A HAND BOOK FOR SITE ENGINEERS

BOILER WATER CIRCULATION PUMPS

POWER SECTOR EASTERN REGION

KOLKATA
 Preface

14th October, 2012

Kolkata

Dear Friends,

BHEL, our great organization, is amidst many a challenges due

to the market environment and our higher management is steering the or-
ganization through these turbulent environment successfully through vari-
ous Strategies and Proactive action plans. One of the major decision taken
was to induct manpower to meet the organizations commitments and
around 20,000 young personals were inducted into the organization during
the period 2007—12. Induction of these young personals changed the
Physical appearance of the organization converting it into a Young Looking
organization. Looking into PSER alone, in 2007, the percentage of Young
Personals below 27 yrs was around 22% which by September 2012 has
become around 62%. The performance of each of these new entrants are
essential and important for the Overall Performance of the Organization.
Hence the new challenge that we have before us is to convert these new
entrants to Competent Young Personals FAST to take independent re-
sponsibilities..

Since time is the essence, hence there has to be a complete

change in the modalities of providing Technical Inputs to these new en-
trants . For our site engineers, erection manuals of Products and Systems
is the main document for providing the Technical input for his area of work.
These Manuals as on date are in Language form with drawings and Sketch-
es in 2-D form which takes longer time for a New Entrant to visualize and
understand . The fastest mode is to provide him all information in VISUAL
formats.like Sequential Photographs , by providing all Drawings and
Sketches in 3-D format, making the Erection Manuals in 3-D drawings in
Animated form for all processes.

Apart from the nature of the formats of providing the information,

a few young entrants also expressed the availability of all associated infor-
mation/guidelines in Totality at one place for getting total Clarity of the Job
to be executed which will help in executing the job Fast and maintaining
Quality. .
 The preparation of this document is an attempt in the direction of the
suggestions given by a few Young Engineers and to meet their need in or-
der to achieve company’s objectives. The First Product chosen was BOIL-
ER WATER CIRCULATING PUMP ( CC PUMP ). This document will re-
quire many a changes / addition to make it more informative and useful
and the process is ON.

Since BOILER WATER CIRCULATING PUMP is a bought out item,

hence getting the Part– Drawings in 3-D format was an issue . For other
products like PULVERIZERS, FANS, AIR PRE-HEATERS, ESP etc , which
are BHEL’s own products, availability of Drawings and Sketches in 3-D for-
mat would not be a problem. Hence Erection Sequences for these products
can be made in 3-D drawings format and a step further can be gone to
make the Erection Manuals in ANIMATION format. We have a Plan to go in
this direction for the remaining products .

I would request all readers to kindly send their views with suggestions
for improvements for this document and also for the other Products’ Docu-
ments in line.

With Best Wishes.

S.K.Thapa
14th October, 2012
PSER, KOLKATA
 CONTENTS
1. Introduction

2. CC Pump DATA Sheets

3. Transportation, Storage & Preservation

4. Stud Tensioning KIT

5. Pump Casing

6. CC Pump Discharge cum Check Valve

7. Motor Erection Photographic Representation

8. PID & Drawing of CC Pump System

9. Photographic representation of CC Pump

Systems

10. TORISHIMA Pump Manual

11. TORISHIMA Pump Presentation

12. HAYWARD TAYLOR Pump Manual

13. HAYWARD TAYLOR Pump Presentation

14. Commissioning

15. FQP

16. Failure Analysis by Trichy Unit

…………...
INTRODUCTION TO CC PUMP
INTRODUCTION TO CC PUMP

Unit Heat Rate of a Thermal Power Plant or the Plant Efficiency is a

function of many a parameters of which the significant are MAIN STEAM
TEMPERATURE, MAIN STEAM PRESSURE, REHEAT STEAM TEMPERA-
TURE, BOILER FEED WATER TEMPERATURE, CONDENSER VACCUME
etc. This can be seen from the diagram on the right side.
.

With Higher Main Steam

Pressure, the Plant Efiicien-
cy goes up. But with Higher
Steam Pressures, the Circu-
lation in the Boiler comes
down due to reduction in the
Density Difference between
Steam and Water ( the main
driving force of water through
the water wall tubes ) and
hence to drive the water
through the Water Walls , a
Pump is to be provided be-
tween the Boiler Drum and the Water Wall Bottom header. The Figure below
shows the decrease in Driving force of Water through Water Wall due to de-
crease in Density Difference at Higher Boiler Pressures.

The Pump which is used to drive Water through the Water Walls at
Higher Boiler pressures is known as BOILER WATER CIRCULATING
PUMP ( CC PUMP ).
 Figures on the side shows the
CC Pump placed between the Drum
and the Down Comer of a 500MW
boiler.

CC PUMP

Once through Super Critical Boilers

has One No CC pump for Low Load
Operation.

CC PUMP
DATA SHEET
KORBA CC PUMP DATA SHEET ( FOR REF )
SINGRAULI 500 MW CC PUMP DATA SHEET ( FOR REF )
TRANSPORTATION
 TRANSPORTATION

Main CC pumps Package consisting of Pump Casing, Wet Motor, Main

Motor Cavity Coolers, Instrumentations for the Cooler System, Pump cas-
ing to Motor Flange Tightening KIT, Gaskets for the Pump Casing to Motor
Flange comes from the Main Pump supplier which generally has been ei-
ther HAYWARD TAYLOR / UK or TORISHIMA / JAPAN so far in Easter Re-
gion Projects.

The auxiliary systems like the Emergency Cooling water system, Cool-
ing Water Pumps, Coolers and Filters for the High Pressure Fill and Purge
systems with associated piping's are supplied by BHEL / Trichy unit..

The Supplies from HAYWARD TAYLOR or TORISHIMA are being sent ei-
ther in Wooden Boxes or in Containers as shown below.

Wooden Boxes Container Boxes

These Boxes/Containers should not be allowed to lie outside in the

Open Yard . The Pump and Motor components are to be removed from the
Boxes and Stored in the Covered Stores STRICTLY as per the Guidelines
given by the respective Suppliers in their MANUALS. Each Supplier has his
own Procedures for STORING and PRESERVING THE MOTOR in the
Covered Store and are completely different .

Details are given in the respective Manuals supplied by the Supplier.

STORAGE
 STORAGE AND PRESERVATION OF CC PUMP MOTOR

Each Supplier of CC Pump has his own special

way of Storing and Preserving the MOTOR in
the Covered store and they are NOT SAME.
Hence the respective suppliers manuals are to
be gone through in details and instruction fol-
lowed as specified.

HAYWARD TAYLOR PUMP MOTOR STOR-

AGE:

Hayward Taylor Motors are to be placed

VERTICALLY and it is to be ensured that all
the BLANKS provided on all OPENINGS on the
Motor exists . MOTORS SHOULD NOT BE ALLOWED TO BE STORED
LYING HORIZONTAL.

It is preferable to have a PLAT-

FORM erected around the Vertically
placed motors so that the pump can be
periodically checked for the INHIBI-
TOR and PUMP Rotor rotated from the
TOP END by removing the TOP CAN-
NISTER COVER.
 Hayward Taylor Motor Storage

PUMP CASE STORAGE

TORISHIMA PUMP MOTOR STORAGE

TORISHIMA MOTORS ARE SUPPLIED WITH NITROGEN GAS FILLED AS

INHIBITOR DURING TRANSPORTATION AND FOR STORAGE UNLIKE
GLYSERINE FILLED IN CASE OF HATWARD TAYLOR MOTORS.

As per Instructions given in the Manual of TORISHIMA Pumps, these Mo-

tors can be stored in the Covered Store lying Horizontal unlike in Hayward
Taylor , where they have to be kept Vertical.

The NITROGEN Inhibitor Gas pressure has to be periodically checked for

its Pressure. Detail instruction are given in the Manual.
STUD TENSIONING KIT
PUMP CASING TO MOTOR FLANGE & MOTOR BODY TO
MOTOR BOTTOM COVER PLATE STUD TENSIONING KIT

The Tightening Procedure of these Bolts as followed by HAYWARD

TAYLOR and TORISHIMA are different and thus the KIT supplied are also
of DIFFERENT TYPES.

HAYWARD TAYLOR PROCEDURE:

HAYWARD TAYLOR follows the concept of

tightening the FLANGE STUDS by using HY-
DRAULIC PRESSURE and thus uses HIGH
PRESSURE HYDRAULIC PUMPS AND
JACKS. As shown in the attached photo-
graphs, jack-nuts are attached to the STUDS
and oil pressure APPLIED BY hand Operated
High Pressure Pump to the tune of 1500 kg/
cm2.

The KIT are sent along with the Main Pump and Motor Supply and all the
items involved lime High Pressure Pump, High Pressure Hoses, Jack-Nuts are
 Pump and Hoses Jacks for fixing to studs

Spare Gasket , one for each pump , are sent for changing when the PUMP
CASING DUMMY PLATE ( assembled for Boiler Hydro Test ) is to be re-
moved for assembling the MOTOR after Boiler Hydro Test.

TORISHIMA PROCEDURE:

Torishima does not use the System of Hydraulic Pressure as is being fol-
lowed by Hayward Taylor but uses the system Of STUD HEATING. The KIT
consists of Rod Type STUD Heaters, and a Heater Panel
 Heater Control Panel Casing Studs

Casing Studs Heating in process

DETAILS OF THE KIT AND THEIR OPERATION ARE GIVEN IN THE PUMP
ERECTION MANUAL.
PUMP CASING
 PUMP CASING

The Pump Casing are different for the Different Pump Suppliers, due to dif-
ference in the Product Design. Hayward Taylor Pumps for 500 MW boilers
has ONE inlet to be connected to the Inlet Pipe from Suction Manifold and
TWO discharges to be connected to Ring Header. Torishima Pumps for
500 MW also has the same constructional feature, but the difference lies in
the Pump Casing To Motor Connecting Flange Studs as seen in the Photo-
graphs below. This is dbecause, Torishima has provided HEAT BARRIER

Hayward Taylor 500 MW Torishima 500 MW Hayward Taylor 660 MW

( ADDITIONAL COOLER ) in between Pump Casing and Motor Flange. In

the case of CC Pumps for Super Critical Boilers, there will be only ONE
OUTLET and ONE INLET.

Pump Casing is lifted and positioned to be

welded to the Suction Pipe from Suction Mani-
fold .

VERTICALITY OF THE PUMP CASE TO BE

STRICTLY WITHIN 1 DEGREE
PUMP DISCHARGE CUM
CHECK VALVE
CC PUMP DISCHARGE VALVE ( STOP CHECK
VALVE )

Two Nos of PUMP DISCHARGE valves are provided on the TWO DIS-
CHAGE limbs of the Pump Casing and the arrangement is the same for
both TORISHIMA and HAYWARD TAYLOR make. There is no discharge
valve provided on the pump casing in case of Super Critical Boilers.

DISCHARGE VALVE DISCHARGE VALVES

These Discharge Valves has Double function as its name indicates as

STOP CHECK VALVE. The valve acts
both as Shut Off valve and also as NRV.
Two nos valves are provided for each
pump and each valve is provided with 2
nos Limit switches for Open and Close in-
dications. These valves are Manually op-
erated.
PUMP ERECTION SEQUENCE

PHOTOGRAPHICALLY
 ERECTION OF MOTOR

The procedure for Motor Erection is almost the same for all makes ex-
cepting in the way the Studs are Tightened. The Stud-Nut connection be-
tween the Pump Casing and the Motor Flange are Tightened by HYDRAU-
LIC Method in case of HAYWARD TAYLOR and by ELECTRIC HEATING
in case of TORISHIMA pumps.

Details of the tightening procedures are given in the ERECTION manual

of the pumps. Please refer Manual for details.

PHOTOGRAPHIC ILLUSTRATION OF THE ERECTION PRO-

CESS OF MOTOR

1. Erection of HOISTS for lift-

ing the MOTOR.

Hoists are suspended from

the SUCTION MANIFOLD
through LUGS provided
on the suction manifold.

2 nos of Hoists are provided

for each Pump
2. Removal of Dummy Plate
from Pump Casing Bottom

Use HYDRAULIC KIT for Hayward

Tayor and ELECTRIC HEATING
arrangement for Torishima make
pumps for removal of the Pump
Casing BLANK.

PUMP CASING

CASING BLANK

\
3. Cleaning and Checking of
Casing Inside

Ensure Perfect cleaning of Casing

Inside before lifting of the Motor.

Check for proper tightening of the

CASING WEAR RING fixed on the
Casing Inside.

MEASURE CASING INTERNAL DI

-AMETER AND RECORD. THIS IS
REQUIRED TO SEE THE CLEAR
ANCE AVAILABLE FOR IMPEL
LER TO ENTER THE CASING
WHILE LIFTING THE MOTOR.
.
4. Draining of the Inhibitor
from the Motor by remov-
ing the Cannister

MOTOR

CANNISTER

DRAINING OF THE
INHIBITOR IN TO
A BUCKET

IMPELLER
5. Carryout thorough Inspection of
the IMPELLER for any Defects
before lifting the Motor up into the
Pump Casing

IMPELLER

6. MEASURE OUTSIDE DIAMETER

OF THE IMPELLER AND
RELATE TO INSIDE DI
AMETER OF THE PUMP
CASING FOR AVAILIBIL
ITY OF REQUIRED
CLEARANCES DURING
IMPELLER INSERTION
AND FOR SMOOTH OP
ERATION. RECORD THE
DIMENSIONS.

“OD” MEASUREMENT

7. MEASURE HEIGHT OF IM-

PELLER FROM MOTOR
FLANGE FACE AND REC-
ORD DIMENSIONS AND
RELATE TO CASING
DEPTH FOR AVAILIBILITY
OF RUNNING CLEARANC-
8. DEPTH MEASUREMENT OF
THE IMPELLER TIP TO MO
TOR FLANGE AND VALUES
RECORDED. COMPARE
THE VALUES WITH THE
CASING DEPTH DATA TO
ENSURE AVAILIBILITY OF
REQUIRED RUNNING
CLEARANCES.

IMPELLER HEIGHT
MEASUREMENT

9 ENSURE PROPER CLEANING

OF SEAL RING SEATING
SURFACE ON THE MOTOR
FLANGE.

SEAL RING SEATING

SURFACE

SEALING RING

SEALING RING
IN PLACE
13. MOTOR MADE VERTICAL FOR FI
NAL LIFTING OF THE MOTOR TO
PUMP CASING.

14. MOTOR BEING LIFTED

10. ARRANGEMENT OF THE 2 NOS
PERMANENT HOISTS ( HOISTS
FIXED TO SUCTION MANI

11. HOOKING UP THE 2 HOISTS

TO THE MOTOR FOR LIFTING.

12. LIFTING OF MOTOR IN PROGRESS

13. MOTOR REACHES PUMP
CASING.

PUMP CASING.

IMPELLER

MOTOR

14. LAST PHASE...IMPELLER BE

NG INSERTED INTO THE
PUMP CASING.
15. MOTOR FLANGE TO PUMP
CASING STUD TIGHTENING
BY HYDRAULIC KIT IN
PROGRESS.

16. MOTOR FLANGE TO PUMP CASING

STUD TIGHTENING COMPLETE AND
MOTOR ERCTION COMPLETED.
DRAWINGS
CC PUMP SYSTEMS

PHOTOGRAPHICALLY
HP FILL AND PURGE
WATER COOLER

COOLER

HP FILL & PURGE

FILTER

HP PURGE WATER SUPPLY HP PURGE WATER SUPPLY FROM

FROM BFP DISCHARGE CEP DISCHARGE
 STRAINER

NON RETURN VALVE

PUMP CASING
INSULATED
 PUMP CASING

HEAT BARRIER

MOTOR

COOLING WATER
FLOW METER
HP FILL & PURGE LINE
CONNECTION
TO MOTOR

COOLING WATER HOSES

VIEW OF CC PUMP\
MOTOR
MOTOR CAVITY WA-
TER FILLING STA-
TION

NON RETURN VALVE

HP FILL & PURGE

STRAINER
660MW CC PUMP

MOTOR

PUMP DISCHARGE

PUMP CASING

MOTOR
COOLING WATER SYSTEM

COOLING WATER OVER HEAD

TANK

COOLING WATER
PUMPS
 PUMP CASING

COOLER

MOTOR

COOLING WATER
SAFETY VALVE

COOLING WATER HOSES

MOTOR CAVITY
TEMP MEASUREMENTS
PUMP DISCHARGE &
CHECK VALVE

LIMIT SWITCHES OF
DISCHARGE CUM
CHECK VALVE
 PUMP SUCTION PUMP CASING
LINE

2 NOS DISCHARGE CUM CC PUMP ASSOCIATED

CHECK VALVES IMPULSE PIPINGS &
INSTRUMENTATIONS