6. Disassembling Procedure 6.0 Flushing and cleaning of pump motor set before disassembling Open Casing drain valve2 slowly till full open and drain Boiler water from pump casing completely. Close Suction & Discharge Main valves fully and confirm Boiler water temp is less than 63 deg. C. Open purge water valve1 slowly and confirm purge water flow to be max. 5L/min. for flushing and cleaning of Motor . After confirming the drained water from valve2 is clean and the color is same as drinking water, close valve1 and open drain valve3 for whole drain from pump/motor set after flushing/cleaning. Valve2 Valve1 Valve3 Disconnect the main cables Remove the motor cooler 6. Disassembling Procedure Disconnect LP cooling water piping from motor cooler and heat barrier Disconnect the HP cooling water piping from motor and HP cooler LP : auxiliary cooling water HP : cooling water inside motor Remove the instruments 6.1 Dismantling motor unit from pump casing 6.1 Dismantling motor unit from pump casing Install the chain/sling on the motor lifting lugs to lift by chain blocks Insert the bolt heater into each of the 16 stud bolts Heat all stud bolts and unscrew all nuts Do not exceed 300 deg.C surface temperature of the stud bolts! Remove all nuts and protect the stud bolt threads Be careful of burns !! 6. Disassembling Procedure 6. Disassembling Procedure 6.1 Dismantling motor unit from pump casing CAUTION while Lifting down Pump/Motor set After removing Stud bolts Nuts, lift down pump/motor set slowly by operating both chain block at same time as in fig.1 till pump/motor set becomes free from pump casing as shown in fig.2. when pump/motor set is lowered down by approx. 100mm. Lift down pump/motor set to Floor Level for transport to Workshop. Fig.2 Chain Block 1 Chain Block 2 Fig.1 While lifting down motor unit, take care not to damage any parts Lower 100 mm Attach the temporary cover to impeller While lifting down motor unit, take care not to damage any parts Lay motor unit on the carrier and transport it to workshop for OH inspection & maintenance 6.1 Dismantling motor unit from pump casing Carrier 6. Disassembling Procedure Disassembling section of Motor unit 6.2.1 6.2.2 6.2.3 6. Disassembling Procedure 6.2 Disassembling of motor unit 6.2.4 HEAT BARRIER DIFFUSER PLAIN BEARING (UPPER) IMPELLER SHAFT Part name of Pump/Motor unit 1 6.2.1 Disassembling Impeller and the Heat Barrier Hex. Bolt (Lock washer) Impeller Hex. nut Plain bearing (2) Remove hex. bolt (first bend back lock washer) then remove impeller (3) Support the heat barrier by chain block then remove heat barrier and upper plain bearing (1) Remove hex. nut (first bend back lock washer) then remove diffuser Hex. Nut (Lock washer) Diffuser Heat barrier SHAFT THRUST BEARING CASE THRUST BEARING SEGMENT(LOWER) THRUST BEARING PLATE Part name of Pump/Motor unit 2 6.2.2 Disassembling Lower Bearing Assembly and Rotor
Hex. nut Thrust bearing case Lower half of thrust bearing Thrust bearing plate Shaft (1) Remove the thrust bearing case with lower half of thrust bearing (2) Remove hex. Bolt and pull the thrust bearing plate from shaft Hex. Bolt Lock washer MOTOR CASING THRUST BEARING SEGMENT(UPPER) PLAIN BEARING (LOWER) BEARING BRACKET Part name of Pump/Motor unit 3 Upper thrust bearing Motor casing Plain bearing Bearing bracket Socket head cap screw (3) Remove the upper half of thrust bearing, bearing bracket, and complete bottom plain bearing Rotor Motor winding Extension Pipe soft sheet soft sheet Sling Sling Boom 6.2.3 Pull out the rotor Prevent damage to the motor windings and coil ends by using soft (e.g. rubber) sheet Attach a temporary pipe and withdraw the rotor by the crane FILTER Part name of Pump/Motor unit 4 6.2.4 Disassembling of the Filter Set Socket head cap screw Filter with insert ring Remove the socket head cap screw and filter set with insert ring (1) Inspect all parts for wear - Replace new parts, if clearance is over the stated maximum clearances as follows Bearing section-1 Bearing section-2 Thrust bearing section c e d a=0 T b h f d1 g d2 Impeller section 7. Overhaul Inspection 7. Overhaul Inspection: To record all data A - A A A Dial gauge Dial gauge Dial gauge Lathe Magnet base (2) Measurement of insulation resistance (4) Run out check of Rotor Max. permissible out-of-round: 0.08mm Motor winding (3) Cleaning of winding set Motor winding ends : Rinsed with water lightly ! Not chemical or mechanical clean up ! Need Dynamic balance test in case of new Impeller 7. Overhaul Inspection Support (5) Check Flow conditions in heat barrier (6) Clean out LP cooling water side of motor cooler. Hydrostatic test of HP cooling water side. Heat barrier cooling water inlet / outlet HP CW side LP CW side - Clean out, if necessary -Pressure drop of heat barrier at nominal flow rate: 0.05 MPa or less 7. Overhaul Inspection (7) Cleaning the filter (8) Visual examination of motor windings Motor winding Filter 7. Overhaul Inspection Life time (Estimated) Impeller 20 Case wearing 5-10 Radial bearings 5-10 Metal sleeves 5-10 Thrust bearing segment 5-10 Thrust bearing plate 5-10 Stator coil 10-15 Gaskets, O-rings, Washers After dismantling these parts, new ones should be installed. * These life times are dependent on operational condition of BCP or plant condition. Also these life time is not guaranteed life but estimated/expected life. (Unit: year) 8. Trouble shooting: Cavity temp high No. Cause Research Remedy 1 Insufficient LP cooling water Examine LP cooling water flow rate. Cooler & HB: Refer to Data sheet Open valve fully. Engage LP cooling water flow. 2 LP cooling water temp. high Examine LP cooling water temp. Outlet temp.: max. 45 deg C Engage LP cooling water temp. 3 Leakage from flange Visual inspection Tighten stud bolts. Exchange gasket if necessary. 4* Leakage from HP cooling piping Visual and liquid dye penetrate examination. Repair by welding. 5* Malfunction of HP cooling water circuit Examine HP cooling water inlet / motor cavity temperature Flushing and cleaning of HP cooling water piping and filter. 6* Fouling of motor cooler tube Examine motor cooler inlet / motor cavity temperature Inspect shell inside via hand-hole. Cleaning of motor cooler tube. No.1, 2 No. 4, 5 No. 6 No. 4, 5 No. 3 Thank you for your kind attention