OPERATING AND MAINTENANCE INSTRUCTIONS OF PUMPS...
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
EQUIPMENT DETAILS
A.
BOILER FEED BOOSTER PUMP
B.
BOILER FEED PUMP
C.
CONDENSATE EXTRACTION PUMP
PART – 5 A. PART – 6
SUB-DELIVERY ITEMS RECIRCULATION CONTROL VALVE DRAWINGS / DOCUMENTS
A.
BOILER FEED BOOSTER PUMP
B.
BOILER FEED PUMP
C.
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
TITLE
1
General System Description
2
Equipment Schedule
3
Sub-Vendor List for Bought-out Items
PART – 2 SYSTEM INFORMATION
1.0
GENERAL SYSTEM DESCRIPTION
1.1
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 Volume–1 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 :
(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
(b)
M/s.Flowserve Sanmar Limited 147, Karapakkam Village CHENNAI – 600 096 Tel : 044-2450 4140 Fax : 044-2450 2124
(c)
M/s.Eagle Seals&Systems India Ltd 212/2, Sholapur-Poona Road Hadapsar PUNE – 411 028 Tel : 020-2650 8100 Fax : 020-2699 3921
(a)
M/s. Waukesha Bearings Argyle House, Joel Street Northwood Hills, Middlesex. Middlesex, United Kingdom, HA 6 1LN
(b)
M/s.Michell Bearings Scotswood Road New Castle Upton Type N E 1 5 6LL, U.K.
(c)
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
(d)
M/s.Colherne Ltd. Lodge Street, Newton Hyde Cheshire, SK 14 4LE United Kingdom Tel : 061-366 6603 Fax : 061-367 8239
BFP & CEP ⇒
BP ⇒
3.2
Journal Bearings :
3.3
Thrust Bearings :
(a)
M/s.Michell Bearings Scotswood Road New Castle Upton Type N E 1 5 6LL, U.K.
(b)
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
(c)
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
(a)
M/s. Voith Turbo GMBH & Co. P.B.No.1555 D-7180, Crailsheim GERMANY
BP & CEP ⇒
BFP
3.4
⇒
Hydraulic Coupling
⇒
3.5.
BFP RC Valve
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
(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
3.7
Suction Strainers BP : Simplex Basket type BFP : Conical type CEP : Simplex Basket type
⇒
Connecting couplings
(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
(b)
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 :
[email protected]
(c)
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
(a)
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
(b)
M/s. Bibby Transmissions Limited. Cannon Way, Mill Street West Dewsbury, Yorkshire, WF 13 1EH, UK
BP, BFP & CEP ⇒
I/A : M/s.Rathi Transpower Pvt. Ltd. Rathi Chambers, 7-Deccan College Road PUNE – 411 006 Tel : 020-26696820, 26694826 Fax : 020-26695655
3.8
3.9
Local Gauge Board Assy with Pre & Temp Instruments
Local Instrument Rack ⇒ for Transmitters, BFP&CEP
(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
(a)
M/s. Nagarjuna Fabricators Plot No. 44-B, Phase-1 IDA, Jeedimetla Hyderabad – 500 855 Tel : 040-23096515 Fax : 040-23413977
(b)
M/s. Procon Instrumentation Pvt. Ltd. 1H, Sakthi Towers 766, Anna Salai Chennai – 600 002 Tel : 044-28524942 Fax : 044-28522348
(c)
M/s. Panam Controls 12-11-1299/3, Raghavendra nagar Warasiguda Secunderabad – 500 061 Tel : 040-27077546 Fax : 040-27070365
(d)
M/s. Instrumentation Limited KOTA – 324 005 Tel : 0744-426309, 423381-85 Fax : 0744-426309
(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)
NOTE :
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
⇒ - Indicates make of the equipment in original supply.
== ## ==
PART - 3
PRESERVATION & STORAGE
LIST OF CONTENTS
STD. NO.
TITLE
HY0490563
TRP Application on Ferrous components of different products
HY0490564
Code of practice for storage of different products and their components
HY0490563
PLANT STANDARD
REV. NO: 04
HYDERABAD
PAGE 1 OF 12
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.
TRP APPLICATION ON FERROUS COMPONENTS OF DIFFERENT PRODUCTS 1.
SCOPE:
1.1
The standard covers the selection and applications of Temporary Rust Preventives (TRP) for different products & their components during production, before despatch and at site.
1.2
This standard supersedes the old company standard and other Product Standards/ documents made on the subject.
2.
GENERAL: The effectiveness of TRP depends on the following aspects:
2.1
Selection of proper TRP.
2.2
Proper preparation of the surface to be protected. Refer plant standard HY 067 41 66.
2.3
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.
2.4
TRP – Reference on manufacturing & erection instructions/drgs. wherever necessary by Engg.
3.
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.
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:
Prepared:
Approved:
Date:
Dt.FEB. 98
STDS. ENGG.
SR.MANAGER STDS. ENGG.
MAY, ‘83
Dt.
Year:
Issued : STANDARDS ENGINEERING DEPARTMENT
PAGE 2 OF 12
PLANT STANDARD HYDERABAD
5.
TRP APPLICATION:
5.1
The application of TRPs is classified in Annexure II keeping in view the finish and the extent of protection required.
5.2
The details of components against each category of application are given productwise in the Annexure III.
6.
PRECAUTIONS FOR APPLICATION:
6.1
The TRP shall be stirred well in the original container so as to make a homogenous mixture of its constituents.
6.2
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.
6.3
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.
6.4
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.
6.5
The quality of preservative layer shall be checked by visual inspection for uniform coat. Any defect observed shall be immediately rectified.
7.
DURABILITY OF PRESERVATION: The durability of preservation varies from 6 months to 1 year depending on the category of TRP application refer Annexure–I. 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.
8.
DETAILS OF REPRESERVATION TECHNIQUES:
8.1
The earlier coating shall be removed by using white spirit.
8.2
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.
8.3
Surfaces prepared for re-preservation shall not be touched by hand.
8.4
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
Copyright and Confidential
Rev. No.04
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.
HY0490563
PLANT STANDARD
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.
HYDERABAD
HY0490563 REV. NO.04 PAGE 3 OF 12
9.
DEPRESERVATION BEFORE ASSEMBLY / ERECTION:
9.1
Depreservation of the various parts shall be done during Assembly/erection period as and when necessary.
9.2
Depreservation of parts consists of removal of TRP coatings from all the machined surfaces with white spirit.
9.3
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.
This standard on preservation of different products and components shall be followed.
2.
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.
3.
The components should be stored in such a way that TRP film does not get damaged.
4.
The surface of TRP coated components shall be examined for damage and corrosion spots regularly.
5.
Represervation shall be followed as per the Tag attached to the component.
6.
Inspect coated and wrapped surfaces. If coating or wrapping appears to have been removed during shipping clean and re-wrap or coat as applicable.
7.
Inspect shafts for adequate preservative and add a heavy film of valvoline TECTYL 894 or Equivalent as necessary.
8.
Rotate the Rotors a few revolutions every month and ensure that the bearings are packed with grease.
PLANT STANDARD HYDERABAD
PAGE 4 OF 12
RECOMMENDED TYPES OF TRPs (Clause – 3) Type of TRP Hard Film Solvent deposited
Soft Film deposited Grease Oil
Powder/ Tablet Paper Gas Crystal
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
ANNEXURE-I
Durability of Protection 6 months
Equivalent Brands HE 1710 (Bhopal)
1 year
HE 1706 (Bhopal)
6 months
HE 1709 (Bhopal)
3 months
HE 1712 (Bhopal)
Smearing Brushing
6 months
Dipping, Rinsing, Spraying,
3 weeks
IOC MultiPurpose Grease No.2 HE 1711 (Bhopal) ESSO: RUST BAN 394
Sprinklin
3 months
Wrapping Filling Inserting
3 months 3 months 3 months
-Do-
6 months
Copyright and Confidential
Rev. No.04
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HY0490563
HY0490563
PLANT STANDARD
REV. NO.04 PAGE 5 OF 12
HYDERABAD TRP APPLICATION CATEGORIES (Clause – 5)
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.
TRP Application Category
A
B
Application Details
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.
Longer duration of protection before despatch to site. Suitable for precision machined surfaces with simple profiles, eg. Rotor Journal Surfaces
C
Apply 2 Coats of Anti Rust solution, steam washable (TRP) (AA55151) / HE1712
D
Apply 2 Coats of Rust Preventive solution, Clear (TRP) (AA55152) / HE1709 Apply 2 Coats of TRP fluid (IS:1153)
E F G H I
ANNEXURE-II
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
Rev. No.04 PAGE 6 OF 12
HYDERABAD
J
K
Application Details
Guide Lines for Selection
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 Suitable for all exposed tapped holes and flanged openings on the pumps and Tubings.
Copyright and Confidential
TRP Application Category
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.
ANNEXURE – II
HY0490563
PLANT STANDARD
REV. NO.04 PAGE 7 OF 12
HYDERABAD PRODUCT COMPONENTS – TRP CATEGORIES (CLAUSE –5.2)
ANNEXURE –III DETAILS OF COMPONENTS
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.
STEAM TURBINE AND COMPRESSORS HP,LP and other rotors. Rotor Journals, Thrust Collars 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
TRP APPLICATION CATEGORY A B B B B B
B B B B B B B B B B B B B
HY0490563 Rev. No.04 PAGE 8 OF 12
PLANT STANDARD HYDERABAD
ANNEXURE –III
C C C C C C
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
C C C C C C C C C C C C C
Copyright and Confidential
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
TRP APPLICATION CATEGORY C
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.
DETAILS OF COMPONENTS
PLANT STANDARD HYDERABAD
HY0490563 REV. NO.04 PAGE 9 OF 12
ANNEXURE –III DETAILS OF COMPONENTS
Copyright and Confidential
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.
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
TRP APPLICATION CATEGORY C C C C C C D/E
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
G G
Oil pipeline outside the governing equipment Other pipings
I I
ELECTRICAL MACHINES Rotor Journals, Slip rings, Journals of Armature
A
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
G G G G G G G
B B G H
HY0490563 Rev. No.04 PAGE 10 OF 12
PLANT STANDARD HYDERABAD ANNEXURE –III
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.
A
D/E F G
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.
D/E
Inside water chamber and shell side of feed water heaters
J
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)
G
G G G
G L
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SWITCHGEAR Hydraulic pistons
TRP APPLICATION CATEGORY
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.
DETAILS OF COMPONENTS
PLANT STANDARD HYDERABAD
HY 0490563 REV. NO.04 PAGE 11 OF 12 ANNEXURE – III
DETAILS OF COMPONENTS BOWL MILLS Machined surfaces
Copyright and Confidential
D/E
Inside Gear case assembly
F
Bearings, Drive couplings, fastener, external/internal threaded surfaces
G
PUMPS Journal Bearings, bearing surfaces and exposed portion of shafts.
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
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
A B
F G K
A F K
Exposed machined surfaces/parting planes of all ferrous fabricated frames including base plates, couplings
B
Fasteners, External/Internal threaded joints
G
Oil pipes when stored for long periods or when despatched loose
I
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
HY0490563
PLANT STANDARD
Rev. No.04
HYDERABAD
PAGE 12 OF 12
ANNEXURE – A
-
Rust preventive oil
M/S. Ceturion coatings, Madras
-
Rust preventive compound (proprietary)
M/S. Agromore Ltd., Bangalore
-
Rust preventive Agents
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)
M/S.
Prosol Chemicals Pvt. Ltd.
M/S.
Futech chemicals (P), Secundeabad -
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)
Copyright and Confidential
M/S. BHEL, Bhopal
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.
LIST OF SUPPLIERS OF TRP
PLANT STANDARD HYDERABAD
HY0490564 REV. NO: 01 PAGE 1 OF 7
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.
CODE OF PRACTICE FOR STORAGE OF DIFFERENT PRODUCTS AND THEIR COMPONENTS 1.0
SCOPE:
1.1
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.
1.2
Reference may be made to the following related standards:
1.2.1
HY 0490561 - Code of practice for storage of preservation of Materials in stores.
1.2.2
HY0674160
1.2.3
HY0490563
2.0
- Code of practice for painting of different products and their components.
- Code of practice for preservation of different products and their components. TYPES OF STORAGE CONDITIONS: The storage conditions are classified as follows:
2.1
Storage condition ‘P’
2.1.1
Denotes storage in a totally enclosed shed under controlled conditions.
2.1.2
The shed shall be free from any kind of corrosive gas like chlorine, ammonia or smoke, chemicals and charged accumulators.
2.1.3
Stored items shall be covered with polythene sheets.
2.2
Storage condition ‘Q’
2.2.1
Denotes storage in a totally enclosed shed.
2.2.2
The shed shall be ventilated dry, free from dust, any kind of gas or chemicals.
2.2.3
Items like Motors, Coils and all spare parts shall be covered with polythene sheet.
Revisions
Issued :
Rev.No.
Rev. Date
Revised:
01
OCT. 93
AGM (E&CC)
STANDARDS ENGINEERING DEPARTMENT Prepared: Approved: Date: SR.MANAGER VNR STDS. ENGG. MAY, ‘83
PAGE 2 OF 7
PLANT STANDARD HYDERABAD
2.3
Storage condition ‘R’
2.3.1
Denotes storage in shed having roof but no side walls.
2.3.2 2.4
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’
2.4.1
Denotes storage in open yard on elevated platform/wooden sleeper.
3.0
GUIDELINES FOR CONSTRUCTION OF STORAGE SHEDS
3.1 3.2 3.3 3.4 3.5
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.
4.0
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.
Copyright and Confidential
Rev. No.01
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HY0490564
PLANT STANDARD HYDERABAD d)
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.
REV. NO.01 PAGE 3 OF 7
Casings i)
e)
HY0490564
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.
6.0)
NOTE 1)
Refer Plant Standard Hy 0490562 for ‘Preservation of Heat Exchangers before shipment.
HY0490564 Rev. No.01
PLANT STANDARD
PAGE 4 OF 7
HYDERABAD Annexure 1
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
P
Maximum Temparature 20º C. Temparature deviation in 24 hours shall not exceed 5º C. Humidity less than 40%.
Q
R S P
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.
Remarks
Copyright and Confidential
INDUSTRIAL TURBINE & COMPRESSORS Instruments like Electromagnetic protection, vibration measuring equipment, Eccentricity mesuring equipment.
Type of storage
Q
Max Temp 20ºC. Temparature deviation in 24 hours shall not exceed 5ºC. Humidity less than 40%
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.
Details of components/parts
HY0490564
PLANT STANDARD
REV. NO.01 PAGE 5 OF 7
HYDERABAD
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.
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
Q
Q
R S
Remarks
HY0490564 Rev. No.01 PAGE 6 OF 7
PLANT STANDARD HYDERABAD
Details of components/parts
Type of storage
Remarks
P
Q
Copyright and Confidential
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
Temparature Range 35-45º C. Relative humidity less than 40%, Dust free atmosphere.
R
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
R Q P
Axial shift indicator, Reverse Running inidcator, vibraton Monitor instrument.
Maximum Temperature deviaton in 24 hours shall not exceed 5º C. Humidity less than 40%
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.
TURBO GENERATORS & AUXILIARIES
HY0490564
PLANT STANDARD
REV. NO.01 PAGE 7 OF 7
HYDERABAD
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.
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
Q
R
Q
Remarks
PART – 4 EQUIPMENT DETAILS
PART – 4
EQUIPMENT DETAILS
LIST OF CONTENTS
SECTION
TITLE
(A)
Boiler Feed Booster Pump
(B)
Boiler Feed Pump
(C)
Condensate Extraction Pump
SECTION - A
BOILER FEED BOOSTER PUMP
PART – 4 EQUIPMENT DETAILS
SECTION - A BOILER FEED BOOSTER PUMP
LIST OF CONTENTS
CHAPTER
TITLE
1
Description
2
Opening Instructions
3
Maintenance Instructions
4
Sub-Vendor’s Drawings / Instructions
SECTION - A BOILER FEED BOOSTER PUMP
CHAPTER – 1 DESCRIPTION LIST OF CONTENTS
1
Introduction
2
Technical Data
2.1
Motor Driven pump
2.2
Turbine driven pumps
2.3
Driver / Pump flexible coupling
3
Description
3.1
Pump casing
3.2
Rotating assembly
3.3
Journal and thrust bearings
3.4
Bearing housings
3.5
Mechanical Seals
3.6
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.
TECHNICAL DATA :
2.1
Motor Driven Pump
2.1.1
Pump Manufacturer Type Direction of rotation (Viewed on non-drive end) Liquid pumped
2.2
Turbine Driven Pump
2.1.2
Pump Type Direction of rotation (Viewed on non-drive end) Liquid pumped
2.3
BHEL FA1B75 Anti-Clockwise Boiler feed water
FA1B75 Clockwise Boiler feed water
Thrust Bearing Manufacturer Type
Michell Bearing / Glacier Double thrust
2.4
Mechanical seal Manufacturer
2.5
BURGMANN, Germany
Driver/Pump Flexible Coupling Manufacturer
3.
DESCRIPTION :
3.1
Pump Casing :
Euroflex, India
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 manufacturer’s 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 60°C. 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.
Introduction
2.
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)
(2)
Pump fails to starts.
Pump performance Low.
Possible Cause
Action
(a) Driver fault.
Check driver.
(b) Power supply fault.
Check supply.
(c) Seizure of pump set
Disconnect couplings and Locate seizure. Overhaul as necessary.
(d) Deareator Level Low- Low
Check deareator.
(e) Pump set tripped.
Investigate cause. Rest trips.
(a) Driver fault
Check driver.
(b) Incorrect rotation.
Check direction of driver.
(c) Pump suction defective.
(d) Excessive wear pump internals.
line
Check deaerator, suction strainer and suction isolating valve, etc.
of
Check clearances and overhaul as necessary.
Symptom (3)
(4)
(5)
Bearings overheating.
Mechanical seals overheating
Excessive noise and/or vibration
Possible Cause
Action
(a) Defective in lubricating oil system.
Check lubricating oil system.
(b) Bearings worn or misaligned.
Examine bearings.
(c) Misalignment of pump.
Check alignment.
(a) Insufficient cooling water.
Check cooling water supply.
(b) Mechanical seal faulty.
Check mechanical seal.
(a) Misalignment of pump.
Check alignment.
(b) Bearing misalignment.
Examine bearing.
(c) Excessive clearance of pump internals.
Check clearances and overhaul as necessary.
(e) Rotating assembly out of balance.
Check dynamic balance.
SECTION – A BOILER FEED BOOSTER PUMP
CHAPTER – 3 MAINTENANCE INSTRUCTIONS
LIST OF CONTENTS
1
Introduction
1.1
Periodic and preventive maintenance
1.2
Routine checks
2
Maintenance Particulars
2.1
Estimated weights
2.2
Joints
2.3
Recommended lubricants
3.
Maintenance procedures
3.1
Preparation for maintenance
3.2
Examine the drive and journal bearing
3.3
Examine the non-drive and journal and thrust bearing
4.
Overhaul
4.1
Preparation for overhaul
4.2
Dismantling the pump
4.3
Inspection and renewal
4.4
Assembling the pump
5
Parts Identification
CHAPTER – 3 MAINTENANCE INSTRUCTIONS
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 manufacturer’s instructions in Chapter-4. 2
MAINTENANCE PARTICULARS :
2.1
Estimated Weights (for lifting purposes)
2.2
2.3
Item
Weight, Kg.
Pump assembly Top half pump casing Pump shaft Impeller Water jacket
2365 760 74.5 127 31
Joints : Joints Between
Material
Section
Top half pump casing/ Bottom half pump casing Pump casing / water jacket Non-drive end bearing Housing / end cover
Brown paper
Two ply
Klingersil 4200 Brown paper
Two ply
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 manufacturer’s instructions for the turbine and the turbo coupling.
3.
MAINTENANCE PROCEDURES : WARNING :
Note :
3.1
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.
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 manufacturer’s 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.
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.
(4)
Withdraw the dowel pins and remove the nuts from the studs securing the top of bearing housing to the bottom half bearing housing.
(5)
Lift away the top half bearing housing complete with the top half oil guards. Remove the top half journal bearing from the shaft.
(7)
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.
(8)
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.
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)
Locate the top half journal bearing in position on the pump shaft.
(11)
Lift the top half bearing housing complete with the top halves of the oil guards onto the bottom half bearing housing.
(12)
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.
3.3.
(13)
Reconnect the drive/pump coupling.
(14)
Replace the instruments and the drive/pump drive coupling guard.
Examine the non-drive End (NDE) Journal and Thrust Bearing : (1)
Disconnect and remove any instrument dismantling procedures.
(2)
Remove the drive / pump drive coupling guard.
(3)
Disconnect the drive / pump coupling.
(4)
Remove the screws securing the bearing housing end cover to the top and bottom half bearing housings. Remove the cover and discard the joint.
CAUTION :
which could interface with the
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.
(5)
Withdraw the dowel pins and remove the nuts from the studs securing the top half bearing housing to the bottom half bearing housing.
(6)
Lift the top half bearing housing complete with the top half oil guard away. Remove the top half journal bearing form the shaft.
(7)
Unclip the spring and remove the split floating oil seal from the bearing housing.
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.
(9)
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.
(10)
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
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.
(12)
Fit a new paper joint onto the end cover and secure the cover to the bottom half bearing housing with the screws.
(13)
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.
Note : (a)
(b)
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.
(15)
Locate the top half journal bearing in position on the pump shaft.
(16)
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.
(17)
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.
4.
(18)
Secure the bearing housing end cover to the top half housing with the screws.
(19)
Install the drive/pump drive coupling spacer and element assemblies.
(20)
Replace the instruments and the drive / pump drive coupling guard.
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 :
4.1
IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE PROCEDURE.
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 manufacturer’s instructions). Isolate the electrical power supplies to all instruments.
CAUTION :
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.
(3)
Check that the pump set suction, discharge and leak-off isolating valves are shut.
(4)
Check that the cooling water has been isolated.
(5)
Open the drain and vent connections and drain the pump casing.
WARNING :
BEFORE PROCEEDING WITH OVERHAUL OF THE PUMP, ENSURE THAT THERE IS NO PRESSURE WITH IN THE PUMP CASING.
(6)
Disconnect and remove any instrument which could interfere with the dismantling procedures.
(7)
Disconnect and remove any small bore pipe work which could interfere with the Dismantling procedures.
(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)
Remove the drive / pump drive coupling guard.
(2)
Remove the drive / pump drive coupling spacer and element assemblies.
CAUTION :
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.
(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.
(4)
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.
(5)
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.
CAUTION :
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.
(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.
(7)
Lift away the top half bearing housing, complete with the top half / oil guard.
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.
(9)
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.
(10)
Remove the grub screws securing the seal sleeve to the shaft.
The thrust carrier ring split line is vertical to the bearing housing horizontal surface.
(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.
(12)
Remove the socket head screws securing the water jackets to the pump casing at the drive and non-drive end of the pump casing.
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.
(14)
Attach lifting equipment to the cast lugs on the top half pump casing.
(15)
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.
(16)
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.
(17)
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.
(18)
Remove the bottom halves of the journal bearings and the oil guards from the drive and non-drive end bottom half bearing housings.
(19)
Slacken the coupling nut lock washer, unscrew and remove the coupling nut.
(20)
Withdraw the pump half coupling from the shaft. Remove and retain the coupling key.
(21)
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 manufacturer’s instructions in Chapter-4.
(22)
Withdraw the drive end water jackets from the shaft, then lift the casing wear ring off the impeller.
(23)
Unlock the thrust collar nut lock-washer, then using the special spanner supplied, unscrew and remove the nut. Remove and retain the lockwasher.
(24)
Withdraw the thrust collar from the shaft. Remove and retain the thrust collar key.
4.3
(25)
Remove and retain the split floating oil seal.
(26)
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 manufacturer’s instructions in Chapter-4.
(27)
Withdraw the non-drive end water jacket from the shaft, then lift the casing wear ring off the impeller.
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.
(2)
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. 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)
4.3.5
Thrust collar and Floating oil seal (1) (2)
4.3.6
Examine the thrust collar for any signs of wear or damage. Examine the floating oil seal for any wear or damage.
Studs, Nuts, Dowels and Keys (1)
(2) (3)
4.3.7
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.
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.
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
4.3.9
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.
4.3.10 Mechanical Seals Information on dismantling and examining the mechanical seals is given in the Manufacturer’s 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)
Support the pump shaft / impeller assembly on wooden trestles.
(2)
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.
(3)
Ensure that a new ‘O’ ring is located in the internal groove of each seal sleeve and the groove in the seal plate face.
(4)
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.
(5)
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.
(6)
Screw on and tighten the coupling nut and screw it in position with the lock screw.
(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.
(8)
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.
(9)
Allow the collar to cool to ambient temperature, then secure it in position with the thrust collar nut and lock-washer.
(10)
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.
(11)
Renew the top / bottom half pump casing joint.
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.
(14)
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.
(15)
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.
(b)
Install the outer halves of the thrust bearing carrier rings and spacers in the bottom half bearing housing.
(c)
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.
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)
Install the split floating oil seal on the pump shaft with the spring.
(17)
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.
(17)
(18)
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.
(19)
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.
(20)
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.
(21)
Secure the bearing housing end cover to the top half housing with the screws.
(22)
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.
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.
(24)
Secure the water jackets to each end of the pump casing with the socket head screws.
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.
(26)
Secure the seal plates to the water jackets with the socket head screws.
(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 manufacturer’s instructions.
5.
(28)
Replace all small bore pipe work and instruments that were removed for dismantling purposes.
(29)
Check the coupling alignment (refer to Illus. No P2424) then install the driver/pump drive coupling spacer and element assemblies. Replace the coupling guard.
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
BOILER FEED BOOSTER PUMP
CHAPTER – 4 SUB – VENDOR’S DRAWINGS / INSTRUCTIONS
LIST OF CONTENTS
1.
Mechanical Seals
2.
Heat Exchangers for Mechanical Seal
3.
Magnetic filters for Mechanical Seal
4.
Thrust Bearing
5.
Connecting coupling between BP & Motor
6.
Suction Strainer before Booster Pump
SECTION – A
BOILER FEED BOOSTER PUMP
CHAPTER – 4 SUB – VENDOR’S DRAWINGS / INSTRUCTIONS
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
BHEL (India)
Pump company
BHEL
Pump type & size
FAIB75
PLEASE READ this manual carefully and OBSERVE the information contained as to Safety
Start up
Removal
Storage
Maintenance
Repair
Installation
If there are any unclear points please contact BURGMANN by all means.
Table of Contents 1.
PRODUCTION INFORMATION .......................................................................... 3
1.1
Manufacture and country of origin ....................................................................... 3
1.2
Declaration .......................................................................................................... 3
1.3
Type designation ................................................................................................. 3
1.4.
Operating conditions ............................................................................................ 3
1.5
Designated use .................................................................................................. 3
1.6
Drawings, diagram .............................................................................................. 4
1.7
Description and function ..................................................................................... 4
1.8
Required space, connecting dimensions ............................................................ 4
1.9
Power requirements ............................................................................................ 4
1.10
Additional equipment ......................................................................................... 5
1.11
Emissions ........................................................................................................... 5
1.12
Copyright ............................................................................................................ 5
2.
SAFETY NOTES ............................................................................................... 6
3.
TRANSPORT, STORAGE, INSTALLATION....................................................... 7
3.1
Recommendation for transport and storage......................................................... 7
3.2
Preparation for assembly .................................................................................... 10
3.3
Assembly / installation ........................................................................................ 10
3.4
Supply connections ............................................................................................. 11
4.
OPERATION ...................................................................................................... 12
4.1
Instructions for start up ....................................................................................... 12
4.2
Instructions for safe operation ............................................................................. 12
4.3
Instructions for worker’s protection ..................................................................... 12
4.4
Directives in case of failure ................................................................................. 13
5.
SERVICING ........................................................................................................ 13
5.1
Maintenance ....................................................................................................... 13
5.2
Reconditioning (repair) ........................................................................................ 13
5.3
Disassembly / removal ........................................................................................ 14
5.4
Spare parts ......................................................................................................... 14
5.5
Required details for enquiries and orders ........................................................... 14
5.6
After-sales service by BURGMANN .................................................................... 15
1.
PRODUCT INFORMATION
1.1
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> operating data 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 µm (=N7=CLA 63).
•
Shaft surface in the area of the M.S.: fine finished Rmax. 5 µm (=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 > MACHINERY> operating data 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 µm (=N7=CLA 63).
•
Shaft surface in the area of the M.S.: fine finished Rmax. 5 µm (=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
