibitive (VCI) paper with its active side facing the surfaces. Fix the ends with adhesive tape. Wrap the surfaces with rubber sheet and then with aluminium foil of thickness 0.05 to 0.1 mm. Fix the adhesive tape. Apply 1 Coat of Rust Preventive Hard Film yellow (HE 1706) /AA55155 and 1 Coat of Rust Preventive Hard Film Black (AA55154)/ HE1710. Apply 2 Coats of Anti Rust solution, steam washable (TRP) (AA55151) / HE1712 Apply 2 Coats of Rust Preventive solution, Clear (TRP) (AA55152) / HE1709 Apply 2 Coats of TRP fluid (IS:1153)
Longer duration of protection before despatch to site. Suitable for precision machined surfaces with simple profiles, eg. Rotor Journal Surfaces
D E F G H I
Apply 1 Coat of Rust inhibitive oil (TRP) (AA55153) / HE1711 Apply Temporary Corrosion Preventive Grease IS:958 liberally and wrap in polythene sheet/bag and tie it with a thread Wrap with 2 layers of VCI paper IS:6263 and one layer of Polythene Sheet. Sprinkle VCI powder/tablets IS:5730 inside pipe. Close the ends by plastic caps and adhesive tape.
Longer duration of protection before despatch to site. Suitable for precision machined surfaces like parting plane suraces, covers, couplings, base plates, machined cross around pipes etc. Steam Turbine components of complicated profiles where steam washing facility is available eg. Steam Turbine rotor components. Steam Turbine components of complicated profiles where there is no facility for steam washing. Steam Turbine components of complicated profiles. The TRP is with brown Pigment. Machined components during the process, Storage on shop floor over 1 month upto 3 months. Suitable for Fasteners, chains, Gear Wheels etc. Suitable for commutator of Armature, Bushings. Inside oil pipes.
HY0490563
PLANT STANDARD
HYDERABAD
ANNEXURE II TRP Application Category J Application Details Guide Lines for Selection
Suitable for all exposed tapped holes and flanged openings on the pumps and Tubings.
Draining after Hydro Test drying with hot air, evacuation of the vessel and Nitrogen blanketing. Keep silica-jel bag inside suction and discharge branches, close all opening close all tapped holes with red plastic caps (HY7242375 for G threads, HY7242579 for NPT threads). Close all flanged openings with suitable metal covers (HY7790963).
Suitable for the water chamber and the shell side of Heat Exchanger
PLANT STANDARD
HYDERABAD
PRODUCT COMPONENTS TRP CATEGORIES (CLAUSE 5.2)
HY0490563
ANNEXURE III DETAILS OF COMPONENTS STEAM TURBINE AND COMPRESSORS HP,LP and other rotors. Rotor Journals, Thrust Collars
TRP APPLICATION CATEGORY A B B B B B
Base plate machined. Crossed around pipes, machined Bearing pedestals with assembled parts and bearing housings Outer machined surfaces HP turbine outer casings Outer machined HP, LP and other rotors. Rotor coupling flange faces, coupling bolt holes Welded low pressure Turbine components Longitudinal Grider and front Outer machined LP upper part outer machined surface LP inner outer casings outer machined surface LP Inner, inner casings outer machined surface Fasteners of Threaded portions Unthreaded portions (M64 and above) HP Exhaust Elbow outer machined surface Shaft lifting and clearance measuring device, machined surface Assembly fixtures for HP Turbine, machined surface Turning over device for HP Turbine, machined surface Transportation device for HP Turbine, machined surface Oil tank Outer machined surface Injector Nb. 300 Outer machined surface Main steam and re-heat strainer body Outer Cast exhaust hood Outer machined surface
B B B B B B B B B B B B B
HY0490563
PLANT STANDARD
HYDERABAD
ANNEXURE III DETAILS OF COMPONENTS Cross around pipes, inner Valves-casings and covers Inner un-machined surface Bearing pedestals with assembled parts and bearing housings Outer un-machined surface HP and outer turbine outer casingInner HP and IP inner casing and diaphram-carrier and guide blade carrierOuter Inner HP, LP and other rotors. All surfaces except journals, Thrust collars Flange cases and coupling bolt holes STEAM TURBINE AND COMPRESSORS Welded low pressure Turbine components Logitudinal Girder and front valves Inner LP upper part, Inner LP Inner, outer casings Inner including blades Outer un-machined LP Inner, inner casings Inner including blades Outer un-machined Cover for shaft sealing casing Inner Steam inlet and extraction connections Inner and outer HP Exhaust elbow Inner Handling Barring Gear and hydraulic Gear oil tank Inner Injector Nb.300 Inner Main steam and re-heat strainer body Inner TRP APPLICATION CATEGORY C C C C C C C
C C C C C C C C C C C C C
PLANT STANDARD
HYDERABAD
HY0490563
ANNEXURE III DETAILS OF COMPONENTS Blanking arrangement for strainer body Oil strainer Main steam and reheat strainer handling device, machined Oil throttle valve, inner Oil stripper journal Cast exhaust hood Inner Compressor Rotor
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectely in any way detrimental to the interest of the company.
TRP APPLICATION CATEGORY C C C C C C D/E G G G G G G G G G I I A
Bearings, Oil seals, couplings, spare blades, gland ring Lifting beams and clamps machined Valves casings and covers Inner machined Spindles Fasteners of Threaded portions Unthreaded portions Emergency Governor Piping of governing and LP bypass central rack and supply unit for valves, inner Suspension arrangement for ESU and interceptor valve Machined surfaces and springs Tools and tackles for governing equipment, machined Oil pipeline outside the governing equipment Other pipings ELECTRICAL MACHINES Rotor Journals, Slip rings, Journals of Armature Stator End Flanges, machined flanges, Machined surfaces of Foundation Frames, Base plates. Machined components, Base plates, Machined surfaces of Oil cooler, Air cooler, Accessories Rotor coupling face, threaded holes of exposed surfaces, bearing shells. Fasteners, internal/external threaded surfaces Commutator of Armature, Bushings
B B G H
HY0490563
PLANT STANDARD
HYDERABAD
ANNEXURE III
DETAILS OF COMPONENTS SWITCHGEAR Hydraulic pistons Operating mechanisms after testing and before shipment HLD Base frame, Machined Flange surfaces and mechanism housing, Terminal butting surfaces. Machined Ferrous components like shafts, pins, gears Springs, links and levers, castings, machined surfaces of fabricated housings, catches, latches, rollers protective pipe flanges. Chains and bearings, pull rod (threaded portion), Base frame Tapped holes, external/internal threaded surfaces, fasteners. HEAT EXCHANGERS inside condenser shells, inside deaerator shells, machined surfaces of flanges and drilled tube sheets/ support plates Inside of Rectangular and very large condensers. Machined surfaces of condenser, tube sheets. Inside water chamber and shell side of feed water heaters OIL FIELD EQUIPMENT Rig instrumentation Valves and disconnectors dampers for gauges, indicating instruments. Mud Agitators Machined surfaces of mud system Hoisting and rotating equipment Rotory, Swivel, travelling block, Hydra Hooks Mud system Centrifugal pump, external surfaces of mud agitators Mud pump external surfaces, loose parts of mud pump. Mud pump internal surfaces with oil contact. Centrifugal pump, mud pump internal surfaces with liquid contact. (Except Oil)
TRP APPLICATION CATEGORY A

D/E F G D/E
G J
G G G
G L
PLANT STANDARD
HYDERABAD
HY 0490563
REV. NO.04 PAGE 11 OF 12 ANNEXURE III
DETAILS OF COMPONENTS BOWL MILLS Machined surfaces Inside Gear case assembly Bearings, Drive couplings, fastener, external/internal threaded surfaces PUMPS Journal Bearings, bearing surfaces and exposed portion of shafts. Exposed machined surfaces of ferrous components like thrust collar large fabricated frames, foundation frames, pump discharge covers, tubular cooler, catridge, keyway blocks of pump casings, Head gears, Canisters, Foundation Rings, elements, CWP parts. Ferrous components stored in assembly shop, freshly machined surfaces with more than 1 to 3 months gap between one operation to another Spare parts, fasteners, external/internal threaded joints All exposed tapped holes and flanged openings on the pumps and tubings GAS TURBINES Journal & Thrust Bearings, Rotor journals & Thrust collars Ferrous components stored in assembly shop, freshly machined surfaces with more than one month gap between operations All exposed tapped holes and flanged openings on the pumps Exposed machined surfaces/parting planes of all ferrous fabricated frames including base plates, couplings Fasteners, External/Internal threaded joints Oil pipes when stored for long periods or when despatched loose Torque converter fill with lube oil, plug all openings If storage and/or despatch period together exceeds 3 months Fuel pump and flow dividers-fill with HSD, plug all openings, if storage and/or despatch period together exceeds 3 months
TRP APPLICATION CATEGORY D/E F G
A B
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectely in any way detrimental to the interest of the company.
F G K
A F K B G I
HY0490563
PLANT STANDARD
HYDERABAD
ANNEXURE A LIST OF SUPPLIERS OF TRP
M/S. BHEL, Bhopal M/S. Ceturion coatings, Madras M/S. Agromore Ltd., Bangalore
Rust preventive oil Rust preventive compound (proprietary)

Rust preventive Agents - --Copyright and Confidential
M/S. Mascot chemical works, Bangalore M/S. Chembond chemicals Pvt. Ltd., Bombay
M/S. Pradeep Metal Treatment Chemical Pvt. Ltd., Thane M/S. Surendra Enterprises, Hyderabad M/S. Canning Mithra phomics Ltd., Bombay M/S. Grawer & Weil (Ind) Ltd., Bombay M/S. Metrit Industries, Bombay M/S. Electro chemicals, Calcutta M/S. CMF Systems, Secunderabad M/S. Peddainton chemicals Industries (Ind), Bombay M/S. Protochem Industries, Bombay M/S. Suprabha protective, Products, Pune M/S. OKS, 5/9, Primorse Road, - 1) Bangalore - 560025 2) 3) 4) 5) 6) 7) 8) 9) Prosol Chemicals Pvt. Ltd. -
--------Rust Poliq N (Proprietary)
OKS 240 Anti seize compound OKS 1140 High Temperature Silicone grease OKS 410 Mos 2 High performance long life grease OKS 300 Mos 2 Mineral oil concentrate (Additive) OKS VCI : 368 N OKS - VCI : 369 N OKS - 2140 OKS - 2160 OKS - 2201 1) Rustex - 221 1) Futech - AR (LT)
M/S. M/S.
Futech chemicals (P), Secundeabad -
PLANT STANDARD
HYDERABAD
HY0490564
REV. NO: 01 PAGE 1 OF 7
CODE OF PRACTICE FOR STORAGE OF DIFFERENT PRODUCTS AND THEIR COMPONENTS 1.0 1.1 SCOPE: This standard covers the requirements of storage conditions applicable for different products and their components (either manufactured, boughtout or subcontracted) at shop, before despatch and at site. The relevant storage condition at site shall be indicated in the despatch note. Reference may be made to the following related standards: HY 0490561 - Code of practice for storage of preservation of Materials in stores. HY0674160 HY0490563 - Code of practice for painting of different products and their components.
1.2 1.2.1 1.2.2 1.2.3 2.0
- Code of practice for preservation of different products and their components. TYPES OF STORAGE CONDITIONS: The storage conditions are classified as follows:
2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.2.3
Storage condition P Denotes storage in a totally enclosed shed under controlled conditions. The shed shall be free from any kind of corrosive gas like chlorine, ammonia or smoke, chemicals and charged accumulators. Stored items shall be covered with polythene sheets. Storage condition Q Denotes storage in a totally enclosed shed. The shed shall be ventilated dry, free from dust, any kind of gas or chemicals. Items like Motors, Coils and all spare parts shall be covered with polythene sheet.
Revisions Rev.No. 01 Rev. Date OCT. 93 Revised: AGM (E&CC)
Issued : STANDARDS ENGINEERING DEPARTMENT Prepared: Approved: Date: SR.MANAGER VNR STDS. ENGG. MAY, 83
HY0490564
Rev. No.01 PAGE 2 OF 7 2.3 2.3.1 2.3.2 2.4 2.4.1 3.0 3.1 3.2 3.3 3.4 3.5 4.0 Storage condition R
PLANT STANDARD
HYDERABAD
Denotes storage in shed having roof but no side walls. The floor shall be either of concrete or wood to take the load of the components/parts to be stored. The shed shall provide protection to the components/parts stored against rain. Storage condition S Denotes storage in open yard on elevated platform/wooden sleeper. GUIDELINES FOR CONSTRUCTION OF STORAGE SHEDS The shed may be constructed on Tubular Truses with Asbestos cement sheet roofing. The sheds/yards shall be provided with path ways to facilitate movement of vehicles. Sheds and storage areas shall be provided with good lighting to facilitate handling of materials at night. All equipment shall be stored on sleepers for easy handling. Necessary lifting equipment shall be provided. STORAGE CONDITIONS FOR DIFFERENT PRODUCTS/COMPONENTS: The details of components to be stored under different storage conditions product wise are indicated in Annexure 1.
5.0
PRECAUTIONS DURING STORAGE The following special precautions shall be taken during storage: a) Instruments: Instruments shall be stored within the original packing boxes as far as possible. Instruments shall be handled carefully. They shall not be stacked on over the other. The cables shall not be twisted. b) Pipes: All pipes upto &including 25mm OD shall be stacked in suitable racks to facilitate access and handling. Pipes above 25 mm OD shall be stacked on wooden sleepers to prevent ingress of dust & moisture. Pipe openings shall be closed with suitable plugs/caps. Deformity during storage shall be avoided. Heat exchangers tubes shall be stored within the original cases in which they are received. C) Rotors: The rotors shall be stored in the original packing boxes. The turbine and compressor rotors shall be rotated once in 3 months to avoid sag due to long storage. i) ii) iii) iv) It shall be rotated by 180 deg, after its receipt at site. It shall be rotated by 90 deg, after 3 months. It shall be rotated by 180 deg, after subsequent 3 months. It shall be rotated by 90 deg, after subsequency 3 months.
PLANT STANDARD
HYDERABAD
d) i) Casings
HY0490564
e)
The parting planes of casings shall be kept on the top to the extent possible. If the casinghas to be kept in inverted position due to unavoidable reasons, the parting planes shall be kept on dry wooden beams. Rubber pads or grease or oilimmersed felt shall be kept between the parting plane and contact surfaces to protect the surfaces. Auxiliary Pumps If the pump is kept idle for 6 months, the bearings of the pumps shall be cleaned and the shaft shall be rotated after pouring oil into the lubricating chambers.
f)
Electrical components: The Handling, storage and preservation of Turbo-generators and auxiliaries shall be as per product standards TG55500 and TG55501.
g)
Operating Mechanism of switchgear The heater shall be switched ON in cold and humid conditions.
h)
H2 seal oil system components, air coolers and accessories, valves. All openings shall be closed with suitable blinds/plugs/caps to prevent the entry of dirt, foreign matter and moisture.
i)
Rubber gaskets and other miscellaneous items. All rubber gaskets shall be applied with a coat of french chalk. Care shall be taken to prevent twisting, deformation and stress during storage. They shall be stacked separately to prevent damage.
j)
Foundation Frames The frames shall be placed over the wooden sleepers at a number of points interposing 10 mm rubber sheets at the resting places. No other load shall be placed over the frames to prevent permanent deformation.
k)
The original steel blanking plates shall be fastened with hardware and sent along with the equipment from the plant. They shall be retained during the entire storage period and removed only at the time of erection. NOTE 1) Refer Plant Standard Hy 0490562 for Preservation of Heat Exchangers before shipment.
6.0)
HY0490564
PLANT STANDARD
HYDERABAD
Annexure 1
Details of components/parts INDUSTRIAL TURBINE & COMPRESSORS Instruments like Electromagnetic protection, vibration measuring equipment, Eccentricity mesuring equipment. Assembled Compressors & Turbines, Rotors, Casings, Valves, Bearing Pedestals, Bearings, Gears, Parting plane bolts, Servomotors (Hydraulic actuators), Inspection shaft with its rings & all precision mechanical equipment, bolts heating equipment, Thermometers, Pressure gauges, mano stats etc. Oil Tanks, oil coolers, Turbine and Compressor Covers, Injectors, Piping and safety membranes, bearing covers Fasteners, oil seals, Couplings etc. Pipes, Flanges, Channels, Sheets etc for construction purpose at site. STEAM TURBINES Instruments, Turbovisory equipment Rotors, HP & MP casings, HPQC stop and governing, valves LPQC inspection valves, Bearing pedestals, Bearings, Non- return valves, Parting plane Bolts, Servo motors, jacking oil pump with its rings, Inspection shaft, Middle LP Body, Bolt heating equipment, Thermometers, Pressure Gauges, manostats etc.. Front and rear LP top and bottom parts.
Type of storage P
Remarks Maximum Temparature 20 C. Temparature deviation in 24 hours shall not exceed 5 C. Humidity less than 40%.
Q
R S P Max Temp 20C. Temparature deviation in 24 hours shall not exceed 5C. Humidity less than 40%
PLANT STANDARD
HYDERABAD
HY0490564
Details of components/parts Main oil Tank, Auxillary Oil Tank, Oil coolers, Turbine Cover, Injector, MP upper and Lower tube fittings, interconnecting piping and safety membranes, piping outside the pedestal, Foundation bolts etc. GAS TURBINES Rotor, HP & LP journals and thrust Collars Base plate. Machined surface of: Inlet casing Compressor casing Turbine casing Bearing housing Assembly fixtures Fuel nozzle Tip assembly Cap Transition piece Lifting beams Bearing liners Fasteners, external & internal Threaded surfaces ELECTRICAL MACHINES Instruments, Thermometers, Pressure Switches, Flow Switches, Rubber and Neoprine, gaskets, V Belts, Stator, Rotor, Bearing pedestals, Bearings, tube oil console with motors, Non return valves, Air coolers, co2 equipment, shaft driven oil pump with pulleys, precision components and machined parts. Oil coolers, Fasteners, Lube oil Piping & Cooling water piping, erection fixtures like Tackles, Mounting Blocks, Extension Beam and MS sheets, outer covers Erection fixtures Transport Frames, Stands, Plates, Foundation Frame.
Type of storage R
Remarks
R S
HY0490564
PLANT STANDARD
HYDERABAD
Details of components/parts TURBO GENERATORS & AUXILIARIES
Type of storage P
Remarks Temparature Range 35-45 C. Relative humidity less than 40%, Dust free atmosphere.
Q Spare items like interrupter assy, fixed contact Assy, moving contact assy, Lam washer, interrupter Disc. Poles of circuit Breaker, operating Mechanism, Base Frame, Structure details BOWL MILLS PUMPS Axial shift indicator, Reverse Running inidcator, vibraton Monitor instrument. R Q P Maximum Temperature deviaton in 24 hours shall not exceed 5 C. Humidity less than 40%
Stator with transportation frame, Rotor, Exciter stator & Gear Box Assy, Exciter Armature, output leads, AVR Cubicle, Field Breaker Cubicle, AVR Accessories, Gas and oil panels, Field Rheostat, Rotor Temperature recorder, Gas and oil panel, Relay control panels HGL components, Internal covers, Rubber packings. End shields, Body of sealings, Bearings, Fan blades, H2 coolers Brush gear, stilling tank, seal oil unit, vacuum unit, PMG, Air coolers, Exciter rear Bearing and Assy, Thermometers. Foundation Frame, Foundation Bolts and Base plates, Mounting Extension and intermediate piece, stand and yoke, Mounting Truck, Covers, Piping Air proof door, supporting frame, slide valves suspension device, Fasteners. SWITCH GEAR
PLANT STANDARD
HYDERABAD
HY0490564
Details of components/parts Instruments, Pressure gauges, Pressure switches, Temperature gauges, Temperature switches, RTDs, Assembled pumps mounted on their individual foundation frames, Drive Motors, Hydralic couplings, connecting couplings with protective gaurds, all types of valves along with actuvators, oil and water coolers, all spare parts except instruments, special tools for maintenance of pumps including pump assy & dismantling fixtures, local panel, column pipes, Discharge Elbows, Foundation ring shafts, Condensate tank/canister, Local panel. Foundation Bolts, fabricated grillages, common for Boiler feed pumps, Hydraulic coupling BFP Motor and Booster pump. HEAT EXCHANGERS Surface condensers and its parts like water chambers, shells, springs, superstructure, Hotwell, Instruments, steam jet Air ejector, and spare nozzles, L.P. Heaters, Chemney steam Condenser, Gland steam Condenser, H.P Heaters, Deaerator and its parts like storage tank, Header Assy, Vent Condenser and its parts like instruments, safety valves, oil coolers, Air coolers, Hydralic coolers, Vacuum pumps, HE tubes
Type of storage
Remarks
PART 4
EQUIPMENT DETAILS
PART 4
EQUIPMENT DETAILS
LIST OF CONTENTS
SECTION (A) (B) (C)
TITLE Boiler Feed Booster Pump Boiler Feed Pump Condensate Extraction Pump
SECTION - A
BOILER FEED BOOSTER PUMP
PART 4
EQUIPMENT DETAILS
SECTION - A BOILER FEED BOOSTER PUMP
LIST OF CONTENTS
CHAPTER 1 2 3 4
TITLE Description Opening Instructions Maintenance Instructions Sub-Vendors Drawings / Instructions
SECTION - A BOILER FEED BOOSTER PUMP
CHAPTER 1 DESCRIPTION LIST OF CONTENTS
1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6
Introduction Technical Data Motor Driven pump Turbine driven pumps Driver / Pump flexible coupling Description Pump casing Rotating assembly Journal and thrust bearings Bearing housings Mechanical Seals Driver / pump coupling
CHAPTER 1
DESCRIPTION
1.
INTRODUCTION :
Three Booster Stage Pumps are supplied to each 500 MW Unit. Each pump consists of FA1B75 type Booster Stage Pump, two are driven by turbine through gear box and one is Motor Driven. The FA1B75 type Booster stage pump is a single stage, horizontal, axial split casing type, having the suction and discharge branches on the casing bottom half, thus allowing the pump internals to be removed without disturbing the suction and discharge pipe work or the alignment between the pump and driving motor. The pump shaft is sealed at the drive and non-drive end by mechanical seals which are flushed by boiler feed water pumped round a closed circuit. The rotating assembly is supported by plain white metal lined journal bearing sand axially located by a double thrust bearing. The bearings in the pump are lubricated by forced oil lubrication system.
2. 2.1 2.1.1 TECHNICAL DATA : Motor Driven Pump Pump Manufacturer Type Direction of rotation (Viewed on non-drive end) Liquid pumped 2.2 2.1.2 Turbine Driven Pump Pump Type Direction of rotation (Viewed on non-drive end) Liquid pumped FA1B75 Clockwise Boiler feed water BHEL FA1B75 Anti-Clockwise Boiler feed water
2.3
Thrust Bearing Manufacturer Type Michell Bearing / Glacier Double thrust
2.4
Mechanical seal Manufacturer BURGMANN, Germany
2.5
Driver/Pump Flexible Coupling Manufacturer Euroflex, India
3. 3.1
DESCRIPTION : Pump Casing : The cast steel pump casing is of the double volute type, split on the horizontal center line. The top and bottom half casing are located to each other by dowel pins and secured by the studs and nuts, sealing at the axial split being effected by a two-ply brown paper joint. The bottom half pump casing has the suction and discharge branches and support feet, cast integrally. The pump casing is machined internally to accept the casing rings and stuffing boxes are also formed at each end of the casing to accommodate the water jackets and the mechanical seals, thus preventing leakage along the pump shaft. The interface of the casing and base plate supports is near the shaft axis. Dowels and a guide key are arranged to maintain longitudinal and transverse alignments whilst accommodating thermal expansion. A tapped air vent connection is provided on the top half casing. Connections are also provided on the suction and discharge branches for pressure gauges and a drain.
3.2
Rotating Assembly : The rotating assembly consists of the shaft, impellers, nuts, keys, seal sleeves, thrust collar, the rotating parts of the mechanical seals and pump half coupling. The double entry impeller is keyed to the shaft and is located axially by an impeller nut on each side of the impeller hub. The impeller is fitted with a wear ring on each shroud, the rings being retained by grub screws. The seal sleeves are keyed to the shaft and are located and secured by grub screws. Leakage between the shaft and sleeve is prevented by an O ring fitted in a groove machined in the bore of the sleeve. The thrust collar is keyed to the shaft and is secured against a shoulder on the shaft by the thrust collar nut. The pump half coupling is keyed to the tapered end of the shaft and is secured by a coupling nut, locked by a lock screw.
3.3
Journal and Thrust Bearings :
The rotating assembly is supported at each end of the shaft by a white metal lined journal bearing and the residual axial thrust is taken up by a tilting pad double thrust bearing mounted at the non-drive end of the pump. The journal bearing shells are of mild steel, white metal lined, thick wall type, and are split on the horizontal plane through the shaft axis. Each bearing is prevented from rotating by a dowel pin located in a recess in the top half bearing housing. The thrust bearing is fitted at the non-drive end of the pump and has eight titling pads in a split carrier ring on each slide of a thrust collar, which is keyed to the pump shaft and secured by a nut and lock-washer. The carrier rings are held in non-drive end bearing housing and are prevented from turning with the thrust collar by dowels locating in slots in the top half of the housing. The thrust pads are retained on the carrier rings by special pad stops screwed into the rings. Machined spacers are fitted behind each carrier ring during manufacturer to effect the axial running position of the rotating assembly. The thrust bearing is provided with for resistance temperature detectors. A split floating oil seal is fitted in a groove in the housing to maintain a level of lubricating oil with in the housing, around the thrust bearing, when the pump is stopped. The floating seal is prevented from turning by an anti-rotation pin fitted in a slot in the bottom half of the housing. An orifice plug fitted at the thrust bearing lubricating oil outlet ensures a flooded bearing housing when the pump is stationary. The bearing are supplied with lubricating oil from the forced lubricating oil system. For further information on the bearings references should be made to be bearing manufacturers instructions at Chapter 4.
3.4 Bearing Housings :
The bearing housings are in the form of cylindrical castings, split horizontally, secured to each bracket, by set screws and dowels located. Each housing is provided with lubricating oil inlet and outlet connections, vent connections and instrument entry points. The top and the bottom halves of the drive end bearing housings are secured together by studs and nuts, and the housing is closed at the drive end by a cover plate. An oil retaining shield at each end of the housing prevents oil leakage from the housing when the pump is running. The top and the bottom halves of the non-drive end bearing housing are secured together by studs and nuts and located by dowel pins. Leakage of lubricating oil from the non-drive end bearing housing is prevented by an oil retaining shield in the in board side of the housing and by a bearing housing end cover and joint secured to the out board side of the housing by hexagon head screws.
3.5
Mechanical seals : The drive and non-drive end seal cooling jackets are fitted with mechanical seals mounted on seal sleeves and located within seal cooling jackets. The cooling jacket, which provides a heat soak barrier between the pump casing and the mechanical seal, is continuously flushed with cooling water from an external source.
A pumping ring incorporated in the mechanical seal pumps a supply of boiler feed water through a heat exchanger in a closed circuit, thus keeping the seal circuit temperature at approximately 60C. For further information on the mechanical seals reference should be made to the manufacturer's instructions at chapter 4.
3.6 Driver / pump coupling :
The drive from the driver to the pump shaft is transmitted through a spacer flexible coupling.
SECTION A BOILER FEED BOOSTER PUMP
CHAPTER 2 OPERATING INSTRUCTIONS
LIST OF CONTENTS
1. 2.
Introduction Fault finding
CHAPTER 2 OPERATING INSTRUCTIONS 1. INTRODUCTION : The type FA1B75 booster stage pump is an integral part of the 50% tandem Boiler pump set and must be operated as a pump set. For operating instructions of the pump set, refer the operating instructions for the pressure stage pumps. 2. FAULT FINDING : Symptom (1) Pump fails to starts. Possible Cause (a) Driver fault. (b) Power supply fault. (c) Seizure of pump set Action Check driver. Check supply. Disconnect couplings and Locate seizure. Overhaul as necessary. Check deareator.
(d) Deareator Level Low- Low (e) Pump set tripped.
Investigate cause. Rest trips. Check driver.
(2)
Pump performance Low.
(a) Driver fault
(b) Incorrect rotation. (c) Pump suction defective. line
Check direction of driver. Check deaerator, suction strainer and suction isolating valve, etc. Check clearances and overhaul as necessary.
(d) Excessive wear pump internals.
of
Symptom (3) Bearings overheating.
Possible Cause (a) Defective in lubricating oil system. (b) Bearings worn or misaligned. (c) Misalignment of pump.
Action Check lubricating oil system.
Examine bearings.
Check alignment. Check cooling water supply.
(4)
Mechanical seals overheating
(a) Insufficient cooling water. (b) Mechanical seal faulty.
Check mechanical seal. Check alignment.
(5)
Excessive noise and/or vibration
(a) Misalignment of pump.
(b) Bearing misalignment. (c) Excessive clearance of pump internals. (e) Rotating assembly out of balance.
Examine bearing. Check clearances and overhaul as necessary. Check dynamic balance.
CHAPTER 3 MAINTENANCE INSTRUCTIONS
LIST OF CONTENTS
1 1.1 1.2 2 2.1 2.2 2.3 3. 3.1 3.2 3.3 4. 4.1 4.2 4.3 4.4 5
Introduction Periodic and preventive maintenance Routine checks Maintenance Particulars Estimated weights Joints Recommended lubricants Maintenance procedures Preparation for maintenance Examine the drive and journal bearing Examine the non-drive and journal and thrust bearing Overhaul Preparation for overhaul Dismantling the pump Inspection and renewal Assembling the pump Parts Identification
1.
INTRODUCTION : It is recommended that a system of routine inspection be established by which the condition of the pump can be determined and recorded for comparison with later inspections. Any defects should be repaired or the components renewed at the earliest opportunity. Certain inspections can only be made when the pump is shut down, but others can be made under operating conditions. A high degree of cleanliness of each pump and of the surrounding areas should be maintained, as this will assist in the early detection of minor leaks or defects which, if unnoticed, could lead to more serious operational or maintenance problems.
1.1
Periodic and preventive Maintenance The pump performance should be used as the criterion for the need to renew wearing parts. The pump may deteriorate due to excessive leakage past the impeller / casing wear rings, or vibration may indicate that the wear rings or bearings are worn. Note : The recommended renewal clearances are 1.5 times the clearances shown on the Sectional Arrangement Drawing HY-DG-188-139-0017. If the pump performance has declined it may be necessary to renew the wearing parts before the recommended clearances are reached.
1.2
Routine Checks : It is essential that the routine checks given in the operating instructions for the pressure stage pump are carried out regularly. The checks concerned with the mechanical condition of the pump are repeated here for the convenience of the maintenance engineers.
1.2.1
Periodic Checks : It is recommended that the following checks are carried out regular intervals. (1) (2) (3) (4) (5) Check that the suction and discharge pressure are normal. Check that the pump bearing lubricating oil pressures and temperatures are normal. Check for leakage from the mechanical seals. Check all joints for leakage. Check for any undue noise or vibration.
(6)
Carry out visual check on all keeps and fastenings, playing particular attender to the holding-down bolts.
Note : Reference should also be made to the manufacturers instructions in Chapter-4. 2 2.1 MAINTENANCE PARTICULARS : Estimated Weights (for lifting purposes) Item Pump assembly Top half pump casing Pump shaft Impeller Water jacket 2.2 Joints : Joints Between Top half pump casing/ Bottom half pump casing Pump casing / water jacket Non-drive end bearing Housing / end cover 2.3 Recommended Lubricants : For the recommended grade of lubricating oil for the journal and thrust bearings of the booster stage pumps, refer to the lubrication schedule included at the end of this chapter. For the grade of lubricant supplied, refer to the manufacturers instructions for the turbine and the turbo coupling. 3. MAINTENANCE PROCEDURES : WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE PROCEDURES. The Booster stage pump is an integral part of the Boiler feed pump set. The following instructions should, therefore, be read in conjunction with those for the pressure stage pump and the associated equipment. Material Brown paper Klingersil 4200 Brown paper Section Two ply Weight, Kg. 2365 760 74.5 127 31
Two ply
Note :
3.1
Preparation for Maintenance : Before commencing any maintenance procedures, the pump set must be Isolated as follows :
(1) (2) 3.2
Isolate the driving motor / turbine. Refer to manufacturers instructions. Isolate the electrical power supplies to all instruments.
Examining the Drive End (DE) Journal Bearing : (1) (2) (3) Disconnect and remove any instruments which could interface with the dismantling procedures. Remove the drive / pump drive coupling guard. Disconnect the drive / pump coupling. The top half bearing housing is located on the bottom half bearing housing by two dowel pins. Care must be taken to avoid damage to the dowel on the holes in the bottom half housing.
COUPLING :
(4)
Withdraw the dowel pins and remove the nuts from the studs securing the top of bearing housing to the bottom half bearing housing. Lift away the top half bearing housing complete with the top half oil guards. Remove the top half journal bearing from the shaft. Take the weight of the pump shaft and rotate the bottom halves of the journal bearing and oil guards around the shaft and lift them away. Examine the journal bearing and shaft journal for signs of damage, scoring or deterioration and examine the journal bearing and the oil guards for wear. Reference should be made to the Sectional Arrangement Drawing HY-DG-188-139-0017 for the clearances of the journal bearing.
(5)
(7)
(8)
Note : Lightly smear the shaft and journal bearing surface with oil before final assembly. (9) Rotate the bottom halves of the journal bearing and all rotating shields around the shaft and into position in the bottom half bearing housing. Release the weight of the pump shaft.
Note : It is recommended that, at this stage, the thrust bearing axial clearance is checked and any necessary adjustments made before proceeding further. Refer to section 3.3. in this chapter. (10) (11) Locate the top half journal bearing in position on the pump shaft. Lift the top half bearing housing complete with the top halves of the oil guards onto the bottom half bearing housing. Locate the top half bearing housing to the bottom half housing with the dowel pins, then secure the top half housing in position with the studs and nuts.
(12)
(13) (14)
Reconnect the drive/pump coupling. Replace the instruments and the drive/pump drive coupling guard.
3.3.
Examine the non-drive End (NDE) Journal and Thrust Bearing : (1) Disconnect and remove any instrument dismantling procedures. which could interface with the
(2) (3) (4)
Remove the drive / pump drive coupling guard. Disconnect the drive / pump coupling. Remove the screws securing the bearing housing end cover to the top and bottom half bearing housings. Remove the cover and discard the joint. The top half bearing housing is located on the bottom half bearing housing by two dowel pins. Care must be taken to avoid damage to the dowels or the holes in the bottom housing.
CAUTION :
(5)
Withdraw the dowel pins and remove the nuts from the studs securing the top half bearing housing to the bottom half bearing housing. Lift the top half bearing housing complete with the top half oil guard away. Remove the top half journal bearing form the shaft. Unclip the spring and remove the split floating oil seal from the bearing housing.
(6)
(7)
Note : The thrust carrier ring split line is vertical to the bearing housing horizontal surface. (8) Remove each thrust carrier ring in turn, as a complete unit, as follows : Rotate the complete carrier ring around the shaft until the half ring with the stop pin can be removed, then rotate the other half ring around the shaft until it can be lifted clear of the shaft. Repeat with the second carrier ring on the other side of the thrust collar. Take the weight of the pump shaft (i.e, support the shaft) and rotate the bottom halves of the journal bearing and the oil guard around the shaft and out of the bottom half bearing housing. Lift the halves of the bearing and guard away. Examine the journal bearing, shaft journal, thrust pads, thrust collar, split oil and oil guard for damage or deterioration. Under normal operation conditions it is not expected that any measurable wear will take place on the thrust pads other than a dulling of the white metal surfaces. It is
(9)
(10)
recommended that when this dulling has spread to more than half the surface area of the pads, they should be renewed. Refer to the Sectional Arrangement Drawing and renew the components if necessary. Note : Lightly smear the shaft, thrust collar faces and bearing surfaces with oil before final assembly. (11) Support the shaft and rotate the bottom halves of the journal bearing and the oil guard around the shaft and into position in the bottom half bearing housing. Install the split floating oil seal on the pump shaft with the spring. Release the weight of the pump shaft. Fit a new paper joint onto the end cover and secure the cover to the bottom half bearing housing with the screws. Install each thrust carrier ring in turn, as a complete until, as follows : Take the half carrier ring with out the stop pin and place it over the shaft with the pad faces touching the thrust collar and rotate it into the bottom half bearing housing, then place the other half carrier ring with the stop pin upon the first and rotate the complete carrier ring on the other side of the thrust collar. Note : The thrust carrier ring split line is vertical to the bearing housing horizontal surface and the stop pin locates in a slot in the top half bearing housing. (14) Check the axial clearance by moving the pump shaft towards the drive end so that the thrust collar is hard against the inner thrust pads; then, using feeler gauges between the outer thrust bearing spacer and the end cover check the clearance. Refer to the Sectional Arrangement Drawing HY-DG188-139-0017 for the original total axial clearance. Any measurable variation should be investigated. Do not insert feeler gauges between the thrust collar and the thrust pads: this may give an inaccurate reading and cause damage to the white metal pad surface. The end cover must be secured in position to check the total axial clearance.
(12)
(13)
Note : (a)
(b)
(15) (16)
Locate the top half journal bearing in position on the pump shaft. Lift the top half bearing housing complete with the top half oil guard onto the bottom half bearing housing ensuring that the carrier ring stop pins are properly located. Locate the top half bearing housing to the bottom half bearing housing with the dowel pins, then secure the top half housing in position with the studs and nuts.
(17)
(18)
Secure the bearing housing end cover to the top half housing with the screws. Install the drive/pump drive coupling spacer and element assemblies. Replace the instruments and the drive / pump drive coupling guard.
(19) (20) 4.
OVERHAUL : The following instructions apply when the pump is due for a complete overhaul and it is necessary to dismantle it to its components parts to examine them for wear. The following procedures are intended as a guide and should be read carefully by the engineer before commencing to dismantling the pump. WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE PROCEDURE.
4.1
Preparation for Overhaul Before commencing overhaul procedures, the pump set must be isolated as follows : (1) (2) Isolate the electrical power supplies to the pump set driving motor / turbine and the lubricating oil system (refer to manufacturers instructions). Isolate the electrical power supplies to all instruments. The pump set pipe work and halves are not in pumps scope of supply. Reference therefore, should be made to the system instructions for the isolation of the pump set.
CAUTION :
(3)
Check that the pump set suction, discharge and leak-off isolating valves are shut. Check that the cooling water has been isolated. Open the drain and vent connections and drain the pump casing. BEFORE PROCEEDING WITH OVERHAUL OF THE PUMP, ENSURE THAT THERE IS NO PRESSURE WITH IN THE PUMP CASING.
(4) (5)
WARNING :
(6)
Disconnect and remove any instrument which could interfere with the dismantling procedures. Disconnect and remove any small bore pipe work which could interfere with the Dismantling procedures.
(7)
(8)
Check that all lifting equipment and special tools are in good condition.
Note : All the shaft nuts have right hand threads. 4.2 Dismantling The Pump : (1) (2) Remove the drive / pump drive coupling guard. Remove the drive / pump drive coupling spacer and element assemblies. The top half bearing housing is located on the bottom half bearing housing by two dowel pins. Care must be taken to avoid damage to the dowels or the holes in the bottom half housing.
CAUTION :
(3)
Withdraw the dowel pins and remove the nuts from the studs securing the drive end top half bearing housing to the bottom half bearing housing. Lift away the top half bearing housing, complete with the top halves of the oil guards. Remove the top half journal bearing form the shaft. Remove the screws securing the bearing housing end cover to the nondrive end top and bottom half bearing housings. Remove the cover and discard the joint. The top half bearing housing is located on the bottom half bearing housing by two dowel pins. Care must be taken to avoid damage to the dowels or the holes in the bottom half housing.
(4)
(5)
CAUTION :
(6)
Withdraw the dowel pins and remove the nuts from the studs securing the non-drive end top half bearing housing to the bottom half bearing housing. Lift away the top half bearing housing, complete with the top half / oil guard. : The thrust carrier ring split line is vertical to the bearing housing horizontal surface.
(7) Note
(8)
Remove each thrust carrier ring in turn, as a complete unit, as follows : Rotate the complete carrier ring around the shaft until the half ring with the stop pin can be removed, then rotate the other half ring around the shaft until it can be lifted clear of the shaft. Repeat with the second carrier ring on the other side of the thrust collar. Slacken the securing socket head cap screws and rotate the mechanical seal eccentric washers to locate in the seal sleeve groove. Lock the washers in this positions. Remove the grub screws securing the seal sleeve to the shaft.
(9)
(10)
(11)
Remove the socket head screws securing the seal plates to the water jackets at the drive and non-drive end of the pump casing. Remove the socket head screws securing the water jackets to the pump casing at the drive and non-drive end of the pump casing.
(12)
CAUSING : The top half pump casing is located on the bottom half casing by two dowel pins. Care must be taken to avoid damage to the dowels or the holes in the bottom half casing. (13) Withdraw the dowel pins and remove the nuts from the studs securing the top half pump casing to the bottom half pump casing. Attach lifting equipment to the cast lugs on the top half pump casing. Use the jacking screws to break the pump casing joint, then lift the top half casing clear of the bottom half casing to expose the rotating assembly. Discard the pump casing joint. Attach lifting equipment to the rotating assembly and lift the assembly complete with casing rings, water jackets and mechanical seals clear of the bottom half pump casing. Transport the assembly to a suitable maintenance area and support the assembly on wooden stands or trestles so that the impeller is clear of the ground. Remove the bottom halves of the journal bearings and the oil guards from the drive and non-drive end bottom half bearing housings. Slacken the coupling nut lock washer, unscrew and remove the coupling nut. Withdraw the pump half coupling from the shaft. Remove and retain the coupling key. Slide the driven end mechanical seal cartridge off the shaft. Remove and retain the sleeve key. For dismantling instructions for the mechanical seal, refer to the manufacturers instructions in Chapter-4. Withdraw the drive end water jackets from the shaft, then lift the casing wear ring off the impeller. Unlock the thrust collar nut lock-washer, then using the special spanner supplied, unscrew and remove the nut. Remove and retain the lockwasher. Withdraw the thrust collar from the shaft. Remove and retain the thrust collar key.
(14) (15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25) (26)
Remove and retain the split floating oil seal. Slide the non-drive end mechanical seal cartridge off the shaft. Remove and retain the sleeve key. For dismantling instructions for the mechanical seal, refer to the manufacturers instructions in Chapter-4. Withdraw the non-drive end water jacket from the shaft, then lift the casing wear ring off the impeller.
(27)
4.3
Inspection and renewal : The pump components should be cleaned thoroughly then inspected for any signs of wear including scoring or wiping. All diametrical clearances should be measured with internal and external micrometers.
4.3.1
Clearances Refer to the Sectional Arrangement Drawing for the details of the clearances. It is recommended that when the pump internal clearances have reached 1.5 times the figure quoted or are expected to do so before the next overhaul, the component or components should be renewed. The main consideration, however, is pump performance and motor power consumption.
4.3.1
(1)
Examine the impeller and casing wear rings for signs of wear or damage. Check the diametrical clearance between the impeller and casing wear rings. Compare the readings obtained with those given. If necessary, renew the wear rings. Renew the impeller wear rings as follows: (a) (b) (c) Remove the grub screws securing the wear rings to the impeller. Machine the wear rings from the impeller eyes. Thoroughly clean the seating and shrink the spare wear rings onto the Impeller shrouds. (d) Secure the wear rings to the impeller shrouds with grub screws. Lock the grub screws by light punching with a center punch at the thread junctions. A. Machine the outside diameter of the impeller wear rings to required diameter to achieve diametrical clearance between the impeller and casing wear rings as given on the Sectional Arrangement Drawings.
(2)
4.3.3
Impeller Examine the impeller for signs of wear or erosion, especially around the blade tips.
4.3.4
Pump Shaft ends Sleeves (1) (2) (3) (4) Examine the pump shaft for signs of damage or bowing and check for concentricity; it should be within 0.05 mm full indicator movement. Check that all threads are in good condition. Check that all keyways are free form burrs. Examine the seal sleeves for any signs of wear or damage.
4.3.5
Thrust collar and Floating oil seal (1) (2) Examine the thrust collar for any signs of wear or damage. Examine the floating oil seal for any wear or damage.
4.3.6
Studs, Nuts, Dowels and Keys (1) The threads of all studs, screws and nuts must be clean, well formed and free from burrs. If the threads are damaged in any way, the component must be renewed. All keys must be good fit in their key ways and must also be flat, parallel and free from burrs. Worn or damaged keys must be renewed. All dowels must be clean and free from damage or deterioration. Worn or damaged dowels must be renewed.
(2) (3)
4.3.7
Joints and O Rings All joints and O rings should be renewed on assembly. Apply soft soap to all O rings prior to assembly.
4.3.8
Journal Bearings Inspect the journal for signs of wear or damage and renew as necessary. Thrust Bearing Under normal operating conditions it is not expected that nay measurable wear will take place on the thrust pads other than a dulling of the white surfaces. It is recommended that when this dulling has spread to more than half the surface area of the pads, they should be renewed. Refer to Manufacturer instructions in Chapter 4.
4.3.9
4.3.10 Mechanical Seals Information on dismantling and examining the mechanical seals is given in the Manufacturers instructions in Chapter 4.
4.3.11 Fitting a Spare Impeller The impeller should only be removed from the shaft if it is found necessary to fit a spare impeller or shaft. To renew the impeller, carry out the following instructions. CAUTION : Before removing the impeller from the pump shaft it is important to identify the correct rotating direction of impeller blades and also the position of the impeller on the pump shaft for assembly purposes. (1) Unlock the impeller nut lock-washers, then using the special spanner provided, unscrew and remove the impeller nuts and lock-washers from each end of the pump shaft. (2) Withdraw the impeller from the pump shaft. Removed and retain the impeller key. (3) Check that the key fits correctly in the spare impeller or shaft key way. (4) Fit the impeller on the shaft, ensuring the impeller key way is lined up accurately with the key. (5) Ensure that the impeller is fitted correctly for the direction of rotation and also its original position on the shaft. (5) Secure the impeller on the pump shaft with the impeller nuts and lockwashers. 4.4 Assembling the Pump To assist the assembly procedure, all fittings and threads should be smeared with anti-scuffing paste. (1) (2) Support the pump shaft / impeller assembly on wooden trestles. Locate the casing wear rings on the impeller shrouds, then slide the water jackets, with new joints fitted, on to each end of the shaft. Ensure that a new O ring is located in the internal groove of each seal sleeve and the groove in the seal plate face. Insert the seal sleeve keys into their keyways and slide the mechanical seal cartridges on to each end of the shaft, ensuring that the sleeve keys engage in the keyways in the bores of the sleeves. Insert the coupling key into its keyway in the shaft and install the half coupling, ensuring that the key engages in the keyway in the half coupling bore. Screw on and tighten the coupling nut and screw it in position with the lock screw.
(3)
(4)
(5)
(6)
(7)
Insert the thrust collar key into its keyway in the shaft. Apply heat to the thrust collar hub until the bore of the collar is expanded sufficiently to slide the collar onto the shaft. Slide the thrust collar onto the shaft until butts against the shoulder, ensuring that the key engages in the keyway in the thrust collar bore.
(8)
(9)
Allow the collar to cool to ambient temperature, then secure it in position with the thrust collar nut and lock-washer. Locate the bottom halves of the journal bearings and the oil guards into the bottom halves of the drive and non-drive end bearing housings. Renew the top / bottom half pump casing joint.
(10)
(11)
Note : The joint should be cut in one piece to fit the outside edges of the top half casing. The internal cutting of the joint should ensure that the joint fits all bore contours accurately. (12) Attach lifting equipment to the rotating assembly and lift into a position above the bottom half pump casing.
Note : Lightly smear the shaft journal and bearing surfaces with lubricating oil. (13) Carefully lower the assembly into he bottom half casing, at the same time locating the casing wear rings in the bottom half casing grooves and ensuring that the water jackets are correctly positioned, taking care not to damage the joints. Fit a new paper joint onto the bearing housing and cover and secure it to the non-drive and bottom half bearing with the screws. Check the axial running clearance of the thrust bearing as follows :(a) Install the inner halves of the thrust bearing carrier rings and spacers in the bottom half housing and move the rotating assembly as far as possible towards the drive end of the pump. Install the outer halves of the thrust bearing carrier rings and spacers in the bottom half bearing housing. Check the axial clearance by moving the pump shaft so that the thrust pads collar is hard against one set of thrust pads and use feeler gauges between the opposite thrust bearing spacer and the bearing housing. The total axial clearance should be 0.35 mm minimum and any measurable variation should be investigated.
(14)
(15)
(b)
(c)
CAUTION : Do not insert feeler gauges between the thrust collar and the thrust pads this may give an inaccurate reading and cause damage to the white metal pad surface. (16) (17) (17) Install the split floating oil seal on the pump shaft with the spring. Locate the top half journal bearings in position on each end of the pump shaft. Lift the drive end top half bearing housing complete with the top halves of the oil guards onto the bottom half bearing housing. Locate the top half bearing housing to the bottom half housing with the dowel pins, then secure the top half housing in position with the studs and nuts. Lift the non- drive end top half bearing housing complete with the top half oil guard onto the bottom half bearing housing, ensuring that the carrier ring stop pins are properly located. Locate the top half bearing housing to the bottom half bearing housing with the dowel pins, then secure the top half housing in position with the studs and nuts. Secure the bearing housing end cover to the top half housing with the screws. Attach lifting equipment to the cast lugs on the top half pump casing and. Ensuring that all joint faces are perfectly clean, lift it carefully on to the bottom half casing.
(18)
(19)
(20)
(21)
(22)
Note : Before securing the top half casing in position, ensure that the rotating assembly turns freely by hand. (23) Locate the top half pump casing to the bottom half casing with the dowel pins, then secure the top half casing in position with the studs and nuts. Check the rotating assembly for freedom of rotation. Secure the water jackets to each end of the pump casing with the socket head screws.
(24)
Note : The mechanical seal is a cartridge assembly and eccentric washers located in the seal sleeve groove set the position of the seal. (25) Slide each seal cartridge into the seal cooling jackets, ensuring the sleeve key locates in the seal sleeve keyway, until the seal plates about the cooling jackets. Secure the seal plates to the water jackets with the socket head screws.
(26)
(27)
Secure the sleeves to the shaft with the grub screws.
CAUTION : It is important to remember to revolve the eccentric washers through 180 and lock with the socket head cap screws prior to starting the pump. Refer to Chapter 4 for the manufacturers instructions. (28) Replace all small bore pipe work and instruments that were removed for dismantling purposes. Check the coupling alignment (refer to Illus. No P2424) then install the driver/pump drive coupling spacer and element assemblies. Replace the coupling guard.
(29)
5.
PARTS IDENTIFICATION When ordering spare parts reference must be made to the pump serial or job Number, Nomenclature, the Sectional Arrangement Drawing and item Number, and the quantity of each component.
SECTION A
CHAPTER 4 SUB VENDORS DRAWINGS / INSTRUCTIONS
LIST OF CONTENTS
1. 2. 3. 4. 5. 6.
Mechanical Seals Heat Exchangers for Mechanical Seal Magnetic filters for Mechanical Seal Thrust Bearing Connecting coupling between BP & Motor Suction Strainer before Booster Pump
SECTION A
1. MECHANICAL SEALS
OPERATING MANUAL
This document was drawn up observing the FC directives Machinery (FN2922) and the German Directives VDI-4500
BURMANN MECHANICAL SEAL (M.S.) 09-11751f2/100-ex1 (Drive End)

These instructions are intended for the assembly, operating and control personnel and should be kept at hand on site. Ultimate user Customer Pump company Pump type & size BHEL (India) BHEL FAIB75
PLEASE READ this manual carefully and OBSERVE the information contained as to Safety Storage Installation Start up Maintenance Removal Repair
If there are any unclear points please contact BURGMANN by all means.
Table of Contents 1. 1.1 1.2 1.3 1.4. 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 2. 3. 3.1 3.2 3.3 3.4 4. 4.1 4.2 4.3 4.4 5. 5.1 5.2 5.3 5.4 5.5 5.6 PRODUCTION INFORMATION .......................................................................... 3 Manufacture and country of origin ....................................................................... 3 Declaration .......................................................................................................... 3 Type designation ................................................................................................. 3 Operating conditions ............................................................................................ 3 Designated use .................................................................................................. 3 Drawings, diagram .............................................................................................. 4 Description and function ..................................................................................... 4 Required space, connecting dimensions ............................................................ 4 Power requirements ............................................................................................ 4 Additional equipment ......................................................................................... 5 Emissions ........................................................................................................... 5 Copyright ............................................................................................................ 5 SAFETY NOTES ............................................................................................... 6 TRANSPORT, STORAGE, INSTALLATION....................................................... 7 Recommendation for transport and storage......................................................... 7 Preparation for assembly .................................................................................... 10 Assembly / installation ........................................................................................ 10 Supply connections ............................................................................................. 11 OPERATION ...................................................................................................... 12 Instructions for start up ....................................................................................... 12 Instructions for safe operation ............................................................................. 12 Instructions for workers protection ..................................................................... 12 Directives in case of failure ................................................................................. 13 SERVICING ........................................................................................................ 13 Maintenance ....................................................................................................... 13 Reconditioning (repair) ........................................................................................ 13 Disassembly / removal ........................................................................................ 14 Spare parts ......................................................................................................... 14 Required details for enquiries and orders ........................................................... 14 After-sales service by BURGMANN .................................................................... 15
1. 1.1
PRODUCT INFORMATION Manufacturer and country of origin FEODOR BURGMANN Dichtungswerk GmbH & Co D- 82502 Wolfratshausen Federal Republic of Germany
1.2
Declaration Within the meaning of the EC-directive >> MACHINERY<< A mechanical seal does not function independently it is intended to be
incorporated in to or assemble with machinery. 1.3 Type designation 09-H75F2/100-ex1 (drive end) For non drive end seal please refer to drg. 09-H75F2/100-EX2 Materials according to drawing and/or to order. 1.4 Operating conditions Pump type & size Medium to be sealed Temperature of medium Stuffing box cooling Pressure to be sealed Supply at API 610 Shaft diameter at seal Shaft speed (approx.) Direction of rotation Mounting position Axial movability of M.S. 1.5 Designated use This mechanical seal is exclusively designed for the use in the specified machine. A different utilization or a utilization going beyond the specification is considered contrary to its designated use and excludes a liability by the manufacturer. : : : : : : : : : : : FA1B75 Boiler feed water 165C by pump jacket cooling 25 bar Plan 23 + filter 82.53 / 80 (stepped) 1495 to 1644 rpm CCW, seen from the driven end horizontal 2 mm
Operation under conditions lying outside those limits stated in paragraph >> operating data << is considered contrary to its designated use. Should the seal be operated under different conditions or at a different application BURGMANN has to be asked for recognition as safe in advance. 1.6 Drawings, diagrams Assembly drawing 09-H75F2/100-EX1 (drive end) The assembly drawing in the original scale and in its latest edition (latest revision) only is decisive for the design and the use in connection with this manual. In the following description all figures in parentheses, e.g. (2) define the respective part item no. in the assembly drawing. 1.7 Description and function Single, balanced mechanical seal (M.S.) for boiler feed pumps. Together with the housing parts (6.4A,16A) supplied the seal forms a pre-mounted unit (seal cartridge), assembled at works, ready to be installed without any adjustment. Assembly fixtures (9) are provide for holding the cartridge in one piece during transport, storage, assembly and disassembly. The seal face (1.1) is loaded by means of multiple springs (1.4). It is arranged rotating on the shaft sleeve. The seat (2) is mounted in a cover (4A) and arranged Stationary. Due to the integrated dual pumping screw at Drive collar (1.5A), Labyrinth Ring (16A) and pumping sleeve in cover (4A) the seal cartridge is un-directional. Torque transmission from mechanical seal to the shaft by means of a key. Axial fixing of the shaft sleeve (6) by means of set screw (12a) 1.8 Required space, connecting dimensions The connecting dimensions of the mechanical seal were checked and approved by the customer on the main drawing. The available mounting space given by the machine was decisive for the design of the housing parts of mechanical seal. The connecting dimensions are checked before shipment with regard to the BURGMANN drawing. 1.9 Power requirements
The total power consumption of the mechanical seal under the considerable influence of the turbulence losses of the rotating seal parts has been calculated for the individual application. To ensure a safe operation the required quantity of circulated liquid will be individually determined by the seal manufacturer by modifying the pumping device in the mechanical seal. The total calculated power consumption of one seal cartridge is approx. 17.4 KW. The pump manufacturer has to take this additional load into consideration when designing the drive. 1.10 Additional equipment For a safe operation of the mechanical seal a circulation circuit is required, from the seal through a heat exchanger (if necessary, also through an additional magnetic separator or filter ) back to the seal, as described in API 610, plan 23. When the shaft rotates the liquid is circulated by a pumping device in the mechanical seal. Jacket cooling of the stuffing box is provide in the pump and should be operated for reasons of longer service life. Safe operation can be expected when observing the following seal circuit temperatures, measured at seal outlet : 1.11 warning temperature : 55 C shut-off temperature : 65 C standstill temperature : 75 C
Emissions A mechanical seal is dynamic seal that cannot be free of leakage due to physical and technical reasons. Seal design, manufacture tolerance, operating conditions, running quality of the machine etc. Mainly define the leakage value. In fact, compared to other sealing systems (e.g. packings) there is few leakage. Small seal leakage is desirable and admissible, because of longer operating life of mechanical seal. If however, leakage exceeds a value of 8 litres per hour, the seal is damaged . It has to be replaced. Hot medium or even steam may splash out if the seal fails. Personal injury may be prevented by the user providing for splash protection and wearing safety goggles. Care has to be taken by the user for proper disposal of the leakage. Components which may get in contact with the leakage have to be erosion resistant or have to be adequately protected.
1.12
Copyright
The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has the copyright in this Manual Buyer, planner and user of the product are authorized for use in connection with further documentation. 2. SAFETY NOTES Any person at the users shop being involved in assembly, disassembly, start up, operation and maintenance of the BURGMANN Mechanical Seal must have read and understood this instruction Manual and in particular the safety notes we recommended the user to have this confirmed. BURGMANN Mechanical seals are manufactured on high quality level and they keep a high working reliability. Yet, if they are not operated within their intended purpose or handled by untrained personnel they may cause risks. The user is asked to check as part of his security program what effect a failure of the mechanical seal might have on the environment and what additional safety measures have to be taken to prevent personal injury. Any operation mode that affects the operational safety of the mechanical seal is not permitted. The pump must be positioned in a way that no persons are endangered if product splashes out in case of seal failure. Leakage of product has to be disposed properly. BURGMANN mechanical seals must be operated maintained or repaired by authorized, trained and instructed personnel only. Any work to be done on the mechanical seal is only permitted when the seal is neither operating nor pressurized. The responsibilities for the respective jobs to be done have to be determined clearly and observed in order to prevent unclear competencies form the point of security. Apart from the notes given in this manual the general regulations for workers protection and those for prevention of accidents have to be observed. Unauthorized modifications or alterations are not permitted as they affect the operational safety of the mechanical seal. 3. 3.1 TRANSPORT, STORAGE, INSTALLATION Recommendation for transport and storage PACKING AND SHIPMENT
If not specified differently in the order the BURGMANN standard packaging is used, suited for dry transport by truck, train or plane. The signs and notes for handling on the packaging have to be observed. In addition seaworthy packing may become necessary. STORAGE AND PRESERVATION Range of validity
The following recommendations apply to all BURGMANN Mechanical Seals which have been supplied and stored in their undamaged original packing as well as to seals which have been installed in a component of a plant (e.g pump, compressor, agitator, etc.) but have not yet been put into operation.
General
BURGMANN mechanical seals for components of power plants are super finished and tested machine elements whose handling during the erecting and start-up period of a power plant as well as during the storage period (in particular of spare parts) entails certain measures to keep the full efficiency of the seals. Sliding materials and elastomers are subject to material-specific and time-based alterations (distortion, aging) which might reduce the full efficiency of the seals. Yet, such processes must not occur automatically. The mechanical seal may be stored welded onto vapour-safe plastics sheets by adding a drying agent e.g. SILICAGEL. Damages caused by improper storage may not be claimed on the BURGMANN company with reference to their warranty. INSTALLED BURGMANN M.S. Components of power plants which are equipped with BURGMANN mechanical seals are usually delivered in a completely mounted state. Often the parts were tested at works beforehand. Start-up at the power plant
For the start up of BURGMANN mechanical seals as well as of possible accessories extra instructions have to be observed which consider the respective conditions. New product plants often have erection times of up to 10 years. In such cases the period between the production of the M.S. and its installation and start-up may exceed the usual period of approximately 2-3 years.
BURGMANN recommend to disassemble such seals in time before the planned start-up of the components of power plant and to sent the seals to the manufacturer or the nearest BURGMANN service centre where they can be checked and reconditioned, if necessary. If this is not possible for primary reasons (distance, dispatch conditions, etc.) other companies (never other seal manufacturers!) may be charged if they are suitably equipped and have the know-how required. Yet, BURGMANNS confirmation for recognition as safe is absolutely necessary in particular with regard to claims under warranty. Preservation in case of installation
Check in case of a preservation of complete plants with mechanical seals installed The compatibility of the chosen preservation agent with the seal materials and with elastomers. No impairment of the seals axial movability by conglutination or by gumming.
We recommend to dry the seal parts after the preceding functional test and to keep them dry when being installed. Values of < 50 % relative humidity are considered as dry condition. If there are uncertainties as to the correct proceeding please contact BURGMANN. STORAGE OF BURGMANN-M.S. Premises The mechanical seals have to be stored in dry, dust free, moderately ventilated and tempered rooms. We recommend relative air humidity below 65 % temperature between 15C and 25C. Direct exposure of the mechanical seal to heat (sun, heating) as well as to oxone, present or produced by ultraviolet light (halogen of fluorescent lamps), must be avoided because of the risk of embrittlement of elastomer materials. Handling Store the seals in their original packing lying on a flat surface. Thus a protection from shocks and from damage of edges is provided. For storage the mechanical seal is welded into vapour-safe plastic sheets by adding the drying agent SILICAGEL . Thus the humidity inside the packaging is stabilized. The packaging should be periodically checked for damage.
An easy control of the package contents is provide due to the transparent polyethylene sheet as well as by the attached package list or the package label. Check the mechanical seal : After a storage period of approximately 2-3 years. After a damage of the packing After a shock on the mechanical seal (e.g. by dropping the packed seal) At the manufacturers or at the nearest service centre. If necessary, a different, evident component authority may be contacted. Yet, BURGMANN must be informed about this fact, as BURGAMANNs confirmation for recognition as a safe is absolutely necessary. NOTE : An installation of the M.S. is possible if the prescribed checks cannot be carried out for special reasons, yet, only if the seal parts have no visible damages.
BURMANN must be informed about this kind of installation. Otherwise a warranty as to leakage and/or operational reliability will be refused by BURGMANN. A possibly increased leakage during start-up will decrease to a normal quantity after the running in period of the sliding faces. If this is not the case or if there are other malfunctions the mechanical seal has to be shut down, removed and checked for reasons of safety. If there is a malfunction which you cannot correct on your own, or if the cause of malfunction is not clearly recognizable please immediately contact the nearest BURGMANN agency, a BURGMANN service centre or the BURGMANN headquarters. Control of humidity inside the packaging
All water vapour-proof sheets inside the package are supplied with humidity indicators which show the relative air humidity inside the packaging. On a scale the colour changes from blue (=dry) to pink (=humid). For check of the stored mechanical seals which should be carried out periodically and should be recorded in-plant the following points have to be observed : Humidity is indicated with values > 50% rel. humidity :
Contact BURGMANN as a control of the seal and new packaging is necessary. Humidity is indicated with values < 50% rel. humidity, yet the storage period of 2-3 years is exceeded.
Contact BURGMANN as a control of the seal and new packaging is necessary. 3.2 Preparation for assembly Check the parts of the machine for : Chamfered edges (sliding cones i.e. 30/2 mm or in accordance with DIN 24960). radiused transmissions Mating fits and O-ring surfaces: fine finished Rz 10 m (=N7=CLA 63). Shaft surface in the area of the M.S.: fine finished Rmax. 5 m (=N6=CLA 32)
Check at the machine : Damage of connecting surfaces to the M.S. Mating dimensions, rectangularity and concentricity to the shaft axis. Direction of rotation must comply with the seal drawing, otherwise contact BURGMANN immediately. Insert a parallel key into the groove provided. Lubricate the shaft slightly in the area of the seal. Elastomers made of EP-rubber must never come into contact with lubricants on the base of material oil (swelling, decomposition) Lubricant for elastomers (o-rings etc.) recommended by BURGMANN. TURMOPOLGREASE SH2 << make Lubricant Consult (LUBCON) 3.3 Assembly / installation The material seal is supplied as a cartridge unit, pre-mounted at works, and does not require any adjustment during installation. This document provides the required information for Installation and removal of the cartridge only. For installation the assembly drawing 09-H75F2/100-EX1 has to be on hand. The mechanical seal has to be installed very carefully and under the cleanest conditions. Do never force during installation.
The order of assembly to install the mechanical seal into the pump depends on the design of the pump and should advisably be determined by the pump manufacturer. Possible installation order : Check of o-rings (5 and 7) have been installed. Feed the complete seal cartridge onto the shaft. The key in the shaft has to be engage into the keyway in the shaft sleeve (6). Avoid bumping the seal cartridge against the shaft or shaft steps as the brittle ceramic components break easily. Bolt the mechanical seal to the assembly flange in such a way that the connections for supply and disposal are positioned in accordance with view X in the drawing. Tighten the set screw (12a) uniformly & firmly. Remove the assembly fixtures (17) and keep them for a later removal of the seal. 3.4 Supply connections The supply connection is designated as a female threaded NPT connection. The connection for supply is marked on the mechanical seal. Remove the plastic protection cap from the supply connection after installation. Supply piping : 4. Use pipes of stainless steel with a big cross-section. Install the pipes continuously rising, as short and convenient as possible for the flow to ensure self-venting. Avoid air inclusions and provide for venting connections, if necessary. Clean the piping thoroughly. Fasten all pipe connections pressure-sealed.
OPERATION
4.1
Instructions for start up Safety checks before start up Seal assembly fixtures disengaged Torque transmission and axial fixing between mechanical seal and shaft duly installed. Supply connections tightened pressure-sealed.
For a safe operation of the mechanical seal a circulation circuit is required. Design in accordance with the scheme in the assembly drawing. Supply fluid flows from stuffing box through a filter and a cooler back to stuffing box, similar to API 610, Plan 23. Forced circulation of the fluid when the shaft rotates by means of a uni-rotational pumping device in the seal. Jacket cooling of the stuffing box is provided in the pump and should be operated for reasons of longer service life. Flood pump and seal cavity (stuffing box) with medium. Thoroughly vent seal cavity and circulation system. After a short startup period repeat the venting procedures several times with the pump being at standstill. Now the seal is ready for operation. 4.2 Instructions for safe operation : Safe operating can be expected when observing the following seal circuit temperatures, measured at seal outlet : Warning temperature Shut-off temperature Standstill temperature : : : 55C 65C 75C
If the operation limit values and the instructions given in this manual are followed a trouble-free operation of the mechanical seal can be expected. 4.3 Instructions for workers protection :
Hot medium or even steam may splash out if the seal falls. Personally injury many be prevented by the user providing for splash protection and wearing safety goggles. Care has to be taken by the use for proper disposal of the leakage. 4.4 Directives in case of failure Try to define the kind of failure and record it. In case of failure due to high leakage the amount of leakage should be observed. Changes of the operating conditions have to be recorded. In case of an unacceptable temperature rise the mechanical seal must be shut down for reasons of safety. A damage of the mechanical seal is indicated by a continuous, flowing leakage. If there is a malfunction which you cannot correct on your own, or if the cause of malfunction is not clearly recognizable please immediately contact the nearest BURGMANN agency, a BURGMANN service centre of the BURGMANN headquarters. During the warranty period the mechanical seal must only be disassembled or removed the BURGMANNs approval or when a BURGMANN representative is present. 5 5.1 SERVICING Maintenance A correctly operated mechanical seal is maintenance-free. Wear parts, however, have to be replaced, if necessary. An inspection of the mechanical seal should be carried out during a revision of the complete plant. We recommend to have this inspection be performed by authorized BURGMANN personnel. If the mechanical seal is disassembled during a revision of the plant the sliding faces should be refinished at the manufacturer and both O-rings and springs should be replaced. 5.2 Reconditioning (repair) If repair is necessary, the complete seal cartridge should be sent to the manufacturer, as this is the best way to find out which components can be reconditioned or which parts must be replaced. Reconditioning of the mechanical seal by the user is not desirable for reasons of operational safety. Repair should only be carried out by BURGMANN service personnel or by trained personnel of the machine manufacturer in suitably
equipped clean rooms. Seal cartridges only should be replaced by the user if possible. 5.3 Disassembly / removal Shut down the pump duly procedure, let it cool down an depressurize it. No product should contact the mechanical seal necessary. Secure the pump against inadvertent start. Observe the safety notes (safety data sheets) drain the pump, if
Mechanical seal cartridges should possibly not be disassembled or extremely cleaned during or after removal so that the damages and their causes may be correctly analysed by qualified personnel of the manufacturer of the user. Any work to be done on the mechanical seal is only permitted when the seal is neither operating nor pressurized. Follow the valid regulations for preventing accidents when disassembling mechanical seals as well as handling hazardous substances if the seals have been already in operation. In case of doubt the necessary information have to be obtained before starting removal disassembly or repair. The disassembly (removal of the seal is carried out in the reverse sequence as described for assembly (set up). The order of disassembly to remove the mechanical seal out of the pump depends on the design of the pump and has to be determined by the pump manufacturer. 5.4 Spare parts Only BURGMANN original spare parts must be used. Otherwise Risks of a seal failure endangering persons and environment. Remove the supply piping. Engage the assembly fixtures (9) into the groove in the shaft sleeve (6) and fasten them. Loosen all the screws (12a). Loosen all screw connections between seal cartridge and the respective machine parts.
Risks of a seal failure, endangering persons and environment. The BURGMANN guarantee for the mechanical seal lapses. 5.5 For a quick exchange a complete spare seal should be on stock.
Required details for enquiries and orders For enquiries and orders the following details are required. BURGMANN commission no. Drawing no. of mechanical seal : 09-H75F2/100-EX1 Part item no. Designation, material number of pieces acc. Of drawing.
5.6
After-sales service by BURGMANN The range of service offered by BURGMANN not only includes advise during the planning stages but also technical support after commissioning. This is supported by a world-wide comprehensive network of subsidiaries, field engineers and service centers. In India please contact first : Headquarter : BURGMANN INDIA Pvt. Ltd. A.K. Industrial Estate Madina Manzila Compound S.V.Road, Goregoan (West) Bombay 400 062 : 874 1534 / 1820 / 1905 Telefax : 022-8 74 8810 Branch Offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad, Surat, Kota, Chandigarh, Visakapatnam, Cochin.
OPERATING MANUAL
This document was drawn up observing the FC directives Machinery (FN2922) and the German Directives VDI-4500
BURMANN MECHANICAL SEAL (M.S.) 09-H751F2/100-EX2 (Non-Drive End)

These instructions are intended for the assembly, operating and control personnel and should be kept at hand on site. Ultimate user Customer Pump company Pump type & size BHEL (India) BHEL FA1B75
PLEASE READ this manual carefully and OBSERVE the information contained as to Safety Storage Installation Start up Maintenance Removal Repair
If there are any unclear points please contact BURGMANN by all means.
Table of Contents 1. 1.1 1.2 1.3 1.4. 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 2. 3. 3.1 3.2 3.3 3.4 4. 4.1 4.2 4.3 4.4 5. 5.1 5.2 5.3 5.4 5.5 5.6 PRODUCTION INFORMATION .......................................................................... 3 Manufacture and country of origin ....................................................................... 3 Declaration .......................................................................................................... 3 Type designation ................................................................................................. 3 Operating conditions ............................................................................................ 3 Designated use .................................................................................................. 3 Drawings, diagram .............................................................................................. 4 Description and function ..................................................................................... 4 Required space, connecting dimensions ............................................................ 4 Power requirements ............................................................................................ 4 Additional equipment ......................................................................................... 5 Emissions ........................................................................................................... 5 Copyright ............................................................................................................ 5 SAFETY NOTES ............................................................................................... 6 TRANSPORT, STORAGE, INSTALLATION....................................................... 7 Recommendation for transport and storage......................................................... 7 Preparation for assembly .................................................................................... 10 Assembly / installation ........................................................................................ 10 Supply connections ............................................................................................. 11 OPERATION ...................................................................................................... 12 Instructions for start up ....................................................................................... 12 Instructions for safe operation ............................................................................. 12 Instructions for workers protection ..................................................................... 12 Directives in case of failure ................................................................................. 13 SERVICING ........................................................................................................ 13 Maintenance ....................................................................................................... 13 Reconditioning (repair) ........................................................................................ 13 Disassembly / removal ........................................................................................ 14 Spare parts ......................................................................................................... 14 Required details for enquiries and orders ........................................................... 14 After-sales service by BURGMANN .................................................................... 15
1. 1.1
PRODUCT INFORMATION Manufacturer and country of origin FEODOR BURGMANN Dichtungswerk GmbH & Co D- 82502 Wolfratshausen Federal Republic of Germany
1.2
Declaration Within the meaning of the EC-directive >> MACHINERY<< A mechanical seal does not function independently it is intended to be
incorporated in to or assemble with machinery. 1.3 Type designation 09-H75F2/100-EX2 (Non-drive end) For non drive end seal please refer to drwg. 09-H75F2/100-EX1 Materials according to drawing and/or to order. 1.4 Operating conditions Pump type & size Medium to be sealed Temperature of medium Stuffing box cooling Pressure to be sealed Supply at API 610 Shaft diameter at seal Shaft speed (approx.) Direction of rotation Mounting position Axial movability of M.S. 1.5 Designated use This mechanical seal is exclusively designed for the use in the specified machine. A different utilization or a utilization going beyond the specification is considered contrary to its designated use and excludes a liability by the manufacturer. : : : : : : : : : : : FA1B75 Boiler feed water 165C by pump jacket cooling 25 bar Plan 23 + filter 82.53 / 80 (stepped) 1495 rpm CCW, seen from the driven end horizontal 2 mm
Operation under conditions lying outside those limits stated in paragraph >> operating data << is considered contrary to its designated use. Should the seal be operated under different conditions or at a different application BURGMANN has to be asked for recognition as safe in advance. 1.6 Drawings, diagrams Assembly drawing 09-H75F2/100-EX2 (Non-drive end) The assembly drawing in the original scale and in its latest edition (latest revision) only is decisive for the design and the use in connection with this manual. In the following description all figures in parentheses, e.g. (2) define the respective part item no. in the assembly drawing. 1.7 Description and function Single, balanced mechanical seal (M.S.) for boiler feed pumps. Together with the housing parts (6.4B,16B) supplied the seal forms a pre-mounted unit (seal cartridge), assembled at works, ready to be installed without any adjustment. Assembly fixtures (9) are provide for holding the cartridge in one piece during transport, storage, assembly and disassembly. The seal face (1.1) is loaded by means of multiple springs (1.4). It is arranged rotating on the shaft sleeve. The seat (2) is mounted in a cover (4B) and arranged Stationary. Due to the integrated dual pumping screw at Drive collar (1.5B), Labyrinth Ring (16B) and pumping sleeve in cover (4B) the seal cartridge is un-directional. Torque transmission from mechanical seal to the shaft by means of a key. Axial fixing of the shaft sleeve (6) by means of set screw (12a) 1.8 Required space, connecting dimensions The connecting dimensions of the mechanical seal were checked and approved by the customer on the main drawing. The available mounting space given by the machine was decisive for the design of the housing parts of mechanical seal. The connecting dimensions are checked before shipment with regard to the BURGMANN drawing. 1.9 Power requirements
The total power consumption of the mechanical seal under the considerable influence of the turbulence losses of the rotating seal parts has been calculated for the individual application. To ensure a safe operation the required quantity of circulated liquid will be individually determined by the seal manufacturer by modifying the pumping device in the mechanical seal. The total calculated power consumption of one seal cartridge is approx. 17.4 KW. The pump manufacturer has to take this additional load into consideration when designing the drive. 1.10 Additional equipment For a safe operation of the mechanical seal a circulation circuit is required, from the seal through a heat exchanger (if necessary, also through an additional magnetic separator or filter ) back to the seal, as described in API 610, plan 23. When the shaft rotates the liquid is circulated by a pumping device in the mechanical seal. Jacket cooling of the stuffing box is provide in the pump and should be operated for reasons of longer service life. Safe operation can be expected when observing the following seal circuit temperatures, measured at seal outlet : 1.11 warning temperature : 55 C shut-off temperature : 65 C standstill temperature : 75 C
Emissions A mechanical seal is dynamic seal that cannot be free of leakage due to physical and technical reasons. Seal design, manufacture tolerance, operating conditions, running quality of the machine etc. Mainly define the leakage value. In fact, compared to other sealing systems (e.g. packings) there is few leakage. Small seal leakage is desirable and admissible, because of longer operating life of mechanical seal. If however, leakage exceeds a value of 8 litres per hour, the seal is damaged . It has to be replaced. Hot medium or even steam may splash out if the seal fails. Personal injury may be prevented by the user providing for splash protection and wearing safety goggles. Care has to be taken by the user for proper disposal of the leakage. Components which may get in contact with the leakage have to be erosion resistant or have to be adequately protected.
1.12
Copyright The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has the copyright in this Manual Buyer, planner and user of the product are authorized for use in connection with further documentation.
2.
SAFETY NOTES Any person at the users shop being involved in assembly, disassembly, start up, operation and maintenance of the BURGMANN Mechanical Seal must have read and understood this instruction Manual and in particular the safety notes we recommended the user to have this confirmed. BURGMANN Mechanical seals are manufactured on high quality level and they keep a high working reliability. Yet, if they are not operated within their intended purpose or handled unexpertly by untrained personnel they may cause risks. The user is asked to check as part of his security program what effect a failure of the mechanical seal might have on the environment and what additional safety measures have to be taken to prevent personal injury. Any operation mode that affects the operational safety of the mechanical seal is not permitted. The pump must be positioned in a way that no persons are endangered if product splashes out in case of seal failure. Leakage of product has to be disposed properly. BURGMANN mechanical seals must be operated maintained or repaired by authorized, trained and instructed personnel only. Any work to be done on the mechanical seal is only permitted when the seal is neither operating nor pressurized. The responsibilities for the respective jobs to be done have to be determined clearly and observed in order to prevent unclear competencies form the point of security Apart from the notes given in this manual the general regulations for workers protection and those for prevention of accidents have to be observed. Unauthorized modifications or alterations are not permitted as they affect the operational safety of the mechanical seal.
3. 3.1
TRANSPORT, STORAGE, INSTALLATION Recommendation for transport and storage PACKING AND SHIPMENT
If not specified differently in the order the BURGMANN standard packaging is used, suited for dry transport by truck, train or plane. The signs and notes for handling on the packaging have to be observed. In addition seaworthy packing may become necessary. STORAGE AND PRESERVATION Range of validity
The following recommendations apply to all BURGMANN Mechanical Seals which have been supplied and stored in their undamaged original packing as well as to seals which have been installed in a component of a plant (e.g pump, compressor, agitator, etc.) but have not yet been put into operation. General
BURGMANN mechanical seals for components of power plants are super finished and tested machine elements whose handling during the erecting and start-up period of a power plant as well as during the storage period (in particular of spare parts) entails certain measures to keep the full efficiency of the seals. Sliding materials and elastomers are subject to material-specific and time-based alterations (distortion, aging) which might reduce the full efficiency of the seals. Yet, such processes must not occur automatically . The mechanical seal may be stored welded onto vapour-safe plastics sheets by adding a drying agent e.g. SILICAGEL. Damages caused by improper storage may not be claimed on the BURGMANN company with reference to their warranty. INSTALLED BURGMANN M.S. Components of power plants which are equipped with BURGMANN mechanical seals are usually delivered in a completely mounted state. Often the parts were tested at works beforehand. Start-up at the power plant
For the start up of BURGMANN mechanical seals as well as of possible accessories extra instructions have to be observed which consider the respective conditions.
New product plants often have erection times of up to 10 years. In such cases the period between the production of the M.S. and its installation and start-up may exceed the usual period of approximately 2-3 years. BURGMANN recommend to disassemble such seals in time before the planned start-up of the components of power plant and to sent the seals to the manufacturer or the nearest BURGMANN service centre where they can be checked and reconditioned, if necessary. If this is not possible for primary reasons (distance, dispatch conditions, etc.) other companies (never other seal manufacturers!) may be charged if they are suitably equipped and have the know-how required. Yet, BURGMANNS confirmation for recognition as safe is absolutely necessary in particular with regard to claims under warranty. Preservation in case of installation
Check in case of a preservation of complete plants with mechanical seals installed the compatibility of the chosen preservation agent with the seal materials and with elastomers. No impairment of the seals axial movability by conglutination or by gumming.
We recommend to dry the seal parts after the preceding functional test and to keep them dry when being installed. Values of < 50 % relative humidity are considered as dry condition. If there are uncertainties as to the correct proceeding please contact BURGMANN. STORAGE OF BURGMANN-M.S. Premises The mechanical seals have to be stored in dry, dust free, moderately ventilated and tempered rooms. We recommend relative air humidity below 65 % temperature between 15C and 25C. Direct exposure of the mechanical seal to heat (sun, heating) as well as to oxone, present or produced by ultraviolet light (halogen of fluorescent lamps), must be avoided because of the risk of embrittlement of elastomer materials. Handling Store the seals in their original packing lying on a flat surface.
Thus a protection from shocks and from damage of edges is provided.
For storage the mechanical seal is welded into vapour-safe plastic sheets by adding the drying agent SILICAGEL . Thus the humidity inside the packaging is stabilized. The packaging should be periodically checked for damage. An easy control of the package contents is provide due to the transparent polyethylene sheet as well as by the attached package list or the package label. Check the mechanical seal : after a storage period of approximately 2-3 years. after a damage of the packing after a shock on the mechanical seal (e.g. by dropping the packed seal) at the manufacturers or at the nearest service centre. If necessary, a different, evident component authority may be contacted. Yet, BURGMANN must be informed about this fact, as BURGAMANNs confirmation for recognition as a safe is absolutely necessary. NOTE : An installation of the M.S. is possible if the prescribed checks cannot be carried out for special reasons, yet, only if the seal parts have no visible damages.
BURMANN must be informed about this kind of installation. Otherwise a warranty as to leakage and/or operational reliability will be refused by BURGMANN. A possibly increased leakage during start-up will decrease to a normal quantity after the running in period of the sliding faces. If this is not the case or if there are other malfunctions the mechanical seal has to be shut down, removed and checked for reasons of safety. If there is a malfunction which you cannot correct on your own, or if the cause of malfunction is not clearly recognizable please immediately contact the nearest BURGMANN agency, a BURGMANN service centre or the BURGMANN headquarters. Control of humidity inside the packaging
All water vapour-proof sheets inside the package are supplied with humidity indicators which show the relative air humidity inside the packaging. On a scale the colour changes from blue (=dry) to pink (=humid). For check of the stored mechanical seals which should be carried out periodically and should be recorded in-plant the following points have to be observed :
Humidity is indicated with values > 50% rel. humidity :
Contact BURGMANN as a control of the seal and new packaging is necessary. Humidity is indicated with values < 50% rel. humidity, yet the storage period of 2-3 years is exceeded. Contact BURGMANN as a control of the seal and new packaging is necessary. 3.2 Preparation for assembly Check the parts of the machine for : Chamfered edges (sliding cones i.e. 30/2 mm or in accordance with DIN 24960). radiused transmissions Mating fits and O-ring surfaces: fine finished Rz 10 m (=N7=CLA 63). Shaft surface in the area of the M.S.: fine finished Rmax. 5 m (=N6=CLA 32)
Check at the machine : Damage of connecting surfaces to the M.S. Mating dimensions, rectangularity and concentricity to the shaft axis. Direction of rotation must comply with the seal drawing, otherwise contact BURGMANN immediately. Insert a parallel key into the groove provided. Lubricate the shaft slightly in the area of the seal. Elastomers made of EP-rubber must never come into contact with lubricants on the base of material oil (swelling, decomposition) Lubricant for elastomers (o-rings etc.) recommended by BURGMANN. TURMOPOLGREASE SH2 << make Lubricant Consult (LUBCON) 3.3 Assembly / installation The mechanical seal is supplied as a cartridge unit, pre-mounted at works, and does not require any adjustment during installation. This document provides the required information for Installation and removal of the cartridge only.
For installation the assembly drawing 09-H75F2/100-EX2 has to be on hand. The mechanical seal has to be installed very carefully and under the cleanest conditions. Do never force during installation. The order of assembly to install the mechanical seal into the pump depends on the design of the pump and should advisably be determined by the pump manufacturer. Possible installation order : Check of o-rings (5 and 7) have been installed. Feed the complete seal cartridge onto the shaft. The key in the shaft has to be engage into the keyway in the shaft sleeve (6). Avoid bumping the seal cartridge against the shaft or shaft steps as the brittle ceramic components break easily. Bolt the mechanical seal to the assembly flange in such a way that the connections for supply and disposal are positioned in accordance with view X in the drawing. Tighten the set screw (12a) uniformly & firmly. Remove the assembly fixtures (17) and keep them for a later removal of the seal.
3.4
Supply connections The supply connection is designated as a female threaded NPT connection. The connection for supply is marked on the mechanical seal. Remove the plastic protection cap from the supply connection after installation.
Supply piping : Use pipes of stainless steel with a big cross-section. Install the pipes continuously rising, as short and convenient as possible for the flow to ensure self-venting. Avoid air inclusions and provide for venting connections, if necessary. Clean the piping thoroughly. Fasten all pipe connections pressure-sealed.
4. 4.1
OPERATION Instructions for start up Safety checks before start up Seal assembly fixtures disengaged Torque transmission and axial fixing between mechanical seal and shaft duly installed. Supply connections tightened pressure-sealed.
For a safe operation of the mechanical seal a circulation circuit is required. Design in accordance with the scheme in the assembly drawing. Supply fluid flows from stuffing box through a filter and a cooler back to stuffing box, similar to API 610, Plan 23. Forced circulation of the fluid when the shaft rotates by means of a unirotational pumping device in the seal. Jacket cooling of the stuffing box is provided in the pump and should be operated for reasons of longer service life. Flood pump and seal cavity (stuffing box) with medium. Thoroughly vent seal cavity and circulation system. After a short startup period repeat the venting procedures several times with the pump being at standstill. Now the seal is ready for operation. 4.2 Instructions for safe operation : Safe operating can be expected when observing the following seal circuit temperatures, measured at seal outlet : Warning temperature Shut-off temperature Standstill temperature : : : 55C 65C 75C
If the operation limit values and the instructions given in this manual are followed a trouble-free operation of the mechanical seal can be expected. 4.3 Instructions for workers protection :
Hot medium or even steam may splash out if the seal falls. Personally injury many be prevented by the user providing for splash protection and wearing safety goggles. Care has to be taken by the use for proper disposal of the leakage. 4.4 Directives in case of failure Try to define the kind of failure and record it. In case of failure due to high leakage the amount of leakage should be observed. Changes of the operating conditions have to be recorded. In case of an unacceptable temperature rise the mechanical seal must be shut down for reasons of safety. A damage of the mechanical seal is indicated by a continuous, flowing leakage. If there is a malfunction which you cannot correct on your own, or if the cause of malfunction is not clearly recognizable please immediately contact the nearest BURGMANN agency, a BURGMANN service centre of the BURGMANN headquarters. During the warranty period the mechanical seal must only be disassembled or removed the BURGMANNs approval or when a BURGMANN representative is present. 5 5.1 SERVICING Maintenance A correctly operated mechanical seal is maintenance-free. Wear parts, however, have to be replaced, if necessary. An inspection of the mechanical seal should be carried out during a revision of the complete plant. We recommend to have this inspection be performed by authorized BURGMANN personnel. If the mechanical seal is disassembled during a revision of the plant the sliding faces should be refinished at the manufacturer and both O-rings and springs should be replaced. 5.2 Reconditioning (repair) If repair is necessary, the complete seal cartridge should be sent to the manufacturer, as this is the best way to find out which components can be reconditioned or which parts must be replaced. Reconditioning of the mechanical seal by the user is not desirable for reasons of operational safety. Repair should only be carried out by BURGMANN service personnel or by trained personnel of the machine manufacturer in suitably equipped clean rooms. Seal cartridges only should be replaced by the user if possible.
5.3
Disassembly / removal Shut down the pump duly procedure, let it cool down an depressurize it.! No product should contact the mechanical seal drain the pump, if necessary.! Secure the pump against inadvertent start.! Observe the safety notes (safety data sheets)! Mechanical seal cartridges should possibly not be disassembled or extremely cleaned during or after removal so that the damages and their causes may be correctly analysed by qualified personnel of the manufacturer of the user. Any work to be done on the mechanical seal is only permitted when the seal is neither operating nor pressurized. Follow the valid regulations for preventing accidents when disassembling mechanical seals as well as handling hazardous substances if the seals have been already in operation. In case of doubt the necessary information have to be obtained before starting removal disassembly or repair. Remove the supply piping. Engage the assembly fixtures (9) into the groove in the shaft sleeve (6) and fasten them. Loosen all the screws (12a). Loosen all screw connections between seal cartridge and the respective machine parts. The disassembly (removal of the seal is carried out in the reverse sequence as described for assembly (set up). The order of disassembly to remove the mechanical seal out of the pump depends on the design of the pump and has to be determined by the pump manufacturer.
5.4
Spare parts Only BURGMANN original spare parts must be used. Otherwise Risks of a seal failure endangering persons and environment.
Risks of a seal failure, endangering persons and environment. The BURGMANN guarantee for the mechanical seal lapses. 5.5 For a quick exchange a complete spare seal should be on stock.
Required details for enquiries and orders For enquiries and orders the following details are required. BURGMANN commission no. Drawing no. of mechanical seal : 09-H75F2/100-EX2 Part item no. Designation, material, number of pieces acc. of drawing.
5.6
After-sales service by BURGMANN The range of service offered by BURGMANN not only includes advise during the planning stages but also technical support after commissioning. This is supported by a world-wide comprehensive network of subsidiaries, field engineers and service centers. In India please contact first : Headquarter : BURGMANN INDIA Pvt. Ltd. A.K. Industrial Estate Madina Manzila Compound S.V.Road, Goregoan (West) Bombay 400 062 : 874 1534 / 1820 / 1905 Telefax : 022-8 74 8810 Branch Offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad, Panvel, Surat, Kota, Chandigarh, Visakapatnam, Cochin.
SECTION B
4. THRUST BEARING
Michell Bearings
Operations, and Maintenance Instructions.
Omega OT Series Thrust Rings

Michell Bearings
Michell Bearings is a trading division of Vinters Engineering PLC. A member of the Rolls Royce Group.
Issue 00
Table of Contents
GENERAL DRAWING OF OT THRUST RING ASSEMBLY WITH SHIMS& LINERS----------- 4 1. INTRODUCTION -------------------------------------------------------------------------------------------- 5 1.1 About the Product ------------------------------------------------------------------------------------- 5 1.2 About this Manual ------------------------------------------------------------------------------------- 5 1.3 Warranty Claims --------------------------------------------------------------------------------------- 6 SAFETY ------------------------------------------------------------------------------------------------------- 7 HANDLING THE BEARING------------------------------------------------------------------------------ 8 3.1 General -------------------------------------------------------------------------------------------------- 8 PREPARATION FOR FIRST INSTALLATION ------------------------------------------------------ 9 ASSEMBLY OF THE BEARING -----------------------------------------------------------------------10 5.1 General -------------------------------------------------------------------------------------------------10 5.2 Assembly of the Thrust ring------------------------------------------------------------------------10 5.2.1 Fitting the Thrust Pad set.--------------------------------------------------------------------10 5.2.2 Fitting Ring Stop, and Liners if applicable -----------------------------------------------11 5.3 Assembling the Thrust rings into the Bearing Casing ---------------------------------------11 5.3.1 Miscellaneous -----------------------------------------------------------------------------------12 5.3.2 Instrumentation ---------------------------------------------------------------------------------12 OPERATING ------------------------------------------------------------------------------------------------13 6.1 Preparation and Inspection before Operation -------------------------------------------------13 6.2 Trial Run------------------------------------------------------------------------------------------------13 6.3 Normal Operation ------------------------------------------------------------------------------------14 6.4 Preparation for Operation after Standstill-------------------------------------------------------14 CARE AND MAINTENANCE ---------------------------------------------------------------------------15 7.1 General -------------------------------------------------------------------------------------------------15 7.2 Tools and Equipment--------------------------------------------------------------------------------15 7.3 Maintenance Schedule------------------------------------------------------------------------------16 7.4 Oil Change ---------------------------------------------------------------------------------------------16 7.4.1 General -------------------------------------------------------------------------------------------16 7.4.2 Procedure for draining oil---------------------------------------------------------------------16 7.4.3 Procedure for refilling the bearing -self contained bearings -------------------------17 7.4.4 Procedure for refilling the bearing - bearings with circulating oil--------------------17 DISMANTLING AN INSTALLED BEARING --------------------------------------------------------18 8.1 General -------------------------------------------------------------------------------------------------18 8.2 Preparation --------------------------------------------------------------------------------------------18 8.2.1 Strip down the bearing until the thrust rings are visible. ------------------------------18 8.2.2 Disconnect and remove any thermometry and instrumentation.--------------------19 8.3 Removing thrust rings -------------------------------------------------------------------------------19 8.4 Removing the Liners, and Shim Pack. Where Applicable. --------------------------------19 8.5 Removing the Thrust Pad Set---------------------------------------------------------------------19 CLEANING AND CHECKING --------------------------------------------------------------------------20 9.1 General -------------------------------------------------------------------------------------------------20 9.2 Checking the Thrust Pad. --------------------------------------------------------------------------21 BEARING PRESERVATION DURING STORAGE---------------------------------------------22
2. 3. 4. 5.
6.
7.
8.
9.
10.
10.1 10.2 10.3 10.4 11.
Before Installation ------------------------------------------------------------------------------------22 Corrosion Protection for Standstill Periods up to 6 Months --------------------------------22 Corrosion Protection for Standstill Periods between 6 Months to 1 Year---------------22 Corrosion Protection for Standstill Periods longer than 1 year----------------------------22 BEARING PRESERVATION DURING TRANSPORT -----------------------------------------22
12. APPENDICES -------------------------------------------------------------------------------------------22 12.1 Ordering Spares --------------------------------------------------------------------------------------22
HEX. SOCKET CSK SCREW 16 LINER ASSY SHIM PACK DOWEL PIN PAD STOP THRUST PAD SET RETAINING RING RETAINING RING
STEEL STEEL STEEL STEEL STEEL WM STEEL STEEL
4
REF PART NAME QTY MATERIAL 6 1 3 2 7 8 5 4
8 7 6 5 4 3 2 1 2 2 2 16 2 1 1
OT Omega Thrust Ring Assembly With Shim Pack, And Liners
1. Introduction
1.1 About the Product
The Omega Series Thrust Rings supplied are part of a standard range of components manufactured by Michell Bearings. The thrust rings are intended to be fitted within a casing supplied by a customer. Depending on the demands specified, the thrust rings will be designed to absorb:
a) A constant load along the shaft in one direction. b) A constant load along the shaft in either direction. c) A constant load in one direction and a temporary load in the opposite direction.
Within the Omega Series a range of sizes are catered for. All Omega thrust rings require continuous lubrication from a pumped oil supply. In some cases, the thrust rings will have machined oil channels and in other cases restriction jet holes.
The system of restriction holes is known as Low Loss lubrication and will give lower power losses than conventional fully immersed rings.
In order to measure pad temperature, Resistance Temperature Devices (RTDs) can be fitted to a number of pads specified by the customer.
1.2 About this Manual This manual contains information about the bearing and its safe operation, and should therefore be read carefully in full before starting work. Since the bearing has a wide range of applications, this manual has been written to cover all current configurations. This manual is to be used by qualified engineers only. The following formats are used to draw attention to particular details:
This symbol signifies a warning. These are instructions that, if ignored, could
result in death or injury. Danger!
This symbol signifies an important point which, If ignored, could result in minor injury or failure to carry out a process correctly.
This symbol signifies additional instructions. This is usually a check. Missing out this stage could lead to an error going unnoticed.
In addition, brackets after a reference to a part description, e.g. thrust pads set (3), retaining ring (2) refer to an item number on a general sub-assembly drawing at the front of this manual. These are used as a reference for the engineer.
1.3 Warranty Claims Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell Bearings. These warranty obligations will automatically become void if the product is:
1. Improperly handled or installed. 2. Supplied with spare parts (or repaired), not approved by Michell Bearings. 3. Exceeding the design operating parameters shown on the arrangement drawing. 4. Subjected to environmental conditions not previously specified.
2. Safety
When installing, operating or maintaining the bearing, danger may arise to the user, the product and plant and/or other assets. Therefore all users responsible for the operation of the machine must understand this manual fully and make sure that all the safety procedures are strictly adhered to.
Pay particular attention to the following general safety notes:
!
machine.
Under no circumstances should the engineer work alone when operating the
! !
At least one of the engineers should be trained in basic first aid techniques
and wear identification that he/she is a first-aider.
No maintenance, assembly, adjustment or any other work should be carried
out on the bearing whilst the shaft is rotating or capable of movement. To avoid accidents, the entire machine should be isolated, with control gear locked off and Not to be used signs applied to the control panels.
!
!
Michell.
Personnel that manipulate the product should be sufficiently trained.
No modifications of the product should be made unless it is approved by
More specific safety notes are also given in the relevant sections, and should be adhered to.
3. Handling the Bearing

3.1 General
This section outlines essential information, which must be referred to when handling the thrust rings. The thrust rings are supplied fully assembled (see arrangement drawing for mass of complete bearing). Omega OT Series thrust rings are not usually fitted with lifting holes. A complete ring may be lifted using straps or slings. When transporting the bearing, it should remain in its packaging. Make sure thrust rings are stored in the intended mounting position, in a dry room only. Please check all product equipment to ensure that it is complete before installation. Any damage due to transit must be reported to Michell immediately. See Section 8 for instructions on how to disassemble the bearing.
Before using any lifting equipment, ensure that it is certified to carry a load
greater than that of the bearing or component.
Take care not to damage bearing components and the running surfaces of the shaft collar by contact with the lifting equipment.
If in doubt, always use mechanical devices where possible. Remember to
bend the knees and not the back when lifting manually.
4. Preparation for First Installation

All Omega OT Series thrust rings are supplied complete. All thrust rings are, for ease of assembly, capable of being split in two halves. If the rings supplied are to be split the RTDs and their cabling should be removed prior to this. Remove all packaging. Refer to Sections 2 and 3 for safety and handling instructions. Dismantle the bearing referring to Section 8, ignoring any references to the shaft or machine. When dismantled, please check all product equipment to ensure that it is complete before installation. Any damage due to transit must be reported to Michell Bearings immediately. All parts are coated in a rust preventative. This must be removed and all parts thoroughly cleaned before installation begins. To remove the rust preventative, white spirit or a strong spirit based cleaner should be used. Note! Do not use paraffin (Kerosene). It is recommended that the bearing casing and all other internal parts are cleaned to prevent dirt getting between the collar and the thrust rings.
If the thrust rings are being fitted into a bearing that has previously been used, ensure that the lubricating pipes have been cleaned to remove any deposits. If there is any dirt in the lubricating system it will damage the new parts fitted.
There may be fumes given off during the cleaning process. Clean parts in a
well-ventilated area. Always follow cleaner manufacturers instructions.
Use a lint free cloth when cleaning the bearing. Particles from other cloths could otherwise get into the lubricating oil and cause overheating, and in extreme cases, failure of the bearing. Once all parts are inspected and cleaned the bearing is ready for installation. Refer to Section 10 if the bearings are to be stored for a period of time before operation.
5. Assembly of the Bearing

5.1 General
The following general points should be noted:
The disassembling and reassembling of the equipment by an individual who is
inexperienced can cause danger. Michell will not take on any liability for any damage resulting from non-compliance with details given in this manual. If in doubt refer to our Service Dept.
Only use tools, which fit correctly to avoid damage to fasteners.
Do not use excessive force.
Use a liquid screw locking compound (e.g. Loctite 222) on all fasteners.
Always follow the instructions on adhesives.
Remove all impurities and foreign objects (e.g. bolts, washers, etc.) from inside the bearing. Ensure bearing is covered when left unattended.
This assembly procedure has been generalised to cover most eventualities. As such it may contain more information than is directly applicable to the bearing being worked on. Read all text and simply ignore any reference to irrelevant items.
5.2 Assembly of the Thrust ring 5.2.1 Fitting the Thrust Pad set. Coat all bearing surfaces in clean oil. Refer to bearing general arrangement drawing for information on the correct grade of lubricant. Place thrust pad set (3) into retaining ring halves (1), (2).
Ensure that the correct handed pads are fitted. The direction of rotation stamped on the pad must agree with that shown on the arrangement drawing.
Secure thrust pad (3) in place with pad stop (4) with hole located in back of thrust pads (3).
10
Ensure that stop (4) is fully locked in place with Loctite 222 or similar adhesive.
Always follow instructions on adhesives.
Make sure pads (3), can move freely, and are not trapped.
Take care not to trap hands when handling the components
5.2.2 Fitting Ring Stop, and Liners if applicable Place shim pack (6), and liners (7), on retaining ring halves (1), (2), and sercuer in place with hex, socket counter sunk screw (8). Ensure that screws (8) are fully locked in place with Loctite 222 or similar adhesive. Fit ring stop (5). Ensure that stop (5) is fully locked in place with Loctite 222 or similar adhesive.
5.3 Assembling the Thrust rings into the Bearing Casing Coat the thrust pads surfaces with clean oil of the correct grade. Some OT Series bearings are supplied with machine liners; these should be fitted at the same time as each thrust ring assembly. Horizontal Bearings: Fit the lower half of the thrust ring(s). Vertical bearings: Fit the entire lower thrust ring.
Care should be taken when handling the components to avoid the risk of trapping hands when assembling. Lower the shaft, complete with collar into the bearing. Horizontal Bearings: Fit the top half of the thrust ring(s), either onto the top of the lower ring, or into the top half casing. Secure the ring with stops. Horizontal bearings: Rotate the thrust ring around until the stop (5) engages in the casing, if half the ring is secured into the top half of the casing, ensure that the bottom half is flush with the casing joint and complete assembly. Vertical Bearings: Fit upper thrust ring and secure in place with stop (5).
Check the bearing alignment, and complete assembly.
11
5.3.1 Miscellaneous Where applicable, connect up oil inlet and outlet. Connect external pipework. 5.3.2 Instrumentation Fit RTDs and instrumentation as necessary.
Ensure that temperature probe assembly is not damaged and is working correctly before fitting it.
Check that the bearing is complete and is fully sealed. For temperature probe fitted bearings; run the bearing and establish a steady state operating temperature then set temperature alarm to 5C above the steady state operating temperature. Shut down temperature alarm is to be set at 10C above steady state operating temperature.
Note! Prior to running the bearing EC regulation state: - The entire machine
has received a Declaration of Conformity, or has been declared exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive. Where applicable
Do not use the bearing unless the lubricating system is operating.
It must be emphasised that any declaration of incorporation issued by Michell Bearings is for the thrust rings and their components and not for the entire bearing. The bearing is now complete; it must not be used until the below items have been dealt with; 1. Lubricating oil has been passed though the bearing. 2. The lubricating oil must be a mineral based turbine oil inhibited against oxidation, corrosion and foaming, with an ISO viscosity grade as indicated on the arrangement drawing. The use of any other oil should be referred to Michell Bearings.
If in doubt with installation please use our Service Department!
12
6. Operating
6.1 Preparation and Inspection before Operation Where necessary fit the temperature probes for measuring the thrust pads, and/or the sump temperature in the relevant connection holes.
Ensure that RTD assembly is not damaged and is working correctly before fitting.
Always follow sealant manufacturers instructions.
Where applicable retighten external oil supply connections. Fill Bearing with oil or start oil system as described in Section 7.4.
Check: 1. That the oil quantity at bearing oil inlet is as specified by Michell Bearings, where applicable. 2. That the temperature monitoring equipment works. The bearing is now ready for operation. It must not be used until the below items have been dealt with:
1. The entire installation has received a Declaration of Conformity, or has been declared exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive. 2. Lubricating oil has been passed though the bearing. 3. Local safety regulations have been met. 6.2 Trial Run For temperature probe fitted bearings, run the bearing and establish a steady state operating temperature. Set temperature alarm to 5C above this steady state operating temperature. Shut down temperature alarm should be set at 10C above steady state operating temperature. Supervise the bearing during the trial run period (approx. 5-10 operating hours). Pay special attention to the following:
1. Oil flow rate and oil inlet pressure in circulating oil system (where applicable) 2. Bearing temperature 3. Occurrence of inadmissible vibrations. 4. Unusual noises or odours
13
If any or all of the above cause concern, or if the monitoring equipment triggers an alarm, stop the machine immediately and carry out an inspection of the bearing to find the cause.
6.3 Normal Operation
Do not touch any moving parts.
If the bearing has been correctly assembled using the procedure already given, there is only a marginal risk of the bearing failing which would normally be due to inadmissible operating conditions. Examples of these conditions are; overspeed, low lubrication levels and excess load. To avoid these situations, follow the following recommendations:
Label Control Panels with the bearing limitations. Do not operate the bearing below the transition speed values indicated in the bearing calculation. Stop the shaft immediately if: Bearing temperature exceeds normal operating temperature by 10C. Never remove plugs, RTDs or seals while the bearing is operating. Regularly inspect all seals and pipework. Any large leakage of lubricant or coolant will indicate that a seal or joint is failing. Maintenance must then be carried out as soon as possible.
The bearing surface and any pipework may be hot during operation. 6.4 Preparation for Operation after Standstill Clean the external parts of the bearing. Dust and dirt impede the radiation of heat. Check with the maintenance schedule in Section 7.3 to see if an oil change is necessary. If required, carry out the oil change as indicated in Section 7.4. Start operating the oil supply system, where applicable, and check that it is working correctly. The supplied oil quantity at the bearing inlet must equal the value indicated in the Michell Calculations. Check the functioning of the temperature monitoring equipment. The bearing is now ready for operation.
14
7. Care and Maintenance

7.1 General Before carrying out any maintenance or inspection work, switch off machinery. Lock off the controls and secure and the isolate shaft.
! !
Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled Not to be used, or similar.
7.2 Tools and Equipment
The following tools and equipment may be necessary to carry out maintenance on the bearing: Allan key set Wrenching key set Open-jawed spanner set Feeler gauges. Emery paper, plain scraper Lifting equipment Permanent sealing compound (e.g. Curil-T) Liquid screw locking compound (e.g. LOCTITE 222) PTFE sealant tape. Oil with the viscosity indicated (see bearing inspection plate) Detergents Clean cloth
15
7.3 Maintenance Schedule For a bearing that is operating constantly, routine maintenance should take place annually. If the user only operates the bearing periodically, maintenance periods may be able to take place less frequently. This is however, at the users discretion. An annual inspection is recommended as a minimum service requirement. A basic guide to maintenance is given in Table 1.
Maintenance work Oil Change (see Section 7.4)
Schedule Bearing in reversing operation: every 3 Months Bearing in continuous operation: every 6 Months
Bearing Inspection
During preventative maintenance work for machine or immediately if: Bearing temperature exceeds 10C over the indicated value (see calculations) Unusual noises or odours occur Unusual changes in the oil colour are visible. Inadmissible vibrations occur. Oil flow rate and oil inlet pressure readings drop below admissible values,
Table 1: Maintenance Schedule
These are estimates only, and frequency may alter depending on site environment. Michell can advise the user accordingly. 7.4 Oil Change 7.4.1 General Oil changes will be at differing periods depending on the frequency of bearing operation and the conditions in which the bearing is operating. Approximate oil change times are indicated in Section 7.3. Please observe the instructions for the use of the lubricating oil. The manufacturer can provide information on waste oil disposal.
Risk of Pollution:
7.4.2 Procedure for draining oil Run the bearing to warm up the oil. This will ease the flow of oil from the bearing, and also remove any impurities and residues.
16
Shut down the machine and secure it against unintended operation. Shut down the oil supply system where applicable.
Do not disconnect the oil inlet and outlet pipework until the bearing has been
drained of oil.
Any oil spillage should be collected in suitable containers. Let off and collect the lubricating oil in the oil supply system where applicable. Loosen and remove the drain plug and washer, and fully drain the bearing of oil.
Beware hot oil.
Collect and dispose of used oil under the correct regulations.
If the oil is visibly altered in colour, or contains unusual residues, an inspection is recommended to eliminate the cause.
7.4.3 Procedure for refilling the bearing -self contained bearings Pour the correct grade of lubricating oil into the filling hole in the casing top. Use the approximate quantity required as shown on the bearing arrangement drawing as a guide. Let the oil settle into the bearing. Check the oil level is approximately at the centre of the oil level gauge, and top up if necessary. Where applicable.
7.4.4 Procedure for refilling the bearing - bearings with circulating oil Clean the oil container and fill up the oil supply system with the correct grade of lubricating oil. Start the oil supply system in order to fill up the bearing with oil.
Check for leaks.
Not enough lubricant leads to temperature rises and therefore damage to the bearing. Too much lubricant leads to leaks.
When pouring, take care not to spill lubricating oil onto the machine or surrounding area.
17
8. Dismantling an Installed Bearing

8.1 General The Procedure given in this section is a full stripdown of a generic Omega OT series bearing. As such it may contain more information than is necessary in some cases. Simply ignore the sections not relevant to the bearing being worked on. Any technical queries can be referred to the Engineering Team at Michell Bearings. Michell recommends that the below safety advice is followed when carrying out maintenance on any bearings. It may be necessary to change the dismantling procedure to suit the design of the bearing casing.
8.2 Preparation Check through the safety procedures at the start of Section 2. Understand and follow the instructions very carefully. Switch off machinery. Lock off controls. Secure and isolate shaft, drain and disconnect cooling system, where applicable. Refer to manufacturer instructions.
the shaft is locked out and labelled Not to be used. Switch off and drain the lubricating oil and oil system (where necessary) as described in Section 7.4. Disconnect and remove any thermometry and instrumentation.
Make sure the workspace is clean. Contamination and damage to the bearing affect operating performance and could lead to premature failure.
Do not use any violence or force.
Take care not to jam hands when manipulating components. . 8.2.1 Strip down the bearing until the thrust rings are visible. Horizontal Bearings: Where applicable, remove the top half of the thrust ring(s). Vertical Bearings: Remove upper thrust ring (where fitted). Vertical Bearings: Jackshaft up until its clear of the lower thrust pads.
18
! !
Follow lifting instructions and safety guidelines in Sections 2 and 3.
Ensure the jacking equipment is safely positioned and certified to carry a load
greater than the mass of the shaft.
Once the shaft is raised, secure it into position using other equipment. Do not
rely on jacking equipment alone. 8.2.2 Disconnect and remove any thermometry and instrumentation. Remove RTDs, and instrumentation connections.
Take care not to damage instrumentation. 8.3 Removing thrust rings Vertical Bearings: Remove lower thrust rings. Horizontal Bearings: If the bottom half of the thrust rings are not visible, follow the below procedure; Tap one end of the ring until the opposite end is visible. Rotate the ring out and remove. 8.4 Removing the Liners, and Shim Pack. Where Applicable. To fully dismantle the thrust ring follow the below procedure: Remove liner retaining screws (8), liners (7), and shim pack (6) from the back of the retaining ring halves (1), (2). 8.5 Removing the Thrust Pad Set Remove thrust pad stops (4) from retaining rings (1), (2). The thrust pads (3) can now be removed from the retaining ring (1), (2).
Take care not to jam hands when manipulating components.
Take care not to damage thrust pad whitemetal surface.
19
9. Cleaning and Checking

9.1 General
! ! !
Only use non-aggressive detergents such as VALVOLINE 150 or Alkaline
cleaning compounds with pH-value 6 to 9, and a short reaction time.
Please observe the instructions for use of the detergents.
Use a lint free cloth when cleaning the bearing. Thread from such cloths could get into the lubricating oil and cause overheating, and in extreme cases, failure of the bearing. Clean the following parts thoroughly:
1. Thrust pad set. 2. Retaining ring. 3. Liners, where applicable 4. Shim pack. 5. Thrust pad stops. In addition inspection may be required on the bearing components, according to the Maintenance Schedule outlined in Section 7.3. The remaining part of this section gives basic inspection guidelines for some major bearing components. However, if any wear or damage is evident on any of the bearing components, consult Michell Bearings immediately as it may adversely affect bearing performance. The following sections assume the bearing has been dismantled according to Section 8.
20
9.2 Checking the Thrust Pad. Examine the Thrust Pads. The appearance of the running surface should be that shown in Figure 11 below.
Figure 11: Thrust Pad Appearance After Use
Inspect the collar surface for any signs of damage. If it is necessary to change the pads, the collar should also be replaced or repaired, otherwise the replacement pads will only have a short life. There may be some scoring and wear on the pads. Provided wear is no greater than 0.125mm the pads are still serviceable. If there is any sign of the bearing surface coming away from the backing material, the pads must be replaced.
21
10. Bearing Preservation during Storage

10.1 Before Installation Make sure thrust rings are stored in the intended mounting position, in a dry room only.
10.2 Corrosion Protection for Standstill Periods up to 6 Months
Dismantle the bearing (see Section 8). Clean the bearing (see Section 9). Assemble the bearing (see Section 5). Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of condensation in the bearing.
10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year Repeat the preservation procedures detailed in Section 10.2.
10.4 Corrosion Protection for Standstill Periods longer than 1 year Dismantle the thrust rings according to Section 8. Preserve and store bearing parts separately.
11. Bearing Preservation During Transport

When the bearing is fitted to the machine during transport: Carry out the corrosion protection procedure described in Section 10.2. Apply liberal lubricant to the running surfaces of the bearing. Secure the shaft against axial and radial movement.
12. Appendices
12.1 Ordering Spares
As a minimum, it is recommended that replacements should be carried for all Whitemetal components. Consideration should also be given to stocking the parts listed below: Jointing compound (i.e. Curil-T) RTD Assemblies (where applicable)
22
Appendix 2 (Table of Torques).
Bolt Size (mm) 6 8 10 12 16 20 24 30 36 42 48 56 64
Tightening Torque (Nm) 4 10 20 35 80-90 155-175 275-305 545-605 950-1050 1520-1680 2300-2520 3690-4070 5560-6150
23
Michell Bearings Scotswood Road Newcastle Upon Tyne NE15 6LL Great Britain Tel: (0191) 273 0291 Fax: (0191) 272 2787
Service Department. Direct: +44(0191) 2565319
Repair Department. Direct: +44(0191) 2565309
Michell Bearings reserve the right to amend these instructions. Michell Bearings 2004.
24
SECTION A
5. CONNECTING COUPLING
EUROFLEX TRANSMISSIONS (India) PVT LTD.

PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR HYDERABAD - 500 037.
STD OM
Page 1 of 4
1. Installation and alignment instructions:
Preliminary Checks All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling accompany all supplies. Carry out the following checks prior to proceeding with the installation work. i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport purposes and for the purpose of compressing the flexing elements at the time of installation. The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling alignment and trial run of the equipment. Couplings and the equipment should not be allowed to operate with gagging screws in position. ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those of the interface dimensions of the equipment shafts and flanges. Coupling model & Rating Hub bore and key way dimensions Locating / Spigot diameter Distance Between Shaft Ends (DBSE) or Distance Between Flange Faces(DBFF) Over all length iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling. iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise called for, should not be disassembled, . v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque wrenches / special spanners. vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying certificates will show the run out values obtained at the time of dynamic balancing. These markings of are meant for match marking and the run out values can be used as a guide for accurate alignment of the equipment.
Prepared SANKAR
Approved KVMR
Date 18-06-2003

STD OM
Page 2 of 4
vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection, with a coat of oil applied and wrapped in moisture proof polythene shrink film. For best results it is recommended that the couplings are left in their original packing and are to be removed just prior to the actual date of installation. For extended periods of storage in the open, it is recommended that the couplings are returned to their original packing and stored with a periodic coat of oil re-applied to them. viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field replacement with components that do not form part of the original set is not to be done. Always replace these components as a set.
2. Initial Assembly and Centering :
Correct careful assembly and centering at the initial stage enables the coupling to provide maximum performance and increases service life.
3. General Limits :
i. Maintain the actual Axial shaft gap to that specified with the following tolerances : 4 bolt couplings : +/- 0.5 mm 6 bolt couplings : +/- 0.4 mm 8 bolt couplings : +/- 0.3 mm As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling drawing. ii.Radial Misalignment : Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower. Note : The above values are to be arrived at after taking into consideration the cold offset values for both axial and radial directions specified by the main equipment manufacturer.
Prepared SANKAR
Approved KVMR
Date 18-06-2003

STD OM
Page 3 of 4
CONFIGURATION-1
Configuration : 1
Couplings with this configuration have hub flanges directly bolting on to the flexing elements. Following is the sequence installation : i. Dismantle the coupling bolts and the gagging screws. ii. Mount the hubs on respective equipment shafts. iii. Position the equipment to the correct DBSE specified. iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance (DBFF) specified on the drawing. v. Clamp two dials as shown and align to within 0.05 mm of TIR. vi. Assemble the flexing elements and spacer in position and hand tighten all coupling bolts, in cylinder head fashion. vii. Tighten all coupling bolts to 50% of the specified torque using a calibrated torque wrench, in a cylindrical head fashion. viii. Recheck the DBSE and radial run out values. Readjust if the same is found disturbed. ix. Tighten all coupling bolts to the specified torquing limit. Prepared SANKAR Approved KVMR Date 18-06-2003

STD OM
Page 4 of 4
IMPORTANT: Care should be exercised to tighten only the lock nuts by holding the bolt head steady in a socket. Coupling bolts will have a very close fit in the flange holes and to the flexing element bushes and hence any forced rotation will result in damage to the close fitting bolt shank and the mating parts.
2 Alignment Procedure / Clamping Arrangment Fig. No. : 1

Max. Alignment Limits TIR-mm Application DRIVER - DRIVEN Dial 1 0.05 Dial 2 0.05
2
Final checking Fig. No. : 2
Max. Alignment Limits TIR-mm Application DRIVER - DRIVEN Dial 1&2 0.05
Prepared SANKAR
Approved KVMR
Date 18-06-2003
Euroflex Transmissions (India) Pvt.Limited

99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149 e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Format No : QF/DES/07 STD OM

Page : 1 off 4
Preliminary Checks All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling accompany all supplies. Carry out the following checks prior to proceeding with the installation work. i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport purposes and for the purpose of compressing the flexing elements at the time of installation. The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling alignment and trial run of the equipment. Couplings and the equipment should not be allowed to operate with gagging screws in position. ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those of the interface dimensions of the equipment shafts and flanges. Coupling model & Rating Hub bore and key way dimensions Locating / Spigot diameter Distance Between Shaft Ends (DBSE) or Distance Between Flange Faces(DBFF) Over all length iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling. iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise called for, should not be disassembled, . v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque wrenches / special spanners. vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying certificates will show the run out values obtained at the time of dynamic balancing. These markings of are meant for match marking and the run out values can be used as a guide for accurate alignment of the equipment. PREPARED SURESH CHECKED SANKAR APPROVED KVMR DATE 18-06-2003


Page : 2 off 4
3. General Limits :
PREPARED SURESH
CHECKED SANKAR
APPROVED KVMR
DATE 18-06-2003


Page : 3 off 4
Configuration : Couplings of this configuration are supplied with a central transmission unit which allows installation with minimum disassembly of the factory tightened main coupling bolts. i. Dismantle the coupling hubs by removing the attachment screws. ii. Mount the hubs on respective equipment shafts. iii. Position the equipment to the correct DBSE specified. iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance specified on the drawing. In case of variation to the specified axial shaft gap , refer to the specific instructions supplied, for using DBSE adjusting shims supplied with the unit. v. Clamp two dials on hub flanges as shown and align to within 0.05 mm of TIR. vi. Disassemble the gagging screws and remove the gagging bush from the position. Re assemble the gagging screws between the adaptor and spacer flanges. The transmission unit can now be compressed, by tightening the gagging screws, adequate to facilitate assembly. vii. Place the transmission unit into the position between the hubs ensuring that the spigot on hubs clears the locating diameter on the adaptor plates.
PREPARED SURESH
CHECKED SANKAR
APPROVED KVMR
DATE 18-06-2003


Page : 4 off 4
IMPORTANT : Slowly loosen & remove the gagging screws thus allowing the transmission unit to regain the original free length. Ensure that the gagging screws are NOT in position at the time of equipment trial run or continuous operation. Remove & store the gagging screws and bushes carefully for future use. viii. Re check the DBSE and radial run out values. Readjust if the same is found disturbed. ix. Tighten all attachment screws / bolts to the specified torque limit.
PREPARED SURESH
CHECKED SANKAR
APPROVED KVMR
DATE 18-06-2003
SECTION B
6. SUCTION STRAINER (BASKET)
SP Patra
Digitally signed by S P Patra DN: CN = S P Patra, C = US, O = DVC, OU = Engineering and Planning Reason: DVC have reviewed this document and taken it for INFORMATION Date: 2009.02.05 15:01:43 +05'30'
SECTION - B
BOILER FEED PUMP
PART 4 EQUIPMENT DETAILS
SECTION - B BOILER FEED PUMP
LIST OF CONTENTS
CHAPTER 1. 2. 3. 4.
TITLE Description Operating Instructions Maintenance Instructions Sub-Vendors Drawings / Instructions
CHAPTER - 1 DESCRIPTION LIST OF CONTENTS
1 2
Introduction Technical Data (Ref. BFP data sheet) Motor driven pump Turbine driven pumps
3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
Description Pump casing Discharge cover Suction guide Ring section assembly Rotating assembly Mechanical seals Journal and thrust bearings Bearing housing Hydraulic balance
CHAPTER 1 DESCRIPTION 1. INTRODUCTION : FK4E36 type Boiler Feed Pump is a four stage horizontal centrifugal pump of barrel design casing. The pump internals are designed as a cartridge which can be easily removed for maintenance without disturbing the suction and discharge pipe work, or the alignment of the pump and the turbo coupling. The pump shaft is sealed at the drive end and non-drive end by Mechanical Seals. The rotating assembly is supported by plain white metal lined journal bearings and axially located by a double titling pad thrust bearing.
3. 3.1
DESCRIPTION: Pump Casing : The pump casing consists of a forged steel barrel with welded suction, discharge branches, inter stage tapping and mounting feet. The drive end of the casing is closed by a suction guide which is entered from the non-drive end of the casing and is located by a spigot against the outer face of the casing. A metaflex joint is located between the suction guide spigot and the casing outer face to prevent leakage between the barrel casing and suction guide. A split pull up ring is secured to the pump casing and suction guide by a ring of screws. Leakage between the suction annulus and the discharge annulus of the pump casing is prevented by a copper coated mild steel joint located between the inner face of the casing and the first stage ring section spigot. The non-drive end of the casing is closed by a discharge cover secured to the casing by a ring of studs, washers and nuts, sealing being effected by a Metaflex joint located in a machined recess in the pump casing. On each side of the casing, on its horizontal centre line, are two support feet which are secured to the base plate pedestals by spacer pieces, washers and holding down bolts, thus allowing for expansion. Transverse keys in the drive end pump feet and longitudinal keys under the casing transfer moments and thrust to the base plate, while allowing the casing, freedom to expand. Provision is made on the pump casing for a drain connection and temperature probes.
3.2
Discharge Cover The discharge cover closes the non-drive end of the pump casing and also forms the balance chamber which, in turn, is closed by the gland housing. The discharge cover is a close fit in the casing bore and is held in place by a ring of studs and nuts. A spring disc is located between the last stage diffuser and out let guide to provide the force required to hold the ring section assembly in place against the drive end of the barrel before start-up. Once running, the discharge pressure assists the spring disc in holding the ring sections in place. The last stage diffuser is free to slide over the out let guide. Two holes are drilled radially through the periphery of the discharge cover to provide outlet connections through which the liquid from the balance chamber is returned to the pump suction piping and two similarly drilled holes are also provided in the discharge cover for the welded connections of the kicker stage deliveries. The non-drive end bearing housing is attached to the gland housing secured to the outer face of the discharge cover by socket head screws and dowel pins. To assist in removing the cover, two tapped holes are provided on the flange for the use of starting screws and a tapped hole is provided on top of the cover for an eye-bolt.
3.3
Suction Guide The suction guide closes the drive end of the pump casing and forms the suction annulus. As a section of the pump cartridge, the suction guide is not secured to the pump casing but is held against an internal shoulder in the casing by the pull up ring. The drive end bearing housing is secured to the outer face of the suction guide by cap screws and dowel pins.
3.4
Ring sections The ring section assembly consist of ring sections which locate one to another by radial dowel pins and are secured to each other by socket head screws in counter bored holes, sealing being effected by metal-to-metal joint faces. Diffusers are dowel and spigot located to the ring sections and secured to the ring section with socket head screws. The outlet guide for the kicker stage impeller is secured to the discharge cover by means of cap screws which are locked in position with plugs. Packing rings are shrunk into the bores of the ring sections and diffusers and are secured by grub screws, the purpose of the packing rings being to restrict the recirculation of the pumped liquid between the stages.
The ring sections and diffusers form the transfer passages from the impeller outlet of one stage of the pump to the impeller inlet of the next stage, and the diffusers are designed to convert some of the kinetic energy of the product into pressure energy. The first stage ring section is spigot located to the suction guide and is radially located by means of a slot in the ring section and a cast key block in the suction guide. At the non-drive end a dowel pin fitted to the outlet guide is located in a hole in the last stage diffuser thus the ring section assembly is kept in its correct position relative to the casing. A circular spring disc is located in the last stage diffuser and over the inner end of the outlet guide. A shoulder on the outlet guide bears against the spring disc and clamps the ring section assembly and suction guide in position. 3.5 Rotating Assembly The dynamically balanced rotating assembly consists of the shaft, impellers, abutment rings, keys, seal sleeves, shaft nuts, balance drum, thrust collar and the pump half coupling. The shaft is chromium plated at each end where it is supported by the journal bearings, and its diameter increases in increments from the non-drive end towards the drive end to facilitate the fitting and removal of the impellers. The impellers are of the single entry shrouded inlet type and are keyed and shrunk onto the shaft, the keys, one per impeller, being alternately fitted on diametrically opposite sides of the shaft to maintain rotational balance. The hub of each impeller butts against a split shear ring fitted in a groove in the shaft. The shear ring is retained by an extension of the impeller hub. The balance drum is keyed and shrunk on the shaft and held in place against the shaft locating shoulder by the balance drum nut and lock-washer. The inner end of the balance drum is recessed and the bore of the recess is a close fit over the kicker stage impeller hub. The face of the balance drum incorporates tapped holes for withdrawal purposes. The rotating parts of the seals are fitted to the shaft where it passes through the seal housings. The seal sleeves are keyed to the shaft and are clamped in position by shaft nut and shaft lock-nuts. The thrust collar which is keyed to the non-drive end of the shaft, has the thrust collar probe indicator fastened and doweled to its hub and is located against a shoulder on the shaft by the thrust collar nut, locked by a lock washer. NOTE : The thrust collar nut has left hand thread.
The pump half coupling is located on the tapered end of the shaft by keys and it is secured by a coupling nut locked by a grub screw.
3.6
MECHANICAL SEAL The drive and non-drive end stuffing boxes are fitted with mechanical seals mounted on seal sleeves and located within seal cooling jackets to prevent feed water escaping along the shaft. Tapped holes are provided on each seal plate and cooling jacket for clarified cooling water inlet and outlet connections.
3.7
Journal and Thrust Bearings The rotating assembly is supported at each of the shaft by a white metal lined journal bearing and the residual thrust is carried by a titling pad double thrust bearing mounted at the non-drive end of the pump. The journal bearing shells are of mild steel, white metal lined, thick wall type and are split on the horizontal plane through the shaft axis. Each bearing is secured in a bearing housing and prevented from rotating by a dowel pin located in the bearing keep. The thrust bearing has eight white metal lined titling pads held in a split carrier ring positioned on each side of the thrust collar. The carrier rings are prevented from rotating with the shaft by dowel pins in each ring which engage in slots in the bearing housing top half. The thrust pads are retained on the carrier rings by a special pad stops screwed into the rings. A split floating oil sealing ring is located in a groove in the thrust bearing housing to restrict the escape of lubricating oil from the thrust bearing chamber. To ensure that the thrust bearing remains flooded, an orifice is fitted at the oil outlet. Machined spacers are fitted behind the carrier rings to effect the axial position setting of the rotating assembly on the original build. The bearings are supplied with lubricating oil from the forced lubrication oil system.
3.8
Bearing Housings The bearing housings are in the form of cylindrical castings split on the horizontal shaft axis. The top and bottom halves, of each bearing housing, are located by fitted bolts and secured together by cap screws. The journal bearing in each housing is located by a dowel pin in the bearing keep and the bearing keep is dowel located to the bottom half housing and secured by cap screws. On the top half housing there is provision for an air vent, vibration probes and a temperature check point. On the bottom half housing there is provision for oil inlet and oil outlet, R.T.D. probe and a temperature gauge.
The drive end bearing housing is secured to the suction guide by cap screws and is radially located by dowel pins fitted in the flange of the suction guide. Oil guards fitted in a groove at each end of the bearing housing are dowel located and serve to prevent oil escaping from the housing. An air breather is screwed into a tapped hole in the top half bearing housing and a tapped hole is provided for a temperature gauge. Connections for an oil inlet and an oil outlet are provided in the bottom half bearing housing. The non-drive end bearing housing, which contains both the journal and thrust bearings, is located by taper dowel pins and secured to the gland housing by cap screws. In addition to the features common to both bearing housings the follow features are included. On the top half housing there are connections for reverse running indicators, an accelerometer and a thrust bearing temperature check point. On the bottom half bearing housing the additional provision is for thrust bearing temperature gauges. Leakage of lubricating oil from the non-drive end bearing housing is prevented by an oil guard in the inboard side of the housing. 3.9 Hydraulic Balance : The rotating assembly is subject to varying forces due to the differential pressure forces acting on the impellers. The pump has therefore been designed so that the shaft is kept in tension by the location of a balance drum at the non-drive end, and is hydraulically balanced so that only a small residual thrust remains, which is carried by the thrust bearing. The main components of the hydraulic balancing arrangement are the balance chamber machined in the discharge cover, the balance drum which is secured to the shaft and the balance drum bush fitted in the bore of the discharge cover. The thrust caused by the discharge pressure acting on the area outside each impeller wear ring on the inlet side of the impeller wear ring is balanced by the same pressure acting on an equal area on the outlet side of each impeller. The thrust caused by the suction pressure acting on the area inside the wear ring on the inlet side of each impeller is overcome by the much greater thrust caused by the discharge pressure acting on an equivalent area on the outlet side of each impeller. The resultant thrust force, due to the different pressures acting on these equal areas, tends to move the rotating assembly towards the drive end of the pump. The thrust force will vary with the load on the pump but the hydraulic balance arrangement will reduce its effect, enabling the residual thrust to be taken by the titling pad thrust bearing. This bearing has a double face so that the surges in opposite directions which occur during the start-up period and during transient conditions will be accommodated.
The hydraulic balance arrangement operates as follows:The pump product passes from the kicker stage of the pump between the balance drum and the bush, and enters the balance chamber at a pressure approximately equal to the suction pressure. Two ports in the discharge cover allow the product to be piped back to the pump suction side. The pressure differential across the balance drum is therefore equal to the across the impellers. The cross-sectional area of the balance drum is sized to give a small residual thrust towards the drive end of the pump.
SECTION - B
BOILER FEED PUMP
CHAPTER - 2 OPERATING INSTRUCTIONS
LIST OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8.
Introduction Preparation for starting Start up Routine checks Trip condition Shut-down Stand by conditions Fault finding
CHAPTER 2 OPERATING INSTRUCTIONS 1. INTRODUCTION The 50% tandem Boiler feed pump set is an integral part of the boiler feed system and the following instructions should be read in conjunction with those for the operation of the associated equipment and the system. 2. PREPARATION FOR STARTING CAUTION : The pump set suction and discharge pipe work and valves are not in pumps supply. Reference, therefore, should be made to the system operating instructions for the control of the valve. (1) (2) Check that the deaerator is filled to normal working level. Check that the control air and electrical supplies are available for the instrumentation, leak-off equipment and valves. Ensure that the suction filter has been primed and ready for operation. Check that the following valves are shut :(a) (b) (c) (d) (e) (5) Pump set suction isolating. Booster stage pump drain isolating. Interconnecting pipe drain isolating. Boiler Feed pump drain isolating. Pump discharge isolating.
(3) (4)
Check that the following valves are open :(a) (b) (c) (d) Leak-off control valves inlet and outlet isolating. Leak-off control. Booster stage pump mechanical seal control and outlet isolating. Boiler feed pump magnetic separator inlet and outlet isolating.
(6)
Check that all the instrument tapping point isolating valves are open and that all drain and equalizing valves are shut. Crack open the pump set suction isolating valve. Open the booster pump air vent valve and vent any trapped air or gases from the pump casing. Shut the booster pump air vent valve when water issues freely from it.
(7) (8)
(9)
(10)
Open the interconnecting pipe work air vent valve and vent any trapped air or gases from the interconnecting pipe. Shut the interconnecting pipe work vent valve when water issues freely from it. Shut the leak-off drain regulating and drain isolating valves when water issues freely from them. Fully open the pump set suction isolating valve. Ensure that the station general service cooling water available for the pump set. Prepare the driving motor for starting. Refer to manufacturers instructions. Prepare the turbo-coupling and lubricating oil system for starting. Refer to the manufacturers instructions in part 3. Ensure that all instruments and coolers have been primed and vented. Ensure that the pre-start checks for the leak-off equipment are carried out. Refer to the manufacturers instructions.
(11)
(12)
(13) (14)
(15) (16)
(17) (18)
3.
START-UP Refer sequential interlocking conditions.
4.
ROUTINE CHECKS (1) (2) (3) (a) (b) (c) (4) (a) (b) (c) (d) (e) (5) (6) (7) Check that the driving motor ammeter reading is normal. Check that all pressure and temperature readings are normal. Check that the lubricating oil is flowing freely through the following flow indicators :Booster pump drive end and non-drive end bearing drain flow. Booster pump side and turbo coupling side driving motor bearing drain flow. Boiler feed pump drive end and non-drive end bearing drain flow. Check that the cooling water from the BFP and booster pumps mechanical seals is flowing freely. Cooling water from motor coolers. Cooling water from mechanical seal coolers. Cooling water from cooling water jackets in BFP and booster pump Cooling water from lubricating oil coolers. Cooling water from working oil coolers. Check the oil level in the fluid coupling tank and top up as necessary. Check for any undue noise or vibration. Check all joints and valve glands for leakages.
(8) (9) (10)
Check the security of all keys and fastenings, paying particular attention to the holding down bolts. Check for leakage from BFP and booster pump mechanical seals. Refer to the manufacturers instructions for the routine checks of the turbo coupling and the driving motor.
5. 6.
TRIP CONDITION : Refer sequential inter locking conditions. SHUT - DOWN (1) (2) (3) (4) (5) (6) Shut the discharge valve. Stop the driving motor by opening the boiler feed pump motor ACB. Check that the electrical lube oil pump starts up as the pump set slow down. Check the pump reverse running indicator. Stop the electrical lube oil pump 15 minutes after the Boiler feed pump set has stopped. Close the cooling water valves to the driving motor air cooler and the working oil cooler of the turbo coupling.
7.
STAND BY CONDITIONS Refer sequential interlocking conditions.
8.
FAULT FINDING Symptom (1) Pump fails to start. Symptom (c) (a) (b) Possible Cause Driving motor fault Power supply fault. Possible Cause Seizure of Pump set. Action Check motor Check motor Breaker. Action Disconnect couplings and locate seizure. Overhaul as necessary Check deaerator water level switches & gauge glass for any Blockage. Investigate cause. Reset trips. Check operation of motor.
(d)
Deaerator level lowlow Pump set tripped.
(e)
(2)
Pump performance low (Pump Discharge pressure low)
(a)
Driving motor faculty
(b) (c) (d) (e) (f) (3) Bearings overheating. (a)
Incorrect rotation Booster stage pump faculty. Excessive wear of pump internals Low Speed Strainer Chocked Defect in lubricating oil system.
Check motor electrical connections. Check booster stage pump (Refer to part 1, chapter 2). Dismantle pump and inspect components. Check Speed Regulation System Clean strainer. Check lubricating oil system. Oil flow to bearing. (Refer to manufacturers instructions in Part 3). Examine Bearings. Check alignment.
(b) (c) (4) Mechanical Seal Temperature high (a)
Bearings worn of misaligned. Misalignment of pump.
Insufficient cooling Water to cooler.
Check Heat Exchanger for blockages and clean.
(5)
Excessive noise and/or vibration (a) (b) (c) (d) (e) (f) Misalignment of pump set. Bearing misalignment Holding down bolts loose. Excessive clearance of pump internals. Rotating assembly out of balance. Excessive piping loads acting on pump branches. Hydraulic Flow Disturbances No flow through pump Check alignment Examine bearings. Tighten holding down bolts. And maintain Dim as per Drg. Check clearances overhaul as necessary. Check dynamic balance. Check piping support and readjust. Increase flow through pump. Avoid long runnings on low flows. a) Check R.C. Valve
(g)
(6)
High Diffl. Temp across suction and discharge of BFPS.
(a)
(b) (c)
Hot start of stand by Pump. Mal-Operation of Instruments.
b) c)
Opening casing drain & R.C. line drains. Check RTD & diff temp. switches.
(7)
H.C. Fusible plugs blown off
(a)
Entrap-off foreign particles between pump internals or pump seizure
a)
Check pump freeness/ rotation. If hard, open and inspect pump internal.
LIST OF CONTENTS
1 1.1 1.2 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5
Introduction Periodic and preventive maintenance Routine checks Maintenance particulars Estimated weights Joints Recommended torque values for threaded fasteners Recommended lubricants Maintenance Procedures Preparation for maintenance Examining the drive end journal and thrust bearing. Examine the non-drive and journal and thrust bearing. Checking the axial running position and thrust bearing clearance. Overhaul Preparation for overhaul Withdrawing the pump cartridge Dismantling the pump cartridge Inspection, renewal and repair procedures Assembling the pump cartridge Installing the pump cartridge Final assembly Parts Identification
CHAPTER 3
MAINTENANCE INSTRUCTIONS
1. INTRODUCTION : It is recommended that a system of routine inspection be established during which the condition of the pump can be determined and recorded for comparison with later inspections. Any defects should be repaired or the components renewed at the earliest opportunity. Certain inspections can only by made when the pump is under shut down but others can be made under operating conditions. A high degree of cleanliness of each pump and of the surrounding areas should be maintained, as this will assist in the early detection of minor leaks or defects which, if unnoticed, could lead to more serious operational or maintenance problems. Periodic and Preventive Maintenance The pump performance should be used as the criterion for the need to renew wearing parts. The pump performance may deteriorate due to excessive leakage past the impeller/diffuser wear rings or vibration may indicate that the wear rings or bearings are worn. Note: The recommended renewal clearances are 1.5 times the clearances shown on the Sectional Arrangement Drawings. If the pump performance has declined it may be necessary to renew the wearing parts before the recommended clearances are reached.
1.1
1.2
Routine Checks It is essential that the routine checks given in Chapter-2, Section-5 are carried out regularly. The checks concerned with the mechanical condition of the pump are repeated here for the convenience of the maintenance engineers.
1.2.1
Periodic Checks It is recommended that the following checks are carried out at regular intervals :(1) (2) (3) (4) (5) (6) Check that the suction and discharge pressures are normal. Check that the pump bearing lubricating oil pressures and temperatures are normal. Check for any leakage from the mechanical seals. Check all joints and valve glands for leakage. Check for any undue noise or vibration. Carryout a visual check on all keeps and fastenings, paying particular attention to the holding-down bolts.
2. 2.1
Maintenance particulars Estimated Weights (for lifting purposes) Item Cartridge assembly Discharge cover Suction guide Pump shaft Ring section, 1st stage Ring section, 2nd / 3rd stage Ring Section, last stage Diffuser Bottom bearing housing, drive end Top bearing housing, drive end Bottom bearing housing, non-drive end Top bearing housing, non-drive end Thrust bearing cover Thrust collar Balance drum Gland housing Weight, kg 1752 1200 216 303 138 144 131 48.5 55 85 145 91.5 30.5 28.8 33 191
2.2
Joints
All the various types of joints, CAF, Metaflex etc. used on the pumps, are to be found in the parts lists on sectional assembly drawings. 2.3 Recommended Torque Values for Threaded Fasteners The following torque figures must be used when assembling the pump. All threads and undersides of heads must be lubricated. Threaded Fastener Pull up rings screws Gland housing/discharge cover screws Diffuser Screw Last stage diffuser screws Thrust collar nut Ring section screws 2.4 Recommended Lubricants This lubricating oil for the journal and thrust bearings of the Booster and Boiler feed pumps will be supplied from the lubricating oil system associated with the turbo coupling. 3. MAINTENANCE PROCEDURES WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE PROCEDURES. Note : The FK4E36 Boiler feed pump is an integral part of the tandem Boiler feed pump set. The following instructions should, therefore, be read in conjunction with those for the Booster pump in Part 1. 3.1 Preparation for Maintenance Before commencing any maintenance procedures, the pump must be isolated as follows :(1) (2) (3) Isolate the electrical power supplies to the pump driving motor and the lubricating oil system. Isolate the electrical power supplies to all instruments. Check that the pump set suction, discharge and leak-off isolating valves are shut. Recommended Torque (Nm) 175 430 40 40 2850 95
(4) (5)
Check that the Mechanical seal lines have been isolated. Open the drain and vent connections, and drain the pump casing.
3.2
BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE PUMP, BE SURE THAT THERE IS NO PRESSURE WITHIN THE PUMP CASING. Examining the drive end (DE) journal bearing. (1) Disconnect and remove any instruments which could interfere with the dismantling procedures.
WARNING:
CAUTION : The top half bearing housing is located on the bottom half bearing housing by two fitted bolts. Care must be taken to avoid damage to the bolts or the holes in the top and bottom half housing. (2) Withdraw the two fitted bolts and remove the cap screws securing the top half bearing housing to the bottom half bearing housing. Also remove the cap screws securing the top half bearing housing to the suction guide. Use two jacking screws in the top half bearing housing to separate it from the bottom half. Lift the top half bearing housing complete with the top halves of the oil guards away. Remove the top half journal bearing from the shaft with the assistance of applying jacking screws to the bearing keep. Take the weight of the pump shaft and rotate the bottom halves of the journal bearing and oil guards around the shaft and lift them away. Examine the journal bearing and shaft journal for signs of damage, scoring of deterioration and examine the journal bearing and the oil guards for wear. Reference should be made to the sectional arrangement drawings, for the clearances of the journal bearing and oil guards. Lightly smear the shaft and journal bearing surfaces with oil before final assembly. Rotate the bottom halves of the journal bearing and oil guards around the shaft and into position in the bottom half bearing housing. Release the weight of the pump shaft. Locate the top half journal bearing in position on the pump shaft. Locate the bearing keep on the dowels and secure it with the cap screws. Lift the top half bearing housing complete with the top halves of the oil guards onto the bottom half bearing housing.
(4)
(6)
(7)
(8)
Note:
(9)
(10)
(11)
(12)
Locate the top half bearing housing to the bottom half housing with the fitted bolts, then secure to the bottom half and the suction guide with the cap screw. Replace the instruments and the turbo coupling/pump drive coupling guard.
(13)
3.3
Examing the Non-drive End (NDE) Journal and Thrust Bearing (1) Disconnect and remove any instruments which could interfere with the dismantling procedure. Remove the fluid coupling/pump drive coupling guard. Remove the fluid coupling/pump drive coupling spacer and element assemblies. Remove the set screws securing the bearing housing end cover to the top half bearing housing.
(2) (3)
(4)
CAUTION : The top half bearing housing is located on the bottom half bearing housing by two fitted bolts. Care must be taken to avoid damage to the bolts or the holes in the top and bottom half housing. (5) Withdraw the fitted bolts and remove the cap screws securing the top half bearing housing to the bottom half bearing housing and the gland housing. Use four jacking screws in the top half bearing housing to separate it from the bottom half. Lift the top half bearing housing complete with the top half oil guard away. Remove the top half journal bearing from the shaft.
(6)
(7)
CAUTION : The thrust cover is located on the bottom half bearing housing by four dowel pins. Care must be taken to avoid damage to the dowels or the locating holes. (8) Remove the cap screws securing the thrust cover to the bottom half bearing housing. Use four jacking screws to separate to the thrust cover from the bottom half bearing housing and lift it way. Lift the top halves of the floating seal carriers away, then take the weight of the pump shaft and rotate the bottom halves of the journal baring, oil guard and floating seal carries around the shaft and lift them away. Unclip the springs and remove the split floating oil seals from the bearing housing.
(9)
(10)
Note : The thrust carrier ring split line is at 90 to the bearing housing horizontal surface. (11) Remove each thrust carrier ring in turn as a complete unit as follows :Rotate the complete carrier around the shaft until the half ring with the stop pin can be removed, then rotate the other half ring around the shaft until it can be lifted clear of the shaft. Repeat with the second carrier ring on the other side of the thrust collar. Examine the journal bearing, shaft journal, thrust pads, thrust collar, split oil seal and oil guard for damage or deterioration. Under normal operating conditions it is not expected that any measurable wear will take place on the thrust pads other than a dulling of the white metal surfaces. It is recommended that when this dulling has spread to more than half the surface area of the pads, they should be renewed.
(12)
Refer to the sectional arrangement drawing for the clearances and renew the journal bearing and oil guard if necessary. Note : Lightly smear the shaft, thrust collar faces and baring surfaces with oil before final assembly. (13) (14) Install each split floating oil seal on the pump shaft with the spring. Take the weight of the pump shaft and rotate the bottom halves of the journal bearing, oil guard and floating seal carriers around the shaft and into position in the bottom half baring housing. Release the weight of the pump shaft. Install each thrust carrier ring in turn as a complete unit as follows:Take the half carrier ring without the stop pin and place it over the shaft with the pad faces touching the thrust collar and rotate it into the bottom half bearing housing, then place the other half carrier ring with the stop pin upon the first and rotate the complete carrier ring until the stop pin locates on the horizontal face of the bottom half bearing housing. Repeat with the second carrier ring on the other side of the thrust collar. The thrust carrier ring split line is at 90 to the bearing housing horizontal surface at the stop pin locates in a slot in the top half bearing housing.
(15)
Note:
CAUTION : Do not insert feeler gauges between the thrust collar and the thrust pads; this may give an inaccurate reading and cause damage to the white metal and surface. (16) Check the axial clearance by moving the pump shaft towards the drive end so that the thrust collar is hard against the inner thrust pads, then using feeler gauges between the outer thrust bearing spacer and the thrust housing inner wall check the clearance. Refer to the Sectional
Arrangement Drawing for the original total axial clearance. Any measurable variation should be investigation. (17) Lift the thrust cover onto the bottom half bearing housing ensuring that the dowel pin for each floating seal carrier are properly located. Locate the thrust cover to the bottom half bearing housing with the dowel pins, then secure the thrust cover with the cap screws. Locate the top half journal bearing in position on the pump shaft. Lift the top half bearing housing complete with the top half oil guard onto the bottom half bearing housing, ensuring that the oil guard and stop pin are properly located. Locate the top half bearing housing to the bottom half housing with the fitted bolts, then secure to the bottom half and gland housing with the appropriate cap screw. Fit a new joint and secure the bearing housing cover to the top half housing with the set screws. Install the coupling/pump drive coupling spacer and element assemblies. Replace the instruments and the coupling pump drive coupling guard.
(18) (19)
(20)
(21)
(22) (23) 3.4
Checking the Axial Running Position and Thrust Bearing clearance Note: This operation is to be carried out during the assembly of the drive end and non-drive and bearing housings. The drive end bearing housing should be assembled without the following components in place. (a) (b) (2) Top half bearing housing and top half journal bearing. Oil guard and oil throwers.
(1)
The non-drive end bearing housing should be assembled without the following components in place. (a) (b) (c) Top half bearing housing, top half journal bearing and thrust cover. Thrust bearing carrier ring assemblies. Oil guard and oil thrower.
(3)
Check the axial running position of the rotating assembly as follows:(a) Move the rotating assembly as far as possible towards the drive end of the pump and, using the outer face of the thrust collar as a datum,
scribe a line on the horizontal surface of the bottom half bearing housing. (b) Move the rotating assembly as far as possible towards the non-drive end of the pump and, using the same datum, scribe a second line on the bottom half bearing housing. Measure the distance between the two lines; this should be approximately 8 mm.
CAUTION : The minimum acceptance total axial travel is 6 mm. (c) Position the inner halves of the thrust bearing carrier rings and spacers in this bottom half housing and move the rotating assembly as far as possible towards the drive end of the pump. Scribe a third line on the surface of the bottom half bearing housing. Using the same datum as before: this line should be offer 0.50 mm towards the non-drive and from midway between the other two lines. CAUTION : Do not insert feeler gauges between the thrust collar and the thrust pads; this may give an inaccurate reading and cause damage to the white metal pad surface. (4) Check the thrust bearing axial clearance as follows : (a) Position the outer halves of the thrust bearing carrier rings and spacers in the bottom half housing.
(b) Check the axial clearance by moving the pump shaft as before and carefully measuring the difference: alternatively, move the pump shaft so that the thrust collar is hard against one set of thrust pads and use feeler gauges between the opposite thrust bearing spacer and the bearing housing. The total axial clearance was Originally as shown on Drawing Nos. measurable variation should be investigated. (5) If spare thrust bearing assemblies are fitted, proceed as follows: (a) With the rotating assembly in the axial running position, accurately measure the distance between the bottom half bearing housing wall and the inner thrust collar face and record the reading. Repeat the procedure between the outer thrust collar face and the bearing wall and record the reading. The spacers should now be removed form the inner and outer thrust carrier ring halves and machined accurately to give the correct thickness as follows:Inner thrust ring spacer thickness Measured distance between housing wall and inner collar face minus thrust ring thickness. Outer thrust ring spacer thickness Measured distance between housing wall and outer collar face minus (thrust ring thickness + axial bearing clearance).
(b)
(i) (ii)
(c) 4. OVERHAUL
Secure the spacers to the thrust carrier ring halves and repeat step as previously described.
WARNING : IT IS ESSENTIAL THAT PLANT SAFETY AND REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE PROCEDURES. The following instructions apply when the pump cartridge is to be removed and dismantled for a complete overhaul. Note: If a replacement cartridge is available, this should be prepared and installed as described in Section 4.6 before proceeding to dismantle and repair the worn cartridge as described in Section 4.3. Reference numbers on components should be re-marked as necessary to facilitate assembling.
4.1
Preparation for Overhaul (1) (2) Prepare the pump for maintenance as described in Section 1.1 Disconnect and remove the following pipes and fittings :(a) (b) (c) (d) (e) (f) (3) (4) (5) (7) The lubricating oil pipe work to and from the pump bearings. The mechanical seal pipe work. The balance chamber return pipe work from the discharge cover. The gland well drain pipe work from the suction guide and the housing. Remove the interstage spool piece and interstage tube. Remove air vents from the drive end bearing housing and the suction guide.
Disconnect and remove any instruments which could interfere with the dismantling procedures. Remove the fluid coupling/pump drive coupling guard. Remove the fluid coupling/pump drive coupling spacer and element assemblies. Check that all lifting equipment and special tools are in good condition.
4.2
Withdrawing the Pump Cartridge (1) Remove the set screws securing the split pull-up ring to the pump casing. The ring can now be removed, the upper half being located by two dowel pins. Secure the first extension sleeve (5) to the drive end bearing housing with screws (12) and (24). Enter the cartridge tensioning screw (10) through the hold on the end plate of the first extension sleeve and screw it into the tapped hole in the end of the pump shaft. Run the nut (11) on to the end of the tensioning screw and tighten it until all cartridge movement is taken up.
(2) (3)
Note : The cartridge axial movement between the last stage diffuser and the outer guide is approximately 2.5 mm. (4) Locate the suction and support jack (7) on the base plate pad. Centralise the roller using the slots provided on the jack base. Jack up the roller until good contact is made with the first extension sleeve (5). Tighten the screws to secure the support jack to the base plate.
CAUTION : The support jack (7) is intended to take the weight of the drive end of the pump cartridge and so facilitate removal of the cartridge. Due to the fine diametrical clearance which exists between the suction guide and the pump casing, extreme caution must be observed when adjusting the height of the support jack roller to avoid over tightening, which may lead to damage to the suction guide or pump casing when withdrawal is attempted. (5) (6) Remove and retain the stud caps. Remove the pump casing/discharge cover nuts, using the hydraulic stud tensioning equipment as follows:(a) (b) (c) (d) Locate the jacking ring and load cell assembly over two pairs of diametrically opposite casing studs and nuts as shown. Screw the load cell onto the stud until it abuts the jacking ring. Connect the load cells to the hydraulic pump by means of the manifold and pipe work. Operate the pump and prime the system with oil, then raise the pressure in the system specified by the supplier of the hydraulic tensioning equipment, to relieve the pre-loading on the studs. Slacken back the casing nuts using a tommy-bar in the holes in the nuts.
(e)
(f) (g) (h) (i)
Relieve the pressure in the hydraulic system and return the oil to the pump by operating the valve on the pump. Unscrew and remove the inserts from the studs, then remove the load cell assemblies from the studs. Unscrew and remove the casing nuts from the casing studs. Repeat the above procedure (a) to (h) to remove the remaining discharge cover nuts, ensuring that the sequence shown is adopted to avoid distortion of the cover.
(7) (8)
Fasten the support columns (15-MD / 16-TD) to the foundation plate (27-MD / 31-TD) with screws (23,26&30). Locate the support rail assembly (A) on the base plate and on the support columns (15-MD / 16-TD). Fit the bracket (2) and wheel mounting assemblies (3-MD / 4-TD) to the discharge cover with screws (14). Using the slots provided in the bracket mounting assembly (2), centralize the bracket by using the jacking screws (19) at each side until the support rails (1) make contact with the rollers. The support rails (1) must be level during this operation. Retain the bracket mounting assembly (2) by tightening the holding down set screws (18). Lock the jacking screws (17) in position with lock-nuts (28). Position the hinged wheel stops across the support rails. Screw the starting screws (A1) into the discharge cover and unseat the cartridge from the pump casing. The suction end support jack (7) and the jacking screws (19) on the support rail assembly (A) which is positioned over the support columns (15-MD / 16-TD) may require individual adjustment to ensure smooth removal of the cartridge. Ensuring that the stops on the support rails (1) are in place, withdraw the cartridge to the first stop. Install the second extension sleeve (6), using screws (29&30). The cartridge can now be withdraw to the second stop position. Repeat this Step until the cartridge is withdrawn to the final stop position. Position the support plate (8) on the pump casing studs and a distance tube (9) on each stud. Then using discharge cover nuts to lock the tubes (9) and support plate (8). Withdraw the dowel pin, from the suction guide, that locates the pull up ring. Secure the lifting plate (21) to the suction guide with the four set pins (22).
(9)
(10)
(11) (12)
(13) (14)
(15)
(16) (17)
(18)
Secure an eye-bolt (20) into the tapped hole provided in the discharge cover. Attach suitable slings to the eye-bolt (20) and the lifting plate (W) and take the weight of the pump cartridge. Unbolt the second extension sleeve (6) from the first extension sleeve (5)) and separate each at the spigot location. Carefully lift the pump cartridge away to a maintenance area and suitably support it on wooden trestle. Ensure that the mounting wheel assembly is clear of the floor.
(19) (20)
Note : The cartridge tensioning screw (10) must not be released during transit of the cartridge. (21) Remove the lifting equipment (20,21&22), mounting wheel assemblies (3MD / 4-TD) and bracket mounting assembly (2) from the pump cartridge.
CAUTION : The cartridge tensioning screw (10) must not be removed. (22) 4.3 Remove and discard the suction Metaflex joint.
Dismantling the Pump Cartridge CAUTION : During dismantling of the pump cartridge, it is essential that the cartridge be firmly supported. The initial dismantling is carried out in the horizontal position, and the final stages with the cartridge supported vertically as shown in the drawing. At no time should be weight of the cartridge be carried by the shaft.
4.3.1
Removing Pump Half Coupling Hub (1) (2) Remove the Cartridge as described in Section 4.2. Install the support frame over the suction guide from the drive end bearing side, then clamp the discharge cover, ring sections and suction guide together with the stay rods, location washers and nuts. Release the nuts securing the cartridge tensioning screw and remove the screw from the shaft end. Remove the screws securing the first extension sleeve to the drive end bearing housing and lift away the first extension sleeve. Remove the coupling nut grub screw, then using the special spanner supplied, unscrew and remove the coupling nut. Withdraw the pump half coupling hub from the pump shaft. Remove and retain the coupling keys.
(3)
(4) (5) 4.3.2
Removing the D.E. Bearing Assembly and Mechanical seal.
CAUTION : The top half bearing housing is located on the bottom half bearing housing by two fitted bolts. Care must be taken to avoid damage to the bolts or the holes in the top and bottom half housing. (1) Withdraw the fitted bolts and remove the cap screws securing the top half bearing housing to the bottom half bearing. Also remove the cap screws securing the top half bearing housing to the suction guide. Use two jacking screws in the top half baring housing to separate it from the bottom half. Lift the top half bearing housing complete with the top halves of the oil guards away. Remove the top half journal bearing from the shaft with the assistance of applying jacking screws to the bearing keep. Take the weight of the pump shaft and rotate the bottom halves of the journal bearing and oil guards around the shaft and lift them away. Using suitable lifting gear, take the weight of housing. the bottom half bearing
(2) (3)
(4) (5) (6)
Withdraw the two taper dowel pins and remove the cap screws securing the bottom half bearing housing to the suction guide, then lift the bottom half housing away. Slacken the grub screws and withdraw the oil thrower from the shaft. Discard the O ring from the groove in the bore of each oil thrower. Refer to Manufacturers mechanical seals. instructions when dismantling the
(7)
NOTE : (8)
Using the pin spanner supplied, unscrew and remove the seal sleeve locknut and seal nut from the shaft. Discard the O ring from the shaft sleeve. Engage the assembly fixtures (eccentric washers) into the groove in the shaft sleeve and fasten them. Loosen all screw connections between seal cartridge and the respective machine parts. Remove the screw connections between seal cartridge and the respective machine parts. Take the weight of the bearing bracket, then remove the Hexagonal socket head cap screws securing the bracket to the suction guide and remove the bracket. Screw the clamping plate on the shaft and secure it to the suction guide with four bolts.
(9) (10) (11) (12)
(13)
4.3.3
Removing the N.D.E. Bearing Assembly and Mechanical Seal (1) Remove the set screws securing the end cover to the bearing housing, then remove the end cover klingerite joint. CAUTION : The top half bearing housing is located on the bottom half bearing housing by two fitted bolts. Care must be taken to avoid damage to the bolts or the holes in the top and bottom half housing. (2) (3) (4) Withdraw the fitted bolts and remove the cap screws securing the top half bearing housing to the bottom half bearing housing and the gland housing. Use four jacking screws in the top half bearing housing to separate it from the bottom half. Lift the top half bearing housing complete with the top half oil guard away. Remove the top half journal bearing from the shaft.
CAUTION : The thrust collar is located on the bottom half bearing housing by four dowel pins. Care must be taken to avoid damage to the dowels or the locating holes. (5) Remove the cap screws securing the thrust cover to the bottom half bearing housing. Use four jacking screw to separate the thrust cover from the bottom half bearing housing and lift it away. Lift the top halves of the floating seal carriers and oil guard away. Unclip the springs and remove the split floating oil seals from the bearing housing. The thrust carrier ring split line is at 90 to the bearing housing horizontal surface. Remove each thrust carrier ring in turn as a complete unit as follows:Rotate the complete carrier ring around the shaft until the half ring with the stop pin can be removed, then rotate the other half ring around the shaft until it can be lifted clear of the shaft. Repeat with the second carrier ring on the other side of the thrust collar. (9) Take the weight of the pump shaft and rotate the bottom halves of the journal bearing and the oil guard around the shaft and out of the bottom half bearing housing.
(6) (7) Note: (8)
CAUTION : The bottom half bearing housing is located on the gland housing by two dowel pins. Care must be taken to avoid damage to the dowels or the holes in the housing/gland housing. (10) Using suitable lifting gear, take the weight of the bottom half bearing housing.
(11)
Withdraw the dowel pins and remove the cap screws securing the bottom half bearing housing to the gland housing, then lift the bottom half bearing housing away. Unlock the lock-washer, then using the special spanner, unscrew and remove the thrust collar nut and lock-washer from the pump shaft.
(12)
Note : The thrust collar nut has left hand thread. (13) Using withdrawal gear as shown on illustration, withdraw the thrust collar/probe indicator assembly from the shaft and remove and retain the thrust collar key from the keyway on the shaft. Check the location of the oil thrower on the shaft for assembly purposes. Slacken the grub screw and withdraw the oil thrower from the shaft. Discard the O ring from the groove in the bore of the thrower. Using the pin spanner, unscrew and remove the shaft lock-nut and seal nut from the shaft. Discard the O ring from the shaft sleeve. Engage the assembly fixtures (eccentric washers) into the groove in the shaft sleeve and fasten them. Loosen all screw connections between seal cartridge and the respective machine parts. Remove the screws securing the seal housing to the gland housing and remove the seal housing. Remove and discard the O rings from the grooves of the outside diameter of the seal housing. Withdraw the three angled locating dowels on the gland housing. Take the weight of the gland housing, then remove the cap screws securing the gland housing to the discharge cover. Separate the gland housing from the discharge cover by applying four jacking screws. Discard the Metaflex joint between the joint faces.
(14) (15) (16) (17) (18) (19)
(20) (21) (22) 4.3.4
Dismantling the Ring Section Assembly (1) (2) Install the support frame and secure it in position with the stay rods. Secure the lifting eyebolt to the discharge cover and to the support frame.
(3)
Using suitable lifting gear carefully lift the ring section assembly into the vertical position.
(4)
Lower the ring section assembly into the support trestle until the support frame rests on the support trestle. Remove the lifting gear.
(5)
Remove the socket set screws that lock the outlet guide plugs, then unscrew the outlet guide plugs. The cap screws securing the outlet guide to the discharge cover can now be removed. Remove the two socket set screws that lock the locating dowels for the outlet guide to the discharge cover.
CAUTION : Care must be taken when raising the discharge cover to avoid damage to the balance drum or the balance drum restriction bush. (6) Remove the top nuts and washers from the stay rods securing the discharge cover in position, then using suitable lifting gear, slowly lift the discharge cover clear of the pump shaft. Release the lock-washer and using the special spanner provided, unscrew and remove the balance drum nut and lock-washer from the shaft.
(7)
Note : The balance drum nut has left hand thread. (8) (9) (10) Withdraw the balance drum from the pump shaft using withdrawal gear similar to that shown on illustration. Remove and retain the balance drum. Remove the stay rods from the support frame. Using a gas heater ring, apply heat to the kicker stage impeller hub, then remove the impeller from the shaft. Remove and retain the shearing and the key from the shaft.
Note : Should the attempt the remove the impeller be unsuccessful immediately after heating, the impeller and the shaft temperature must be allowed to cool down to the ambient temperature before another attempt is made to remove the impeller. This procedure applies to all the impellers. (11) (12) (13) Remove the outlet guide, then remove and retain the disc spring. Remove the socket head screws securing the last stage diffuser to the last stage ring section. Lift the last stage diffuser clear of the pump shaft. Apply heat to the rear hub of the fourth stage impeller and pull the impeller from its location on the shaft. Remove the impeller, shear ring and impeller key.
WARNING : THE INTERESTAGE DIFFUSERS AND RING SECTIONS ARE LOCATED TO EACH OTHER BY DOWEL PINS AND WILL PROBABLY LIFT AS AN ASSEMBLY. CHECK THAT THE DIFFUSER IS SECURED BEFORE LIFTING OVER THE SHAFT.
(14) (15) (16) (17) (18) (19) (20) 4.4
Remove the outlet guide, then remove and retain the disc spring. Suitably sling and lift the last stage ring section clear of the pump shaft. Remove the socket head screws securing the last stage diffuser to the last stage ring section. Lift the last stage diffuser clear of the pump shaft. Repeat steps (13) to (15) to remove the remaining impellers, ring sections and diffusers. Screw the lifting eye-bolt onto the non-drive end of the pump shaft, then using suitable lifting gear take the weight of the pump shaft. Unscrew and remove the clamping plate from the drive end of the pump shaft. Carefully lift the pump shaft until the drive end of the shaft is clear of the suction guide.
Inspection, Renewal and Repair Procedures The pump components should be completely cleaned before inspecting for any signs of wear including scoring, wiping or ridging. All diametrical clearance should be measured with internal and external micrometers.
4.4.1
Clearances Refer to the Sectional Arrangement Drawings for details of the clearances. It is recommended that when the pump internal clearances have reached 1.5 times the figure quoted or are expected to do so before the next overhaul, the component or components should be renewed. The main considerations, however, are pump performance and motor power consumption.
4.4.2
Pump Shaft (1) (2) (3) Examine the shaft for any signs of damage or bowing and check for concentricity; it should be within 0.05 mm full indicator movement. Check that all threads are in good condition. Check that the keyways are free from burrs.
4.4.3
Impellers (1) (2) Examine the impellers for signs of wear or erosion, particularly at the waterways and the tips of the blades. Check that the keyways are free from burrs.
(3)
Examine the impeller wear rings for wear or ovality. Renew or repair as necessary.
CAUTION : If the impeller wear rings required to be renewed it is important to note that the impeller is balanced during manufacture. However, if it is considered expedient to assemble and operate the pump without checking the balance, BHEL/PUMPS, should first be consulted. 4.4.4 Ring Sections, Diffusers, Balance Drum and Suction Guide (1) (2) Examine the ring sections, diffusers and suction guide for signs of wear or erosion, particularly in the flow passages. Examine the bores of the ring section and diffuser wear rings and the balance drum bush for signs of wear or ovality. Renew or repair as necessary. The wear rings and balance drum bush are a shrink fit in their respective components, and are secured radially by grub screws. The wear rings should be renewed as follows :(a) (b) (c) (d) Note : Remove the grub screws and machine the wear ring from its seating. Thoroughly clean the seating and shrink the new ring into position. Secure the war ring in position with grub screws. Lock the grub screws by lightly punching with a centre punch at the thread junction. Lightly machine the internal or external surface of the wear ring to rectify any distortion which may have occurred during fitting. The impeller wear rings supplied as spares are left 3 mm oversize on the outside diameter for final machining after fitting and due note should be taken of this when assessing the possible renewal of the ring section and diffuser wear rings. The ring section and diffuser wear rings supplied as spares are left 3 mm undersize in the bore for final machining.
(3) (4)
4.4.5
Journal Bearings Inspect the journal bearings for signs of wear or damage and renew as necessary.
4.4.6
Thrust Bearings Under normal operating conditions it is not expected that any measurable wear will take place on the thrust pads other than a dulling of the white metal surfaces. It is recommended that when this dulling has spread to more than half the surface area of the pads, they should be removed.
4.4.7
Mechanical Seals A correctly operated mechanical seal is maintenance free, wear parts, however, have to be replaced, if necessary.
4.4.8
Joints All joints and O rings should be renewed on assembly, as should any backing ring which shows signs of damage or distortion. Apply soft soap to all O rings prior to assembly.
4.4.9
Studs, Bolts, Screws and Nuts The threads of all studs, bolts, screws and nuts must be clean, well formed and free from burs. If the threads are damaged in any way the component must be renewed.
4.4.10 Dowels All dowels must be clean and free from damage. Worn or damage dowels must be renewed. 4.4.11 Keys All keys must be a good fit in their keyways and must also be flat, parallel and free from burrs. Worn or damage keys must be renewed. 4.4.12 Cleanliness All components must be perfectly clean and all bores and oil ways must be cleaned out before the pump is assembled. 4.4.13 Dynamic Balance Each components of the rotating assembly is first dynamically balanced individually during manufacture, then the entire assembly consisting of shaft, shaft sleeves, impellers, balance drum, pump half coupling, thrust collar, nuts, keys and rotating seal faces is assembled and dynamically balanced as a unit. Always consider the effect on dynamic balance when renewing or repairing individual parts.
If it is considered expedient to assemble and operate the pump without checking the dynamic balance, BHEL Pumps Ltd., should first be consulted. When suitable workshop facilities are available the recommended method of checking the dynamic balance of the resulting assembly is as follows : (1) Support the assembly at the bearing centre lines and check that it is dynamically balanced with 630M g cm N Where M = rotor weight (kg) N = pump speed (rev / min.) (2) Dynamic balance is to be achieved by removing metal from the impeller shrouds within the following limits.
CAUTION : (a) The thickness of the impeller shroud must not be reduced by more than 1.6 mm at any point. (b) No metal is to be removed from an impeller within 12.7 mm of the periphery. (c) The weight of metal to be removed is to be calculated in the form of a segment, the arc length of which does not exceed 0.1 of the circumference of the impeller. (d) If the amount of the metal to be removed exceeds the limits imposed by (a) and (c), BHEL pumps Ltd., should be consulted. Note : The dynamic balance can be checked and trimmed in-situ by BHEL, Pumps Personnel, using specialized equipment to establish the degree and location of the unbalance and correcting this by adding balance weights to the peripheries of the coupling flange and the thrust collar. 4.5 Assembling the pump cartridge To assist the assembling procedures all fittings and threads should be smeared with anti-scuffing paste. 4.5.1 Assembling the ring Section Assembly (1) (2) (3) Ensure that the inspection, repair and renewal procedures have been properly carried out. Suitably support the shaft on wooden trestles in the horizontal position. Insert the drive end gland sleeve key and the first stage impeller key in their keyways in the shaft. Also, locate the shearing in the shaft recess provided for the first stage impeller.
(4)
Apply heat evenly around the hub of the first stage impeller, using a gas heating rings, then slide the impeller over the shaft and key until it butts against the shearing.
CAUTION : Force should not be used when fitting the impeller. If the impeller does not butt against the shaft shoulder, remove the impeller and check for burrs or dirt which may have been overlooked during inspection. Clean up as necessary and repeat step (4). Do not attempt to fit the impeller if the shaft is above ambient temperature. (5) Replace the support frame on the top of the support trestle, then lift the suction guide and lower and secure it into the support trestle as shown on Drawing. Lift the first stage ring section and lower it onto the suction guide, ensuring that the slot at top dead centre engage over the key block on the suction guide. Screw the lifting eye-bolt onto the non-drive end of the pump shaft, then suitably sling and carefully lift the shaft into the vertical position. Carefully lower the drive end of the pump shaft into the suction guide bore until the impeller eye wear ring enters the first stage ring section casing wear ring. Remove the lifting lug from the pump shaft. Screw the clamping plate onto the pump shaft and secure it to the suction guide. Suitably sling and lift the interstage diffuser over the shaft and into position on the first stage ring section. Ensure that the dowel pins are properly located then secure to the first stage ring section with the cap screws. Suitably sling and lift the second stage ring section over the shaft and into position on the interstage diffuser and first stage ring section. Ensure that the radial dowel position marks match-up with the same marks as that on the first stage ring section. Secure the second stage ring section to the first stage ring section with the socket head screws. Before Proceeding any further with the assembly, check the total axial travel as follows :(a) (b) (c) Screw the lifting eye-bolt onto the non-drive end of the pump shaft and suitably sling. Take the weight of the pump shaft and allow the first stage impeller to rest on the first stage ring section. Using the upper face of the second stage ring section as a datum, mark a pencil line on the shaft.
(6)
(7) (8)
(9) (10)
(11)
(12) (13)
(d)
Remove the screws securing the clamping plate to the suction guide, then unscrew the clamping plate along the shaft until the plate has a gap of slightly more than 10 mm from the suction guide flange. Reposition the securing screws finger tight. Lift the pump shaft as far as possible towards the non-drive end of the pump and, using the same datum, mark a second line on the pump shaft. Measure the distance between the two lines: this should be approximately 9 mm.
(e)
(f)
CAUTION : The minimum acceptable total shaft travel is 7.5 mm. (g) Lower the shaft until the first stage impeller rests on the first stage ring section then raise the shaft by about 2 mm and place suitable packing between the floor and the shaft drive end, to take the weight of the shaft assembly. Allow the shaft to rest on the packing. This will now permit the following impeller to about firmly against the shear ring, rather than the casing wear ring on the ring section. Remove the sling and lifting eye bolt from the shaft.
(14) (15)
Insert the second stage impeller key in the shaft keyway, then locate the impeller split shearing in the shaft recess. Apply heat evenly around the hub of the second stage impeller, using the gas heating ring, then slide the impeller onto the shaft and key until it butts against the split shear ring. Repeat stops (10) to (15) to install the remaining interstage diffusers/ ring sections and impellers. Lift the last stage diffuser over the shaft and into position on the last stage ring section. Secure the last stage diffuser to the last stage ring section with the socket head screws. Lift the disc spring over the shaft and into position on the last stage diffuser spigot. Lift the outlet guide over the shaft and into position on the last stage diffuser. Position the shear ring on the shaft recess and the impeller key for the kicker stage impeller. Apply heat evenly around the hub of the kicker stage impeller using gas heating ring, then slide the impeller over the shaft until it butts against the shear ring.
(16) (17) (18) (19) (20) (21) (22)
(23)
Insert the balance drum key into its keyway in the shaft, then using the gas heating ring supplied, heat the balance drum and slide it onto the shaft and key until it butts against the shaft shoulder, place a new packing ring and the packing ring follower in the bore of the balance drum. Locate the new lock-washer against the balance drum, then screw on and tighten the balance drum nut, finally locking the nut in position with the lock-washer. The balance drum nut has left hand thread. Screw the four tie rods into the support frame as shown in the Drawing. Suitably sling the discharge cover and lift it to a position above the shaft. Carefully lower the discharge cover over the shaft and tie rods into position on the last stage diffuser, taking care to prevent fouling between the balance drum and bush. Ensure that the dowel pins are properly located. Replace the location washers and nuts on the tie rods and secure the ring section assembly together as shown in the Drawing. Secure the clamping plate to the suction guide by drawing up the fixing screws. Secure the lifting eye-bolt onto the discharge cover and support frame. Using suitable lifting gear, carefully lift the ring section assembly clear of the support trestles. Lower the ring section assembly into the horizontal position and support it at each and with wooden support trestles. Remove the lifting gear, lifting eye-bolts and clamping plate.
(24)
Note: (25) (26) (27)
(28) (29) (30) (31) (32) (33) 4.5.2
Installing the mechanical seals : CAUTION: 1. 2. 3. 4. The rotating assembly must be supported on wooden trestles during the assembly.
For installation the assembly drawing shave to be on hand. The mechanical seal has to be installed very carefully and under the cleanest conditions. Do never force during installation. To facilitate assembly, surfaces over which O-rings are to be fed may be thinly lubricated with water, alcohol or silicon grease. Elastomers made of EP rubber must never come into contact with lubricants on the base of mineral oil (swelling, decomposition).
5. 6. 7. 8. 9. 10. 4.5.3
As lubricant for elastomers (O-rings etc.) should be used. The mechanical seal is supplied as a cartridge unit, pre-mounted at works and does not require any adjustment during assembly. Bolt the mechanical seal to the pump housing in the way that the connections are positioned. Insert O-rings on the shaft. Clamp the shaft sleeve axially with special nuts. Apply the torque smoothly and without interruption. Do not knock the wrench. Remove the assembly fixtures and keep them for a later removal of the seals.
Assembling the D.E. Bearing Assembly (1) (2) (3) (4) Note: (5) Ensure that the bearing bracket is located and secured to the suction guide with the dowel pins, studs and nuts. Locate a new O ring in the groove of each of the oil throwers, then slide the throwers onto the shaft. Lift the bottom half bearing housing into position and locate and secure it to the suction guide with the taper dowel pins and cap screws. Position the throwers to correspond with the reference made during dismantling and secure each thrower to the shaft with the grub screw. Lightly smear the shaft and journal bearing surfaces with oil before final assembly. Take the weight of the pump shaft and rotate the bottom halves of the journal bearing and oil guards around the shaft and into position in the bottom half bearing housing. Release the weight of the pump shaft. Locate the top half journal bearing in position on the pump shaft and install the bearing keep which is positioned by the two dowel pins and secured by cap screws. Lift the top half bearing housing complete with the top halves of the oil guards onto the bottom half housing. Locate the top half bearing housing to the bottom half with the dowel pins, then secure the top half housing in position with the cap screws. Insert the coupling keys into the keyways in the shaft, then install the pump half coupling over the keys and onto the shaft.
(6)
(7) (8) (9)
(10) 4.5.4
Screw the coupling nut onto the shaft and tighten with the special spanner provided. Lock the nut in position with the grub screw.
Assembly the N.D.E. Bearing Assembly (1) (2) (3) (4) Ensure that the gland housing is located and secured to the discharge cover with the dowel p9ins and cap screws. Locate a new O ring in the groove of the oil thrower, then slide the thrower onto the shaft. Insert the thrust collar key into the keyway in the pump shaft. Apply heat evenly around the thrust collar hub, using the gas ring supplied, then slide the thrust collar onto the shaft and over the key until it abuts the shoulder on the shaft. Allow the thrust collar to cool to ambient temperature, then slide the probe indicator onto the shaft to locate on the dowels and abut the thrust collar. Secure with the cap screws. Locate a new lock-washer on the shaft and secure the thrust collar nut on the shaft and lock it in position with the lock-washer.
(5)
(6)
Note: The thrust collar nut has a left hand thread. (7) (8) Lift the bottom half bearing housing into position and locate and secure it to the gland housing with the taper dowel pins and cap screws. Position the thrower to correspond with the reference made during dismantling and secure the thrower to the shaft with the grub screw.
Note : Lightly smear the shaft, thrust collar faces and journal bearing surfaces with oil before final assembly. (9) Take the weight of the pump shaft and rotate the bottom halves of the journal bearing and oil guard around the shaft and into position in the bottom half bearing housing. Install the split floating oil seals on the pump shaft with the spring. Release the weight of the pump shaft. Install each thrust carrier ring in turn as a complete unit as follows: Take the half carrier ring without the stop pin and place it cover the shaft with the pad faces touching the thrust collar and rotate it into the bottom half bearing housing, then place the other half carrier ring with the stop pin upon the first and rotate the complete carrier ring until the stop pin locates on the horizontal face of the bottom half bearing housing. Repeat with the second carrier ring on the other side of the thrust collar. Note : The thrust carrier ring split line is at 90 to the bearing housing horizontal surface and the stop pins locate in a slot in the top half bearing housing.
(10)
(11) (12)
Check the total axial clearance (refer to Section 3.6). Locate the top half journal bearing in position on the pump shaft and install the bearing keep which is positioned by the two dowel pins and secured by cap screws. Lift the top half bearing housing complete with the top half oil guard onto the bottom half bearing housing, ensuring that the carrier ring stop pins are properly located. Locate the top half bearing housing to the bottom half bearing housing with the dowel pins, then secure the top half housing in position with the cap screws. Secure the bearing housing and cover to the housing with the set pins.
(13)
(14)
(15)
4.6 Installing the Pump Cartridge Note : The following instructions assume that the withdrawal equipment as shown on Drawing has not been disturbed. (1) (2) Secure the first extension sleeve (5) to the drive end bearing housing. Enter the cartridge tensioning screw (10) through the hole on the end plate of the first extension sleeve and screw it into the tapped hole in the end of the pump shaft. Run the nut (11) on the end of the tensioning screw and tighten it until all cartridge movement is taken up. Remove the nuts, spacers and the stay rods securing the ring section assembly together. Check that the Metaflex joint is properly located on the discharge cover spigot. Locate the Metaflex joint on the suction guide spigot. Locate the joint on first stage ring section spigot. Withdraw the dowel pin from the suction guide that locates the pull up ring. Secure the lifting plate (21) to the suction guide with the four set pins (22). Screw and eye-bolt (20) into the tapped hole provided in the discharge cover. Attach suitable slings to the eye-bolt and lifting plate (21) and take the weight of the pump cartridge. Secure the cradle roller assembly bracket to the discharge cover with the screws provided. Carefully lift the cartridge assembly and lower it onto the support rail (1) as shown on Drawing.
(3) (4) (5) (6) (7) (8) (9)
(10) (11)
Note : Provided that the withdrawal gear has remained in position following cartridge withdrawal the cradle should be correctly aligned for the cartridge insertion. It is important, therefore, that the cartridge be aligned to the cradle and not vice versa. (12) (13) Bolt the second stage sleeve (6), which is still secured to the other three extension sleeves, to the first extension sleeve (5). Take the weight of the cartridge extension sleeve assembly (5/6) on the drive end support jack (7) roller and remove the distance tubes (9) and support plate (8) from the pump casing studs. Remove the slings, lifting plate (21) and eye-bolt (20) from the pump cartridge. Replace the dowel pin which was removed from the suction guide to accommodate the lifting plate. Swing the hinged wheel stops into the stop position on the support rail assembly (1).
(14)
(15)
CAUTION : When installing the pump cartridge, ensure that the suction guide is radially central with the casing bore by adjusting the roller support jack. (16) (17) Carefully push the cartridge into the pump casing until the outer extension sleeve (6) can be removed. Repeat step (16), removing the extension sleeves (6) as necessary until the suction guide and discharge cover are properly located in the pump casing. Ensure that the discharge cover is correctly seated, then fit two nuts onto the casing studs. Locate and secure the pull up ring on the suction guide and pump casing. Tighten screws to a torque of 175 Nm.
(18) (19)
(20)
Fit the remaining nuts onto the casing studs and evenly tighten all around using the tommy bar supplied.
Note : Check that there is no clearance between the discharge cover and the pump casing. (21) Dismantling and remove the tensioning stud (10), first stage extension sleeve (5), drive end support jack (7), bracket mounting assembly (2), mounting wheel assembly (3-MD / 4-TD), support rail assembly (1) and support columns (15-MD / 16-TD) from the pump and base plate and return to store, in readiness for future overhauls.
(22)
Tighten the casing nuts using the hydraulic stud tensioning equipment supplied as follows:(a) (b) (c) (d) Locate the jacking ring and load cell assembly over two pairs of diametrically opposite casing studs until it abuts the jacking ring. Screw the load cell on to the stud until it abuts the jacking ring. Connect the load cells to the hydraulic pump by means of the manifold and pipe work. Operate the pump and prime the system with oil, then raise the pressure in the system to 5000 lbf/in2 and tighten the discharge cover nuts with the bar. Relief the pressure in the hydraulic system and return the oil to the pump by operating the valve on the pump. Unscrew and remove the load cell from the studs, then remove the load cell assemblies from the studs. Repeat steps (1) to (6) until all the remaining nuts have been tightened. Repeat steps (a) to (f) until all the nuts have been tensioned to a pressure which will give a load of 72 kN on the casing studs. See hydraulic stud tensioning equipment suppliers recommended pressure to achieve this.
(e) (f) (g) (h)
(23) 4.7
Replace the stud caps and secure in position.
Final Assembly (1) (2) (3) (4) (5) Install the pump cartridge as described in Section 4.6. Check the coupling alignment. Refer to illustration. Install the fluid coupling/pump drive flexible coupling spacer and element assemblies. Replace the fluid coupling/pump drive coupling guard. Install the following fittings and pipes that were removed during the dismantling procedure :(a) (b) (c) The balance chamber return pipes between the discharge cover and suction side. The lubricating oil pipes to and from the pump bearings. The bearing brackets gland well drain pipe work.
(6) (7) 5.
Install and connect all instruments that dismantling procedures.
were removed during the
Replace any lagging and cladding removed during the dismantling procedures.
PARTS IDENTIFICATION When ordering spare parts, reference must be made to the pump Serial or Job Number, Nomenclature and Sectional Arrangement Drawing, Item Number, and quantity of each component.
CHAPTER 4 SUB-VENDORS DRAWINGS / INSTRUCTIONS
LIST OF CONTENTS
1 2 3 4 5 6
Mechanical Seals Mechanical Seal Heat Exchanger Mechanical Seal Magnetic Filter Thrust Bearing Connecting couplings (BFP & HC, HC & Motor) Suction Strainer before BFP
SECTION B
BOILER FEED PUMP
4. THRUST BEARING
Michell Bearings
Operations, and Maintenance Instructions.
Omega OT Series Thrust Rings

Michell Bearings
Michell Bearings is a trading division of Vinters Engineering PLC. A member of the Rolls Royce Group.
Issue 00
Table of Contents
GENERAL DRAWING OF OT THRUST RING ASSEMBLY WITH SHIMS& LINERS----------- 4 1. INTRODUCTION -------------------------------------------------------------------------------------------- 5 1.1 About the Product ------------------------------------------------------------------------------------- 5 1.2 About this Manual ------------------------------------------------------------------------------------- 5 1.3 Warranty Claims --------------------------------------------------------------------------------------- 6 SAFETY ------------------------------------------------------------------------------------------------------- 7 HANDLING THE BEARING------------------------------------------------------------------------------ 8 3.1 General -------------------------------------------------------------------------------------------------- 8 PREPARATION FOR FIRST INSTALLATION ------------------------------------------------------ 9 ASSEMBLY OF THE BEARING -----------------------------------------------------------------------10 5.1 General -------------------------------------------------------------------------------------------------10 5.2 Assembly of the Thrust ring------------------------------------------------------------------------10 5.2.1 Fitting the Thrust Pad set.--------------------------------------------------------------------10 5.2.2 Fitting Ring Stop, and Liners if applicable -----------------------------------------------11 5.3 Assembling the Thrust rings into the Bearing Casing ---------------------------------------11 5.3.1 Miscellaneous -----------------------------------------------------------------------------------12 5.3.2 Instrumentation ---------------------------------------------------------------------------------12 OPERATING ------------------------------------------------------------------------------------------------13 6.1 Preparation and Inspection before Operation -------------------------------------------------13 6.2 Trial Run------------------------------------------------------------------------------------------------13 6.3 Normal Operation ------------------------------------------------------------------------------------14 6.4 Preparation for Operation after Standstill-------------------------------------------------------14 CARE AND MAINTENANCE ---------------------------------------------------------------------------15 7.1 General -------------------------------------------------------------------------------------------------15 7.2 Tools and Equipment--------------------------------------------------------------------------------15 7.3 Maintenance Schedule------------------------------------------------------------------------------16 7.4 Oil Change ---------------------------------------------------------------------------------------------16 7.4.1 General -------------------------------------------------------------------------------------------16 7.4.2 Procedure for draining oil---------------------------------------------------------------------16 7.4.3 Procedure for refilling the bearing -self contained bearings -------------------------17 7.4.4 Procedure for refilling the bearing - bearings with circulating oil--------------------17 DISMANTLING AN INSTALLED BEARING --------------------------------------------------------18 8.1 General -------------------------------------------------------------------------------------------------18 8.2 Preparation --------------------------------------------------------------------------------------------18 8.2.1 Strip down the bearing until the thrust rings are visible. ------------------------------18 8.2.2 Disconnect and remove any thermometry and instrumentation.--------------------19 8.3 Removing thrust rings -------------------------------------------------------------------------------19 8.4 Removing the Liners, and Shim Pack. Where Applicable. --------------------------------19 8.5 Removing the Thrust Pad Set---------------------------------------------------------------------19 CLEANING AND CHECKING --------------------------------------------------------------------------20 9.1 General -------------------------------------------------------------------------------------------------20 9.2 Checking the Thrust Pad. --------------------------------------------------------------------------21 BEARING PRESERVATION DURING STORAGE---------------------------------------------22
2. 3. 4. 5.
6.
7.
8.
9.
10.
10.1 10.2 10.3 10.4 11.
Before Installation ------------------------------------------------------------------------------------22 Corrosion Protection for Standstill Periods up to 6 Months --------------------------------22 Corrosion Protection for Standstill Periods between 6 Months to 1 Year---------------22 Corrosion Protection for Standstill Periods longer than 1 year----------------------------22 BEARING PRESERVATION DURING TRANSPORT -----------------------------------------22
12. APPENDICES -------------------------------------------------------------------------------------------22 12.1 Ordering Spares --------------------------------------------------------------------------------------22
HEX. SOCKET CSK SCREW 16 LINER ASSY SHIM PACK DOWEL PIN PAD STOP THRUST PAD SET RETAINING RING RETAINING RING
STEEL STEEL STEEL STEEL STEEL WM STEEL STEEL
4
REF PART NAME QTY MATERIAL 6 1 3 2 7 8 5 4
8 7 6 5 4 3 2 1 2 2 2 16 2 1 1
OT Omega Thrust Ring Assembly With Shim Pack, And Liners
1. Introduction
1.1 About the Product
The Omega Series Thrust Rings supplied are part of a standard range of components manufactured by Michell Bearings. The thrust rings are intended to be fitted within a casing supplied by a customer. Depending on the demands specified, the thrust rings will be designed to absorb:
a) A constant load along the shaft in one direction. b) A constant load along the shaft in either direction. c) A constant load in one direction and a temporary load in the opposite direction.
Within the Omega Series a range of sizes are catered for. All Omega thrust rings require continuous lubrication from a pumped oil supply. In some cases, the thrust rings will have machined oil channels and in other cases restriction jet holes.
The system of restriction holes is known as Low Loss lubrication and will give lower power losses than conventional fully immersed rings.
In order to measure pad temperature, Resistance Temperature Devices (RTDs) can be fitted to a number of pads specified by the customer.
1.2 About this Manual This manual contains information about the bearing and its safe operation, and should therefore be read carefully in full before starting work. Since the bearing has a wide range of applications, this manual has been written to cover all current configurations. This manual is to be used by qualified engineers only. The following formats are used to draw attention to particular details:
This symbol signifies a warning. These are instructions that, if ignored, could
result in death or injury. Danger!
This symbol signifies an important point which, If ignored, could result in minor injury or failure to carry out a process correctly.
In addition, brackets after a reference to a part description, e.g. thrust pads set (3), retaining ring (2) refer to an item number on a general sub-assembly drawing at the front of this manual. These are used as a reference for the engineer.
1.3 Warranty Claims Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell Bearings. These warranty obligations will automatically become void if the product is:
1. Improperly handled or installed. 2. Supplied with spare parts (or repaired), not approved by Michell Bearings. 3. Exceeding the design operating parameters shown on the arrangement drawing. 4. Subjected to environmental conditions not previously specified.
2. Safety
When installing, operating or maintaining the bearing, danger may arise to the user, the product and plant and/or other assets. Therefore all users responsible for the operation of the machine must understand this manual fully and make sure that all the safety procedures are strictly adhered to.
Pay particular attention to the following general safety notes:
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machine.
Under no circumstances should the engineer work alone when operating the
! !
At least one of the engineers should be trained in basic first aid techniques
and wear identification that he/she is a first-aider.
No maintenance, assembly, adjustment or any other work should be carried
out on the bearing whilst the shaft is rotating or capable of movement. To avoid accidents, the entire machine should be isolated, with control gear locked off and Not to be used signs applied to the control panels.
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Michell.
Personnel that manipulate the product should be sufficiently trained.
No modifications of the product should be made unless it is approved by
More specific safety notes are also given in the relevant sections, and should be adhered to.
3. Handling the Bearing

3.1 General
This section outlines essential information, which must be referred to when handling the thrust rings. The thrust rings are supplied fully assembled (see arrangement drawing for mass of complete bearing). Omega OT Series thrust rings are not usually fitted with lifting holes. A complete ring may be lifted using straps or slings. When transporting the bearing, it should remain in its packaging. Make sure thrust rings are stored in the intended mounting position, in a dry room only. Please check all product equipment to ensure that it is complete before installation. Any damage due to transit must be reported to Michell immediately. See Section 8 for instructions on how to disassemble the bearing.
Before using any lifting equipment, ensure that it is certified to carry a load
greater than that of the bearing or component.
Take care not to damage bearing components and the running surfaces of the shaft collar by contact with the lifting equipment.
If in doubt, always use mechanical devices where possible. Remember to
bend the knees and not the back when lifting manually.
4. Preparation for First Installation

All Omega OT Series thrust rings are supplied complete. All thrust rings are, for ease of assembly, capable of being split in two halves. If the rings supplied are to be split the RTDs and their cabling should be removed prior to this. Remove all packaging. Refer to Sections 2 and 3 for safety and handling instructions. Dismantle the bearing referring to Section 8, ignoring any references to the shaft or machine. When dismantled, please check all product equipment to ensure that it is complete before installation. Any damage due to transit must be reported to Michell Bearings immediately. All parts are coated in a rust preventative. This must be removed and all parts thoroughly cleaned before installation begins. To remove the rust preventative, white spirit or a strong spirit based cleaner should be used. Note! Do not use paraffin (Kerosene). It is recommended that the bearing casing and all other internal parts are cleaned to prevent dirt getting between the collar and the thrust rings.
If the thrust rings are being fitted into a bearing that has previously been used, ensure that the lubricating pipes have been cleaned to remove any deposits. If there is any dirt in the lubricating system it will damage the new parts fitted.
Use a lint free cloth when cleaning the bearing. Particles from other cloths could otherwise get into the lubricating oil and cause overheating, and in extreme cases, failure of the bearing. Once all parts are inspected and cleaned the bearing is ready for installation. Refer to Section 10 if the bearings are to be stored for a period of time before operation.
5. Assembly of the Bearing

5.1 General
The following general points should be noted:
The disassembling and reassembling of the equipment by an individual who is
inexperienced can cause danger. Michell will not take on any liability for any damage resulting from non-compliance with details given in this manual. If in doubt refer to our Service Dept.
Only use tools, which fit correctly to avoid damage to fasteners.
Do not use excessive force.
Use a liquid screw locking compound (e.g. Loctite 222) on all fasteners.
Remove all impurities and foreign objects (e.g. bolts, washers, etc.) from inside the bearing. Ensure bearing is covered when left unattended.
This assembly procedure has been generalised to cover most eventualities. As such it may contain more information than is directly applicable to the bearing being worked on. Read all text and simply ignore any reference to irrelevant items.
5.2 Assembly of the Thrust ring 5.2.1 Fitting the Thrust Pad set. Coat all bearing surfaces in clean oil. Refer to bearing general arrangement drawing for information on the correct grade of lubricant. Place thrust pad set (3) into retaining ring halves (1), (2).
Ensure that the correct handed pads are fitted. The direction of rotation stamped on the pad must agree with that shown on the arrangement drawing.
Secure thrust pad (3) in place with pad stop (4) with hole located in back of thrust pads (3).
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Ensure that stop (4) is fully locked in place with Loctite 222 or similar adhesive.
Make sure pads (3), can move freely, and are not trapped.
Take care not to trap hands when handling the components
5.2.2 Fitting Ring Stop, and Liners if applicable Place shim pack (6), and liners (7), on retaining ring halves (1), (2), and sercuer in place with hex, socket counter sunk screw (8). Ensure that screws (8) are fully locked in place with Loctite 222 or similar adhesive. Fit ring stop (5). Ensure that stop (5) is fully locked in place with Loctite 222 or similar adhesive.
5.3 Assembling the Thrust rings into the Bearing Casing Coat the thrust pads surfaces with clean oil of the correct grade. Some OT Series bearings are supplied with machine liners; these should be fitted at the same time as each thrust ring assembly. Horizontal Bearings: Fit the lower half of the thrust ring(s). Vertical bearings: Fit the entire lower thrust ring.
Care should be taken when handling the components to avoid the risk of trapping hands when assembling. Lower the shaft, complete with collar into the bearing. Horizontal Bearings: Fit the top half of the thrust ring(s), either onto the top of the lower ring, or into the top half casing. Secure the ring with stops. Horizontal bearings: Rotate the thrust ring around until the stop (5) engages in the casing, if half the ring is secured into the top half of the casing, ensure that the bottom half is flush with the casing joint and complete assembly. Vertical Bearings: Fit upper thrust ring and secure in place with stop (5).
Check the bearing alignment, and complete assembly.
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5.3.1 Miscellaneous Where applicable, connect up oil inlet and outlet. Connect external pipework. 5.3.2 Instrumentation Fit RTDs and instrumentation as necessary.
Ensure that temperature probe assembly is not damaged and is working correctly before fitting it.
Check that the bearing is complete and is fully sealed. For temperature probe fitted bearings; run the bearing and establish a steady state operating temperature then set temperature alarm to 5C above the steady state operating temperature. Shut down temperature alarm is to be set at 10C above steady state operating temperature.
Note! Prior to running the bearing EC regulation state: - The entire machine
has received a Declaration of Conformity, or has been declared exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive. Where applicable
Do not use the bearing unless the lubricating system is operating.
It must be emphasised that any declaration of incorporation issued by Michell Bearings is for the thrust rings and their components and not for the entire bearing. The bearing is now complete; it must not be used until the below items have been dealt with; 1. Lubricating oil has been passed though the bearing. 2. The lubricating oil must be a mineral based turbine oil inhibited against oxidation, corrosion and foaming, with an ISO viscosity grade as indicated on the arrangement drawing. The use of any other oil should be referred to Michell Bearings.
If in doubt with installation please use our Service Department!
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6. Operating
6.1 Preparation and Inspection before Operation Where necessary fit the temperature probes for measuring the thrust pads, and/or the sump temperature in the relevant connection holes.
Ensure that RTD assembly is not damaged and is working correctly before fitting.
Where applicable retighten external oil supply connections. Fill Bearing with oil or start oil system as described in Section 7.4.
Check: 1. That the oil quantity at bearing oil inlet is as specified by Michell Bearings, where applicable. 2. That the temperature monitoring equipment works. The bearing is now ready for operation. It must not be used until the below items have been dealt with:
1. The entire installation has received a Declaration of Conformity, or has been declared exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive. 2. Lubricating oil has been passed though the bearing. 3. Local safety regulations have been met. 6.2 Trial Run For temperature probe fitted bearings, run the bearing and establish a steady state operating temperature. Set temperature alarm to 5C above this steady state operating temperature. Shut down temperature alarm should be set at 10C above steady state operating temperature. Supervise the bearing during the trial run period (approx. 5-10 operating hours). Pay special attention to the following:
1. Oil flow rate and oil inlet pressure in circulating oil system (where applicable) 2. Bearing temperature 3. Occurrence of inadmissible vibrations. 4. Unusual noises or odours
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If any or all of the above cause concern, or if the monitoring equipment triggers an alarm, stop the machine immediately and carry out an inspection of the bearing to find the cause.
6.3 Normal Operation
If the bearing has been correctly assembled using the procedure already given, there is only a marginal risk of the bearing failing which would normally be due to inadmissible operating conditions. Examples of these conditions are; overspeed, low lubrication levels and excess load. To avoid these situations, follow the following recommendations:
Label Control Panels with the bearing limitations. Do not operate the bearing below the transition speed values indicated in the bearing calculation. Stop the shaft immediately if: Bearing temperature exceeds normal operating temperature by 10C. Never remove plugs, RTDs or seals while the bearing is operating. Regularly inspect all seals and pipework. Any large leakage of lubricant or coolant will indicate that a seal or joint is failing. Maintenance must then be carried out as soon as possible.
The bearing surface and any pipework may be hot during operation. 6.4 Preparation for Operation after Standstill Clean the external parts of the bearing. Dust and dirt impede the radiation of heat. Check with the maintenance schedule in Section 7.3 to see if an oil change is necessary. If required, carry out the oil change as indicated in Section 7.4. Start operating the oil supply system, where applicable, and check that it is working correctly. The supplied oil quantity at the bearing inlet must equal the value indicated in the Michell Calculations. Check the functioning of the temperature monitoring equipment. The bearing is now ready for operation.
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7. Care and Maintenance

7.1 General Before carrying out any maintenance or inspection work, switch off machinery. Lock off the controls and secure and the isolate shaft.
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the shaft is locked out and labelled Not to be used, or similar.
7.2 Tools and Equipment
The following tools and equipment may be necessary to carry out maintenance on the bearing: Allan key set Wrenching key set Open-jawed spanner set Feeler gauges. Emery paper, plain scraper Lifting equipment Permanent sealing compound (e.g. Curil-T) Liquid screw locking compound (e.g. LOCTITE 222) PTFE sealant tape. Oil with the viscosity indicated (see bearing inspection plate) Detergents Clean cloth
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7.3 Maintenance Schedule For a bearing that is operating constantly, routine maintenance should take place annually. If the user only operates the bearing periodically, maintenance periods may be able to take place less frequently. This is however, at the users discretion. An annual inspection is recommended as a minimum service requirement. A basic guide to maintenance is given in Table 1.
Maintenance work Oil Change (see Section 7.4)
Schedule Bearing in reversing operation: every 3 Months Bearing in continuous operation: every 6 Months
Bearing Inspection
During preventative maintenance work for machine or immediately if: Bearing temperature exceeds 10C over the indicated value (see calculations) Unusual noises or odours occur Unusual changes in the oil colour are visible. Inadmissible vibrations occur. Oil flow rate and oil inlet pressure readings drop below admissible values,
Table 1: Maintenance Schedule
These are estimates only, and frequency may alter depending on site environment. Michell can advise the user accordingly. 7.4 Oil Change 7.4.1 General Oil changes will be at differing periods depending on the frequency of bearing operation and the conditions in which the bearing is operating. Approximate oil change times are indicated in Section 7.3. Please observe the instructions for the use of the lubricating oil. The manufacturer can provide information on waste oil disposal.
Risk of Pollution:
7.4.2 Procedure for draining oil Run the bearing to warm up the oil. This will ease the flow of oil from the bearing, and also remove any impurities and residues.
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Shut down the machine and secure it against unintended operation. Shut down the oil supply system where applicable.
Do not disconnect the oil inlet and outlet pipework until the bearing has been
drained of oil.
Any oil spillage should be collected in suitable containers. Let off and collect the lubricating oil in the oil supply system where applicable. Loosen and remove the drain plug and washer, and fully drain the bearing of oil.
Beware hot oil.
Collect and dispose of used oil under the correct regulations.
If the oil is visibly altered in colour, or contains unusual residues, an inspection is recommended to eliminate the cause.
7.4.3 Procedure for refilling the bearing -self contained bearings Pour the correct grade of lubricating oil into the filling hole in the casing top. Use the approximate quantity required as shown on the bearing arrangement drawing as a guide. Let the oil settle into the bearing. Check the oil level is approximately at the centre of the oil level gauge, and top up if necessary. Where applicable.
7.4.4 Procedure for refilling the bearing - bearings with circulating oil Clean the oil container and fill up the oil supply system with the correct grade of lubricating oil. Start the oil supply system in order to fill up the bearing with oil.
Check for leaks.
Not enough lubricant leads to temperature rises and therefore damage to the bearing. Too much lubricant leads to leaks.
When pouring, take care not to spill lubricating oil onto the machine or surrounding area.
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8. Dismantling an Installed Bearing

8.1 General The Procedure given in this section is a full stripdown of a generic Omega OT series bearing. As such it may contain more information than is necessary in some cases. Simply ignore the sections not relevant to the bearing being worked on. Any technical queries can be referred to the Engineering Team at Michell Bearings. Michell recommends that the below safety advice is followed when carrying out maintenance on any bearings. It may be necessary to change the dismantling procedure to suit the design of the bearing casing.
8.2 Preparation Check through the safety procedures at the start of Section 2. Understand and follow the instructions very carefully. Switch off machinery. Lock off controls. Secure and isolate shaft, drain and disconnect cooling system, where applicable. Refer to manufacturer instructions.
the shaft is locked out and labelled Not to be used. Switch off and drain the lubricating oil and oil system (where necessary) as described in Section 7.4. Disconnect and remove any thermometry and instrumentation.
Make sure the workspace is clean. Contamination and damage to the bearing affect operating performance and could lead to premature failure.
Do not use any violence or force.
Take care not to jam hands when manipulating components. . 8.2.1 Strip down the bearing until the thrust rings are visible. Horizontal Bearings: Where applicable, remove the top half of the thrust ring(s). Vertical Bearings: Remove upper thrust ring (where fitted). Vertical Bearings: Jackshaft up until its clear of the lower thrust pads.
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Follow lifting instructions and safety guidelines in Sections 2 and 3.
Ensure the jacking equipment is safely positioned and certified to carry a load
greater than the mass of the shaft.
Once the shaft is raised, secure it into position using other equipment. Do not
rely on jacking equipment alone. 8.2.2 Disconnect and remove any thermometry and instrumentation. Remove RTDs, and instrumentation connections.
Take care not to damage instrumentation. 8.3 Removing thrust rings Vertical Bearings: Remove lower thrust rings. Horizontal Bearings: If the bottom half of the thrust rings are not visible, follow the below procedure; Tap one end of the ring until the opposite end is visible. Rotate the ring out and remove. 8.4 Removing the Liners, and Shim Pack. Where Applicable. To fully dismantle the thrust ring follow the below procedure: Remove liner retaining screws (8), liners (7), and shim pack (6) from the back of the retaining ring halves (1), (2). 8.5 Removing the Thrust Pad Set Remove thrust pad stops (4) from retaining rings (1), (2). The thrust pads (3) can now be removed from the retaining ring (1), (2).
Take care not to jam hands when manipulating components.
Take care not to damage thrust pad whitemetal surface.
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9. Cleaning and Checking

9.1 General
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Only use non-aggressive detergents such as VALVOLINE 150 or Alkaline
cleaning compounds with pH-value 6 to 9, and a short reaction time.
Please observe the instructions for use of the detergents.
Use a lint free cloth when cleaning the bearing. Thread from such cloths could get into the lubricating oil and cause overheating, and in extreme cases, failure of the bearing. Clean the following parts thoroughly:
1. Thrust pad set. 2. Retaining ring. 3. Liners, where applicable 4. Shim pack. 5. Thrust pad stops. In addition inspection may be required on the bearing components, according to the Maintenance Schedule outlined in Section 7.3. The remaining part of this section gives basic inspection guidelines for some major bearing components. However, if any wear or damage is evident on any of the bearing components, consult Michell Bearings immediately as it may adversely affect bearing performance. The following sections assume the bearing has been dismantled according to Section 8.
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9.2 Checking the Thrust Pad. Examine the Thrust Pads. The appearance of the running surface should be that shown in Figure 11 below.
Figure 11: Thrust Pad Appearance After Use
Inspect the collar surface for any signs of damage. If it is necessary to change the pads, the collar should also be replaced or repaired, otherwise the replacement pads will only have a short life. There may be some scoring and wear on the pads. Provided wear is no greater than 0.125mm the pads are still serviceable. If there is any sign of the bearing surface coming away from the backing material, the pads must be replaced.
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10. Bearing Preservation during Storage

10.1 Before Installation Make sure thrust rings are stored in the intended mounting position, in a dry room only.
10.2 Corrosion Protection for Standstill Periods up to 6 Months
Dismantle the bearing (see Section 8). Clean the bearing (see Section 9). Assemble the bearing (see Section 5). Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of condensation in the bearing.
10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year Repeat the preservation procedures detailed in Section 10.2.
10.4 Corrosion Protection for Standstill Periods longer than 1 year Dismantle the thrust rings according to Section 8. Preserve and store bearing parts separately.
11. Bearing Preservation During Transport

When the bearing is fitted to the machine during transport: Carry out the corrosion protection procedure described in Section 10.2. Apply liberal lubricant to the running surfaces of the bearing. Secure the shaft against axial and radial movement.
12. Appendices
12.1 Ordering Spares
As a minimum, it is recommended that replacements should be carried for all Whitemetal components. Consideration should also be given to stocking the parts listed below: Jointing compound (i.e. Curil-T) RTD Assemblies (where applicable)
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Bolt Size (mm) 6 8 10 12 16 20 24 30 36 42 48 56 64
Tightening Torque (Nm) 4 10 20 35 80-90 155-175 275-305 545-605 950-1050 1520-1680 2300-2520 3690-4070 5560-6150
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Service Department. Direct: +44(0191) 2565319
Repair Department. Direct: +44(0191) 2565309
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INSTRUCTIONS for INSTALLING & OPERATING
NE269 (8X8) THRSUT BEARING
for
BHARAT HEAVY ELECTRICALS LTD. Hyderabad,
P. O. No. F603P608 September 2005
K I N G S B U R Y, I N C. 10385 Drummond Road, Philadelphia, PA Phone: 215-824-4000 Fax: 215-824-4233 Kingsbury Reference No. K033016
CONTENTS Page No. CHAPTER 1 - GENERAL INFORMATION 1.1 1.2 1.3 1.4 1.5 INTRODUCTION .................................................................................................. 1 PRINCIPAL DATA................................................................................................ 1 ILLUSTRATIONS .................................................................................................1 GENERAL DESCRIPTION ...................................................................................1 DETAILED DESCRIPTION ..................................................................................1
CHAPTER 2 - INSTALLATION 2.1 2.2 2.3 2.4 DISASSEMBLY, CLEANING, AND INSPECTION ...........................................3 INITIAL ASSEMBLY ............................................................................................3 END PLAY .............................................................................................................4 FINAL ASSEMBLY ..............................................................................................5
CHAPTER 3 - OPERATING INSTRUCTIONS 3.1 3.2 3.3 LUBRICATION AND COOLING .........................................................................6 GRADE OF OIL .....................................................................................................6 OPERATION ..........................................................................................................6
CHAPTER 4 - CARE AND MAINTENANCE 4.1 4.2 4.3 TROUBLESHOOTING ..........................................................................................7 INSPECTION AND REPLACEMENT ..................................................................7 SERVICE ................................................................................................................8
CHAPTER 1 - GENERAL INFORMATION 1.1 Introduction
a. The NE8269 thrust bearing assembly consists of two subassemblies. Each subassembly has eight pads, four of which are equipped with Resistance Temperature Detectors (R.T.D.). The subassemblies are split with an attached split filler plate. 1.2 Principal Data NE8269 Non-Equalizing (NE) Bearing Outer diameter of bearing (mm) ............................................................................................. 297.0 Inner diameter of bearing (mm) ..............................................................................................160.0 Number of pads (each side) ............................................................................................................ 8 Recommended end play (mm) ....................................................................................... 0.36 - 0.46 1.3 Illustrations
Kingsbury Drawing #481202 ............................................................................................. Figure 1 1.4 General Description
a. The double thrust bearing assembly presented in Figure 1 is a non-equalizing design, which means that the axial pad positions have very limited adjustment capability under load. Eight thrust pads are positioned on each side of the collar. The assembly is capable of accommodating thrust load in either axial direction. The thrust of the rotating element is transferred through the collar to the pads, the carrier ring, the housing, and foundation. b. In operation, each pad is free to pivot slightly in relation to the collar surface. This allows the oil to form wedge-shaped films between the pads and collar. These films, thickest at the leading edge, are self-renewing, as long as the shaft rotates and lubrication is provided. 1.5 Detailed Description (See Figure 1)
a. The thrust bearing assembly consists of two split carrier rings (1), in which the thrust pads (2, 3) are equally spaced between pad retainer and screws (4, 4-1). The head of the pad retainer holds the pads loosely in position by engaging recesses machined in the radial sides of each pad.
b. Socket head shoulder screws (8) are used to locate and hold the instrumented thrust pads (3) located near the carrier ring joint. c. The thrust pads (2, 3) are made of steel and are faced with babbitt. They are free to tilt slightly, allowing the wedge-shaped oil films to develop. The plain pads are interchangeable. However, the pads equipped with R.T.D.s have specific locations within each subassembly and must not be interchanged. Instrument lead wires must be routed through the grooves provided in the carrier ring. The leads may be secured using the wire clamps (7) and screws (7.1) provided. d. The carrier rings are located in the housing and secured against rotation by antirotation keys (6) secured with screws (6-1). e. The filler plates (5) are used to set rotor end play (See Section 2.3), which is the axial clearance between the thrust bearing sub-assemblies. The filler plates are secured to the back of each carrier ring (1) with filler plate mounting screws (5-1).
CHAPTER 2 - INSTALLATION 2.1 Disassembly, Cleaning, and Inspection
a. As packed for shipment, the bearing elements and surfaces are protected against physical abuse and corrosion. They have been brushed with a neutral waterproof coating and are protected against contact with wood or damp packing material. Subsequent damage may occur if the proper precautions are not observed during storage, inspection, and installation. b. Remove the packaging materials from each bearing assembly and lay the assembly on a clean, flat surface. c. Separate the thrust bearing subassemblies at the joints.
d. Remove the pad retaining screws (8) from the back face of the subassemblies. Remove the loose pads (3). e. Loosen and remove the pad retainer screws and pad retainers (4, 4-1) in sequence, removing all loose thrust pads (2). f. Clean off all anti-rust preservative with a mixture of oil and solvent or kerosene. Use lint-free rags or cloth for cleaning. CAUTION A poorly cleaned bearing will score and wear out rapidly. A bearing surface is not clean until a white cloth wiped over it shows no soil. CAUTION Protect the babbitted pad faces at all times! g. Inspect all parts after cleaning. Remove any raised metal on the babbitt faces with a scraper. h. Remove displaced metal or rust on the collar face using a fine oil stone. Deep rust requires refinishing. 2.2 Initial Assembly a. b. Oil all parts when assembling. Place the carrier ring halves (1) on a clean, flat surface.
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c. Refer to Figure 1. Starting near the carrier ring joint (the end without the thruhole for the shoulder screw (8)), place a plain thrust pad (1) atop the carrier ring, followed by a pad retainer (4) atop the threaded hole in the carrier ring. The retainer must engage the slot in the side of the pad. d. Continue placing pads, followed by retainers, until all of the plain pads and retainers have been located. e. Secure the retainers in place by installing the flat head socket screws (4-1).
f. Place the instrumented pads (3) into the remaining positions and secure with socket head shoulder screws (8). g. 2.3 End play must now be accounted for. Refer to Section 2.3, End Play.
End Play
a. End play is defined as the axial float of the thrust collar between the thrust bearing sub-assemblies. It is provided to allow for oil film formation and thermal expansion. b. Thrust bearing end play is determined by the thickness of the filler plates (5) fastened to the back of each carrier ring. c. To determine the required filler plate thickness, place each thrust bearing subassembly on a surface plate and lay a flat plate atop the pad surfaces. Use an inside micrometer or snap gauge and measure the height between the surface and top plate adjacent to each pad. Average the eight readings to determine the average stacked height. NOTE For accurate results, the flat plate should have a 32 rms finish and be flat within 0.03 mm. The plate should weight at least 45 kgs. CAUTION Babbitt is a soft metal that is easily damaged. Do not drop or twist the surface plate atop the babbitted surfaces! d. Use an outside micrometer to measure the filler plate thickness. Record the measurement.
e. With the thrust collar (rotor) in the desired running position, use an inside micrometer to measure the average available space. Carefully measure and record the space between the collar and each end of the housing. Perform measurements in at least three locations. Average the readings to determine the average available space. f. The difference between the average stacked height and average available space (for each side of the collar) represents the desired filler plate thickness. The calculated filler plate thickness in the normally unloaded bearing must be further reduced by the desired end play (See Section 1.2). g. If the filler plates are not the required thicknesses, they must be ground. NOTE The filler plates should be ground on the side of the filler plate mounting screw (5-1) counter bores. The filler plate must be ground flat within 0.013 mm. surface finish should be 32 rms or better. The
h. Once installation is complete, verify the end play by moving the rotor fore and aft while accurately measuring the change in position. Correct as required. 2.4 Final Assembly
a. Attach the finished filler plates (5) to the carrier rings (1) using the filler plate mounting screws (5-1). b. c. installation. Wet the collar faces with oil. Bump the rotor to one side to provide clearance for one thrust subassembly
d. Place the lower half of the partial assembly (the halves without the anti-rotation key (6)) over the shaft and roll it into the housing, bringing the bearing joint even with the housing joint. e. Place the upper half atop the lower and roll the subassembly to seat the antirotation key.
CAUTION The instrument lead wires are easily damaged by rough or careless handling. Assist the leads each time the assembly is rotated.
f. above. g. h.
Bump the rotor against the bearing and install the second subassembly as noted
Pour oil over the entire assembly. Complete housing assembly.
CHAPTER 3 - OPERATING INSTRUCTIONS 3.1 Lubrication and Cooling
a. These bearings are intended for lubrication from the main oil system. The rate of circulation should keep the oil outlet temperature within 14-17C above the inlet temperature. b. 3.2 Control the oil flow by throttling or using orifice plugs on the oil inlet only.
Grade of Oil
a. Correct oil viscosity is important. Changing to a lighter oil may cause the lubricating films to become dangerously thin. The use of a heavier oil will needlessly increase friction and power losses. b. Oil must be clean and free from grit and other abrasive substances. Fine grit has a scouring action, and dirty or old oil may cause corrosion or sludge. 3.3 Operation
a. The bearing surfaces, when running, are completely separated by oil. Since there is virtually no wear, no adjustment is provided. The original dull gray appearance of the thrust pad faces may remain the same after years of service. This can be expected if the unit is clean when installed and is supplied with clean, cool oil of proper viscosity. b. Oil flow through the bearings must be established prior to shaft rotation.
CHAPTER 4 - CARE AND MAINTENANCE 4.1 Troubleshooting SYMPTOM HIGH BEARING TEMPERATURE CAUSE Low oil flow High oil inlet temperature Contaminated lube oil Damaged journal BABBITT LINING: Scored Cracked Separated from pad body 4.2 Low oil flow Dirty Oil Excessive vibration Poor bond REMEDY Check & clean filters & sump. Check oil cooling medium. Increase cooling water flow. Check for proper oil level. Check and clean lube oil system. Filter/replace oil. Disassemble and inspect. Increase oil flow. Replace pads. Filter/replace oil and replace pads. Balance rotor. Replace pads. Replace pads.
Inspection and Replacement
a. An inspection of the thrust pads or collar faces cannot be performed without raising the housing cover. Thrust bearing end play, pad temperature, oil outlet temperature, and oil filter condition should be used to assess bearing health. b. housing. When distress is suspected, secure the unit and lift off the upper portion of the
c. With the cover raised, the radial edges of the thrust pads and exposed collar surfaces can be inspected. d. If babbitt overlay along the pads radial edges is not visible, withdraw a pad for full surface inspection. e. If the pad does not exhibit displaced babbitt, it is unlikely that the remaining pads will be damaged. When the babbitt becomes hot enough to flow, it is picked up by the rotating collar and is quickly carried through all of the pads.
f. If an overlay of babbitt is evident along the pads radial edges, the bearing must be disassembled. The severity of damage determines the extent of repair. g. Refer to Section 2.2 for the reinstallation procedure. 4.3 Service
a. In correspondence and when ordering parts, refer to the Kingsbury Drawing and Order numbers. b. Prompt service is available. Please contact: Kingsbury, Inc. Repair and Service Division 3615 Davisville Road Hatboro, PA 19040 U.S.A. Phone: 215-956-0565 Fax: 215-956-9027
481202.dwf :Library
8 7 6 5 4
ITEM INST RUMENT ATION R.T .D. MINCO MODEL #S308PD4S160BO,
2
ZONE LT R A ALL
RE VISIONS DESCRIPTION
A DDED TEXT "OF FIL LER PLATE" TO ID DIM . ON BACK VIEW . A DDED CARRIER ID DIM . TO SE C. E-E. ADDED TOTAL AXIAL C LEARANCE NOTE TO SIDE VIEW. ADDED TECHNICAL DATA. CHANGED SHOE M AT'L FROM STEEL TO CHROM E COPPER. REM OVED BEARING CAPACITY FROM SPECS., REM OVED R EFERENCE TO CHR CU SHOES, ECN #6004358
1
CHANGED APPROVED
M EB 06 /10/04 R JM 06 /24/04
RECOMMENDED TOTAL END PLAY .36mm [.014] TO .46mm [.018].

H
PLATINUM, 100 OHMS @ 0 ~C (32 ~F), 4-WIRES, #30-AWG, STRANDED, 4064.0/160.00 LG. LEADS, TEFLON INSULATED & STAINLESS STE EL BRAID OVERALL
2A, BOM
N H 8/3/04
H JG 8/3/04
G
THRUST COLLAR FACES MUST BE FLAT & SQUARE WITH SHAFT AXIS FINISH VERY SMOOT H (16 RMS) BY L APPING OR OTHERWISE COLLAR NOT SUPPLIED BY KINGSBURY 48.0 mm [1.89 in]
n194.0 m m [7.64 in] I.D. OF FILL ER PLATE
22.5 TYP
A C
2 3
7.1
5 5 5-1
n297.0 m m [11.69 in] TYP EXTERNAL PAD DIAMETER
F
n323.85 m m 12.750 in HOUSING BORE 323.99 12.756
F
323.64 12.742 n323.50 mm 12.736 in BEARING O.D.
n300.0 m m [11.81 in] COLLAR
n270.0 mm [10.63 in]
qJOINT
.8 m m [.03 in] 160.0 mm [6.30 in] TYP INTERNAL PAD DIAMETER
E
11.1 m m [.44 in] TYP
[
E
3
GRIND THIS SIDE ONLY 3 4 4-1
SECTION B-B SCALE 1 / 2
GRIND T HIS SIDE ONLY 15.0 mm [.59 in]
B
15.0 m m [.59 in]
SECTION A-A SCALE 1 / 2
143.75 mm 5.659 in 143.65 5.656 TOTAL AXIAL CLEARANCE OF 0.5 mm [.02 in] INCLUDED IN TOTAL BRG. WIDTH
KINGSBURY TO SUPPLY 15m m[.591] NOMINAL THK PLAT E, CUSTOMER TO GRIND PLATE TO OBTAIN DESIRED END PLAY. (AROUND ~9.649m m [.3799])
n178.5 mm [7.03 in] ID
OF BASE IRNG 6 6-1
16.7 mm [.66 in] TYP

n3.4 mm [.13 in]
4.7 m m [.19 in]
17.7 mm [.70 in] TYP
C
5
7 6.0 mm [.24 in]
23.8 m m [.94 in] TYP
5-1
SECTION E-E SCALE 1 / 2

TECHNICAL DATA:
17.0 m m [.67 in]
-SHAFT DIA.= 138.0 mm [5.43 in] -ROTATIONAL SPEED, DESIGN/MAX.= 5465/6100 rpm -THRUST LOAD, M AX.= 120 KN
B
SECTION C-C SCALE 1 : 1
M5 x 6mm SHANK DIA x 12mm LG SHANK #10-24 x 3/8 LG CONCORD #770-1101 #10-24 x 3/4 LG M6x1.0-6H x 16 mm LG M6X1.0 x 20mm L ONG PAD RETAINER
057958 007717 003974 002875 162375-001 039138 481208-002 2001114 267368-006 165251-001 379507-002
4 10 10 2 2 12 2 16 16 16 4
SOCKET HEAD SHOULDER SCREW
8 7.1 7 6-1 6 5-1 5 4-1 4 3-1 3 2 1 ITE M
-THRUST SURFACE AREA= 1,635.0 sq.mm. [64.37 sq.in.] -THRUST PRESSURE= 2,889 KN/m.sq. -TOTAL AXIAL CLEARANCE= 0.5 mm [.02 in.] -POWER LOSS= 43 KW -OIL GRADE= 32/46-ISO VG -OIL VISCOSITY POISE= 0.18 -OIL INLET TEMPERATURE= 55 ~C -OIL FLOW= 5,673 liters/hr PER SIDE
CW CARRIER RING DESCRIPTION

UNLESS OTHERWISE SPECIFIED
FILL ISTE R HEAD MACHINE SCREW WIRE CLAMP FILL ISTE R HEAD MACHINE SCREW 8.00" KEY, BASE RING BUTTON HEAD CAP SCREW FILL ER PLATE, NE 8269 FLAT HEAD SOCKET SCREW PAD RETAINER 1.00 DIA. SHOE SUPPORT NE 269 CENTE R PIVOT SHOE ASM, W/INTR. 481204-002 12 NE 269 CENTE R PIVOT SHOE ASM, W/BUTTON 481203-002 2 NE 8269 CARRIER RING, CENTER PIVOT SHOE S, SPECIAL THK PART NUMBER QTY TITLE LIST OF MATERIAL
THIRD ANGLE PROJECTION

RELEASED
Kingsbury, Inc.
10385 DRUMMOND RD. PHILADELPHIA, PA.
DRAWING TITLE:
HJG HJG JAC wed
8/4/04 5/21/2004 5/21/2004 4/26/2004 SIZE
A
THIS D OCU MENT CONTAINS CONFIDENTIAL PROPRIETA DESIGN INFORMATION OF KINGSBURY INC. A USE OF THIS RY LL INFORMATION IS EXPRESSLY RESERV ED. TH DOCUMEN IS SUBMITTED TO YO TH RECIPIENT, UNDER A CO IS T U, E NFIDENTIAL RELATIONSH FO A SPECIFIC PU IP R RPO AND YOU, BY ACCEPTIN THIS DOCUMENT ASSU SE, G ME CUSTOD AND AGREE: (1) THAT Y THIS DOCUMENT WILL N BE COPIED IN WHOLE OR IN PART, N ITS CONTENTS REV OT OR EALED TO ANY PERSON EXCEPT TO M EET THE PURPOSE FOR WHICH IT WAS D ELIV ERED TO YO (2) THAT ANY SPECIA FEATU U; L RES PECULIAR TO THIS DESIGN WILL NOT BE INCO RPORA TED IN O THER PROJECTS; A ND (3) THAT THIS D RAWING OR ANY DESIGN DETAIL OR CONCEPT D ISCLOSED H EREIN WILL N BE USED IN A OT NY WAY DETRIM TAL TO OR IN COMPETITION WITH KINGSBURY INC. EN NOTICE: K GSBURY INC. O IN WNS THE COPYRIGH IN THIS DRAWIN UNAUTH T G. ORIZED CO PYING, AD APTATION, DISTRIBUTION OR DISPLAY IS PROHIBITED.
ENGINEER
S URFACE 125 [32] R OUGHNES S
CHECKED DRAWN BY
269 (8x8) (NE) NON- EQULAIZING BEARING IN HALVES, W/INSTR. (2x2), A W/15mm SPACERS
DRAWING N O. REV
DIMENSIONING POSITION INCH [MIL LIMETER]

DO NOT SCALE DRAWING
BHARAT HEAVY E LECTRICAL S ITEM N O. 481202-T1 K.O. K033016
E
SCALE
75333
1=2
CALC. WT.
481202
SHEET
B
1
O F
1 of 1
SECTION B
BOILER FEED PUMP
5. CONNECTING COUPLINGS

STD OM
Page 1 of 4
Preliminary Checks All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling accompany all supplies. Carry out the following checks prior to proceeding with the installation work. i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport purposes and for the purpose of compressing the flexing elements at the time of installation. The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling alignment and trial run of the equipment. Couplings and the equipment should not be allowed to operate with gagging screws in position. ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those of the interface dimensions of the equipment shafts and flanges. Coupling model & Rating Hub bore and key way dimensions Locating / Spigot diameter Distance Between Shaft Ends (DBSE) or Distance Between Flange Faces(DBFF) Over all length iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling. iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise called for, should not be disassembled, . v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque wrenches / special spanners. vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying certificates will show the run out values obtained at the time of dynamic balancing. These markings of are meant for match marking and the run out values can be used as a guide for accurate alignment of the equipment.
Prepared SANKAR
Approved KVMR
Date 18-06-2003

STD OM
Page 2 of 4
3. General Limits :
Prepared SANKAR
Approved KVMR
Date 18-06-2003

STD OM
Page 3 of 4
CONFIGURATION-1
Configuration : 1
Couplings with this configuration have hub flanges directly bolting on to the flexing elements. Following is the sequence installation : i. Dismantle the coupling bolts and the gagging screws. ii. Mount the hubs on respective equipment shafts. iii. Position the equipment to the correct DBSE specified. iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance (DBFF) specified on the drawing. v. Clamp two dials as shown and align to within 0.05 mm of TIR. vi. Assemble the flexing elements and spacer in position and hand tighten all coupling bolts, in cylinder head fashion. vii. Tighten all coupling bolts to 50% of the specified torque using a calibrated torque wrench, in a cylindrical head fashion. viii. Recheck the DBSE and radial run out values. Readjust if the same is found disturbed. ix. Tighten all coupling bolts to the specified torquing limit. Prepared SANKAR Approved KVMR Date 18-06-2003

STD OM
Page 4 of 4
IMPORTANT: Care should be exercised to tighten only the lock nuts by holding the bolt head steady in a socket. Coupling bolts will have a very close fit in the flange holes and to the flexing element bushes and hence any forced rotation will result in damage to the close fitting bolt shank and the mating parts.
2 Alignment Procedure / Clamping Arrangment Fig. No. : 1

Max. Alignment Limits TIR-mm Application DRIVER - DRIVEN Dial 1 0.05 Dial 2 0.05
2
Final checking Fig. No. : 2
Max. Alignment Limits TIR-mm Application DRIVER - DRIVEN Dial 1&2 0.05
Prepared SANKAR
Approved KVMR
Date 18-06-2003


Page : 1 off 4
Preliminary Checks All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling accompany all supplies. Carry out the following checks prior to proceeding with the installation work. i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport purposes and for the purpose of compressing the flexing elements at the time of installation. The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling alignment and trial run of the equipment. Couplings and the equipment should not be allowed to operate with gagging screws in position. ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those of the interface dimensions of the equipment shafts and flanges. Coupling model & Rating Hub bore and key way dimensions Locating / Spigot diameter Distance Between Shaft Ends (DBSE) or Distance Between Flange Faces(DBFF) Over all length iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling. iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise called for, should not be disassembled, . v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque wrenches / special spanners. vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying certificates will show the run out values obtained at the time of dynamic balancing. These markings of are meant for match marking and the run out values can be used as a guide for accurate alignment of the equipment. PREPARED SURESH CHECKED SANKAR APPROVED KVMR DATE 18-06-2003


Page : 2 off 4
3. General Limits :
PREPARED SURESH
CHECKED SANKAR
APPROVED KVMR
DATE 18-06-2003


Page : 3 off 4
Configuration : Couplings of this configuration are supplied with a central transmission unit which allows installation with minimum disassembly of the factory tightened main coupling bolts. i. Dismantle the coupling hubs by removing the attachment screws. ii. Mount the hubs on respective equipment shafts. iii. Position the equipment to the correct DBSE specified. iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance specified on the drawing. In case of variation to the specified axial shaft gap , refer to the specific instructions supplied, for using DBSE adjusting shims supplied with the unit. v. Clamp two dials on hub flanges as shown and align to within 0.05 mm of TIR. vi. Disassemble the gagging screws and remove the gagging bush from the position. Re assemble the gagging screws between the adaptor and spacer flanges. The transmission unit can now be compressed, by tightening the gagging screws, adequate to facilitate assembly. vii. Place the transmission unit into the position between the hubs ensuring that the spigot on hubs clears the locating diameter on the adaptor plates.
PREPARED SURESH
CHECKED SANKAR
APPROVED KVMR
DATE 18-06-2003


Page : 4 off 4
IMPORTANT : Slowly loosen & remove the gagging screws thus allowing the transmission unit to regain the original free length. Ensure that the gagging screws are NOT in position at the time of equipment trial run or continuous operation. Remove & store the gagging screws and bushes carefully for future use. viii. Re check the DBSE and radial run out values. Readjust if the same is found disturbed. ix. Tighten all attachment screws / bolts to the specified torque limit.
PREPARED SURESH
CHECKED SANKAR
APPROVED KVMR
DATE 18-06-2003
SECTION B
BOILER FEED PUMP
6. SUCTION STRAINER (CONICAL)
SP Patra
SECTION - C
CONDENSATE EXTRACTION PUMP TYPE : EN6J40/500
PART 4
EQUIPMENT DETAILS
SECTION - C
CONDENSATE EXTRACTION PUMP
LIST OF CONTENTS
CHAPTER 1 2 3 4
TITLE Description Operating Instructions Maintenance Instructions Sub-vendors Drawings / Instructions
SECTION C
CHAPTER 1
DESCRIPTION
LIST OF CONTENTS
1 2 3 3.1 3.2 3.3 3.4 3.5
General specification General Description Associated equipment Canister and foundation ring Discharge headpiece Motor Stool Stuffing box assembly Combined thrust and journal Bearing Assembly
3.6 4
Coupling Driving motor
CHAPTER 1 DESCRIPTION 1. GENERAL SPECIFICATION Pump Designation Type Number of Stages Number of Pump Set 2. GENERAL DESCRIPTION The condensate extraction pumps are of the vertical centrifugal canister type with the driving motor supported on a fabricated motor stool. The motor stool is supported on a fabricated head piece which is secured to a fabricated canister. The canister is secured to a foundation ring which is held to the floor with nuts on foundation bolts. The pump stage casings form an interconnected assembly which is attached to the underside of the headpiece and is suspended within the canister. The head piece is provided with a stuffing box which contains a mechanical seal to prevent pump leakage. Small bore pipe work, for sealing purpose, is connected to the stuffing box. The head piece also supports the water cooled oil lubricated thrust and journal bearing. The pump discharge branch and vent pipe are integral with the head piece and the pump suction branch is integral with the canister. The motor stool, secured to the top of the head piece, supports the driving motor. Cooling water pipe work along with the oil filling/vent pipe and gauge glass extension pipe are attached to the motor stool. Apertures formed on the motor stood and head piece provide access to the coupling, thrust bearing and mechanical seal. : : : : EN6J40/500 Vertical, canister 6 3
Each pump is driven by an electric motor mounted on the motor stool. The motor is supplied by BHEL, Bhopal/Hardwar. The motor shaft is connected to a top shaft via a flexible spacer coupling and the top shaft connects to the intermediate shaft via a solid muff coupling. The intermediate shaft in turn is connected to a bottom shaft through a muff coupling. The top shaft passes through the combined thrust and journal bearing and stuffing box, and also carries the fourth to sixth stage rotating assemblies. The intermediate shaft carries second and third stage rotating assemblies. The bottom shaft carries the first stage rotating assembly. The shafts are supported by two cutless rubber bearings at the first stage and by a single cutless rubber bearing at the second to sixth stages. The thrust bearing absorbs the downward axial thrust from the pump rotating assembly, and the white metal lined journal bearing with in the thrust bearing assembly supports the shafts along with the cutless rubber journal bearing within each intermediate stage assembly and element assembly. A snubber secured into the bottom of the canister engages the suction bell mouth fitted to the first stage casing. This arrangement provides support to the bottom end of the pump. 3. ASSOCIATED EQUIPMENT
3.1 Canister and Foundation Ring The canister is a fabricated tubular chamber formed with a dished bottom end which is closed by a snubber which is located and secured to the bottom of the canister by screws, tab-washers and dowels. Leakage between the canister and snubber is prevented by a joint, and a cylindrical extension of the snubber provides rigid support to the first stage pump casing assembly. A suction branch integral with the canister is positioned above floor level and a flange provided below the suction branch accommodates screws for securing the canister to the foundation ring. The canister top flange supports the discharge head piece.
The foundation ring is provided with holes for foundation bolts and tapped holes for canister securing screws. The foundation bolts and foundation ring are grouted to the floor. 3.2 Discharge Head piece The fabricated head piece, secured to the pump canister with screws, incorporates the discharge branch and supports the thrust bearing housing and motor stool. The head piece is sealed where the shaft passes through by a stuffing box which incorporates a mechanical seal. Small bore pipe work connects to the stuffing box, for inlet and outlet sealing water. The outlet pipe work, which returns the sealing water to the pump suction, is provided with two orifice plates. A vent pipe provided with a spigot flange is incorporated within the structure of the head piece for connecting to condenser. A Valve is provided for installing between the vent pipe and condenser. Tapped holes on the inner flange situated on the underside of the head piece provide location for the top rising main screws and holes drilled through the outlet of the outer flange provide location for screws which secure the head piece to the canister flange. Tapped holes provided on the inner flange situated on the topside of the head piece, provide location for the stuffing box securing screws. Tapped holes on the topside outer flange provide location for the motor stool securing bolts. Apertures formed on the head piece provide access to the stuffing box and are closed by wire mesh guards. Lugs are situated at the top of the headpiece for lifting purposes.
3.3
Motor Stool The fabricated motor stool is dowelled to the head piece and secured by bolts. A recess formed on the top flange of the motor stool locates the driving motor, which is secured with screws to the motor stool. Small bore pipe work is provided within the motor stool for thrust bearing inlet and outlet oil cooling water. A combined oil filler and vent pipe extends through the side of the motor stool. The thrust bearing oil level gauge glass is secured to a pipe which also extends through the side of the motor stool. Apertures formed on the motor stool provide access to the flexible spacer coupling and thrust bearing, and are closed by wire mesh guards.
3.4
Stuffing Box Assembly The stuffing box is secured to the head piece with
3.4.1 Mechanical Seal :
screws, leakages being prevented by a joint. The entry of pumped condensate at the underside of the stuffing box is restricted by a gap between a restriction bush, secured with screws to the stuffing box and a sleeve secured to the shaft with Loctite. The stationary seal face of the mechanical seal is retained by an O ring in the seal plate, and the rotating components of the mechanical seal are retained on a sleeve held by a retaining collar. The retaining collar is secured to the sleeve with grub screws and secured to the shaft with grub screws. The seal is of 'cartridge' type and seal setting is done by seal manufacturer at their works itself. The seal plate is spigot located and secured to the stuffing box with screws, leakage being prevented by an O ring. Tapped holes are provided on the seal plate for jacking screws, to assist with dismantling. Small bore pipe work connects to the seal plate to sealing water purposes.
Two additional orifice plates are supplied for each pump to be installed in clients small bore pipe work which connects to the common discharge. This feature enables an adequate flow of flushing water to be maintained at the stuffing box, during the time the pump is on standby. Further particulars for the mechanical seal are contained in Chapter 4. 3.5 Combined Thrust and Journal Bearing Assembly The combined thrust and journal, water cooled bearing assembly is mounted on the head piece and absorbs the pump hydraulic downward thrust, and takes the weight of the pump rotating assembly. The casing base plate is spigot-located on to an adaptor plate which also locates by spigot to the head piece. The casing base plate and adapter plate are secured together with nuts on studs, and the adaptor plate is secured to the head piece with screws. The thrust collar which is a tight fit and keyed on the shaft is retained against a shoulder on a shaft by the thrust collar nut. Tapped holes are provided on the collar for fitting and removal purposes. The thrust is absorbed by the white metal faced thrust pads fitted to the base plate, under the collar. White metal lined journal pads are fitted in the casing and locate the collar radially. The casing top is closed by a split cover secured to the casing with bolts, the halves of the split cover being secured together with nuts on fitted studs and nuts on bolts. Taped holes on the split covers facilitate eye-bolts for lifting and removal purposes. Provisions is also available for a temperature probe. Leakage between the split cover and casing is prevented by a joint. Leakage between the sleeve and the underside of the base plate is prevented by a joint. The bearing casing is supplied with inlet and outlet cooling water connections, an oil level gauge, a combined air vent and oil filler and an oil drain plug on the base plate. Tapped holes in the casing facilitate jacking screws for dismantling purposes.
Leakage between the casing and base plate is prevented by an O ring fitted in a groove machined in the base plate. For further particulars refer to the bearing manufacturers instructions contained in Chapter-4. 3.6 Couplings The drive from the motor to the top shaft is transmitted via a spacer type flexible coupling. Each half coupling is a tight fit and keyed to its respective shafts, the halves being connected by means of a spacer which interconnects via flexible membranes at each end. The coupling is designed to accommodate a certain amount of both offset and angular misalignment and also any free end float or vertical movement of the shafts. The top shaft half coupling abuts the thrust collar nut, and a recess machined in the bore of the top shaft half coupling accommodates a thrust plate which corresponds with the LEF button. For further particulars refer to the spacer coupling manufacturers instructions contained in chapter-4. 4.0 DRIVING MOTOR The vertical driving motor is mounted and secured to a spigot flange provided on the motor stool. For further particulars and information for the driving motor, refer to the motor manufacturers instructions not contained in this manual. The driving motor is supplied by BHEL, Bhopal/Hardwar.
SECTION - C
LIST OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8.
Introduction Pre-start checks Start-up Pump running checks Normal shut-down Preparing a pump for standby Stud-down when the pump is to be isolated Fault finding
INTRODUCTION The following operating instructions are applicable to the mentioned type of condensate extraction pumps, and should be read in conjunction with those for the operation of the pump driving motor and the station operating instructions. The pump driving motor, pump suction and discharge pipe work, valves and control equipment are not supplied by BHEL, Hyderabad therefore the installation should include all the necessary ancillary equipment to facilitate satisfactory operation and prevent any malfunction at an early stage. The three condensate extraction pumps are designed as 50% duty pumps and their normal mode of operation permits two pumps running, and one on standby. To obtain the maximum attainable working life, continuous running is recommended.
PRE-START CHECKS Following an overhaul or maintenance procedure, check that the following steps have been carried out along with the motor manufacturers instructions. (1) (2) Ensure that the power supply is available to the driving motor. Check the oil level in the thrust bearing gauge glass. Top up the thrust bearing, if necessary.
(3) (4) (5)
Ensure that the cooling water is available to the thrust bearing. Ensure that the sealing water is available to the stuffing box. Ensure that the pump discharge isolating valve is shut. If the pump is to be started with the discharge valve open, it is essential that the discharge line is full to prevent the pump running out of its characteristic, and imposing an overload on the driving motor.
CAUTION :
(6) (7) (8)
Ensure that the pump suction isolating valve is open. Ensure that the discharge pressure gauge isolating valve is open. Ensure that the valve on the air vent pipe to the condenser is open. The valve should be locked in the Open position.
START - UP (1) Ensure that the pre-start checks have been carried out. (a) The pump must not be started unless the canister is full of condensate. (b) The suction isolating valve must not be used for throttling the pump output: the discharge valve should be used for this purpose. (2) Refer to the motor manufacturers instructions and start the driving motor. Ensure that the motor direction of rotation is correct. CAUTION : The pump must not be run for an extended period with the discharge valve closed.
CAUTION :
(3)
Slowly open the discharge valve and fill the system pipe work with condensate. When the system pressure stabilizes fully open the discharge isolating valve.
(4)
Check the following readings if the appropriate instruments are available. (a) (b) (c) (d) Pump suction pressure. Pump discharge pressure. Pump suction temperature. Motor current. Refer to the motor manufacturers instructions.
(5) (6) (7) (8) 4
Check the oil level in the thrust bearing gauge glass. Check the mechanical seal for leakage. Check all joints above floor level for leaks. Check for any undue noise or vibration.
PUMP RUNNING CHECKS The following checks should be carried out at regular intervals :(1) Check that the following readings are normal if the appropriate instruments are available. (a) (b) (c) (d) (2) (3) Suction pressure. Discharge pressure. Suction temperature. Motor current. Refer to the motor manufacturers instructions.
Check the oil level in the thrust bearing gauge glass; top up if necessary. Check the mechanical seal for leakage.
(4) (5) (6) 5
Check all joints above floor level for leaks. Check the accessible fastenings for security. Check for any undue noise or vibration.
NORMAL SHUT-DOWN (1) Stop the pump driving motor. Refer to the motor manufacturers instructions. (2) (3) Shut the pump discharge isolating valve. Unlock and shut the valve on the air vent pipe to the condenser. Lock the valve. Note : Refer to the station operating instructions.
PREPARING A PUMP FOR STANDY If a duty pump should fail or extra duty is required, the standby pump should be ready for immediate start-up. To prepare a pump for standby, the following procedures must be carried out in conjunction manufacturers instructions and the station operating procedures. (1) (2) (3) Check the oil level in the thrust bearing gauge glass; top up if necessary. Ensure that cooling water is available to the thrust bearing. Ensure that sealing water is available to the mechanical seal. with the motor
Note : Constant sealing water is supplied to the stuffing box mechanical seal on each pump from the common discharge pipe work via small bore pipe work, which prevents the ingress of air when a pump is stationery. Two orifice plates are fitted in each set of small bore supply pipe work. (4) Ensure that the pump discharge isolating valve is shut.
CAUTION :
If the pump is to be started with the discharge valve open, it is essential that the discharge line is full to prevent the pump running out of its characteristic and imposing an overload on the driving motor.
(5) (6) (7) (8)
Ensure that the pump suction isolating valve is open. Ensure that the canister is full. Ensure that the discharge pressure gauge isolating valve is open. Unlock and open the valve on the air vent pipe to the condenser. Lock the valve in the open position.
SHUT-DOWN WHEN THE PUNP IS TO BE ISOLATED : (1) Stop the pump driving motor. Refer to the motor manufacturers instructions. (2) (3) (4) Shut the pump discharge isolating valve. Shut the pump suction isolating valve. Isolate the electrical power supply from the pump driving motor. Refer to the motor manufacturers instructions. (5) (6) (7) Isolate the cooling water supply to the thrust bearing. Isolate the sealing water supply to the mechanical seal. Unlock and shut the valve on the air vent pipe to the condenser. Lock the valve. Note : (8) Refer to the station operating instructions. Evacuate the accumulated condensate from the canister.
FAULT FINDING Symptom Possible Cause (a) Electrical supply to the driving motor isolated or faulty. Seizure of the pump or motor. Action Check the electrical supply. Refer to the motor manufacturers instructions. Remove the pump set. Disconnect the pump from the motor to establish locality and cause of seizure. Dismantle and renew the pump or motor components as necessary. Remove and examine thrust and journal bearings. Refer to Chapter 3. Check the motor and electrical supply. Refer to motor manufacturers instructions. Check the motor terminals at the starter. Refer to the motor manufacturers instructions. Check the valve. Remove the pump set, dismantle the pump and renew components as necessary, Refer Chapter 3.
(1)
Pump fails to start
(b)
(c)
Thrust and journal bearing seized. Motor power faulty.
(2)
Pump performance low
(a)
(b)
Incorrect rotation.
(c) (d)
Discharge valve not fully open. Excessive clearance between the impeller wear rings and casing wear rings.
(3)
Excessive noise and/or vibration
(a)
Pump or motor rotating assembly out of balance.
Dismantle the pump or motor and check components for dynamic balance. Refer to dynamic balance, Section 8.11, Chapter 3. Dismantle the thrust bearing and dismantle the pump and check the pump and shaft bushes; renew as necessary. Refer Chapter 3. Refer to the motor manufacturers instructions. Dismantle the pump and check for wear. Renew components as necessary. Refer to Chapter 3. Refer to the motor manufacturers instructions. Ensure that all accessible fastenings and corresponding pipe work are secure.
(b)
Journal bearing, thrust bearing, or bearing bushes on the pump, or bottom shaft worn. Journal bearings on the motor worn. Excessive wear of pump internals.
(c) (d)
(e) (f)
Excessive wear in motor internals. Securing arrangements loose.
SECTION - C CONDENSATE EXTRACTION PUMP CHAPTER 3 MAINTENANCE INSTRUCTIONS LIST OF CONTENTS 1 1.1 1.2 2 3 4 5 5.1 6 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 8.5 Tools Recommended lubricants Weights Maintenance procedures Examining the combined thrust and journal bearings Removing the driving motor Dismantling procedures Preparation prior to removing the motor stool, headpiece and pump Removing the motor stool, headpiece and pump. Dismantling the headpiece and pump Inspection and renewal Clearances Impellers Shaft sleeves and bearings Pump Shafts Combined thrust and journal bearing Introduction Periodic and preventive maintenance Routine checks
8.6 8.7 8.8 8.9 8.10 8.11 8.12 9 9.1 10 11 12 13
Mechanical seals Flexible couplings Keys Nuts, Bolts & studs Joints, O rings and locking device Dynamic balancing Cleanliness Assembling procedure Assembling the pump and head piece Installing pump, head piece and motor stool Installing the drive motor Final assembling and connection Parts identification
CHAPTER 3 MAINTENANCE INSTRUCTIONS 1 INTRODUCTION It is recommended that a system of routine inspection and maintenance is established during which the condition of the various components in the pump set can be determined and recorded for comparison with later inspections. Any defects should be repaired or the components renewed at the earliest opportunity. Certain inspections can only be made when the plant is shut down, but others can be made under operating conditions. It is essential that all lifting tackle and equipment is maintained in a serviceable condition and that safety rules and regulations are observed at all times. A high degree of cleanliness of the equipment and surrounding area should be maintained as this will assist in the detection of minor leaks and defects which, if unnoticed, could lead to more serious defects.
1.1
Periodic and Preventive Maintenance The following are the primary criteria for examination and renewal of wearing parts and it is recommended that these aspects are checked regularly during every shift. (1) Reduction in pump performance, ie., reduction in discharge pressure or a sustained increase in motor power consumption. (2) (3) Excessive vibration. Excessive leakage at the pump mechanical seal plate.
1.2
Routine Checks It is essential that the pump running check given in Chapter 2, Section 4, are carried out regularly. The checks concerned with the mechanical condition of the pump set are repeated here for the convenience of the maintenance engineers. (1) (2) (3) (4) (5) (6) (7) Check that the pump discharge pressure is normal. Check that the motor current is normal. Check the oil level in the thrust bearing gauge glass. Check the stuffing box for excessive leakage. Check the accessible joints for leaks. Check the accessible fastenings for security. Check for any undue noise or vibration.
TOOLS The following tools and equipment are available for use on the pumps. When not in use they should be safety stored. Any defects or shortages should be remedied at the earliest opportunity, otherwise maintenance and overhaul may be hindered. No. off 1 1 set 1 set Tool and Purpose C spanner for impeller nuts and muff coupling nuts. Withdrawal and fitting gear, thrust bearing. Withdrawal and fitting gear first stage.
RECOMMENDED LUBRICANTS
Refer to the thrust bearing manufacturers instructions in Chapter 5 for the recommended lubricant. 4 WEIGHTS Item Pump (less motor, canister and foundation ring) Rotating assembly Canister Foundation ring Head piece Shaft, bottom Impeller, 1st stage Impeller, 2nd to last stage Ring main, top. 7 stage Ring main bottom Suction bell mouth Casing, 1st stage Casing, intermediate 2nd stage Casing, last stage Shaft, top / intermediate Motor stool Weight, kg 5080 547 1920 145 1032 109 50 31 93 145 64 640 235 191 171 417
MAINTENANCE PROCEDURES
5.1
Examining the combined thrust and journal bearing Note : The following instructions should be read in conjunction with the thrust bearing manufacturers instructions contained in Chapter-4. (1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been carried out. (2) (3) Remove the access covers from the motor stool and headpiece. Remove the nuts and bolts and remove the spacer and membranes from the pump and motor half couplings. Note : The flanges of the spacer and half couplings should be marked in relation to each other for ease of assembling. (4) Remove the drain plug from the base plate and drain the oil from the thrust bearing. (5) (6) Remove the oil gauge glass and pipe extension to avoid any damage. Disconnect and remove the combined oil filler and vent pipe to avoid any damage. (7) (8) Remove the bearing inlet and outlet cooling water pipe work. Remove the bearing cover securing screws and remove the halves of the cover, with the cooler attached. Note : Tapped holes are provided in the cover for lifting purposes. (9) Unlock the lock-washers and remove the anti-vortex shroud securing screws. Raise the shrouds to gain access to the journal pads. (10) Remove the journal pads from the casing, by inserting a suitable screwed rod into the tapped hole provided on each journal pad. Carefully slide each pad around and out from the casing. (11) Examine the journal bearings. Refer to the bearing manufacturers instructions contained in Chapter-4. (12) Apply a film of oil to each journal and install the pads into location in the casing and around the shaft. Remove the temporary screwed rod from each journal pad.
(13)
Locate a temporary face plate on the pump shaft end and a similar temporary face plate on the motor shaft end. Secure each face plate to its respective shaft end with a center bolt.
(14)
Locate temporary bolts and nuts between the motor and pump half couplings.
Note :
Do not tighten the temporary nuts and bolts between the half couplings at this stage.
(15)
Remove the nuts securing the bearing casing and base plate to the adapter plate.
(16) (17)
Remove the access guards from the head piece. Disconnect the inlet and outlet mechanical seal sealing water pipe work. This will avoid any unnecessary strain and protect the seal, during any movement of the shaft, whilst examining the thrust pads.
(18)
Remove the screws on the seal plate and slacken the grub screws which lock the seal retaining collar and seal sleeve to the pump shaft.
Note : (19)
Check that the seal plate is free within its normal location. Insert starting screws into the tapped holes provided in the thrust bearing casing and carefully break the seal between the casing and base plate.
(20)
Tighten the nuts on the temporary bolts between the half couplings, and raise the shaft assembly by 8 mm, to ensure that the thrust collar is clear of the thrust pads.
(21)
Lift the thrust casing from the base plate to gain access to the thrust pads. Support the thrust casing on temporary supports placed between the base plate and casing. Remove the starting screws from the casing.
CAUTION : Avoid any damage to the O ring provided in the base plate.
(22)
With sufficient access available to the thrust pads, remove each pad from the groove formed in the base plate.
(23)
Examine the thrust pads. Refer to the bearing manufacturers instructions contained in Chapter-4.
(24)
Apply a film of oil to each thrust pad and install the pads into the place in the groove formed in the bas plate.
Note :
Ensure that the thrust pads are correctly fitted and prevented from rotating by means of the thrust pad stop.
(25)
Lift the thrust casing, remove the temporary supports and lower the casing onto the base plate.
(26)
Unscrew the nuts on the temporary bolts, between the half couplings and carefully lower the shaft assembly to return to its original position. The thrust collar will rest on the thrust pads.
(27) (28) (29)
Locate and secure the seal plate with the screw to the stuffing box. Secure the thrust casing to the base plate with the nuts on the studs. Locate the anti-vortex should into the thrust casing and secure it with the screws the new lock-washers to the casing. Lock the screws with their lock-washers.
(30)
Fit a new cover joint to the casing and locate and secure the cover halves, with attached cooler, to the casing with screws.
(31)
Install and connect the pipe extension and oil gauge glass to the casing assembly.
(32) (33) (34)
Fit the drain plug to the thrust bearing base plate Connect and secure the combined oil filler and vent pipe to the casing. Remove the combined air vent/oil filler and fill the bearing to the correct level with the recommended lubricant. Replace the combined air vent/oil filler.
(35) (36)
Connect and secure the bearing inlet and outlet cooling water pipe work. Remove the temporary nuts and bolts from the coupling halves and remove each temporary face plate from the pump and motor shaft ends.
(37)
Check the coupling alignment. Refer to the information contained in illustration P2424.
(38)
Ensure that the seal assembly is secured with its screws to the stuffing box. Refer to the instructions indicated on the seal drawing.
Note : The mechanical seal must be removed during the dismantling in Section and renewed during the assembling in Section 9. (39) Secure the inlet and outlet sealing water pipe work to the mechanical seal plate. (40) (41) Secure the access guards to the headpiece. Install and secure the coupling spacer and membranes to the respective pump and motor half couplings, with the nuts and bolts. Refer to the coupling manufacturers instructions in Chapter-4. (42) (43) Secure the access guards to the motor stool. Prepare the pump for start-up. Refer to Chapter-2, Operating Instructions, Section-2, Pre-Start Checks. 6 REMOVING THE DRIVING MOTOR Note : The following instructions should be read in conjunction with the motor manufacturers instructions. (1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been carried out. (2) Isolate and remove the electrical supply cables from the driving motor. Refer to the motor manufacturers instructions. (3) (4) Remove the access covers from the motor stool. Remove the nuts and bolts and remove the spacer and membranes from the pump and motor half couplings. Refer to the coupling manufacturers instructions in Chapter-4. Note : The flanges of the spacer and half couplings should be marked in relation to each other for ease of assembling.
(5)
Attach suitable lifting gear to the lifting lugs provided on the motor. Unscrew and remove the screws securing the motor to the motor stool, and carefully lift the motor from the motor stool with its half coupling attached.
(6) 7. 7.1
Lower the motor onto suitable supports and remove the lifting gear.
DISMANTLING PROCEDURES Preparation Prior to Removing the Motor Stool, Headpiece and Pump (1) Ensure that the procedures for removing the driving motor in Section 6 have been carried out. (2) Withdraw the half coupling from the pump top shaft with the withdrawal gear provided. Remove the half coupling key from the shaft and retain it. Refer to the coupling manufacturers instructions in Chapter-4. (3) Remove the oil drain plug from the thrust bearing and drain the oil into a suitable container. When the oil has drained replace the drain plug. Refer to the thrust bearing manufacturers instructions in Chapter-4. (4) Disconnect and remove the thrust bearing cooling water inlet and outlet pipe work. Remove the combined air vent/oil filler pipe work, oil level gauge associated pipe work and oil drain pipe work.
7.2
Remove the Motor Stool, Headpiece and Pump Note : Ensure that the preparation procedures have been carried out in Section 7.1. (1) Attach suitable lifting gear to the motor stool, then remove the motor stool securing screws and carefully remove the motor stool from the head piece. (2) (3) Remove the access covers from the headpiece. Disconnect and remove the inlet and outlet sealing water pipe work from the stuffing box. (4) Disconnect the seal assembly . Refer to the instructions given on the seal drawing.
(5) Note :
Remove the thrust collar lock-nut from the shaft with the spanner provided. As the lock-nut is unscrewed, the rotating assembly will gradually drop to its lowest position, with each impeller resting in its casing.
(6)
Remove the bearing cover securing screws and lift and remove the cover, with the cooler attached, to gain access to the internals of the thrust bearing. Remove and discard the cover joint.
Note : (7)
Tapped holes are provided in the cover for lifting purposes. Unlock the lock-washers and remove the anti-vortex shroud securing screws. Remove the shroud to gain access to the journal pads.
(8)
Remove the journal pads from the casing, by inserting a suitable screwed rod into the tapped hole provided on each pad. Carefully slide each pad around and out from the casing.
(9)
Attach suitable lifting gear to the thrust collar and with the withdrawal gear supplied withdraw the thrust collar from the shaft. Remove and retain the collar key. Lower the thrust collar onto supports and remove the lifting gear.
Note :
During removal of the thrust collar, ensure that the corresponding bearing faces are not damaged.
(10)
Remove the nuts from the studs securing the casing and base plate to the adaptor plate. Attach suitable lifting gear to the casing and remove the casing clear from the base plate and shaft.
(11) (12) (13)
Lower the casing onto suitable supports and remove the lifting gear. Remove the thrust pads from the groove formed in the base plate. Refer to the bearing manufacturers instructions in Chapter-4. Insert jacking screws into the tapped holes provided on the base plate. Screw in the jacking screws to separate the base plate from the adaptor plate. Lift the base plate away with the sleeve attached.
(14)
Remove the screw securing the sleeve to the base plate. Remove the sleeve and remove and discard the joint. Remove and discard the O ring from the base plate.
(15)
Remove the seal assembly from the stuffing box. Refer to the mechanical seal manufacturer's instructions on the seal drawing.
(16)
Remove the seal nut from the shaft and remove the seal plate from the stuffing box.
(17)
Remove the stuffing box securing screws and screw in jacking screws into the tapped holed provided. Attach suitable lifting gear and remove the stuffing box from the headpiece and shaft. Lower the stuffing box onto suitable supports and remove the lifting gear. Unlock-washers then remove the screws from the underside of the stuffing box and remove the restriction bush.
(18)
Remove the nuts and bolts securing the discharge branch to the discharge pipe work.
(19) (20)
Attach suitable lifting gear to the lugs provided on the head piece. Remove the screws securing the headpiece to the canister. With the lifting gear attached, carefully raise the headpiece and pump assembly from the canister. Remove and discard the joint. Cover the canister opening with a suitable temporary cover.
(21)
Transport the headpiece and pump assembly to a suitable maintenance area. Carefully lower and support the headpiece and pump assembly in the horizontal position.
CAUTION : The pump must not pivot on the first stage casing.
7.3
Dismantling the Head piece and pump: CAUTION : (a) The head piece, pump casing and rising mains must be supported on the horizontal position.
(b)
The pump top shaft must be suitably supported in the horizontal position.
(c)
Before dismantling the assembly, mark the headpiece, pump casings, rising mains and bell mouth to ensure correct assembly.
(1)
Before proceeding any further check the total axial travel as follows:(a) Push the pump shaft until it abuts at the suction end. Lay a straight edge across the face of the head piece, at the stuffing box adjoining face, and with a pencil scribe a line on the top shaft. (b) (c) Pull the pump shaft until it abuts at the discharge end. Lay the straight edge across the face of the head piece and scribe a second line on the top shaft. (d) Measure the distance between the two scribe lines which indicate the total axial travel of the rotating assembly.
Note : The correct total axial travel should measure 8 to10 mm. CAUTION : (2) The pump to shaft and casings must be supported.
Attach suitable lifting gear to the suction bell mouth, unlock the tab washers and remove the screws securing the bell mouth to the first stage pump casing, then lift the bell mouth clear off the pump shaft. Discard the tab-washers and the O ring. Lower the bell mouth on suitable supports and remove the lifting gear.
Note :
The bell mouth incorporates a casing wear ring and Cutless rubber bearing.
(3)
Release the lock-washer securing the shaft nut and using the special spanner supplied, remove the nut from the shaft. Discard the lock-washer.
(4) (5)
Remove the first stage bottom sleeve from the shaft. Attach lifting gear to the first stage impeller and withdraw the impeller from the pump shaft using the withdrawal gear supplied. Remove and retain the
impeller key. Lower the impeller onto suitable supports and remove the lifting gear. (6) Attach lifting gear to the first stage pump casing, unlock the tab-washers and remove the screws securing the first stage casing to the Element-I. Insert starting screws into the tapped holes provided in the first stage casing and tighten them to assist with removal of the casing. Move the first stage casing along and clear from the shaft. Remove and discard the O ring, and Lower the casing onto suitable supports. Remove the lifting gear. Note : The first stage casing incorporates a casing wear ring and a Cutless rubber bearing. (7) Remove the grub screws and remove the shaft tube from the first stage casing. Discard the O ring. (8) Remove the first stage top sleeve from the shaft.
Note : Support the shaft. 9) Attach lifting gear to Element-I, unlock the tab washers and remove the screws securing the Element-I to Element-II. Insert starting screws into the tapped holes provided in Element-I and tighten them to assist removal of the Element. Move the Element-I along and clear from the shaft. Remove and discard the 'O' ring and lower the casing onto suitable supports. Remove the lifting gear. Note : 10) The Element -I incorporates a cutless rubber bearing. Remove the grub screws and remove the shaft sleeve of Element-I. Remove and retain the sleeve key. 11) 12) Repeat step (9) to remove Element-II. Attach separate lifting gear to the bottom shaft. Remove the lock washer and slacken back the lock nut securing the bottom shaft to the muff coupling. Screw the coupling nut clear off the coupling, and withdraw the bottom shaft from the coupling and lift it away. Remove and retain the coupling key and shear ring halves.
Note : Support the intermediate shaft prior to withdrawal of bottom shaft. 13) 14) Repeat step (12) to withdraw the muff coupling from intermediate shaft. Repeat step (9) and (10) t remove Element-III.
Note : Support the intermediate shaft. Element-III incorporates a cutless rubber bearing. 15) Release the lock washer securing the second stage impeller nut, then using the special spanner provided, remove the nut. 16) Pull the shaft sleeves from the bottom of second stage impeller, remove and retain the sleeve keys. Note : Support the shaft. 17) Using the withdrawal gear supplied, withdraw the second stage impeller from the shaft, remove and retain the impeller key. 18) Attach lifting gear to the second stage pump casing, unlock the tab washers and remove the screws securing the second stage casing to the third stage casing, then remove the second stage casing from the shaft. Discard the tab-washers and the O ring. Note : The second stage casing incorporates a casing wear ring and a Cutless rubber bearing. 19) 20) Pull the intermediate sleeve from the shaft. Repeat Steps (17 to 19) to remove the third stage impeller and pump casing. 21) Attach lifting gear to the bottom rising main, unlock the tab-washers and remove the screws securing the rising main to the fourth stage pump casing. Lift the rising main clear off the shaft. Discard the tab-washers and the O ring. 22) Attach separate lifting gear to the intermediate shaft. Release the lockwasher and slacken back the lock-nut securing the bottom shaft to the muff coupling. Screw the coupling nut clear of the coupling, and withdraw the
intermediate shaft from the coupling and lift it away. Remove and retain the coupling key and the shear ring halves. 23) 24) Repeat step (22) to withdraw the muff coupling from the top shaft. Repeat steps (17) to (19) to remove the fifth and sixth stage impellers and pump casings. Note : 25) Continue to support the shaft. Attach a suitable lifting sling to the top shaft and remove it from the head piece. Lower the shaft onto suitable supports and remove the lifting sling. Note : 8. 8.1 The head piece should remain supported in the horizontal position.
INSPECTION AND RENEWAL Clearances (1) Refer to the sectional arrangement for details of clearances. It is recommended that when the pump internal diametrical clearances have reached twice the mean of the figures quoted or are expected to before the next overhaul, the component or components should be renewed. The main considerations, however, are pump performance and motor power consumption. (2) Casing wear rings and impeller wear rings are normally supplied undersize and oversize respectively on the wearing surfaces, so that they can be machined to give the appropriate clearance. Note : (a) The impeller wear rings are pressed on to the impellers and retained by grub screws, and the casing wear rings are pressed into their respective casings and also retained by grub screws. (b) if the impeller or casing wear rings require to be renewed the wear rings must be machined from the casing or impeller, and new wear rings pressed on and secured by grub screws. (4) A shaft sleeve fitted to the top shaft, in way of the mechanical seal, is held by loctite. If the sleeve has to be renewed it must be machined from the shaft and a new sleeve fitted and secured by loctite.
8.2
Impeller (1) (2) Examine the shaft sleeves for wear and damage. Renew as necessary. Ensure that the impeller wear rings are correctly fitted and secured.
8.3
Shaft Sleeves and Bearings (1) (2) Examine the shaft sleeves for wear and damage. Renew as necessary. Examine the journal bearings from wear and damage. Renew as necessary. Refer to Section 8.1 Step (4).
8.4
Pump Shafts Examine the shafts for damage or bowing and check for concentricity. Each shaft must be within 0.05 mm full indicator movement.
8.5
Combined Thrust and Journal Bearing Refer to the manufacturers instructions in Chapter 4.
8.6
Mechanical Seal (1) Renew the mechanical seal. Refer to the seal manufacturers instructions in Chapter-4. (2) (3) Check that the water passageways formed on the seal plate are clear. Examine the stuffing box restriction bush. Renew as necessary.
8.7
Flexible Coupling Refer to the manufacturers instructions in Chapter-4.
8.8
Keys All keys must be a good fit in their keyways and reference marks must be clearly legible. They must be flat, parallel and free from burrs. Worn or damaged keys must be renewed.
8.9
Nuts, Bolts and Studs
Examine all studs, nuts and bolts for damage or deterioration. Renew as necessary. 8.10 Joints, O Rings and Locking Devices All joints O rings and locking devices must be renewed on assembly. 8.11 Dynamic Balance If any of the impellers or the coupling hub are renewed, it should be noted that the new components are dynamically balanced during manufacture. If, however, the dynamic balance of any components is checked and is found to be out with the limit of 2835 M/N g cm per plane of measurement, the following rules must be adhered to when removing metal to effect the balance. Note M = weight of the component (kg) N = pump speed (rev/min) CAUTION : (1) The thickness of the impeller shroud must not be reduced by more than 1.6 mm at any point. (2) No meal is to be removed from the impeller within 12.7 mm of its periphery. (3) The weight of metal to be removed is to be calculated in the from of segment, the arc length of which does not exceed 0.1 of the circumstance of the impeller. (4) If the amount of metal to be removed exceeds the limits imposed by (1) and (3), BHEL, Hyderabad, should be consulted. 8.12 Cleanliness All components must be perfectly clean and free from burrs, and all water passages must be cleaned out before the pump is assembled. Check that all small bore pipe work is clear. 9 9.1 ASSEMBLING PROCEDURES Assembling the Pump and Head piece
During assembly, it is recommended that colloidal graphite or similar is applied to the shaft and bores of the impeller and shaft sleeves, allowed to dry and then polished. CAUTION : The pump shaft and casings must be suitably supported in the horizontal position whilst assembling the pump. Note : (a) The following torque figures must be used when assembling the pump:Sixth stage casing to head piece. First to third and fourth to last stage castings, inclusive 700 Nm 1350 Nm
Bottom rising main to third and fourth stage casing Bell mouth to first stage casing Head piece to canister Motor stool to head piece (b)
140 Nm 50 Nm 290 Nm 220 Nm
Observe the match marks made prior to dismantling to ensure correct assembly.
(1) (2)
Ensure that the head piece is supported in the horizontal position. Install the last stage shaft sleeve on the top shaft, to abut the sleeve fitted on the shaft by loctite.
(3)
Attach lifting gear to the top shaft, and carefully install the shaft in the head piece. Support the shaft and remove the lifting gear.
Note :
When installing the sixth stage casing, adjust the top shaft supports to the ensure that the shaft is supported at all times.
(4)
Locate a new O ring on the spigot of the last stage pump casing, attach lifting gear and install the casing on the top rising main. Secure the pump casing to the rising main with the screws and new tab-washers.
Note :
(a)
Observe the note following Step (4).
(b)
When installing the pump casing, ensure that the Cutless rubber journal bearing does not become damaged.
(c) (6)
Do not bend over the lock-washer tabs meantime.
Install the sixth stage impeller key in the shaft, then install the impeller on the shaft, to locate on the key and abut the last stage shaft sleeve.
(7)
Repeat Steps (5) and (6) to install the fifth and fourth stage pump casing and impellers.
(8)
Screw the impeller nut onto the shaft and, using the special spanner provided, tighten the nut against the hub of the fifth stage impeller.
(9)
Before proceeding further, check the total axial travel as follows :(a) Push the pump shaft until it abuts at the suction end. Lay a straight edge across the face of the head piece, at the stuffing box adjoining face, and with a pencil scribe a line on the top shaft. (b) Pull the pump shaft until it abuts at the discharge end. Lay the straight edge across the face of the head piece and scribe a second line on the top shaft. (c) Measure the distance between the two scribed lines which indicate the total axial travel to the rotating assembly. (e) The total axial travel is 8 to 10 mm, and if this is not achieved, the cause must be established and the fault must be corrected before proceeding.
(10)
Slide the muff coupling nut, lock-nut and a new lock-washer onto the top shaft, beyond the shear ring groove in the shaft, then install the shear ring halves in the groove, and the coupling key in the shaft.
(11)
Slide the coupling sleeve onto the shaft, to abut the shear ring, then screw the coupling nut into the bore of the sleeve. Tighten the nut to pull the sleeve hard against the shear ring and secure it with the lock-nut and lockwasher.
(12)
Install the muff coupling nut, lock-nut, new lock-washer, shear ring halves and coupling key on the bottom shaft as described in Step (8). Sling the bottom shaft and install it in the muff coupling sleeve, ensuring that the spigot on the shaft end engages in the recess in the end of the top shaft. Tighten and lock the coupling nut as described in Step (9). Support the bottom shaft and remove the lifting gear.
(13)
Install the bottom rising main as described in step (4), then install the third and second stage pump casings and impellers as described in Steps (6) to (7). Continue to support the bottom shaft and the pump casings.
(14)
Install the sleeve keys on the shaft, at the bottom of the second stage impeller. Install the sleeves to locate on the keys and abut the second stage impeller.
(15)
Repeat steps (8), (9) and (5) to assemble impeller, nut, check total float and assemble Element-IV.
(16)
Install the sleeve keys of Element-III on the shaft. Install the sleeve to locate on the key and abut the shoulder on the shaft. Lock the sleeve on to the shaft with grub screws provided.
(17) (18)
Repeat steps (10,11 &12) to assemble the muff coupling and bottom shaft. With the total axial travel checked, and corrected as necessary, bend over the tabs on the tab-washers on all the pump casing screws, stages 2 to 6.
(19)
Ensure that the first stage shaft tube is in place in the first stage pump casing, with new O rings, then locate a new O ring on the spigot of the first stage casing.
(20)
Sling the first stage pump casing and carefully install it over the shaft, to locate on the second stage casing, and secure it with the screws and new tab-washers. Do not bend over the washer tabs meantime.
(21)
Install the first stage top sleeve on the shaft, to abut the shoulder on the shaft, and locate the first stage impeller key in the keyway in the shaft.
(22)
Sling the first stage impeller and install it on the shaft, to abut the first stage top sleeve.
Note : Ensure that the direction of rotation of the impeller is correct. (23) Install the first stage bottom sleeve on the shaft and secure the assembly with the shaft nut and new lock-washer. (24) Install the bell mouth on the first stage casing, with a new O ring, and secure it with the screws and new tab-washers. (25) Check the total axial travel as described in Step (9) then bend over the tabs on the lock-washers. 10 INSTALLING PUMP, HEAD PIECE AND MOTOR STOOL (1) Attach suitable lifting gear to the lugs on the head piece. Carefully lift the head piece and pump from the horizontal to the vertical position and use adequate supports as necessary. CAUTION : Care must be exercised to ensure that the pump does not pivot on the first stage casing or attached bell mouth. Ensure that the pump is supported thus avoiding the possibility of bowing. (2) (3) Remove the temporary cover from the canister. Lower the pump and head piece into the canister and ensure that the pump discharge pipe is in line with the corresponding discharge pipe work. Continue to lower the assembly until the head piece rests on the canister. Ensure that the suction bell mouth is engaged on the snubber within the canister and that the holes in the head piece correspond with the holes in the canister. (4) Secure the headpiece to the canister with the screws and remove the lifting gear from the head piece.
(5) (6)
Secure the pump discharge pipe work to the pump discharge branch. Secure the restriction bush with screws and lock-washers to the underside of the stuffing box or seal housing.
(7)
Locate the seal sleeve key in the key way in the shaft, and secure it with the countersunk screw.
(8)
Install the mechanical seal. Refer seal manufacturer's instructions on the seal drawing.
Note : The mechanical seal is of cartridge design. CAUTION : Do not tighten the seal plate securing screws at this stage. (a) Screw the seal sleeve nut and the lock-nut/thrower onto the shaft and leave loose meantime. (9) Locate and secure the adaptor plate with screw to the top of the head piece. Note : During manufacture of the pump set, the adapter plate is machined to a specific thickness and locates between the thrust bearing base plate and headpiece. The adaptor plate determines the position of the rotating assembly when the thrust bearing is assembled. (10) Fit a new joint to the sleeve and insert the sleeve into the thrust bearing base plate. Secure the sleeve to the base plate with the screws and fit a new O ring to the base plate. Refer to the bearing manufacturers instructions. (11) Note : Lift the bearing base plate onto the adaptor plate studs. Ensure that the drain hole on the base plate is positioned to accommodate the drain pipe work. When the motor stool is assembled.
(12)
Apply a film of oil to the thrust pads and insert the thrust pads onto the base plate and move the pads around the groove to abut the pad stop. Refer to the bearing manufacturers instructions.
(13) (14)
Lift the bearing casing onto the base plate. Secure the bearing casing and base plate to the adaptor plate with nuts on the adaptor plate studs.
Note :
Ensure that the casing is located to accommodate the corresponding oil level gauge pipe work.
(15)
Fit the collar key to the shaft and attach suitable lifting gear to the thrust collar. Engage the collar onto the shaft and with the use of the assembly gear fit the collar to the shaft. Remove the assembly gear.
(16)
Screw the thrust collar nut onto the haft, to abut the thrust collar, then using the special spanner provided, tighten the nut to raise the pump shaft into its corrected running position.
(17)
Apply a film of oil to the journal pads and locate the journal pads, between the casing and collar. Locate the journal pads by inserting a screwed rod into the tapped hole provided in each pad. Remove the screwed rod.
(18)
Locate and secure the anti-vortex shroud with lock-washers and screws to the casing. Tighten the screws and secure the screws with the lockwashers.
(19)
Fit a new cover joint to the casing. Install the cover with attached cooler. Secure the cover to the casing with screws. Refer to the bearing manufacturers instructions.
Note :
(a)
Tapped holes are provided in the cover for lifting purposes.
(b)
Ensure that the cover is located in the casing to accommodate the corresponding cooling water small bore pipe work.
(20)
Fit the half coupling to the shaft. Attach suitable lifting gear to the half coupling and lift the half coupling on the shaft to abut the thrust collar nut, using the assembly gear supplied. Remove the assembly gear from the half coupling.
(21)
Tighten the seal plate securing screws. Tighten the grub screws in the seal sleeve until they contact the shaft. Disengage the eccentric washers / assembly fixture from the seal sleeve. Mechanical seal is of cartridge design. Refer to the seal manufacturer's drawings / instructions.
(22) (23)
Secure the inlet and outlet sealing water pipe work to the stuffing box. Attach suitable lifting gear to the motor stool and lift the motor stool onto the spigot flange provided on the headpiece.
Note :
Ensure that the motor stool is positioned on the headpiece to accommodate cooling water, oil level, oil filling pipe work and oil drain pipe work associated with the thrust and journal bearing.
(24)
Secure the motor stool with the screws and remove the lifting gear from the motor stool.
(25)
Connect and secure the thrust bearing cooling water inlet and outlet pipe work, oil filter and air vent pipe work, oil level pipe work and gauge. Fit the oil drain pipe work to the thrust bearing and fit the drain plug.
(26)
Fill the thrust bearing to the correct level with the recommended lubricant. Refer to the thrust bearing manufacturers instructions.
11.
INSTALLING THE DRIVING MOTOR Note : The following instructions should be read in conjunction with the motor manufacturers instructions. (1) Ensure that the motor half coupling is fitted. Refer to the coupling manufacturers drawings / instructions. (2) Attach suitable lifting gear to the lifting hooks provided on the motor. Lift the motor onto the motor stool. Note : Ensure that the motor is positioned on the stool to accommodate the associated supply cables and cooling water pipe work, etc. (3) Secure the motor to the stool with the nuts and bolts, and remove the lifting gear. (4) Check the alignment between the pump and motor half couplings. Refer to illustration for Checking coupling alignment. (5) With the coupling alignment checked and satisfactory, assemble the coupling spacer and membranes. Note : The flanges of the spacer and half couplings were previously marked in relation to each other for assembly purposes. Ensure that the marks on the flanges coincide. (6) Secure the half couplings, spacer and membranes with the nuts and bolts. Refer to the coupling manufacturers drawings / instructions. (7) Secure the access covers to the motor stool.
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FINAL ASSEMBLING AND CONNECTION
(1) (2) (3) (4)
Connect and secure the air vent pipe to the pump. Ensure that the cooling water is available to the thrust bearing. Ensure that the sealing water is available to the stuffing box. Connect and secure the electrical power supply cables to the driving motor. Refer to the motor manufacturers instructions.
(5)
Return all tools and lifting gear to their storage area. Refer to Chapter 2 and carry out the Pre-start checks.
13.
PARTS IDENTIFICATION When ordering spare parts reference must be made to the pump Serial or Job Number, Nomenclature, the Sectional Arrangement Drawing, the Item Number, and the Quantity of each components.
SECTION C
CHAPTER 4
SUB-VENDORS DRAWINGS / INSTRUCTIONS
1 2 3 4
Mechanical Seal Connecting coupling Thrust & Journal Bearing Suction Strainer
SECTION C
1. MECHANICAL SEAL
OPERATING MANUAL
NO.
OPERATING MANUAL FOR
BURGMANN MECHANICAL SEAL (M.S.)
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TABLE OF CONTENTS
Foreword General Information Product Information Manufacturer and country of origin Declaration Type Designation Operating Conditions Designated Use Description and Function Required Space, connecting dimensions Drawings, Diagrams Safety Notes 6 Transport, Storage and Installation Packing and Storage Preparation for Assembly Special Instructions Installation Directives in case of Failure Servicing Tungsten Carbide Designs Circulation Buffer Fluid After Sales Service by BURGMANN Disposal of Burgmann Mechanical Seal Copyright
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1 2 3-5 3 3 3 3 4 4 4 4
2.3 2.4 2.5 2.6 2.7 2.8
3 4. 4.1 4.2 4.3 4.4 4.5
5- 9 6 6-7 8 9 9 10 - 13 10 10 10 10-12 12 13
5. 5.1 5.2 5.3 5.4 5.5 6.
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FOREWORD
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Dear Sir,
Thank you for purchasing the Burgmann Mechanical Seal (M.S.). We at Burgmann are confident that your new purchase will greatly expand your working capacity and efficiency. This Operating Manual shows you how to get the most out of your new Burgmann Mechanical Seal (M.S.). Whether you are installing, operating or servicing, this manual will show you how to do it - quickly and easily. Please take some time to go through this manual before installation. You don't have to read it all at once. We just want you to know what a great Mechanical Seal (M.S.). you have. We've taken a great deal of care in preparing this manual so that you will never be left wondering how to perform a certain function. Nevertheless, even after reading this manual if you still aren't sure about something, please feel free to contact your nearest sales or service center of Burgmann or our HQ. We shall be too glad to answer your queries.
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BURGMANN
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1. GENERAL INFORMATION
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DESCRIPTION Customer Machine Manufacturer Customer PO No. Drawing Nos. Burgmann W.O.
DETAILS Bharat Heavy Electricals Ltd B.H.E.L
III IV V
F6 04 D989 09-H75N/100-E3
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2.1 MANUFACTURER AND COUNTRY OF ORIGIN
BURGMANN INDIA PVT. LTD. A. K. Industrial Estate, Veer Savarkar Flyover, Goregaon (West), Mumbai-400 062. INDIA.
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2.2 DECLARATION within the meaning of the EC-directive >> MACHINERY << A mechanical seal does not function independently. It is intended to be incorporated into or assembled with machinery.
2.3 TYPE DESIGNATION

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MECHANICAL SEAL DRG. NO. : 09-H75N/100-E3 The materials of the mechanical seal depend on the application and are fixed in the order. They may vary from those stated in the drawing.
2.4 OPERATING CONDITIONS

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MECHANICAL SEAL DRG. NO. : 09-H75N/100-E3 Kind of Machine Medium to be sealed Suction Pr. Discharge Pr. Temperature Max.
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: -:: FULL VACUUM : 3 Kg/cm2 : 200O C : 1000 RPM
Speed
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2.5 DESIGNATED USE This mechanical seal is exclusively designed for the use in the specified machine. A different utilisation or a utilisation going beyond the specification is considered contrary to its designated use and excludes a liability by the manufacturer. Operation under conditions lying outside those limits stated in paragraph >> operating data << is considered contrary to its designated use. Should the seal be operated under different conditions or at a different application BURGMANN has to be asked for recognition as safe in advance.
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2.6 DESCRIPTION AND FUNCTION

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The BURGMANN Mechanical Seal mentioned in clause 2.3 & 2.4 has been supplied in cartridge construction, in this, the seal can be installed directly on the pump casing without any adjustment. The seal forms a pre-mounted unit (seal cartridge), asembled at works, ready to be installed without any adjustment. Assembly Fixtures (24) are provided for holding the cartridge in one piece during transport, storage, assembly and disassembly.
2.7 REQUIRED SPACE, CONNECTING DIMENSIONS

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The connecting dimensions of the Mechanical Seal were checked and approved by the customer on the main drawing.
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The available mounting space given by the machine was decisive for the design of the gland parts of Mechanical Seal. The connecting dimension was checked before shipment with regard to the BURGMANN drawing. 2.8 DRAWINGS, DIAGRAMS Assembly drawing Nos.
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09-H75N/100-E3
The assembly drawing in the original scale and in its latest edition (latest revision) only is decisive for the design and use. In the following description all figures in parentheses, e.g.(2) define the respective part item no. in the assembly drawing.
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3. SAFETY NOTES
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Any person at the user's shop being involved in assembly, disassembly, operation and maintenance of the BURGMANN Mechanical Seal must have read and understood this Instruction Manual and in particular the safety notes. We recommend the user to have this confirmed.
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BURGMANN Mechanical Seals are manufactured on a high quality level (ISO 9001) and they keep a high working reliability. Yet, if they are not operated within their intended purpose or handled inexpertly by untrained personnel they may cause risks.
The user is asked to check as part of his security program what effects a failure of the Mechanical Seal might have on the environment and what additional safety measures have to be taken to prevent personal injury.
Any operation mode that affects the operational safety of the mechanical seal is not permitted.
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TRANSPORT / STORAGE / INSTALLATION
4.1 PACKING AND STORAGE
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If not specified differently in the order the BURGMANN standard packaging is used, suited for dry transport by truck, train or plane. The signs and notes for handling on the packaging have to be observed. Notes for incoming inspection Check packaging for visible damages. Open packaging carefully. do not damage or lose parts supplied separately Check if consignment is complete (delivery note). Inform the supplier immediately in writing if parts are damaged or missing. These recommendations apply to all BURGMANN mechanical seals which have been supplied and stored in their undamaged original packaging, as well as to seals which have been installed in a component of a plant. (e.g. pump, compressor, etc.) but have not yet been put into operation. A preservation of the BURGMANN mechanical seals is not necessary. Do not use corrosion protection agents. There is the risk of deposition or chemical attack of the elastomeric secondary seals.
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Check in case of a preservation of complete plants with mechanical seals installed: the compatibility of the chosen preservation agent with the seal materials and with the elastomers no impairment of the seal's axial movability by conglutination or by gumming Sliding materials and elastomers are subject to material-specific and time-based alterations (distortion, ageing) which might reduce the full efficiency of the seals. yet, this may be avoided by observing the storage instructions. Damages caused by improper storage may not be claimed on the BURGMANN company with regard to their warranty. Store the seal in the original packing lying on a flat surface.
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The mechanical seals have to be stored in dry, dustfree, moderately ventilated and tempered rooms. We recommend : relative air humidity below 65%, temperature between 15oC and 25oC.
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4.1 PACKING AND STORAGE ( cont....) Direct exposure of the mechanical seal to heat (sun, heating) as well as to ozone, present or produced by ultraviolet light (halogen or fluorescent lamps), must be avoided because of the risk of embrittlement of elastomeric materials. Check the mechanical seal: after a storage period of approximately 4 years after a damage of the packaging after a shock on the mechanical seal (e.g. by dropping the packed seal) at the manufacturer's or at the nearest service centre.
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4.2 PREPARATION FOR ASSEMBLY General Instructions Utmost care must be taken to ensure cleanliness during assembly; it is especially important to avoid damage to the elastomers. - Observe the assembly dimensions. - Observe the axial run-out and concentricity tolerances as stated in the valid design manual.
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All the shoulders over which elastomers are to be pushed must be chamfered by 2mm x 30. Their surfaces must be free of any damages and their edges rounded off. - The shaft must show the following surface roughness values in the vicinity of radial sealing elements : (Dynamic sealing part (spring loaded unit of the seal) Ra 1.0.m. Static seal part of Ra 2.5.m) - For cartridge seals, the seal can be assembled directly after taking precautions on the shaft. - Profile rings of Statotherm can only be deformed axially (radial deformation results in destruction). - To reduce frictional forces during assembly of the seal, the shaft is thinly lubricated with oil or silicon grease in the zone of the seal rings. Warning : This does not apply to rubber bellows seals. Warning : In the electric dip-painting range the O-rings must be free from silicon grease and must be mounted free from silicon grease. Warning : Under no circumstances must O-rings made of Ethylene Propylene rubber come into contact with mineral oil or grease. It is recommended to use silicon grease. - Never cover the sliding faces with a lubricant as they must be assembled completely dry, clean and dust-free. - When pressing in stationery seals, make sure that the pressure distribution is uniform. The O-ring must be fitted using water or alcohol only. - For heat dissipation and lubrication of single-acting mechanical seals, there should be a recirculation from pump discharge to seal. This measure prevents medium deposits in the sealing area. - Thoroughly vent the stuffing box before starting and remove the assembly fixture before start-up. In the event of any particular problems, please contact Burgmann India, or one of our sales/service offices in your area.
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4.3 SPECIAL INSTRUCTIONS The Burgmann mechanical seals H75N are independent of the direction of rotation. The set screws with cup points must be renewed after every dismounting; they must be fastened with Loctite Nr. 241 or a similar Product. 4.4 INSTALLATION All steps on (in) which the seal is to be mounted should have a 2 x 30 bevel and all sharp edges should be chamfered. The shaft surface should be smooth machined and ground in the areas where radial seal elements are to be located (R = 2.5.m.) The nutation of the shaft should not exceed 100 .m. and although the seal can absorb slight vibration, sources of vibration should be eliminated. Extreme cleanliness must be observed during installation, and damage to the seal faces and mounting rings must be avoided. The O-rings may be oiled to reduce friction, during installation of the seal. EP-rubber O-rings are an exception, however, and should not come into contact with oil or grease; In this case lubrication with glycerine or water is recommended. Special care must be taken when mounting O-rings of doublePTFE-coated elastomers; apart from having a 2 x 30 mm bevel, all edges should be deburred and rounded. When mounting O-rings of double PTFE-coated elastomers care must be taken to position the rings with the butt of the outer coating facing away from the direction of installation, otherwise splitting or stripping of the coating is possible.
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Crowned drive pins must be replaced whenever the seal is dismantled. During insertion of the stationary seats, especially those of special carbon, care must be taken to exert pressure evenly. 4.5 DIRECTIVES IN CASE OF FAILURE Try to define the kind of failure and record it and immediately contact Burgmann India or nearest BURGMANN Service Centre.
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During the warranty period the mechanical seal must only be disassembled or removed with BURGMANN's approval or when a BURGMANN representative is present.
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5.1 TUNGSTEN CARBIDE DESIGNS

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5
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Are extremely wear resistant but have poor emergency running properties. For this reason provisions must be made to ensure lubrication. 5.2 CIRCULATION To reduce frictional heat and prevent sedimentation in the seal faces a circulation line from the discharge of the pump to the seal stuffing-box necessary. Normally a -inch pipe is sufficient.
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5.3 BUFFER FLUID When operating double mechanical seals care must be taken to ensure circulation of the buffer fluid. The pressure of the buffer fluid should be 1.5--2 bar higher than the internal pressure and the rate of flow should be adjusted so that the outlet temperature dose not exceed 60C. The outlet must be located at the highest point of the stuffing-box to prevent bubble formation.
If you have any special problems please contact BURGMANN Head Quarters or the corresponding sales/service office in your area. 5.4 AFTER-SALES SERVICE BY BURGMANN The range of services offered by Burgmann not only includes advice during the planning stages but also technical support after commissioning. This is support by a world comprehensive network of subsidaries, field engineers and service centres.
MUMBAI (HEAD QUARTERS)

BURGMANN INDIA PVT. LTD. A.K.INDUSTRIAL ESTATE, VEER SAVARKAR FLYOVER, GOREGAON(WEST) MUMBAI-400 062. TEL: 022-28741534 FAX: 022-28748810. SG
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SERVICE CENTRES
BANGALORE 3390/41,3rd Cross,5th Main, RPC Layout,Vijayanagar, Bangalore 560 040. Tele Fax : 080-23305137 Email : bangalore@burgmannmail.com BARODA 17-A Nutan Bharat Society, Near Nutan Bharat Club, Alkapuri, Baroda 390 007. Tel. : 0265 233 9151 Fax. : 0265 233 9149 Email: baroda@burgmannmail.com COCHIN 34/749A, Thrikkovil Road, Edapally,Cochin 682 024. Kerala, India. Telefax. : 0484 2331 708 Email : cochin@burgmannmail.com
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CHENNAI N Block, New No. 5,Old No.320, 25 Street, Anna Nagar (East), Chennai 600 102. Telefax.: 044 2620 6968. Touchtel : 52020649 Email : chennai@burgmannmail.com DELHI 40/55, 1st Floor, Chittaranjan Park, New Delhi 110 019. Tel : 011 2642 2533, 011 2648 3347 Fax : 011 2648 3275 Email : delhi@burgmannmail.com KOLKATA 903-Krishna, 224 Acharya Jagdish Chandra Bose Road, Kolkata 700 017. Tel. : 033 2240 9829 Fax : 033 2240 6480 Email : kolkata@burgmannmail.com
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HYDERABAD 5D, Dhruvatara Apartments, Amruta Estate, Somajiguda, Hyderabad 500 482. Telefax : 040 2331 6577 Email: hyderabad@burgmannmail.com
KOTA Ashirwad Pearl,10-F-12, Flat No. S1,Parijat Scheme Mahaveer Nagar III, Kota, Rajasthan, Kota 324 005. Telefax : 0744 247 6537 Tele/Answering Machine 0744 3090472 Email : kota@burgmannmail.com VISAKHAPATNAM Flat No. 301, Eswar Homes, 3rd Floor, 1st Lane, Dwarakanagar, Visakhapatnam 530 016. Telefax: 0891 254 0360 Tele : 0891 551 6503 Email : vizag@burgmannmail.com
PUNE H 198, Mantri Market, Pune Solapur Road, Hadapsar, Pune 411 028. Telefax : 020 2682 1713 Email : pune@burgmannmail.com
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MUMBAI Excl Industrial Products Pvt. Ltd., A.K. Industrial Estate, Veer Savarkar Flyover, S.V.Road, Goregaon (W), Mumbai 400 062. Telefax: 022 2877 6896 Email : exclmum@burgmannmail.com PUNE Excl Industrial Products Pvt. Ltd., C 2, Amar Enclave, Opp. A.S.P.T. Wanowire, Pune Solapur Road, Hadapsar, Pune 411 013. Tel. : 020 2681 6646/4024366/2682 1943 Fax. : 020 2687 7000 Email : info@ burgmannmail.com PANVEL Excl Industrial Products Pvt. Ltd., 1st Floor, Om Hari Darshan Apts., Plot No. 34, V. M. Road, Sector 1, Opp. CIDCO Office, New Panvel 410 206. Telefax : 022 2746 9152/3958 1948 Email : excl@burgmannmail.com
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SURAT Excl Industrial Products Pvt. Ltd., B 1/14, Vishal Nagar, Near Gujarat Gas Circle, Above Vijay Dairy, Adajan Road, Surat 395 009. Telefax: 0261 269 3538 Email : exclsurat@ burgmannmail.com
5.7
DISPOSAL OF BURGMANN MECHANICAL SEAL Usually, the BURGMANN mechanical seals can be easily disposed after a thorough cleaning. Metal parts (steels, stainless steels, non-ferrous heavy metals divided into the different groups belong to scrap metal waste.
- Synthetic materials/ plastics ( elastomers, PTFE )special waste. - Attention ! Material containing fluorine must not be burnt. Some synthetic materials divided into the different groups can be recycled. - Ceramic materials (synthetic carbons, ceramics, carbides ) belong to waste products. They can be separated from their housing materials, as they are physiologically recognised as safe.
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6. COPYRIGHT BURGMANN has a copy right in this manual. Buyer, planner and user of the product are authorised for use in connection with further documentation. We reserve the right to carry out technical modifications which might become necessary to improve our products but are not mentioned in this manual yet.
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SECTION C
2. CONNECTING COUPLING
INSTALLATION, OPERATION & MAINTENANCE MANUAL OF CONNECTING COUPLINGS (FOR CONDENSATE EXTRACTION PUMP)
COUPLING TYPE : 8GBL-200
PROJECT : 500 MW THERMAL POWER PLANTS
CONTENTS GENERAL NOTES (DOS & DONTS)
DESCRIPTION OF COUPLINGS/OPERATING CONDITONS INSTALLATION INSTRUCTIONS MAINTENANCE INSTRUCTIONS ALIGNMENT INSTRUCTIONS
COUPLING ASSEMBLY DRAWING
INSTALLATION, OPERATION & MAINTENANCE MANUAL
GENERAL NOTES It is essential that all the instructions contained in the following documents be carried out by a competent person. Should any problems be anticipated or encountered then Euroflex Transmissions personnel are available for site visits or, alternatively, repairs and overhauls can be undertaken in our works. Prior to performing any maintenance work (including inspections) it is essential that the power supply is isolated and that no accidental movement of rotating machinery is possible. This product is designed for a specific purpose. It is vital that it is not used for any purpose other than that for which it is designed and supplied, and that the limits of its capacities, as detailed here or in any other document, are not exceeded. No liability will be accepted and any other warranty, either expressed or implied, will be null and void should any component of whatever kind, including nuts, bolts and washers, be used in the assembly, or modifications be made to all or part of the product which are not supplied, specified or agreed by Euroflex Transmissions.
DOS The following instructions should be read and understood prior to starting any assembly or maintenance work on the disc coupling. Prior to filling any component, care should be taken to ensure that it is clean and free from any dirt. Where hub/shaft connections require a standard interference fit the hubs may be heated in oil at 200-250 Celsius and rapidly positioned on the shaft. It is essential that this heat is evenly applied over the whole hub and that spot heating is avoided. DONTS
Do not use any component that is not supplied or approved by Euroflex Transmissions in the assembly of this product. Do not attempt, where the weight of the unit is excessive, to lift the coupling without the use of lifting equipment. The inherent balance of these couplings could be disturbed if they are allowed to be knocked either by striking or rolling. Care should be taken when transporting and fitting to avoid such knocks. This particularly when a coupling is specifically balanced.
DESCRIPTION OF COUPLING The coupling is of the dry laminated diaphragm or disc type. Flexibility is obtained by the deformation of the disc packs, within defined limits, which are separated by a tubular spacer. Individual laminations are of regular polygonal profiles which are assembled into a stack of previously designated thickness and secured by bushing. Flexibility is accomplished by connecting through the bushed holes, on a common pitch circle diameter, by means of bolts, alternately, to driving and driven components. The bolts, bushes and associated holes are machined to close limits associated with fitted bolts. Due to the need for reasonable ease of assembly, interference fits are undesirable and, consequently, tolerances are such as to allow for a close slide or slight transition fit. To compensate for these clearances and to ensure the best possible concentricity between components, the pitch circle diameter of the bolt holes in the flexible element is made smaller that that of the mating holes in the adjacent components. On assembly, all inherent clearances are, therefore, eliminated. Coupling bolts are sized such that they are capable of including a load equivalent to 4 times the tensile load in the flexible element laminations, between driving and driven bolt, when transmitting the full rated continuous torque of the coupling. This assumes a coefficient of friction between the various components of 0.25 but experience has shown that, due to the high loads induced, minute compressive deformation is sufficient to raise this to about 0.3. The reason for adopting this principle of using large, highly loaded, bolts is two-fold a (to prevent interface slip, as already mentioned, and b) to eliminate any chance of bolt bending due to the overhung radial loading imposed by the flexible element. Avoiding either slip or bending helps to avoid fretting which occurs when bolts are designed only to drive in shear. In general, the design is identical to a large number of units already in operation. OPERATING CONDITIONS In operating the flexible elements are subjected to both tensile and bending stresses, each having an influence on the allowable magnitude of the other. It is important, therefore, that the operating limits of the various deflections for which the coupling is designed to accommodate, are kept, as far as practicable, within those indicated on the Allowable Misalignment Curve which was individually supplied with the final engineering data. In practice, the initial alignment of the coupling should be as close as possible and within the alignment limits given in the Installation Instructions. This will allow for changes during operating to remain within allowable limits. As the Euroflex units are designed to transmit the torque in friction between the driving and driven bolts and the flexible elements, it is essential that, should the need arise, these bolts should be correctly tightened to the torque indicated on the assembly drawing or in the Installation and Maintenance instructions. Torque and speed should remain within the originally specified conditions.
INSTALLATION INSTRUCTIONS
GENERAL No liability will be accepted, and any warranty, either expressed or implied, will be null and void should any components of whatsoever kind, including nuts, bolts and washers, be used in the assembly or any modifications be made to all or part of the unit which are not supplied, specified or agreed by Euroflex Transmissions Ltd. For general Safety, Alignment and Maintenance Instructions see other sections of this manual. IMPORTANT When tightening any bolts or screws, this should be done evenly, i.e. cylinder head fashion, to 50% torque then to 100% torque in the same sequence. Threads should be lubricated with Molybdenum Disulphide grease or equivalent.
INSTALLATION INSTRUCTIONS
1.
With the Motor Rotor in its central axial position, check the distance between the machinery shaft ends is xxx +/-0.1mm (This gives a 0.7 mm pre-stretch when the coupling is installed. Check that the parallel & angular misalignment of shafts is within the limits defined on the separate Alignment Instructions sheet. Fit the Hubs (items 1 & 2) to their relevant shafts, ensuring that the Motor hub (item 1) face finishes flush with the motor shaft end. Check the distance between the Hub faces is xxx mm +/-0.25 mm. Insert the Spacer Assembly (item 3) between the Hubs and align Match Marks (or Serial Numbers) by rotating the Spacer or machinery shafts. Insert the Element Assemblies (item 4) between the Spacer & Hub flanges (item 1,2 & 3) Fit Coupling Bolts, Overload Washers & Nuts (item 5/6/7) as indicated on the drawing and torque tighten, cylinder head fashion, to the value shown on the drawing, ensuring threads are correctly lubricated.
2.
3.
4. 5.
6.
7.
MAINTENANCE INSTRUCTIONS
General maintenance of the coupling consists of an annual (or other agreed period) check of the following : Axial, Angular & Parallel misalignment to ensure these are still within acceptable limits and that no major machinery movements have occurred. All bolts to ensure they are correctly tightened. The Flexible Elements, by visual inspection, for signs of fatigue cracking local to the washer anchor points or general signs of fretting corrosion. Slight bowing or S like distortion of the laminations is not detrimental to the unit operation.
NOTE : Any requirement for spare part should be made quoting the Original Purchaser, Original Order Number & the Coupling Serial Number (this will be etched on the major coupling flanges as BTLxxxx and should appear on all post production Quality documents).
ALIGNMENT INSTRUCTIONS Euroflex Transmissions couplings will accept substantial amounts of misalignment, the configuration of each individual unit defining the actual acceptable level. The allowable misalignment is shown graphically on a curve produced uniquely for any unit. This curve shows the maximum permitted level of misalignment for operation and is NOT intended to define setup limits. ALIGNMENT METHOD : Each company ahs its own method for aligning machinery all of which well documented in both internal and freely available documents and books. Hence it is not our intention to describe methods for setting machines. Instead, the following gives guidelines for quick checks for alignment suitable after initial installation and for general maintenance checks. AXIAL : The suggested limits for axial set-up distance between the machinery shafts will, generally, be specified in the installation instructions unique for the coupling. However, as a general rule, the following may be used. 4-bolt couplings:- +/- 0.4mm 6-bolt couplings:- +/- 0.3mm 8-bolt couplings:- +/- 0.2mm 12-bolt couplings:- +/- 0.2mm These values may be exceeded in certain cases and, if no reference is made in the unique installation instructions, reference should be made to Euroflex Transmissions. PARALLEL/RADIAL/ANGULAR : Having basically aligned the machinery shafts using one of the established techniques, the coupling may be installed as per the instructions. It is then worth performing a check to establish that the overall alignment is correct for the particular coupling. This may be simply performed by one of the following two methods: Attach a dial indicator securely to the back of one of the coupling flanges, with the needle in contact with the flange face the other side of the flexible element as near the outside periphery as possible. Rotate the machinery & coupling and locate the minimum reading position. At this position, set the dial reading to zero. Rotate the machinery again and record the maximum reading over 360 degrees. Divide this maximum value by the coupling flange diameter to gain a value in mm/mm, which should be no greater than that shown in the following list. (This should be repeated at both flexible elements in a spacer coupling). An alternative method is, where possible to accurately measure the distance across the flanges which sandwich the flexible element to obtain a maximum and minimum value. The difference between these two values should the be divided by the flange outside diameter to obtain a value in mm/mm, which should be no greater than that
shown in the following list. (This should be repeated at both flexible elements in a spacer coupling). 4-bolt couplings:- +/- 0.004mm 6-bolt couplings:- +/- 0.003mm 8-bolt couplings:- +/- 0.002mm 10-bolt couplings:- +/- 0.015mm NOTE : These values are intended as guides only and, in certain cases, may be exceeded, IF IN DOUBT, CONTACT EUROFLEX TRANSMISSIONS.
SECTION C
3. THRUST CUM JOURNAL BEARING
Michell Bearings A Vickers company
Operations and Maintenance Instructions for Standard Vertical Bearings
Customer: B.H.E.L - Hyderabad
Project : COND. EXTRN PUMP FOR 500MW TPS Drawing Number: 58227 Bearing Model : 8 DNT
Version date 14 December 1998
Operation and Maintenance Instructions for Standard Vertical Bearings.

1 PRELIMINARY NOTES.---------------------------------------------------------------------------- 2 .1 Introduction. ---------------------------------------------------------------------------------------- 2 .2 Safety. ----------------------------------------------------------------------------------------------- 3 2 DESCRIPTION. --------------------------------------------------------------------------------------- 5 .1 Introduction. ---------------------------------------------------------------------------------------- 5 3 HANDLING THE BEARING. ---------------------------------------------------------------------- 6 .1 Introduction. ---------------------------------------------------------------------------------------- 6 .2 Points on Handling.------------------------------------------------------------------------------- 6 4 INSTALLATION.-------------------------------------------------------------------------------------- 7 .1 Introduction. ---------------------------------------------------------------------------------------- 7 .2 Assembly of the Bearing. ----------------------------------------------------------------------- 8 .3 Points before use.------------------------------------------------------------------------------- 14 5 OPERATING.---------------------------------------------------------------------------------------- 15 .1 Introduction. -------------------------------------------------------------------------------------- 15 .2 Operating Risks.--------------------------------------------------------------------------------- 15 6 CARE AND MAINTENANCE.------------------------------------------------------------------- 16 .1 Introduction. -------------------------------------------------------------------------------------- 16 .2 Procedures.--------------------------------------------------------------------------------------- 16 .3 Maintenance Schedule. ----------------------------------------------------------------------- 17 .4 Dismantling. -------------------------------------------------------------------------------------- 18 .5 Maintenance.------------------------------------------------------------------------------------- 21 APPENDIX 1 (SPARES). --------------------------------------------------------------------------- 25 .1 Ordering. ------------------------------------------------------------------------------------------ 25 APPENDIX 2 (TABLE OF TORQUES). -------------------------------------------------------- 26
Operation and Maintenance Instructions for Standard Vertical Bearings
1 PRELIMINARY NOTES.
.1 Introduction.
This manual is to be used by qualified engineers only. It contains information that will familiarise the user with the machine and its safe operation. It is recommended that the health and safety advice given in this manual is followed and is kept in mind throughout all aspects of installation, storage, operation, etc.
- General points on safety can be found in the first section. - More specific points on safety can be found in each separate section.
* Make sure that all safety points are clearly understood and carefully noted. *
Warrantee.
Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell Bearings. These warranty obligations will automatically become void if the product is: 1) Subjected to overloads. 2) Improperly handled. 3) Supplied with spare parts not approved by Michell Bearings. 4) Exceeding, or falling short of the technical characteristics specified.
Page 2
.2 Safety.
When operating the machine danger may arise to the user, the product and plant and/or other assets. Therefore when running the machine make sure that all the safety procedures given in this manual are strictly adhered to.
The below procedures should be noted.
1 Under no circumstances should the engineer work alone when operating the machine.
2 At least one of the engineers should be trained in basic first aid techniques and wear clear identification to show that he/she is a first aider.
3 No maintenance, assembly, adjustment or any other work should be carried out on the bearing whilst the shaft is rotating or capable of movement.
4 Personnel that manipulate the product should be sufficiently trained.
5 No modifications of the product should be made unless it is approved by Michell.
6 All users responsible for the operation of the machine must understand the chapters fully and be familiar with the associated dangers described. These are instructions that, if ignored, could result in death or injury.
Page 3
Before working on the bearing the engineers should familiarise themselves with the layout of the manual. Attention is drawn to the following formats:
This symbol signifies a warning. These are instructions that, if
ignored could result in death or injury.
This symbol signifies that attention should be made by the operator. If ignored it could result in minor injury or failure to carry out a particular process correctly.
Page 4
2 DESCRIPTION.
.1 Introduction.
The bearing supplied is one of the Michell Standard Vertical Series, as manufactured by Michell Bearings. The Standard Vertical Series are a standard range of vertical bearings. Within the series a range of types are catered for; i) S Type: This is a single thrust and guide bearing. It is designed to absorb lateral forces from a rotating shaft, as well as a force along the shaft in one direction only. ii) D Type: This is a double thrust and guide bearing, designed to absorb lateral forces from a rotating shaft, as well as a force along the shaft in either direction.
The standard S Type may also be supplied with a Surge ring, designed to absorb a temporary upward force.
All types of bearing can be fitted with a variety of Resistance Temperature Devices (RTDs) to measure the temperature of the lubricating oil or pads. The Standard Vertical Series are usually self contained with water coolers, the bearings can also be modified for different methods of cooling (i.e. natural air cooled, fan cooled and circulated oil variations) with minimum modifications to the basic casing.
The bearing can also be insulated as an option to protect against stray currents whilst the machine is in operation.
Page 5
3 HANDLING THE BEARING.
.1 Introduction.
This section points out the relevant information essential when handing the bearing. The bearing is supplied fully assembled (see arrangement drawing for mass of complete bearing). Threaded holes are provided for the fitting of eyebolts on the bearing casing and other components. It is advisable to keep the bearing within any casing and packaging until it is necessary to remove it for assembly.
.2 Points on Handling.
Under no circumstances should the completed bearing be
handled manually.
Before using any lifting equipment, ensure that it is certified to
carry a load greater than that of the bearing.
When handling the bearing use only provided lifting points.
Make sure bearings are stored in the intended mounting position in a dry room only. Please check all product equipment to ensure that it is complete before installation. Any damage due to transit must be reported to Michell straight away.
Page 6
4 INSTALLATION.
.1 Introduction.
Prior to installation the bearing should be dismantled into a series of subassemblies.
Do not touch moving parts.
Additionally the following sub-assemblies may also be present and can be handled manually; Circular Cooler(s), Journal Pads, Oil level gauge, RTD assembly, Air Vent, Lower Thrust Pads and Anti-Vortex Shroud or Upper Surge face.
The bearing is also supplied with Curil T sealant.
Remove all packaging. All parts are coated in a rust preventative. This must be removed and all parts thoroughly cleaned before installation begins. To remove the rust preventative, white spirit or a strong spirit based cleaner should be used.
There may be fumes given off during the cleaning process. Clean
parts in a well ventilated area. Always follow cleaner manufacturers instructions.
Use a lint free cloth when cleaning the bearing.
Page 7
.2 Assembly of the Bearing.
The disassembling and reassembling of the equipment by an
individual who is inexperienced can cause danger. Michell will not take on any liability for any damage resulting from non-compliance with details given in this manual.
To assemble the bearing the below procedure should be followed which if carried out correctly could increase the working life of the machine. 1. Coat all bearing surfaces in clean oil of the correct grade. 2. Place jointing on the sleeve.
Care should be taken when handling components to avoid the risk of trapping hands when assembling. 3. Secure the sleeve to the baseplate with tapbolts.
If the bearing is fitted with dust seals, do not fit tapbolts. 4. Dust Seal Fitted Bearings: Fit seal housing to the sleeve and secure it in place with screws. Fit seal into housing. Fit seal cover and secure with tapbolts
Page 8
Dust seals require some time to bed in. Do not fully tighten the securing bolts. For the first month operation, gradually tighten the tapbolts. 5. Position the baseplate on to the studs located on the supporting structure and set baseplate concentric with centreline of machine. 6. Fit thrust pad stop to baseplate.
Ensure that stop is fully tightened and locked in place with Loctite 222 or similar adhesive.
7. Fit lower thrust pads and push well in.
Check that the clearance between the pads is correct. The clearance is given on the arrangement drawing.
Ensure that RTD fitted pads are in the correct position, as shown on the arrangement drawing. 8. Place O-Ring into the groove in the baseplate. 9. Fit collar to the shaft and ensure that it runs true. 10.Lower the collar until it rests on the lower thrust pads.
Page 9
Check alignment. Follow the below procedure: Check that no thrust pads are loose (i.e. all pads are firmly clamped by the collar). Use feeler gauges to check the clearances between the thrust pads pivots and the baseplate. The clearances should be equal and no greater than 0.04mm.
When using feeler gauges, take care not to damage the Whitemetal surfaces. 11.Fit the journal pad stop to the casing.
12. Coat both the casing and baseplate mating surfaces with sealant.
13. Lower casing into position. 14. Secure casing and base plate to the supporting structure using studs and nuts. Torque nuts to value indicated in Appendix 2.
Page 10
This Appendix should be adhered to as over tightening could damage the shell. 15. Fit journal pads.
Ensure that RTD fitted pads are in the correct position, as shown on the arrangement drawing. 16.For bearings fitted with anti vortex shrouds, assemble the shroud, and bolt on to the casing.
17.For double thrust (D type) bearings: Assemble the upper thrust rings, pads and stops.
Fit thrust ring on top of the journal housing in the casing.
18. For Surge ring fitted bearings; Assemble Surge ring. Bolt Surge ring to the journal housing in the casing. 19.Place jointing in position on the casing.
Page 11
20.For bearings fitted with internal cooler, fit cooler to cover.
Take care not to overtighten the securing bolts on the cooler. Overtightening may damage the cooler. 21. Fit cover and cooler assembly to the casing. Secure the cover to the casing. Torque cover securing bolts to value indicated in Appendix 2.
Check the cooler. Ensure that leakage from the cooler is not possible. 22. Dust Seal Fitted Bearings: Fit the dust seal into the top of the cover. Fit seal cover and secure it in place with tapbolts. 23.Fan Cooled Bearings: Assemble fan and fit it to the shaft. Fit RTDs, pipework elbows and any extension pieces required to allow connections to pass through fan shroud. Fit fan shroud to bearing casing. Secure it in place with capscrews.
Ensure that fan shroud does not foul the fan.
24.Fit and seal in oil level gauge, blanking plugs and any thermometry or detectors.
Page 12
Ensure that RTD assembly is not damaged and is working correctly before fitting it.
Ensure that all plugs, pipework joints and instruments are secure and sealed. 25. Connect up external pipework. 26. Remove air vent and fill bearing with oil up to the standing oil level marked on the oil level gauge.
For temperature probe fitted bearings; run the bearing and establish a steady state operating temperature then set temperature alarm to 5C above the steady state operating temperature. Shut down temperature alarm is to be set at 10C above steady state operating temperature.
Page 13
.3 Points before use.
The bearing is now complete, it must not be used until the items below have been dealt with; 1. The entire machine has received a Declaration of Conformity, or has been declared exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive.
2. Lubricating oil has passed through the bearing and is at the proper level. Note!! The lubricating oil must be a mineral based turbine oil inhibited against oxidation, corrosion and foaming, with an ISO viscosity grade as indicated on the arrangement drawing. The use of any other oil should be referred to Michell Bearings.
Do not use the bearing unless the cooling system is operating.
3. Local safety regulations have been met.
Page 14
5 OPERATING.
.1 Introduction.
This section points out the risks that can occur when operating the machine.
.2 Operating Risks.
If the bearing has been correctly assembled, using the procedure already given, there is only a marginal risk of the bearing failing which would be due to the design conditions being exceeded. Examples of these conditions are; overspeed, low lubrication levels and excess load. In order to avoid these situations, it is suggested that; i) Control panels are labelled with the bearing limitations. ii) The shaft should be stopped immediately if; a) Coolant circulation fails. b) Bearing temperature exceeds normal operating temperature by 10C.
The users attention is drawn to the fact that both the pipework and bearing surface may be hot during operation.
Where bearings are fan cooled, the fan shroud must not be removed whilst the bearing is operating.
In order to avoid leakage of lubricant, plugs, RTDs and seals must never be removed while the bearing is operating.
Page 15
6 CARE AND MAINTENANCE.
.1 Introduction. This section demonstrates the care and maintenance needed for the smooth operation of the machine.
.2 Procedures.
Once the steady state operating temperature has been determined, the alarm point should be set at 5C above this. Shut down is to occur at 10C above the steady state operating temperature.
Regular inspection should be made of all seals and pipework. Any large leakage of lubricant or coolant or sudden increase in leakage will indicate that a seal or join is failing. Maintenance must then be carried out as soon as possible.
If a bearing is fan cooled, the air inlet and outlets must be periodically inspected in order to prevent the build up of dirt and waste material. Such a build up will lead to there being insufficient air flow and overheating will occur.
Collect used oil and dispose of under the correct regulations.
Page 16
.3 Maintenance Schedule.
Oil changes will be at differing periods depending on the frequency of bearing operation and the conditions in which the bearing is operating. Approximate oil change times are indicated below.
Conditions. Constant Operation, dusty atmosphere. Constant Operation. Periodic Operation.
Oil Change Period. Three Months.
Six Months. At routine maintenance.
For a bearing that is operating constantly, routine maintenance should take place annually. If the user only operates the bearing periodically, maintenance periods may be able to take place less frequently, this is however at the users discretion. An annual inspection is recommended as a minimum service requirement.
Page 17
.4 Dismantling.
The below procedure should be followed when dismantling the bearing.
1. Switch off machinery. Lock off controls. Secure and isolate shaft.
Ensure control gear, barring gear and any other equipment
capable of moving the shaft is locked out and labelled Not to be used.
Beware hot oil. Allow machinery to cool off before proceeding
further. 2. Where a bearing is fitted with continuous circulation of oil, allow the circulation to continue whilst the bearing is cooling. 3. Switch off, drain and disconnect cooling system. 4. Switch off and drain the oil supply.
Do not disconnect the oil inlet and outlet pipework until the
bearing has been drained of oil. 5. Remove drain plug and fully drain oil from bearing.
Any oil spillage should be collected in suitable containers. 6. Disconnect and remove any thermometry and instrumentation. With fan cooled bearings this may not be possible, see next stage.
Page 18
7. Fan Cooled Bearings: Remove any connections passing through the fan shroud. Remove capscrews and lift off fan shroud. Dismantle and remove the fan Remove any instrumentation, pipework and thermometry now visible. 8. Remove the top dust seal. 9. Remove cover and cooler assembly.
Before removing bolts, fit eye bolts and lifting gear to the cover.
Ensure that the eye bolts are tight and secure.
carry a load greater than the mass of the component or subassembly.
When removing the cover and cooler, take care not to damage any equipment. 10.Remove upper surge ring, upper thrust ring or vortex shroud. 11.Fit lifting bolts and remove the journal pads from the casing.
The surge ring and journal pads will be oily and may stick. They will also be very slippery when handling. Take care to avoid dropping and damaging the pads and ring.
Page 19
12.Remove fasteners and lift off casing.
Before removing bolts, fit eyebolts and lifting gear to the casing.
Ensure that the eyebolts are tight and secure.
carry a load greater than the mass of the component or subassembly. 13.Jack up the shaft until there is a clearance between the collar and the lower thrust pads.
Ensure that jacking equipment is safely positioned and certified
to carry a load greater than the mass of the shaft.
Once the shaft is raised, secure it in position using other
equipment. Do not rely on jacking equipment alone. 14.Remove thrust pads by sliding out.
The thrust pads will be oily and may stick to the casing. The pads will also be slippery when handling. Take care to avoid dropping and damaging pads.
Page 20
.5 Maintenance.
With the bearing dismantled, (refer to assembly drawing with parts list) examine the thrust pads, journal pads and surge ring. The appearance should be that shown in Figure 1 and Figure 2 overleaf. There may be some scoring and wear on the pads and ring, but provided wear is no greater than 0.125 mm the pads and ring are still serviceable. If there is any sign of the White metal surface coming away from the pad or ring, they must be replaced.
Examine the jointing between the casing and cover and that between the base plate and the sleeve. If the jointing has decayed so that it is either disintegrating or leaking, it should be replaced.
Examine the O-Ring, if it has started to leak or decay, it should be replaced.
Inspect the collar surface for any sign of damage. If it is necessary to replace the pads, the collar should also be replaced and repaired, otherwise the replacement pads will have a short life.
Page 21
Figure 1 Thrust Pad Appearance
Figure 2 Journal Pad Appearance
Page 22
Clean the cooler assembly, using the below routine;
1. Remove cooler assembly from bearing cover. 2. Clean the bore of the tubes using a high pressure water jet or steam cleaning. 3. Any remaining deposits or blockages can be removed by using a cleaning rod or hypochlorite based cleaning solution.
There may be fumes given off during the cleaning process. Clean
parts in a well-ventilated area. Always follow cleaner manufacturers instructions.
When using cleaning rods, take care not to damage the cooler tubes.
Page 23
If the bearing is air or fan cooled, the spaces between each of the cooling fins must be cleaned. With fan cooled bearings, the fan and shroud should be inspected for any signs of damage caused by the two fouling each other. If there is any damage, the parts should be repaired and alignment of fan and shroud checked on re-assembly.
Where dust seals are fitted, these should be removed from their housings and inspected. If the seal has started to break up, or has become clogged up with dust and oil, it should be replaced.
Prior to re-assembly, all the old sealant should be removed and fresh sealant applied in the positions identified in the section on Installation (4.2).
Page 24
Appendix 1 (Spares).
.1 Ordering.
As a minimum, replacements should be carried for all Whitemetal components.
When replacing thrust and journal pads, please ensure that these are the correct hand. The direction of rotation stamped on the replacement pads must be the same as that on the old pads.
Consideration should also be given to holding the consumable parts listed below:
O-Rings Casing/Cover jointing Sleeve/Baseplate jointing RTD assemblies Washers Dust Seals
Page 25

Bolt Size (mm) 6 8 10 12 16 20 24 30 36 42 48 56 64 Tightening Torque (Nm) 4 10 20 35 80-90 155-175 275-305 545-605 950-1050 1520-1680 2300-2520 3690-4070 5560-6150
Page 26
SECTION C
4. SUCTION STRAINER (BASKET)
SP Patra
PART - 5
SUB-DELIVERY ITEMS
BFP RECIRCULATION CONTROL VALVE

(M/S. CONTROL COMPONENTS INC., USA)
500MW TPS
B73G
Filter/Regulator B73G - - -
Port 2 ....1/4" 3 ....3/8" 4 ....1/2" Adjustment Thread Form K....Knob A....PTF B....ISO Rc taper T ....T-bar G....ISO G parallel Drain Bowl A....Automatic D....Metal with liquid level indicator Q....Manual, 1/4 turn P....Transparent with guard T ....Transparent Diaphragm Element 1 ....5 m N....Non-relieving 2 ....25 m R....Relieving 3 ....40 m
Installation & Maintenance Instructions

Spring (Outlet Pressure Range) * F ....0,3 to 4 bar (5 to 60 psig) M...0,3 to 10 bar (5 to 150 psig) S....0,7 to 17 bar (10 to 250 psig) Gauge G....With N....Without
* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges. TECHNICAL DATA Fluid: Compressed air Maximum pressure: Transparent bowl: 10 bar (150 psig) Metal bowl: 17 bar (250 psig) Operating temperature*: Transparent bowl: -34 to +50C (-30 to +125F) Metal bowl: -34 to +80C (-30 to +175F) * Air supply must be dry enough to avoid ice formation at temperatures below +2C (+35F). Particle removal: 5 m, 25 m, or 40 m filter element Air quality: Within ISO 8573-1, Class 3 and Class 5 (particulates) Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar (90 psig) set pressure and 1 bar (15 psig) droop from set: 50 dm3/s (106 scfm) Nominal bowl size: 0,1 litre (3.5 fluid ounce) Manual drain connection: 1/8" Automatic drain connection: 1/8" Automatic drain operating conditions (float operated): Bowl pressure required to close drain: Greater than 0,3 bar (5 psig) Bowl pressure required to open drain: Less than 0,2 bar (3 psig) Minimum air flow required to close drain: 0,1 dm3/s (0.2 scfm) Manual operation: Depress pin inside drain outlet to drain bowl Gauge ports: 14 PTF with PTF main ports Rc1/4 with ISO Rc main ports Rc1/8 with ISO G main ports Materials: Body: Aluminum Bonnet: Aluminum Valve: Brass Bowl: Transparent: Polycarbonate Transparent with guard: Polycarbonate, steel guard Metal: Aluminum Metal bowl liquid level indicator lens: Transparent nylon Element: Sintered polypropylene Elastomers: Neoprene and nitrile REPLACEMENT ITEMS Service Kit (includes items circled on exploded view): Relieving.............................................................4383-600 Nonrelieving .......................................................4383-601 Liquid level lens kit (43, 45, 46, 47) ......................4380-020 Filter element, 5m, red speckles (50).....................4438-01 Filter element, 25m, blue speckles (50) .................4438-02 Filter element, 40m, no speckles (50)....................4438-03 Manual drain (18, 19, 20) ..........................................619-50 Automatic drain (21, 22, 23) .................................4000-51R Tamper resistant cover (knob adjustment only).......4455-51 PANEL MOUNTING DIMENSIONS Panel mounting hole diameter: 48 mm (1.89") Panel thickness: 2 to 6 mm (0.06" to 0.24") INSTALLATION 1. Shut off air pressure. Install filter/regulator in air line vertically (bowl down), with air flow in direction of arrow on body, upstream of lubricators and cycling valves, as close as possible to the device being serviced. 2. Connect piping to proper ports using pipe thread sealant on male threads only. Do not allow sealant to enter interior of unit. 3. Push bowl, or bowl with guard, into body and turn fully clockwise before pressurizing. 4. Flexible tube with 5mm (3/16") minimum I.D. can be connected to the automatic drain. Drain may fail to operate if the tube I.D. is less than 5mm (3/16"). Avoid restrictions in the tube.
Norgren 2000
5. Install a pressure gauge or plug the gauge ports. Gauge ports can also be used as additional outlets for regulated air.
1 12
ADJUSTMENT 1. Before applying inlet pressure to filter/regulator, turn adjustment (1 or 7) counterclockwise to remove all force on regulating spring (12). 2. Apply inlet pressure, then turn adjustment (1 or 7) clockwise to increase and counterclockwise to decrease pressure setting. 3. Always approach the desired pressure from a lower pressure. When reducing from a higher to a lower setting, first reduce to some pressure less than that desired, then bring up to the desired pressure. NOTE With non-relieving filter/regulators, make pressure reductions with some air flow in the system. If made under no flow (dead-end) conditions, the filter/regulator will trap the over-pressure in the downstream line. 4. KNOB ADJUSTMENT. Push knob down to lock pressure setting. Pull knob up to release. Install tamper resistant cover (see Replacement Items) to make setting tamper resistant. 5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock pressure setting. SERVICING 1. Open manual drain to expel accumulated liquids. Keep liquids below baffle (49). 2. Clean or replace filter element when dirty. DISASSEMBLY 1. Filter/regulator can be disassembled without removal from air line. 2. Shut off inlet pressure. Reduce pressure in inlet and outlet lines to zero. 3. Turn adjustment (1 or 7) fully counterclockwise. 4. Remove bowl - push into body and turn counterclockwise. 5. Disassemble in general accordance with the item numbers on exploded view. Do not remove the drains unless replacement is necessary. Remove and replace drains only if they malfunction. CLEANING 1. Clean plastic bowl (25, 35) with warm water only. Clean other parts with warm water and soap. 2. Rinse and dry parts. Blow out internal passages in body (16) with clean, dry compressed air. Blow air through filter element (50) from inside to outside to remove surface contaminants. 3. Inspect parts. Replace those found to be damaged. Replace plastic bowl with a metal bowl if plastic bowl shows signs of cracking or cloudiness. ASSEMBLY 1. Lubricate the following items with o-ring grease. 4 (Thrust washer) - outer circumference and both sides. 5, 7 (Adjusting screw) - threads and tip. 18, 28, 37 (Manual drain body) - the portion of the body that contacts the bowl, and the hole that accommodates the stem of drain valve (19, 29, 38). 53 (Valve) - stem. 26, 34, 47, 54 (O-rings) 2. Assemble the unit as shown on the exploded view. Push bowl, or bowl with guard, into body and turn fully clockwise. 3. Torque Table Item Torque in Nm (Inch-Pounds) 2, 9 (Screw) 2,3 to 3,4 (20 to 30) 22, 32, 41 (Nut) 2,3 to 2,8 (20 to 25) 43 (Screw) 1,7 to 3,4 (15 to 30) 49 (Baffle), 51 (Louver) 1,1 to 2,2 (10 to 20)
3 2
13 16
15
5 14 53 6 7 8 10 9 54 52
51
50 11 49
26 18 21
25
17 20 19
23
24
22
28
34 31 35 33 30
27
29 32 47 37 36 42 39 38 41 44 40 48 46 45 43
IM-180.300.01 (2/00)
a subsidiary of IMI plc
Supersedes 9/98
B73G
Installation & Maintenance Instructions
CAUTION Water vapor will pass through these units and could condense into liquid form downstream as air temperature drops. Install an air dryer if water condensation could have a detrimental effect on the application. WARNING These products are intended for use in industrial compressed air systems only. Do not use these products where pressures and temperatures can exceed those listed under Technical Data. Polycarbonate plastic bowls can be damaged and possibly burst if exposed to such substances as certain solvents, strong alkalies, compressor oils containing esterbased additives or synthetic oils. Fumes of these substances in contact with the polycarbonate bowl, externally or internally, can also result in damage. Clean with warm water only. Use metal bowl in applications where a plastic bowl might be exposed to substances that are incompatible with polycarbonate. If outlet pressure in excess of the filter/regulator pressure setting could cause downstream equipment to rupture or malfunction, install a pressure relief device downstream of the filter/regulator. The relief pressure and flow capacity of the relief device must satisfy system requirements. The accuracy of the indication of pressure gauges can change, both during shipment (despite care in packaging) and during the service life. If a pressure gauge is to be used with these products and if inaccurate indications may be hazardous to personnel or property, the gauge should be calibrated before initial installation and at regular intervals during use. Before using these products with fluids other than air, for non industrial applications, or for life-support systems consult Norgren.
Norgren 2000
IM-180.300.02 (2/00)
a subsidiary of IMI plc
Supersedes 9/98
PART - 6
DRAWINGS / DOCUMENTS
INDEX
SECTION-A : BOILER FEED BOOSTER PUMP SECTION-B : BOILER FEED PUMP SECTIONC : CONDENSATE EXTRACTION PUMP
LIST OF DRAWINGS
Erection & Maintenance
S.No.
01. 02. 03. 04.
Description of Drawing
Sectional Assembly of Booster Pump Outline Arrangement of MDBP Outline Arrangement of TDBP Key & Holding down bolts details for MDBP & TDBP Spanner (Coupling Nut) Hook Spanner (Var. No. 9, 10, 11&12)
Drawing No.
HY-DG-1-18000-56321 HY-DG-1-18000-56311 HY-DG-1-18000-56312 3 189 005 4854
05. 06.
2 180 291 3317 FP90016
Informative Drawings
S.No.
07.
Estimated Performance Curves of
Drawing No.
HY-DG-3-18900-65322
MDBP
08. Estimated Performance Curves of HY-DG-3-18900-65324
TDBP
09. Estimated Performance Curves of BP-NPSHR HY-DC-4-18000-68804
250 240 230 220 HEAD (mlc) 210

B
REV. DATE ALTERED CHKD. & APPD.
REV. DATE
ALTERED CHKD. & APPD.
MIN. RC FLOW
15 4
A T 50
0R
PM
at 5
Hz
1 .5
Hz
A
D C
200 190 180 170 160 150 950

A T 47 .5 H z
NOTE : MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS INDICATED ONLY FOR THE PURPOSE OF CALCULATING BFP SET SHUT OFF PRESSURES AT RC FLOW. PARAMETERS AT 50Hz:EMERGENCY OPERATION
920
207.5
162.1 0.905
80.0
588
1495
4.15
C MCR WITH
U/F OPERATION
900
208
160.1
0.907
80.0
578
1495
4.05
POWER (kW)
750 550 350 150 90

B
AT 51.5Hz
C A D
AT 50Hz
BEST EFFICIENCY POINT DESIGN CONDITION OPERATING CONDITION
855
210
161.1 0.9070
80.0
554
1495
3.9
990
FLOW (m3/hr)
205
161.8 0.9054
81.5
614
1495
4.5
NPSHR (mlc)
REF
A
HEAD (mlc)
TEMP. (0 C)
SP. GR.
EFFICIENCY (%)
POWER (kW)
SPEED (RPM)
80 70 EFFICIENCY (%) 60 50 40 30 20 10 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 SUCTION FLOW (m3/hr)
A
JOB NO. : 270

STATUS : CONTRACT 7 NPSHR-3% (mlc) 6 5
1540 RPM 1495 RPM
D
DAMODAR VALLEY CORPORATION KOLKATA
DRG. / REF. NO. (INTERNAL)
MEJIA PHASE - II THERMAL POWER STATION 2 x 500 MW - UNIT 1 & 2

NAME PRPD. CHKD. APPD.
D.K.Gupta M.M.R. B.RAJKUMAR
3 189 005 5322
PUMPS ENGINEERING
BHARAT HEAVY ELECTRICALS LTD. HYDERABAD
SIGN.
-sd/-sd/-sd/-
DATE 26.04.08 26.04.08 26.04.08
4 3 2
TITLE
PUMP TYPE : FA 1B 75
DRG. NO. : SHEET NO. : 1
ESTIMATED PERFORMANCE CURVES OF MD BOOSTER PUMP
HY-DG -3-18900-55322
NO. OF SHEETS :
TEST CODE HIS REV.
00
270 260 250 240 HEAD (mlc) 230 220 210 200 190 180 170 1150 POWER (kW) 950 750 550
MIN. RC FLOW
REV. DATE ALTERED

1644 R PM ( CO RR
REV. DATE
CHKD. & APPD.

ESP ON D
ING
TO
TUR
B IN
ET
R IP
SPE ED )
NOTE : MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS INDICATED ONLY FOR THE PURPOSE OF CALCULATING BFP SET SHUT OFF PRESSURES AT RC FLOW.
D C A
D C B A
EMERGENCY OPERATION MCR WITH U/F BEST EFFICIENCY POINT DESIGN CAPACITY OPERATING CONDITION
920 900 855 990

FLOW (m3/hr)
226 216 193
162.1 0.9050 160.1 0.9070 161.1 0.9070
80.5 80.0 79.5
637 600 513
1550 1518 1439
4.3 4.1 3.9
205
HEAD (mlc)
161.8 0.9054
TEMP. (0C) SP. GR.
81.5
EFFICIENCY (%)
614
POWER (kW)
1495
SPEED (RPM)
4.5
NPSHR (mlc)
R PM 1644
REF
C D A
350 150 90
A
1550 RPM 1644 RPM
B D A C
JOB NO. : 270

8 NPSHR-3% (mlc) 7 6 5 4 3 2 STATUS : CONTRACT DRG. / REF. NO. (INTERNAL)

KOLKATA
3 189 005 5324
MEJIA PHASE -II THERMAL POWER STATION 2 x 500 MW - UNIT 1 & 2

NAME
PRPD. D.K.GUPTA
PUMPS ENGINEERING
SIGN.
-sd/-sd/-sd/-
DATE
28.04.08 28.04.08 28.04.08
1495 RPM
BHARAT HEAVY ELECTRICALS LTD. CHKD. M.M.R HYDERABAD

APPD.
B.RAJKUMAR
TITLE ESTIMATED PERFORMANCE CURVES OF TD BOOSTER PUMP
PUMP TYPE : FA1B75
DRG. NO.: HY-DG -3-18900-55324

SHEET NO.: 1
NO. OF SHEETS : 1
TEST CODE HIS REV.
ESTIMATED PERFORMANCE CURVES OF BP - NPSHR

CUSTOMER
DRAWING NO: HY-DC-418000-58805
REV
00
PUMP TYPE:
FA1B75 SHEET 2 OF 2
ALL CURVES AT BP SPEED 1495 RPM
16 15 14 13 12 11 10 NPSHR (mlc) 9 8 7 6
NPSHR 0 % Hd NPSHR 1 % Hd NPSHR FOR 40000 HR LIFE
5 4 3 2 1 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 FLOW (Cu.m / Hr)
NPSHR 3 %Hd
HYDERABAD
BHEL
PUMPS ENGINEERING
PREPARED BY: D.K.GUPTA
CHECKED BY: M.M.R.
APPROVED BY: B.RAJ KUMAR
DATE: 16.05.08
SECTION B BOILER FEED PUMP CHAPTER 5 LIST OF DRAWINGS
Erection & Maintenance S.No. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. Description of Drawing Sectional Assembly of TD&MDBFP Foundation Arrangement of MDBFP G.A. Drg. of TDBFP set G.A. Drg. of MDBFP set G.A. & Found. of MDBFP HC Coolers Outline Arrangement of TD&MDBFP Key & Holding down bolts details for TDBFP Key & Holding down bolts details for MDBFP Alignment Diagram of MDBFP set PID of Feed Water of MDBFP set PID of Sealing & Cooling water of MDBFP set PID of Lube oil & Working oil system of MDBFP set PID of Lube oil system of TDBFP set PID of Feed Water of TDBFP set PID of Sealing & Cooling water of TDBFP set Instrument Schedule of MDBFP set Instrument Schedule of TDBFP set Drawing No. HY-DG-1-18000-56314&13 HY-DG-1-18000-56306 HY-DG-1-18000-56307 HY-DG-1-18000-56308 HY-DG-1-18000-56322 HY-DG-1-18000-56310&09 3 180 00 5 5065 3 180 00 5 5064 3 180 00 5 4907 HY-DG-1-18000-56315 HY-DG-1-18000-56316
12.
HY-DG-1-18000-56317
13. 14. 15. 16. 17.
HY-DG-1-18000-56318 HY-DG-1-18000-56319 HY-DG-1-18000-56320 HY-SC-4-18000-58794 HY-SC-4-18000-58795
S.No.
Drawing No.
18.
Recommended list of Annunciation & Trips for MDBFP Sequential Interlocking conditions of MDBFP BFP & CEP utility requirements Lube oil requirement of BFP & CEP Cartridge withdrawal arrangement Method of checking coupling alignment Thrust collar withdrawal plate Withdrawal plates of mech seal sleeves Balance drum withdrawal plate Tube spanner, balance drum Tube spanner, shaft Tube spanner, coupling nut Recommended analog inputs to DDCMIS for MDBFP set INFORMATIVE DRAWINGS
HY-DC-4-18000-58811
19.
HY-DC-4-18000-58812
20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
HY-DC-4-18000-58810 HY-DC-4-18000-58806 1 180 005 5249 3 180 00 5 4908 4 180 291 4277 4 180 291 4280 & 4285 4 180 291 4283 2 180 291 3314 2 180 291 3315 2 180 291 3316 HY-DC-4-18000-58813
31.
Estimated Performance Curves of MDBFP Estimated Performance Curves of TDBFP Estimated performance curve of Kicker stage impeller Design characteristic curves of MD BFP set at various speeds
HY-DG-3-18000-65321
32.
HY-DG-3-18000-65323
33.
HY-DG-4-18000-58800
34.
HY-DG-4-18000-68801
S.No.
Drawing No.
35.
Design characteristic curves of TD BFP set at various speeds Design characteristic curves of BFP Kicker stage at various speeds Estimated Performance Curves of BFP-NPSHR Special Tools & Tackles for BFP set Schedule of Motors for BFP & CEP Schedule of solenoid valves of BFP&CEP Schedule of Actuators for BFP&CEP Technical data sheet of BFP set BFP inter stage characteristic curve for 2nd stage tap off at design capacity
HY-DG-4-18000-68802
36.
HY-DG-4-18000-68649
37.
HY-DG-4-18000-68804
38. 39. 40. 41. 42. 43.
HY-DG-249-139-0040 HY-SC-4-18000-58807 HY-SC-4-18000-58808 HY-SC-4-18000-58809 HY-DC-4-18000-58814 HY-DC-4-18000-68799
= # =
SP Patra
Digitally signed by S P Patra DN: CN = S P Patra, C = IN, O = DVC, OU = Engineering and Planning Reason: I have reviewed this document and approved under CAT I Date: 2008.04.22 16:07:46 +05'30'
SP Patra
SP Patra
SP Patra
SP Patra
TD-106-1 Rev No. 5
PROJECT:
Form No. DAMODAR VALLEY CORPORATION KOLKATA MEJIA PHASE - II THERMAL POWER STATION 2 x 500 MW - UNIT 1 & 2
HY-DC-4-18000-58813 Rev. No.01 Page 2 of 4
LIST OF RECOMMENDED ANALOG INPUT TO DDCMIS MOTOR DRIVEN BOILER FEED PUMP SET
--------------------------------------------------------------------------------------------------------------------------SLNO DESCRIPTION OF INPUT

COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED, It must not be used directly or indirectly in any way detrimental to the interest of the company.
INITIATING KKS TAG NO. DEVICE ---------------------------------------------------------------------------------------------------------------------------
1. BFP & BOOSTER PUMPS.

1. 2. 3. 4. . 5. 6. 7. . BFP BEARING (DE) METAL TEMP. BFP BEARING (NDE) METAL TEMP. BFP THRUST BEARING BEARING METAL TEMP. BOOSTER PUMP BEARING (DE) MEATL TEMP BOOSTER PUMP BEARING (NDE) MEATL TEMP. BOOSTER PUMP THRUST BEARING MEATL TEMP BOOSTER PUMP THRUST & NDE BEARING DRAIN OIL TEMP. RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 LAC03 CT 103 LAC03 CT 104 LAC03 CT 105 TO 108 LAC13 CT 106 LAC13 CT 105 LAC13 CT 101 TO 104 LAC13 CT 107
8.
9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
BOOSTER PUMP DE BEARING DRAIN OIL TEMP. BFP BEARING (DE) DRAIN OIL TEMP. BFP THRUST & NDE DRAIN OIL TEMP. BFP SUCTION FEED WATER TEMP. BFP DISCHARGE FEED WATER TEMP. BFP BARREL TEMP. TOP BFP BARREL TEMP. BOTTOM BP MECH. SEAL COOLER NDE, S.W INLET TEMP. BP MECH. SEAL COOLER NDE, S.W OUTLET TEMP. BP MECH. SEAL COOLER DE, S.W INLET TEMP. BP MECH. SEAL COOLER DE, S.W OUTLET TEMP. BFP MECH. SEAL COOLER DE, S.W OUTLET TEMP. BFP MECH. SEAL COOLER DE, S.W INLET TEMP. BFP MECH. SEAL COOLER NDE, S.W OUTLET TEMP. BFP MECH. SEAL COOLER NDE, S.W INLET TEMP. BP MECH. SEAL COOLER NDE, C.W OUTLET TEMP. BP MECH. SEAL COOLER DE, C.W OUTLET TEMP. BFP MECH. SEAL COOLER NDE, C.W OUTLET TEMP. BFP MECH. SEAL COOLER DE, C.W OUTLET TEMP.
RTDPT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100
LAC13 CT 108 LAC03 CT 109 LAC03 CT 110 LAB13 CT 103 TO 105 LAB23 CT 101 TO 103 LAC03 CT 101 LAC03 CT 102 PGB41 CT 101 PGB41 CT 102 PGB41 CT 103 PGB41 CT 104 PGB41 CT 105 PGB41 CT 107 PGB41 CT 106 PGB41 CT 108 PGB41 CT 109 PGB41 CT 110 PGB41 CT 111 PGB41 CT 112
FP10957
Ref. Doc
24. 25. 26.
TD-106-2 Rev No. 5
PROJECT:
HY-DC-4-18000-58813 Rev No .01 Page 3 of 4
--------------------------------------------------------------------------------------------------------------------------SLNO DESCRIPTION OF INPUT INITIATING KKS TAG NO. DEVICE --------------------------------------------------------------------------------------------------------------------------27.

28. 29.
DIFF. PR. ACROSS BP SUC. STRAINER

DIFF. PR. ACROSS BFP SUC. STRAINER BFP DISCHARGE PRESSURE BFP SUCTION PRESSURE BFP DE (H&V) VIBRATION MONITORING BFP NDE (H&V) VIBRATION MONITORING KEY PHASER BFP
DIFF.PR. TRANSMITTER LAB13CP103

DIFF. PR. TRANSMITTER PR. TRANSMITTER PR. TRANSMITTER VIB.TRANSDUSER VIB.TRANSDUSER KEY PHASER LAB13CP104 LAB23CP102 LAB13CP105 LAC03 CY101, 102 LAC03 CY103, 104 LAC03 CS101
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.
30. 31. 32. 33.
2. MOTOR.
1. 2. 3. 4. MOTOR BEARING(BP END) METAL TEMP. MOTOR BEARING(HC END) METAL TEMP. MOTOR STATOR WINDING TEMP. MOTOR BEARING(BP END) DRAIN OIL TEMP. MOTOR BEARING(HC END) DRAIN OIL TEMP. RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 LAC03 CT 125 LAC03 CT 126 LAC03 CT 111 TO 122 LAC03 CT 123 LAC03 CT 124
5.
3. HYDRAULIC COUPLING.
1. 2. 3. 4. 5. 6. 7. 8. 9. H.C BEARING NO.1 METAL TEMP. H.C BEARING NO.2 METAL TEMP. H.C BEARING NO.3/4 OIL TEMP. H.C BEARING NO.5 METAL TEMP. H.C BEARING NO.6 METAL TEMP. H.C BEARING NO.7 METAL TEMP. H.C BEARING NO.8 METAL TEMP. H.C BEARING NO.9/10 OIL TEMP. H.C BEARING NO.11 METAL TEMP. RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 RTD PT 100 SPEED TRANSDUCER SPEED TRANSDUCER RTD PT 100 LAC23 CT 101 LAC23 CT 102 LAC23 CT 103 LAC23 CT 104 LAC23 CT 105 LAC23 CT 106 LAC23 CT 107 LAC23 CT 108 LAC23 CT 109 LAC23 CT 110 LAC23 CS 101
10. H.C BEARING NO.12 METAL TEMP.

11. BFP SPEED (4 - 20ma SIGNAL)
12. BFP SPEED (4 - 20ma SIGNAL)
LAC23 CS 102
FP10957
Ref. Doc
13. H.C WORKING OIL TEMP.UP UP STEAM OF COOLER 14 . H.C WORKING OIL TEMP. DOWN STEAM OF COOLER
LAC23 CT 111 TO 113
RTD PT 100
LAC23 CT 114
TD-106-2 Rev No. 5
PROJECT:
HY-DC-4-18000-58813 Rev No .01 Page 4 of 4

RTD PT 100 RTD PT 100 PRESSURE TRANSMITTER PRESSURE TRANSMITTER LAC23 CT 115 LAC23 CT 116 TO 118
15. LUBE OIL TEMP. UP STEAM OF COOLER 16. LUBE OIL TEMP. DOWN STEAM OF COOLER 17. WORKING OIL PRESSURE
LAC23 CP 101 TO 103
18. LUBE OIL PRESSURE
FP10957
Ref. Doc
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.
LAC23 CP 104 TO 106
REV. DATE
REV. DATE
3200 3000 2800 2600 HEAD (mlc) 2400 2200 2000 1800 D 1600 1400 1200 7500 POWER (kW) 6500 5500 4500 3500 90
A B D A C MIN. RECIRCULATION FLOW C
57 7 5R PM ( Hy
d.
Co
up
lin
gM
ax
NOTE :
.o utp ut sp ee d)
1. DISCHARGE FLOW AT THE FOLLOWING CONDITIONS ARE WITH INTER STAGE & KICKER STAGE CLOSED.
PARAMETERS AT 50Hz EMERGENCY OPERATION MCR WITH U/F BEST EFFICIENCY POINT DESIGN CAPACITY OPERATING CONDITION 920 900 855 990
FLOW (m3/hr)
2313 2227 1985 2050
161.1 0.9050 160.1 0.907 161.1 0.907 162.8 0.9054
81.0 81.0 80.0 81.0
6475 6112 5240 6177
5675 5565 5260 5465
52 51 44
C B A
50
NPSHR (mlc)
REF
HEAD (mlc)
TEMP. (0 C)
SP. GR.
EFFICIENCY (%)
POWER (kW)
SPEED (RPM)
80 70 EFFICIENCY(%) 60 50 40 30 20 10 0 0
C A B D
JOB NO. : 270 STATUS : CONTRACT 80 NPSHR-3% (mlc)

5775 RPM
CUSTOMER
- DAMODAR VALLEY CORPORATION

KOLKATA
DRG. / REF. NO. (INTERNAL) 3 180 0055321
70 60 50 40 30

NAME
PRPD.
D.K.GUPTA M.M.R B.RAJKUMAR
PUMPS ENGINEERING
BHARAT HEAVY ELECTRICALS LTD. CHKD. HYDERABAD
APPD.
SIGN.
-sd/-sd/-sd/-
DATE
25.04.08 25.04.08 25.04.08
TITLE ESTIMATED PERFORMANCE CURVES OF MD BOILER FEED PUMP
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 SUCTION FLOW (m3/hr)
PUMP TYPE : FK 4E 36 TEST CODE HIS DRG. NO. : REV.
HY-DG -3-18000-55321
NO. OF SHEETS : 1
SHEET NO.: 1
00
REV. DATE
REV. DATE
3400 3200 3000 2800 HEAD (mlc) 2600 2400 2200 2000 1800 1600 1400 7500 POWER (kW) 6500 5500
B D C
M IN . R EC IR C ULAT ION FLOW
601 2R PM ( TU
RB IN E
TR
IP S PE ED )
NOTE : 1. DISCHARGE FLOW AT THE FOLLOWING CONDITIONS ARE WITH INTERSTAGE & KICKER STAGE CLOSED.
D C A
D C B A
A
EMERGENCY OPERATION MCR WITH U/F BEST EFFICIENCY POINT DESIGN CAPACITY OPERATING CONDITION
920 900 855 990

FLOW (m3/hr)
2294 2219 2002 2050
162.1 0.9050 160.1 0.9070 161.1 0.9070 161.8 0.9054
81.0 81.0 80.0 81.0
6422 6090 5285 6178
5665 5550 5260 5465
49.5 49 43
50
NPSHR (mlc)
REF
HEAD (mlc)
TEMP. (0 C)
SP. GR.
EFFICIENCY (%)
POWER (kW)
SPEED (RPM)
4500 3500 90
A
D C A B
JOB NO. : 270

STATUS : CONTRACT DRG. / REF. NO. (INTERNAL) 80
6012 RPM

KOLKATA
3 180 0055323 NPSHR-3% 0H (mlc)
MEJIA PHASE - II THERMAL POWER STATION 2 x 500 MW - UNIT 1 & 2 NAME

PRPD. D.K.GUPTA
70 60 50 40 30
PUMPS ENGINEERING
SIGN.
-sd/-sd/-sd/-
DATE 28.04.08 28.04.08 28.04.08
BHARAT HEAVY ELECTRICALS LTD. CHKD. M.M.R HYDERABAD

APPD.
B.RAJKUMAR
PUMP TYPE : FK4E36
TITLE ESTIMATED PERFORMANCE CURVES OF TD BOILER FEED PUMP
TEST CODE HIS REV. DRG. NO. : HY-DG -3-18000-55323 00

NO. OF SHEETS : 1
SHEET NO. : 1
SP Patra
ESTIMATED PERFORMANCE CURVE KICKER STAGE IMPELLER AT DESIGN CAPACITY

CUSTOMER
DRAWING NO:
HY-DG-270-139-0033
( INT. REF. NO. : 41800058800-Sh.2)
REV 00
PUMP TYPE: FK4E36 EFFY (%) 67 POWER (kW) 138.45
TEST CODE: HIS SPEED (rpm) 5465 SH 2 OF2
FLOW (m3/hr) 150+30
HEAD (mwc) 209
TEMP (deg C) 162.8
SP GR 0.9054
NOTE: 1) KICKERSTAGE OUTLET FLOW REQUIRED IS 150 m3 / hr.
500 400 HEAD(mwc) 300 200 100 0 150 POWER(kw) 130 110 90 80 70 60 EFFICIENCY( %) 50 40 30 20 10 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260
IN E T R IP S DESI P EED GN S 601 2 PE ED rpm 5 465 rp m TUR B
FLOW (m3/hr) (TOTAL KICKERSTAGE FLOW INCLUDING CONST. BAL. DRUM LEAKAGE FLOW OF 30 m3/hr. )
BHEL HYDERABAD
PUMPS ENGINEERING
SP Patra
Digitally signed by S P Patra DN: CN = S P Patra, C = US, O = DVC, OU = Engineering and Planning Reason: I have reviewed this document Date: 2008.06.14 14:21:50 +05'30'
DESIGN CHARACTERISTIC CURVES OF MD BFP SET AT VARIOUS SPEEDS

CUSTOMER
DRAWING NO: HY-DG-4-18000-58801 REV
00
PUMP TYPE: BFP - FK4E36 BP - FA1B75

SH. 2 OF 2.
3400 3200 3000 2800 2600 2400 BFP + BP HEAD (MLC) 2200 2000 1800 1600 1400 1200 1000 A - DESIGN CAPACITY B - BEST EFFICIENCY POINT C - MCR WITH U/F D - EMERGENCY OPERATION 800 600 400 200 0 0
SPEED DEPEND SET POINT FLOW FOR BFP TRIP
MIN. RECIRCULATION FLOW

HY D. CO UP LIN GM
AX .O UT
PU T
SP EE D
D C B A
MAX. FLOW
2 3 4
5 6 7
8 9 10 11 13 12
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 CAPACITY (Cu.m/Hr.) 1 2 3 4 5 6 7 8 9 10 11 12 13
SL NO
BFP SPEED (RPM) 5775 BP SPEED (RPM) 1495
5675 5565 5465 5260 5000 4500 4000 3500 3000 1495 1495 1495 1495 1495 1495 1495 1495 1495
2500 2000 1500 1495 1495 1495
HYDERABAD
PUMPS ENGINEERING
PREPARED BY:
CHECKED BY:
APPROVED BY:
DATE: 16.05.08
D.K.GUPTA
M.M.R.
B.RAJ KUMAR
SP Patra
DESIGN CHARACTERISTIC CURVES OF TD BFP SET AT VARIOUS SPEEDS.

CUSTOMER
DRAWING NO: HY-DG-4-18000-58802 REV 00
PUMP TYPE:
BFP - FK4E36 BP - FA1B75

SH. 2 OF 2.
3600 3400 3200 3000 2800 2600 2400 2200 HEAD (MLC) 2000 1800 1600 1400 1200 1000 800 A - DESIGN CAPACITY B - BEST EFFICIENCY POINT C - MCR WITH U/F D - EMERGENCY OPERATION 600 400 200 0 0
SPEED DEPEND SET POINT FLOW FOR BFP TRIP MIN. RECIRCULATION FLOW
TU
RB
IN E
TR
IP
SP
EE
60
12 rp
D C A
MA X.
FL OW
5 6
2 3 4
7 8 9 10 11 12 13 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 CAPACITY (Cu.m / Hr.)
SL NO BFP SPEED (RPM) BP SPEED (RPM)
1 6012
2 5665
10
11
12
13
5550 5465 5260 5000 4500 4000 3500 3000 1518 1495 1439 1368 1231 1094
D.K.GUPTA
2500 2000 1500 684 547

DATE: 16.05.08
1644 1550
957
M.M.R.
821
410
HYDERABAD
PUMPS ENGINEERING
PREPARED BY: CHECKED BY: APPROVED BY:

B.RAJ KUMAR
S P Patra
Digitally signed by S P Patra DN: CN = S P Patra, C = US, O = DVC, OU = Engineering and Planning Reason: I have reviewed this document and approved under CAT I Date: 2008.06.26 13:24:21 +05'30'
TECHNICAL DATA SHEET OF BFP
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 2 of 13
CLAUSE NO. 1.01.00 1.02.00 1.02.01 1.02.02 1.02.03 1.03.00 1.03.01 1.03.02 1.03.03 1.03.04 1.04.00 1.04.01 1.04.02 1.04.03 1.04.05
DESCRIPTION BOILER FEED PUMP Booster/ Main pump suction flow Design inlet condition : Suction temperature Suction pressure (Booster) Specific Gravity NPSH required for Booster Pump/Main Pump 3% head breakdown 1% head breakdown 0% head breakdown 40,000 hrs erosion life of first stage impeller Design discharge conditions : Total dynamic head for pumping Suction temp. for main pump Dynamic head of BFP / BP Shut off head (BFP+Booster), at RC flow with (+) 3% tolerance as per HIS Pump Speeds (Design condition) Main pump (MD & TD) Booster pump (MD & TD) Power Consumption at design condition : Main pump input (MD & TD)
UNITS kg/hr 896445(990 m3/hr)
Deg. C
kg/cm2 (a)
161.8 9.129 0.9054
m m m m
4.5/50 5.1/54 5.5/59 8.1/93
m Deg. C
mlc
2255 (BFP+BP) 161.8 2050 / 205 (2580+219)*1.03=2883
1.05.00 1.05.01 1.05.02 1.06.00 1.06.01
rpm rpm
5465 1495
kW
6177
1.06.02 1.06.03 1.06.04 1.06.05 1.06.06 1.06.07 1.06.08
Booster pump input (MD & TD) Losses in hydraulic coupling (MD BFP) Losses in step up gear box (MD BFP) Total output required at motor shaft (MD BFP) Efficiency of main pump (MD & TD) Efficiency of Booster pump (MD & TD) Efficiency of drive motor at 100% load
kW kW kW kW % % %
614 624 451 7866 81 81.5 97.4
1.07.00 1.07.01 1.07.02 1.08.00 1.08.01
Suction Specific Speeds Booster pump, US units Main pump, first stage, US units Maximum BFP/Booster pump speed Maximum design pump speed rpm 5775 / MD BFP 1540 at 51.5Hz / MD BP 6012 at Turbine trip speed/ TD BFP & 1644 at Turbine trip speed / TD BP 52/4.15 (MD) 49.5/4.3 (TD) (Informative only) 3060/232.5 (MD) 3290/269 (TD) (Informative only) MD=230+(7)* / 2860+(86)* TD=266+(8)* / 3062+(92)* 9267 7872
1.08.02
NPSH required at the maximum speed at 3% head break down
1.08.03
Pump shut off head at maximum speed
1.08.04
Pump TDH with minimum required recirculation flow and running at maximum speed (BP/BFP) Values indicated as (*) are (+3)% tolerance values as per HIS
1.09.00 1.09.01 1.09.02 1.09.03 1.09.04
Recirculation data Normal recirculation flow, (for extended period) Onset recirculation flow Breakdown control valve design flow Breakdown control valve design pressure drop m3/hr m3/hr m3/hr kg/cm2 400 250 400 270
1.10.00 1.10.01 1.10.02
Hydraulic Coupling Rated input speed Corresponding output speeds at the extreme positions of the control element Maximum Minimum Corresponding useful flow control range of output speeds Maximum Minimum Maximum continuous output torque (Design condition) Rated output speed Make & Model (Hyd. Coupling) Manufacturer (BFP) Model number and no. of pumps / Unit Casing outer, type (Barrel, etc.) Casing inner, type (radially split etc.) Casing design pressure and minimum wall thickness Type of pedestal and sole plates rpm 1495
rpm rpm
5775 1500
1.10.03
rpm rpm kg-m rpm
5775 1500 1096 5465 Voith,Germany/VOITH INDIA BHEL / Hyderabad FK4E36 / 3 Nos. Barrel Radially split 356 kg/cm2 / 126mm Fabricated
1.10.04
1.10.05 1.10.08
1.11.00 1.12.00 1.13.00 1.14.00 1.15.00
1.16.00
1.17.00 1.17.01 1.17.02
Suction connections : Size / Schedule Location, top / bottom mm OD 406.43 x 9.53 (BW) Top for MD BFP & bottom for TD BFP
1.18.00 1.18.01 1.18.02
Discharge Connection : Size / Schedule Location, top / bottom OD 355.6 x 50 (BW) Top for MD BFP & bottom for TD BFP
1.19.00 1.19.01 1.19.02 1.19.03 1.20.00
Warm-up connections : Size Quantity and location Warmup flow, m3/hr Reheat Attemperator and attemperator connection Pipe size (Reheat Attemperation) Pipe size (Super heater Attemperation) Weld end details Super heater Flange, 2 , ANSI B16.5 88.9 x 11.13 88.9 x 15.24 CL.2500, WNRF ( Kicker) CL.1500, WNRF( Inter stg.) - NA -
1.20.01 1.20.02 1.20.03
1.21.00 1.21.01 1.21.02 1.21.00
Balancing Device leak-off connection Type Size / Schedule Direction of rotation from drive end CW or CCW Flanged ND2 CL.300 CCW
1.22.00 1.22.01 1.22.02
Shaft Total shaft length Shaft diameter at bearings (nominal) mm mm 2700 131 Drive end 110 Non-drive end 143 DE / 120 NDE 135 130 80-140 Press fit 89 2030
1.22.03 1.22.04 1.22.05 1.22.06 1.22.07 1.22.08 1.22.09 1.25.00 1.25.01 1.25.02 1.25.03 1.25.04 1.25.05 1.25.06 1.25.07 1.26.00 1.27.00 1.28.00
Shaft diameter at seals (nominal) Shaft diameter at impeller (nominal) Shaft diameter at balancing drum (nominal) Shrink fit at impellers Shrink fit at balancing drum Shaft static deflection (at rest) Shaft span between bearing centers Bearings : L/D ratio at bearings (L-Brg. length, D-Shaft dia.) Journal bearings - type Journal bearings size (dia.) Journal bearings length Journal bearings clearance Thrust bearings -type Thrust bearing design capacity % of axial thrust carried by the thrust bearing At what loads is thrust brg. loaded ? Type of axial balancing device (drum / opposed
mm mm mm microns microns microns mm
0.77 - DE, 0.73 - NDE Thick wall babbit lined mm mm microns 130- DE, 110 - NDE 100- DE, 80 - NDE 150 Tilting pad tonnes % 14.45 5 All loads Drum
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 7 of 13 Drum m3/hr 30 ( New clearances) Yes
1.28.00
Type of axial balancing device (drum / opposed impeller) Balancing device leak off flow Can balancing device handle axial thrust at all loads and conditions Method of indicating ( displacement ) shaft axial position
1.29.00 1.30.00
Yes / No
1.31.00
- NA microns New - 205, Worn - 308 Diffuser 12
1.32.00 1.33.00 1.34.00
Balancing device radial clearance Pump designed with diffuser or volute Number of diffuser / volute blades (tongues), First stage No. of blades Normal stages Diffuser / volute tongue ID first stage Tongue ID, Normal stages Impeller OD, First stage Impeller OD, Normal stage Clearance between impeller vane diffuser/volute tongue, First stage Clearance between impeller vane diffuser/volute tongue, Normal stage tip and
1.35.00 1.35.01 1.35.02 1.35.03 1.35.04 1.35.05
mm mm mm mm mm
366 366 355 355 4
1.35.06
tip
and
mm
1.35.07 1.35.08 1.36.00 1.37.00 1.37.01 1.37.02 1.37.03
Dia. clearances at impeller wear ring, first stage Dia. clearances at impeller wear ring, normal stage Impeller eye dia., first stage Impeller eye area, first stage Impeller / diffuser width ratio, first stage Impeller / diffuser width ratio, normal stage No. of Impeller vanes, first stage
mm mm mm mm2
0.58 0.58 210 23365 0.69 0.69 7
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 8 of 13 7 Staggered
1.37.04 1.38.00
No. of Impeller vanes, normal stage Impeller vane mounting arrangement between impeller (in line/staggered) Rotor weight GD2 of pump motor First stage impeller polar moment of inertia First stage impeller transverse moment of inertia Normal stage impeller polar moment of inertia Normal stage impeller transverse moment of inertia Location of center of gravity of the Rotor (Datum line at) Permissible maximum unbalance in any plane kg kg-m2 kg-m2 kg-m2 kg-m2 kg-m2
1.39.00 1.40.00 1.40.01 1.40.02 1.40.03 1.40.04
551 2040 0.325 0.1625 0.315 0.1575
1.41.00
mm
1448
1.42.00
gm-cm
630W/N
1.43.00 1.43.01 1.43.02 1.43.03 1.43.04 1.43.05 1.44.00 1.44.01 1.44.02 1.44.03 1.44.04 1.44.05
Bearing lubrication : Type Required flow per journal bearing Required flow to thrust bearing Bearing temp. (recom/max) Oil pressure required (min./recom/max.) Pump Shaft at coupling Diameter Key way size (if applicable) Type of fit Space between shafts End float required mm mm mm 126 Double key (32x18x133) Taper fitting 340 1.48 cold m3/hr m3/hr C ata Pressurized oil 0.42 13.44 100/80 (Thrust / Journal) 2.5 / 3.0 / 3.5
1.45.00 1.45.01 1.45.02 1.45.03 1.46.00
Drive Shaft at coupling Diameter Key way size (if applicable) Type of fit Space envelope required to remove rotating element, including laydown space for casing or casing parts Rotor removal cradle (Number required) Rotor handling device (Number required) End covers for pump flushing, when internals are removed (each pump) Combined first and second critical speed of the set Booster Pumps Manufacturer Model number and No. of pumps Casing type Casing design pressure Casing minimum wall thickness Pedestals and sole plates Suction connections : a) Size / Schedule b) Weld end details c) Location top / bottom Discharge connections : kg/cm2 mm type BHEL / Hyderabad FA1B75 / 3 Nos. Horizontally split, Volute 33.5 25 Fabricated rpm mm mm mm mm 130 31 x 170 x 18 Shrink fitting 3200
1.46.00 1.46.00 1.47.00
One Nil One
1.48.00 1.49.00 1.49.01 1.49.02 1.49.03 1.49.04 1.49.05 1.49.06 1.49.07
- NA- (Due to fluid coupling B/W pipe & motor)
14, ANSI B16.5, CL-300 Flanged, WNRF Sides
1.49.08
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 10 of 13 12, ANSI B16.5, CL-300 Flanged, WNRF Sides
1.49.08
Discharge connections : d) Size / Schedule e) Weld end details f) Location top / bottom
1.49.11
Direction of rotation from drive end CW or CCW Shaft length Shaft diameters at bearings, at seals, at impeller Shrink fit impeller Shaft static deflection Shaft span between bearing centers mm mm microns microns mm
MDBP-CW TDBP-CCW 1711 80, 101, 101 Press fit 113 1310
1.49.12 1.49.13 1.49.14 1.49.15 1.49.16
1.49.18
Journal bearings type, size (dia.), length
mm & microns
Thin wall babbit lined, Dia 80, L=60, 150mic.
1.49.19
Thrust bearing type Size (dia.) Design load mm kg 76 3262 Double volute 2 mm 810 Double entry mm mm mm mm mm2 750 0.66 -NA264 4147
1.49.20 1.49.20.1 1.49.20.2 1.49.21.1 1.49.21.2 1.49.22.1 1.49.22.2 1.49.22.3 1.49.22.4
Pump designed with diffuser or volute Number of diffuser / volute blades Diffuser / volute tongue ID Impeller type Impeller OD Diametrical clearances at impeller wearing ring Diametrical clearances at impeller hub Impeller eye dia. Impeller eye area
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 11 of 13 -NA6 kg kg-m2 280 8.4
1.49.22.5 1.49.22.6 1.49.23 1.49.24
Impeller / diffuser width ratio Number of impeller vanes Rotor weight GD2 of pump rotor
1.49.29 1.49.29.1 1.49.29.2 1.49.29.3 1.49.29.4 1.49.29.5 1.49.30 1.49.30.1 1.49.30.2 1.49.30.3 1.49.30.4
Bearing lubrication Type Require flow per journal bearing Require flow to thrust bearing Bearing temp. (recom / max) Oil pressure required (min./recom/max) Pump Shaft at coupling Diameter Key way size (if applicable) Type of fit Space between shafts mm mm mm 82 80 x 22 x 9 Taper fitting 155 m3/hr m3/hr C ata Pressurised oil 0.3 0.72 65 / 80 1.6 / 2.5 / 3.5
1.49.31 1.49.31.1 1.49.31.2 1.49.31.3 1.49.32 1.49.32.1 1.49.32.2
Drive Shaft at coupling Diameter Key way size (if applicable) Type of fit Recommended hole size of Suction Strainer For startup Permanent, if desired by owner 250 microns 315 microns mm mm 90 24 x 8 x 137 Push fit
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 12 of 13 Cartridge type, Mechanical As Per Approved Vendor SIL CAR 1 / N17 carbon 1750 bar-m/sec
1.50.00
Type of seals (Booster pump / main pump)
1.50.01 1.50.02 1.50.03
Model / make Material of rotating / stationary faces Design P.V. factor Additional Data :
1.51.00 1.51.01 1.51.02 1.51.03 1.51.04 1.52.00 1.52.01 1.52.02 1.52.03 1.52.04 1.53.00 1.53.01 1.53.02 1.53.03 1.53.04 1.53.05 1.54.00 1.54.01
Working oil coolers for Hydraulic Couplings Make Type of cooler Fluid medium Operating flow rate Lube oil coolers for Hydraulic Couplings Make Type of cooler Fluid medium Operating flow rate AOP Motor for Hydraulic Coupling Make AOP motor type Motor rating Speed Voltage Connecting Couplings for MD BFP Make As Per Approved Vendor kW rpm V Voith, DE 200 LA2 30 2950 415, 3 phase m3/hr Voith, Duplex
Oil Shell side, WaterTube side 51 Shell side, 75 Tube side
Voith, Duplex
Oil Shell side, WaterTube side
m3/hr
78Shell side, 120 Tube side
DRG. NO. : HY-DC-4-18000-58814 INTL. NO. : FP41800058814 Rev. No. 00 Page 13 of 13 Flexible Membrane
1.54.02 1.54.03
Type Model No. / Rating a. Booster pump / Motor b. Hyd. Coupling / Motor c. Hyd. Coupling / BFP
735 kW 10000 kW 10000 kW
SP Patra
BFP INTERSTAGE CHARACTERISTIC CURVE ( 2ND STAGE TAP OFF), AT DESIGN CONDN. PROJECT : CUSTOMER DAMODAR VALLEY CORPORATION KOLKATA
DRAWING NO: HY-DG-270-139-0032 (INT. REF. NO. : 418058799)
REV 00
PUMP TYPE:
FK4E36 SH. 2 OF2.
NOTE:1. BFP SPEED (DESIGN CONDITION) ---- 5465 RPM 2. BFP SUCTION FLOW ---- 990 cu.m./ hr. 3. INTERSTAGE TAP OFF FLOW ---- 55 cu.m./ hr. ( 2nd stage)
1700 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 90 80 70
546 5 rp
60 1
2r
pm
(T R
IP
SP
EE
D)
HEAD (mwc)
m( DE
SIG
NS
PE
ED
EFFICIENCY (%)
60 50 40 30 20 10 0 0 200 400 600 800 1000 1200 1400
FLOW (Cu.m/hr)
HYDERABAD
BHEL
PUMPS ENGINEERING
SECTION C CONDENSATE EXTRACTION PUMP LIST OF DRAWINGS Erection & Maintenance S.No.
01. 02. 03.
Sectional Assembly of CEP General Arrangement of CEP Schematic diagram of Sealing and Cooling water for CEP Instrumentation Scheme for CEP Instrumentation Schedule for CEP Recommended list of analog inputs to owners DDCMIS for CEP Sequential Interlocking conditions of CEP Thrust bearing withdrawal & assy tools Impeller withdrawal & assy tools C Spanner (Var.no. 12 & 13)
Drawing No.
HY-DG-1-18100-56323 HY-DG-1-18100-56324 HY-DG-2-18100-54890
04. 05. 06.
HY-DG-2-18100-54891 HY-SC-4-18100-58818 HY-DC-4-18000-58819
07. 08. 09. 10.
HY-DC-4-18100-58824 1 181 231 3686 2 181 231 3616 FP 90016
Informative Drawings
11. Estimated Performance Curves of CEP NPSHR Estimated Performance Curves of CEP Design characteristic curves of 2 CEPs in operation Technical Data of CEP HY-DG-4-18100-68817
12. 13.
HY-DG-3-18100-65325 HY-DG-4-18100-58821
14.
HY-DC-4-18100-58820
= # =
DRG APPROVED AGAINST INFN CATEGORY VIDE DVC LETTER EDCON/MECH/MS-1&2(PH-II)/996 DT.7.3.08.
APPROVED IN CAT-I, VIDE DVC LETTER: EDCON/MECH/ MS-1&2(PH-II) 996 DT.7.3.08
SP Patra
SP Patra
ESTIMATED PERFORMANCE CURVES OF CONDESATE EXTRACTION PUMP NPSHR

CUSTOMER
DRAWING NO: HY-DC-4-18100-58817
REV 00
PUMP TYPE:
EN6J40/500 SHEET 2 OF 2
NPSHR FOR 40000 HR LIFE
4 NPSHR (mlc)
NPSHR 0 % Hd NPSHR 1 % Hd
NPSHR 3 %Hd
0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 FLOW (Cu.m / Hr)
HYDERABAD
BHEL
PUMPS ENGINEERING
PREPARED BY:
CHECKED BY:
APPROVED BY:
DATE:
D.K.GUPTA
M.M.R
B.RAJ KUMAR
16.05.08
500 450 400

Min. Recirculation Flow
REV.
DATE
ALTERED : APPD :
REV. DATE
ALTERED : APPD :
REV. DATE
ALTERED : APPD :
HEAD (mwc)
350 300 250

B A D C
51 .5 Hz 50 Hz 47 .5 Hz
745
235
46 0.9902
79.0
712
1486
3.4
280
C B
710 620
240 215
46 46
0.9902 0.9902
80.5 80.0
637 633
1486 1486
3.2 2.65
268 303
200 150 100 900

A
A
51.5 HZ 50 HZ 47.5 HZ
800
CAPACITY (cu. m./ h r.)
275
HEAD (mlc)
49.2
TEMP ( C)
0.9899
81.0
732
POWER ( kw)
1486
SPEED ( RPM)
3.05
NPSHR (mlc)
275
ACTUAL
DEV.HEAD
POWER(KW)
700 500 300 100 90

A
FOR INFORMATION
REF
SP. GR. EFFICIENCY (%)
(mlc)
NOTE : A - DESIGN CONDITION. B - BEST EFFICIENCY POINT-MCR WITH 3% MU 1. SHUT OFF HEAD AT 50Hz = 350mlc. C - VWO FLOW WITH 10% MARGIN 2. INPUT POWERS AT B,C &D ARE CALCULATED D - MAX FLOW CONDITION BASED ON ACTUAL HEADS GENERATED AT 50 Hz.
80 70
JOB NO. STATUS
: 270 : CONTRACT

KOLKATA
EFFICIENCY (%)
60 50 40 30 20 10 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200
A 50 HZ
DRG. / REF. NO. (INTERNAL)
5 4 3 2 1
3 181 00 6 5325
NPSHR (mlc) (3%H)
PUMPS ENGINEERING
BHARAT HEAVY ELECTRICALS LTD. PRPD HYDERABAD. CHKD. APPD
NAME
REDDY M.M.R. B.R.K.
SIGN.
Sd/Sd/Sd/-
DATE
14.05.08 14.05.08 14.05.08
TITLE
PUMP TYPE : EN6J40/500 DRG. NO. :
SUCTION FLOW (Cu.m/Hr)
CEP ESTIMATED PERFORMANCE CURVES
HY-DG -3-18100-65325 00 SHEET NO. : NO. OF SHEETS : 1 1
TEST CODE HIS REV.
S P Patra
COND. FLOW,
(rpm) (mlc)
HEAD
TEMP
SP.GR
SPEED
SHUT OFF HEAD
HEAD (m/c)
HYDERABAD
CUSTOMER
BHEL
2 x 500 MW - UNIT 1 & 2
2 PUMPS (cub.m./Hr)
(mwc)
(deg.C)
A B C D
1600 1240 1420 1490
275 215 240 235
49.2 46 46 46
0.9902 0.9902 0.9902 0.9896
1486 1486 1486 1486
350
A = DESIGN CONDITION. B = BEST EFFICIENCY POINT-MCR WITH 3%MU C = VWO FLOW WITH 10% MARGIN D = MAXM. FLOW CONDITION
400
MEJIA PHASE - II THERMAL POWER STATION
DESIGN CHARACTERISTIC CURVE , OPERATION OF TWO CEPs.
PUMPS ENGINEERING
A
AT 4 AT 5 1.5 H z 7.5 H z
350
300
PREPARED BY:
D.K.Gupta
250
200
150
DRAWING NO:
PUMP TYPE:
CHECKED BY:
MMR
100
50
EN6J40/500
APPROVED BY:
HY-DG-4-18100-68821 REV 00
BRK
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 FLOW (Cu.m/Hr)
DATE:
SH : 2 OF 2
20.05.08
SP Patra
Digitally signed by S P Patra DN: CN = S P Patra, C = US, O = DVC, OU = Engineering and Planning Reason: I have reviewed this document and approved under CAT I Date: 2008.06.06 15:20:44 +05'30'
TECHNICAL DATA SHEET OF CEP
DRG NO. : HY-DC-4-18100-58820 INTL. NO. : FP41810058820 Rev No. 00 Page 2 of 5
CLAUSE NO. 1.01.00 1.02.00 1.02.01 1.02.02 1.02.03 Design flow rate
DESCRIPTION
UNITS kg/hr 791920 (800m/hr)
Design inlet condition :
Inlet temperature Specific gravity NPSH required at pump mounting flange for
Deg.C
49.2
0.9899
a) b) c) d)
3% head breakdown 1% head breakdown 0% head breakdown 40,000 hrs. erosion life of first stage impeller
m m m m
3.05
4.2
4.4
4.8
1.03.00 1.03.01 1.03.02 1.04.03
Design discharge conditions : Discharge pressure TDH Shut off head ( )* indicates (+) 3% tolerance as per HIS Pump speed Power Consumption at design condition :
Kg/cm2 m m
23.485
275
350 + (10.5)* = 360.5
1.04.00 1.05.00 1.05.01 1.05.02 1.05.03 1.05.04
rpm
1486
Power input to motor at 50 Hz Loss in motor at 50 Hz Power input to pump at 50 Hz Efficiency of pump alone
kw kw kw %
732
31
701 81.0
CLAUSE NO. 1.05.05 1.06.00 1.07.00 1.08.00
DESCRIPTION Overall efficiency of pump set Suction Specific speed for first stage (US units) Canister losses External seal water requirment from alternate sealing (When three pumps are not running). Minimum flow for continuous stable operation On set recirculation low (if any) Peripheral speed at the eye of first stage impeller, Maximum residual thrust Manufacturer Model Number and No. of pumps Number of stages Type of first stage impeller Impeller diameter, Suction specific speeds (US Units) Design pressure components of bowl and discharge
UNITS % 77.6
10981
mwc m3/hr m3/hr m3/hr m/sec kg
0.4
6 per pump
1.09.00 1.10.00 1.11.00 1.12.00 1.13.00 1.14.00 1.15.00 1.16.00 1.17.00 1.18.00 1.19.00
300
N.A
19.21
2732
BHEL / Hyderabad
EN6J40/500, 3 Nos.
6 (Six)
Double suction, radial
mm
388 (OD)
10981
kgm2 (g)
39
1.20.00 1.20.01 1.20.02 1.20.03
Outer casing (canister) : Minimum wall thickness Design pressure Depth below pump mounting flange mm ata mm 12
5892
CLAUSE NO. 1.21.00 1.21.01 1.21.02 1.21.03 1.22.00 1.22.01 1.22.02 1.22.03 1.23.00 1.23.01 1.23.02 1.24.00 1.25.00 1.25.01 1.25.02 1.25.03 1.26.00 1.26.01 1.26.02 1.26.03
DESCRIPTION Suction connection : Size / schedule Type of connection with piping Height of centerline above pump mounting flange Discharge connection : Size / schedule Type of connection with piping Height of centerline above pump mounting flange Critical speeds :
UNITS
20, ANSI B16.5, CL-150
Flanged, WNRF
mm
1320
12, ANSI B16.5, CL-300
Flanged, WNRF
mm
2020
First critical speed in water Second critical speed in water GD2 of rotor including coupling Top shaft :
rpm rpm kgm2
3380
5798
32
Length Diameter Span between bearings Intermediate shaft :
mm mm mm
3606
100 (max)
1350
Length Diameter Span between bearings
mm mm mm
3167
87
1350
CLAUSE NO. 1.27.00 1.27.01 1.27.02 1.27.03 1.28.00 1.29.00 1.29.01 1.29.02 1.30.00 1.30.01 1.30.02 1.30.03 1.30.04 1.31.00 1.31.01 1.31.02 1.32.00 1.33.00 1.33.00 1.33.00 1.33.01 Bottom shaft : Length Diameter
DESCRIPTION
UNITS
mm mm mm
2607 88 (max) 1350 Muff Coupling
Span between bearings (max) Method of coupling with adjacent shafting Radial bearings :
Type & Number Size Thrust bearing : mm
Cutless Rubber, 8 Nos
100
Located in pump / motor Type & number Design load Maximum load Bearing lubrication type : kg kg
In pump
Tilting pad, 1 no.
2732
6038
Radial bearing Thrust bearing Recommended hole size of suction strainer Shaft sealing : Method of shaft sealing Make of seal Mechanical seal cooling
Condensate
Sump oil
400 microns
Mechanical seal
As per CUSTOMER approved vender From CEP common discharge

BFP BHEL Manual For 500MW

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BHARAT HEAVY ELECTRICALS LIMITED

RAMACHANDRAPURAM :: HYDERABAD 502 032

OPERATING AND MAINTENANCE INSTRUCTIONS OF PUMPS

MEJIA PHASE-II T.P.S - 2x500MW, UNIT-1&2

DAMODAR VALLEY CORPORATION

PRESERVATION & STORAGE

PART 4 A. B. C. PART 5 A. PART 6 A. B. C.

NOTE : A note gives supplementary information where considered necessary.

SUB VENDOR LIST FOR BOUGHT-OUT ITEMS

Mechanical Seals : BFP & CEP

Thrust Bearings : BP & CEP

Connecting couplings BP, BFP & CEP

Local Gauge Board Assy with Pre & Temp Instruments

Local Instrument Rack for Transmitters, BFP&CEP

Reverse Rotation Monitoring System of TD &MD BFPs

- Indicates make of the equipment in original supply.

PRESERVATION & STORAGE

STD. NO. HY0490563 HY0490564

Copyright and Confidential

Copyright and Confidential

ANNEXURE-I Equivalent Brands HE 1710 (Bhopal) HE 1706 (Bhopal) HE 1709 (Bhopal)

Soft Film deposited Grease Oil

Powder/ Tablet Paper Gas Crystal

Wrapping Filling Inserting

3 months 3 months 3 months

Guide Lines for Selection

Copyright and Confidential

Copyright and Confidential

TRP APPLICATION CATEGORY A B B B B B

Copyright and Confidential

TRP APPLICATION CATEGORY C C C C C C D/E G G G G G G G G G I I A

Copyright and Confidential

TRP APPLICATION CATEGORY A

TRP APPLICATION CATEGORY D/E F G

Copyright and Confidential

Rust preventive oil Rust preventive compound (proprietary)

Rust preventive Agents - --Copyright and Confidential

--------Rust Poliq N (Proprietary)

Futech chemicals (P), Secundeabad -

1.2 1.2.1 1.2.2 1.2.3 2.0

Copyright and Confidential

2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.2.3

Revisions Rev.No. 01 Rev. Date OCT. 93 Revised: AGM (E&CC)

Copyright and Confidential

Copyright and Confidential

Copyright and Confidential

Details of components/parts TURBO GENERATORS & AUXILIARIES

Copyright and Confidential

Copyright and Confidential

SECTION (A) (B) (C)

BOILER FEED BOOSTER PUMP

SECTION - A BOILER FEED BOOSTER PUMP

TITLE Description Opening Instructions Maintenance Instructions Sub-Vendors Drawings / Instructions

SECTION - A BOILER FEED BOOSTER PUMP

CHAPTER 1 DESCRIPTION LIST OF CONTENTS

1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 3.4 3.5 3.6

Thrust Bearing Manufacturer Type Michell Bearing / Glacier Double thrust

Mechanical seal Manufacturer BURGMANN, Germany

Driver/Pump Flexible Coupling Manufacturer Euroflex, India

Journal and Thrust Bearings :

SECTION A BOILER FEED BOOSTER PUMP

CHAPTER 2 OPERATING INSTRUCTIONS

Introduction Fault finding