TORISHIMA

Boiler Circulation Pumps

HLAV
Contents

6. Disassembling procedure
7. Overhaul Inspection
8. Trouble shooting


Training course 3
Disassembling and Inspection

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