Вы находитесь на странице: 1из 675

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 SUB-DELIVERY ITEMS

A. RECIRCULATION CONTROL VALVE

PART – 6 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
BFP & CEP ⇒ 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

BP ⇒ (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

3.2 Journal Bearings : (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
3.3 Thrust Bearings : (a) M/s.Michell Bearings
Scotswood Road
BP & CEP ⇒ 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

BFP ⇒ (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

3.4 Hydraulic Coupling (a) M/s. Voith Turbo GMBH & Co.
P.B.No.1555
D-7180, Crailsheim
GERMANY

⇒ I/A: M/s.Voith India Pvt. Ltd.


P.O. Industrial Estate
Nacharam,
HYDERABAD-500 076
Tel : 040-2717 3561, 3592
Fax : 040-2727 1141

3.5. BFP RC Valve (a) M/s. Dresser Produits Industriels, France


I.A. : M/s. Dresser Valves India Pvt Ltd.
No.12, 2nd Floor, D-Block, Doshi Gardens
174, Arcot Road, Vadapalani
Chennai – 600 026
Tel : 040-52134056, 24802393
Fax : 040-52134057
⇒ (b) M/s. Control Components Inc.,
22591, Avenida Empresa
Rancho Margarita
California 92688 U.S.A
I.A. : M/s. Control Components India
Flat no. 5-B,
377-A, Prince Anwar Shah Road
Kolkata – 700 068
Tel : 033-24833583
Fax : 033-24822052

3.6 Suction Strainers ⇒ (a) M/s. Gujarat Otofilt


BP : Simplex Basket type Plot no. 3712, Phase-IV
BFP : Conical type GIDC Estate, P.B.No. 67
CEP : Simplex Basket type 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 : otoklin@vsnl.com

(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

3.7 Connecting couplings (a) M/s. Euroflex Transmissions India Pvt.Ltd


Plot No.99, CIE Phase-II
BP, BFP & CEP ⇒ 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

I/A : M/s.Rathi Transpower Pvt. Ltd.


Rathi Chambers, 7-Deccan College Road
PUNE – 411 006
Tel : 020-26696820, 26694826
Fax : 020-26695655
(c) M/s. Unique Transmissions (India) Pvt.Ltd.
Mercantile Building,
10/1 D, Lalbazar Street
3rd Floor (Rear Block)
KOLKATA – 700 001
Tel : 033-2220 0366, 2248 0231
Fax : 033-2230 6593

3.8 Local Gauge Board Assy with (a) M/s. Nagarjuna Fabricators
Pre & Temp Instruments 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

3.9 Local Instrument Rack ⇒ (a) M/s. Instrumentation Limited


for Transmitters, BFP&CEP KOTA – 324 005
Tel : 0744-426309, 423381-85
Fax : 0744-426309
3.10 Reverse Rotation Monitoring (a) M/s.Bently Nevada Corporation
System of TD &MD BFPs P.O.Box No.157
⇒ 1617, Water Street
Minden, Nevada, USA 89423
Through :
M/s.Bently Nevada (Sales&Services) Ltd
AIFACS Building, 1-Rafi Marg
NEW DELHI – 110 001
Tel : 011-23355899, extn. 505
Fax : 011-23737608

(b) M/s. Shinkawa Electric Co. Ltd, Japan


Through :
M/s.Forbes Marshall
A-34/35, MIDC Estate, H-Block
Pimpri, Pune – 411 018
Tel : 020-27442020, extn. 355
Fax : 020-27442040

NOTE : ⇒ - Indicates make of the equipment in original supply.

== ## ==
PART - 3

PRESERVATION & STORAGE

LIST OF CONTENTS

STD. NO. 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

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/
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

documents made on the subject.


It must not be used directly or indirectly in any way detrimental to the interest of the company.

2. GENERAL:

The effectiveness of TRP depends on the following aspects:

2.1 Selection of proper TRP.


Copyright and Confidential

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. Issued :


Cl. No. 2.4 added. Cl. Nos. 4.1 to 4.4 deleted. STANDARDS ENGINEERING DEPARTMENT
Annexures I, II, & III modified.
Rev.No. 04 Amd. No. Reaffirmed: Prepared: Approved: Date:

Dt.FEB. 98 Dt. Year: STDS. ENGG. SR.MANAGER MAY, ‘83


STDS. ENGG.
HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 2 OF 12

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:

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.
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

Copyright and Confidential


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
HY0490563
PLANT STANDARD
REV. NO.04
HYDERABAD
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.
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.

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
Copyright and Confidential

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.
HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 4 OF 12

RECOMMENDED TYPES OF TRPs


(Clause – 3) ANNEXURE-I

Type of TRP Description of Method of Durability of Equivalent


TRP/SPEC. No. Application Protection Brands
Rust Preventive Dipping, 6 months HE 1710
Hard Film Hard Film Black Spraying, (Bhopal)
Solvent AA55154 Brushing

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
deposited Rust Preventive Dipping, 1 year HE 1706

It must not be used directly or indirectly in any way detrimental to the interest of the company.
Hard Film Yellow Spraying, (Bhopal)
AA55155 Brushing
Rust preventive 6 months HE 1709
solution, clear (TRP) (Bhopal)
Soft Film AA55152 -Do-
deposited Rust solution, Steam 3 months HE 1712

Copyright and Confidential


washable (TRP) (Bhopal)
AA55151
Grease Temporary Corrosion Smearing 6 months IOC Multi-
Preservative Grease Brushing Purpose Grease
IS:958 No.2
Oil Rust inhibitive oil Dipping, 3 weeks HE 1711
(TRP) AA55153 Rinsing, (Bhopal)
Temporary corrosion Spraying, 6 months ESSO: RUST
Preventive Fluid BAN 394
IS:1153
Powder/ Volatile Corrosive Sprinklin 3 months
Tablet inhibitor (VCI)
powder/tablet
IS:5730
Paper VCI paper IS:6263 Wrapping 3 months
Gas Nitrogen Blanketing Filling 3 months
Crystal Silica-jel Inserting 3 months
HY0490563
PLANT STANDARD
REV. NO.04
HYDERABAD
PAGE 5 OF 12

TRP APPLICATION CATEGORIES


(Clause – 5) ANNEXURE-II

TRP Application Details Guide Lines for Selection


Appli-
cation
Category
Apply 1 Coat of Rust Preventive Hard Film Longer duration of protection before
yellow (HE 1706) / AA55155 and 1 Coat of despatch to site. Suitable for
Rust Preventive Hard Film Black precision machined surfaces with
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

(AA55154)/HE1710. Wrap the surfaces with simple profiles, eg. Rotor Journal
It must not be used directly or indirectly in any way detrimental to the interest of the company.

A Volatile Corrosive inhibitive (VCI) paper Surfaces


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.
Copyright and Confidential

Apply 1 Coat of Rust Preventive Hard Film Longer duration of protection before
yellow (HE 1706) /AA55155 and 1 Coat of despatch to site. Suitable for
B Rust Preventive Hard Film Black precision machined surfaces like
(AA55154)/ HE1710. parting plane suraces, covers,
couplings, base plates, machined
cross around pipes etc.
Apply 2 Coats of Anti Rust solution, steam Steam Turbine components of
C washable (TRP) (AA55151) / HE1712 complicated profiles where steam
washing facility is available eg.
Steam Turbine rotor components.
Apply 2 Coats of Rust Preventive solution, Steam Turbine components of
D Clear (TRP) (AA55152) / HE1709 complicated profiles where there is
no facility for steam washing.
Apply 2 Coats of TRP fluid (IS:1153) Steam Turbine components of
E complicated profiles. The TRP is
with brown Pigment.
Apply 1 Coat of Rust inhibitive oil (TRP) Machined components during the
F (AA55153) / HE1711 process, Storage on shop floor over
1 month upto 3 months.
Apply Temporary Corrosion Preventive Suitable for Fasteners, chains, Gear
G Grease IS:958 liberally and wrap in Wheels etc.
polythene sheet/bag and tie it with a thread
H Wrap with 2 layers of VCI paper IS:6263 Suitable for commutator of
and one layer of Polythene Sheet. Armature, Bushings.
Sprinkle VCI powder/tablets IS:5730 inside Inside oil pipes.
I pipe. Close the ends by plastic caps and
adhesive tape.
HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 6 OF 12

ANNEXURE – II

TRP Application Details Guide Lines for Selection


Appli-
cation
Category
Draining after Hydro Test drying with hot Suitable for the water chamber and
J air, evacuation of the vessel and Nitrogen the shell side of Heat Exchanger

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
blanketing.

It must not be used directly or indirectly in any way detrimental to the interest of the company.
Keep silica-jel bag inside suction and Suitable for all exposed tapped
discharge branches, close all opening close holes and flanged openings on the
K all tapped holes with red plastic caps pumps and Tubings.
(HY7242375 for G threads, HY7242579 for
NPT threads). Close all flanged openings
with suitable metal covers (HY7790963).

Copyright and Confidential


HY0490563
PLANT STANDARD
REV. NO.04
HYDERABAD
PAGE 7 OF 12

PRODUCT COMPONENTS – TRP CATEGORIES


(CLAUSE –5.2)
ANNEXURE –III

DETAILS OF COMPONENTS TRP APPLICATION


CATEGORY
STEAM TURBINE AND COMPRESSORS
HP,LP and other rotors.
Rotor Journals, Thrust Collars A
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

Base plate machined. B


It must not be used directly or indirectly in any way detrimental to the interest of the company.

Crossed around pipes, machined B


Bearing pedestals with assembled parts and bearing housings
Outer machined surfaces B
HP turbine outer casings
Outer machined B
HP, LP and other rotors.
Rotor coupling flange faces, coupling bolt holes B
Copyright and Confidential

Welded low pressure Turbine components


Longitudinal Grider and front
Outer machined
LP upper part outer machined surface B
LP inner outer casings outer machined surface B
LP Inner, inner casings outer machined surface B
Fasteners of Threaded portions
Unthreaded portions (M64 and above) B
HP Exhaust Elbow outer machined surface B
Shaft lifting and clearance measuring device, machined surface B
Assembly fixtures for HP Turbine, machined surface B
Turning over device for HP Turbine, machined surface B
Transportation device for HP Turbine, machined surface B
Oil tank
Outer machined surface B
Injector Nb. 300
Outer machined surface B
Main steam and re-heat strainer body
Outer B
Cast exhaust hood
Outer machined surface B
HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 8 OF 12

ANNEXURE –III

DETAILS OF COMPONENTS TRP APPLICATION


CATEGORY
Cross around pipes, inner C
Valves-casings and covers
Inner un-machined surface C
Bearing pedestals with assembled parts and bearing housings

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
Outer un-machined surface C

It must not be used directly or indirectly in any way detrimental to the interest of the company.
HP and outer turbine outer casing-
Inner C
HP and IP inner casing and diaphram-carrier and guide blade carrier-
Outer C
Inner C
HP, LP and other rotors.

Copyright and Confidential


All surfaces except journals, Thrust collars
Flange cases and coupling bolt holes C

STEAM TURBINE AND COMPRESSORS

Welded low pressure Turbine components -


Logitudinal Girder and front valves
Inner C
LP upper part,
Inner C
LP Inner, outer casings C
Inner including blades C
Outer un-machined C
LP Inner, inner casings
Inner including blades C
Outer un-machined C
Cover for shaft sealing casing
Inner C
Steam inlet and extraction connections
Inner and outer C
HP Exhaust elbow
Inner C
Handling Barring Gear and hydraulic Gear oil tank
Inner C
Injector Nb.300
Inner C
Main steam and re-heat strainer body
Inner C
HY0490563
PLANT STANDARD
REV. NO.04
HYDERABAD
PAGE 9 OF 12

ANNEXURE –III

DETAILS OF COMPONENTS TRP APPLICATION


CATEGORY
Blanking arrangement for strainer body C
Oil strainer C
Main steam and reheat strainer handling device, machined C
Oil throttle valve, inner C
Oil stripper journal C
Cast exhaust hood
Inner C
Compressor Rotor D/E
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

Bearings, Oil seals, couplings, spare blades, gland ring G


It must not be used directly or indirectely in any way detrimental to the interest of the company.

Lifting beams and clamps machined G


Valves – casings and covers
Inner machined G
Spindles G
Fasteners of Threaded portions
Unthreaded portions G
Emergency Governor G
Copyright and Confidential

Piping of governing and LP bypass central rack and supply


unit for valves, inner G
Suspension arrangement for ESU and interceptor valve
Machined surfaces and springs G
Tools and tackles for governing equipment, machined G

Oil pipeline outside the governing equipment I


Other pipings I

ELECTRICAL MACHINES A
Rotor Journals, Slip rings, Journals of Armature
Stator End Flanges, machined flanges, Machined surfaces of
Foundation Frames, Base plates. B
Machined components, Base plates, Machined surfaces of
Oil cooler, Air cooler, Accessories B
Rotor coupling face, threaded holes of exposed surfaces,
bearing shells. Fasteners, internal/external threaded surfaces G
Commutator of Armature, Bushings H
HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 10 OF 12

ANNEXURE –III

DETAILS OF COMPONENTS TRP APPLICATION


CATEGORY
SWITCHGEAR
Hydraulic pistons A
Operating mechanisms after testing and before shipment HLD
Base frame, Machined Flange surfaces and mechanism housing,

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
Terminal butting surfaces. D/E

It must not be used directly or indirectly in any way detrimental to the interest of the company.
Machined Ferrous components like shafts, pins, gears
Springs, links and levers, castings, machined surfaces of F
fabricated housings, catches, latches, rollers protective pipe
flanges.
Chains and bearings, pull rod (threaded portion), Base frame G
Tapped holes, external/internal threaded surfaces, fasteners.

Copyright and Confidential


HEAT EXCHANGERS D/E
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. G
Inside water chamber and shell side of feed water heaters J
OIL FIELD EQUIPMENT
Rig instrumentation
Valves and disconnectors dampers for gauges, indicating G
instruments.
Mud Agitators
Machined surfaces of mud system G
Hoisting and rotating equipment
Rotory, Swivel, travelling block, Hydra Hooks G
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. G

Centrifugal pump, mud pump internal surfaces with L


liquid contact. (Except Oil)
HY 0490563
PLANT STANDARD
REV. NO.04
HYDERABAD
PAGE 11 OF 12

ANNEXURE – III

DETAILS OF COMPONENTS TRP APPLICATION


CATEGORY
BOWL MILLS
Machined surfaces D/E
Inside Gear case assembly F
Bearings, Drive couplings, fastener, external/internal threaded G
surfaces
PUMPS
Journal Bearings, bearing surfaces and exposed portion of shafts. A
Exposed machined surfaces of ferrous components like thrust
collar large fabricated frames, foundation frames, pump discharge B
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

covers, tubular cooler, catridge, keyway blocks of pump casings,


It must not be used directly or indirectely in any way detrimental to the interest of the company.

Head gears, Canisters, Foundation Rings, elements, CWP parts.


Ferrous components stored in assembly shop, freshly machined F
surfaces with more than 1 to 3 months gap between one operation
to another
Spare parts, fasteners, external/internal threaded joints G

All exposed tapped holes and flanged openings on the pumps and K
Copyright and Confidential

tubings
GAS TURBINES
Journal & Thrust Bearings, Rotor journals & Thrust collars A
Ferrous components stored in assembly shop, freshly
machined surfaces with more than one month gap between F
operations
All exposed tapped holes and flanged openings on the pumps K
Exposed machined surfaces/parting planes of all ferrous fabricated B
frames including base plates, couplings
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
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 12 OF 12

ANNEXURE – A

LIST OF SUPPLIERS OF TRP

M/S. BHEL, Bhopal - Rust preventive oil

M/S. Ceturion coatings, Madras - Rust preventive compound (proprietary)

M/S. Agromore Ltd., Bangalore - Rust preventive Agents

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.
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 - -“-

Copyright and Confidential


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 - Rust Poliq – N (Proprietary)

M/S. OKS, 5/9, Primorse Road, - 1) OKS – 240 Anti – seize compound
Bangalore - 560025 2) OKS – 1140 High Temperature Silicone grease
3) OKS – 410 Mos 2 High performance long life grease
4) OKS – 300 Mos 2 Mineral oil concentrate (Additive)
5) OKS – VCI : 368 N
6) OKS - VCI : 369 N
7) OKS - 2140
8) OKS - 2160
9) OKS - 2201

M/S. Prosol Chemicals Pvt. Ltd. - 1) Rustex - 221


M/S. Futech chemicals (P), Secundeabad - 1) Futech - AR (LT)
HY0490564
PLANT STANDARD REV. NO: 01
HYDERABAD
PAGE 1 OF 7

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.
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.

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 - Code of practice for painting of different products and their components.

1.2.3 HY0490563 - Code of practice for preservation of different products and their
Copyright and Confidential

components.
2.0 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 :
STANDARDS ENGINEERING
DEPARTMENT
Rev.No. Rev. Date Revised: Prepared: Approved: Date:
SR.MANAGER
01 OCT. 93 AGM (E&CC) VNR STDS. ENGG. MAY, ‘83
HY0490564
Rev. No.01
PLANT STANDARD
HYDERABAD
PAGE 2 OF 7

2.3 Storage condition ‘R’

2.3.1 Denotes storage in shed having roof but no side walls.

2.3.2 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.
2.4 Storage condition ‘S’

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
2.4.1 Denotes storage in open yard on elevated platform/wooden sleeper.

It must not be used directly or indirectly in any way detrimental to the interest of the company.
3.0 GUIDELINES FOR CONSTRUCTION OF STORAGE SHEDS

3.1 The shed may be constructed on Tubular Truses with Asbestos cement sheet roofing.
3.2 The sheds/yards shall be provided with path ways to facilitate movement of vehicles.
3.3 Sheds and storage areas shall be provided with good lighting to facilitate handling of
materials at night.

Copyright and Confidential


3.4 All equipment shall be stored on sleepers for easy handling.
3.5 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) It shall be rotated by 180 deg, after its receipt at site.


ii) It shall be rotated by 90 deg, after 3 months.
iii) It shall be rotated by 180 deg, after subsequent 3 months.
iv) It shall be rotated by 90 deg, after subsequency 3 months.
HY0490564
PLANT STANDARD
REV. NO.01
HYDERABAD
PAGE 3 OF 7

d) Casings

i) 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.
e) 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.
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.

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


Copyright and Confidential

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
HYDERABAD
PAGE 4 OF 7

Annexure 1

Details of components/parts Type of Remarks


storage
INDUSTRIAL TURBINE & COMPRESSORS Maximum Temparature 20º
Instruments like Electromagnetic protection, C. Temparature deviation in
vibration measuring equipment, Eccentricity P 24 hours shall not exceed
mesuring equipment. 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.
Assembled Compressors & Turbines, Rotors,
Casings, Valves, Bearing Pedestals, Bearings,
Gears, Parting plane bolts, Servomotors
(Hydraulic actuators), Inspection shaft with its Q
rings & all precision mechanical equipment,
bolts heating equipment, Thermometers,

Copyright and Confidential


Pressure gauges, mano stats etc.

Oil Tanks, oil coolers, Turbine and Compressor


Covers, Injectors, Piping and safety membranes, R
bearing covers Fasteners, oil seals, Couplings
etc.
Pipes, Flanges, Channels, Sheets etc for S
construction purpose at site.
STEAM TURBINES
P Max Temp 20ºC.
Instruments, Turbovisory equipment Temparature deviation in 24
hours shall not exceed 5ºC.
Humidity less than 40%
Rotors, HP & MP casings, HPQC stop and
governing, valves LPQC inspection valves,
Bearing pedestals, Bearings, Non- return valves, Q
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.
HY0490564
PLANT STANDARD
REV. NO.01
HYDERABAD
PAGE 5 OF 7

Details of components/parts Type of Remarks


storage
Main oil Tank, Auxillary Oil Tank, Oil coolers,
Turbine Cover, Injector, MP upper and Lower tube R
fittings, interconnecting piping and safety
membranes, piping outside the pedestal, Foundation
bolts etc.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

GAS TURBINES
It must not be used directly or indirectly in any way detrimental to the interest of the company.

Rotor, HP & LP journals and thrust Collars Base


plate. Q
Machined surface of:
Inlet casing
Compressor casing
Turbine casing
Copyright and Confidential

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, Q
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, R
Mounting Blocks, Extension Beam and MS sheets,
outer covers Erection fixtures
Transport Frames, Stands, Plates, Foundation S
Frame.
HY0490564
Rev. No.01
PLANT STANDARD
HYDERABAD
PAGE 6 OF 7

Details of components/parts Type of Remarks


storage
TURBO GENERATORS & AUXILIARIES
P Temparature Range
Stator with transportation frame, Rotor, Exciter 35-45º C. Relative
stator & Gear Box Assy, Exciter Armature, output humidity less than

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
leads, AVR Cubicle, Field Breaker Cubicle, AVR 40%, Dust free

It must not be used directly or indirectly in any way detrimental to the interest of the company.
Accessories, Gas and oil panels, Field Rheostat, atmosphere.
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, Q

Copyright and Confidential


vacuum unit, PMG, Air coolers, Exciter rear Bearing
and Assy, Thermometers.
Foundation Frame, Foundation Bolts and Base
plates, Mounting Extension and intermediate piece, R
stand and yoke, Mounting Truck, Covers, Piping
Air proof door, supporting frame, slide valves
suspension device, Fasteners.
SWITCH GEAR
Q
Spare items like interrupter assy, fixed contact Assy,
moving contact assy, Lam washer, interrupter Disc.
Poles of circuit Breaker, operating Mechanism, Base R
Frame, Structure details
BOWL MILLS Q
PUMPS Maximum
P Temperature
Axial shift indicator, Reverse Running inidcator, deviaton in 24 hours
vibraton Monitor instrument. shall not exceed 5º
C. Humidity less
than 40%
HY0490564
PLANT STANDARD
REV. NO.01
HYDERABAD
PAGE 7 OF 7

Details of components/parts Type of Remarks


storage
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
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.

and water coolers, all spare parts except instruments, Q


It must not be used directly or indirectly in any way detrimental to the interest of the company.

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 R
and Booster pump.
Copyright and Confidential

HEAT EXCHANGERS

Surface condensers and its parts like water Q


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
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 BHEL
Type FA1B75
Direction of rotation Anti-Clockwise
(Viewed on non-drive end)
Liquid pumped Boiler feed water

2.2 Turbine Driven Pump

2.1.2 Pump

Type FA1B75
Direction of rotation Clockwise
(Viewed on non-drive end)
Liquid pumped Boiler feed water

2.3 Thrust Bearing

Manufacturer Michell Bearing / Glacier


Type Double thrust
2.4 Mechanical seal

Manufacturer BURGMANN, Germany

2.5 Driver/Pump Flexible Coupling

Manufacturer Euroflex, India

3. DESCRIPTION :

3.1 Pump Casing :

The cast steel pump casing is of the double volute type, split on the horizontal
center line. The top and bottom half casing are located to each other by dowel pins
and secured by the studs and nuts, sealing at the axial split being effected by a
two-ply brown paper joint.

The bottom half pump casing has the suction and discharge branches and support
feet, cast integrally.

The pump casing is machined internally to accept the casing rings and stuffing
boxes are also formed at each end of the casing to accommodate the water
jackets and the mechanical seals, thus preventing leakage along the pump shaft.
The interface of the casing and base plate supports is near the shaft axis. Dowels
and a guide key are arranged to maintain longitudinal and transverse alignments
whilst accommodating thermal expansion.

A tapped air vent connection is provided on the top half casing. Connections are
also provided on the suction and discharge branches for pressure gauges and a
drain.

3.2 Rotating Assembly :

The rotating assembly consists of the shaft, impellers, nuts, keys, seal sleeves,
thrust collar, the rotating parts of the mechanical seals and pump half coupling.

The double entry impeller is keyed to the shaft and is located axially by an impeller
nut on each side of the impeller hub. The impeller is fitted with a wear ring on each
shroud, the rings being retained by grub screws.

The seal sleeves are keyed to the shaft and are located and secured by grub
screws. Leakage between the shaft and sleeve is prevented by an ‘O’ ring fitted in a
groove machined in the bore of the sleeve. The thrust collar is keyed to the shaft
and is secured against a shoulder on the shaft by the thrust collar nut. The pump
half coupling is keyed to the tapered end of the shaft and is secured by a coupling
nut, locked by a lock screw.
3.3 Journal and Thrust Bearings :

The rotating assembly is supported at each end of the shaft by a white


metal lined journal bearing and the residual axial thrust is taken up by a tilting pad
double thrust bearing mounted at the non-drive end of the pump.

The journal bearing shells are of mild steel, white metal lined, thick wall type, and
are split on the horizontal plane through the shaft axis. Each bearing is prevented
from rotating by a dowel pin located in a recess in the top half bearing housing.

The thrust bearing is fitted at the non-drive end of the pump and has eight titling
pads in a split carrier ring on each slide of a thrust collar, which is keyed to the
pump shaft and secured by a nut and lock-washer. The carrier rings are held in
non-drive end bearing housing and are prevented from turning with the thrust
collar by dowels locating in slots in the top half of the housing. The thrust pads are
retained on the carrier rings by special pad stops screwed into the rings. Machined
spacers are fitted behind each carrier ring during manufacturer to effect the axial
running position of the rotating assembly. The thrust bearing is provided with for
resistance temperature detectors.

A split floating oil seal is fitted in a groove in the housing to maintain a level of
lubricating oil with in the housing, around the thrust bearing, when the pump is
stopped. The floating seal is prevented from turning by an anti-rotation pin fitted in
a slot in the bottom half of the housing. An orifice plug fitted at the thrust bearing
lubricating oil outlet ensures a flooded bearing housing when the pump is
stationary. The bearing are supplied with lubricating oil from the forced lubricating
oil system.

For further information on the bearings references should be made to be bearing


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 Possible Cause Action

(1) Pump fails (a) Driver fault. Check driver.


to starts.
(b) Power supply fault. Check supply.

(c) Seizure of pump set Disconnect couplings and


Locate seizure. Overhaul
as necessary.

(d) Deareator Level Check deareator.


Low- Low

(e) Pump set tripped. Investigate cause.


Rest trips.

(2) Pump (a) Driver fault Check driver.


performance
Low.
(b) Incorrect rotation. Check direction of driver.

(c) Pump suction line Check deaerator, suction


defective. strainer and suction
isolating valve, etc.

(d) Excessive wear of Check clearances and


pump internals. overhaul as necessary.
Symptom Possible Cause Action

(3) Bearings (a) Defective in lubricating Check lubricating oil system.


overheating. oil system.

(b) Bearings worn or Examine bearings.


misaligned.

(c) Misalignment of pump. Check alignment.

(4) Mechanical (a) Insufficient cooling Check cooling water supply.


seals water.
overheating
(b) Mechanical seal faulty. Check mechanical seal.

(5) Excessive (a) Misalignment of pump. Check alignment.


noise and/or
vibration
(b) Bearing misalignment. Examine bearing.

(c) Excessive clearance of Check clearances and


pump internals. overhaul as necessary.

(e) Rotating assembly out Check dynamic balance.


of 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) Check that the suction and discharge pressure are normal.
(2) Check that the pump bearing lubricating oil pressures and temperatures
are normal.
(3) Check for leakage from the mechanical seals.
(4) Check all joints for leakage.
(5) 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)

Item Weight, Kg.

Pump assembly 2365


Top half pump casing 760
Pump shaft 74.5
Impeller 127
Water jacket 31

2.2 Joints :

Joints Between Material Section

Top half pump casing/ Brown paper Two ply


Bottom half pump casing
Pump casing / water jacket Klingersil 4200
Non-drive end bearing Brown paper Two ply
Housing / end cover

2.3 Recommended Lubricants :

For the recommended grade of lubricating oil for the journal and thrust
bearings of the booster stage pumps, refer to the lubrication schedule included at
the end of this chapter. For the grade of lubricant supplied, refer to the
manufacturer’s instructions for the turbine and the turbo coupling.

3. MAINTENANCE PROCEDURES :

WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND


REGULATIONS ARE OBSERVED AT ALL TIMES DURING
MAINTENANCE PROCEDURES.
Note : 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.

3.1 Preparation for Maintenance :

Before commencing any maintenance procedures, the pump set must be


Isolated as follows :
(1) Isolate the driving motor / turbine. Refer to manufacturer’s instructions.
(2) Isolate the electrical power supplies to all instruments.

3.2 Examining the Drive End (DE) Journal Bearing :

(1) Disconnect and remove any instruments which could interface with the
dismantling procedures.
(2) Remove the drive / pump drive coupling guard.
(3) 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.
(13) Reconnect the drive/pump coupling.

(14) Replace the instruments and the drive/pump drive coupling guard.

3.3. Examine the non-drive End (NDE) Journal and Thrust Bearing :

(1) Disconnect and remove any instrument which could interface with the
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 : 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-DG-
188-139-0017 for the original total axial clearance. Any measurable
variation should be investigated.

Note : (a) 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.
(b) 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.
(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.

4. OVERHAUL :

The following instructions apply when the pump is due for a complete
overhaul and it is necessary to dismantle it to its components parts to examine
them for wear. The following procedures are intended as a guide and should be
read carefully by the engineer before commencing to dismantling the pump.

WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND


REGULATIONS ARE OBSERVED AT ALL TIMES DURING
MAINTENANCE PROCEDURE.

4.1 Preparation for Overhaul

Before commencing overhaul procedures, the pump set must be isolated


as follows :

(1) Isolate the electrical power supplies to the pump set driving motor / turbine
and the lubricating oil system (refer to manufacturer’s instructions).
(2) 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 non-
drive 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 : 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) 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.
(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 lock-
washer.

(24) Withdraw the thrust collar from the shaft. Remove and retain the thrust
collar key.
(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.

4.3 Inspection and renewal :

The pump components should be cleaned thoroughly then inspected for any
signs of wear including scoring or wiping.

All diametrical clearances should be measured with internal and external


micrometers.

4.3.1 Clearances

Refer to the Sectional Arrangement Drawing for the details of the


clearances. It is recommended that when the pump internal clearances have
reached 1.5 times the figure quoted or are expected to do so before the next
overhaul, the component or components should be renewed. The main
consideration, however, is pump performance and motor power consumption.

4.3.1 (1) Examine the impeller and casing wear rings for signs of wear or damage.
Check the diametrical clearance between the impeller and casing wear
rings. Compare the readings obtained with those given. If necessary, renew
the wear rings.

(2) Renew the impeller wear rings as follows:

(a) Remove the grub screws securing the wear rings to the impeller.
(b) Machine the wear rings from the impeller eyes.
(c) 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) Examine the pump shaft for signs of damage or bowing and check for
concentricity; it should be within 0.05 mm full indicator movement.
(2) Check that all threads are in good condition.
(3) Check that all keyways are free form burrs.
(4) Examine the seal sleeves for any signs of wear or damage.

4.3.5 Thrust collar and Floating oil seal

(1) Examine the thrust collar for any signs of wear or damage.
(2) Examine the floating oil seal for any wear or damage.

4.3.6 Studs, Nuts, Dowels and Keys

(1) The threads of all studs, screws and nuts must be clean, well formed and
free from burrs. If the threads are damaged in any way, the component
must be renewed.
(2) 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.
(3) All dowels must be clean and free from damage or deterioration. Worn or
damaged dowels must be renewed.

4.3.7 Joints and ‘O’ Rings

All joints and ‘O’ rings should be renewed on assembly. Apply soft soap to
all ‘O’ rings prior to assembly.

4.3.8 Journal Bearings

Inspect the journal for signs of wear or damage and renew as necessary.
4.3.9 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 lock-
washers.

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.
(17) Lift the drive end top half bearing housing complete with the top halves of
the oil guards onto the bottom half bearing housing.

(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.

(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.

5. PARTS IDENTIFICATION

When ordering spare parts reference must be made to the pump serial or
job Number, Nomenclature, the Sectional Arrangement Drawing and item Number,
and the quantity of each component.
SECTION – A

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<<

A mechanical seal does not function independently it is intended to be


incorporated in to or assemble with machinery.

1.3 Type designation

09-H75F2/100-ex1 (drive end)

For non drive end seal please refer to drg. 09-H75F2/100-EX2

Materials according to drawing and/or to order.

1.4 Operating conditions

Pump type & size : FA1B75


Medium to be sealed : Boiler feed water
Temperature of medium : 165°C
Stuffing box cooling : by pump jacket cooling
Pressure to be sealed : 25 bar
Supply at API 610 : Plan 23 + filter
Shaft diameter at seal : 82.53 / 80 (stepped)
Shaft speed (approx.) : 1495 to 1644 rpm
Direction of rotation : CCW, seen from the driven end
Mounting position : horizontal
Axial movability of M.S. : ± 2 mm
1.5 Designated use

This mechanical seal is exclusively designed for the use in the specified machine.
A different utilization or a utilization going beyond the specification is considered
contrary to its designated use and excludes a liability by the manufacturer.
Operation under conditions lying outside those limits stated in paragraph >>
operating data << is considered contrary to its designated use.

Should the seal be operated under different conditions or at a different application


BURGMANN has to be asked for recognition as safe in advance.

1.6 Drawings, diagrams

Assembly drawing 09-H75F2/100-EX1 (drive end)

The assembly drawing in the original scale and in its latest edition (latest revision)
only is decisive for the design and the use in connection with this manual.
In the following description all figures in parentheses, e.g. (2) define the respective
part item no. in the assembly drawing.

1.7 Description and function

Single, balanced mechanical seal (M.S.) for boiler feed pumps.

Together with the housing parts (6.4A,16A) supplied the seal forms a pre-mounted
unit (seal cartridge), assembled at works, ready to be installed without any
adjustment.

Assembly fixtures (9) are provide for holding the cartridge in one piece during
transport, storage, assembly and disassembly.

The seal face (1.1) is loaded by means of multiple springs (1.4). It is arranged
rotating on the shaft sleeve.

The seat (2) is mounted in a cover (4A) and arranged Stationary.

Due to the integrated dual pumping screw at Drive collar (1.5A), Labyrinth Ring
(16A) and pumping sleeve in cover (4A) the seal cartridge is un-directional.

Torque transmission from mechanical seal to the shaft by means of a key.

Axial fixing of the shaft sleeve (6) by means of set screw (12a)

1.8 Required space, connecting dimensions

The connecting dimensions of the mechanical seal were checked and approved by
the customer on the main drawing.

The available mounting space given by the machine was decisive for the design of
the housing parts of mechanical seal. The connecting dimensions are checked
before shipment with regard to the BURGMANN drawing.

1.9 Power requirements


The total power consumption of the mechanical seal under the considerable
influence of the turbulence losses of the rotating seal parts has been calculated for
the individual application. To ensure a safe operation the required quantity of
circulated liquid will be individually determined by the seal manufacturer by
modifying the pumping device in the mechanical seal.

The total calculated power consumption of one seal cartridge is approx. 17.4 KW.
The pump manufacturer has to take this additional load into consideration when
designing the drive.

1.10 Additional equipment

For a safe operation of the mechanical seal a circulation circuit is required, from the
seal through a heat exchanger (if necessary, also through an additional magnetic
separator or filter ) back to the seal, as described in API 610, plan 23. When the
shaft rotates the liquid is circulated by a pumping device in the mechanical seal.

Jacket cooling of the stuffing box is provide in the pump and should be operated for
reasons of longer service life.

Safe operation can be expected when observing the following seal circuit
temperatures, measured at seal outlet :

• warning temperature : 55° C

• shut-off temperature : 65° C

• standstill temperature : 75° C

1.11 Emissions

A mechanical seal is dynamic seal that cannot be free of leakage due to physical
and technical reasons. Seal design, manufacture tolerance, operating conditions,
running quality of the machine etc. Mainly define the leakage value. In fact,
compared to other sealing systems (e.g. packings) there is few leakage.

Small seal leakage is desirable and admissible, because of longer operating life of
mechanical seal. If however, leakage exceeds a value of 8 litres per hour, the seal
is damaged . It has to be replaced.

Hot medium or even steam may splash out if the seal fails. Personal injury may be
prevented by the user providing for splash protection and wearing safety goggles.
Care has to be taken by the user for proper disposal of the leakage.

Components which may get in contact with the leakage have to be erosion
resistant or have to be adequately protected.

1.12 Copyright
The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has the copyright
in this Manual Buyer, planner and user of the product are authorized for use in
connection with further documentation.

2. SAFETY NOTES

Any person at the user’s shop being involved in assembly, disassembly, start up,
operation and maintenance of the BURGMANN Mechanical Seal must have read
and understood this instruction Manual and in particular the safety notes we
recommended the user to have this confirmed.

BURGMANN Mechanical seals are manufactured on high quality level and they
keep a high working reliability. Yet, if they are not operated within their intended
purpose or handled by untrained personnel they may cause risks.

The user is asked to check as part of his security program what effect a failure of
the mechanical seal might have on the environment and what additional safety
measures have to be taken to prevent personal injury.

Any operation mode that affects the operational safety of the mechanical seal is not
permitted.

The pump must be positioned in a way that no persons are endangered if product
splashes out in case of seal failure. Leakage of product has to be disposed
properly.

BURGMANN mechanical seals must be operated maintained or repaired by


authorized, trained and instructed personnel only.

Any work to be done on the mechanical seal is only permitted when the seal is
neither operating nor pressurized.

The responsibilities for the respective jobs to be done have to be determined


clearly and observed in order to prevent unclear competencies form the point of
security.

Apart from the notes given in this manual the general regulations for worker’s
protection and those for prevention of accidents have to be observed.

Unauthorized modifications or alterations are not permitted as they affect the


operational safety of the mechanical seal.

3. TRANSPORT, STORAGE, INSTALLATION

3.1 Recommendation for transport and storage

PACKING AND SHIPMENT


If not specified differently in the order the BURGMANN standard packaging is used,
suited for dry transport by truck, train or plane. The signs and notes for handling on
the packaging have to be observed.

In addition seaworthy packing may become necessary.

STORAGE AND PRESERVATION

• Range of validity

The following recommendations apply to all BURGMANN Mechanical Seals which


have been supplied and stored in their undamaged original packing as well as to
seals which have been installed in a component of a plant (e.g pump, compressor,
agitator, etc.) but have not yet been put into operation.

• General

BURGMANN mechanical seals for components of power plants are super finished
and tested machine elements whose handling during the erecting and start-up
period of a power plant as well as during the storage period (in particular of spare
parts) entails certain measures to keep the full efficiency of the seals.

Sliding materials and elastomers are subject to material-specific and time-based


alterations (distortion, aging) which might reduce the full efficiency of the seals.
Yet, such processes must not occur automatically.

The mechanical seal may be stored welded onto vapour-safe plastics sheets by
adding a drying agent e.g. “SILICAGEL”.

Damages caused by improper storage may not be claimed on the BURGMANN


company with reference to their warranty.

INSTALLED BURGMANN – M.S.

Components of power plants which are equipped with BURGMANN mechanical


seals are usually delivered in a completely mounted state. Often the parts were
tested at works beforehand.

• Start-up at the power plant

For the start up of BURGMANN mechanical seals as well as of possible


accessories extra instructions have to be observed which consider the respective
conditions.

New product plants often have erection times of up to 10 years. In such cases the
period between the production of the M.S. and its installation and start-up may
exceed the usual period of approximately 2-3 years.
BURGMANN recommend to disassemble such seals in time before the planned
start-up of the components of power plant and to sent the seals to the manufacturer
or the nearest BURGMANN service centre where they can be checked and
reconditioned, if necessary.

If this is not possible for primary reasons (distance, dispatch conditions, etc.) other
companies (never other seal manufacturers!) may be charged if they are suitably
equipped and have the know-how required. Yet, BURGMANN’S confirmation for
recognition as safe is absolutely necessary in particular with regard to claims under
warranty.

• Preservation in case of installation

Check in case of a preservation of complete plants with mechanical seals installed

• The compatibility of the chosen preservation agent with the seal materials and
with elastomers.

• No impairment of the seal’s axial movability by conglutination or by gumming.

We recommend to dry the seal parts after the preceding functional test and to
keep them dry when being installed. Values of < 50 % relative humidity are
considered as dry condition. If there are uncertainties as to the correct proceeding
please contact BURGMANN.
STORAGE OF BURGMANN-M.S.

Premises

The mechanical seals have to be stored in dry, dust free, moderately ventilated and
tempered rooms. We recommend relative air humidity below 65 % temperature
between 15°C and 25°C.
Direct exposure of the mechanical seal to heat (sun, heating) as well as to oxone,
present or produced by ultraviolet light (halogen of fluorescent lamps), must be
avoided because of the risk of embrittlement of elastomer materials.

Handling

Store the seals in their original packing lying on a flat surface.

Thus a protection from shocks and from damage of edges is provided.

For storage the mechanical seal is welded into vapour-safe plastic sheets by
adding the drying agent “ SILICAGEL ”. Thus the humidity inside the packaging is
stabilized.

The packaging should be periodically checked for damage.


An easy control of the package contents is provide due to the transparent
polyethylene sheet as well as by the attached package list or the package label.
Check the mechanical seal :

After a storage period of approximately 2-3 years.

After a damage of the packing

After a shock on the mechanical seal (e.g. by dropping the packed seal)

At the manufacturer’s or at the nearest service centre.

If necessary, a different, evident component authority may be contacted. Yet,


BURGMANN must be informed about this fact, as BURGAMANN’s confirmation for
recognition as a safe is absolutely necessary.

NOTE : An installation of the M.S. is possible if the prescribed checks cannot


be carried out for special reasons, yet, only if the seal parts have no
visible damages.

BURMANN must be informed about this kind of installation. Otherwise a warranty


as to leakage and/or operational reliability will be refused by BURGMANN.
A possibly increased leakage during start-up will decrease to a normal quantity
after the running in period of the sliding faces.

If this is not the case or if there are other malfunctions the mechanical seal has to
be shut down, removed and checked for reasons of safety.

If there is a malfunction which you cannot correct on your own, or if the cause of
malfunction is not clearly recognizable please immediately contact the nearest
BURGMANN agency, a BURGMANN service centre or the BURGMANN
headquarters.

• Control of humidity inside the packaging

All water vapour-proof sheets inside the package are supplied with humidity
indicators which show the relative air humidity inside the packaging. On a scale the
colour changes from blue (=dry) to pink (=humid).

For check of the stored mechanical seals which should be carried out periodically
and should be recorded in-plant the following points have to be observed :

• Humidity is indicated with values > 50% rel. humidity :

⇒ Contact BURGMANN as a control of the seal and new packaging is necessary.

• Humidity is indicated with values < 50% rel. humidity, yet the storage period of
2-3 years is exceeded.
⇒ Contact BURGMANN as a control of the seal and new packaging is necessary.

3.2 Preparation for assembly

Check the parts of the machine for :

• Chamfered edges (sliding cones i.e. 30°/2 mm or in accordance with DIN


24960).

• radiused transmissions

• Mating fits and O-ring surfaces: fine finished Rz 10 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 << make Lubricant Consult (LUBCON)

3.3 Assembly / installation

The material seal is supplied as a cartridge unit, pre-mounted at works, and does
not require any adjustment during installation. This document provides the required
information for Installation and removal of the cartridge only.

For installation the assembly drawing 09-H75F2/100-EX1 has to be on hand.


The mechanical seal has to be installed very carefully and under the cleanest
conditions.

Do never force during installation.


The order of assembly to install the mechanical seal into the pump depends on the
design of the pump and should advisably be determined by the pump
manufacturer.

Possible installation order :

• Check of o-rings (5 and 7) have been installed.

• Feed the complete seal cartridge onto the shaft.

The key in the shaft has to be engage into the keyway in the shaft sleeve (6).

Avoid bumping the seal cartridge against the shaft or shaft steps as the brittle
ceramic components break easily.

• Bolt the mechanical seal to the assembly flange in such a way that the
connections for supply and disposal are positioned in accordance with view
“X” in the drawing.

• Tighten the set screw (12a) uniformly & firmly.

• Remove the assembly fixtures (17) and keep them for a later removal of the
seal.

3.4 Supply connections

The supply connection is designated as a female threaded NPT connection.

The connection for supply is marked on the mechanical seal.

• Remove the plastic protection cap from the supply connection after
installation.
Supply piping :

• Use pipes of stainless steel with a big cross-section.

• Install the pipes continuously rising, as short and convenient as possible for
the flow to ensure self-venting.
• Avoid air inclusions and provide for venting connections, if necessary.

• Clean the piping thoroughly. Fasten all pipe connections pressure-sealed.

4. OPERATION
4.1 Instructions for start up

Safety checks before start up

• Seal assembly fixtures disengaged

• Torque transmission and axial fixing between mechanical seal and shaft duly
installed.

• Supply connections tightened pressure-sealed.

For a safe operation of the mechanical seal a circulation circuit is required. Design
in accordance with the scheme in the assembly drawing. Supply fluid flows from
stuffing box through a filter and a cooler back to stuffing box, similar to API 610,
Plan 23.

Forced circulation of the fluid when the shaft rotates by means of a uni-rotational
pumping device in the seal.

Jacket cooling of the stuffing box is provided in the pump and should be operated
for reasons of longer service life.

• Flood pump and seal cavity (stuffing box) with medium.

• Thoroughly vent seal cavity and circulation system.

• After a short startup period repeat the venting procedures several times with
the pump being at standstill.

Now the seal is ready for operation.

4.2 Instructions for safe operation :

Safe operating can be expected when observing the following seal circuit
temperatures, measured at seal outlet :

• Warning temperature : 55°C

• Shut-off temperature : 65°C

• Standstill temperature : 75°C

If the operation limit values and the instructions given in this manual are followed a
trouble-free operation of the mechanical seal can be expected.

4.3 Instructions for worker’s protection :


Hot medium or even steam may splash out if the seal falls. Personally injury many
be prevented by the user providing for splash protection and wearing safety
goggles. Care has to be taken by the use for proper disposal of the leakage.

4.4 Directives in case of failure

Try to define the kind of failure and record it.

In case of failure due to high leakage the amount of leakage should be observed.
Changes of the operating conditions have to be recorded. In case of an
unacceptable temperature rise the mechanical seal must be shut down for reasons
of safety.

A damage of the mechanical seal is indicated by a continuous, flowing leakage.

If there is a malfunction which you cannot correct on your own, or if the cause of
malfunction is not clearly recognizable please immediately contact the nearest
BURGMANN agency, a BURGMANN service centre of the BURGMANN
headquarters.

During the warranty period the mechanical seal must only be disassembled or
removed the BURGMANN’s approval or when a BURGMANN representative is
present.

5 SERVICING

5.1 Maintenance

A correctly operated mechanical seal is maintenance-free. Wear parts, however,


have to be replaced, if necessary.

An inspection of the mechanical seal should be carried out during a revision of the
complete plant. We recommend to have this inspection be performed by
authorized BURGMANN personnel.

If the mechanical seal is disassembled during a revision of the plant the sliding
faces should be refinished at the manufacturer and both O-rings and springs
should be replaced.

5.2 Reconditioning (repair)

If repair is necessary, the complete seal cartridge should be sent to the


manufacturer, as this is the best way to find out which components can be
reconditioned or which parts must be replaced.

Reconditioning of the mechanical seal by the user is not desirable for reasons of
operational safety. Repair should only be carried out by BURGMANN service
personnel or by trained personnel of the machine manufacturer in suitably
equipped clean rooms. Seal cartridges only should be replaced by the user if
possible.

5.3 Disassembly / removal

• Shut down the pump duly procedure, let it cool down an depressurize it.

• No product should contact the mechanical seal ⇒ drain the pump, if


necessary.

• Secure the pump against inadvertent start.

• Observe the safety notes (safety data sheets)

Mechanical seal cartridges should possibly not be disassembled or extremely


cleaned during or after removal so that the damages and their causes may be
correctly analysed by qualified personnel of the manufacturer of the user.

Any work to be done on the mechanical seal is only permitted when the seal is
neither operating nor pressurized.

Follow the valid regulations for preventing accidents when disassembling


mechanical seals as well as handling hazardous substances if the seals have been
already in operation. In case of doubt the necessary information have to be
obtained before starting removal disassembly or repair.

• Remove the supply piping.

• Engage the assembly fixtures (9) into the groove in the shaft sleeve (6) and
fasten them.
• Loosen all the screw’s (12a).

• Loosen all screw connections between seal cartridge and the respective
machine parts.

The disassembly (removal of the seal is carried out in the reverse sequence
as described for assembly (set up).

The order of disassembly to remove the mechanical seal out of the pump
depends on the design of the pump and has to be determined by the pump
manufacturer.

5.4 Spare parts

• Only BURGMANN original spare parts must be used. Otherwise

• Risks of a seal failure endangering persons and environment.


Risks of a seal failure, endangering persons and environment.

The BURGMANN guarantee for the mechanical seal lapses.

• For a quick exchange a complete spare seal should be on stock.

5.5 Required details for enquiries and orders

For enquiries and orders the following details are required.

• BURGMANN commission no.

• Drawing no. of mechanical seal : 09-H75F2/100-EX1

• Part item no. Designation, material number of pieces acc. Of drawing.

5.6 After-sales service by BURGMANN

The range of service offered by BURGMANN not only includes advise during the
planning stages but also technical support after commissioning. This is supported
by a world-wide comprehensive network of subsidiaries, field engineers and
service centers.

In India please contact first :

Headquarter :

BURGMANN INDIA Pvt. Ltd.


A.K. Industrial Estate
Madina Manzila Compound
S.V.Road, Goregoan (West)
Bombay – 400 062
: 874 1534 / 1820 / 1905
Telefax : 022-8 74 8810

Branch Offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad, Surat, Kota,
Chandigarh, Visakapatnam, Cochin.
OPERATING MANUAL
This document was drawn up observing the FC directives

Machinery (FN2922) and the German Directives VDI-4500

BURMANN MECHANICAL SEAL (M.S.)

09-H751F2/100-EX2

(Non-Drive End)

These instructions are intended


for the assembly, operating and
control personnel and should be
kept at hand on site.

Ultimate user

Customer BHEL (India)

Pump company BHEL

Pump type & size FA1B75

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<<

A mechanical seal does not function independently it is intended to be


incorporated in to or assemble with machinery.

1.3 Type designation

09-H75F2/100-EX2 (Non-drive end)

For non drive end seal please refer to drwg. 09-H75F2/100-EX1

Materials according to drawing and/or to order.

1.4 Operating conditions

Pump type & size : FA1B75


Medium to be sealed : Boiler feed water
Temperature of medium : 165°C
Stuffing box cooling : by pump jacket cooling
Pressure to be sealed : 25 bar
Supply at API 610 : Plan 23 + filter
Shaft diameter at seal : 82.53 / 80 (stepped)
Shaft speed (approx.) : 1495 rpm
Direction of rotation : CCW, seen from the driven end
Mounting position : horizontal
Axial movability of M.S. : ± 2 mm
1.5 Designated use

This mechanical seal is exclusively designed for the use in the specified machine.
A different utilization or a utilization going beyond the specification is considered
contrary to its designated use and excludes a liability by the manufacturer.
Operation under conditions lying outside those limits stated in paragraph >>
operating data << is considered contrary to its designated use.

Should the seal be operated under different conditions or at a different application


BURGMANN has to be asked for recognition as safe in advance.

1.6 Drawings, diagrams

Assembly drawing 09-H75F2/100-EX2 (Non-drive end)

The assembly drawing in the original scale and in its latest edition (latest revision)
only is decisive for the design and the use in connection with this manual.

In the following description all figures in parentheses, e.g. (2) define the respective
part item no. in the assembly drawing.

1.7 Description and function

Single, balanced mechanical seal (M.S.) for boiler feed pumps.

Together with the housing parts (6.4B,16B) supplied the seal forms a pre-mounted
unit (seal cartridge), assembled at works, ready to be installed without any
adjustment.

Assembly fixtures (9) are provide for holding the cartridge in one piece during
transport, storage, assembly and disassembly.

The seal face (1.1) is loaded by means of multiple springs (1.4). It is arranged
rotating on the shaft sleeve.

The seat (2) is mounted in a cover (4B) and arranged Stationary.

Due to the integrated dual pumping screw at Drive collar (1.5B), Labyrinth Ring
(16B) and pumping sleeve in cover (4B) the seal cartridge is un-directional.

Torque transmission from mechanical seal to the shaft by means of a key.

Axial fixing of the shaft sleeve (6) by means of set screw (12a)

1.8 Required space, connecting dimensions

The connecting dimensions of the mechanical seal were checked and approved by
the customer on the main drawing.

The available mounting space given by the machine was decisive for the design of
the housing parts of mechanical seal. The connecting dimensions are checked
before shipment with regard to the BURGMANN drawing.

1.9 Power requirements


The total power consumption of the mechanical seal under the considerable
influence of the turbulence losses of the rotating seal parts has been calculated for
the individual application. To ensure a safe operation the required quantity of
circulated liquid will be individually determined by the seal manufacturer by
modifying the pumping device in the mechanical seal.

The total calculated power consumption of one seal cartridge is approx. 17.4 KW.
The pump manufacturer has to take this additional load into consideration when
designing the drive.

1.10 Additional equipment

For a safe operation of the mechanical seal a circulation circuit is required, from the
seal through a heat exchanger (if necessary, also through an additional magnetic
separator or filter ) back to the seal, as described in API 610, plan 23. When the
shaft rotates the liquid is circulated by a pumping device in the mechanical seal.

Jacket cooling of the stuffing box is provide in the pump and should be operated for
reasons of longer service life.

Safe operation can be expected when observing the following seal circuit
temperatures, measured at seal outlet :

• warning temperature : 55° C

• shut-off temperature : 65° C

• standstill temperature : 75° C

1.11 Emissions

A mechanical seal is dynamic seal that cannot be free of leakage due to physical
and technical reasons. Seal design, manufacture tolerance, operating conditions,
running quality of the machine etc. Mainly define the leakage value. In fact,
compared to other sealing systems (e.g. packings) there is few leakage.

Small seal leakage is desirable and admissible, because of longer operating life of
mechanical seal. If however, leakage exceeds a value of 8 litres per hour, the seal
is damaged . It has to be replaced.

Hot medium or even steam may splash out if the seal fails. Personal injury may be
prevented by the user providing for splash protection and wearing safety goggles.
Care has to be taken by the user for proper disposal of the leakage.
Components which may get in contact with the leakage have to be erosion
resistant or have to be adequately protected.
1.12 Copyright

The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has the copyright
in this Manual Buyer, planner and user of the product are authorized for use in
connection with further documentation.

2. SAFETY NOTES

Any person at the user’s shop being involved in assembly, disassembly, start up,
operation and maintenance of the BURGMANN Mechanical Seal must have read
and understood this instruction Manual and in particular the safety notes we
recommended the user to have this confirmed.

BURGMANN Mechanical seals are manufactured on high quality level and they
keep a high working reliability. Yet, if they are not operated within their intended
purpose or handled unexpertly by untrained personnel they may cause risks.

The user is asked to check as part of his security program what effect a failure of
the mechanical seal might have on the environment and what additional safety
measures have to be taken to prevent personal injury.

Any operation mode that affects the operational safety of the mechanical seal is not
permitted.

The pump must be positioned in a way that no persons are endangered if product
splashes out in case of seal failure. Leakage of product has to be disposed
properly.

BURGMANN mechanical seals must be operated maintained or repaired by


authorized, trained and instructed personnel only.

Any work to be done on the mechanical seal is only permitted when the seal is
neither operating nor pressurized.

The responsibilities for the respective jobs to be done have to be determined


clearly and observed in order to prevent unclear competencies form the point of
security

Apart from the notes given in this manual the general regulations for worker’s
protection and those for prevention of accidents have to be observed.

Unauthorized modifications or alterations are not permitted as they affect the


operational safety of the mechanical seal.

3. TRANSPORT, STORAGE, INSTALLATION

3.1 Recommendation for transport and storage

PACKING AND SHIPMENT


If not specified differently in the order the BURGMANN standard packaging is used,
suited for dry transport by truck, train or plane. The signs and notes for handling on
the packaging have to be observed.

In addition seaworthy packing may become necessary.

STORAGE AND PRESERVATION

• Range of validity

The following recommendations apply to all BURGMANN Mechanical Seals which


have been supplied and stored in their undamaged original packing as well as to
seals which have been installed in a component of a plant (e.g pump, compressor,
agitator, etc.) but have not yet been put into operation.

• General

BURGMANN mechanical seals for components of power plants are super finished
and tested machine elements whose handling during the erecting and start-up
period of a power plant as well as during the storage period (in particular of spare
parts) entails certain measures to keep the full efficiency of the seals.

Sliding materials and elastomers are subject to material-specific and time-based


alterations (distortion, aging) which might reduce the full efficiency of the seals.
Yet, such processes must not occur automatically
.
The mechanical seal may be stored welded onto vapour-safe plastics sheets by
adding a drying agent e.g. “SILICAGEL”.

Damages caused by improper storage may not be claimed on the BURGMANN


company with reference to their warranty.

INSTALLED BURGMANN – M.S.

Components of power plants which are equipped with BURGMANN mechanical


seals are usually delivered in a completely mounted state. Often the parts were
tested at works beforehand.

• Start-up at the power plant

For the start up of BURGMANN mechanical seals as well as of possible


accessories extra instructions have to be observed which consider the respective
conditions.
New product plants often have erection times of up to 10 years. In such cases the
period between the production of the M.S. and its installation and start-up may
exceed the usual period of approximately 2-3 years.

BURGMANN recommend to disassemble such seals in time before the planned


start-up of the components of power plant and to sent the seals to the manufacturer
or the nearest BURGMANN service centre where they can be checked and
reconditioned, if necessary.

If this is not possible for primary reasons (distance, dispatch conditions, etc.) other
companies (never other seal manufacturers!) may be charged if they are suitably
equipped and have the know-how required. Yet, BURGMANN’S confirmation for
recognition as safe is absolutely necessary in particular with regard to claims under
warranty.

• Preservation in case of installation

Check in case of a preservation of complete plants with mechanical seals installed

• the compatibility of the chosen preservation agent with the seal materials and
with elastomers.

• No impairment of the seal’s axial movability by conglutination or by gumming.

We recommend to dry the seal parts after the preceding functional test and to
keep them dry when being installed. Values of < 50 % relative humidity are
considered as dry condition. If there are uncertainties as to the correct proceeding
please contact BURGMANN.

STORAGE OF BURGMANN-M.S.

Premises

The mechanical seals have to be stored in dry, dust free, moderately ventilated and
tempered rooms. We recommend relative air humidity below 65 % temperature
between 15°C and 25°C.

Direct exposure of the mechanical seal to heat (sun, heating) as well as to oxone,
present or produced by ultraviolet light (halogen of fluorescent lamps), must be
avoided because of the risk of embrittlement of elastomer materials.

Handling

• Store the seals in their original packing lying on a flat surface.

Thus a protection from shocks and from damage of edges is provided.


For storage the mechanical seal is welded into vapour-safe plastic sheets by
adding the drying agent “ SILICAGEL ”. Thus the humidity inside the packaging is
stabilized.

The packaging should be periodically checked for damage.

An easy control of the package contents is provide due to the transparent


polyethylene sheet as well as by the attached package list or the package label.
Check the mechanical seal :

• after a storage period of approximately 2-3 years.

• after a damage of the packing

• after a shock on the mechanical seal (e.g. by dropping the packed seal)

at the manufacturer’s or at the nearest service centre.

If necessary, a different, evident component authority may be contacted. Yet,


BURGMANN must be informed about this fact, as BURGAMANN’s confirmation for
recognition as a safe is absolutely necessary.

NOTE : An installation of the M.S. is possible if the prescribed checks cannot


be carried out for special reasons, yet, only if the seal parts have no
visible damages.

BURMANN must be informed about this kind of installation. Otherwise a warranty


as to leakage and/or operational reliability will be refused by BURGMANN.

A possibly increased leakage during start-up will decrease to a normal quantity


after the running in period of the sliding faces.

If this is not the case or if there are other malfunctions the mechanical seal has to
be shut down, removed and checked for reasons of safety.

If there is a malfunction which you cannot correct on your own, or if the cause of
malfunction is not clearly recognizable please immediately contact the nearest
BURGMANN agency, a BURGMANN service centre or the BURGMANN
headquarters.

• Control of humidity inside the packaging

All water vapour-proof sheets inside the package are supplied with humidity
indicators which show the relative air humidity inside the packaging. On a scale the
colour changes from blue (=dry) to pink (=humid).

For check of the stored mechanical seals which should be carried out periodically
and should be recorded in-plant the following points have to be observed :
• Humidity is indicated with values > 50% rel. humidity :

⇒ Contact BURGMANN as a control of the seal and new packaging is necessary.

• Humidity is indicated with values < 50% rel. humidity, yet the storage period of
2-3 years is exceeded.

⇒ Contact BURGMANN as a control of the seal and new packaging is necessary.

3.2 Preparation for assembly

Check the parts of the machine for :

• Chamfered edges (sliding cones i.e. 30°/2 mm or in accordance with DIN


24960).

• radiused transmissions

• Mating fits and O-ring surfaces: fine finished Rz 10 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 << make Lubricant Consult (LUBCON)

3.3 Assembly / installation

The mechanical seal is supplied as a cartridge unit, pre-mounted at works, and


does not require any adjustment during installation. This document provides the
required information for Installation and removal of the cartridge only.
For installation the assembly drawing 09-H75F2/100-EX2 has to be on hand.
The mechanical seal has to be installed very carefully and under the cleanest
conditions.

Do never force during installation.

The order of assembly to install the mechanical seal into the pump depends on the
design of the pump and should advisably be determined by the pump
manufacturer.

Possible installation order :

• Check of o-rings (5 and 7) have been installed.

• Feed the complete seal cartridge onto the shaft.

The key in the shaft has to be engage into the keyway in the shaft sleeve (6).

Avoid bumping the seal cartridge against the shaft or shaft steps as the brittle
ceramic components break easily.

• Bolt the mechanical seal to the assembly flange in such a way that the
connections for supply and disposal are positioned in accordance with view
“X” in the drawing.

• Tighten the set screw (12a) uniformly & firmly.

• Remove the assembly fixtures (17) and keep them for a later removal of the
seal.

3.4 Supply connections

The supply connection is designated as a female threaded NPT connection.


The connection for supply is marked on the mechanical seal.

• Remove the plastic protection cap from the supply connection after
installation.

Supply piping :

• Use pipes of stainless steel with a big cross-section.

• Install the pipes continuously rising, as short and convenient as possible for
the flow to ensure self-venting.

• Avoid air inclusions and provide for venting connections, if necessary.

• Clean the piping thoroughly. Fasten all pipe connections pressure-sealed.


4. OPERATION

4.1 Instructions for start up

Safety checks before start up

• Seal assembly fixtures disengaged

• Torque transmission and axial fixing between mechanical seal and shaft duly
installed.

• Supply connections tightened pressure-sealed.

For a safe operation of the mechanical seal a circulation circuit is required. Design
in accordance with the scheme in the assembly drawing. Supply fluid flows from
stuffing box through a filter and a cooler back to stuffing box, similar to API 610,
Plan 23.

Forced circulation of the fluid when the shaft rotates by means of a unirotational
pumping device in the seal.

Jacket cooling of the stuffing box is provided in the pump and should be operated
for reasons of longer service life.

• Flood pump and seal cavity (stuffing box) with medium.

• Thoroughly vent seal cavity and circulation system.

• After a short startup period repeat the venting procedures several times with
the pump being at standstill.

Now the seal is ready for operation.

4.2 Instructions for safe operation :

Safe operating can be expected when observing the following seal circuit
temperatures, measured at seal outlet :

• Warning temperature : 55°C

• Shut-off temperature : 65°C

• Standstill temperature : 75°C

If the operation limit values and the instructions given in this manual are followed a
trouble-free operation of the mechanical seal can be expected.

4.3 Instructions for worker’s protection :


Hot medium or even steam may splash out if the seal falls. Personally injury many
be prevented by the user providing for splash protection and wearing safety
goggles. Care has to be taken by the use for proper disposal of the leakage.

4.4 Directives in case of failure

Try to define the kind of failure and record it.

In case of failure due to high leakage the amount of leakage should be observed.
Changes of the operating conditions have to be recorded. In case of an
unacceptable temperature rise the mechanical seal must be shut down for reasons
of safety.

A damage of the mechanical seal is indicated by a continuous, flowing leakage.


If there is a malfunction which you cannot correct on your own, or if the cause of
malfunction is not clearly recognizable please immediately contact the nearest
BURGMANN agency, a BURGMANN service centre of the BURGMANN
headquarters.

During the warranty period the mechanical seal must only be disassembled or
removed the BURGMANN’s approval or when a BURGMANN representative is
present.

5 SERVICING

5.1 Maintenance

A correctly operated mechanical seal is maintenance-free. Wear parts, however,


have to be replaced, if necessary.

An inspection of the mechanical seal should be carried out during a revision of the
complete plant. We recommend to have this inspection be performed by
authorized BURGMANN personnel.

If the mechanical seal is disassembled during a revision of the plant the sliding
faces should be refinished at the manufacturer and both O-rings and springs
should be replaced.

5.2 Reconditioning (repair)

If repair is necessary, the complete seal cartridge should be sent to the


manufacturer, as this is the best way to find out which components can be
reconditioned or which parts must be replaced.

Reconditioning of the mechanical seal by the user is not desirable for reasons of
operational safety. Repair should only be carried out by BURGMANN service
personnel or by trained personnel of the machine manufacturer in suitably
equipped clean rooms. Seal cartridges only should be replaced by the user if
possible.
5.3 Disassembly / removal
• Shut down the pump duly procedure, let it cool down an depressurize it.!
• No product should contact the mechanical seal ⇒ drain the pump, if
necessary.!
• Secure the pump against inadvertent start.!
• Observe the safety notes (safety data sheets)!
Mechanical seal cartridges should possibly not be disassembled or extremely
cleaned during or after removal so that the damages and their causes may be
correctly analysed by qualified personnel of the manufacturer of the user.

Any work to be done on the mechanical seal is only permitted when the seal is
neither operating nor pressurized.

Follow the valid regulations for preventing accidents when disassembling


mechanical seals as well as handling hazardous substances if the seals have been
already in operation. In case of doubt the necessary information have to be
obtained before starting removal disassembly or repair.

• Remove the supply piping.

• Engage the assembly fixtures (9) into the groove in the shaft sleeve (6) and
fasten them.

• Loosen all the screw’s (12a).

• Loosen all screw connections between seal cartridge and the respective
machine parts.

The disassembly (removal of the seal is carried out in the reverse sequence
as described for assembly (set up).

The order of disassembly to remove the mechanical seal out of the pump
depends on the design of the pump and has to be determined by the pump
manufacturer.

5.4 Spare parts

• Only BURGMANN original spare parts must be used. Otherwise

• Risks of a seal failure endangering persons and environment.


Risks of a seal failure, endangering persons and environment.

The BURGMANN guarantee for the mechanical seal lapses.

• For a quick exchange a complete spare seal should be on stock.

5.5 Required details for enquiries and orders

For enquiries and orders the following details are required.

• BURGMANN commission no.

• Drawing no. of mechanical seal : 09-H75F2/100-EX2

• Part item no. Designation, material, number of pieces acc. of drawing.

5.6 After-sales service by BURGMANN

The range of service offered by BURGMANN not only includes advise during the
planning stages but also technical support after commissioning. This is supported
by a world-wide comprehensive network of subsidiaries, field engineers and
service centers.

In India please contact first :

Headquarter :

BURGMANN INDIA Pvt. Ltd.


A.K. Industrial Estate
Madina Manzila Compound
S.V.Road, Goregoan (West)
Bombay – 400 062
: 874 1534 / 1820 / 1905
Telefax : 022-8 74 8810

Branch Offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad, Panvel,


Surat, Kota, Chandigarh, Visakapatnam, Cochin.
SECTION – B

BOILER FEED BOOSTER PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

4. THRUST BEARING
Michell Bearings
Operations, and Maintenance
Instructions.

Omega OT Series
Thrust Rings
Michell Bearings
Michell Bearings is a trading division of Vinters Engineering PLC.
A member of the Rolls Royce Group.

Issue 00
Table of Contents

GENERAL DRAWING OF OT THRUST RING ASSEMBLY WITH SHIMS& LINERS----------- 4


1. INTRODUCTION -------------------------------------------------------------------------------------------- 5
1.1 About the Product ------------------------------------------------------------------------------------- 5
1.2 About this Manual ------------------------------------------------------------------------------------- 5
1.3 Warranty Claims --------------------------------------------------------------------------------------- 6
2. SAFETY ------------------------------------------------------------------------------------------------------- 7
3. HANDLING THE BEARING------------------------------------------------------------------------------ 8
3.1 General -------------------------------------------------------------------------------------------------- 8
4. PREPARATION FOR FIRST INSTALLATION ------------------------------------------------------ 9
5. ASSEMBLY OF THE BEARING -----------------------------------------------------------------------10
5.1 General -------------------------------------------------------------------------------------------------10
5.2 Assembly of the Thrust ring------------------------------------------------------------------------10
5.2.1 Fitting the Thrust Pad set.--------------------------------------------------------------------10
5.2.2 Fitting Ring Stop, and Liners if applicable -----------------------------------------------11
5.3 Assembling the Thrust rings into the Bearing Casing ---------------------------------------11
5.3.1 Miscellaneous -----------------------------------------------------------------------------------12
5.3.2 Instrumentation ---------------------------------------------------------------------------------12
6. OPERATING ------------------------------------------------------------------------------------------------13
6.1 Preparation and Inspection before Operation -------------------------------------------------13
6.2 Trial Run------------------------------------------------------------------------------------------------13
6.3 Normal Operation ------------------------------------------------------------------------------------14
6.4 Preparation for Operation after Standstill-------------------------------------------------------14
7. CARE AND MAINTENANCE ---------------------------------------------------------------------------15
7.1 General -------------------------------------------------------------------------------------------------15
7.2 Tools and Equipment--------------------------------------------------------------------------------15
7.3 Maintenance Schedule------------------------------------------------------------------------------16
7.4 Oil Change ---------------------------------------------------------------------------------------------16
7.4.1 General -------------------------------------------------------------------------------------------16
7.4.2 Procedure for draining oil---------------------------------------------------------------------16
7.4.3 Procedure for refilling the bearing -self contained bearings -------------------------17
7.4.4 Procedure for refilling the bearing - bearings with circulating oil--------------------17
8. DISMANTLING AN INSTALLED BEARING --------------------------------------------------------18
8.1 General -------------------------------------------------------------------------------------------------18
8.2 Preparation --------------------------------------------------------------------------------------------18
8.2.1 Strip down the bearing until the thrust rings are visible. ------------------------------18
8.2.2 Disconnect and remove any thermometry and instrumentation.--------------------19
8.3 Removing thrust rings -------------------------------------------------------------------------------19
8.4 Removing the Liners, and Shim Pack. Where Applicable. --------------------------------19
8.5 Removing the Thrust Pad Set---------------------------------------------------------------------19
9. CLEANING AND CHECKING --------------------------------------------------------------------------20
9.1 General -------------------------------------------------------------------------------------------------20
9.2 Checking the Thrust Pad. --------------------------------------------------------------------------21
10. BEARING PRESERVATION DURING STORAGE---------------------------------------------22

2
10.1 Before Installation ------------------------------------------------------------------------------------22
10.2 Corrosion Protection for Standstill Periods up to 6 Months --------------------------------22
10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year---------------22
10.4 Corrosion Protection for Standstill Periods longer than 1 year----------------------------22
11. BEARING PRESERVATION DURING TRANSPORT -----------------------------------------22
12. APPENDICES -------------------------------------------------------------------------------------------22
12.1 Ordering Spares --------------------------------------------------------------------------------------22

3
8 HEX. SOCKET CSK SCREW 16 STEEL
7 LINER ASSY 2 STEEL

4
6 SHIM PACK 2
5 DOWEL PIN 2 STEEL
4 PAD STOP 16 STEEL
3 THRUST PAD SET 2 STEEL WM
2 RETAINING RING 1 STEEL
1 RETAINING RING 1 STEEL
REF PART NAME QTY MATERIAL

6 1 3 2 7

5 4

OT Omega Thrust Ring Assembly With Shim Pack, And Liners


1. Introduction

1.1 About the Product

The “Omega” Series Thrust Rings supplied are part of a standard range of components
manufactured by Michell Bearings. The thrust rings are intended to be fitted within a casing
supplied by a customer. Depending on the demands specified, the thrust rings will be
designed to absorb:

a) A constant load along the shaft in one direction.


b) A constant load along the shaft in either direction.
c) A constant load in one direction and a temporary load in the opposite direction.

Within the “Omega” Series a range of sizes are catered for. All “Omega” thrust rings require
continuous lubrication from a pumped oil supply. In some cases, the thrust rings will have
machined oil channels and in other cases restriction jet holes.

The system of restriction holes is known as ‘Low Loss’ lubrication and will give lower power
losses than conventional fully immersed rings.

In order to measure pad temperature, Resistance Temperature Devices (RTDs) can be fitted
to a number of pads specified by the customer.

1.2 About this Manual

• This manual contains information about the bearing and its safe operation, and should
therefore be read carefully in full before starting work.
• Since the bearing has a wide range of applications, this manual has been written to cover
all current configurations.
• This manual is to be used by qualified engineers only.
• The following formats are used to draw attention to particular details:

! This symbol signifies a warning. These are instructions that, if ignored, could
result in death or injury. Danger!

This symbol signifies an important point which, If ignored, could result in


minor injury or failure to carry out a process correctly.

5
This symbol signifies additional instructions. This is usually a check. Missing
out this stage could lead to an error going unnoticed.

In addition, brackets after a reference to a part description, e.g. thrust pads set (3),
retaining ring (2) refer to an item number on a general sub-assembly drawing at the
front of this manual. These are used as a reference for the engineer.

1.3 Warranty Claims

• Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell
Bearings.
• These warranty obligations will automatically become void if the product is:

1. Improperly handled or installed.


2. Supplied with spare parts (or repaired), not approved by Michell Bearings.
3. Exceeding the design operating parameters shown on the arrangement drawing.
4. Subjected to environmental conditions not previously specified.

6
2. Safety

When installing, operating or maintaining the bearing, danger may arise to the user, the
product and plant and/or other assets. Therefore all users responsible for the operation of the
machine must understand this manual fully and make sure that all the safety procedures are
strictly adhered to.

Pay particular attention to the following general safety notes:

! Under no circumstances should the engineer work alone when operating the
machine.

! At least one of the engineers should be trained in basic first aid techniques
and wear identification that he/she is a first-aider.

! No maintenance, assembly, adjustment or any other work should be carried


out on the bearing whilst the shaft is rotating or capable of movement. To avoid
accidents, the entire machine should be isolated, with control gear locked off and “Not
to be used” signs applied to the control panels.

! Personnel that manipulate the product should be sufficiently trained.

! No modifications of the product should be made unless it is approved by


Michell.

More specific safety notes are also given in the relevant sections, and should be adhered to.

7
3. Handling the Bearing

3.1 General

This section outlines essential information, which must be referred to when handling the thrust
rings.
• The thrust rings are supplied fully assembled (see arrangement drawing for mass of
complete bearing).
• Omega “OT” Series thrust rings are not usually fitted with lifting holes. A complete ring
may be lifted using straps or slings.
• When transporting the bearing, it should remain in its packaging.
• Make sure thrust rings are stored in the intended mounting position, in a dry room only.
Please check all product equipment to ensure that it is complete before installation. Any
damage due to transit must be reported to Michell immediately.
• See Section 8 for instructions on how to disassemble the bearing.

! Before using any lifting equipment, ensure that it is certified to carry a load
greater than that of the bearing or component.

Take care not to damage bearing components and the running surfaces of the
shaft collar by contact with the lifting equipment.

! If in doubt, always use mechanical devices where possible. Remember to


bend the knees and not the back when lifting manually.

8
4. Preparation for First Installation

• All Omega “OT’’ Series thrust rings are supplied complete. All thrust rings are, for ease of
assembly, capable of being split in two halves. If the rings supplied are to be split the
RTDs and their cabling should be removed prior to this.
• Remove all packaging.
• Refer to Sections 2 and 3 for safety and handling instructions.
• Dismantle the bearing referring to Section 8, ignoring any references to the shaft or
machine.
• When dismantled, please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell Bearings immediately.
• All parts are coated in a rust preventative. This must be removed and all parts thoroughly
cleaned before installation begins. To remove the rust preventative, white spirit or a strong
spirit based cleaner should be used. Note! Do not use paraffin (Kerosene).
• It is recommended that the bearing casing and all other internal parts are cleaned to
prevent dirt getting between the collar and the thrust rings.

If the thrust rings are being fitted into a bearing that has previously been
used, ensure that the lubricating pipes have been cleaned to remove any deposits. If
there is any dirt in the lubricating system it will damage the new parts fitted.

! There may be fumes given off during the cleaning process. Clean parts in a
well-ventilated area. Always follow cleaner manufacturers’ instructions.

Use a lint free cloth when cleaning the bearing. Particles from other cloths
could otherwise get into the lubricating oil and cause overheating, and in extreme
cases, failure of the bearing.

• Once all parts are inspected and cleaned the bearing is ready for installation.
• Refer to Section 10 if the bearings are to be stored for a period of time before operation.

9
5. Assembly of the Bearing

5.1 General

The following general points should be noted:

! The disassembling and reassembling of the equipment by an individual who is


inexperienced can cause danger. Michell will not take on any liability for any damage
resulting from non-compliance with details given in this manual. If in doubt refer to our
Service Dept.

Only use tools, which fit correctly to avoid damage to fasteners.

! Do not use excessive force.

Use a liquid screw locking compound (e.g. Loctite 222) on all fasteners.

! Always follow the instructions on adhesives.

Remove all impurities and foreign objects (e.g. bolts, washers, etc.) from inside
the bearing. Ensure bearing is covered when left unattended.

This assembly procedure has been generalised to cover most eventualities. As such it may
contain more information than is directly applicable to the bearing being worked on. Read all
text and simply ignore any reference to irrelevant items.

5.2 Assembly of the Thrust ring


5.2.1 Fitting the Thrust Pad set.
• Coat all bearing surfaces in clean oil. Refer to bearing general arrangement drawing for
information on the correct grade of lubricant.
• Place thrust pad set (3) into retaining ring halves (1), (2).

Ensure that the correct handed pads are fitted. The direction of rotation
stamped on the pad must agree with that shown on the arrangement drawing.

• Secure thrust pad (3) in place with pad stop (4) with hole located in back of thrust pads (3).

10
• Ensure that stop (4) is fully locked in place with Loctite 222 or similar adhesive.


! Always follow instructions on adhesives.

• Make sure pads (3), can move freely, and are not trapped.

Take care not to trap hands when handling the components

5.2.2 Fitting Ring Stop, and Liners if applicable


• Place shim pack (6), and liners (7), on retaining ring halves (1), (2), and sercuer in place
with hex, socket counter sunk screw (8).
• Ensure that screws (8) are fully locked in place with Loctite 222 or similar adhesive.
• Fit ring stop (5).
• Ensure that stop (5) is fully locked in place with Loctite 222 or similar adhesive.

! Always follow instructions on adhesives.

5.3 Assembling the Thrust rings into the Bearing Casing

• Coat the thrust pads surfaces with clean oil of the correct grade.

• Some OT Series bearings are supplied with machine liners; these should be fitted at the

same time as each thrust ring assembly.

• Horizontal Bearings: Fit the lower half of the thrust ring(s).

• Vertical bearings: Fit the entire lower thrust ring.

Care should be taken when handling the components to avoid the risk of
trapping hands when assembling.

• Lower the shaft, complete with collar into the bearing.

• Horizontal Bearings: Fit the top half of the thrust ring(s), either onto the top of the lower

ring, or into the top half casing. Secure the ring with stops.

• Horizontal bearings: Rotate the thrust ring around until the stop (5) engages in the casing,

if half the ring is secured into the top half of the casing, ensure that the bottom half is flush

with the casing joint and complete assembly.

• Vertical Bearings: Fit upper thrust ring and secure in place with stop (5).

• Check the bearing alignment, and complete assembly.

11
5.3.1 Miscellaneous
• Where applicable, connect up oil inlet and outlet.
• Connect external pipework.
5.3.2 Instrumentation
• Fit RTDs and instrumentation as necessary.

Ensure that temperature probe assembly is not damaged and is working


correctly before fitting it.

Check that the bearing is complete and is fully sealed.


• For temperature probe fitted bearings; run the bearing and establish a steady state
operating temperature then set temperature alarm to 5°C above the steady state operating
temperature. Shut down temperature alarm is to be set at 10°C above steady state
operating temperature.

! Note! Prior to running the bearing EC regulation state: - The entire machine
has received a Declaration of Conformity, or has been declared exempt from the
Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive.
Where applicable

! Do not use the bearing unless the lubricating system is operating.


It must be emphasised that any declaration of incorporation issued by
Michell Bearings is for the thrust rings and their components and not for
the entire bearing.
The bearing is now complete; it must not be used until the below items
have been dealt with;
1. Lubricating oil has been passed though the bearing.
2. The lubricating oil must be a mineral based turbine oil inhibited
against oxidation, corrosion and foaming, with an ISO viscosity grade
as indicated on the arrangement drawing.
The use of any other oil should be referred to Michell Bearings.
If in doubt with installation please use our Service
Department!

12
6. Operating

6.1 Preparation and Inspection before Operation

• Where necessary fit the temperature probes for measuring the thrust pads, and/or the
sump temperature in the relevant connection holes.

Ensure that RTD assembly is not damaged and is working correctly before
fitting.

! Always follow sealant manufacturers’ instructions.


• Where applicable retighten external oil supply connections.
• Fill Bearing with oil or start oil system as described in Section 7.4.

Check:
1. That the oil quantity at bearing oil inlet is as specified by Michell Bearings, where
applicable.
2. That the temperature monitoring equipment works.

• The bearing is now ready for operation. It must not be used until the below items have
been dealt with:

1. The entire installation has received a Declaration of Conformity, or has been declared
exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery
Directive.
2. Lubricating oil has been passed though the bearing.
3. Local safety regulations have been met.
6.2 Trial Run

• For temperature probe fitted bearings, run the bearing and establish a steady state
operating temperature. Set temperature alarm to 5°C above this steady state operating
temperature. Shut down temperature alarm should be set at 10°C above steady state
operating temperature.
• Supervise the bearing during the trial run period (approx. 5-10 operating hours).
• Pay special attention to the following:

1. Oil flow rate and oil inlet pressure in circulating oil system (where applicable)
2. Bearing temperature
3. Occurrence of inadmissible vibrations.
4. Unusual noises or odours

13
• If any or all of the above cause concern, or if the monitoring equipment triggers an alarm,
stop the machine immediately and carry out an inspection of the bearing to find the cause.

6.3 Normal Operation

! Do not touch any moving parts.


• If the bearing has been correctly assembled using the procedure already given, there is
only a marginal risk of the bearing failing which would normally be due to inadmissible
operating conditions. Examples of these conditions are; overspeed, low lubrication levels
and excess load. To avoid these situations, follow the following recommendations:

• Label Control Panels with the bearing limitations.


• Do not operate the bearing below the transition speed values indicated in the bearing
calculation.
• Stop the shaft immediately if: Bearing temperature exceeds normal operating
temperature by 10°C.
• Never remove plugs, RTDs or seals while the bearing is operating.
• Regularly inspect all seals and pipework. Any large leakage of lubricant or coolant will
indicate that a seal or joint is failing. Maintenance must then be carried out as soon as
possible.

The bearing surface and any pipework may be hot during operation.
6.4 Preparation for Operation after Standstill

• Clean the external parts of the bearing. Dust and dirt impede the radiation of heat.
• Check with the maintenance schedule in Section 7.3 to see if an oil change is necessary.
If required, carry out the oil change as indicated in Section 7.4.
• Start operating the oil supply system, where applicable, and check that it is working
correctly. The supplied oil quantity at the bearing inlet must equal the value indicated in
the Michell Calculations.
• Check the functioning of the temperature monitoring equipment.
• The bearing is now ready for operation.

14
7. Care and Maintenance

7.1 General

• Before carrying out any maintenance or inspection work, switch off machinery. Lock off the
controls and secure and the isolate shaft.

! Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled “Not to be used”, or similar.

! Do not touch any moving parts.

7.2 Tools and Equipment

The following tools and equipment may be necessary to carry out maintenance on the
bearing:
• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges.
• Emery paper, plain scraper
• Lifting equipment
• Permanent sealing compound (e.g. Curil-T)
• Liquid screw locking compound (e.g. LOCTITE 222)
• PTFE sealant tape.
• Oil with the viscosity indicated (see bearing inspection plate)
• Detergents
• Clean cloth

15
7.3 Maintenance Schedule

• For a bearing that is operating constantly, routine maintenance should take place annually.
• If the user only operates the bearing periodically, maintenance periods may be able to take
place less frequently. This is however, at the users’ discretion. An annual inspection is
recommended as a minimum service requirement.
• A basic guide to maintenance is given in Table 1.

Maintenance work Schedule


Oil Change (see Section 7.4) • Bearing in reversing operation: every 3 Months
• Bearing in continuous operation: every 6 Months
Bearing Inspection During preventative maintenance work for machine or
immediately if:
• Bearing temperature exceeds 10°C over the indicated
value (see calculations)
• Unusual noises or odours occur
• Unusual changes in the oil colour are visible.
• Inadmissible vibrations occur.
• Oil flow rate and oil inlet pressure readings drop
below admissible values,

Table 1: Maintenance Schedule

• These are estimates only, and frequency may alter depending on site environment.
Michell can advise the user accordingly.
7.4 Oil Change

7.4.1 General
• Oil changes will be at differing periods depending on the frequency of bearing operation
and the conditions in which the bearing is operating. Approximate oil change times are
indicated in Section 7.3.
• Please observe the instructions for the use of the lubricating oil. The manufacturer
can provide information on waste oil disposal.

! Risk of Pollution:

7.4.2 Procedure for draining oil


• Run the bearing to warm up the oil. This will ease the flow of oil from the bearing, and also
remove any impurities and residues.

16
• Shut down the machine and secure it against unintended operation.
• Shut down the oil supply system where applicable.

! Do not disconnect the oil inlet and outlet pipework until the bearing has been
drained of oil.

Any oil spillage should be collected in suitable containers.


• Let off and collect the lubricating oil in the oil supply system where applicable.
• Loosen and remove the drain plug and washer, and fully drain the bearing of oil.

! Beware hot oil.

Collect and dispose of used oil under the correct regulations.

If the oil is visibly altered in colour, or contains unusual residues, an inspection


is recommended to eliminate the cause.

7.4.3 Procedure for refilling the bearing -self contained bearings


• Pour the correct grade of lubricating oil into the filling hole in the casing top. Use the
approximate quantity required as shown on the bearing arrangement drawing as a guide.
• Let the oil settle into the bearing. Check the oil level is approximately at the centre of the
oil level gauge, and top up if necessary. Where applicable.

7.4.4 Procedure for refilling the bearing - bearings with circulating oil
• Clean the oil container and fill up the oil supply system with the correct grade of lubricating
oil.
• Start the oil supply system in order to fill up the bearing with oil.

Check for leaks.

Not enough lubricant leads to temperature rises and therefore damage to the
bearing. Too much lubricant leads to leaks.

When pouring, take care not to spill lubricating oil onto the machine or
surrounding area.

17
8. Dismantling an Installed Bearing

8.1 General

• The Procedure given in this section is a full stripdown of a generic Omega “OT” series
bearing. As such it may contain more information than is necessary in some cases.
Simply ignore the sections not relevant to the bearing being worked on. Any technical
queries can be referred to the Engineering Team at Michell Bearings.
• Michell recommends that the below safety advice is followed when carrying out
maintenance on any bearings. It may be necessary to change the dismantling procedure
to suit the design of the bearing casing.

8.2 Preparation

• Check through the safety procedures at the start of Section 2. Understand and follow the
instructions very carefully.
• Switch off machinery. Lock off controls. Secure and isolate shaft, drain and disconnect
cooling system, where applicable. Refer to manufacturer instructions.

! Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled “Not to be used”.
• Switch off and drain the lubricating oil and oil system (where necessary) as described in
Section 7.4.
• Disconnect and remove any thermometry and instrumentation.

Make sure the workspace is clean. Contamination and damage to the bearing
affect operating performance and could lead to premature failure.

! Do not use any violence or force.

Take care not to jam hands when manipulating components.


.
8.2.1 Strip down the bearing until the thrust rings are visible.
• Horizontal Bearings: Where applicable, remove the top half of the thrust ring(s).

• Vertical Bearings: Remove upper thrust ring (where fitted).

• Vertical Bearings: Jackshaft up until it’s clear of the lower thrust pads.

18
! Follow lifting instructions and safety guidelines in Sections 2 and 3.

! Ensure the jacking equipment is safely positioned and certified to carry a load

greater than the mass of the shaft.

! Once the shaft is raised, secure it into position using other equipment. Do not
rely on jacking equipment alone.

8.2.2 Disconnect and remove any thermometry and instrumentation.


• Remove RTDs, and instrumentation connections.

Take care not to damage instrumentation.

8.3 Removing thrust rings


Vertical Bearings: Remove lower thrust rings.

• Horizontal Bearings: If the bottom half of the thrust rings are not visible, follow the below
procedure;
• Tap one end of the ring until the opposite end is visible.

• Rotate the ring out and remove.


8.4 Removing the Liners, and Shim Pack. Where Applicable.

• To fully dismantle the thrust ring follow the below procedure:

• Remove liner retaining screws (8), liners (7), and shim pack (6) from the back of the
retaining ring halves (1), (2).
8.5 Removing the Thrust Pad Set

• Remove thrust pad stops (4) from retaining rings (1), (2).

• The thrust pads (3) can now be removed from the retaining ring (1), (2).

Take care not to jam hands when manipulating components.

Take care not to damage thrust pad whitemetal surface.

19
9. Cleaning and Checking

9.1 General

! Only use non-aggressive detergents such as VALVOLINE 150 or Alkaline


cleaning compounds with pH-value 6 to 9, and a short reaction time.

! Please observe the instructions for use of the detergents.

! There may be fumes given off during the cleaning process. Clean parts in a
well-ventilated area. Always follow cleaner manufacturers’ instructions.

Use a lint free cloth when cleaning the bearing. Thread from such cloths could
get into the lubricating oil and cause overheating, and in extreme cases, failure of the
bearing.

• Clean the following parts thoroughly:

1. Thrust pad set.


2. Retaining ring.
3. Liners, where applicable
4. Shim pack.
5. Thrust pad stops.

• In addition inspection may be required on the bearing components, according to the


Maintenance Schedule outlined in Section 7.3.
• The remaining part of this section gives basic inspection guidelines for some major bearing
components. However, if any wear or damage is evident on any of the bearing
components, consult Michell Bearings immediately as it may adversely affect bearing
performance.
• The following sections assume the bearing has been dismantled according to Section 8.

20
9.2 Checking the Thrust Pad.

• Examine the Thrust Pads. The appearance of the running surface should be that shown in
Figure 11 below.

Figure 11: Thrust Pad Appearance After Use

• Inspect the collar surface for any signs of damage. If it is necessary to change the pads,
the collar should also be replaced or repaired, otherwise the replacement pads will only
have a short life. There may be some scoring and wear on the pads. Provided wear is no
greater than 0.125mm the pads are still serviceable. If there is any sign of the bearing
surface coming away from the backing material, the pads must be replaced.

21
10. Bearing Preservation during Storage

10.1 Before Installation

• Make sure thrust rings are stored in the intended mounting position, in a dry room only.

10.2 Corrosion Protection for Standstill Periods up to 6 Months

• Dismantle the bearing (see Section 8).


• Clean the bearing (see Section 9).
• Assemble the bearing (see Section 5).
• Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of
condensation in the bearing.

10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year

• Repeat the preservation procedures detailed in Section 10.2.

10.4 Corrosion Protection for Standstill Periods longer than 1 year

• Dismantle the thrust rings according to Section 8.


• Preserve and store bearing parts separately.

11. Bearing Preservation During Transport

When the bearing is fitted to the machine during transport:


• Carry out the corrosion protection procedure described in Section 10.2.
• Apply liberal lubricant to the running surfaces of the bearing.
• Secure the shaft against axial and radial movement.

12. Appendices

12.1 Ordering Spares

• As a minimum, it is recommended that replacements should be carried for all Whitemetal


components. Consideration should also be given to stocking the parts listed below:
• Jointing compound (i.e. Curil-T)
• RTD Assemblies (where applicable)

22
Appendix 2 (Table of Torque’s).

Bolt Size (mm) Tightening Torque (Nm)


6 4
8 10
10 20
12 35
16 80-90
20 155-175
24 275-305
30 545-605
36 950-1050
42 1520-1680
48 2300-2520
56 3690-4070
64 5560-6150

23
Michell Bearings Service Department.
Scotswood Road Direct: +44(0191) 2565319
Newcastle Upon Tyne
NE15 6LL Repair Department.
Great Britain Direct: +44(0191) 2565309
Tel: (0191) 273 0291
Fax: (0191) 272 2787

Michell Bearings reserve the right to amend these instructions.


© Michell Bearings 2004.

24
SECTION – A

BOILER FEED BOOSTER PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

5. CONNECTING COUPLING
STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 1 of 4

1. Installation and alignment instructions:

Preliminary Checks

All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling
accompany all supplies. Carry out the following checks prior to proceeding with the installation work.

i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport
purposes and for the purpose of compressing the flexing elements at the time of installation.

The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling
alignment and trial run of the equipment.

Couplings and the equipment should not be allowed to operate with gagging screws in position.

ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those
of the interface dimensions of the equipment shafts and flanges.

Coupling model & Rating


Hub bore and key way dimensions
Locating / Spigot diameter
Distance Between Shaft Ends (DBSE)
or Distance Between Flange Faces(DBFF)
Over all length

iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling.

iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise
called for, should not be disassembled, .

v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque
wrenches / special spanners.

vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with
numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying
certificates will show the run out values obtained at the time of dynamic balancing.

These markings of are meant for match marking and the run out values can be used as a guide for accurate
alignment of the equipment.

Prepared Approved Date

SANKAR KVMR 18-06-2003


STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 2 of 4

vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection,
with a coat of oil applied and wrapped in moisture proof polythene shrink film.

For best results it is recommended that the couplings are left in their original packing and are to be removed just
prior to the actual date of installation.

For extended periods of storage in the open, it is recommended that the couplings are returned to their original
packing and stored with a periodic coat of oil re-applied to them.

viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field
replacement with components that do not form part of the original set is not to be done. Always replace these
components as a set.

2. Initial Assembly and Centering :

Correct careful assembly and centering at the initial stage enables the coupling to provide maximum
performance and increases service life.

3. General Limits :

i. Maintain the actual Axial shaft gap to that specified with the following tolerances :

4 bolt couplings : +/- 0.5 mm


6 bolt couplings : +/- 0.4 mm
8 bolt couplings : +/- 0.3 mm

As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling
drawing.

ii.Radial Misalignment : Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower.

Note : The above values are to be arrived at after taking into


consideration the cold offset values for both axial and radial directions specified by the main equipment
manufacturer.

Prepared Approved Date

SANKAR KVMR 18-06-2003


STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 3 of 4

CONFIGURATION-1

Configuration : 1

Couplings with this configuration have hub flanges directly bolting on to the flexing elements. Following is the
sequence installation :

i. Dismantle the coupling bolts and the gagging screws.

ii. Mount the hubs on respective equipment shafts.

iii. Position the equipment to the correct DBSE specified.

iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance
(DBFF)
specified on the drawing.

v. Clamp two dials as shown and align to within 0.05 mm of TIR.

vi. Assemble the flexing elements and spacer in position and hand tighten all coupling bolts, in cylinder head
fashion.

vii. Tighten all coupling bolts to 50% of the specified torque using a calibrated torque wrench, in a cylindrical
head fashion.

viii. Recheck the DBSE and radial run out values. Readjust if the same is found disturbed.

ix. Tighten all coupling bolts to the specified torquing limit.

Prepared Approved Date

SANKAR KVMR 18-06-2003


STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 4 of 4

IMPORTANT:

Care should be exercised to tighten only the lock nuts by holding the bolt head steady in a socket. Coupling bolts
will have a very close fit in the flange holes and to the flexing element bushes and hence any forced rotation will
result in damage to the close fitting bolt shank and the mating parts.

1
1

2
Alignment Procedure / Clamping Arrangment 2

Fig. No. : 1
Max. Alignment Limits TIR-mm
Final checking
Max. Alignment Limits TIR-mm Application Dial 1&2
Application Dial 1 Dial 2 0.05
DRIVER - DRIVEN
DRIVER - DRIVEN 0.05 0.05
Fig. No. : 2

Prepared Approved Date

SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 1 off 4

1. Installation and alignment instructions:

Preliminary Checks

All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling
accompany all supplies. Carry out the following checks prior to proceeding with the installation work.

i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport
purposes and for the purpose of compressing the flexing elements at the time of installation.

The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling
alignment and trial run of the equipment.

Couplings and the equipment should not be allowed to operate with gagging screws in position.

ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those
of the interface dimensions of the equipment shafts and flanges.

Coupling model & Rating


Hub bore and key way dimensions
Locating / Spigot diameter
Distance Between Shaft Ends (DBSE)
or Distance Between Flange Faces(DBFF)
Over all length

iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling.

iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise
called for, should not be disassembled, .

v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque
wrenches / special spanners.

vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with
numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying
certificates will show the run out values obtained at the time of dynamic balancing.

These markings of are meant for match marking and the run out values can be used as a guide for accurate
alignment of the equipment.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 2 off 4

vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection,
with a coat of oil applied and wrapped in moisture proof polythene shrink film.

For best results it is recommended that the couplings are left in their original packing and are to be removed just
prior to the actual date of installation.

For extended periods of storage in the open, it is recommended that the couplings are returned to their original
packing and stored with a periodic coat of oil re-applied to them.

viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field
replacement with components that do not form part of the original set is not to be done. Always replace these
components as a set.

2. Initial Assembly and Centering :

Correct careful assembly and centering at the initial stage enables the coupling to provide maximum
performance and increases service life.

3. General Limits :

i. Maintain the actual Axial shaft gap to that specified with the following tolerances :

4 bolt couplings : +/- 0.5 mm


6 bolt couplings : +/- 0.4 mm
8 bolt couplings : +/- 0.3 mm

As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling
drawing.

ii.Radial Misalignment : Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower.

Note : The above values are to be arrived at after taking into


consideration the cold offset values for both axial and radial directions specified by the main equipment
manufacturer.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 3 off 4

Configuration :

Couplings of this configuration are supplied with a central transmission unit which allows installation
with minimum disassembly of the factory tightened main coupling bolts.

i. Dismantle the coupling hubs by removing the attachment screws.


ii. Mount the hubs on respective equipment shafts.

iii. Position the equipment to the correct DBSE specified.

iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance
specified on the drawing.

In case of variation to the specified axial shaft gap , refer to the specific instructions supplied, for using DBSE
adjusting shims supplied with the unit.

v. Clamp two dials on hub flanges as shown and align to within 0.05 mm of TIR.

vi. Disassemble the gagging screws and remove the gagging bush from the position. Re assemble the gagging
screws between the adaptor and spacer flanges. The transmission unit can now be compressed, by tightening
the gagging screws, adequate to facilitate assembly.

vii. Place the transmission unit into the position between the hubs ensuring that the spigot on hubs clears the
locating diameter on the adaptor plates.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 4 off 4

IMPORTANT :
Slowly loosen & remove the gagging screws thus allowing the transmission unit to regain the original free length.
Ensure that the gagging screws are NOT in position at the time of equipment trial run or continuous operation.
Remove & store the gagging screws and bushes carefully for future use.

viii. Re check the DBSE and radial run out values. Readjust if the same is found disturbed.

ix. Tighten all attachment screws / bolts to the specified torque limit.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


SECTION – B

BOILER FEED BOOSTER PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

6. SUCTION STRAINER (BASKET)


Digitally signed by S P Patra
DN: CN = S P Patra, C =

SP US, O = DVC, OU =
Engineering and Planning
Reason: DVC have reviewed
this document and taken it

Patra for INFORMATION


Date: 2009.02.05 15:01:43
+05'30'
SECTION - B

BOILER FEED PUMP


PART – 4

EQUIPMENT DETAILS

SECTION - B

BOILER FEED PUMP

LIST OF CONTENTS

CHAPTER TITLE

1. Description

2. Operating Instructions

3. Maintenance Instructions

4. Sub-Vendor’s Drawings / Instructions


SECTION - B

BOILER FEED PUMP

CHAPTER - 1

DESCRIPTION

LIST OF CONTENTS

1 Introduction
2 Technical Data (Ref. BFP data sheet)
Motor driven pump
Turbine driven pumps
3 Description
3.1 Pump casing
3.2 Discharge cover
3.3 Suction guide
3.4 Ring section assembly
3.5 Rotating assembly
3.6 Mechanical seals
3.7 Journal and thrust bearings
3.8 Bearing housing
3.9 Hydraulic balance
CHAPTER – 1

DESCRIPTION

1. INTRODUCTION :

FK4E36 type Boiler Feed Pump is a four stage horizontal centrifugal pump of
barrel design casing.

The pump internals are designed as a cartridge which can be easily removed for
maintenance without disturbing the suction and discharge pipe work, or the
alignment of the pump and the turbo coupling.

The pump shaft is sealed at the drive end and non-drive end by Mechanical Seals.
The rotating assembly is supported by plain white metal lined journal bearings and
axially located by a double titling pad thrust bearing.

3. DESCRIPTION:

3.1 Pump Casing :

The pump casing consists of a forged steel barrel with welded suction, discharge
branches, inter stage tapping and mounting feet. The drive end of the casing is
closed by a suction guide which is entered from the non-drive end of the casing
and is located by a spigot against the outer face of the casing.

A metaflex joint is located between the suction guide spigot and the casing
outer face to prevent leakage between the barrel casing and suction guide. A split
pull up ring is secured to the pump casing and suction guide by a ring of screws.
Leakage between the suction annulus and the discharge annulus of the pump
casing is prevented by a copper coated mild steel joint located between the inner
face of the casing and the first stage ring section spigot. The non-drive end of the
casing is closed by a discharge cover secured to the casing by a ring of studs,
washers and nuts, sealing being effected by a Metaflex joint located in a machined
recess in the pump casing. On each side of the casing, on its horizontal centre
line, are two support feet which are secured to the base plate pedestals by spacer
pieces, washers and holding down bolts, thus allowing for expansion. Transverse
keys in the drive end pump feet and longitudinal keys under the casing transfer
moments and thrust to the base plate, while allowing the casing, freedom to
expand.

Provision is made on the pump casing for a drain connection and temperature
probes.
3.2 Discharge Cover

The discharge cover closes the non-drive end of the pump casing and also
forms the balance chamber which, in turn, is closed by the gland housing. The
discharge cover is a close fit in the casing bore and is held in place by a ring of
studs and nuts. A spring disc is located between the last stage diffuser and out let
guide to provide the force required to hold the ring section assembly in place
against the drive end of the barrel before start-up. Once running, the discharge
pressure assists the spring disc in holding the ring sections in place. The last
stage diffuser is free to slide over the out let guide.

Two holes are drilled radially through the periphery of the discharge cover
to provide outlet connections through which the liquid from the balance chamber is
returned to the pump suction piping and two similarly drilled holes are also
provided in the discharge cover for the welded connections of the kicker stage
deliveries. The non-drive end bearing housing is attached to the gland housing
secured to the outer face of the discharge cover by socket head screws and dowel
pins.

To assist in removing the cover, two tapped holes are provided on the
flange for the use of starting screws and a tapped hole is provided on top of the
cover for an eye-bolt.

3.3 Suction Guide

The suction guide closes the drive end of the pump casing and forms the
suction annulus. As a section of the pump cartridge, the suction guide is not
secured to the pump casing but is held against an internal shoulder in the casing
by the pull up ring.

The drive end bearing housing is secured to the outer face of the suction
guide by cap screws and dowel pins.

3.4 Ring sections

The ring section assembly consist of ring sections which locate one to
another by radial dowel pins and are secured to each other by socket head screws
in counter bored holes, sealing being effected by metal-to-metal joint faces.
Diffusers are dowel and spigot located to the ring sections and secured to the ring
section with socket head screws. The outlet guide for the kicker stage impeller is
secured to the discharge cover by means of cap screws which are locked in
position with plugs. Packing rings are shrunk into the bores of the ring sections
and diffusers and are secured by grub screws, the purpose of the packing rings
being to restrict the recirculation of the pumped liquid between the stages.
The ring sections and diffusers form the transfer passages from the
impeller outlet of one stage of the pump to the impeller inlet of the next stage, and
the diffusers are designed to convert some of the kinetic energy of the product into
pressure energy.
The first stage ring section is spigot located to the suction guide and is
radially located by means of a slot in the ring section and a cast key block in the
suction guide. At the non-drive end a dowel pin fitted to the outlet guide is located
in a hole in the last stage diffuser thus the ring section assembly is kept in its
correct position relative to the casing. A circular spring disc is located in the last
stage diffuser and over the inner end of the outlet guide. A shoulder on the outlet
guide bears against the spring disc and clamps the ring section assembly and
suction guide in position.

3.5 Rotating Assembly

The dynamically balanced rotating assembly consists of the shaft,


impellers, abutment rings, keys, seal sleeves, shaft nuts, balance drum, thrust
collar and the pump half coupling.

The shaft is chromium plated at each end where it is supported by the


journal bearings, and its diameter increases in increments from the non-drive end
towards the drive end to facilitate the fitting and removal of the impellers.

The impellers are of the single entry shrouded inlet type and are keyed
and shrunk onto the shaft, the keys, one per impeller, being alternately fitted on
diametrically opposite sides of the shaft to maintain rotational balance.

The hub of each impeller butts against a split shear ring fitted in a groove
in the shaft. The shear ring is retained by an extension of the impeller hub.

The balance drum is keyed and shrunk on the shaft and held in place
against the shaft locating shoulder by the balance drum nut and lock-washer. The
inner end of the balance drum is recessed and the bore of the recess is a close fit
over the kicker stage impeller hub. The face of the balance drum incorporates
tapped holes for withdrawal purposes.

The rotating parts of the seals are fitted to the shaft where it passes
through the seal housings. The seal sleeves are keyed to the shaft and are
clamped in position by shaft nut and shaft lock-nuts.

The thrust collar which is keyed to the non-drive end of the shaft, has the
thrust collar probe indicator fastened and doweled to its hub and is located against
a shoulder on the shaft by the thrust collar nut, locked by a lock washer.

NOTE : The thrust collar nut has left hand thread.

The pump half coupling is located on the tapered end of the shaft by keys
and it is secured by a coupling nut locked by a grub screw.
3.6 MECHANICAL SEAL

The drive and non-drive end stuffing boxes are fitted with mechanical
seals mounted on seal sleeves and located within seal cooling jackets to prevent
feed water escaping along the shaft. Tapped holes are provided on each seal
plate and cooling jacket for clarified cooling water inlet and outlet connections.

3.7 Journal and Thrust Bearings

The rotating assembly is supported at each of the shaft by a white metal


lined journal bearing and the residual thrust is carried by a titling pad double thrust
bearing mounted at the non-drive end of the pump.

The journal bearing shells are of mild steel, white metal lined, thick wall
type and are split on the horizontal plane through the shaft axis. Each bearing is
secured in a bearing housing and prevented from rotating by a dowel pin located
in the bearing keep.

The thrust bearing has eight white metal lined titling pads held in a split
carrier ring positioned on each side of the thrust collar. The carrier rings are
prevented from rotating with the shaft by dowel pins in each ring which engage in
slots in the bearing housing top half. The thrust pads are retained on the carrier
rings by a special pad stops screwed into the rings.

A split floating oil sealing ring is located in a groove in the thrust bearing
housing to restrict the escape of lubricating oil from the thrust bearing chamber. To
ensure that the thrust bearing remains flooded, an orifice is fitted at the oil outlet.

Machined spacers are fitted behind the carrier rings to effect the axial
position setting of the rotating assembly on the original build. The bearings are
supplied with lubricating oil from the forced lubrication oil system.

3.8 Bearing Housings

The bearing housings are in the form of cylindrical castings split on the
horizontal shaft axis. The top and bottom halves, of each bearing housing, are
located by fitted bolts and secured together by cap screws. The journal bearing in
each housing is located by a dowel pin in the bearing keep and the bearing keep is
dowel located to the bottom half housing and secured by cap screws. On the top
half housing there is provision for an air vent, vibration probes and a temperature
check point. On the bottom half housing there is provision for oil inlet and oil outlet,
R.T.D. probe and a temperature gauge.
The drive end bearing housing is secured to the suction guide by cap
screws and is radially located by dowel pins fitted in the flange of the suction
guide. Oil guards fitted in a groove at each end of the bearing housing are dowel
located and serve to prevent oil escaping from the housing.
An air breather is screwed into a tapped hole in the top half bearing
housing and a tapped hole is provided for a temperature gauge. Connections for
an oil inlet and an oil outlet are provided in the bottom half bearing housing.
The non-drive end bearing housing, which contains both the journal and
thrust bearings, is located by taper dowel pins and secured to the gland housing
by cap screws. In addition to the features common to both bearing housings the
follow features are included. On the top half housing there are connections for
reverse running indicators, an accelerometer and a thrust bearing temperature
check point. On the bottom half bearing housing the additional provision is for
thrust bearing temperature gauges. Leakage of lubricating oil from the non-drive
end bearing housing is prevented by an oil guard in the inboard side of the
housing.

3.9 Hydraulic Balance :

The rotating assembly is subject to varying forces due to the differential


pressure forces acting on the impellers. The pump has therefore been designed so
that the shaft is kept in tension by the location of a balance drum at the non-drive
end, and is hydraulically balanced so that only a small residual thrust remains,
which is carried by the thrust bearing. The main components of the hydraulic
balancing arrangement are the balance chamber machined in the discharge cover,
the balance drum which is secured to the shaft and the balance drum bush fitted in
the bore of the discharge cover. The thrust caused by the discharge pressure
acting on the area outside each impeller wear ring on the inlet side of the impeller
wear ring is balanced by the same pressure acting on an equal area on the outlet
side of each impeller. The thrust caused by the suction pressure acting on the
area inside the wear ring on the inlet side of each impeller is overcome by the
much greater thrust caused by the discharge pressure acting on an equivalent
area on the outlet side of each impeller. The resultant thrust force, due to the
different pressures acting on these equal areas, tends to move the rotating
assembly towards the drive end of the pump.

The thrust force will vary with the load on the pump but the hydraulic
balance arrangement will reduce its effect, enabling the residual thrust to be taken
by the titling pad thrust bearing. This bearing has a double face so that the surges
in opposite directions which occur during the start-up period and during transient
conditions will be accommodated.
The hydraulic balance arrangement operates as follows:-

The pump product passes from the kicker stage of the pump between the
balance drum and the bush, and enters the balance chamber at a pressure
approximately equal to the suction pressure. Two ports in the discharge cover
allow the product to be piped back to the pump suction side. The pressure
differential across the balance drum is therefore equal to the across the impellers.
The cross-sectional area of the balance drum is sized to give a small residual
thrust towards the drive end of the pump.
SECTION - B

BOILER FEED PUMP

CHAPTER - 2

OPERATING INSTRUCTIONS

LIST OF CONTENTS

1. Introduction
2. Preparation for starting
3. Start – up
4. Routine checks
5. Trip condition
6. Shut-down
7. Stand by conditions
8. Fault finding
CHAPTER – 2

OPERATING INSTRUCTIONS

1. INTRODUCTION

The 50% tandem Boiler feed pump set is an integral part of the boiler feed
system and the following instructions should be read in conjunction with those for
the operation of the associated equipment and the system.

2. PREPARATION FOR STARTING

CAUTION : The pump set suction and discharge pipe work and valves are not in
pumps supply. Reference, therefore, should be made to the system operating
instructions for the control of the valve.

(1) Check that the deaerator is filled to normal working level.

(2) Check that the control air and electrical supplies are available for the
instrumentation, leak-off equipment and valves.

(3) Ensure that the suction filter has been primed and ready for operation.

(4) Check that the following valves are shut :-

(a) Pump set suction isolating.


(b) Booster stage pump drain isolating.
(c) Interconnecting pipe drain isolating.
(d) Boiler Feed pump drain isolating.
(e) Pump discharge isolating.

(5) Check that the following valves are open :-

(a) Leak-off control valves inlet and outlet isolating.


(b) Leak-off control.
(c) Booster stage pump mechanical seal control and outlet isolating.
(d) Boiler feed pump magnetic separator inlet and outlet isolating.

(6) Check that all the instrument tapping point isolating valves are open and
that all drain and equalizing valves are shut.

(7) Crack open the pump set suction isolating valve.

(8) Open the booster pump air vent valve and vent any trapped air or gases
from the pump casing.

(9) Shut the booster pump air vent valve when water issues freely from it.
(10) Open the interconnecting pipe work air vent valve and vent any trapped air
or gases from the interconnecting pipe.

(11) Shut the interconnecting pipe work vent valve when water issues freely
from it.

(12) Shut the leak-off drain regulating and drain isolating valves when water
issues freely from them.

(13) Fully open the pump set suction isolating valve.

(14) Ensure that the station general service cooling water available for the
pump set.

(15) Prepare the driving motor for starting. Refer to manufacturer’s instructions.

(16) Prepare the turbo-coupling and lubricating oil system for starting. Refer to
the manufacturer’s instructions in part 3.

(17) Ensure that all instruments and coolers have been primed and vented.

(18) Ensure that the pre-start checks for the leak-off equipment are carried out.
Refer to the manufacturer’s instructions.

3. START-UP

Refer sequential interlocking conditions.

4. ROUTINE CHECKS

(1) Check that the driving motor ammeter reading is normal.


(2) Check that all pressure and temperature readings are normal.
(3) Check that the lubricating oil is flowing freely through the following flow
indicators :-
(a) Booster pump drive end and non-drive end bearing drain flow.
(b) Booster pump side and turbo coupling side driving motor bearing drain
flow.
(c) Boiler feed pump drive end and non-drive end bearing drain flow.
(4) Check that the cooling water from the BFP and booster pumps mechanical
seals is flowing freely.
(a) Cooling water from motor coolers.
(b) Cooling water from mechanical seal coolers.
(c) Cooling water from cooling water jackets in BFP and booster pump
(d) Cooling water from lubricating oil coolers.
(e) Cooling water from working oil coolers.
(5) Check the oil level in the fluid coupling tank and top up as necessary.
(6) Check for any undue noise or vibration.
(7) Check all joints and valve glands for leakages.
(8) Check the security of all keys and fastenings, paying particular attention to
the holding down bolts.
(9) Check for leakage from BFP and booster pump mechanical seals.
(10) Refer to the manufacturer’s instructions for the routine checks of the turbo
coupling and the driving motor.

5. TRIP CONDITION : Refer sequential inter locking conditions.

6. SHUT - DOWN

(1) Shut the discharge valve.


(2) Stop the driving motor by opening the boiler feed pump motor ACB.
(3) Check that the electrical lube oil pump starts up as the pump set slow
down.
(4) Check the pump reverse running indicator.
(5) Stop the electrical lube oil pump 15 minutes after the Boiler feed pump set
has stopped.
(6) Close the cooling water valves to the driving motor air cooler and the
working oil cooler of the turbo coupling.

7. STAND BY CONDITIONS

Refer sequential interlocking conditions.

8. FAULT FINDING

Symptom Possible Cause Action

(1) Pump fails to (a) Driving motor fault Check motor


start.
(b) Power supply fault. Check motor Breaker.
Symptom Possible Cause Action

(c) Seizure of Pump set. Disconnect couplings and


locate seizure. Overhaul as
necessary
(d) Deaerator level low- Check deaerator water level
low switches & gauge glass for
any Blockage.
(e) Pump set tripped. Investigate cause.
Reset trips.

(2) Pump (a) Driving motor faculty Check operation of motor.


performance
low (Pump
Discharge
pressure low)
(b) Incorrect rotation Check motor electrical
connections.
(c) Booster stage pump Check booster stage pump
faculty. (Refer to part 1, chapter 2).
(d) Excessive wear of Dismantle pump and inspect
pump internals components.
(e) Low Speed Check Speed Regulation
System
(f) Strainer Chocked Clean strainer.

(3) Bearings (a) Defect in lubricating oil Check lubricating oil system.
overheating. system. Oil flow to bearing. (Refer to
manufacturer’s instructions in
Part 3).
(b) Bearings worn of Examine Bearings.
misaligned.
(c) Misalignment of Check alignment.
pump.
(4) Mechanical Seal
Temperature high
(a) Insufficient cooling Check Heat Exchanger for
Water to cooler. blockages and clean.

(5) Excessive noise


and/or vibration
(a) Misalignment of pump Check alignment
set.
(b) Bearing misalignment Examine bearings.
(c) Holding down bolts Tighten holding down bolts.
loose. And maintain Dim as per Drg.
(d) Excessive clearance Check clearances overhaul as
of pump internals. necessary.
(e) Rotating assembly out Check dynamic balance.
of balance.
(f) Excessive piping loads Check piping support and re-
acting on pump adjust.
branches.
(g) Hydraulic Flow Increase flow through pump.
Disturbances Avoid long runnings on low
flows.
(6) High Diffl. (a) No flow through pump a) Check R.C. Valve
Temp across
suction and
discharge of
BFPS.
(b) Hot start of stand by b) Opening casing drain &
Pump. R.C. line drains.
(c) Mal-Operation of c) Check RTD & diff temp.
Instruments. switches.
(7) H.C. Fusible (a) Entrap-off foreign a) Check pump freeness/
plugs blown - particles between rotation. If hard, open
off pump internals or and inspect pump
pump seizure internal.
SECTION - B

BOILER FEED 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 torque values for
threaded fasteners
2.4 Recommended lubricants
3 Maintenance Procedures
3.1 Preparation for maintenance
3.2 Examining the drive end journal and
thrust bearing.
3.3 Examine the non-drive and journal and
thrust bearing.
3.4 Checking the axial running position and
thrust bearing clearance.
4 Overhaul
4.1 Preparation for overhaul
4.2 Withdrawing the pump cartridge
4.3 Dismantling the pump cartridge
4.4 Inspection, renewal and repair
procedures
4.5 Assembling the pump cartridge
4.6 Installing the pump cartridge
4.7 Final assembly
5 Parts Identification
CHAPTER – 3

MAINTENANCE INSTRUCTIONS

1. INTRODUCTION :

It is recommended that a system of routine inspection be established


during which the condition of the pump can be determined and recorded for
comparison with later inspections. Any defects should be repaired or the
components renewed at the earliest opportunity. Certain inspections can only by
made when the pump is under shut down but others can be made under operating
conditions.
A high degree of cleanliness of each pump and of the surrounding areas
should be maintained, as this will assist in the early detection of minor leaks or
defects which, if unnoticed, could lead to more serious operational or maintenance
problems.
1.1 Periodic and Preventive Maintenance

The pump performance should be used as the criterion for the need to
renew wearing parts. The pump performance may deteriorate due to excessive
leakage past the impeller/diffuser wear rings or vibration may indicate that the
wear rings or bearings are worn.

Note: The recommended renewal clearances are 1.5 times the clearances
shown on the Sectional Arrangement Drawings. If the pump performance
has declined it may be necessary to renew the wearing parts before the
recommended clearances are reached.

1.2 Routine Checks

It is essential that the routine checks given in Chapter-2, Section-5 are


carried out regularly. The checks concerned with the mechanical condition of the
pump are repeated here for the convenience of the maintenance engineers.

1.2.1 Periodic Checks

It is recommended that the following checks are carried out at regular


intervals :-

(1) Check that the suction and discharge pressures are normal.
(2) Check that the pump bearing lubricating oil pressures and temperatures
are normal.
(3) Check for any leakage from the mechanical seals.
(4) Check all joints and valve glands for leakage.
(5) Check for any undue noise or vibration.
(6) Carryout a visual check on all keeps and fastenings, paying particular
attention to the holding-down bolts.
2. Maintenance particulars

2.1 Estimated Weights (for lifting purposes)


Item Weight, kg
Cartridge assembly 1752
Discharge cover 1200
Suction guide 216
Pump shaft 303
Ring section, 1st stage 138
Ring section, 2nd / 3rd stage 144
Ring Section, last stage 131
Diffuser 48.5
Bottom bearing housing, drive end 55
Top bearing housing, drive end 85
Bottom bearing housing, non-drive end 145
Top bearing housing, non-drive end 91.5
Thrust bearing cover 30.5
Thrust collar 28.8
Balance drum 33
Gland housing 191
2.2 Joints

All the various types of joints, CAF, Metaflex etc. used on the pumps, are
to be found in the parts lists on sectional assembly drawings.

2.3 Recommended Torque Values for Threaded Fasteners

The following torque figures must be used when assembling the pump. All
threads and undersides of heads must be lubricated.

Threaded Fastener Recommended Torque (Nm)


Pull up rings screws 175
Gland housing/discharge 430
cover screws
Diffuser Screw 40
Last stage diffuser screws 40
Thrust collar nut 2850
Ring section screws 95

2.4 Recommended Lubricants

This lubricating oil for the journal and thrust bearings of the Booster and
Boiler feed pumps will be supplied from the lubricating oil system associated with
the turbo coupling.

3. MAINTENANCE PROCEDURES

WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND


REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE
PROCEDURES.

Note : The FK4E36 Boiler feed pump is an integral part of the tandem Boiler feed
pump set. The following instructions should, therefore, be read in
conjunction with those for the Booster pump in Part 1.

3.1 Preparation for Maintenance

Before commencing any maintenance procedures, the pump must be


isolated as follows :-

(1) Isolate the electrical power supplies to the pump driving motor and the
lubricating oil system.
(2) Isolate the electrical power supplies to all instruments.
(3) Check that the pump set suction, discharge and leak-off isolating valves
are shut.
(4) Check that the Mechanical seal lines have been isolated.
(5) Open the drain and vent connections, and drain the pump casing.

WARNING: BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE


PUMP, BE SURE THAT THERE IS NO PRESSURE WITHIN THE
PUMP CASING.
3.2 Examining the drive end (DE) journal bearing.

(1) Disconnect and remove any instruments which could interfere with the
dismantling procedures.

CAUTION : The top half bearing housing is located on the bottom half bearing
housing by two fitted bolts. Care must be taken to avoid damage to
the bolts or the holes in the top and bottom half housing.

(2) Withdraw the two fitted bolts and remove the cap screws securing the top
half bearing housing to the bottom half bearing housing. Also remove the
cap screws securing the top half bearing housing to the suction guide.

(4) Use two jacking screws in the top half bearing housing to separate it from
the bottom half.

(6) Lift the top half bearing housing complete with the top halves of the oil
guards away. Remove the top half journal bearing from the shaft with the
assistance of applying jacking screws to the bearing keep.

(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
of deterioration and examine the journal bearing and the oil guards for
wear. Reference should be made to the sectional arrangement drawings,
for the clearances of the journal bearing and oil guards.

Note: Lightly smear the shaft and journal bearing surfaces with oil before final
assembly.

(9) Rotate the bottom halves of the journal bearing and oil guards around the
shaft and into position in the bottom half bearing housing. Release the
weight of the pump shaft.

(10) Locate the top half journal bearing in position on the pump shaft. Locate
the bearing keep on the dowels and secure it with the cap screws.

(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
fitted bolts, then secure to the bottom half and the suction guide with the
cap screw.

(13) Replace the instruments and the turbo coupling/pump drive coupling
guard.

3.3 Examing the Non-drive End (NDE) Journal and Thrust Bearing

(1) Disconnect and remove any instruments which could interfere with the
dismantling procedure.

(2) Remove the fluid coupling/pump drive coupling guard.

(3) Remove the fluid coupling/pump drive coupling spacer and element
assemblies.

(4) Remove the set screws securing the bearing housing end cover to the top
half bearing housing.

CAUTION : The top half bearing housing is located on the bottom half bearing
housing by two fitted bolts. Care must be taken to avoid damage to
the bolts or the holes in the top and bottom half housing.

(5) Withdraw the fitted bolts and remove the cap screws securing the top half
bearing housing to the bottom half bearing housing and the gland housing.

(6) Use four jacking screws in the top half bearing housing to separate it from
the bottom half.

(7) Lift the top half bearing housing complete with the top half oil guard away.
Remove the top half journal bearing from the shaft.

CAUTION : The thrust cover is located on the bottom half bearing housing by
four dowel pins. Care must be taken to avoid damage to the dowels
or the locating holes.

(8) Remove the cap screws securing the thrust cover to the bottom half
bearing housing. Use four jacking screws to separate to the thrust cover
from the bottom half bearing housing and lift it way.

(9) Lift the top halves of the floating seal carriers away, then take the weight of
the pump shaft and rotate the bottom halves of the journal baring, oil guard
and floating seal carries around the shaft and lift them away.

(10) Unclip the springs and remove the split floating oil seals from the bearing
housing.
Note : The thrust carrier ring split line is at 90° to the bearing housing horizontal
surface.

(11) Remove each thrust carrier ring in turn as a complete unit as follows :-
Rotate the complete carrier around the shaft until the half ring with the stop
pin can be removed, then rotate the other half ring around the shaft until it
can be lifted clear of the shaft. Repeat with the second carrier ring on the
other side of the thrust collar.

(12) Examine the journal bearing, shaft journal, thrust pads, thrust collar, split
oil seal and oil guard for damage or deterioration. Under normal operating
conditions it is not expected that any measurable wear will take place on
the thrust pads other than a dulling of the white metal surfaces. It is
recommended that when this dulling has spread to more than half the
surface area of the pads, they should be renewed.

Refer to the sectional arrangement drawing for the clearances and renew the
journal bearing and oil guard if necessary.

Note : Lightly smear the shaft, thrust collar faces and baring surfaces with oil
before final assembly.

(13) Install each split floating oil seal on the pump shaft with the spring.

(14) Take the weight of the pump shaft and rotate the bottom halves of the
journal bearing, oil guard and floating seal carriers around the shaft and
into position in the bottom half baring housing. Release the weight of the
pump shaft.

(15) Install each thrust carrier ring in turn as a complete unit as follows:-
Take the half carrier ring without the stop pin and place it over the shaft
with the pad faces touching the thrust collar and rotate it into the bottom
half bearing housing, then place the other half carrier ring with the stop pin
upon the first and rotate the complete carrier ring until the stop pin locates
on the horizontal face of the bottom half bearing housing. Repeat with the
second carrier ring on the other side of the thrust collar.

Note: The thrust carrier ring split line is at 90° to the bearing housing horizontal
surface at the stop pin locates in a slot in the top half bearing housing.

CAUTION : Do not insert feeler gauges between the thrust collar and the thrust
pads; this may give an inaccurate reading and cause damage to the
white metal and surface.

(16) Check the axial clearance by moving the pump shaft towards the drive end
so that the thrust collar is hard against the inner thrust pads, then using
feeler gauges between the outer thrust bearing spacer and the thrust
housing inner wall check the clearance. Refer to the Sectional
Arrangement Drawing for the original total axial clearance. Any
measurable variation should be investigation.

(17) Lift the thrust cover onto the bottom half bearing housing ensuring that the
dowel pin for each floating seal carrier are properly located. Locate the
thrust cover to the bottom half bearing housing with the dowel pins, then
secure the thrust cover with the cap screws.

(18) Locate the top half journal bearing in position on the pump shaft.

(19) Lift the top half bearing housing complete with the top half oil guard onto
the bottom half bearing housing, ensuring that the oil guard and stop pin
are properly located.

(20) Locate the top half bearing housing to the bottom half housing with the
fitted bolts, then secure to the bottom half and gland housing with the
appropriate cap screw.

(21) Fit a new joint and secure the bearing housing cover to the top half
housing with the set screws.

(22) Install the coupling/pump drive coupling spacer and element assemblies.

(23) Replace the instruments and the coupling pump drive coupling guard.

3.4 Checking the Axial Running Position and Thrust Bearing clearance

Note: This operation is to be carried out during the assembly of the drive end
and non-drive and bearing housings.

(1) The drive end bearing housing should be assembled without the following
components in place.

(a) Top half bearing housing and top half journal bearing.

(b) Oil guard and oil throwers.

(2) The non-drive end bearing housing should be assembled without the
following components in place.

(a) Top half bearing housing, top half journal bearing and thrust cover.

(b) Thrust bearing carrier ring assemblies.

(c) Oil guard and oil thrower.

(3) Check the axial running position of the rotating assembly as follows:-

(a) Move the rotating assembly as far as possible towards the drive end
of the pump and, using the outer face of the thrust collar as a datum,
scribe a line on the horizontal surface of the bottom half bearing
housing.

(b) Move the rotating assembly as far as possible towards the non-drive
end of the pump and, using the same datum, scribe a second line on
the bottom half bearing housing. Measure the distance between the
two lines; this should be approximately 8 mm.

CAUTION : The minimum acceptance total axial travel is 6 mm.

(c) Position the inner halves of the thrust bearing carrier rings and
spacers in this bottom half housing and move the rotating assembly
as far as possible towards the drive end of the pump. Scribe a third
line on the surface of the bottom half bearing housing. Using the
same datum as before: this line should be offer 0.50 mm towards the
non-drive and from midway between the other two lines.

CAUTION : Do not insert feeler gauges between the thrust collar and the thrust
pads; this may give an inaccurate reading and cause damage to the
white metal pad surface.

(4) Check the thrust bearing axial clearance as follows :

(a) Position the outer halves of the thrust bearing carrier rings and
spacers in the bottom half housing.

(b) Check the axial clearance by moving the pump shaft as before and
carefully measuring the difference: alternatively, move the pump shaft
so that the thrust collar is hard against one set of thrust pads and use
feeler gauges between the opposite thrust bearing spacer and the
bearing housing. The total axial clearance was Originally as shown on
Drawing Nos. measurable variation should be investigated.

(5) If spare thrust bearing assemblies are fitted, proceed as follows:

(a) With the rotating assembly in the axial running position, accurately
measure the distance between the bottom half bearing housing wall
and the inner thrust collar face and record the reading. Repeat the
procedure between the outer thrust collar face and the bearing wall
and record the reading.

(b) The spacers should now be removed form the inner and outer thrust
carrier ring halves and machined accurately to give the correct
thickness as follows:-

(i) Inner thrust ring spacer thickness – Measured distance between


housing wall and inner collar face minus thrust ring thickness.

(ii) Outer thrust ring spacer thickness – Measured distance between


housing wall and outer collar face minus (thrust ring thickness + axial
bearing clearance).
(c) Secure the spacers to the thrust carrier ring halves and repeat step
as previously described.

4. OVERHAUL

WARNING : IT IS ESSENTIAL THAT PLANT SAFETY AND REGULATIONS ARE


OBSERVED AT ALL TIMES DURING MAINTENANCE
PROCEDURES.

The following instructions apply when the pump cartridge is to be removed and
dismantled for a complete overhaul.

Note: If a replacement cartridge is available, this should be prepared and


installed as described in Section 4.6 before proceeding to dismantle and
repair the worn cartridge as described in Section 4.3. Reference numbers
on components should be re-marked as necessary to facilitate
assembling.

4.1 Preparation for Overhaul

(1) Prepare the pump for maintenance as described in Section 1.1

(2) Disconnect and remove the following pipes and fittings :-

(a) The lubricating oil pipe work to and from the pump bearings.

(b) The mechanical seal pipe work.

(c) The balance chamber return pipe work from the discharge cover.

(d) The gland well drain pipe work from the suction guide and the
housing.

(e) Remove the interstage spool piece and interstage tube.

(f) Remove air vents from the drive end bearing housing and the suction
guide.

(3) Disconnect and remove any instruments which could interfere with the
dismantling procedures.

(4) Remove the fluid coupling/pump drive coupling guard.

(5) Remove the fluid coupling/pump drive coupling spacer and element
assemblies.

(7) Check that all lifting equipment and special tools are in good condition.
4.2 Withdrawing the Pump Cartridge

(1) Remove the set screws securing the split pull-up ring to the pump casing.
The ring can now be removed, the upper half being located by two dowel
pins.

(2) Secure the first extension sleeve (5) to the drive end bearing housing with
screws (12) and (24).

(3) Enter the cartridge tensioning screw (10) through the hold on the end plate
of the first extension sleeve and screw it into the tapped hole in the end of
the pump shaft. Run the nut (11) on to the end of the tensioning screw and
tighten it until all cartridge movement is taken up.

Note : The cartridge axial movement between the last stage diffuser and the
outer guide is approximately 2.5 mm.

(4) Locate the suction and support jack (7) on the base plate pad. Centralise
the roller using the slots provided on the jack base. Jack up the roller until
good contact is made with the first extension sleeve (5). Tighten the
screws to secure the support jack to the base plate.

CAUTION : The support jack (7) is intended to take the weight of the drive end of
the pump cartridge and so facilitate removal of the cartridge. Due to
the fine diametrical clearance which exists between the suction guide
and the pump casing, extreme caution must be observed when
adjusting the height of the support jack roller to avoid over tightening,
which may lead to damage to the suction guide or pump casing when
withdrawal is attempted.

(5) Remove and retain the stud caps.

(6) Remove the pump casing/discharge cover nuts, using the hydraulic stud
tensioning equipment as follows:-

(a) Locate the jacking ring and load cell assembly over two pairs of
diametrically opposite casing studs and nuts as shown.

(b) Screw the load cell onto the stud until it abuts the jacking ring.

(c) Connect the load cells to the hydraulic pump by means of the manifold
and pipe work.

(d) Operate the pump and prime the system with oil, then raise the
pressure in the system specified by the supplier of the hydraulic
tensioning equipment, to relieve the pre-loading on the studs.

(e) Slacken back the casing nuts using a tommy-bar in the holes in the
nuts.
(f) Relieve the pressure in the hydraulic system and return the oil to the
pump by operating the valve on the pump.

(g) Unscrew and remove the inserts from the studs, then remove the load
cell assemblies from the studs.

(h) Unscrew and remove the casing nuts from the casing studs.

(i) Repeat the above procedure (a) to (h) to remove the remaining
discharge cover nuts, ensuring that the sequence shown is adopted to
avoid distortion of the cover.

(7) Fasten the support columns (15-MD / 16-TD) to the foundation plate
(27-MD / 31-TD) with screws (23,26&30).

(8) Locate the support rail assembly (A) on the base plate and on the support
columns (15-MD / 16-TD). Fit the bracket (2) and wheel mounting
assemblies (3-MD / 4-TD) to the discharge cover with screws (14).

(9) Using the slots provided in the bracket mounting assembly (2), centralize
the bracket by using the jacking screws (19) at each side until the support
rails (1) make contact with the rollers. The support rails (1) must be level
during this operation.

(10) Retain the bracket mounting assembly (2) by tightening the holding down
set screws (18). Lock the jacking screws (17) in position with lock-nuts
(28).

(11) Position the hinged wheel stops across the support rails.

(12) Screw the starting screws (A1) into the discharge cover and unseat the
cartridge from the pump casing. The suction end support jack (7) and the
jacking screws (19) on the support rail assembly (A) which is positioned
over the support columns (15-MD / 16-TD) may require individual
adjustment to ensure smooth removal of the cartridge.

(13) Ensuring that the stops on the support rails (1) are in place, withdraw the
cartridge to the first stop.

(14) Install the second extension sleeve (6), using screws (29&30). The
cartridge can now be withdraw to the second stop position. Repeat this
Step until the cartridge is withdrawn to the final stop position.

(15) Position the support plate (8) on the pump casing studs and a distance
tube (9) on each stud. Then using discharge cover nuts to lock the tubes
(9) and support plate (8).

(16) Withdraw the dowel pin, from the suction guide, that locates the pull up
ring.

(17) Secure the lifting plate (21) to the suction guide with the four set pins (22).
(18) Secure an eye-bolt (20) into the tapped hole provided in the discharge
cover. Attach suitable slings to the eye-bolt (20) and the lifting plate (W)
and take the weight of the pump cartridge.

(19) Unbolt the second extension sleeve (6) from the first extension sleeve (5))
and separate each at the spigot location.

(20) Carefully lift the pump cartridge away to a maintenance area and suitably
support it on wooden trestle. Ensure that the mounting wheel assembly is
clear of the floor.

Note : The cartridge tensioning screw (10) must not be released during transit of
the cartridge.

(21) Remove the lifting equipment (20,21&22), mounting wheel assemblies (3-
MD / 4-TD) and bracket mounting assembly (2) from the pump cartridge.

CAUTION : The cartridge tensioning screw (10) must not be removed.

(22) Remove and discard the suction Metaflex joint.

4.3 Dismantling the Pump Cartridge

CAUTION : During dismantling of the pump cartridge, it is essential that the


cartridge be firmly supported. The initial dismantling is carried out in
the horizontal position, and the final stages with the cartridge
supported vertically as shown in the drawing. At no time should be
weight of the cartridge be carried by the shaft.

4.3.1 Removing Pump Half Coupling Hub

(1) Remove the Cartridge as described in Section 4.2.

(2) Install the support frame over the suction guide from the drive end bearing
side, then clamp the discharge cover, ring sections and suction guide
together with the stay rods, location washers and nuts.

(3) Release the nuts securing the cartridge tensioning screw and remove the
screw from the shaft end. Remove the screws securing the first extension
sleeve to the drive end bearing housing and lift away the first extension
sleeve.

(4) Remove the coupling nut grub screw, then using the special spanner
supplied, unscrew and remove the coupling nut.

(5) Withdraw the pump half coupling hub from the pump shaft. Remove and
retain the coupling keys.

4.3.2 Removing the D.E. Bearing Assembly and Mechanical seal.


CAUTION : The top half bearing housing is located on the bottom half bearing
housing by two fitted bolts. Care must be taken to avoid damage to
the bolts or the holes in the top and bottom half housing.

(1) Withdraw the fitted bolts and remove the cap screws securing the top half
bearing housing to the bottom half bearing. Also remove the cap screws
securing the top half bearing housing to the suction guide.

(2) Use two jacking screws in the top half baring housing to separate it from
the bottom half.

(3) Lift the top half bearing housing complete with the top halves of the oil
guards away. Remove the top half journal bearing from the shaft with the
assistance of applying jacking screws to the bearing keep.

(4) 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.

(5) Using suitable lifting gear, take the weight of the bottom half bearing
housing.

(6) Withdraw the two taper dowel pins and remove the cap screws securing
the bottom half bearing housing to the suction guide, then lift the bottom
half housing away.

(7) Slacken the grub screws and withdraw the oil thrower from the shaft.
Discard the “O” ring from the groove in the bore of each oil thrower.

NOTE : Refer to Manufacturer’s instructions when dismantling the


mechanical seals.

(8) Using the pin spanner supplied, unscrew and remove the seal sleeve
locknut and seal nut from the shaft. Discard the ‘O’ ring from the shaft
sleeve.

(9) Engage the assembly fixtures (eccentric washers) into the groove in the
shaft sleeve and fasten them.

(10) Loosen all screw connections between seal cartridge and the respective
machine parts.

(11) Remove the screw connections between seal cartridge and the respective
machine parts.

(12) Take the weight of the bearing bracket, then remove the Hexagonal socket
head cap screws securing the bracket to the suction guide and remove the
bracket.

(13) Screw the clamping plate on the shaft and secure it to the suction guide
with four bolts.
4.3.3 Removing the N.D.E. Bearing Assembly and Mechanical Seal

(1) Remove the set screws securing the end cover to the bearing
housing, then remove the end cover klingerite joint.

CAUTION : The top half bearing housing is located on the bottom half bearing
housing by two fitted bolts. Care must be taken to avoid damage to
the bolts or the holes in the top and bottom half housing.

(2) Withdraw the fitted bolts and remove the cap screws securing the top half
bearing housing to the bottom half bearing housing and the gland housing.

(3) Use four jacking screws in the top half bearing housing to separate it from
the bottom half.

(4) Lift the top half bearing housing complete with the top half oil guard away.
Remove the top half journal bearing from the shaft.

CAUTION : The thrust collar is located on the bottom half bearing housing by
four dowel pins. Care must be taken to avoid damage to the dowels
or the locating holes.

(5) Remove the cap screws securing the thrust cover to the bottom half
bearing housing. Use four jacking screw to separate the thrust cover from
the bottom half bearing housing and lift it away.

(6) Lift the top halves of the floating seal carriers and oil guard away.

(7) Unclip the springs and remove the split floating oil seals from the bearing
housing.

Note: The thrust carrier ring split line is at 90° 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 and rotate the bottom halves of the
journal bearing and the oil guard around the shaft and out of the bottom
half bearing housing.

CAUTION : The bottom half bearing housing is located on the gland housing by
two dowel pins. Care must be taken to avoid damage to the dowels
or the holes in the housing/gland housing.

(10) Using suitable lifting gear, take the weight of the bottom half bearing
housing.
(11) Withdraw the dowel pins and remove the cap screws securing the bottom
half bearing housing to the gland housing, then lift the bottom half bearing
housing away.

(12) Unlock the lock-washer, then using the special spanner, unscrew and
remove the thrust collar nut and lock-washer from the pump shaft.

Note : The thrust collar nut has left hand thread.

(13) Using withdrawal gear as shown on illustration, withdraw the thrust


collar/probe indicator assembly from the shaft and remove and retain the
thrust collar key from the keyway on the shaft.

(14) Check the location of the oil thrower on the shaft for assembly purposes.

(15) Slacken the grub screw and withdraw the oil thrower from the shaft.
Discard the ‘O’ ring from the groove in the bore of the thrower.

(16) Using the pin spanner, unscrew and remove the shaft lock-nut and seal
nut from the shaft. Discard the ‘O’ ring from the shaft sleeve.

(17) Engage the assembly fixtures (eccentric washers) into the groove in the
shaft sleeve and fasten them.

(18) Loosen all screw connections between seal cartridge and the respective
machine parts.

(19) Remove the screws securing the seal housing to the gland housing and
remove the seal housing. Remove and discard the ‘O’ rings from the
grooves of the outside diameter of the seal housing.

(20) Withdraw the three angled locating dowels on the gland housing.

(21) Take the weight of the gland housing, then remove the cap screws
securing the gland housing to the discharge cover.

(22) Separate the gland housing from the discharge cover by applying four
jacking screws. Discard the Metaflex joint between the joint faces.

4.3.4 Dismantling the Ring Section Assembly

(1) Install the support frame and secure it in position with the stay rods.

(2) Secure the lifting eyebolt to the discharge cover and to the support frame.

(3) Using suitable lifting gear carefully lift the ring section assembly into the
vertical position.
(4) Lower the ring section assembly into the support trestle until the support
frame rests on the support trestle.

Remove the lifting gear.

(5) Remove the socket set screws that lock the outlet guide plugs, then
unscrew the outlet guide plugs. The cap screws securing the outlet guide
to the discharge cover can now be removed. Remove the two socket set
screws that lock the locating dowels for the outlet guide to the discharge
cover.

CAUTION : Care must be taken when raising the discharge cover to avoid
damage to the balance drum or the balance drum restriction bush.

(6) Remove the top nuts and washers from the stay rods securing the
discharge cover in position, then using suitable lifting gear, slowly lift the
discharge cover clear of the pump shaft.

(7) Release the lock-washer and using the special spanner provided, unscrew
and remove the balance drum nut and lock-washer from the shaft.

Note : The balance drum nut has left hand thread.

(8) Withdraw the balance drum from the pump shaft using withdrawal gear
similar to that shown on illustration. Remove and retain the balance drum.

(9) Remove the stay rods from the support frame.

(10) Using a gas heater ring, apply heat to the kicker stage impeller hub, then
remove the impeller from the shaft. Remove and retain the shearing and
the key from the shaft.

Note : Should the attempt the remove the impeller be unsuccessful immediately
after heating, the impeller and the shaft temperature must be allowed to
cool down to the ambient temperature before another attempt is made to
remove the impeller. This procedure applies to all the impellers.

(11) Remove the outlet guide, then remove and retain the disc spring.

(12) Remove the socket head screws securing the last stage diffuser to the last
stage ring section. Lift the last stage diffuser clear of the pump shaft.

(13) Apply heat to the rear hub of the fourth stage impeller and pull the impeller
from its location on the shaft. Remove the impeller, shear ring and impeller
key.

WARNING : THE INTERESTAGE DIFFUSERS AND RING SECTIONS ARE


LOCATED TO EACH OTHER BY DOWEL PINS AND WILL
PROBABLY LIFT AS AN ASSEMBLY. CHECK THAT THE
DIFFUSER IS SECURED BEFORE LIFTING OVER THE SHAFT.
(14) Remove the outlet guide, then remove and retain the disc spring.

(15) Suitably sling and lift the last stage ring section clear of the pump shaft.

(16) Remove the socket head screws securing the last stage diffuser to the last
stage ring section. Lift the last stage diffuser clear of the pump shaft.

(17) Repeat steps (13) to (15) to remove the remaining impellers, ring sections
and diffusers.

(18) Screw the lifting eye-bolt onto the non-drive end of the pump shaft, then
using suitable lifting gear take the weight of the pump shaft.

(19) Unscrew and remove the clamping plate from the drive end of the pump
shaft.

(20) Carefully lift the pump shaft until the drive end of the shaft is clear of the
suction guide.

4.4 Inspection, Renewal and Repair Procedures

The pump components should be completely cleaned before inspecting for


any signs of wear including scoring, wiping or ridging.

All diametrical clearance should be measured with internal and external


micrometers.

4.4.1 Clearances

Refer to the Sectional Arrangement Drawings for details of the clearances.


It is recommended that when the pump internal clearances have reached 1.5
times the figure quoted or are expected to do so before the next overhaul, the
component or components should be renewed. The main considerations,
however, are pump performance and motor power consumption.

4.4.2 Pump Shaft

(1) Examine the shaft for any signs of damage or bowing and check for
concentricity; it should be within 0.05 mm full indicator movement.

(2) Check that all threads are in good condition.

(3) Check that the keyways are free from burrs.

4.4.3 Impellers

(1) Examine the impellers for signs of wear or erosion, particularly at the
waterways and the tips of the blades.

(2) Check that the keyways are free from burrs.


(3) Examine the impeller wear rings for wear or ovality. Renew or repair as
necessary.

CAUTION : If the impeller wear rings required to be renewed it is important to


note that the impeller is balanced during manufacture. However, if it
is considered expedient to assemble and operate the pump without
checking the balance, BHEL/PUMPS, should first be consulted.

4.4.4 Ring Sections, Diffusers, Balance Drum and Suction Guide

(1) Examine the ring sections, diffusers and suction guide for signs of wear or
erosion, particularly in the flow passages.

(2) Examine the bores of the ring section and diffuser wear rings and the
balance drum bush for signs of wear or ovality. Renew or repair as
necessary.

(3) The wear rings and balance drum bush are a shrink fit in their respective
components, and are secured radially by grub screws.

(4) The wear rings should be renewed as follows :-

(a) Remove the grub screws and machine the wear ring from its seating.

(b) Thoroughly clean the seating and shrink the new ring into position.

(c) Secure the war ring in position with grub screws. Lock the grub
screws by lightly punching with a centre punch at the thread junction.

(d) Lightly machine the internal or external surface of the wear ring to
rectify any distortion which may have occurred during fitting.

Note : The impeller wear rings supplied as spares are left 3 mm oversize on
the outside diameter for final machining after fitting and due note
should be taken of this when assessing the possible renewal of the
ring section and diffuser wear rings. The ring section and diffuser
wear rings supplied as spares are left 3 mm undersize in the bore for
final machining.

4.4.5 Journal Bearings

Inspect the journal bearings for signs of wear or damage and renew as
necessary.
4.4.6 Thrust Bearings

Under normal operating conditions it is not expected that any measurable


wear will take place on the thrust pads other than a dulling of the white metal
surfaces. It is recommended that when this dulling has spread to more than half
the surface area of the pads, they should be removed.

4.4.7 Mechanical Seals

A correctly operated mechanical seal is maintenance free, wear parts,


however, have to be replaced, if necessary.

4.4.8 Joints

All joints and ‘O’ rings should be renewed on assembly, as should any
backing ring which shows signs of damage or distortion. Apply soft soap to all ‘O’
rings prior to assembly.

4.4.9 Studs, Bolts, Screws and Nuts

The threads of all studs, bolts, screws and nuts must be clean, well formed
and free from burs. If the threads are damaged in any way the component must be
renewed.

4.4.10 Dowels

All dowels must be clean and free from damage. Worn or damage dowels
must be renewed.

4.4.11 Keys

All keys must be a good fit in their keyways and must also be flat, parallel and free
from burrs. Worn or damage keys must be renewed.

4.4.12 Cleanliness

All components must be perfectly clean and all bores and oil ways must be
cleaned out before the pump is assembled.

4.4.13 Dynamic Balance

Each components of the rotating assembly is first dynamically balanced


individually during manufacture, then the entire assembly consisting of shaft, shaft
sleeves, impellers, balance drum, pump half coupling, thrust collar, nuts, keys and
rotating seal faces is assembled and dynamically balanced as a unit. Always
consider the effect on dynamic balance when renewing or repairing individual
parts.
If it is considered expedient to assemble and operate the pump without
checking the dynamic balance, BHEL Pumps Ltd., should first be consulted.

When suitable workshop facilities are available the recommended method


of checking the dynamic balance of the resulting assembly is as follows :

(1) Support the assembly at the bearing centre lines and check that it is

dynamically balanced with 630M g cm


N

Where M = rotor weight (kg)

N = pump speed (rev / min.)

(2) Dynamic balance is to be achieved by removing metal from the impeller


shrouds within the following limits.

CAUTION : (a) The thickness of the impeller shroud must not be reduced by
more than 1.6 mm at any point.

(b) No metal is to be removed from an impeller within 12.7 mm of the


periphery.

(c) The weight of metal to be removed is to be calculated in the form


of a segment, the arc length of which does not exceed 0.1 of the
circumference of the impeller.

(d) If the amount of the metal to be removed exceeds the limits


imposed by (a) and (c), BHEL pumps Ltd., should be consulted.

Note : The dynamic balance can be checked and trimmed in-situ by BHEL,
Pumps Personnel, using specialized equipment to establish the degree
and location of the unbalance and correcting this by adding balance
weights to the peripheries of the coupling flange and the thrust collar.

4.5 Assembling the pump cartridge

To assist the assembling procedures all fittings and threads should be


smeared with anti-scuffing paste.

4.5.1 Assembling the ring Section Assembly

(1) Ensure that the inspection, repair and renewal procedures have been
properly carried out.

(2) Suitably support the shaft on wooden trestles in the horizontal position.

(3) Insert the drive – end gland sleeve key and the first stage impeller key in
their keyways in the shaft. Also, locate the shearing in the shaft recess
provided for the first stage impeller.
(4) Apply heat evenly around the hub of the first stage impeller, using a gas
heating rings, then slide the impeller over the shaft and key until it butts
against the shearing.

CAUTION : Force should not be used when fitting the impeller. If the impeller
does not butt against the shaft shoulder, remove the impeller and
check for burrs or dirt which may have been overlooked during
inspection. Clean up as necessary and repeat step (4). Do not
attempt to fit the impeller if the shaft is above ambient temperature.

(5) Replace the support frame on the top of the support trestle, then lift the
suction guide and lower and secure it into the support trestle as shown on
Drawing.

(6) Lift the first stage ring section and lower it onto the suction guide,
ensuring that the slot at top dead centre engage over the key block on the
suction guide.

(7) Screw the lifting eye-bolt onto the non-drive end of the pump shaft, then
suitably sling and carefully lift the shaft into the vertical position.

(8) Carefully lower the drive end of the pump shaft into the suction guide bore
until the impeller eye wear ring enters the first stage ring section casing
wear ring. Remove the lifting lug from the pump shaft.

(9) Screw the clamping plate onto the pump shaft and secure it to the suction
guide.

(10) Suitably sling and lift the interstage diffuser over the shaft and into position
on the first stage ring section. Ensure that the dowel pins are properly
located then secure to the first stage ring section with the cap screws.

(11) Suitably sling and lift the second stage ring section over the shaft and into
position on the interstage diffuser and first stage ring section. Ensure that
the radial dowel position marks match-up with the same marks as that on
the first stage ring section.

(12) Secure the second stage ring section to the first stage ring section with the
socket head screws.

(13) Before Proceeding any further with the assembly, check the total axial
travel as follows :-

(a) Screw the lifting eye-bolt onto the non-drive end of the pump shaft
and suitably sling.

(b) Take the weight of the pump shaft and allow the first stage impeller
to rest on the first stage ring section.

(c) Using the upper face of the second stage ring section as a datum,
mark a pencil line on the shaft.
(d) Remove the screws securing the clamping plate to the suction guide,
then unscrew the clamping plate along the shaft until the plate has a
gap of slightly more than 10 mm from the suction guide flange.
Reposition the securing screws finger tight.

(e) Lift the pump shaft as far as possible towards the non-drive end of
the pump and, using the same datum, mark a second line on the
pump shaft.

(f) Measure the distance between the two lines: this should be
approximately 9 mm.

CAUTION : The minimum acceptable total shaft travel is 7.5 mm.

(g) Lower the shaft until the first stage impeller rests on the first stage
ring section then raise the shaft by about 2 mm and place suitable
packing between the floor and the shaft drive end, to take the weight
of the shaft assembly. Allow the shaft to rest on the packing. This will
now permit the following impeller to about firmly against the shear
ring, rather than the casing wear ring on the ring section. Remove the
sling and lifting eye – bolt from the shaft.

(14) Insert the second stage impeller key in the shaft keyway, then locate the
impeller split shearing in the shaft recess.

(15) Apply heat evenly around the hub of the second stage impeller, using the
gas heating ring, then slide the impeller onto the shaft and key until it butts
against the split shear ring.

(16) Repeat stops (10) to (15) to install the remaining interstage diffusers/ ring
sections and impellers.

(17) Lift the last stage diffuser over the shaft and into position on the last stage
ring section.

(18) Secure the last stage diffuser to the last stage ring section with the socket
head screws.

(19) Lift the disc spring over the shaft and into position on the last stage
diffuser spigot.

(20) Lift the outlet guide over the shaft and into position on the last stage
diffuser.

(21) Position the shear ring on the shaft recess and the impeller key for the
kicker stage impeller.

(22) Apply heat evenly around the hub of the kicker stage impeller using gas
heating ring, then slide the impeller over the shaft until it butts against the
shear ring.
(23) Insert the balance drum key into its keyway in the shaft, then using the gas
heating ring supplied, heat the balance drum and slide it onto the shaft and
key until it butts against the shaft shoulder, place a new packing ring and
the packing ring follower in the bore of the balance drum.

(24) Locate the new lock-washer against the balance drum, then screw on and
tighten the balance drum nut, finally locking the nut in position with the
lock-washer.

Note: The balance drum nut has left hand thread.

(25) Screw the four tie rods into the support frame as shown in the Drawing.

(26) Suitably sling the discharge cover and lift it to a position above the shaft.

(27) Carefully lower the discharge cover over the shaft and tie rods into position
on the last stage diffuser, taking care to prevent fouling between the
balance drum and bush. Ensure that the dowel pins are properly located.

(28) Replace the location washers and nuts on the tie rods and secure the ring
section assembly together as shown in the Drawing.

(29) Secure the clamping plate to the suction guide by drawing up the fixing
screws.

(30) Secure the lifting eye-bolt onto the discharge cover and support frame.

(31) Using suitable lifting gear, carefully lift the ring section assembly clear of
the support trestles.

(32) Lower the ring section assembly into the horizontal position and support it
at each and with wooden support trestles.

(33) Remove the lifting gear, lifting eye-bolts and clamping plate.

4.5.2 Installing the mechanical seals :

CAUTION: The rotating assembly must be supported on wooden trestles during


the assembly.

1. For installation the assembly drawing shave to be on hand.

2. The mechanical seal has to be installed very carefully and under the
cleanest conditions.

3. Do never force during installation.

4. To facilitate assembly, surfaces over which O-rings are to be fed may be


thinly lubricated with water, alcohol or silicon grease. Elastomers made of
EP rubber must never come into contact with lubricants on the base of
mineral oil (swelling, decomposition).
5. As lubricant for elastomers (O-rings etc.) should be used.

6. The mechanical seal is supplied as a cartridge unit, pre-mounted at works


and does not require any adjustment during assembly.

7. Bolt the mechanical seal to the pump housing in the way that the
connections are positioned.

8. Insert O-rings on the shaft.

9. Clamp the shaft sleeve axially with special nuts. Apply the torque smoothly
and without interruption. Do not knock the wrench.

10. Remove the assembly fixtures and keep them for a later removal of the
seals.

4.5.3 Assembling the D.E. Bearing Assembly

(1) Ensure that the bearing bracket is located and secured to the suction
guide with the dowel pins, studs and nuts.

(2) Locate a new ‘O’ ring in the groove of each of the oil throwers, then slide
the throwers onto the shaft.

(3) Lift the bottom half bearing housing into position and locate and secure it
to the suction guide with the taper dowel pins and cap screws.

(4) Position the throwers to correspond with the reference made during
dismantling and secure each thrower to the shaft with the grub screw.

Note: Lightly smear the shaft and journal bearing surfaces with oil before final
assembly.

(5) Take the weight of the pump shaft and rotate the bottom halves of the
journal bearing and oil guards around the shaft and into position in the
bottom half bearing housing. Release the weight of the pump shaft.

(6) Locate the top half journal bearing in position on the pump shaft and install
the bearing keep which is positioned by the two dowel pins and secured by
cap screws.

(7) Lift the top half bearing housing complete with the top halves of the oil
guards onto the bottom half housing.

(8) Locate the top half bearing housing to the bottom half with the dowel pins,
then secure the top half housing in position with the cap screws.

(9) Insert the coupling keys into the keyways in the shaft, then install the
pump half coupling over the keys and onto the shaft.
(10) Screw the coupling nut onto the shaft and tighten with the special spanner
provided. Lock the nut in position with the grub screw.

4.5.4 Assembly the N.D.E. Bearing Assembly

(1) Ensure that the gland housing is located and secured to the discharge
cover with the dowel p9ins and cap screws.

(2) Locate a new “O” ring in the groove of the oil thrower, then slide the
thrower onto the shaft.

(3) Insert the thrust collar key into the keyway in the pump shaft.

(4) Apply heat evenly around the thrust collar hub, using the gas ring supplied,
then slide the thrust collar onto the shaft and over the key until it abuts the
shoulder on the shaft.

(5) Allow the thrust collar to cool to ambient temperature, then slide the probe
indicator onto the shaft to locate on the dowels and abut the thrust collar.
Secure with the cap screws.

(6) Locate a new lock-washer on the shaft and secure the thrust collar nut on
the shaft and lock it in position with the lock-washer.

Note: The thrust collar nut has a left hand thread.

(7) Lift the bottom half bearing housing into position and locate and secure it
to the gland housing with the taper dowel pins and cap screws.

(8) Position the thrower to correspond with the reference made during
dismantling and secure the thrower to the shaft with the grub screw.

Note : Lightly smear the shaft, thrust collar faces and journal bearing surfaces
with oil before final assembly.

(9) Take the weight of the pump shaft and rotate the bottom halves of the
journal bearing and oil guard around the shaft and into position in the
bottom half bearing housing. Install the split floating oil seals on the pump
shaft with the spring. Release the weight of the pump shaft.

(10) Install each thrust carrier ring in turn as a complete unit as follows:

Take the half carrier ring without the stop pin and place it cover the shaft
with the pad faces touching the thrust collar and rotate it into the bottom
half bearing housing, then place the other half carrier ring with the stop pin
upon the first and rotate the complete carrier ring until the stop pin locates
on the horizontal face of the bottom half bearing housing. Repeat with the
second carrier ring on the other side of the thrust collar.

Note : The thrust carrier ring split line is at 90° to the bearing housing horizontal
surface and the stop pins locate in a slot in the top half bearing housing.
(11) Check the total axial clearance (refer to Section 3.6).

(12) Locate the top half journal bearing in position on the pump shaft and install
the bearing keep which is positioned by the two dowel pins and secured by
cap screws.

(13) 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.

(14) Locate the top half bearing housing to the bottom half bearing housing
with the dowel pins, then secure the top half housing in position with the
cap screws.

(15) Secure the bearing housing and cover to the housing with the set pins.

4.6 Installing the Pump Cartridge

Note : The following instructions assume that the withdrawal equipment as shown
on Drawing has not been disturbed.

(1) Secure the first extension sleeve (5) to the drive end bearing housing.

(2) Enter the cartridge tensioning screw (10) through the hole on the end plate
of the first extension sleeve and screw it into the tapped hole in the end of
the pump shaft. Run the nut (11) on the end of the tensioning screw and
tighten it until all cartridge movement is taken up.

(3) Remove the nuts, spacers and the stay rods securing the ring section
assembly together.

(4) Check that the Metaflex joint is properly located on the discharge cover
spigot.

(5) Locate the Metaflex joint on the suction guide spigot.

(6) Locate the joint on first stage ring section spigot.

(7) Withdraw the dowel pin from the suction guide that locates the pull up ring.

(8) Secure the lifting plate (21) to the suction guide with the four set pins (22).

(9) Screw and eye-bolt (20) into the tapped hole provided in the discharge
cover. Attach suitable slings to the eye-bolt and lifting plate (21) and take
the weight of the pump cartridge.

(10) Secure the cradle roller assembly bracket to the discharge cover with the
screws provided.

(11) Carefully lift the cartridge assembly and lower it onto the support rail (1) as
shown on Drawing.
Note : Provided that the withdrawal gear has remained in position following
cartridge withdrawal the cradle should be correctly aligned for the cartridge
insertion. It is important, therefore, that the cartridge be aligned to the
cradle and not vice versa.

(12) Bolt the second stage sleeve (6), which is still secured to the other three
extension sleeves, to the first extension sleeve (5).

(13) Take the weight of the cartridge extension sleeve assembly (5/6) on the
drive end support jack (7) roller and remove the distance tubes (9) and
support plate (8) from the pump casing studs.

(14) Remove the slings, lifting plate (21) and eye-bolt (20) from the pump
cartridge. Replace the dowel pin which was removed from the suction
guide to accommodate the lifting plate.

(15) Swing the hinged wheel stops into the stop position on the support rail
assembly (1).

CAUTION : When installing the pump cartridge, ensure that the suction guide is
radially central with the casing bore by adjusting the roller support
jack.

(16) Carefully push the cartridge into the pump casing until the outer extension
sleeve (6) can be removed.

(17) Repeat step (16), removing the extension sleeves (6) as necessary until
the suction guide and discharge cover are properly located in the pump
casing.

(18) Ensure that the discharge cover is correctly seated, then fit two nuts onto
the casing studs.

(19) Locate and secure the pull up ring on the suction guide and pump casing.
Tighten screws to a torque of 175 Nm.

(20) Fit the remaining nuts onto the casing studs and evenly tighten all around
using the tommy bar supplied.

Note : Check that there is no clearance between the discharge cover and the
pump casing.

(21) Dismantling and remove the tensioning stud (10), first stage extension
sleeve (5), drive end support jack (7), bracket mounting assembly (2),
mounting wheel assembly (3-MD / 4-TD), support rail assembly (1) and
support columns (15-MD / 16-TD) from the pump and base plate and
return to store, in readiness for future overhauls.
(22) Tighten the casing nuts using the hydraulic stud tensioning equipment
supplied as follows:-

(a) Locate the jacking ring and load cell assembly over two pairs of
diametrically opposite casing studs until it abuts the jacking ring.

(b) Screw the load cell on to the stud until it abuts the jacking ring.

(c) Connect the load cells to the hydraulic pump by means of the
manifold and pipe work.

(d) Operate the pump and prime the system with oil, then raise the
pressure in the system to 5000 lbf/in2 and tighten the discharge
cover nuts with the bar.

(e) Relief the pressure in the hydraulic system and return the oil to the
pump by operating the valve on the pump.

(f) Unscrew and remove the load cell from the studs, then remove the
load cell assemblies from the studs.

(g) Repeat steps (1) to (6) until all the remaining nuts have been
tightened.

(h) Repeat steps (a) to (f) until all the nuts have been tensioned to a
pressure which will give a load of 72 kN on the casing studs. See
hydraulic stud tensioning equipment supplier’s recommended
pressure to achieve this.

(23) Replace the stud caps and secure in position.

4.7 Final Assembly

(1) Install the pump cartridge as described in Section 4.6.

(2) Check the coupling alignment. Refer to illustration.

(3) Install the fluid coupling/pump drive flexible coupling spacer and element
assemblies.

(4) Replace the fluid coupling/pump drive coupling guard.

(5) Install the following fittings and pipes that were removed during the
dismantling procedure :-

(a) The balance chamber return pipes between the discharge cover and
suction side.

(b) The lubricating oil pipes to and from the pump bearings.

(c) The bearing brackets gland well drain pipe work.


(6) Install and connect all instruments that were removed during the
dismantling procedures.

(7) Replace any lagging and cladding removed during the dismantling
procedures.

5. PARTS IDENTIFICATION

When ordering spare parts, reference must be made to the pump Serial or
Job Number, Nomenclature and Sectional Arrangement Drawing, Item Number,
and quantity of each component.
SECTION - B

BOILER FEED PUMP

CHAPTER – 4

SUB-VENDOR’S DRAWINGS / INSTRUCTIONS

LIST OF CONTENTS

1 Mechanical Seals
2 Mechanical Seal Heat Exchanger
3 Mechanical Seal Magnetic Filter
4 Thrust Bearing
5 Connecting couplings (BFP & HC, HC & Motor)
6 Suction Strainer before BFP
SECTION – B

BOILER FEED PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

4. THRUST BEARING
Michell Bearings
Operations, and Maintenance
Instructions.

Omega OT Series
Thrust Rings
Michell Bearings
Michell Bearings is a trading division of Vinters Engineering PLC.
A member of the Rolls Royce Group.

Issue 00
Table of Contents

GENERAL DRAWING OF OT THRUST RING ASSEMBLY WITH SHIMS& LINERS----------- 4


1. INTRODUCTION -------------------------------------------------------------------------------------------- 5
1.1 About the Product ------------------------------------------------------------------------------------- 5
1.2 About this Manual ------------------------------------------------------------------------------------- 5
1.3 Warranty Claims --------------------------------------------------------------------------------------- 6
2. SAFETY ------------------------------------------------------------------------------------------------------- 7
3. HANDLING THE BEARING------------------------------------------------------------------------------ 8
3.1 General -------------------------------------------------------------------------------------------------- 8
4. PREPARATION FOR FIRST INSTALLATION ------------------------------------------------------ 9
5. ASSEMBLY OF THE BEARING -----------------------------------------------------------------------10
5.1 General -------------------------------------------------------------------------------------------------10
5.2 Assembly of the Thrust ring------------------------------------------------------------------------10
5.2.1 Fitting the Thrust Pad set.--------------------------------------------------------------------10
5.2.2 Fitting Ring Stop, and Liners if applicable -----------------------------------------------11
5.3 Assembling the Thrust rings into the Bearing Casing ---------------------------------------11
5.3.1 Miscellaneous -----------------------------------------------------------------------------------12
5.3.2 Instrumentation ---------------------------------------------------------------------------------12
6. OPERATING ------------------------------------------------------------------------------------------------13
6.1 Preparation and Inspection before Operation -------------------------------------------------13
6.2 Trial Run------------------------------------------------------------------------------------------------13
6.3 Normal Operation ------------------------------------------------------------------------------------14
6.4 Preparation for Operation after Standstill-------------------------------------------------------14
7. CARE AND MAINTENANCE ---------------------------------------------------------------------------15
7.1 General -------------------------------------------------------------------------------------------------15
7.2 Tools and Equipment--------------------------------------------------------------------------------15
7.3 Maintenance Schedule------------------------------------------------------------------------------16
7.4 Oil Change ---------------------------------------------------------------------------------------------16
7.4.1 General -------------------------------------------------------------------------------------------16
7.4.2 Procedure for draining oil---------------------------------------------------------------------16
7.4.3 Procedure for refilling the bearing -self contained bearings -------------------------17
7.4.4 Procedure for refilling the bearing - bearings with circulating oil--------------------17
8. DISMANTLING AN INSTALLED BEARING --------------------------------------------------------18
8.1 General -------------------------------------------------------------------------------------------------18
8.2 Preparation --------------------------------------------------------------------------------------------18
8.2.1 Strip down the bearing until the thrust rings are visible. ------------------------------18
8.2.2 Disconnect and remove any thermometry and instrumentation.--------------------19
8.3 Removing thrust rings -------------------------------------------------------------------------------19
8.4 Removing the Liners, and Shim Pack. Where Applicable. --------------------------------19
8.5 Removing the Thrust Pad Set---------------------------------------------------------------------19
9. CLEANING AND CHECKING --------------------------------------------------------------------------20
9.1 General -------------------------------------------------------------------------------------------------20
9.2 Checking the Thrust Pad. --------------------------------------------------------------------------21
10. BEARING PRESERVATION DURING STORAGE---------------------------------------------22

2
10.1 Before Installation ------------------------------------------------------------------------------------22
10.2 Corrosion Protection for Standstill Periods up to 6 Months --------------------------------22
10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year---------------22
10.4 Corrosion Protection for Standstill Periods longer than 1 year----------------------------22
11. BEARING PRESERVATION DURING TRANSPORT -----------------------------------------22
12. APPENDICES -------------------------------------------------------------------------------------------22
12.1 Ordering Spares --------------------------------------------------------------------------------------22

3
8 HEX. SOCKET CSK SCREW 16 STEEL
7 LINER ASSY 2 STEEL

4
6 SHIM PACK 2
5 DOWEL PIN 2 STEEL
4 PAD STOP 16 STEEL
3 THRUST PAD SET 2 STEEL WM
2 RETAINING RING 1 STEEL
1 RETAINING RING 1 STEEL
REF PART NAME QTY MATERIAL

6 1 3 2 7

5 4

OT Omega Thrust Ring Assembly With Shim Pack, And Liners


1. Introduction

1.1 About the Product

The “Omega” Series Thrust Rings supplied are part of a standard range of components
manufactured by Michell Bearings. The thrust rings are intended to be fitted within a casing
supplied by a customer. Depending on the demands specified, the thrust rings will be
designed to absorb:

a) A constant load along the shaft in one direction.


b) A constant load along the shaft in either direction.
c) A constant load in one direction and a temporary load in the opposite direction.

Within the “Omega” Series a range of sizes are catered for. All “Omega” thrust rings require
continuous lubrication from a pumped oil supply. In some cases, the thrust rings will have
machined oil channels and in other cases restriction jet holes.

The system of restriction holes is known as ‘Low Loss’ lubrication and will give lower power
losses than conventional fully immersed rings.

In order to measure pad temperature, Resistance Temperature Devices (RTDs) can be fitted
to a number of pads specified by the customer.

1.2 About this Manual

• This manual contains information about the bearing and its safe operation, and should
therefore be read carefully in full before starting work.
• Since the bearing has a wide range of applications, this manual has been written to cover
all current configurations.
• This manual is to be used by qualified engineers only.
• The following formats are used to draw attention to particular details:

! This symbol signifies a warning. These are instructions that, if ignored, could
result in death or injury. Danger!

This symbol signifies an important point which, If ignored, could result in


minor injury or failure to carry out a process correctly.

5
This symbol signifies additional instructions. This is usually a check. Missing
out this stage could lead to an error going unnoticed.

In addition, brackets after a reference to a part description, e.g. thrust pads set (3),
retaining ring (2) refer to an item number on a general sub-assembly drawing at the
front of this manual. These are used as a reference for the engineer.

1.3 Warranty Claims

• Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell
Bearings.
• These warranty obligations will automatically become void if the product is:

1. Improperly handled or installed.


2. Supplied with spare parts (or repaired), not approved by Michell Bearings.
3. Exceeding the design operating parameters shown on the arrangement drawing.
4. Subjected to environmental conditions not previously specified.

6
2. Safety

When installing, operating or maintaining the bearing, danger may arise to the user, the
product and plant and/or other assets. Therefore all users responsible for the operation of the
machine must understand this manual fully and make sure that all the safety procedures are
strictly adhered to.

Pay particular attention to the following general safety notes:

! Under no circumstances should the engineer work alone when operating the
machine.

! At least one of the engineers should be trained in basic first aid techniques
and wear identification that he/she is a first-aider.

! No maintenance, assembly, adjustment or any other work should be carried


out on the bearing whilst the shaft is rotating or capable of movement. To avoid
accidents, the entire machine should be isolated, with control gear locked off and “Not
to be used” signs applied to the control panels.

! Personnel that manipulate the product should be sufficiently trained.

! No modifications of the product should be made unless it is approved by


Michell.

More specific safety notes are also given in the relevant sections, and should be adhered to.

7
3. Handling the Bearing

3.1 General

This section outlines essential information, which must be referred to when handling the thrust
rings.
• The thrust rings are supplied fully assembled (see arrangement drawing for mass of
complete bearing).
• Omega “OT” Series thrust rings are not usually fitted with lifting holes. A complete ring
may be lifted using straps or slings.
• When transporting the bearing, it should remain in its packaging.
• Make sure thrust rings are stored in the intended mounting position, in a dry room only.
Please check all product equipment to ensure that it is complete before installation. Any
damage due to transit must be reported to Michell immediately.
• See Section 8 for instructions on how to disassemble the bearing.

! Before using any lifting equipment, ensure that it is certified to carry a load
greater than that of the bearing or component.

Take care not to damage bearing components and the running surfaces of the
shaft collar by contact with the lifting equipment.

! If in doubt, always use mechanical devices where possible. Remember to


bend the knees and not the back when lifting manually.

8
4. Preparation for First Installation

• All Omega “OT’’ Series thrust rings are supplied complete. All thrust rings are, for ease of
assembly, capable of being split in two halves. If the rings supplied are to be split the
RTDs and their cabling should be removed prior to this.
• Remove all packaging.
• Refer to Sections 2 and 3 for safety and handling instructions.
• Dismantle the bearing referring to Section 8, ignoring any references to the shaft or
machine.
• When dismantled, please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell Bearings immediately.
• All parts are coated in a rust preventative. This must be removed and all parts thoroughly
cleaned before installation begins. To remove the rust preventative, white spirit or a strong
spirit based cleaner should be used. Note! Do not use paraffin (Kerosene).
• It is recommended that the bearing casing and all other internal parts are cleaned to
prevent dirt getting between the collar and the thrust rings.

If the thrust rings are being fitted into a bearing that has previously been
used, ensure that the lubricating pipes have been cleaned to remove any deposits. If
there is any dirt in the lubricating system it will damage the new parts fitted.

! There may be fumes given off during the cleaning process. Clean parts in a
well-ventilated area. Always follow cleaner manufacturers’ instructions.

Use a lint free cloth when cleaning the bearing. Particles from other cloths
could otherwise get into the lubricating oil and cause overheating, and in extreme
cases, failure of the bearing.

• Once all parts are inspected and cleaned the bearing is ready for installation.
• Refer to Section 10 if the bearings are to be stored for a period of time before operation.

9
5. Assembly of the Bearing

5.1 General

The following general points should be noted:

! The disassembling and reassembling of the equipment by an individual who is


inexperienced can cause danger. Michell will not take on any liability for any damage
resulting from non-compliance with details given in this manual. If in doubt refer to our
Service Dept.

Only use tools, which fit correctly to avoid damage to fasteners.

! Do not use excessive force.

Use a liquid screw locking compound (e.g. Loctite 222) on all fasteners.

! Always follow the instructions on adhesives.

Remove all impurities and foreign objects (e.g. bolts, washers, etc.) from inside
the bearing. Ensure bearing is covered when left unattended.

This assembly procedure has been generalised to cover most eventualities. As such it may
contain more information than is directly applicable to the bearing being worked on. Read all
text and simply ignore any reference to irrelevant items.

5.2 Assembly of the Thrust ring


5.2.1 Fitting the Thrust Pad set.
• Coat all bearing surfaces in clean oil. Refer to bearing general arrangement drawing for
information on the correct grade of lubricant.
• Place thrust pad set (3) into retaining ring halves (1), (2).

Ensure that the correct handed pads are fitted. The direction of rotation
stamped on the pad must agree with that shown on the arrangement drawing.

• Secure thrust pad (3) in place with pad stop (4) with hole located in back of thrust pads (3).

10
• Ensure that stop (4) is fully locked in place with Loctite 222 or similar adhesive.


! Always follow instructions on adhesives.

• Make sure pads (3), can move freely, and are not trapped.

Take care not to trap hands when handling the components

5.2.2 Fitting Ring Stop, and Liners if applicable


• Place shim pack (6), and liners (7), on retaining ring halves (1), (2), and sercuer in place
with hex, socket counter sunk screw (8).
• Ensure that screws (8) are fully locked in place with Loctite 222 or similar adhesive.
• Fit ring stop (5).
• Ensure that stop (5) is fully locked in place with Loctite 222 or similar adhesive.

! Always follow instructions on adhesives.

5.3 Assembling the Thrust rings into the Bearing Casing

• Coat the thrust pads surfaces with clean oil of the correct grade.

• Some OT Series bearings are supplied with machine liners; these should be fitted at the

same time as each thrust ring assembly.

• Horizontal Bearings: Fit the lower half of the thrust ring(s).

• Vertical bearings: Fit the entire lower thrust ring.

Care should be taken when handling the components to avoid the risk of
trapping hands when assembling.

• Lower the shaft, complete with collar into the bearing.

• Horizontal Bearings: Fit the top half of the thrust ring(s), either onto the top of the lower

ring, or into the top half casing. Secure the ring with stops.

• Horizontal bearings: Rotate the thrust ring around until the stop (5) engages in the casing,

if half the ring is secured into the top half of the casing, ensure that the bottom half is flush

with the casing joint and complete assembly.

• Vertical Bearings: Fit upper thrust ring and secure in place with stop (5).

• Check the bearing alignment, and complete assembly.

11
5.3.1 Miscellaneous
• Where applicable, connect up oil inlet and outlet.
• Connect external pipework.
5.3.2 Instrumentation
• Fit RTDs and instrumentation as necessary.

Ensure that temperature probe assembly is not damaged and is working


correctly before fitting it.

Check that the bearing is complete and is fully sealed.


• For temperature probe fitted bearings; run the bearing and establish a steady state
operating temperature then set temperature alarm to 5°C above the steady state operating
temperature. Shut down temperature alarm is to be set at 10°C above steady state
operating temperature.

! Note! Prior to running the bearing EC regulation state: - The entire machine
has received a Declaration of Conformity, or has been declared exempt from the
Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive.
Where applicable

! Do not use the bearing unless the lubricating system is operating.


It must be emphasised that any declaration of incorporation issued by
Michell Bearings is for the thrust rings and their components and not for
the entire bearing.
The bearing is now complete; it must not be used until the below items
have been dealt with;
1. Lubricating oil has been passed though the bearing.
2. The lubricating oil must be a mineral based turbine oil inhibited
against oxidation, corrosion and foaming, with an ISO viscosity grade
as indicated on the arrangement drawing.
The use of any other oil should be referred to Michell Bearings.
If in doubt with installation please use our Service
Department!

12
6. Operating

6.1 Preparation and Inspection before Operation

• Where necessary fit the temperature probes for measuring the thrust pads, and/or the
sump temperature in the relevant connection holes.

Ensure that RTD assembly is not damaged and is working correctly before
fitting.

! Always follow sealant manufacturers’ instructions.


• Where applicable retighten external oil supply connections.
• Fill Bearing with oil or start oil system as described in Section 7.4.

Check:
1. That the oil quantity at bearing oil inlet is as specified by Michell Bearings, where
applicable.
2. That the temperature monitoring equipment works.

• The bearing is now ready for operation. It must not be used until the below items have
been dealt with:

1. The entire installation has received a Declaration of Conformity, or has been declared
exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery
Directive.
2. Lubricating oil has been passed though the bearing.
3. Local safety regulations have been met.
6.2 Trial Run

• For temperature probe fitted bearings, run the bearing and establish a steady state
operating temperature. Set temperature alarm to 5°C above this steady state operating
temperature. Shut down temperature alarm should be set at 10°C above steady state
operating temperature.
• Supervise the bearing during the trial run period (approx. 5-10 operating hours).
• Pay special attention to the following:

1. Oil flow rate and oil inlet pressure in circulating oil system (where applicable)
2. Bearing temperature
3. Occurrence of inadmissible vibrations.
4. Unusual noises or odours

13
• If any or all of the above cause concern, or if the monitoring equipment triggers an alarm,
stop the machine immediately and carry out an inspection of the bearing to find the cause.

6.3 Normal Operation

! Do not touch any moving parts.


• If the bearing has been correctly assembled using the procedure already given, there is
only a marginal risk of the bearing failing which would normally be due to inadmissible
operating conditions. Examples of these conditions are; overspeed, low lubrication levels
and excess load. To avoid these situations, follow the following recommendations:

• Label Control Panels with the bearing limitations.


• Do not operate the bearing below the transition speed values indicated in the bearing
calculation.
• Stop the shaft immediately if: Bearing temperature exceeds normal operating
temperature by 10°C.
• Never remove plugs, RTDs or seals while the bearing is operating.
• Regularly inspect all seals and pipework. Any large leakage of lubricant or coolant will
indicate that a seal or joint is failing. Maintenance must then be carried out as soon as
possible.

The bearing surface and any pipework may be hot during operation.
6.4 Preparation for Operation after Standstill

• Clean the external parts of the bearing. Dust and dirt impede the radiation of heat.
• Check with the maintenance schedule in Section 7.3 to see if an oil change is necessary.
If required, carry out the oil change as indicated in Section 7.4.
• Start operating the oil supply system, where applicable, and check that it is working
correctly. The supplied oil quantity at the bearing inlet must equal the value indicated in
the Michell Calculations.
• Check the functioning of the temperature monitoring equipment.
• The bearing is now ready for operation.

14
7. Care and Maintenance

7.1 General

• Before carrying out any maintenance or inspection work, switch off machinery. Lock off the
controls and secure and the isolate shaft.

! Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled “Not to be used”, or similar.

! Do not touch any moving parts.

7.2 Tools and Equipment

The following tools and equipment may be necessary to carry out maintenance on the
bearing:
• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges.
• Emery paper, plain scraper
• Lifting equipment
• Permanent sealing compound (e.g. Curil-T)
• Liquid screw locking compound (e.g. LOCTITE 222)
• PTFE sealant tape.
• Oil with the viscosity indicated (see bearing inspection plate)
• Detergents
• Clean cloth

15
7.3 Maintenance Schedule

• For a bearing that is operating constantly, routine maintenance should take place annually.
• If the user only operates the bearing periodically, maintenance periods may be able to take
place less frequently. This is however, at the users’ discretion. An annual inspection is
recommended as a minimum service requirement.
• A basic guide to maintenance is given in Table 1.

Maintenance work Schedule


Oil Change (see Section 7.4) • Bearing in reversing operation: every 3 Months
• Bearing in continuous operation: every 6 Months
Bearing Inspection During preventative maintenance work for machine or
immediately if:
• Bearing temperature exceeds 10°C over the indicated
value (see calculations)
• Unusual noises or odours occur
• Unusual changes in the oil colour are visible.
• Inadmissible vibrations occur.
• Oil flow rate and oil inlet pressure readings drop
below admissible values,

Table 1: Maintenance Schedule

• These are estimates only, and frequency may alter depending on site environment.
Michell can advise the user accordingly.
7.4 Oil Change

7.4.1 General
• Oil changes will be at differing periods depending on the frequency of bearing operation
and the conditions in which the bearing is operating. Approximate oil change times are
indicated in Section 7.3.
• Please observe the instructions for the use of the lubricating oil. The manufacturer
can provide information on waste oil disposal.

! Risk of Pollution:

7.4.2 Procedure for draining oil


• Run the bearing to warm up the oil. This will ease the flow of oil from the bearing, and also
remove any impurities and residues.

16
• Shut down the machine and secure it against unintended operation.
• Shut down the oil supply system where applicable.

! Do not disconnect the oil inlet and outlet pipework until the bearing has been
drained of oil.

Any oil spillage should be collected in suitable containers.


• Let off and collect the lubricating oil in the oil supply system where applicable.
• Loosen and remove the drain plug and washer, and fully drain the bearing of oil.

! Beware hot oil.

Collect and dispose of used oil under the correct regulations.

If the oil is visibly altered in colour, or contains unusual residues, an inspection


is recommended to eliminate the cause.

7.4.3 Procedure for refilling the bearing -self contained bearings


• Pour the correct grade of lubricating oil into the filling hole in the casing top. Use the
approximate quantity required as shown on the bearing arrangement drawing as a guide.
• Let the oil settle into the bearing. Check the oil level is approximately at the centre of the
oil level gauge, and top up if necessary. Where applicable.

7.4.4 Procedure for refilling the bearing - bearings with circulating oil
• Clean the oil container and fill up the oil supply system with the correct grade of lubricating
oil.
• Start the oil supply system in order to fill up the bearing with oil.

Check for leaks.

Not enough lubricant leads to temperature rises and therefore damage to the
bearing. Too much lubricant leads to leaks.

When pouring, take care not to spill lubricating oil onto the machine or
surrounding area.

17
8. Dismantling an Installed Bearing

8.1 General

• The Procedure given in this section is a full stripdown of a generic Omega “OT” series
bearing. As such it may contain more information than is necessary in some cases.
Simply ignore the sections not relevant to the bearing being worked on. Any technical
queries can be referred to the Engineering Team at Michell Bearings.
• Michell recommends that the below safety advice is followed when carrying out
maintenance on any bearings. It may be necessary to change the dismantling procedure
to suit the design of the bearing casing.

8.2 Preparation

• Check through the safety procedures at the start of Section 2. Understand and follow the
instructions very carefully.
• Switch off machinery. Lock off controls. Secure and isolate shaft, drain and disconnect
cooling system, where applicable. Refer to manufacturer instructions.

! Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled “Not to be used”.
• Switch off and drain the lubricating oil and oil system (where necessary) as described in
Section 7.4.
• Disconnect and remove any thermometry and instrumentation.

Make sure the workspace is clean. Contamination and damage to the bearing
affect operating performance and could lead to premature failure.

! Do not use any violence or force.

Take care not to jam hands when manipulating components.


.
8.2.1 Strip down the bearing until the thrust rings are visible.
• Horizontal Bearings: Where applicable, remove the top half of the thrust ring(s).

• Vertical Bearings: Remove upper thrust ring (where fitted).

• Vertical Bearings: Jackshaft up until it’s clear of the lower thrust pads.

18
! Follow lifting instructions and safety guidelines in Sections 2 and 3.

! Ensure the jacking equipment is safely positioned and certified to carry a load

greater than the mass of the shaft.

! Once the shaft is raised, secure it into position using other equipment. Do not
rely on jacking equipment alone.

8.2.2 Disconnect and remove any thermometry and instrumentation.


• Remove RTDs, and instrumentation connections.

Take care not to damage instrumentation.

8.3 Removing thrust rings


Vertical Bearings: Remove lower thrust rings.

• Horizontal Bearings: If the bottom half of the thrust rings are not visible, follow the below
procedure;
• Tap one end of the ring until the opposite end is visible.

• Rotate the ring out and remove.


8.4 Removing the Liners, and Shim Pack. Where Applicable.

• To fully dismantle the thrust ring follow the below procedure:

• Remove liner retaining screws (8), liners (7), and shim pack (6) from the back of the
retaining ring halves (1), (2).
8.5 Removing the Thrust Pad Set

• Remove thrust pad stops (4) from retaining rings (1), (2).

• The thrust pads (3) can now be removed from the retaining ring (1), (2).

Take care not to jam hands when manipulating components.

Take care not to damage thrust pad whitemetal surface.

19
9. Cleaning and Checking

9.1 General

! Only use non-aggressive detergents such as VALVOLINE 150 or Alkaline


cleaning compounds with pH-value 6 to 9, and a short reaction time.

! Please observe the instructions for use of the detergents.

! There may be fumes given off during the cleaning process. Clean parts in a
well-ventilated area. Always follow cleaner manufacturers’ instructions.

Use a lint free cloth when cleaning the bearing. Thread from such cloths could
get into the lubricating oil and cause overheating, and in extreme cases, failure of the
bearing.

• Clean the following parts thoroughly:

1. Thrust pad set.


2. Retaining ring.
3. Liners, where applicable
4. Shim pack.
5. Thrust pad stops.

• In addition inspection may be required on the bearing components, according to the


Maintenance Schedule outlined in Section 7.3.
• The remaining part of this section gives basic inspection guidelines for some major bearing
components. However, if any wear or damage is evident on any of the bearing
components, consult Michell Bearings immediately as it may adversely affect bearing
performance.
• The following sections assume the bearing has been dismantled according to Section 8.

20
9.2 Checking the Thrust Pad.

• Examine the Thrust Pads. The appearance of the running surface should be that shown in
Figure 11 below.

Figure 11: Thrust Pad Appearance After Use

• Inspect the collar surface for any signs of damage. If it is necessary to change the pads,
the collar should also be replaced or repaired, otherwise the replacement pads will only
have a short life. There may be some scoring and wear on the pads. Provided wear is no
greater than 0.125mm the pads are still serviceable. If there is any sign of the bearing
surface coming away from the backing material, the pads must be replaced.

21
10. Bearing Preservation during Storage

10.1 Before Installation

• Make sure thrust rings are stored in the intended mounting position, in a dry room only.

10.2 Corrosion Protection for Standstill Periods up to 6 Months

• Dismantle the bearing (see Section 8).


• Clean the bearing (see Section 9).
• Assemble the bearing (see Section 5).
• Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of
condensation in the bearing.

10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year

• Repeat the preservation procedures detailed in Section 10.2.

10.4 Corrosion Protection for Standstill Periods longer than 1 year

• Dismantle the thrust rings according to Section 8.


• Preserve and store bearing parts separately.

11. Bearing Preservation During Transport

When the bearing is fitted to the machine during transport:


• Carry out the corrosion protection procedure described in Section 10.2.
• Apply liberal lubricant to the running surfaces of the bearing.
• Secure the shaft against axial and radial movement.

12. Appendices

12.1 Ordering Spares

• As a minimum, it is recommended that replacements should be carried for all Whitemetal


components. Consideration should also be given to stocking the parts listed below:
• Jointing compound (i.e. Curil-T)
• RTD Assemblies (where applicable)

22
Appendix 2 (Table of Torque’s).

Bolt Size (mm) Tightening Torque (Nm)


6 4
8 10
10 20
12 35
16 80-90
20 155-175
24 275-305
30 545-605
36 950-1050
42 1520-1680
48 2300-2520
56 3690-4070
64 5560-6150

23
Michell Bearings Service Department.
Scotswood Road Direct: +44(0191) 2565319
Newcastle Upon Tyne
NE15 6LL Repair Department.
Great Britain Direct: +44(0191) 2565309
Tel: (0191) 273 0291
Fax: (0191) 272 2787

Michell Bearings reserve the right to amend these instructions.


© Michell Bearings 2004.

24
INSTRUCTIONS

for

INSTALLING & OPERATING

NE269 (8X8) THRSUT BEARING

for

BHARAT HEAVY ELECTRICALS LTD.

Hyderabad,

P. O. No. F603P608

September 2005

K I N G S B U R Y, I N C.
10385 Drummond Road, Philadelphia, PA
Phone: 215-824-4000
Fax: 215-824-4233

Kingsbury Reference No. K033016


CONTENTS

Page
No.

CHAPTER 1 - GENERAL INFORMATION

1.1 INTRODUCTION .................................................................................................. 1

1.2 PRINCIPAL DATA................................................................................................ 1

1.3 ILLUSTRATIONS .................................................................................................1

1.4 GENERAL DESCRIPTION ...................................................................................1

1.5 DETAILED DESCRIPTION ..................................................................................1

CHAPTER 2 - INSTALLATION

2.1 DISASSEMBLY, CLEANING, AND INSPECTION ...........................................3

2.2 INITIAL ASSEMBLY ............................................................................................3

2.3 END PLAY .............................................................................................................4

2.4 FINAL ASSEMBLY ..............................................................................................5

CHAPTER 3 - OPERATING INSTRUCTIONS

3.1 LUBRICATION AND COOLING .........................................................................6

3.2 GRADE OF OIL .....................................................................................................6

3.3 OPERATION ..........................................................................................................6

CHAPTER 4 - CARE AND MAINTENANCE

4.1 TROUBLESHOOTING ..........................................................................................7

4.2 INSPECTION AND REPLACEMENT ..................................................................7

4.3 SERVICE ................................................................................................................8


CHAPTER 1 - GENERAL INFORMATION

1.1 Introduction

a. The NE8269 thrust bearing assembly consists of two subassemblies. Each


subassembly has eight pads, four of which are equipped with Resistance Temperature Detectors
(R.T.D.). The subassemblies are split with an attached split filler plate.

1.2 Principal Data

NE8269 Non-Equalizing (NE) Bearing

Outer diameter of bearing (mm) ............................................................................................. 297.0

Inner diameter of bearing (mm) ..............................................................................................160.0

Number of pads (each side) ............................................................................................................ 8

Recommended end play (mm) ....................................................................................... 0.36 - 0.46

1.3 Illustrations

Kingsbury Drawing #481202 ............................................................................................. Figure 1

1.4 General Description

a. The double thrust bearing assembly presented in Figure 1 is a non-equalizing


design, which means that the axial pad positions have very limited adjustment capability under
load. Eight thrust pads are positioned on each side of the collar. The assembly is capable of
accommodating thrust load in either axial direction. The thrust of the rotating element is
transferred through the collar to the pads, the carrier ring, the housing, and foundation.

b. In operation, each pad is free to pivot slightly in relation to the collar surface.
This allows the oil to form wedge-shaped films between the pads and collar. These films,
thickest at the leading edge, are self-renewing, as long as the shaft rotates and lubrication is
provided.

1.5 Detailed Description (See Figure 1)

a. The thrust bearing assembly consists of two split carrier rings (1), in which the
thrust pads (2, 3) are equally spaced between pad retainer and screws (4, 4-1). The head of the
pad retainer holds the pads loosely in position by engaging recesses machined in the radial sides
of each pad.

1
b. Socket head shoulder screws (8) are used to locate and hold the instrumented
thrust pads (3) located near the carrier ring joint.
c. The thrust pads (2, 3) are made of steel and are faced with babbitt. They are free
to tilt slightly, allowing the wedge-shaped oil films to develop. The plain pads are
interchangeable. However, the pads equipped with R.T.D.s have specific locations within each
subassembly and must not be interchanged. Instrument lead wires must be routed through the
grooves provided in the carrier ring. The leads may be secured using the wire clamps (7) and
screws (7.1) provided.

d. The carrier rings are located in the housing and secured against rotation by anti-
rotation keys (6) secured with screws (6-1).

e. The filler plates (5) are used to set rotor end play (See Section 2.3), which is the
axial clearance between the thrust bearing sub-assemblies. The filler plates are secured to the
back of each carrier ring (1) with filler plate mounting screws (5-1).

2
CHAPTER 2 - INSTALLATION

2.1 Disassembly, Cleaning, and Inspection

a. As packed for shipment, the bearing elements and surfaces are protected against
physical abuse and corrosion. They have been brushed with a neutral waterproof coating and are
protected against contact with wood or damp packing material. Subsequent damage may occur if
the proper precautions are not observed during storage, inspection, and installation.

b. Remove the packaging materials from each bearing assembly and lay the
assembly on a clean, flat surface.

c. Separate the thrust bearing subassemblies at the joints.

d. Remove the pad retaining screws (8) from the back face of the subassemblies.
Remove the loose pads (3).

e. Loosen and remove the pad retainer screws and pad retainers (4, 4-1) in sequence,
removing all loose thrust pads (2).

f. Clean off all anti-rust preservative with a mixture of oil and solvent or kerosene.
Use lint-free rags or cloth for cleaning.

CAUTION
A poorly cleaned bearing will score and wear out rapidly.
A bearing surface is not clean until a white cloth wiped
over it shows no soil.

CAUTION
Protect the babbitted pad faces at all times!

g. Inspect all parts after cleaning. Remove any raised metal on the babbitt faces
with a scraper.

h. Remove displaced metal or rust on the collar face using a fine oil stone. Deep
rust requires refinishing.

2.2 Initial Assembly

a. Oil all parts when assembling.

b. Place the carrier ring halves (1) on a clean, flat surface.

3
c. Refer to Figure 1. Starting near the carrier ring joint (the end without the thru-
hole for the shoulder screw (8)), place a plain thrust pad (1) atop the carrier ring, followed by a
pad retainer (4) atop the threaded hole in the carrier ring. The retainer must engage the slot in
the side of the pad.

d. Continue placing pads, followed by retainers, until all of the plain pads and
retainers have been located.

e. Secure the retainers in place by installing the flat head socket screws (4-1).

f. Place the instrumented pads (3) into the remaining positions and secure with
socket head shoulder screws (8).

g. End play must now be accounted for. Refer to Section 2.3, End Play.

2.3 End Play

a. End play is defined as the axial float of the thrust collar between the thrust
bearing sub-assemblies. It is provided to allow for oil film formation and thermal expansion.

b. Thrust bearing end play is determined by the thickness of the filler plates (5)
fastened to the back of each carrier ring.

c. To determine the required filler plate thickness, place each thrust bearing sub-
assembly on a surface plate and lay a flat plate atop the pad surfaces. Use an inside micrometer
or snap gauge and measure the height between the surface and top plate adjacent to each pad.
Average the eight readings to determine the average stacked height.

NOTE
For accurate results, the flat plate should have a 32 rms finish
and be flat within 0.03 mm. The plate should weight at least 45
kgs.

CAUTION
Babbitt is a soft metal that is easily damaged. Do not drop or
twist the surface plate atop the babbitted surfaces!

d. Use an outside micrometer to measure the filler plate thickness. Record the
measurement.

4
e. With the thrust collar (rotor) in the desired running position, use an inside
micrometer to measure the average available space. Carefully measure and record the space
between the collar and each end of the housing. Perform measurements in at least three
locations. Average the readings to determine the average available space.

f. The difference between the average stacked height and average available space
(for each side of the collar) represents the desired filler plate thickness. The calculated filler
plate thickness in the normally unloaded bearing must be further reduced by the desired end play
(See Section 1.2).

g. If the filler plates are not the required thicknesses, they must be ground.

NOTE
The filler plates should be ground on the side of the filler plate
mounting screw (5-1) counter bores.

The filler plate must be ground flat within 0.013 mm. The
surface finish should be 32 rms or better.

h. Once installation is complete, verify the end play by moving the rotor fore and aft
while accurately measuring the change in position. Correct as required.

2.4 Final Assembly

a. Attach the finished filler plates (5) to the carrier rings (1) using the filler plate
mounting screws (5-1).

b. Wet the collar faces with oil.

c. Bump the rotor to one side to provide clearance for one thrust subassembly
installation.

d. Place the lower half of the partial assembly (the halves without the anti-rotation
key (6)) over the shaft and roll it into the housing, bringing the bearing joint even with the
housing joint.

e. Place the upper half atop the lower and roll the subassembly to seat the anti-
rotation key.

5
CAUTION
The instrument lead wires are easily damaged by rough or careless
handling. Assist the leads each time the assembly is rotated.

f. Bump the rotor against the bearing and install the second subassembly as noted
above.

g. Pour oil over the entire assembly.

h. Complete housing assembly.

6
CHAPTER 3 - OPERATING INSTRUCTIONS

3.1 Lubrication and Cooling

a. These bearings are intended for lubrication from the main oil system. The rate of
circulation should keep the oil outlet temperature within 14-17°C above the inlet temperature.

b. Control the oil flow by throttling or using orifice plugs on the oil inlet only.

3.2 Grade of Oil

a. Correct oil viscosity is important. Changing to a lighter oil may cause the
lubricating films to become dangerously thin. The use of a heavier oil will needlessly increase
friction and power losses.

b. Oil must be clean and free from grit and other abrasive substances. Fine grit has a
scouring action, and dirty or old oil may cause corrosion or sludge.

3.3 Operation

a. The bearing surfaces, when running, are completely separated by oil. Since there
is virtually no wear, no adjustment is provided. The original dull gray appearance of the thrust
pad faces may remain the same after years of service. This can be expected if the unit is clean
when installed and is supplied with clean, cool oil of proper viscosity.

b. Oil flow through the bearings must be established prior to shaft rotation.

7
CHAPTER 4 - CARE AND MAINTENANCE

4.1 Troubleshooting

SYMPTOM CAUSE REMEDY

Low oil flow Check & clean filters & sump.


HIGH
BEARING High oil inlet Check oil cooling medium. Increase cooling
TEMPERATURE temperature water flow. Check for proper oil level.
Contaminated lube Check and clean lube oil system.
oil Filter/replace oil.
Damaged journal Disassemble and inspect.
BABBITT LINING: Low oil flow Increase oil flow. Replace pads.
Scored Dirty Oil Filter/replace oil and replace pads.
Cracked Excessive vibration Balance rotor. Replace pads.
Separated from Poor bond Replace pads.
pad body

4.2 Inspection and Replacement

a. An inspection of the thrust pads or collar faces cannot be performed without


raising the housing cover. Thrust bearing end play, pad temperature, oil outlet temperature, and
oil filter condition should be used to assess bearing health.

b. When distress is suspected, secure the unit and lift off the upper portion of the
housing.

c. With the cover raised, the radial edges of the thrust pads and exposed collar
surfaces can be inspected.

d. If babbitt overlay along the pads’ radial edges is not visible, withdraw a pad for
full surface inspection.

e. If the pad does not exhibit displaced babbitt, it is unlikely that the remaining pads
will be damaged. When the babbitt becomes hot enough to flow, it is picked up by the rotating
collar and is quickly carried through all of the pads.

8
f. If an overlay of babbitt is evident along the pads’ radial edges, the bearing must be
disassembled. The severity of damage determines the extent of repair.
g. Refer to Section 2.2 for the reinstallation procedure.

4.3 Service

a. In correspondence and when ordering parts, refer to the Kingsbury Drawing and
Order numbers.

b. Prompt service is available. Please contact:

Kingsbury, Inc.
Repair and Service Division
3615 Davisville Road
Hatboro, PA 19040 U.S.A.

Phone: 215-956-0565
Fax: 215-956-9027

9
481202.dwf :Library
8 7 6 5 4 3 2 1
ITEM INST RUMENT ATION RE VISIONS
ZONE LT R DESCRIPTION CHANGED APPROVED
A DDED TEXT "OF FIL LER PLATE" TO ID DIM . ON BACK VIEW .
R.T .D. MINCO MODEL #S308PD4S160BO,
RECOMMENDED TOTAL END PLAY .36mm [.014] TO .46mm [.018]. PLATINUM, 100 OHMS @ 0 ~C (32 ~F), 4-WIRES, #30-AWG,
ALL A
A DDED CARRIER ID DIM . TO SE C. E-E. ADDED TOTAL AXIAL
M EB 06 /10/04 R JM 06 /24/04
1 STRANDED, 4064.0/160.00 LG. LEADS, TEFLON
C LEARANCE NOTE TO SIDE VIEW. ADDED TECHNICAL DATA.
CHANGED SHOE M AT'L FROM STEEL TO CHROM E COPPER.
INSULATED & STAINLESS STE EL BRAID OVERALL
H 2A,
B
REM OVED BEARING CAPACITY FROM SPECS., REM OVED
R EFERENCE TO CHR CU SHOES, ECN #6004358
N H 8/3/04 H JG 8/3/04
H
BOM

G G
THRUST COLLAR FACES MUST BE
FLAT & SQUARE WITH SHAFT AXIS
FINISH VERY SMOOT H (16 RMS)
BY L APPING OR OTHERWISE
22.5° TYP 48.0 mm [1.89 in] n194.0 m m [7.64 in] I.D.
COLLAR NOT SUPPLIED
BY KINGSBURY OF FILL ER PLATE

1 1

7.1 5°
A B 3
5 5-1
C
n297.0 m m [11.69 in] TYP
2 EXTERNAL PAD DIAMETER
3

F F
m m 12.750 in HOUSING BORE
n323.50 mm 12.736 in BEARING O.D.

C qJOINT 2

n270.0 mm [10.63 in]


n300.0 m m [11.81 in]
.8 m m [.03 in] 160.0 mm [6.30 in] TYP
INTERNAL PAD DIAMETER
]

E E
12.742

12.756

COLLAR
[

11.1 m m [.44 in] TYP


323.64

n323.85
323.99

E GRIND THIS SIDE ONLY


E
3
3

4 4-1

SECTION B-B GRIND T HIS SIDE ONLY A B SECTION A-A


SCALE 1 / 2 8 SCALE 1 / 2
15.0 mm [.59 in] 15.0 m m [.59 in]

143.75 mm 5.659 in
143.65 5.656 [ ]
TOTAL AXIAL CLEARANCE
OF 0.5 mm [.02 in] INCLUDED
IN TOTAL BRG. WIDTH

D KINGSBURY TO SUPPLY 15m m[.591]


NOMINAL THK PLAT E, D
CUSTOMER TO GRIND PLATE TO
OBTAIN DESIRED END PLAY.
(AROUND ~9.649m m [.3799])

n178.5 mm [7.03 in] ID


OF BASE IRNG
6 6-1

16.7 mm [.66 in] TYP


n3.4 mm [.13 in]
4.7 m m [.19 in] 17.7 mm [.70 in] TYP

C 7
C
5
6.0 mm [.24 in]

23.8 m m [.94 in] TYP

SECTION E-E
5-1 SCALE 1 / 2
TECHNICAL DATA:
17.0 m m [.67 in]
-SHAFT DIA.= 138.0 mm [5.43 in]
M5 x 6mm SHANK DIA x 12mm LG 057958 4 SOCKET HEAD SHOULDER SCREW 8
SHANK
-ROTATIONAL SPEED, DESIGN/MAX.= 5465/6100 rpm
#10-24 x 3/8 LG 007717 10
FILL ISTE R HEAD MACHINE SCREW 7.1
CONCORD #770-1101 003974 WIRE CLAMP 10 7
-THRUST LOAD, M AX.= 120 KN
#10-24 x 3/4 LG 002875 2
FILL ISTE R HEAD MACHINE SCREW 6-1
B -THRUST SURFACE AREA= 1,635.0 sq.mm. [64.37 sq.in.] 162375-001 2
8.00" KEY, BASE RING 6 B
M6x1.0-6H x 16 mm LG 039138 12
BUTTON HEAD CAP SCREW 5-1
-THRUST PRESSURE= 2,889 KN/m.sq. 481208-002 2
FILL ER PLATE, NE 8269 5
M6X1.0 x 20mm L ONG 2001114 16
FLAT HEAD SOCKET SCREW 4-1
SECTION C-C -TOTAL AXIAL CLEARANCE= 0.5 mm [.02 in.] PAD RETAINER 267368-006 PAD RETAINER 16 4
SCALE 1 : 1 165251-001 16
1.00 DIA. SHOE SUPPORT 3-1
-POWER LOSS= 43 KW 379507-002 4
NE 269 CENTE R PIVOT SHOE ASM, 3
W/INTR.
-OIL GRADE= 32/46-ISO VG 481204-002 12 NE 269 CENTE R PIVOT SHOE ASM, 2
W/BUTTON
-OIL VISCOSITY POISE= 0.18 CW CARRIER RING 481203-002 2 NE 8269 CARRIER RING, CENTER 1
PIVOT SHOE S, SPECIAL THK
DESCRIPTION PART NUMBER QTY TITLE ITE M
-OIL INLET TEMPERATURE= 55 ~C
LIST OF MATERIAL

Kingsbury, Inc.
UNLESS OTHERWISE SPECIFIED 10385 DRUMMOND RD.
-OIL FLOW= 5,673 liters/hr PER SIDE PHILADELPHIA, PA.
THIRD ANGLE PROJECTION
DRAWING TITLE:

RELEASED HJG 8/4/04 269 (8x8) (NE) NON- EQULAIZING


A ENGINEER HJG 5/21/2004
BEARING IN HALVES, W/INSTR. (2x2), A
S URFACE 125 [32]
JAC 5/21/2004
W/15mm SPACERS
THIS DOCUMENT CONTAINS CONFIDENTIAL PROPRIETARY DESIGN INFORMATION OF KINGSBURY INC. ALL USE OF THIS CHECKED
INFORMATION IS EXPRESSLY RESERVED. THIS DOCUMENT IS SUBMITTED TO YOU, THE RECIPIENT, UNDER A CONFIDENTIAL
RELATIONSHIP FOR A SPECIFIC PURPOSE, AND YOU, BY ACCEPTING THIS DOCUMENT ASSUME CUSTODY AND AGREE: (1) THAT R OUGHNES S
THIS DOCUMENT WILL NOT BE COPIED IN WHOLE OR IN PART, NOR ITS CONTENTS REVEALED TO ANY PERSON EXCEPT TO MEET DRAWN BY wed 4/26/2004 SIZE DRAWING NO.
THE PURPOSE FOR WHICH IT WAS DELIVERED TO YOU; (2) THAT ANY SPECIAL FEATURES PECULIAR TO THIS DESIGN WILL NOT BE REV
INCORPORATED IN OTHER PROJECTS; AND (3) THAT THIS DRAWING OR ANY DESIGN DETAIL OR CONCEPT DISCLOSED HEREIN WILL
DIMENSIONING POSITION BHARAT HEAVY
NOT BE USED IN ANY WAY DETRIMENTAL TO OR IN COMPETITION WITH KINGSBURY INC.
NOTICE:
KINGSBURY INC. OWNS THE COPYRIGHT IN THIS DRAWING. UNAUTHORIZED
COPYING, ADAPTATION, DISTRIBUTION OR DISPLAY IS PROHIBITED.
INCH [MIL LIMETER] E LECTRICAL S
E 75333 481202 B
ITEM NO.
481202-T1 CALC. WT.
DO NOT SCALE DRAWING K.O.
K033016
SCALE 1=2 SHEET 1 OF 1

8 7 6 5 4 3 2 1
1 of 1
SECTION – B

BOILER FEED PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

5. CONNECTING COUPLINGS
STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 1 of 4

1. Installation and alignment instructions:

Preliminary Checks

All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling
accompany all supplies. Carry out the following checks prior to proceeding with the installation work.

i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport
purposes and for the purpose of compressing the flexing elements at the time of installation.

The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling
alignment and trial run of the equipment.

Couplings and the equipment should not be allowed to operate with gagging screws in position.

ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those
of the interface dimensions of the equipment shafts and flanges.

Coupling model & Rating


Hub bore and key way dimensions
Locating / Spigot diameter
Distance Between Shaft Ends (DBSE)
or Distance Between Flange Faces(DBFF)
Over all length

iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling.

iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise
called for, should not be disassembled, .

v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque
wrenches / special spanners.

vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with
numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying
certificates will show the run out values obtained at the time of dynamic balancing.

These markings of are meant for match marking and the run out values can be used as a guide for accurate
alignment of the equipment.

Prepared Approved Date

SANKAR KVMR 18-06-2003


STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 2 of 4

vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection,
with a coat of oil applied and wrapped in moisture proof polythene shrink film.

For best results it is recommended that the couplings are left in their original packing and are to be removed just
prior to the actual date of installation.

For extended periods of storage in the open, it is recommended that the couplings are returned to their original
packing and stored with a periodic coat of oil re-applied to them.

viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field
replacement with components that do not form part of the original set is not to be done. Always replace these
components as a set.

2. Initial Assembly and Centering :

Correct careful assembly and centering at the initial stage enables the coupling to provide maximum
performance and increases service life.

3. General Limits :

i. Maintain the actual Axial shaft gap to that specified with the following tolerances :

4 bolt couplings : +/- 0.5 mm


6 bolt couplings : +/- 0.4 mm
8 bolt couplings : +/- 0.3 mm

As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling
drawing.

ii.Radial Misalignment : Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower.

Note : The above values are to be arrived at after taking into


consideration the cold offset values for both axial and radial directions specified by the main equipment
manufacturer.

Prepared Approved Date

SANKAR KVMR 18-06-2003


STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 3 of 4

CONFIGURATION-1

Configuration : 1

Couplings with this configuration have hub flanges directly bolting on to the flexing elements. Following is the
sequence installation :

i. Dismantle the coupling bolts and the gagging screws.

ii. Mount the hubs on respective equipment shafts.

iii. Position the equipment to the correct DBSE specified.

iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance
(DBFF)
specified on the drawing.

v. Clamp two dials as shown and align to within 0.05 mm of TIR.

vi. Assemble the flexing elements and spacer in position and hand tighten all coupling bolts, in cylinder head
fashion.

vii. Tighten all coupling bolts to 50% of the specified torque using a calibrated torque wrench, in a cylindrical
head fashion.

viii. Recheck the DBSE and radial run out values. Readjust if the same is found disturbed.

ix. Tighten all coupling bolts to the specified torquing limit.

Prepared Approved Date

SANKAR KVMR 18-06-2003


STD OM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOT NO.99,CIE.PHASE-II, GANDHI NAGAR, BALANAGAR
HYDERABAD - 500 037.
Page 4 of 4

IMPORTANT:

Care should be exercised to tighten only the lock nuts by holding the bolt head steady in a socket. Coupling bolts
will have a very close fit in the flange holes and to the flexing element bushes and hence any forced rotation will
result in damage to the close fitting bolt shank and the mating parts.

1
1

2
Alignment Procedure / Clamping Arrangment 2

Fig. No. : 1
Max. Alignment Limits TIR-mm
Final checking
Max. Alignment Limits TIR-mm Application Dial 1&2
Application Dial 1 Dial 2 0.05
DRIVER - DRIVEN
DRIVER - DRIVEN 0.05 0.05
Fig. No. : 2

Prepared Approved Date

SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 1 off 4

1. Installation and alignment instructions:

Preliminary Checks

All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling
accompany all supplies. Carry out the following checks prior to proceeding with the installation work.

i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport
purposes and for the purpose of compressing the flexing elements at the time of installation.

The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling
alignment and trial run of the equipment.

Couplings and the equipment should not be allowed to operate with gagging screws in position.

ii. Cross check the following coupling data as per the assembly drawing / dimensional test certificates with those
of the interface dimensions of the equipment shafts and flanges.

Coupling model & Rating


Hub bore and key way dimensions
Locating / Spigot diameter
Distance Between Shaft Ends (DBSE)
or Distance Between Flange Faces(DBFF)
Over all length

iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling.

iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise
called for, should not be disassembled, .

v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque
wrenches / special spanners.

vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with
numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying
certificates will show the run out values obtained at the time of dynamic balancing.

These markings of are meant for match marking and the run out values can be used as a guide for accurate
alignment of the equipment.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 2 off 4

vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection,
with a coat of oil applied and wrapped in moisture proof polythene shrink film.

For best results it is recommended that the couplings are left in their original packing and are to be removed just
prior to the actual date of installation.

For extended periods of storage in the open, it is recommended that the couplings are returned to their original
packing and stored with a periodic coat of oil re-applied to them.

viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field
replacement with components that do not form part of the original set is not to be done. Always replace these
components as a set.

2. Initial Assembly and Centering :

Correct careful assembly and centering at the initial stage enables the coupling to provide maximum
performance and increases service life.

3. General Limits :

i. Maintain the actual Axial shaft gap to that specified with the following tolerances :

4 bolt couplings : +/- 0.5 mm


6 bolt couplings : +/- 0.4 mm
8 bolt couplings : +/- 0.3 mm

As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling
drawing.

ii.Radial Misalignment : Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower.

Note : The above values are to be arrived at after taking into


consideration the cold offset values for both axial and radial directions specified by the main equipment
manufacturer.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 3 off 4

Configuration :

Couplings of this configuration are supplied with a central transmission unit which allows installation
with minimum disassembly of the factory tightened main coupling bolts.

i. Dismantle the coupling hubs by removing the attachment screws.


ii. Mount the hubs on respective equipment shafts.

iii. Position the equipment to the correct DBSE specified.

iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance
specified on the drawing.

In case of variation to the specified axial shaft gap , refer to the specific instructions supplied, for using DBSE
adjusting shims supplied with the unit.

v. Clamp two dials on hub flanges as shown and align to within 0.05 mm of TIR.

vi. Disassemble the gagging screws and remove the gagging bush from the position. Re assemble the gagging
screws between the adaptor and spacer flanges. The transmission unit can now be compressed, by tightening
the gagging screws, adequate to facilitate assembly.

vii. Place the transmission unit into the position between the hubs ensuring that the spigot on hubs clears the
locating diameter on the adaptor plates.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


Euroflex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STD OM
Tel:23079775, 23076970, 23078243 / Fax: +91-40-23079523 & 27847149
e-mail: euroflex@satyam.net.in / Website: www.euroflex.co.in
Page : 4 off 4

IMPORTANT :
Slowly loosen & remove the gagging screws thus allowing the transmission unit to regain the original free length.
Ensure that the gagging screws are NOT in position at the time of equipment trial run or continuous operation.
Remove & store the gagging screws and bushes carefully for future use.

viii. Re check the DBSE and radial run out values. Readjust if the same is found disturbed.

ix. Tighten all attachment screws / bolts to the specified torque limit.

PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003


SECTION – B

BOILER FEED PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

6. SUCTION STRAINER (CONICAL)


Digitally signed by S P Patra
DN: CN = S P Patra, C = US,

SP O = DVC, OU = Engineering
and Planning
Reason: DVC have reviewed
this document and taken it for

Patra INFORMATION
Date: 2009.02.05 15:00:55
+05'30'
SECTION - C

CONDENSATE

EXTRACTION PUMP

TYPE : EN6J40/500
PART – 4

EQUIPMENT DETAILS

SECTION - C

CONDENSATE EXTRACTION PUMP

LIST OF CONTENTS

CHAPTER TITLE

1 Description

2 Operating Instructions

3 Maintenance Instructions

4 Sub-vendor’s Drawings / Instructions


SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 1

DESCRIPTION

LIST OF CONTENTS

1 General specification

2 General Description

3 Associated equipment

3.1 Canister and foundation ring

3.2 Discharge headpiece

3.3 Motor Stool

3.4 Stuffing box assembly

3.5 Combined thrust and journal

Bearing Assembly

3.6 Coupling

4 Driving motor
CHAPTER – 1

DESCRIPTION

1. GENERAL SPECIFICATION

Pump Designation : EN6J40/500

Type : Vertical, canister

Number of Stages : 6

Number of Pump Set : 3

2. GENERAL DESCRIPTION

The condensate extraction pumps are of the vertical centrifugal canister type with the
driving motor supported on a fabricated motor stool. The motor stool is supported on
a fabricated head piece which is secured to a fabricated canister. The canister is
secured to a foundation ring which is held to the floor with nuts on foundation bolts.

The pump stage casings form an interconnected assembly which is attached to the
underside of the headpiece and is suspended within the canister.

The head piece is provided with a stuffing box which contains a mechanical seal to
prevent pump leakage. Small bore pipe work, for sealing purpose, is connected to
the stuffing box. The head piece also supports the water cooled oil lubricated thrust
and journal bearing.

The pump discharge branch and vent pipe are integral with the head piece and the
pump suction branch is integral with the canister.

The motor stool, secured to the top of the head piece, supports the driving motor.
Cooling water pipe work along with the oil filling/vent pipe and gauge glass extension
pipe are attached to the motor stool.

Apertures formed on the motor stood and head piece provide access to the coupling,
thrust bearing and mechanical seal.
Each pump is driven by an electric motor mounted on the motor stool. The motor is
supplied by BHEL, Bhopal/Hardwar. The motor shaft is connected to a top shaft via a
flexible spacer coupling and the top shaft connects to the intermediate shaft via a
solid muff coupling. The intermediate shaft in turn is connected to a bottom shaft
through a muff coupling. The top shaft passes through the combined thrust and
journal bearing and stuffing box, and also carries the fourth to sixth stage rotating
assemblies. The intermediate shaft carries second and third stage rotating
assemblies. The bottom shaft carries the first stage rotating assembly. The shafts are
supported by two cutless rubber bearings at the first stage and by a single cutless
rubber bearing at the second to sixth stages. The thrust bearing absorbs the
downward axial thrust from the pump rotating assembly, and the white metal lined
journal bearing with in the thrust bearing assembly supports the shafts along with the
cutless rubber journal bearing within each intermediate stage assembly and element
assembly.

A snubber secured into the bottom of the canister engages the suction bell mouth
fitted to the first stage casing. This arrangement provides support to the bottom end
of the pump.

3. ASSOCIATED EQUIPMENT

3.1 Canister and Foundation Ring

The canister is a fabricated tubular chamber formed with a dished bottom end which
is closed by a snubber which is located and secured to the bottom of the canister by
screws, tab-washers and dowels. Leakage between the canister and snubber is
prevented by a joint, and a cylindrical extension of the snubber provides rigid support
to the first stage pump casing assembly.

A suction branch integral with the canister is positioned above floor level
and a flange provided below the suction branch accommodates screws for
securing the canister to the foundation ring. The canister top flange supports the
discharge head piece.
The foundation ring is provided with holes for foundation bolts and
tapped holes for canister securing screws. The foundation bolts and foundation
ring are grouted to the floor.

3.2 Discharge Head piece

The fabricated head piece, secured to the pump canister with screws,
incorporates the discharge branch and supports the thrust bearing housing and
motor stool. The head piece is sealed where the shaft passes through by a stuffing
box which incorporates a mechanical seal.

Small bore pipe work connects to the stuffing box, for inlet and outlet
sealing water. The outlet pipe work, which returns the sealing water to the pump
suction, is provided with two orifice plates. A vent pipe provided with a spigot
flange is incorporated within the structure of the head piece for connecting to
condenser. A Valve is provided for installing between the vent pipe and
condenser.

Tapped holes on the inner flange situated on the underside of the head
piece provide location for the top rising main screws and holes drilled through the
outlet of the outer flange provide location for screws which secure the head piece
to the canister flange. Tapped holes provided on the inner flange situated
on the topside of the head piece, provide location for the stuffing box securing
screws. Tapped holes on the topside outer flange provide location for the motor
stool securing bolts.

Apertures formed on the head piece provide access to the stuffing box and
are closed by wire mesh guards.

Lugs are situated at the top of the headpiece for lifting purposes.
3.3 Motor Stool

The fabricated motor stool is dowelled to the head piece and secured by
bolts. A recess formed on the top flange of the motor stool locates the driving
motor, which is secured with screws to the motor stool.

Small bore pipe work is provided within the motor stool for thrust bearing
inlet and outlet oil cooling water. A combined oil filler and vent pipe extends
through the side of the motor stool. The thrust bearing oil level gauge glass is
secured to a pipe which also extends through the side of the motor stool.
Apertures formed on the motor stool provide access to the flexible spacer coupling
and thrust bearing, and are closed by wire mesh guards.

3.4 Stuffing Box Assembly

3.4.1 Mechanical Seal : The stuffing box is secured to the head piece with
screws, leakages being prevented by a joint.

The entry of pumped condensate at the underside of the stuffing box is


restricted by a gap between a restriction bush, secured with screws to the stuffing
box and a sleeve secured to the shaft with “Loctite”.

The stationary seal face of the mechanical seal is retained by an “O” ring
in the seal plate, and the rotating components of the mechanical seal are retained
on a sleeve held by a retaining collar. The retaining collar is secured to the sleeve
with grub screws and secured to the shaft with grub screws.

The seal is of 'cartridge' type and seal setting is done by seal manufacturer
at their works itself.

The seal plate is spigot located and secured to the stuffing box with
screws, leakage being prevented by an “O” ring. Tapped holes are provided on the
seal plate for jacking screws, to assist with dismantling. Small bore pipe work
connects to the seal plate to sealing water purposes.
Two additional orifice plates are supplied for each pump to be installed in
client’s small bore pipe work which connects to the common discharge. This
feature enables an adequate flow of flushing water to be maintained at the stuffing
box, during the time the pump is on standby.

Further particulars for the mechanical seal are contained in Chapter – 4.

3.5 Combined Thrust and Journal Bearing Assembly

The combined thrust and journal, water cooled bearing assembly is


mounted on the head piece and absorbs the pump hydraulic downward thrust, and
takes the weight of the pump rotating assembly.

The casing base plate is spigot-located on to an adaptor plate which also


locates by spigot to the head piece. The casing base plate and adapter plate are
secured together with nuts on studs, and the adaptor plate is secured to the head
piece with screws.

The thrust collar which is a tight fit and keyed on the shaft is retained
against a shoulder on a shaft by the thrust collar nut. Tapped holes are provided
on the collar for fitting and removal purposes. The thrust is absorbed by the white
metal faced thrust pads fitted to the base plate, under the collar. White metal lined
journal pads are fitted in the casing and locate the collar radially.

The casing top is closed by a split cover secured to the casing with bolts,
the halves of the split cover being secured together with nuts on fitted studs and
nuts on bolts. Taped holes on the split covers facilitate eye-bolts for lifting and
removal purposes. Provisions is also available for a temperature probe. Leakage
between the split cover and casing is prevented by a joint. Leakage between the
sleeve and the underside of the base plate is prevented by a joint. The bearing
casing is supplied with inlet and outlet cooling water connections, an oil level
gauge, a combined air vent and oil filler and an oil drain plug on the base plate.
Tapped holes in the casing facilitate jacking screws for dismantling purposes.
Leakage between the casing and base plate is prevented by an “O” ring fitted in a
groove machined in the base plate.

For further particulars refer to the bearing manufacturer’s instructions


contained in Chapter-4.

3.6 Couplings

The drive from the motor to the top shaft is transmitted via a spacer type
flexible coupling. Each half coupling is a tight fit and keyed to its respective shafts,
the halves being connected by means of a spacer which interconnects via flexible
membranes at each end.

The coupling is designed to accommodate a certain amount of both offset


and angular misalignment and also any free end float or vertical movement of the
shafts.

The top shaft half coupling abuts the thrust collar nut, and a recess
machined in the bore of the top shaft half coupling accommodates a thrust plate
which corresponds with the LEF button.

For further particulars refer to the spacer coupling manufacturer’s


instructions contained in chapter-4.

4.0 DRIVING MOTOR

The vertical driving motor is mounted and secured to a spigot flange


provided on the motor stool.

For further particulars and information for the driving motor, refer to the
motor manufacturer’s instructions not contained in this manual. The driving motor
is supplied by BHEL, Bhopal/Hardwar.
SECTION - C

CONDENSATE EXTRACTION PUMP

CHAPTER – 2

OPERATING INSTRUCTIONS

LIST OF CONTENTS

1. Introduction

2. Pre-start checks

3. Start-up

4. Pump running checks

5. Normal shut-down

6. Preparing a pump for standby

7. Stud-down when the pump is to be isolated

8. Fault finding
CHAPTER – 2

OPERATING INSTRUCTIONS

1 INTRODUCTION

The following operating instructions are applicable to the mentioned type


of condensate extraction pumps, and should be read in conjunction with those for
the operation of the pump driving motor and the station operating instructions.

The pump driving motor, pump suction and discharge pipe work, valves
and control equipment are not supplied by BHEL, Hyderabad therefore the
installation should include all the necessary ancillary equipment to facilitate
satisfactory operation and prevent any malfunction at an early stage.

The three condensate extraction pumps are designed as 50% duty pumps
and their normal mode of operation permits two pumps running, and one on
standby.

To obtain the maximum attainable working life, continuous running is


recommended.

2 PRE-START CHECKS

Following an overhaul or maintenance procedure, check that the following


steps have been carried out along with the motor manufacturer’s instructions.

(1) Ensure that the power supply is available to the driving motor.

(2) Check the oil level in the thrust bearing gauge glass. Top up the thrust
bearing, if necessary.
(3) Ensure that the cooling water is available to the thrust bearing.

(4) Ensure that the sealing water is available to the stuffing box.

(5) Ensure that the pump discharge isolating valve is shut.

CAUTION : If the pump is to be started with the discharge valve open, it is


essential that the discharge line is full to prevent the pump running
out of its characteristic, and imposing an overload on the driving
motor.

(6) Ensure that the pump suction isolating valve is open.

(7) Ensure that the discharge pressure gauge isolating valve is open.

(8) Ensure that the valve on the air vent pipe to the condenser is open. The
valve should be locked in the “Open” position.

3 START - UP

(1) Ensure that the pre-start checks have been carried out.

CAUTION : (a) The pump must not be started unless the canister is full of
condensate.

(b) The suction isolating valve must not be used for throttling the
pump output: the discharge valve should be used for this
purpose.

(2) Refer to the motor manufacturer’s instructions and start the driving motor.
Ensure that the motor direction of rotation is correct.

CAUTION : The pump must not be run for an extended period with the discharge
valve closed.
(3) Slowly open the discharge valve and fill the system pipe work with
condensate. When the system pressure stabilizes fully open the discharge
isolating valve.

(4) Check the following readings if the appropriate instruments are available.

(a) Pump suction pressure.

(b) Pump discharge pressure.

(c) Pump suction temperature.

(d) Motor current. Refer to the motor manufacturer’s instructions.

(5) Check the oil level in the thrust bearing gauge glass.

(6) Check the mechanical seal for leakage.

(7) Check all joints above floor level for leaks.

(8) Check for any undue noise or vibration.

4 PUMP RUNNING CHECKS

The following checks should be carried out at regular intervals :-

(1) Check that the following readings are normal if the appropriate
instruments are available.

(a) Suction pressure.

(b) Discharge pressure.

(c) Suction temperature.

(d) Motor current. Refer to the motor manufacturer’s instructions.

(2) Check the oil level in the thrust bearing gauge glass; top up if necessary.

(3) Check the mechanical seal for leakage.


(4) Check all joints above floor level for leaks.

(5) Check the accessible fastenings for security.

(6) Check for any undue noise or vibration.

5 NORMAL SHUT-DOWN

(1) Stop the pump driving motor. Refer to the motor manufacturer’s
instructions.

(2) Shut the pump discharge isolating valve.

(3) Unlock and shut the valve on the air vent pipe to the condenser. Lock the
valve.

Note : Refer to the station operating instructions.

6 PREPARING A PUMP FOR STANDY

If a duty pump should fail or extra duty is required, the standby pump
should be ready for immediate start-up. To prepare a pump for standby, the
following procedures must be carried out in conjunction with the motor
manufacturer’s instructions and the station operating procedures.

(1) Check the oil level in the thrust bearing gauge glass; top up if necessary.

(2) Ensure that cooling water is available to the thrust bearing.

(3) Ensure that sealing water is available to the mechanical seal.

Note : Constant sealing water is supplied to the stuffing box mechanical seal on
each pump from the common discharge pipe work via small bore pipe
work, which prevents the ingress of air when a pump is stationery. Two
orifice plates are fitted in each set of small bore supply pipe work.

(4) Ensure that the pump discharge isolating valve is shut.


CAUTION : If the pump is to be started with the discharge valve open, it is
essential that the discharge line is full to prevent the pump running
out of its characteristic and imposing an overload on the driving
motor.

(5) Ensure that the pump suction isolating valve is open.

(6) Ensure that the canister is full.

(7) Ensure that the discharge pressure gauge isolating valve is open.

(8) Unlock and open the valve on the air vent pipe to the condenser. Lock the
valve in the open position.

7 SHUT-DOWN WHEN THE PUNP IS TO BE ISOLATED :

(1) Stop the pump driving motor. Refer to the motor manufacturer’s
instructions.

(2) Shut the pump discharge isolating valve.

(3) Shut the pump suction isolating valve.

(4) Isolate the electrical power supply from the pump driving motor. Refer to
the motor manufacturer’s instructions.

(5) Isolate the cooling water supply to the thrust bearing.

(6) Isolate the sealing water supply to the mechanical seal.

(7) Unlock and shut the valve on the air vent pipe to the condenser. Lock the
valve.

Note : Refer to the station operating instructions.

(8) Evacuate the accumulated condensate from the canister.


8 FAULT FINDING

Symptom Possible Cause Action


(1) Pump fails to start (a) Electrical supply to Check the electrical supply.
the driving motor Refer to the motor
isolated or faulty. manufacturer’s instructions.
(b) Seizure of the pump Remove the pump set.
or motor. Disconnect the pump from
the motor to establish
locality and cause of
seizure. Dismantle and
renew the pump or motor
components as necessary.
(c) Thrust and journal Remove and examine thrust
bearing seized. and journal bearings. Refer
to Chapter 3.
(2) Pump (a) Motor power faulty. Check the motor and
performance electrical supply. Refer to
low motor manufacturer’s
instructions.
(b) Incorrect rotation. Check the motor terminals at
the starter. Refer to the
motor manufacturer’s
instructions.
(c) Discharge valve not Check the valve.
fully open.
(d) Excessive clearance Remove the pump set,
between the impeller dismantle the pump and
wear rings and renew components as
casing wear rings. necessary, Refer Chapter 3.
(3) Excessive (a) Pump or motor Dismantle the pump or
noise and/or rotating assembly motor and check
vibration out of balance. components for dynamic
balance. Refer to dynamic
balance, Section 8.11,
Chapter 3.
(b) Journal bearing, Dismantle the thrust bearing
thrust bearing, or and dismantle the pump and
bearing bushes on check the pump and shaft
the pump, or bottom bushes; renew as
shaft worn. necessary. Refer Chapter 3.
(c) Journal bearings on Refer to the motor
the motor worn. manufacturer’s instructions.
(d) Excessive wear of Dismantle the pump and
pump internals. check for wear. Renew
components as necessary.
Refer to Chapter 3.
(e) Excessive wear in Refer to the motor
motor internals. manufacturer’s instructions.
(f) Securing Ensure that all accessible
arrangements loose. fastenings and
corresponding pipe work are
secure.
SECTION - C

CONDENSATE EXTRACTION PUMP

CHAPTER – 3

MAINTENANCE INSTRUCTIONS

LIST OF CONTENTS

1 Introduction
1.1 Periodic and preventive maintenance
1.2 Routine checks
2 Tools
3 Recommended lubricants
4 Weights
5 Maintenance procedures
5.1 Examining the combined thrust and journal
bearings
6 Removing the driving motor
7 Dismantling procedures
7.1 Preparation prior to removing the motor stool,
headpiece and pump
7.2 Removing the motor stool, headpiece and
pump.
7.3 Dismantling the headpiece and pump
8 Inspection and renewal
8.1 Clearances
8.2 Impellers
8.3 Shaft sleeves and bearings
8.4 Pump Shafts
8.5 Combined thrust and journal bearing
8.6 Mechanical seals
8.7 Flexible couplings
8.8 Keys
8.9 Nuts, Bolts & studs
8.10 Joints, “O” rings and locking device
8.11 Dynamic balancing
8.12 Cleanliness
9 Assembling procedure
9.1 Assembling the pump and head piece
10 Installing pump, head piece and motor stool
11 Installing the drive motor
12 Final assembling and connection
13 Parts identification
CHAPTER – 3

MAINTENANCE INSTRUCTIONS

1 INTRODUCTION

It is recommended that a system of routine inspection and maintenance is


established during which the condition of the various components in the pump set
can be determined and recorded for comparison with later inspections. Any
defects should be repaired or the components renewed at the earliest opportunity.

Certain inspections can only be made when the plant is shut down, but
others can be made under operating conditions.

It is essential that all lifting tackle and equipment is maintained in a


serviceable condition and that safety rules and regulations are observed at all
times.

A high degree of cleanliness of the equipment and surrounding area


should be maintained as this will assist in the detection of minor leaks and defects
which, if unnoticed, could lead to more serious defects.

1.1 Periodic and Preventive Maintenance

The following are the primary criteria for examination and renewal of wearing parts
and it is recommended that these aspects are checked regularly during every shift.

(1) Reduction in pump performance, ie., reduction in discharge pressure or a


sustained increase in motor power consumption.

(2) Excessive vibration.

(3) Excessive leakage at the pump mechanical seal plate.


1.2 Routine Checks

It is essential that the pump running check given in Chapter 2, Section 4,


are carried out regularly. The checks concerned with the mechanical condition of
the pump set are repeated here for the convenience of the maintenance
engineers.

(1) Check that the pump discharge pressure is normal.

(2) Check that the motor current is normal.

(3) Check the oil level in the thrust bearing gauge glass.

(4) Check the stuffing box for excessive leakage.

(5) Check the accessible joints for leaks.

(6) Check the accessible fastenings for security.

(7) Check for any undue noise or vibration.

2 TOOLS

The following tools and equipment are available for use on the pumps.
When not in use they should be safety stored. Any defects or shortages should be
remedied at the earliest opportunity, otherwise maintenance and overhaul may be
hindered.

No. off Tool and Purpose


1 “C” spanner for impeller nuts and muff coupling nuts.
1 set Withdrawal and fitting gear, thrust bearing.
1 set Withdrawal and fitting gear first stage.

3 RECOMMENDED LUBRICANTS
Refer to the thrust bearing manufacturer’s instructions in Chapter 5 for the
recommended lubricant.

4 WEIGHTS

Item Weight, kg
Pump (less motor, canister and foundation ring) 5080
Rotating assembly 547
Canister 1920
Foundation ring 145
Head piece 1032
Shaft, bottom 109
Impeller, 1st stage 50
Impeller, 2nd to last stage 31
Ring main, top. 7 stage 93
Ring main bottom 145
Suction bell mouth 64
Casing, 1st stage 640
Casing, intermediate 2nd stage 235
Casing, last stage 191
Shaft, top / intermediate 171
Motor stool 417

5 MAINTENANCE PROCEDURES
5.1 Examining the combined thrust and journal bearing

Note : The following instructions should be read in conjunction with the thrust
bearing manufacturer’s instructions contained in Chapter-4.

(1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been
carried out.

(2) Remove the access covers from the motor stool and headpiece.

(3) Remove the nuts and bolts and remove the spacer and membranes from
the pump and motor half couplings.

Note : The flanges of the spacer and half couplings should be marked in relation
to each other for ease of assembling.

(4) Remove the drain plug from the base plate and drain the oil from the thrust
bearing.

(5) Remove the oil gauge glass and pipe extension to avoid any damage.

(6) Disconnect and remove the combined oil filler and vent pipe to avoid any
damage.

(7) Remove the bearing inlet and outlet cooling water pipe work.

(8) Remove the bearing cover securing screws and remove the halves of the
cover, with the cooler attached.

Note : Tapped holes are provided in the cover for lifting purposes.

(9) Unlock the lock-washers and remove the anti-vortex shroud securing
screws. Raise the shrouds to gain access to the journal pads.

(10) Remove the journal pads from the casing, by inserting a suitable screwed
rod into the tapped hole provided on each journal pad. Carefully slide each
pad around and out from the casing.

(11) Examine the journal bearings. Refer to the bearing manufacturer’s


instructions contained in Chapter-4.

(12) Apply a film of oil to each journal and install the pads into location in the
casing and around the shaft. Remove the temporary screwed rod from
each journal pad.
(13) Locate a temporary face plate on the pump shaft end and a similar
temporary face plate on the motor shaft end. Secure each face plate to its
respective shaft end with a center bolt.

(14) Locate temporary bolts and nuts between the motor and pump half
couplings.

Note : Do not tighten the temporary nuts and bolts between the half
couplings at this stage.

(15) Remove the nuts securing the bearing casing and base plate to the
adapter plate.

(16) Remove the access guards from the head piece.

(17) Disconnect the inlet and outlet mechanical seal sealing water pipe work.
This will avoid any unnecessary strain and protect the seal, during any
movement of the shaft, whilst examining the thrust pads.

(18) Remove the screws on the seal plate and slacken the grub screws which
lock the seal retaining collar and seal sleeve to the pump shaft.

Note : Check that the seal plate is free within its normal location.

(19) Insert starting screws into the tapped holes provided in the thrust bearing
casing and carefully break the seal between the casing and base plate.

(20) Tighten the nuts on the temporary bolts between the half couplings, and
raise the shaft assembly by 8 mm, to ensure that the thrust collar is clear
of the thrust pads.

(21) Lift the thrust casing from the base plate to gain access to the thrust pads.
Support the thrust casing on temporary supports placed between the base
plate and casing. Remove the starting screws from the casing.

CAUTION : Avoid any damage to the “O” ring provided in the base plate.

(22) With sufficient access available to the thrust pads, remove each pad from
the groove formed in the base plate.
(23) Examine the thrust pads. Refer to the bearing manufacturer’s instructions
contained in Chapter-4.

(24) Apply a film of oil to each thrust pad and install the pads into the place in
the groove formed in the bas plate.

Note : Ensure that the thrust pads are correctly fitted and prevented from
rotating by means of the thrust pad stop.

(25) Lift the thrust casing, remove the temporary supports and lower the casing
onto the base plate.

(26) Unscrew the nuts on the temporary bolts, between the half couplings and
carefully lower the shaft assembly to return to its original position. The
thrust collar will rest on the thrust pads.

(27) Locate and secure the seal plate with the screw to the stuffing box.

(28) Secure the thrust casing to the base plate with the nuts on the studs.

(29) Locate the anti-vortex should into the thrust casing and secure it with the
screws the new lock-washers to the casing. Lock the screws with their
lock-washers.

(30) Fit a new cover joint to the casing and locate and secure the cover halves,
with attached cooler, to the casing with screws.

(31) Install and connect the pipe extension and oil gauge glass to the casing
assembly.

(32) Fit the drain plug to the thrust bearing base plate

(33) Connect and secure the combined oil filler and vent pipe to the casing.

(34) Remove the combined air vent/oil filler and fill the bearing to the correct
level with the recommended lubricant. Replace the combined air vent/oil
filler.

(35) Connect and secure the bearing inlet and outlet cooling water pipe work.

(36) Remove the temporary nuts and bolts from the coupling halves and
remove each temporary face plate from the pump and motor shaft ends.
(37) Check the coupling alignment. Refer to the information contained in
illustration P2424.

(38) Ensure that the seal assembly is secured with its screws to the stuffing
box. Refer to the instructions indicated on the seal drawing.

Note : The mechanical seal must be removed during the dismantling in Section
and renewed during the assembling in Section 9.

(39) Secure the inlet and outlet sealing water pipe work to the mechanical seal
plate.

(40) Secure the access guards to the headpiece.

(41) Install and secure the coupling spacer and membranes to the respective
pump and motor half couplings, with the nuts and bolts. Refer to the
coupling manufacturer’s instructions in Chapter-4.

(42) Secure the access guards to the motor stool.

(43) Prepare the pump for start-up. Refer to Chapter-2, Operating Instructions,
Section-2, Pre-Start Checks.

6 REMOVING THE DRIVING MOTOR

Note : The following instructions should be read in conjunction with the motor
manufacturer’s instructions.

(1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been
carried out.

(2) Isolate and remove the electrical supply cables from the driving motor.
Refer to the motor manufacturer’s instructions.

(3) Remove the access covers from the motor stool.

(4) Remove the nuts and bolts and remove the spacer and membranes from
the pump and motor half couplings. Refer to the coupling manufacturer’s
instructions in Chapter-4.

Note : The flanges of the spacer and half couplings should be marked in
relation to each other for ease of assembling.
(5) Attach suitable lifting gear to the lifting lugs provided on the motor.
Unscrew and remove the screws securing the motor to the motor stool,
and carefully lift the motor from the motor stool with its half coupling
attached.

(6) Lower the motor onto suitable supports and remove the lifting gear.

7. DISMANTLING PROCEDURES

7.1 Preparation Prior to Removing the Motor Stool, Headpiece and Pump

(1) Ensure that the procedures for removing the driving motor in Section 6
have been carried out.

(2) Withdraw the half coupling from the pump top shaft with the withdrawal
gear provided. Remove the half coupling key from the shaft and retain it.
Refer to the coupling manufacturer’s instructions in Chapter-4.

(3) Remove the oil drain plug from the thrust bearing and drain the oil into a
suitable container. When the oil has drained replace the drain plug. Refer
to the thrust bearing manufacturer’s instructions in Chapter-4.

(4) Disconnect and remove the thrust bearing cooling water inlet and outlet
pipe work. Remove the combined air vent/oil filler pipe work, oil level
gauge associated pipe work and oil drain pipe work.

7.2 Remove the Motor Stool, Headpiece and Pump

Note : Ensure that the preparation procedures have been carried out in
Section 7.1.

(1) Attach suitable lifting gear to the motor stool, then remove the motor stool
securing screws and carefully remove the motor stool from the head piece.

(2) Remove the access covers from the headpiece.

(3) Disconnect and remove the inlet and outlet sealing water pipe work from
the stuffing box.

(4) Disconnect the seal assembly . Refer to the instructions given on the seal
drawing.
(5) Remove the thrust collar lock-nut from the shaft with the spanner provided.

Note : As the lock-nut is unscrewed, the rotating assembly will gradually drop
to its lowest position, with each impeller resting in its casing.

(6) Remove the bearing cover securing screws and lift and remove the cover,
with the cooler attached, to gain access to the internals of the thrust
bearing. Remove and discard the cover joint.

Note : Tapped holes are provided in the cover for lifting purposes.

(7) Unlock the lock-washers and remove the anti-vortex shroud securing
screws. Remove the shroud to gain access to the journal pads.

(8) Remove the journal pads from the casing, by inserting a suitable screwed
rod into the tapped hole provided on each pad. Carefully slide each pad
around and out from the casing.

(9) Attach suitable lifting gear to the thrust collar and with the withdrawal gear
supplied withdraw the thrust collar from the shaft. Remove and retain the
collar key. Lower the thrust collar onto supports and remove the lifting
gear.

Note : During removal of the thrust collar, ensure that the corresponding
bearing faces are not damaged.

(10) Remove the nuts from the studs securing the casing and base plate to the
adaptor plate. Attach suitable lifting gear to the casing and remove the
casing clear from the base plate and shaft.

(11) Lower the casing onto suitable supports and remove the lifting gear.

(12) Remove the thrust pads from the groove formed in the base plate.

(13) Refer to the bearing manufacturer’s instructions in Chapter-4. Insert


jacking screws into the tapped holes provided on the base plate. Screw in
the jacking screws to separate the base plate from the adaptor plate. Lift
the base plate away with the sleeve attached.
(14) Remove the screw securing the sleeve to the base plate. Remove the
sleeve and remove and discard the joint. Remove and discard the “O” ring
from the base plate.

(15) Remove the seal assembly from the stuffing box. Refer to the mechanical
seal manufacturer's instructions on the seal drawing.

(16) Remove the seal nut from the shaft and remove the seal plate from the
stuffing box.

(17) Remove the stuffing box securing screws and screw in jacking screws into
the tapped holed provided. Attach suitable lifting gear and remove the
stuffing box from the headpiece and shaft. Lower the stuffing box onto
suitable supports and remove the lifting gear. Unlock-washers then
remove the screws from the underside of the stuffing box and remove the
restriction bush.

(18) Remove the nuts and bolts securing the discharge branch to the discharge
pipe work.

(19) Attach suitable lifting gear to the lugs provided on the head piece.

(20) Remove the screws securing the headpiece to the canister. With the lifting
gear attached, carefully raise the headpiece and pump assembly from the
canister. Remove and discard the joint. Cover the canister opening with a
suitable temporary cover.

(21) Transport the headpiece and pump assembly to a suitable maintenance


area. Carefully lower and support the headpiece and pump assembly in
the horizontal position.

CAUTION : The pump must not pivot on the first stage casing.

7.3 Dismantling the Head piece and pump:

CAUTION : (a) The head piece, pump casing and rising mains must be
supported on the horizontal position.
(b) The pump top shaft must be suitably supported in the
horizontal position.

(c) Before dismantling the assembly, mark the headpiece, pump


casings, rising mains and bell mouth to ensure correct
assembly.

(1) Before proceeding any further check the total axial travel as follows:-

(a) Push the pump shaft until it abuts at the suction end. Lay a straight
edge across the face of the head piece, at the stuffing box adjoining
face, and with a pencil scribe a line on the top shaft.

(b) Pull the pump shaft until it abuts at the discharge end.

(c) Lay the straight edge across the face of the head piece and scribe a
second line on the top shaft.

(d) Measure the distance between the two scribe lines which indicate
the total axial travel of the rotating assembly.

Note : The correct total axial travel should measure 8 to10 mm.

CAUTION : The pump to shaft and casings must be supported.

(2) Attach suitable lifting gear to the suction bell mouth, unlock the tab
washers and remove the screws securing the bell mouth to the first stage
pump casing, then lift the bell mouth clear off the pump shaft. Discard the
tab-washers and the “O” ring. Lower the bell mouth on suitable supports
and remove the lifting gear.

Note : The bell mouth incorporates a casing wear ring and Cutless rubber
bearing.

(3) Release the lock-washer securing the shaft nut and using the special
spanner supplied, remove the nut from the shaft. Discard the lock-washer.

(4) Remove the first stage bottom sleeve from the shaft.

(5) Attach lifting gear to the first stage impeller and withdraw the impeller from
the pump shaft using the withdrawal gear supplied. Remove and retain the
impeller key. Lower the impeller onto suitable supports and remove the
lifting gear.

(6) Attach lifting gear to the first stage pump casing, unlock the tab-washers
and remove the screws securing the first stage casing to the Element-I.
Insert starting screws into the tapped holes provided in the first stage
casing and tighten them to assist with removal of the casing. Move the
first stage casing along and clear from the shaft. Remove and discard the
“O” ring, and Lower the casing onto suitable supports. Remove the lifting
gear.

Note : The first stage casing incorporates a casing wear ring and a Cutless
rubber bearing.

(7) Remove the grub screws and remove the shaft tube from the first stage
casing. Discard the “O” ring.

(8) Remove the first stage top sleeve from the shaft.

Note : Support the shaft.

9) Attach lifting gear to Element-I, unlock the tab washers and remove the
screws securing the Element-I to Element-II. Insert starting screws into the
tapped holes provided in Element-I and tighten them to assist removal of
the Element. Move the Element-I along and clear from the shaft. Remove
and discard the 'O' ring and lower the casing onto suitable supports.
Remove the lifting gear.

Note : The Element -I incorporates a cutless rubber bearing.

10) Remove the grub screws and remove the shaft sleeve of Element-I.
Remove and retain the sleeve key.

11) Repeat step (9) to remove Element-II.

12) Attach separate lifting gear to the bottom shaft. Remove the lock washer
and slacken back the lock nut securing the bottom shaft to the muff
coupling. Screw the coupling nut clear off the coupling, and withdraw the
bottom shaft from the coupling and lift it away. Remove and retain the
coupling key and shear ring halves.
Note : Support the intermediate shaft prior to withdrawal of bottom shaft.

13) Repeat step (12) to withdraw the muff coupling from intermediate shaft.

14) Repeat step (9) and (10) t remove Element-III.

Note : Support the intermediate shaft. Element-III incorporates a cutless rubber


bearing.

15) Release the lock washer securing the second stage impeller nut, then
using the special spanner provided, remove the nut.

16) Pull the shaft sleeves from the bottom of second stage impeller, remove
and retain the sleeve keys.

Note : Support the shaft.

17) Using the withdrawal gear supplied, withdraw the second stage impeller
from the shaft, remove and retain the impeller key.

18) Attach lifting gear to the second stage pump casing, unlock the tab
washers and remove the screws securing the second stage casing to the
third stage casing, then remove the second stage casing from the shaft.
Discard the tab-washers and the “O” ring.

Note : The second stage casing incorporates a casing wear ring and a Cutless
rubber bearing.

19) Pull the intermediate sleeve from the shaft.

20) Repeat Steps (17 to 19) to remove the third stage impeller and pump
casing.

21) Attach lifting gear to the bottom rising main, unlock the tab-washers and
remove the screws securing the rising main to the fourth stage pump
casing. Lift the rising main clear off the shaft. Discard the tab-washers and
the “O” ring.

22) Attach separate lifting gear to the intermediate shaft. Release the lock-
washer and slacken back the lock-nut securing the bottom shaft to the muff
coupling. Screw the coupling nut clear of the coupling, and withdraw the
intermediate shaft from the coupling and lift it away. Remove and retain the
coupling key and the shear ring halves.

23) Repeat step (22) to withdraw the muff coupling from the top shaft.

24) Repeat steps (17) to (19) to remove the fifth and sixth stage impellers and
pump casings.

Note : Continue to support the shaft.

25) Attach a suitable lifting sling to the top shaft and remove it from the head
piece. Lower the shaft onto suitable supports and remove the lifting sling.

Note : The head piece should remain supported in the horizontal position.

8. INSPECTION AND RENEWAL

8.1 Clearances

(1) Refer to the sectional arrangement for details of clearances. It is


recommended that when the pump internal diametrical clearances have
reached twice the mean of the figures quoted or are expected to before
the next overhaul, the component or components should be renewed. The
main considerations, however, are pump performance and motor power
consumption.

(2) Casing wear rings and impeller wear rings are normally supplied undersize
and oversize respectively on the wearing surfaces, so that they can be
machined to give the appropriate clearance.

Note : (a) The impeller wear rings are pressed on to the impellers and retained
by grub screws, and the casing wear rings are pressed into their
respective casings and also retained by grub screws.

(b) if the impeller or casing wear rings require to be renewed the wear
rings must be machined from the casing or impeller, and new wear
rings pressed on and secured by grub screws.

(4) A shaft sleeve fitted to the top shaft, in way of the mechanical seal, is held
by loctite. If the sleeve has to be renewed it must be machined from the
shaft and a new sleeve fitted and secured by loctite.
8.2 Impeller

(1) Examine the shaft sleeves for wear and damage. Renew as necessary.

(2) Ensure that the impeller wear rings are correctly fitted and secured.

8.3 Shaft Sleeves and Bearings

(1) Examine the shaft sleeves for wear and damage. Renew as necessary.

(2) Examine the journal bearings from wear and damage. Renew as
necessary. Refer to Section 8.1 Step (4).

8.4 Pump Shafts

Examine the shafts for damage or bowing and check for concentricity. Each shaft
must be within 0.05 mm full indicator movement.

8.5 Combined Thrust and Journal Bearing

Refer to the manufacturer’s instructions in Chapter 4.

8.6 Mechanical Seal

(1) Renew the mechanical seal. Refer to the seal manufacturer’s instructions
in Chapter-4.

(2) Check that the water passageways formed on the seal plate are clear.

(3) Examine the stuffing box restriction bush. Renew as necessary.

8.7 Flexible Coupling

Refer to the manufacturer’s instructions in Chapter-4.

8.8 Keys

All keys must be a good fit in their keyways and reference marks must be
clearly legible. They must be flat, parallel and free from burrs. Worn or damaged
keys must be renewed.

8.9 Nuts, Bolts and Studs


Examine all studs, nuts and bolts for damage or deterioration. Renew as
necessary.

8.10 Joints, “O” Rings and Locking Devices

All joints “O” rings and locking devices must be renewed on assembly.

8.11 Dynamic Balance

If any of the impellers or the coupling hub are renewed, it should be noted
that the new components are dynamically balanced during manufacture. If,
however, the dynamic balance of any components is checked and is found to be
out with the limit of 2835 M/N g cm per plane of measurement, the following rules
must be adhered to when removing metal to effect the balance.

Note M = weight of the component (kg)

N = pump speed (rev/min)

CAUTION : (1) The thickness of the impeller shroud must not be reduced by
more than 1.6 mm at any point.

(2) No meal is to be removed from the impeller within 12.7 mm of


its periphery.

(3) The weight of metal to be removed is to be calculated in the


from of segment, the arc length of which does not exceed 0.1
of the circumstance of the impeller.

(4) If the amount of metal to be removed exceeds the limits


imposed by (1) and (3), BHEL, Hyderabad, should be
consulted.

8.12 Cleanliness

All components must be perfectly clean and free from burrs, and all water
passages must be cleaned out before the pump is assembled. Check that all small
bore pipe work is clear.

9 ASSEMBLING PROCEDURES

9.1 Assembling the Pump and Head piece


During assembly, it is recommended that colloidal graphite or similar is
applied to the shaft and bores of the impeller and shaft sleeves, allowed to dry and
then polished.

CAUTION : The pump shaft and casings must be suitably supported in the
horizontal position whilst assembling the pump.

Note : (a) The following torque figures must be used when assembling the
pump:-

Sixth stage casing to head piece. 700 Nm

First to third and fourth to last stage castings, inclusive 1350 Nm

Bottom rising main to third and fourth stage casing 140 Nm

Bell mouth to first stage casing 50 Nm

Head piece to canister 290 Nm

Motor stool to head piece 220 Nm

(b) Observe the match marks made prior to dismantling to ensure


correct assembly.

(1) Ensure that the head piece is supported in the horizontal position.

(2) Install the last stage shaft sleeve on the top shaft, to abut the sleeve fitted
on the shaft by loctite.

(3) Attach lifting gear to the top shaft, and carefully install the shaft in the head
piece. Support the shaft and remove the lifting gear.

Note : When installing the sixth stage casing, adjust the top shaft supports to
the ensure that the shaft is supported at all times.

(4) Locate a new “O” ring on the spigot of the last stage pump casing, attach
lifting gear and install the casing on the top rising main. Secure the pump
casing to the rising main with the screws and new tab-washers.

Note : (a) Observe the note following Step (4).


(b) When installing the pump casing, ensure that the Cutless
rubber journal bearing does not become damaged.

(c) Do not bend over the lock-washer tabs meantime.

(6) Install the sixth stage impeller key in the shaft, then install the impeller on
the shaft, to locate on the key and abut the last stage shaft sleeve.

(7) Repeat Steps (5) and (6) to install the fifth and fourth stage pump casing
and impellers.

(8) Screw the impeller nut onto the shaft and, using the special spanner
provided, tighten the nut against the hub of the fifth stage impeller.

(9) Before proceeding further, check the total axial travel as follows :-

(a) Push the pump shaft until it abuts at the suction end. Lay a straight
edge across the face of the head piece, at the stuffing box adjoining
face, and with a pencil scribe a line on the top shaft.

(b) Pull the pump shaft until it abuts at the discharge end. Lay the
straight edge across the face of the head piece and scribe a second
line on the top shaft.

(c) Measure the distance between the two scribed lines which indicate
the total axial travel to the rotating assembly.

(e) The total axial travel is 8 to 10 mm, and if this is not achieved, the
cause must be established and the fault must be corrected before
proceeding.

(10) Slide the muff coupling nut, lock-nut and a new lock-washer onto the top
shaft, beyond the shear ring groove in the shaft, then install the shear ring
halves in the groove, and the coupling key in the shaft.

(11) Slide the coupling sleeve onto the shaft, to abut the shear ring, then screw
the coupling nut into the bore of the sleeve. Tighten the nut to pull the
sleeve hard against the shear ring and secure it with the lock-nut and lock-
washer.
(12) Install the muff coupling nut, lock-nut, new lock-washer, shear ring halves
and coupling key on the bottom shaft as described in Step (8). Sling the
bottom shaft and install it in the muff coupling sleeve, ensuring that the
spigot on the shaft end engages in the recess in the end of the top shaft.
Tighten and lock the coupling nut as described in Step (9). Support the
bottom shaft and remove the lifting gear.

(13) Install the bottom rising main as described in step (4), then install the third
and second stage pump casings and impellers as described in Steps (6) to
(7). Continue to support the bottom shaft and the pump casings.

(14) Install the sleeve keys on the shaft, at the bottom of the second stage
impeller. Install the sleeves to locate on the keys and abut the second
stage impeller.

(15) Repeat steps (8), (9) and (5) to assemble impeller, nut, check total float
and assemble Element-IV.

(16) Install the sleeve keys of Element-III on the shaft. Install the sleeve to
locate on the key and abut the shoulder on the shaft. Lock the sleeve on
to the shaft with grub screws provided.

(17) Repeat steps (10,11 &12) to assemble the muff coupling and bottom shaft.

(18) With the total axial travel checked, and corrected as necessary, bend over
the tabs on the tab-washers on all the pump casing screws, stages 2 to 6.

(19) Ensure that the first stage shaft tube is in place in the first stage pump
casing, with new “O” rings, then locate a new “O” ring on the spigot of the
first stage casing.

(20) Sling the first stage pump casing and carefully install it over the shaft, to
locate on the second stage casing, and secure it with the screws and new
tab-washers. Do not bend over the washer tabs meantime.

(21) Install the first stage top sleeve on the shaft, to abut the shoulder on the
shaft, and locate the first stage impeller key in the keyway in the shaft.
(22) Sling the first stage impeller and install it on the shaft, to abut the first
stage top sleeve.

Note : Ensure that the direction of rotation of the impeller is correct.

(23) Install the first stage bottom sleeve on the shaft and secure the assembly
with the shaft nut and new lock-washer.

(24) Install the bell mouth on the first stage casing, with a new “O” ring, and
secure it with the screws and new tab-washers.

(25) Check the total axial travel as described in Step (9) then bend over the
tabs on the lock-washers.

10 INSTALLING PUMP, HEAD PIECE AND MOTOR STOOL

(1) Attach suitable lifting gear to the lugs on the head piece. Carefully lift the
head piece and pump from the horizontal to the vertical position and use
adequate supports as necessary.

CAUTION : Care must be exercised to ensure that the pump does not pivot
on the first stage casing or attached bell mouth. Ensure that the
pump is supported thus avoiding the possibility of bowing.

(2) Remove the temporary cover from the canister.

(3) Lower the pump and head piece into the canister and ensure that the
pump discharge pipe is in line with the corresponding discharge pipe work.
Continue to lower the assembly until the head piece rests on the canister.
Ensure that the suction bell mouth is engaged on the snubber within the
canister and that the holes in the head piece correspond with the holes in
the canister.

(4) Secure the headpiece to the canister with the screws and remove the
lifting gear from the head piece.
(5) Secure the pump discharge pipe work to the pump discharge branch.

(6) Secure the restriction bush with screws and lock-washers to the underside
of the stuffing box or seal housing.

(7) Locate the seal sleeve key in the key way in the shaft, and secure it with
the countersunk screw.

(8) Install the mechanical seal. Refer seal manufacturer's instructions on the
seal drawing.

Note : The mechanical seal is of cartridge design.

CAUTION : Do not tighten the seal plate securing screws at this stage.

(a) Screw the seal sleeve nut and the lock-nut/thrower onto the shaft and
leave loose meantime.

(9) Locate and secure the adaptor plate with screw to the top of the head
piece.

Note : During manufacture of the pump set, the adapter plate is machined to
a specific thickness and locates between the thrust bearing base plate
and headpiece. The adaptor plate determines the position of the
rotating assembly when the thrust bearing is assembled.

(10) Fit a new joint to the sleeve and insert the sleeve into the thrust bearing
base plate. Secure the sleeve to the base plate with the screws and fit a
new “O” ring to the base plate. Refer to the bearing manufacturer’s
instructions.

(11) Lift the bearing base plate onto the adaptor plate studs.

Note : Ensure that the drain hole on the base plate is positioned to
accommodate the drain pipe work. When the motor stool is assembled.
(12) Apply a film of oil to the thrust pads and insert the thrust pads onto the
base plate and move the pads around the groove to abut the pad stop.
Refer to the bearing manufacturer’s instructions.

(13) Lift the bearing casing onto the base plate.

(14) Secure the bearing casing and base plate to the adaptor plate with nuts on
the adaptor plate studs.

Note : Ensure that the casing is located to accommodate the corresponding oil
level gauge pipe work.

(15) Fit the collar key to the shaft and attach suitable lifting gear to the thrust
collar. Engage the collar onto the shaft and with the use of the assembly
gear fit the collar to the shaft. Remove the assembly gear.

(16) Screw the thrust collar nut onto the haft, to abut the thrust collar, then
using the special spanner provided, tighten the nut to raise the pump shaft
into its corrected running position.

(17) Apply a film of oil to the journal pads and locate the journal pads, between
the casing and collar. Locate the journal pads by inserting a screwed rod
into the tapped hole provided in each pad. Remove the screwed rod.

(18) Locate and secure the anti-vortex shroud with lock-washers and screws to
the casing. Tighten the screws and secure the screws with the lock-
washers.

(19) Fit a new cover joint to the casing. Install the cover with attached cooler.
Secure the cover to the casing with screws. Refer to the bearing
manufacturer’s instructions.

Note : (a) Tapped holes are provided in the cover for lifting purposes.
(b) Ensure that the cover is located in the casing to accommodate the
corresponding cooling water small bore pipe work.

(20) Fit the half coupling to the shaft. Attach suitable lifting gear to the half
coupling and lift the half coupling on the shaft to abut the thrust collar nut,
using the assembly gear supplied. Remove the assembly gear from the
half coupling.

(21) Tighten the seal plate securing screws. Tighten the grub screws in the seal
sleeve until they contact the shaft. Disengage the eccentric washers /
assembly fixture from the seal sleeve.

Mechanical seal is of cartridge design.

Refer to the seal manufacturer's drawings / instructions.

(22) Secure the inlet and outlet sealing water pipe work to the stuffing box.

(23) Attach suitable lifting gear to the motor stool and lift the motor stool onto
the spigot flange provided on the headpiece.

Note : Ensure that the motor stool is positioned on the headpiece to


accommodate cooling water, oil level, oil filling pipe work and oil drain
pipe work associated with the thrust and journal bearing.

(24) Secure the motor stool with the screws and remove the lifting gear from
the motor stool.

(25) Connect and secure the thrust bearing cooling water inlet and outlet pipe
work, oil filter and air vent pipe work, oil level pipe work and gauge. Fit the
oil drain pipe work to the thrust bearing and fit the drain plug.

(26) Fill the thrust bearing to the correct level with the recommended lubricant.
Refer to the thrust bearing manufacturer’s instructions.
11. INSTALLING THE DRIVING MOTOR

Note : The following instructions should be read in conjunction with the motor
manufacturer’s instructions.

(1) Ensure that the motor half coupling is fitted. Refer to the coupling
manufacturer’s drawings / instructions.

(2) Attach suitable lifting gear to the lifting hooks provided on the motor. Lift
the motor onto the motor stool.

Note : Ensure that the motor is positioned on the stool to accommodate the
associated supply cables and cooling water pipe work, etc.

(3) Secure the motor to the stool with the nuts and bolts, and remove the
lifting gear.

(4) Check the alignment between the pump and motor half couplings. Refer to
illustration for Checking coupling alignment.

(5) With the coupling alignment checked and satisfactory, assemble the
coupling spacer and membranes.

Note : The flanges of the spacer and half couplings were previously marked
in relation to each other for assembly purposes. Ensure that the marks
on the flanges coincide.

(6) Secure the half couplings, spacer and membranes with the nuts and bolts.
Refer to the coupling manufacturer’s drawings / instructions.

(7) Secure the access covers to the motor stool.

12 FINAL ASSEMBLING AND CONNECTION


(1) Connect and secure the air vent pipe to the pump.

(2) Ensure that the cooling water is available to the thrust bearing.

(3) Ensure that the sealing water is available to the stuffing box.

(4) Connect and secure the electrical power supply cables to the driving
motor. Refer to the motor manufacturer’s instructions.

(5) Return all tools and lifting gear to their storage area. Refer to Chapter 2
and carry out the Pre-start checks.

13. PARTS IDENTIFICATION

When ordering spare parts reference must be made to the pump Serial or
Job Number, Nomenclature, the Sectional Arrangement Drawing, the Item
Number, and the Quantity of each components.
SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB-VENDOR’S DRAWINGS / INSTRUCTIONS

1 Mechanical Seal

2 Connecting coupling

3 Thrust & Journal Bearing

4 Suction Strainer
SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

1. MECHANICAL SEAL
OPERATING MANUAL
NO.
OPERATING MANUAL
FOR
BURGMANN
MECHANICAL SEAL (M.S.)
10
9
8
7
6
5
4
3
2

11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- TABLE OF CONTENTS PAGE

0 Foreword 1
1 General Information 2

2 Product Information 3-5


2.1 Manufacturer and country of origin 3
2.2 Declaration 3
10

2.3 Type Designation 3


2.4 Operating Conditions 3
2.5 Designated Use 4
9

2.6 Description and Function 4


2.7 Required Space, connecting dimensions 4
8

2.8 Drawings, Diagrams 4


7

3 Safety Notes 6
4. Transport, Storage and Installation 5- 9
4.1 Packing and Storage 6
6

4.2 Preparation for Assembly 6-7


4.3 Special Instructions 8
5

4.4 Installation 9
4.5 Directives in case of Failure 9
4

5. Servicing 10 - 13
5.1 Tungsten Carbide Designs 10
5.2 Circulation 10
3

5.3 Buffer Fluid 10


5.4 After Sales Service by BURGMANN 10-12
2

5.5 Disposal of Burgmann Mechanical Seal 12


6. Copyright 13
11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- FOREWORD

Section

0 Dear Sir,

Page 1 of 13 Thank you for purchasing the Burgmann Mechanical Seal (M.S.).
We at Burgmann are confident that your new purchase will greatly
expand your working capacity and efficiency.
This Operating Manual shows you how to get the most out of your new
10

Burgmann Mechanical Seal (M.S.). Whether you are installing,


operating or servicing, this manual will show you how to do it - quickly
and easily.
9

Please take some time to go through this manual before installation. You
don't have to read it all at once. We just want you to know what a great
Mechanical Seal (M.S.). you have.
8

We've taken a great deal of care in preparing this manual so that you will
never be left wondering how to perform a certain function. Nevertheless,
even after reading this manual if you still aren't sure about something,
7

please feel free to contact your nearest sales or service center of


Burgmann or our HQ. We shall be too glad to answer your queries.
6
5

BURGMANN
4
3
2

11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

1. GENERAL INFORMATION
Section

SR. DESCRIPTION DETAILS


Page 2 of 13 NO.
I Customer Bharat Heavy Electricals Ltd
II Machine Manufacturer B.H.E.L
III Customer PO No. F6 04 D989
10

IV Drawing Nos. 09-H75N/100-E3


V Burgmann W.O. 14910
9
8
7
6
5
4
3
2

11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- 2. PRODUCT INFORMATION

Section

2 2.1 MANUFACTURER AND COUNTRY OF ORIGIN

Page 3 of 13 BURGMANN INDIA PVT. LTD.


A. K. Industrial Estate, Veer Savarkar Flyover,
Goregaon (West),
Mumbai-400 062.
10

INDIA.

2.2 DECLARATION
9

within the meaning of the EC-directive >> MACHINERY <<


A mechanical seal does not function independently. It is intended
8

to be incorporated into or assembled with machinery.


7

2.3 TYPE DESIGNATION


6

MECHANICAL SEAL DRG. NO. : 09-H75N/100-E3

The materials of the mechanical seal depend on the application and


are fixed in the order. They may vary from those stated in the
5

drawing.
4

2.4 OPERATING CONDITIONS


3

MECHANICAL SEAL DRG. NO. : 09-H75N/100-E3


Kind of Machine : --
Medium to be sealed :-
2

Suction Pr. : FULL VACUUM


Discharge Pr. : 3 Kg/cm2
Temperature Max. : 200O C
11/06/05

Speed : 1000 RPM


0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- 2.5 DESIGNATED USE

Section This mechanical seal is exclusively designed for the use in the
specified machine. A different utilisation or a utilisation going
2 beyond the specification is considered contrary to its designated
use and excludes a liability by the manufacturer.

Page 4 of 13 Operation under conditions lying outside those limits stated in


paragraph >> operating data << is considered contrary to its
designated use.
10

Should the seal be operated under different conditions or at a


different application BURGMANN has to be asked for recognition as
safe in advance.
9

2.6 DESCRIPTION AND FUNCTION


8

The BURGMANN Mechanical Seal mentioned in clause 2.3 & 2.4


has been supplied in cartridge construction, in this, the seal can be
7

installed directly on the pump casing without any adjustment. The


seal forms a pre-mounted unit (seal cartridge), asembled at works,
ready to be installed without any adjustment.
6

Assembly Fixtures (24) are provided for holding the cartridge in one
piece during transport, storage, assembly and disassembly.
5

2.7 REQUIRED SPACE, CONNECTING DIMENSIONS


4

The connecting dimensions of the Mechanical Seal were checked


and approved by the customer on the main drawing.
3

The available mounting space given by the machine was decisive


for the design of the gland parts of Mechanical Seal. The
connecting dimension was checked before shipment with regard to
2

the BURGMANN drawing.

2.8 DRAWINGS, DIAGRAMS


Assembly drawing Nos. 09-H75N/100-E3
11/06/05
0

The assembly drawing in the original scale and in its latest edition
SG
PP

(latest revision) only is decisive for the design and use.


Approved

In the following description all figures in parentheses, e.g.(2) define


Revision

Revised

the respective part item no. in the assembly drawing.


Date
OPERATING MANUAL
NO.

- 3. SAFETY NOTES

Section

3 Any person at the user's shop being involved in assembly,


disassembly, operation and maintenance of the BURGMANN
Mechanical Seal must have read and understood this
Page 5 of 13 Instruction Manual and in particular the safety notes. We
recommend the user to have this confirmed.
10

BURGMANN Mechanical Seals are manufactured on a high


quality level (ISO 9001) and they keep a high working reliability.
Yet, if they are not operated within their intended purpose or
handled inexpertly by untrained personnel they may cause risks.
9

The user is asked to check as part of his security program what


8

effects a failure of the Mechanical Seal might have on the


environment and what additional safety measures have to be
taken to prevent personal injury.
7

Any operation mode that affects the operational safety of the


6

mechanical seal is not permitted.


5
4
3
2

11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.
4. TRANSPORT / STORAGE / INSTALLATION
-
4.1 PACKING AND STORAGE
Section
If not specified differently in the order the BURGMANN standard
4 packaging is used, suited for dry transport by truck, train or plane.
The signs and notes for handling on the packaging have to be
observed.
Page 6 of 13 Notes for incoming inspection
- Check packaging for visible damages.
- Open packaging carefully. do not damage or lose parts -
supplied separately
10

- Check if consignment is complete (delivery note). Inform the


supplier immediately in writing if parts are damaged or
missing.
9

These recommendations apply to all BURGMANN mechanical seals


which have been supplied and stored in their undamaged original
packaging, as well as to seals which have been installed in a
component of a plant. (e.g. pump, compressor, etc.) but have not
8

yet been put into operation.


A preservation of the BURGMANN mechanical seals is not
7

necessary.
- Do not use corrosion protection agents.
- There is the risk of deposition or chemical attack of the
6

elastomeric secondary seals.

Check in case of a preservation of complete plants with


5

mechanical seals installed:


- the compatibility of the chosen preservation agent with the
seal materials and with the elastomers
- no impairment of the seal's axial movability by
4

conglutination or by gumming

Sliding materials and elastomers are subject to material-specific


3

and time-based alterations (distortion, ageing) which might reduce


the full efficiency of the seals. yet, this may be avoided by
observing the storage instructions.
2

Damages caused by improper storage may not be claimed on


the BURGMANN company with regard to their warranty.

Store the seal in the original packing lying on a flat surface.


11/06/05

The mechanical seals have to be stored in dry, dustfree, moderately


0

SG

ventilated and tempered rooms. We recommend : relative air


PP

humidity below 65%, temperature between 15oC and 25oC.


Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- 4.1 PACKING AND STORAGE ( cont....)

Section Direct exposure of the mechanical seal to heat (sun, heating) as


well as to ozone, present or produced by ultraviolet light
4 (halogen or fluorescent lamps), must be avoided because of the
risk of embrittlement of elastomeric materials.
Page 7 of 13
Check the mechanical seal:
- after a storage period of approximately 4 years
- after a damage of the packaging
- after a shock on the mechanical seal (e.g. by dropping
10

the packed seal)


- at the manufacturer's or at the nearest service centre.
9

4.2 PREPARATION FOR ASSEMBLY

General Instructions
8

Utmost care must be taken to ensure cleanliness during assembly;


it is especially important to avoid damage to the elastomers.
7

- Observe the assembly dimensions.


- Observe the axial run-out and concentricity tolerances as stated in
the valid design manual.
6
5
4
3
2

11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

Section
-
4

Page 8 of 13
- All the shoulders over which elastomers
- are to be pushed must be chamfered by 2mm x 30°. Their
surfaces must be free of any damages and their edges rounded
off.
10

- The shaft must show the following surface roughness values in the
vicinity of radial sealing elements :
(Dynamic sealing part (spring loaded unit of the seal) Ra ≤1.0µ.m.
Static seal part of Ra ≤ 2.5µ.m)
9

- For cartridge seals, the seal can be assembled directly after


taking precautions on the shaft.
- Profile rings of Statotherm® can only be deformed axially (radial
8

deformation results in destruction).


- To reduce frictional forces during assembly of the seal, the shaft
is thinly lubricated with oil or silicon grease in the zone of the seal
7

rings.

Warning : This does not apply to rubber bellows seals.


6

Warning : In the electric dip-painting range the O-rings must be


free from silicon grease and must be mounted free from silicon
grease.
Warning : Under no circumstances must O-rings made of
5

Ethylene Propylene rubber come into contact with mineral oil


or grease. It is recommended to use silicon grease.
4

- Never cover the sliding faces with a lubricant as they must be


assembled completely dry, clean and dust-free.
- When pressing in stationery seals, make sure that the pressure
3

distribution is uniform. The O-ring must be fitted using water or


alcohol only.
- For heat dissipation and lubrication of single-acting mechanical
seals, there should be a recirculation from pump discharge to
2

seal.
This measure prevents medium deposits in the sealing area.
- Thoroughly vent the stuffing box before starting and remove the
assembly fixture before start-up.
11/06/05

In the event of any particular problems, please contact Burgmann


0

India, or one of our sales/service offices in your area.


SG
PP
Approved
Revision

Revised
Date
7
OPERATING MANUAL
NO.

- 4.3 SPECIAL INSTRUCTIONS

Section The Burgmann mechanical seals H75N are independent of the


direction of rotation. The set screws with cup points must be
4 renewed after every dismounting; they must be fastened with
Loctite Nr. 241 or a similar Product.
Page 9 of 13
4.4 INSTALLATION

All steps on (in) which the seal is to be mounted should have a 2 x


30° bevel and all sharp edges should be chamfered. The shaft
10

surface should be smooth machined and ground in the areas where


radial seal elements are to be located (Rτ = 2.5µ.m.)
9

The nutation of the shaft should not exceed 100 µ.m. and although
the seal can absorb slight vibration, sources of vibration should be
eliminated. Extreme cleanliness must be observed during
installation, and damage to the seal faces and mounting rings must
8

be avoided. The O-rings may be oiled to reduce friction, during


installation of the seal. EP-rubber O-rings are an exception,
however, and should not come into contact with oil or grease;
7

In this case lubrication with glycerine or water is


recommended.
6

Special care must be taken when mounting O-rings of double-


PTFE-coated elastomers; apart from having a 2 x 30° mm bevel, all
edges should be deburred and rounded. When mounting O-rings
of double PTFE-coated elastomers care must be taken to
5

position the rings with the butt of the outer coating facing
away from the direction of installation, otherwise splitting or
stripping of the coating is possible.
4

Crowned drive pins must be replaced whenever the seal is


3

dismantled. During insertion of the stationary seats, especially


those of special carbon, care must be taken to exert pressure
evenly.
2

4.5 DIRECTIVES IN CASE OF FAILURE

Try to define the kind of failure and record it and immediately


contact Burgmann India or nearest BURGMANN Service Centre.
11/06/05

During the warranty period the mechanical seal must only be


0

disassembled or removed with BURGMANN's approval or when a


SG
PP

BURGMANN representative is present.


Approved
Revision

Revised
Date
OPERATING MANUAL
NO.
5 SERVICING
-
5.1 TUNGSTEN CARBIDE DESIGNS
Section

5 Are extremely wear resistant but have poor emergency running


properties. For this reason provisions must be made to ensure
lubrication.
Page 10of 13
5.2 CIRCULATION

To reduce frictional heat and prevent sedimentation in the seal


faces a circulation line from the discharge of the pump to the seal
10

stuffing-box necessary. Normally a ¼-inch pipe is sufficient.


9

5.3 BUFFER FLUID

When operating double mechanical seals care must be taken to


ensure circulation of the buffer fluid. The pressure of the buffer fluid
8

should be 1.5--2 bar higher than the internal pressure and the rate
of flow should be adjusted so that the outlet temperature dose not
exceed 60°C. The outlet must be located at the highest point of the
7

stuffing-box to prevent bubble formation.


6

If you have any special problems please contact BURGMANN Head


Quarters or the corresponding sales/service office in your area.
5

5.4 AFTER-SALES SERVICE BY BURGMANN

The range of services offered by Burgmann not only includes advice


4

during the planning stages but also technical support after


commissioning. This is support by a world comprehensive network of
subsidaries, field engineers and service centres.
3

MUMBAI (HEAD QUARTERS)


BURGMANN INDIA PVT. LTD.
2

A.K.INDUSTRIAL ESTATE,
VEER SAVARKAR FLYOVER,
GOREGAON(WEST)
MUMBAI-400 062.
TEL: 022-28741534
FAX: 022-28748810.
11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- SERVICE CENTRES
BANGALORE BARODA
Section 3390/41,3rd Cross,5th Main, 17-A Nutan Bharat Society,
RPC Layout,Vijayanagar, Near Nutan Bharat Club,
5 Bangalore – 560 040. Alkapuri,
Tele Fax : 080-23305137 Baroda – 390 007.
Email : bangalore@burgmannmail.com Tel. : 0265 233 9151
Page 11of 13 Fax. : 0265 233 9149
Email: baroda@burgmannmail.com
CHENNAI COCHIN
“N” Block, New No. 5,Old No.320, 34/749A, Thrikkovil Road,
10

25 Street, Anna Nagar (East), Edapally,Cochin – 682 024.


Chennai – 600 102. Kerala, India.
Telefax.: 044 2620 6968. Telefax. : 0484 2331 708
Touchtel : 52020649 Email : cochin@burgmannmail.com
9

Email : chennai@burgmannmail.com

DELHI HYDERABAD
40/55, 1st Floor, 5D, Dhruvatara Apartments,
8

Chittaranjan Park, Amruta Estate, Somajiguda,


New Delhi – 110 019. Hyderabad – 500 482.
Tel : 011 2642 2533, 011 2648 3347 Telefax : 040 2331 6577
7

Fax : 011 2648 3275 Email: hyderabad@burgmannmail.com


Email : delhi@burgmannmail.com

KOLKATA KOTA
6

903-Krishna, Ashirwad Pearl,10-F-12,


224 Acharya Jagdish Chandra Bose Flat No. S1,Parijat Scheme
Road, Mahaveer Nagar III,
Kolkata – 700 017. Kota, Rajasthan,
5

Tel. : 033 2240 9829 Kota – 324 005.


Fax : 033 2240 6480 Telefax : 0744 247 6537
Email : kolkata@burgmannmail.com Tele/Answering Machine 0744
4

3090472
Email : kota@burgmannmail.com

PUNE VISAKHAPATNAM
3

H– 198, Mantri Market, Flat No. 301, Eswar Homes,


Pune Solapur Road, 3rd Floor, 1st Lane,
Hadapsar, Dwarakanagar,
2

Pune – 411 028. Visakhapatnam – 530 016.


Telefax : 020 2682 1713 Telefax: 0891 254 0360
Email : pune@burgmannmail.com Tele : 0891 551 6503
Email : vizag@burgmannmail.com
11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.
SERVICE CENTRES
-
MUMBAI PANVEL
Section Excl Industrial Products Pvt. Ltd., Excl Industrial Products Pvt. Ltd.,
5 A.K. Industrial Estate, 1st Floor, Om – Hari Darshan Apts.,
Veer Savarkar Flyover, Plot No. 34, V. M. Road,
S.V.Road, Goregaon (W), Sector 1, Opp. CIDCO Office,
Mumbai – 400 062. New Panvel – 410 206.
Page 12of 13 Telefax: 022 2877 6896 Telefax : 022 2746 9152/3958 1948
Email : Email : excl@burgmannmail.com
exclmum@burgmannmail.com
10

PUNE SURAT
Excl Industrial Products Pvt. Ltd., Excl Industrial Products Pvt. Ltd.,
C – 2, Amar Enclave, B 1/14, Vishal Nagar,
Opp. A.S.P.T. Near Gujarat Gas Circle,
9

Wanowire, Above Vijay Dairy,


Pune – Solapur Road, Adajan Road,
Hadapsar, Surat – 395 009.
Pune – 411 013. Telefax: 0261 269 3538
8

Tel. : 020 2681 6646/4024366/2682 Email : exclsurat@ burgmannmail.com


1943
Fax. : 020 2687 7000
7

Email : info@ burgmannmail.com

5.7 DISPOSAL OF BURGMANN MECHANICAL SEAL


6

Usually, the BURGMANN mechanical seals can be easily disposed


after a thorough cleaning.
5

Metal parts (steels, stainless steels, non-ferrous heavy metals


divided into the different groups belong to scrap metal waste.
4

- Synthetic materials/ plastics ( elastomers, PTFE )special waste.


- Attention ! Material containing fluorine must not be burnt.
- Some synthetic materials divided into the different groups can
3

be recycled.
- Ceramic materials (synthetic carbons, ceramics, carbides ) belong
to waste products. They can be separated from their housing
2

materials, as they are physiologically recognised as safe.


11/06/05
0

SG
PP
Approved
Revision

Revised
Date
OPERATING MANUAL
NO.

- 6. COPYRIGHT
BURGMANN has a copy right in this manual. Buyer, planner and
Section user of the product are authorised for use in connection with further
5 documentation.

We reserve the right to carry out technical modifications which


Page 13of 13 might become necessary to improve our products but are not
mentioned in this manual yet.
10
9
8
7
6
5
4
3
2

11/06/05
0

SG
PP
Approved
Revision

Revised
Date
SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

2. CONNECTING COUPLING
INSTALLATION, OPERATION & MAINTENANCE

MANUAL OF CONNECTING COUPLINGS

(FOR CONDENSATE EXTRACTION PUMP)

COUPLING TYPE : 8GBL-200

PROJECT : 500 MW THERMAL POWER PLANTS

CONTENTS

• GENERAL NOTES (DO’S & DON’TS)

• DESCRIPTION OF COUPLINGS/OPERATING CONDITONS

• INSTALLATION INSTRUCTIONS

• MAINTENANCE INSTRUCTIONS

• ALIGNMENT INSTRUCTIONS

• COUPLING ASSEMBLY DRAWING

INSTALLATION, OPERATION & MAINTENANCE

MANUAL
GENERAL NOTES

• It is essential that all the instructions contained in the following documents be carried
out by a competent person. Should any problems be anticipated or encountered then
Euroflex Transmissions personnel are available for site visits or, alternatively, repairs
and overhauls can be undertaken in our works.

• Prior to performing any maintenance work (including inspections) it is essential that the
power supply is isolated and that no accidental movement of rotating machinery is
possible.

• This product is designed for a specific purpose. It is vital that it is not used for any
purpose other than that for which it is designed and supplied, and that the limits of it’s
capacities, as detailed here or in any other document, are not exceeded.

• No liability will be accepted and any other warranty, either expressed or implied, will be
null and void should any component of whatever kind, including nuts, bolts and
washers, be used in the assembly, or modifications be made to all or part of the
product which are not supplied, specified or agreed by Euroflex Transmissions.

DO’S

• The following instructions should be read and understood prior to starting any
assembly or maintenance work on the disc coupling.

• Prior to filling any component, care should be taken to ensure that it is clean and free
from any dirt.

• Where hub/shaft connections require a standard interference fit the hubs may be
heated in oil at 200-250 Celsius and rapidly positioned on the shaft. It is essential that
this heat is evenly applied over the whole hub and that spot heating is avoided.

DON’TS

• Do not use any component that is not supplied or approved by Euroflex Transmissions
in the assembly of this product.

• Do not attempt, where the weight of the unit is excessive, to lift the coupling without the
use of lifting equipment.

• The inherent balance of these couplings could be disturbed if they are allowed to be
knocked either by striking or rolling. Care should be taken when transporting and fitting
to avoid such knocks. This particularly when a coupling is specifically balanced.
DESCRIPTION OF COUPLING

The coupling is of the dry laminated diaphragm or disc type. Flexibility is obtained by the
deformation of the disc packs, within defined limits, which are separated by a tubular
spacer.

Individual laminations are of regular polygonal profiles which are assembled into a stack of
previously designated thickness and secured by bushing. Flexibility is accomplished by
connecting through the bushed holes, on a common pitch circle diameter, by means of
bolts, alternately, to driving and driven components.

The bolts, bushes and associated holes are machined to close limits associated with “fitted
bolts”. Due to the need for reasonable ease of assembly, interference fits are undesirable
and, consequently, tolerances are such as to allow for a close slide or slight transition fit.
To compensate for these clearances and to ensure the best possible concentricity
between components, the pitch circle diameter of the bolt holes in the flexible element is
made smaller that that of the mating holes in the adjacent components. On assembly, all
inherent clearances are, therefore, eliminated. Coupling bolts are sized such that they are
capable of including a load equivalent to 4 times the tensile load in the flexible element
laminations, between driving and driven bolt, when transmitting the full rated continuous
torque of the coupling. This assumes a coefficient of friction between the various
components of 0.25 but experience has shown that, due to the high loads induced, minute
compressive deformation is sufficient to raise this to about 0.3.

The reason for adopting this principle of using large, highly loaded, bolts is two-fold a (to
prevent interface slip, as already mentioned, and b) to eliminate any chance of bolt
bending due to the overhung radial loading imposed by the flexible element. Avoiding
either slip or bending helps to avoid fretting which occurs when bolts are designed only to
drive in shear.

In general, the design is identical to a large number of units already in operation.

OPERATING CONDITIONS

In operating the flexible elements are subjected to both tensile and bending stresses, each
having an influence on the allowable magnitude of the other. It is important, therefore, that
the operating limits of the various deflections for which the coupling is designed to
accommodate, are kept, as far as practicable, within those indicated on the “Allowable
Misalignment Curve” which was individually supplied with the final engineering data.

In practice, the initial alignment of the coupling should be as close as possible and within
the alignment limits given in the “Installation Instructions”. This will allow for changes
during operating to remain within allowable limits.

As the Euroflex units are designed to transmit the torque in friction between the driving and
driven bolts and the flexible elements, it is essential that, should the need arise, these
bolts should be correctly tightened to the torque indicated on the assembly drawing or in
the “Installation and Maintenance instructions”.
Torque and speed should remain within the originally specified conditions.
INSTALLATION INSTRUCTIONS

GENERAL

No liability will be accepted, and any warranty, either expressed or implied, will be null and
void should any components of whatsoever kind, including nuts, bolts and washers, be
used in the assembly or any modifications be made to all or part of the unit which are not
supplied, specified or agreed by Euroflex Transmissions Ltd.

For general Safety, Alignment and Maintenance Instructions see other sections of this
manual.
IMPORTANT

When tightening any bolts or screws, this should be done evenly, i.e. cylinder head
fashion, to 50% torque then to 100% torque in the same sequence.

Threads should be lubricated with Molybdenum Disulphide grease or equivalent.

INSTALLATION INSTRUCTIONS

1. With the Motor Rotor in it’s central axial position, check the distance between the
machinery shaft ends is xxx +/-0.1mm (This gives a 0.7 mm pre-stretch when the
coupling is installed.

2. Check that the parallel & angular misalignment of shafts is within the limits defined on
the separate Alignment Instructions sheet.

3. Fit the Hubs (items 1 & 2) to their relevant shafts, ensuring that the Motor hub (item
1) face finishes flush with the motor shaft end.

4. Check the distance between the Hub faces is xxx mm +/-0.25 mm.

5. Insert the Spacer Assembly (item 3) between the Hubs and align Match Marks (or
Serial Numbers) by rotating the Spacer or machinery shafts.

6. Insert the Element Assemblies (item 4) between the Spacer & Hub flanges (item 1,2
& 3)

7. Fit Coupling Bolts, Overload Washers & Nuts (item 5/6/7) as indicated on the drawing
and torque tighten, cylinder head fashion, to the value shown on the drawing,
ensuring threads are correctly lubricated.
MAINTENANCE INSTRUCTIONS

General maintenance of the coupling consists of an annual (or other agreed period) check
of the following :

• Axial, Angular & Parallel misalignment to ensure these are still within acceptable
limits and that no major machinery movements have occurred.

• All bolts to ensure they are correctly tightened.

• The Flexible Elements, by visual inspection, for signs of fatigue cracking local to the
washer anchor points or general signs of fretting corrosion. Slight bowing or “S” like
distortion of the laminations is not detrimental to the unit operation.

NOTE : Any requirement for spare part should be made quoting the Original Purchaser,
Original Order Number & the Coupling Serial Number (this will be etched
on the major coupling flanges as BTLxxxx and should appear on all post
production Quality documents).
ALIGNMENT INSTRUCTIONS

Euroflex Transmissions couplings will accept substantial amounts of misalignment, the


configuration of each individual unit defining the actual acceptable level. The allowable
misalignment is shown graphically on a curve produced uniquely for any unit. This curve
shows the maximum permitted level of misalignment for operation and is NOT intended to
define setup limits.

ALIGNMENT METHOD :

Each company ahs it’s own method for aligning machinery all of which well documented in
both internal and freely available documents and books. Hence it is not our intention to
describe methods for setting machines. Instead, the following gives guidelines for quick
checks for alignment suitable after initial installation and for general maintenance checks.

AXIAL :

The suggested limits for axial set-up distance between the machinery shafts will, generally,
be specified in the installation instructions unique for the coupling. However, as a general
rule, the following may be used.

4-bolt couplings:- +/- 0.4mm


6-bolt couplings:- +/- 0.3mm
8-bolt couplings:- +/- 0.2mm
12-bolt couplings:- +/- 0.2mm

These values may be exceeded in certain cases and, if no reference is made in the unique
installation instructions, reference should be made to Euroflex Transmissions.

PARALLEL/RADIAL/ANGULAR :

Having basically aligned the machinery shafts using one of the established techniques, the
coupling may be installed as per the instructions. It is then worth performing a check to
establish that the overall alignment is correct for the particular coupling. This may be
simply performed by one of the following two methods:

• Attach a dial indicator securely to the back of one of the coupling flanges, with the
needle in contact with the flange face the other side of the flexible element as near
the outside periphery as possible. Rotate the machinery & coupling and locate the
minimum reading position. At this position, set the dial reading to zero. Rotate the
machinery again and record the maximum reading over 360 degrees. Divide this
maximum value by the coupling flange diameter to gain a value in mm/mm, which
should be no greater than that shown in the following list. (This should be repeated at
both flexible elements in a spacer coupling).

• An alternative method is, where possible to accurately measure the distance across
the flanges which sandwich the flexible element to obtain a maximum and minimum
value. The difference between these two values should the be divided by the flange
outside diameter to obtain a value in mm/mm, which should be no greater than that
shown in the following list. (This should be repeated at both flexible elements in a
spacer coupling).

4-bolt couplings:- +/- 0.004mm


6-bolt couplings:- +/- 0.003mm
8-bolt couplings:- +/- 0.002mm
10-bolt couplings:- +/- 0.015mm

NOTE : These values are intended as guides only and, in certain cases, may be
exceeded, IF IN DOUBT, CONTACT EUROFLEX TRANSMISSIONS.
SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

3. THRUST CUM JOURNAL BEARING


Michell Bearings

A Vickers company

Operations and Maintenance


Instructions for Standard Vertical Bearings

Customer: B.H.E.L - Hyderabad

Project : COND. EXTRN PUMP FOR 500MW TPS

Drawing Number: 58227

Bearing Model : 8 DNT

Version date – 14 December 1998


Operation and Maintenance Instructions for
Standard Vertical Bearings.

1 PRELIMINARY NOTES.---------------------------------------------------------------------------- 2

.1 Introduction. ---------------------------------------------------------------------------------------- 2

.2 Safety. ----------------------------------------------------------------------------------------------- 3

2 DESCRIPTION. --------------------------------------------------------------------------------------- 5

.1 Introduction. ---------------------------------------------------------------------------------------- 5

3 HANDLING THE BEARING. ---------------------------------------------------------------------- 6

.1 Introduction. ---------------------------------------------------------------------------------------- 6

.2 Points on Handling.------------------------------------------------------------------------------- 6

4 INSTALLATION.-------------------------------------------------------------------------------------- 7

.1 Introduction. ---------------------------------------------------------------------------------------- 7

.2 Assembly of the Bearing. ----------------------------------------------------------------------- 8

.3 Points before use.------------------------------------------------------------------------------- 14

5 OPERATING.---------------------------------------------------------------------------------------- 15

.1 Introduction. -------------------------------------------------------------------------------------- 15

.2 Operating Risks.--------------------------------------------------------------------------------- 15

6 CARE AND MAINTENANCE.------------------------------------------------------------------- 16

.1 Introduction. -------------------------------------------------------------------------------------- 16

.2 Procedures.--------------------------------------------------------------------------------------- 16

.3 Maintenance Schedule. ----------------------------------------------------------------------- 17

.4 Dismantling. -------------------------------------------------------------------------------------- 18

.5 Maintenance.------------------------------------------------------------------------------------- 21

APPENDIX 1 (SPARES). --------------------------------------------------------------------------- 25

.1 Ordering. ------------------------------------------------------------------------------------------ 25

APPENDIX 2 (TABLE OF TORQUE’S). -------------------------------------------------------- 26

1
Operation and Maintenance Instructions for Standard Vertical Bearings

1 PRELIMINARY NOTES.

.1 Introduction.

This manual is to be used by qualified engineers only. It contains information


that will familiarise the user with the machine and its safe operation. It is
recommended that the health and safety advice given in this manual is
followed and is kept in mind throughout all aspects of installation, storage,
operation, etc.

- General points on safety can be found in the first section.


- More specific points on safety can be found in each separate section.

* Make sure that all safety points are clearly understood and carefully noted. *

Warrantee.
Unless otherwise stated all warranty claims shall be dealt with in accordance
with Michell Bearings.
These warranty obligations will automatically become void if the product is:
1) Subjected to overloads.
2) Improperly handled.
3) Supplied with spare parts not approved by Michell Bearings.
4) Exceeding, or falling short of the technical characteristics specified.

Page 2
Operation and Maintenance Instructions for Standard Vertical Bearings

.2 Safety.

When operating the machine danger may arise to the user, the product and
plant and/or other assets. Therefore when running the machine make sure
that all the safety procedures given in this manual are strictly adhered to.

The below procedures should be noted.

1 Under no circumstances should the engineer work alone when operating the
machine.

2 At least one of the engineers should be trained in basic first aid techniques
and wear clear identification to show that he/she is a first aider.

3 No maintenance, assembly, adjustment or any other work should be carried


out on the bearing whilst the shaft is rotating or capable of movement.

4 Personnel that manipulate the product should be sufficiently trained.

5 No modifications of the product should be made unless it is approved by


Michell.

6 All users responsible for the operation of the machine must understand the
chapters fully and be familiar with the associated dangers described. These
are instructions that, if ignored, could result in death or injury.

Page 3
Operation and Maintenance Instructions for Standard Vertical Bearings

Before working on the bearing the engineers should familiarise themselves


with the layout of the manual.
Attention is drawn to the following formats:

! This symbol signifies a warning. These are instructions that, if


ignored could result in death or injury.

This symbol signifies that attention should be made by the


operator. If ignored it could result in minor injury or failure to carry out a
particular process correctly.

This symbol signifies additional instructions. This is usually a


check. Missing out this stage could lead to an error going unnoticed.

Page 4
Operation and Maintenance Instructions for Standard Vertical Bearings

2 DESCRIPTION.

.1 Introduction.

The bearing supplied is one of the Michell Standard Vertical Series, as


manufactured by Michell Bearings. The Standard Vertical Series are a
standard range of vertical bearings.
Within the series a range of types are catered for;
i) S Type: This is a single thrust and guide bearing. It is designed to absorb
lateral forces from a rotating shaft, as well as a force along the shaft in one
direction only.
ii) D Type: This is a double thrust and guide bearing, designed to absorb
lateral forces from a rotating shaft, as well as a force along the shaft in either
direction.

The standard S Type may also be supplied with a Surge ring, designed to
absorb a temporary upward force.

All types of bearing can be fitted with a variety of Resistance Temperature


Devices (RTDs) to measure the temperature of the lubricating oil or pads. The
Standard Vertical Series are usually self contained with water coolers, the
bearings can also be modified for different methods of cooling (i.e. natural air
cooled, fan cooled and circulated oil variations) with minimum modifications to
the basic casing.

The bearing can also be insulated as an option to protect against stray


currents whilst the machine is in operation.

Page 5
Operation and Maintenance Instructions for Standard Vertical Bearings

3 HANDLING THE BEARING.

.1 Introduction.

This section points out the relevant information essential when handing the
bearing.
The bearing is supplied fully assembled (see arrangement drawing for mass
of complete bearing). Threaded holes are provided for the fitting of eyebolts
on the bearing casing and other components.
It is advisable to keep the bearing within any casing and packaging until it is
necessary to remove it for assembly.

.2 Points on Handling.

! Under no circumstances should the completed bearing be


handled manually.

! Before using any lifting equipment, ensure that it is certified to


carry a load greater than that of the bearing.

! When handling the bearing use only provided lifting points.

Make sure bearings are stored in the intended mounting position in a dry
room only.
Please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell straight
away.

Page 6
Operation and Maintenance Instructions for Standard Vertical Bearings

4 INSTALLATION.

.1 Introduction.

Prior to installation the bearing should be dismantled into a series of sub-


assemblies.

! Do not touch moving parts.

Additionally the following sub-assemblies may also be present and can be


handled manually; Circular Cooler(s), Journal Pads, Oil level gauge, RTD
assembly, Air Vent, Lower Thrust Pads and Anti-Vortex Shroud or Upper
Surge face.

The bearing is also supplied with Curil T sealant.

Remove all packaging. All parts are coated in a rust preventative. This must
be removed and all parts thoroughly cleaned before installation begins. To
remove the rust preventative, white spirit or a strong spirit based cleaner
should be used.

! There may be fumes given off during the cleaning process. Clean
parts in a well ventilated area. Always follow cleaner manufacturers’
instructions.

Use a lint free cloth when cleaning the bearing.

Page 7
Operation and Maintenance Instructions for Standard Vertical Bearings

.2 Assembly of the Bearing.

! The disassembling and reassembling of the equipment by an


individual who is inexperienced can cause danger. Michell will not take
on any liability for any damage resulting from non-compliance with
details given in this manual.

To assemble the bearing the below procedure should be followed which if


carried out correctly could increase the working life of the machine.

1. Coat all bearing surfaces in clean oil of the correct grade.

2. Place jointing on the sleeve.

Care should be taken when handling components to avoid the

risk of trapping hands when assembling.

3. Secure the sleeve to the baseplate with tapbolts.

If the bearing is fitted with dust seals, do not fit tapbolts.

4. Dust Seal Fitted Bearings:

• Fit seal housing to the sleeve and secure it in place with screws.

• Fit seal into housing.

• Fit seal cover and secure with tapbolts

Page 8
Operation and Maintenance Instructions for Standard Vertical Bearings

Dust seals require some time to bed in. Do not fully tighten the

securing bolts. For the first month operation, gradually tighten the

tapbolts.

5. Position the baseplate on to the studs located on the supporting structure

and set baseplate concentric with centreline of machine.

6. Fit thrust pad stop to baseplate.

Ensure that stop is fully tightened and locked in place with Loctite

222 or similar adhesive.

! Always follow instructions on adhesives.

7. Fit lower thrust pads and push well in.

Check that the clearance between the pads is correct. The

clearance is given on the arrangement drawing.

Ensure that RTD fitted pads are in the correct position, as shown

on the arrangement drawing.

8. Place O-Ring into the groove in the baseplate.

9. Fit collar to the shaft and ensure that it runs true.

10.Lower the collar until it rests on the lower thrust pads.

Page 9
Operation and Maintenance Instructions for Standard Vertical Bearings

Check alignment. Follow the below procedure:

• Check that no thrust pads are loose (i.e. all pads are firmly clamped by the

collar).

• Use feeler gauges to check the clearances between the thrust pads pivots

and the baseplate. The clearances should be equal and no greater than

0.04mm.

When using feeler gauges, take care not to damage the

Whitemetal surfaces.

11.Fit the journal pad stop to the casing.

Ensure that stop is fully tightened and locked in place with Loctite

222 or similar adhesive.

! Always follow the instructions on adhesives.

12. Coat both the casing and baseplate mating surfaces with sealant.

! Always follow sealant manufacturers’ instructions.

13. Lower casing into position.

14. Secure casing and base plate to the supporting structure using studs and

nuts. Torque nuts to value indicated in Appendix 2.

Page 10
Operation and Maintenance Instructions for Standard Vertical Bearings

This Appendix should be adhered to as over tightening could

damage the shell.

15. Fit journal pads.

Ensure that RTD fitted pads are in the correct position, as shown

on the arrangement drawing.

16.For bearings fitted with anti vortex shrouds, assemble the shroud, and bolt

on to the casing.

17.For double thrust (D type) bearings:

• Assemble the upper thrust rings, pads and stops.

Ensure that stop is fully tightened and locked in place with Loctite

222 or similar adhesive.

! Always follow instructions on adhesives.

• Fit thrust ring on top of the journal housing in the casing.

18. For Surge ring fitted bearings;

• Assemble Surge ring.

• Bolt Surge ring to the journal housing in the casing.

19.Place jointing in position on the casing.

Page 11
Operation and Maintenance Instructions for Standard Vertical Bearings

20.For bearings fitted with internal cooler, fit cooler to cover.

Take care not to overtighten the securing bolts on the cooler.

Overtightening may damage the cooler.

21. Fit cover and cooler assembly to the casing. Secure the cover to the

casing. Torque cover securing bolts to value indicated in Appendix 2.

Check the cooler. Ensure that leakage from the cooler is not

possible.

22. Dust Seal Fitted Bearings:

• Fit the dust seal into the top of the cover.

• Fit seal cover and secure it in place with tapbolts.

23.Fan Cooled Bearings:

• Assemble fan and fit it to the shaft.

• Fit RTDs, pipework elbows and any extension pieces required to allow

connections to pass through fan shroud.

• Fit fan shroud to bearing casing. Secure it in place with capscrews.

Ensure that fan shroud does not foul the fan.

24.Fit and seal in oil level gauge, blanking plugs and any thermometry or

detectors.

Page 12
Operation and Maintenance Instructions for Standard Vertical Bearings

! Always follow sealant manufacturers’ instructions.

Ensure that RTD assembly is not damaged and is working

correctly before fitting it.

Ensure that all plugs, pipework joints and instruments are secure

and sealed.

25. Connect up external pipework.

26. Remove air vent and fill bearing with oil up to the standing oil level

marked on the oil level gauge.

For temperature probe fitted bearings; run the bearing and establish a steady

state operating temperature then set temperature alarm to 5°C above the

steady state operating temperature. Shut down temperature alarm is to be set

at 10°C above steady state operating temperature.

Page 13
Operation and Maintenance Instructions for Standard Vertical Bearings

.3 Points before use.

The bearing is now complete, it must not be used until the items below

have been dealt with;

1. The entire machine has received a Declaration of Conformity, or has

been declared exempt from the Supply of Machinery (Safety

Regulations) Act 1992 and the Machinery Directive.

2. Lubricating oil has passed through the bearing and is at the proper

level.

Note!!

The lubricating oil must be a mineral based turbine oil inhibited against

oxidation, corrosion and foaming, with an ISO viscosity grade as

indicated on the arrangement drawing.

The use of any other oil should be referred to Michell Bearings.

! Do not use the bearing unless the cooling system is operating.

3. Local safety regulations have been met.

Page 14
Operation and Maintenance Instructions for Standard Vertical Bearings

5 OPERATING.

.1 Introduction.

This section points out the risks that can occur when operating the machine.

! Do not touch any moving parts.

.2 Operating Risks.

If the bearing has been correctly assembled, using the procedure already
given, there is only a marginal risk of the bearing failing which would be due to
the design conditions being exceeded. Examples of these conditions are;
overspeed, low lubrication levels and excess load. In order to avoid these
situations, it is suggested that;
i) Control panels are labelled with the bearing limitations.
ii) The shaft should be stopped immediately if;
a) Coolant circulation fails.
b) Bearing temperature exceeds normal operating temperature by
10°C.

The users’ attention is drawn to the fact that both the pipework and
bearing surface may be hot during operation.

Where bearings are fan cooled, the fan shroud must not be removed whilst
the bearing is operating.

In order to avoid leakage of lubricant, plugs, RTDs and seals must never be
removed while the bearing is operating.

Page 15
Operation and Maintenance Instructions for Standard Vertical Bearings

6 CARE AND MAINTENANCE.

.1 Introduction.

This section demonstrates the care and maintenance needed for the smooth
operation of the machine.

! Do not touch any moving parts.

.2 Procedures.

Once the steady state operating temperature has been determined, the alarm
point should be set at 5°C above this. Shut down is to occur at 10°C above
the steady state operating temperature.

Regular inspection should be made of all seals and pipework. Any large
leakage of lubricant or coolant or sudden increase in leakage will indicate that
a seal or join is failing. Maintenance must then be carried out as soon as
possible.

If a bearing is fan cooled, the air inlet and outlets must be periodically
inspected in order to prevent the build up of dirt and waste material. Such a
build up will lead to there being insufficient air flow and overheating will occur.

Collect used oil and dispose of under the correct regulations.

Page 16
Operation and Maintenance Instructions for Standard Vertical Bearings

.3 Maintenance Schedule.

Oil changes will be at differing periods depending on the frequency of bearing


operation and the conditions in which the bearing is operating. Approximate
oil change times are indicated below.

Conditions. Oil Change Period.


Constant Operation, dusty Three Months.
atmosphere.
Constant Operation. Six Months.
Periodic Operation. At routine maintenance.

For a bearing that is operating constantly, routine maintenance should take


place annually. If the user only operates the bearing periodically, maintenance
periods may be able to take place less frequently, this is however at the users’
discretion. An annual inspection is recommended as a minimum service
requirement.

Page 17
Operation and Maintenance Instructions for Standard Vertical Bearings

.4 Dismantling.

The below procedure should be followed when dismantling the bearing.

1. Switch off machinery. Lock off controls. Secure and isolate shaft.

! Ensure control gear, barring gear and any other equipment

capable of moving the shaft is locked out and labelled “Not to be

used”.

! Beware hot oil. Allow machinery to cool off before proceeding

further.

2. Where a bearing is fitted with continuous circulation of oil, allow the

circulation to continue whilst the bearing is cooling.

3. Switch off, drain and disconnect cooling system.

4. Switch off and drain the oil supply.

! Do not disconnect the oil inlet and outlet pipework until the

bearing has been drained of oil.

5. Remove drain plug and fully drain oil from bearing.

Any oil spillage should be collected in suitable containers.

6. Disconnect and remove any thermometry and instrumentation. With fan

cooled bearings this may not be possible, see next stage.

Page 18
Operation and Maintenance Instructions for Standard Vertical Bearings

7. Fan Cooled Bearings:

• Remove any connections passing through the fan shroud.

• Remove capscrews and lift off fan shroud.

• Dismantle and remove the fan

• Remove any instrumentation, pipework and thermometry now visible.

8. Remove the top dust seal.

9. Remove cover and cooler assembly.

! Before removing bolts, fit eye bolts and lifting gear to the cover.

Ensure that the eye bolts are tight and secure.

! Before using any lifting equipment, ensure that it is certified to

carry a load greater than the mass of the component or sub-

assembly.

When removing the cover and cooler, take care not to damage

any equipment.

10.Remove upper surge ring, upper thrust ring or vortex shroud.

11.Fit lifting bolts and remove the journal pads from the casing.

The surge ring and journal pads will be oily and may stick. They

will also be very slippery when handling. Take care to avoid dropping

and damaging the pads and ring.

Page 19
Operation and Maintenance Instructions for Standard Vertical Bearings

12.Remove fasteners and lift off casing.

! Before removing bolts, fit eyebolts and lifting gear to the casing.

Ensure that the eyebolts are tight and secure.

! Before using any lifting equipment, ensure that it is certified to

carry a load greater than the mass of the component or sub-

assembly.

13.Jack up the shaft until there is a clearance between the collar and the

lower thrust pads.

! Ensure that jacking equipment is safely positioned and certified

to carry a load greater than the mass of the shaft.

! Once the shaft is raised, secure it in position using other

equipment. Do not rely on jacking equipment alone.

14.Remove thrust pads by sliding out.

The thrust pads will be oily and may stick to the casing. The
pads will also be slippery when handling. Take care to avoid dropping
and damaging pads.

Page 20
Operation and Maintenance Instructions for Standard Vertical Bearings

.5 Maintenance.

With the bearing dismantled, (refer to assembly drawing with parts list)
examine the thrust pads, journal pads and surge ring. The appearance should
be that shown in Figure 1 and Figure 2 overleaf. There may be some scoring
and wear on the pads and ring, but provided wear is no greater than 0.125
mm the pads and ring are still serviceable. If there is any sign of the White
metal surface coming away from the pad or ring, they must be replaced.

Examine the jointing between the casing and cover and that between the
base plate and the sleeve. If the jointing has decayed so that it is either
disintegrating or leaking, it should be replaced.

Examine the O-Ring, if it has started to leak or decay, it should be replaced.

Inspect the collar surface for any sign of damage. If it is necessary to replace
the pads, the collar should also be replaced and repaired, otherwise the
replacement pads will have a short life.

Page 21
Operation and Maintenance Instructions for Standard Vertical Bearings

Figure 1 Thrust Pad Appearance

Figure 2 Journal Pad Appearance

Page 22
Operation and Maintenance Instructions for Standard Vertical Bearings

Clean the cooler assembly, using the below routine;

1. Remove cooler assembly from bearing cover.

2. Clean the bore of the tubes using a high pressure water jet or steam

cleaning.

3. Any remaining deposits or blockages can be removed by using a cleaning

rod or hypochlorite based cleaning solution.

! There may be fumes given off during the cleaning process. Clean
parts in a well-ventilated area. Always follow cleaner manufacturers’
instructions.

When using cleaning rods, take care not to damage the cooler
tubes.

Page 23
Operation and Maintenance Instructions for Standard Vertical Bearings

If the bearing is air or fan cooled, the spaces between each of the cooling fins
must be cleaned. With fan cooled bearings, the fan and shroud should be
inspected for any signs of damage caused by the two fouling each other. If
there is any damage, the parts should be repaired and alignment of fan and
shroud checked on re-assembly.

Where dust seals are fitted, these should be removed from their housings and
inspected. If the seal has started to break up, or has become clogged up with
dust and oil, it should be replaced.

Prior to re-assembly, all the old sealant should be removed and fresh sealant

applied in the positions identified in the section on Installation (4.2).

Page 24
Operation and Maintenance Instructions for Standard Vertical Bearings

Appendix 1 (Spares).

.1 Ordering.

As a minimum, replacements should be carried for all Whitemetal


components.

When replacing thrust and journal pads, please ensure that


these are the correct hand. The direction of rotation stamped on the
replacement pads must be the same as that on the old pads.

Consideration should also be given to holding the consumable parts listed


below:

O-Rings
Casing/Cover jointing
Sleeve/Baseplate jointing
RTD assemblies
Washers
Dust Seals

Page 25
Operation and Maintenance Instructions for Standard Vertical Bearings

Appendix 2 (Table of Torque’s).

Bolt Size (mm) Tightening Torque (Nm)


6 4
8 10
10 20
12 35
16 80-90
20 155-175
24 275-305
30 545-605
36 950-1050
42 1520-1680
48 2300-2520
56 3690-4070
64 5560-6150

Page 26
Michell Bearings
Scotswood Road
Newcastle Upon Tyne
NE15 6LL
Great Britain
Tel: (0191) 273 0291
Fax: (0191) 272 2787
Michell Bearings reserve the right to amend these instructions.
© Michell Bearings 1997.
SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

4. SUCTION STRAINER (BASKET)


Digitally signed by S P Patra
DN: CN = S P Patra, C = US,

SP O = DVC, OU = Engineering
and Planning
Reason: DVC have reviewed
this document and taken it for

Patra INFORMATION
Date: 2009.02.05 15:00:03
+05'30'
PART - 5

SUB-DELIVERY ITEMS

BFP RECIRCULATION
CONTROL VALVE

(M/S. CONTROL COMPONENTS INC., USA)


500MW TPS
B73G
Filter/Regulator Installation & Maintenance
B73G - ★★★ - ★★★ - ★★★ Instructions

Port Thread Form Adjustment Drain Bowl Element Diaphragm Spring (Outlet Pressure Range) * Gauge
2 ....1/4" A....PTF K....Knob A....Automatic D....Metal with liquid level indicator 1 ....5 μm N....Non-relieving F ....0,3 to 4 bar (5 to 60 psig) G....With
3 ....3/8" B....ISO Rc taper T ....T-bar Q....Manual, 1/4 turn P....Transparent with guard 2 ....25 μm R....Relieving M...0,3 to 10 bar (5 to 150 psig) N....Without
4 ....1/2" G....ISO G parallel T ....Transparent 3 ....40 μm S....0,7 to 17 bar (10 to 250 psig)
* Outlet pressure can be adjusted to pressures in excess of, and less than, those specified. Do not use these units to control pressures outside of the specified ranges.
TECHNICAL DATA 5. Install a pressure gauge or plug the gauge ports. Gauge
Fluid: Compressed air ports can also be used as additional outlets for regulated air.
Maximum pressure: 1 12
Transparent bowl: 10 bar (150 psig) ADJUSTMENT
Metal bowl: 17 bar (250 psig) 1. Before applying inlet pressure to filter/regulator, turn
Operating temperature*: adjustment (1 or 7) counterclockwise to remove all force
Transparent bowl: -34° to +50°C (-30° to +125°F) on regulating spring (12).
2. Apply inlet pressure, then turn adjustment (1 or 7) 3 13
Metal bowl: -34° to +80°C (-30° to +175°F)
* Air supply must be dry enough to avoid ice formation at clockwise to increase and counterclockwise to decrease 2
temperatures below +2°C (+35°F). pressure setting. 16
Particle removal: 5 μm, 25 μm, or 40 μm filter element 3. Always approach the desired pressure from a lower
Air quality: Within ISO 8573-1, Class 3 and Class 5 pressure. When reducing from a higher to a lower
(particulates) setting, first reduce to some pressure less than that 15
4
Typical flow with 10 bar (150 psig) inlet pressure, 6,3 bar desired, then bring up to the desired pressure.
(90 psig) set pressure and 1 bar (15 psig) droop from NOTE
set: 50 dm3/s (106 scfm) With non-relieving filter/regulators, make pressure
Nominal bowl size: 0,1 litre (3.5 fluid ounce) reductions with some air flow in the system. If
Manual drain connection: 1/8" made under no flow (dead-end) conditions, the 5
Automatic drain connection: 1/8" filter/regulator will trap the over-pressure in the
Automatic drain operating conditions (float operated): downstream line. 14
4. KNOB ADJUSTMENT. Push knob down to lock pressure 53
Bowl pressure required to close drain: Greater than 0,3
bar (5 psig) setting. Pull knob up to release. Install tamper resistant
6 54
Bowl pressure required to open drain: Less than 0,2 bar cover (see Replacement Items) to make setting tamper
(3 psig) resistant.
52
Minimum air flow required to close drain: 0,1 dm3/s (0.2 5. T-BAR ADJUSTMENT. Tighten lock nut (8) to lock 7
scfm) pressure setting. 8
Manual operation: Depress pin inside drain outlet to 10 51
SERVICING
drain bowl 1. Open manual drain to expel accumulated liquids. Keep 9
Gauge ports: liquids below baffle (49).
1⁄4 PTF with PTF main ports 2. Clean or replace filter element when dirty.
Rc1/4 with ISO Rc main ports 50
Rc1/8 with ISO G main ports DISASSEMBLY
Materials: 1. Filter/regulator can be disassembled without removal 11
Body: Aluminum from air line.
Bonnet: Aluminum 2. Shut off inlet pressure. Reduce pressure in inlet and 49
Valve: Brass outlet lines to zero.
Bowl: 3. Turn adjustment (1 or 7) fully counterclockwise.
Transparent: Polycarbonate 4. Remove bowl - push into body and turn 26
Transparent with guard: Polycarbonate, steel guard counterclockwise.
Metal: Aluminum 5. Disassemble in general accordance with the item 18
21
Metal bowl liquid level indicator lens: Transparent nylon numbers on exploded view. Do not remove the drains 25
Element: Sintered polypropylene unless replacement is necessary. Remove and replace
Elastomers: Neoprene and nitrile drains only if they malfunction.
23 24
REPLACEMENT ITEMS CLEANING 17
Service Kit (includes items circled on exploded view): 1. Clean plastic bowl (25, 35) with warm water only. Clean
Relieving.............................................................4383-600 other parts with warm water and soap. 20
Nonrelieving .......................................................4383-601 2. Rinse and dry parts. Blow out internal passages in body 19
Liquid level lens kit (43, 45, 46, 47) ......................4380-020 (16) with clean, dry compressed air. Blow air through
Filter element, 5μm, red speckles (50).....................4438-01 filter element (50) from inside to outside to remove 22
Filter element, 25μm, blue speckles (50) .................4438-02 surface contaminants.
Filter element, 40μm, no speckles (50)....................4438-03 3. Inspect parts. Replace those found to be damaged.
Manual drain (18, 19, 20) ..........................................619-50 Replace plastic bowl with a metal bowl if plastic bowl
Automatic drain (21, 22, 23) .................................4000-51R shows signs of cracking or cloudiness. 34
28
Tamper resistant cover (knob adjustment only).......4455-51 31
ASSEMBLY
PANEL MOUNTING DIMENSIONS 1. Lubricate the following items with o-ring grease. 27 35
Panel mounting hole diameter: 48 mm (1.89") 4 (Thrust washer) - outer circumference and both sides.
Panel thickness: 2 to 6 mm (0.06" to 0.24") 5, 7 (Adjusting screw) - threads and tip. 33
18, 28, 37 (Manual drain body) - the portion of the 30
INSTALLATION body that contacts the bowl, and the hole that 29
1. Shut off air pressure. Install filter/regulator in air line - accommodates the stem of drain valve (19, 29, 38).
● vertically (bowl down),
53 (Valve) - stem. 32
● with air flow in direction of arrow on body,
26, 34, 47, 54 (O-rings)
● upstream of lubricators and cycling valves, 47
2. Assemble the unit as shown on the exploded view. Push
● as close as possible to the device being serviced.
bowl, or bowl with guard, into body and turn fully 37 40
2. Connect piping to proper ports using pipe thread sealant 48
clockwise.
on male threads only. Do not allow sealant to enter 3. Torque Table 46
36 45
interior of unit. Item Torque in Nm (Inch-Pounds)
3. Push bowl, or bowl with guard, into body and turn fully 43
2, 9 (Screw) 2,3 to 3,4 (20 to 30) 42
clockwise before pressurizing. 22, 32, 41 (Nut) 2,3 to 2,8 (20 to 25)
4. Flexible tube with 5mm (3/16") minimum I.D. can be 39
43 (Screw) 1,7 to 3,4 (15 to 30)
connected to the automatic drain. Drain may fail to 38
49 (Baffle), 51 (Louver) 1,1 to 2,2 (10 to 20)
operate if the tube I.D. is less than 5mm (3/16"). Avoid
restrictions in the tube. 41 44

© Norgren 2000
IM-180.300.01 (2/00)
a subsidiary of IMI plc Supersedes 9/98
B73G
Installation & Maintenance
Instructions
CAUTION
Water vapor will pass through these units and could
condense into liquid form downstream as air temperature
drops. Install an air dryer if water condensation could have
a detrimental effect on the application.
WARNING
These products are intended for use in industrial
compressed air systems only. Do not use these products
where pressures and temperatures can exceed those listed
under Technical Data.
Polycarbonate plastic bowls can be damaged and
possibly burst if exposed to such substances as certain
solvents, strong alkalies, compressor oils containing ester-
based additives or synthetic oils. Fumes of these
substances in contact with the polycarbonate bowl,
externally or internally, can also result in damage. Clean
with warm water only.
Use metal bowl in applications where a plastic bowl
might be exposed to substances that are incompatible with
polycarbonate.
If outlet pressure in excess of the filter/regulator
pressure setting could cause downstream equipment to
rupture or malfunction, install a pressure relief device
downstream of the filter/regulator. The relief pressure and
flow capacity of the relief device must satisfy system
requirements.
The accuracy of the indication of pressure gauges can
change, both during shipment (despite care in packaging)
and during the service life. If a pressure gauge is to be
used with these products and if inaccurate indications may
be hazardous to personnel or property, the gauge should be
calibrated before initial installation and at regular intervals
during use.
Before using these products with fluids other than air,
for non industrial applications, or for life-support systems
consult Norgren.

© Norgren 2000
IM-180.300.02 (2/00)
a subsidiary of IMI plc Supersedes 9/98
PART - 6

DRAWINGS / DOCUMENTS

INDEX

SECTION-A : BOILER FEED BOOSTER PUMP

SECTION-B : BOILER FEED PUMP

SECTION–C : CONDENSATE EXTRACTION PUMP


SECTION – A

BOILER FEED BOOSTER PUMP

LIST OF DRAWINGS

Erection & Maintenance

S.No. Description of Drawing Drawing No.

01. Sectional Assembly of Booster Pump HY-DG-1-18000-56321

02. Outline Arrangement of MDBP HY-DG-1-18000-56311

03. Outline Arrangement of TDBP HY-DG-1-18000-56312

04. Key & Holding down bolts details for 3 189 005 4854
MDBP & TDBP

05. Spanner (Coupling Nut) 2 180 291 3317


06. Hook Spanner (Var. No. 9, 10, 11&12) FP90016

Informative Drawings

S.No. Description of Drawing Drawing No.

07. Estimated Performance Curves of HY-DG-3-18900-65322


MDBP

08. Estimated Performance Curves of HY-DG-3-18900-65324


TDBP

09. Estimated Performance Curves of HY-DC-4-18000-68804


BP-NPSHR
REV. DATE ALTERED REV. DATE ALTERED
250 REV. DATE ALTERED

CHKD. & APPD. CHKD. & APPD. CHKD. & APPD.


240 MIN. RC FLOW

230
15 4
0R
PM
220 at 5
1 .5
A T 50 Hz
Hz
D
210 NOTE : MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
HEAD (mlc)

A
B
C INDICATED ONLY FOR THE PURPOSE OF CALCULATING
200 BFP SET SHUT OFF PRESSURES AT RC FLOW.
A T 47
.5 H z
190
PARAMETERS AT 50Hz:-
180
EMERGENCY
170 D
OPERATION 920 207.5 162.1 0.905 80.0 588 1495 4.15
160
C MCR WITH
150 U/F OPERATION 900 208 160.1 0.907 80.0 578 1495 4.05

950
AT 51.5Hz BEST
B
POWER (kW)

750 EFFICIENCY 3.9


AT 50Hz 855 210 161.1 0.9070 80.0 554 1495
C POINT
A
550 D
B
DESIGN
350 A CONDITION 990 205 161.8 0.9054 81.5 614 1495 4.5

150
OPERATING FLOW HEAD TEMP. SP. GR. EFFICIENCY POWER SPEED NPSHR
REF (m3/hr) (mlc)
CONDITION (mlc) (0 C) (%) (kW) (RPM)
90
A
80

70
JOB NO. : 270
DAMODAR VALLEY CORPORATION
60
EFFICIENCY (%)

STATUS : CONTRACT KOLKATA


50 7 DRG. / REF. NO. MEJIA PHASE - II THERMAL POWER STATION
(INTERNAL) 2 x 500 MW - UNIT 1 & 2
NPSHR-3% ∆Η (mlc)

40