BFBP Maintenance Instruction For HZB200-430 PDF [PDF]

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Document No.: Revision:



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1



2015-4



BFBP MAINTENANCE INSTRUCTION FOR HZB200-430



Owner: COLOMBIA GECELCA 3.2 Contract No.：14 泵-45



Address: No.80 Hangdu Road, Shanghai, Post Code: 201316 China Tel: 86-21-33758800-2157 Fax: 86-21-33758710 Website: http://www.spem.com.cn Email: [email protected]



CONTENT 1 



GENERAL REMARKS ......................................................................................... 1  1.1  About this manual ............................................................................................... 1  1.2  Guarantee ............................................................................................................ 1  2  SAFETY ............................................................................................................... 2  2.1  Marking of instructions in the operating manual ................................................ 2  2.2  Qualification and training of personnel .............................................................. 2  2.3  Danger on non-observation of the safety regulations ......................................... 2  2.4  Safety-guided working ........................................................................................ 2  2.5  Safety instructions for user / operator ................................................................. 2  2.6  Safety instructions for maintenance, inspection and assembly jobs ................... 3  2.7  Prohibition of unauthorized rebuilding measures or alterations ......................... 3  2.8  Inadmissible operating modes............................................................................. 3  2.9  Explosion protection ........................................................................................... 3  3  PACKAGE、 TRANSPORT & STORAGE ......................................................... 4  3.1  Package ............................................................................................................... 4  3.2  Transport/Lifting ................................................................................................. 4  3.3  Storage ................................................................................................................ 5  4  DESCRIPTION OF EQUIPMENT ........................................................................ 6  5  SCOPE .................................................................................................................... 7  5.1  Equipment condition ........................................................................................... 7  5.2  General overhaul information and advice ........................................................... 7  5.3  Shipping from site ............................................................................................... 8  5.4  Completion of booster pump overhaul ............................................................... 9  5.5  Scheduled maintenance ....................................................................................... 9  5.6  Fault diagnoses.................................................................................................. 10  6  MAINTENCE PARTICULARS ........................................................................... 12  6.1  Estimated weights ............................................................................................. 12  6.2  Joints ................................................................................................................. 12  7  LUBRICANT ....................................................................................................... 13  8  ROUTINE MAINTENANCE .............................................................................. 14  8.1  Preparation for maintenance ............................................................................. 14  8.2  Examining the bearing ...................................................................................... 14  8.3  Check mechanical seal ...................................................................................... 18  9  OVERHAUL ........................................................................................................ 21  9.1  Preparation ........................................................................................................ 21  9.2  Examination and cleanliness ............................................................................. 21  9.3  Balancing marks................................................................................................ 21  9.4  General information on dismantling and assembly .......................................... 21  9.5  Booster pump disassembly ............................................................................... 22  9.6  Inspection, renewal and repair procedures........................................................ 23 



9.7  Assembling the booster pump ........................................................................... 25  10  LUBRICANTION ................................................................................................ 27 



1



GENERAL REMARKS



1.1 About this manual The operating manual contains important information on how to operate the pump safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and life of the pump. How to use this manual The operating manual must always be available wherever the pump is in use. These instructions must be read an applied by any person in charge of carrying out work with and on the pump, such as transport, storage, installation, operation and maintenance. This manual should be used together with all other machine documentation in order to have accurate information of your pump. Do not start or operate this pump unless you have complete understanding of the pump system and all auxiliary systems (driver, cooling, seal flushing ...). 1.2 Guarantee Guarantee is assumed according to the contractual agreements. The normal warranty covers manufacturing or material defect, it does not cover the damage caused by improper storage conditions, incorrect installation, operation and using against designated use. During the period of guarantee, repairs or modifications only can be made by our service personnel or with our agreement.



2 SAFETY This operating manual contains basic information, which has to be observed on the installation, commissioning, operation and maintenance. Therefore this operating manual has to be available constantly on site for the use of service or site personnel and has to be read prior to commissioning and/or assembly/disassembly of the pump. Not only have the general safety instructions to be observed, which are given under this main point "Safety", but also the special safety instructions given below in the operating manual. 2.1 Marking of instructions in the operating manual The safety instructions contain in these operating instructions, which – if not observed - may result in harm to persons. general danger sign warnings against electrical voltage explosion protection with the special sign safety instructions which – if not observed –may cause risks for the machine



ATTENTION



2.2 Qualification and training of personnel The personnel for service, maintenance, inspection and assembly has to hold the necessary qualifications for this kind of jobs. Range of responsibility, competence and the monitoring of the personnel have to be fixed clearly by the user. In case the personnel should not have the required knowledge, they have to be trained and instructed. This may be undertaken by the manufacturer of the machine, if required, on user's request. Further the user has to ensure that the personnel has a complete understanding of the contents of the manufacturer's instruction manual. 2.3 Danger on non-observation of the safety regulations By non-observation of the safety regulations danger may arise for persons as well as for environment and machinery and may lead to a complete loss of any claims for damages. Non-observance may lead for example to the following dangers: Failure of important functions of machine/plant Failure of required procedures of maintenance and repair Endangering of people by electrical, mechanical and chemical impacts Endangering of environment by leakage of dangerous materials 2.4 Safety-guided working The safety regulations given in this operating manual which consist of national regulations on accident prevention, as well as company- internal job, operating and safety regulations issued by the user, have to be observed. 2.5 Safety instructions for user / operator In case hot or cold machine parts may lead to any danger, they have to be secured by user against touching. Safety guards for rotating parts (e.g. coupling guard) may not be removed from machine during operation.



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Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be disposed of in such a way as to prevent any endangering of people and environment. Legal regulations have to be observed. Endangering by electricity has to be excluded



2.6 Safety instructions for maintenance, inspection and assembly jobs - The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by authorized and skilled personnel only, who have been adequately informed by studying the operating manual carefully. - Basically any works on the machine may be carried out only during shut-down of the machine. The procedure described in the operating manual for the shut-down of the machine has to be strictly adhered to. The machine has to be locked against unauthorized or involuntary start-up. - Employees with long hair must tie it back. No loose clothing or jewellery, including rings, should be worn. There is a risk of injury as a result, for example, of such objects getting caught or pulled in. - Pumps or aggregates delivering media hazardous to health have to be decontaminated. - Immediately following the end of the works, all safety and protective devices have to be reassembled respectively have to be put to work again. - On a repeated start-up all points given in the paragraph initial commissioning have to be observed again. 2.7 Prohibition of unauthorized rebuilding measures or alterations - Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer. Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee safety. The use of other parts may lead to a loss of the manufacturer's liability for the consequences. 2.8 Inadmissible operating modes - The operational safety of the delivered machine is only guaranteed by proper use acc. to the data of the technical agreement. - The limits given in the data sheet must not be exceeded in any case. 2.9 Explosion protection - Any designation on the pump refers to that pump component only. Shaft coupling, driving motor (e.g. electric motor) and auxiliary systems (shaft sealing, lubricating oil system, etc.) must be looked at separately. - Improper operating methods that result in the specified temperatures being exceeded (exceeding or falling short of the operating data, falling short of the minimum delivery flow, reduction or failure of cooling water or circulation delivery, etc.) should be avoided at all costs. - Before starting the pump makes sure that the pump system (suction pipe and shaft seal) is completely full of delivery fluid. This prevents the existence of any potentially explosive atmosphere in the system. - Monitor pump operation constantly (instruments such as: manometers, thermometers, speed counters, ammeters, etc.).。 - Maintain the pump properly. Only machines that are in perfect technical condition can guarantee safe operation.



3



PACKAGE、 TRANSPORT & STORAGE



3.1 Package General Ancillary items shall be prepared for storage in accordance with applicable manufacturer’s recommendations. 3.1.1 Products shall be attached with pack list before shipment. 3.1.2 Package shall meet the regulation of GB/T13384. 3.1.3 Products could be packed according to pack list after paint is dry and checked up，then put pack lists to each case. 3.1.4 Package shall steady to avoid damage products in transportation and disassembly due to slide and impact, such as fixing rotor. The inlets and outlets of pump, pipe holes and instrument interface shall be covered with covering plates or plugs to avoid ingress of foreign matters. 3.1.5 It is necessary to check up all of parts, units, technical documents and pack lists .If pass, then envelop cases. Technical documents shall be putted into waterproof packaging. 3.1.6 Cases shall be marked with: customer and address; type and name of product; rough weight and net weight; size of case (length, width, height, unit: cm); manufactory and address necessary transport mark and standard no. of product. 3.2 Transport/Lifting General remarks For all transport jobs the general rules of engineering and regulations on the prevention of accidents have to be strictly observed. For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named. Transport Transport devices (including vehicles) have to be checked for the admissible load weight. Total weight of the delivered goods see dispatch documents. The load has to be secured during transport against shifting. Lifting Check of the load suspension devices / ropes It has to be assured that admissible, undamaged ropes and lifting devices will be used. The loading capacity of the lifting devices and the ropes has to be suitable to take up the weight of the goods to be lifted. Load weight indications of the delivered units are given in the installation plan respectively the dispatch documents. Never stay within the range of suspended Fastening of the sling ropes on crates The points for the fastening of sling ropes on closed crates are marked. As the center of gravity (mass) cannot be recognized in closed crates, the sling rope fastening has always to be done at the marked spots.. Fastening spots for equipments



In case lifting lugs or bars are attached at the baseplate, the unpacked unit has to be fastened at these spots by shackling the rope. Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the complete assembled pump or even the whole unit. The eyebolts are only meant for the lifting of the loosened parts during assembly and disassembly 3.3 Storage Pump and accessories shall be provided with damp proof and rust preventive means to ensure no rust and damage occurs within one year. If over twelve months, it is necessary to disassemble single volute pump to check 、 spot-check core of barrel casing pump and re-carry out rust-proofing treatment. Duration of validity of oil seal is twelve months, it shall be checked timely. Centrifugal pumps which are not installed and commissioned immediately after delivery can be stored for the period determined by the dispatch preservation. The pump unit can be stored in a clean and dry warehouse without maintenance measures up to the time given by the dispatch preservation. To avoid the forming of condensate and consequently corrosion ATTENTION (especially in the gap areas), bearing damage and contamination, a dry room, possibly with constant temperature as well as a clean, shock- free storage space has to be selected. ATTENTION In each case unfavourable climatic circumstances will have a negative influence on period of proper preservation. In case the units are not or no longer enclosed in a special packing the following has to be observed: ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying temperatures (day/night), acidy or alcaline ambience, danger of contamination (dirt etc.) the connection flanges of the pumps have to be plugged airtight. ATTENTION If the bearing housing is only be filled with lubricating oil for intermediate start-up. Turn pump rotor by hand at least 5 revolution in the proper direction every month. Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety precautions specified by the manufacturers.



4 DESCRIPTION OF EQUIPMENT The type HZB 200-430 pump is a horizontal, radially spilt, single-stage, double-suction, single volute pump. Integral suction and discharge nozzles are set at the top of the pump. The volute casing is an integral part of the pipe work. For overhauls the heavy piping has not to be removed. The internal parts with shaft, impeller and casing cover can be removed towards non-driven side. The internal parts are surrounded on all sides by the liquid and thus uniform heating is assured. The pump comprises steel casting with integral suction and discharge nozzles and bolted chrome steel DE and NDE suction covers. The rotating assembly comprising principally the shaft and the impeller is supported by DE journal bearings and NDE journal bearings and angular contact ball bearings (back-to-back). Impeller: Closed double suction design impellers are used. The impeller is key-driven and axially retained with threaded sleeves. Wear ring: Replaced case and impeller wear ring provides close running clearances and result in savings of spare part costs at purchase and repairs. Shaft: Accurate machining provides precision fits and clearance for assembly and operation. Machined shoulders provide positive location of mounted parts. Gasket: Fully confined compression gaskets between case and case covers. Shaft seal: Single mechanical seals are fitted at both ends of the pump casing. Bearing： The bearing housings are screwed with the suction covers. After assembly of the bearing housings and the rotating assembly to the pump casing, the bearing housings are aligned by centring of the shaft within the bore of the suction covers, and the bearing housings are positioned by dowel pins. Sleeve bearings absorb the radial loads in the bearing housing of two sides. A duplex angular contact ball roller bearings (back-to-back) are installed in the N.D.E. bearing housing to assure freedom from interference with the radial bearing and take up the residual axial forces. Lubrication of each bearing is by means of a lubrication ring which rotates on a sleeve. Each bearing housing is provided with an oil indicator, an oil constant level oiler and an air breather. The lubrication oil is cooled by the oil cooler at the bottom of bearing housing. The journal bearing depends on throwers to dip into the oil reservoir and throw oil into troughs on the shaft. Oil flows through the bearings and returns to the reservoir. The rolling bearing depends on lubricating rings to dip into the oil reservoir and throw oil into troughs on the rolling bearing. Oil flows through the bearings and returns to the reservoir.



5 SCOPE This section contains general information and advice on booster pump maintenance procedures for a horizontal pumpset. These general instructions are provided as guidelines to aid and direct a safe and efficient maintenance project. It also provides a general booster pump set maintenance schedule that can be adapted and used as required when a specific site maintenance schedule is not available. It is essential that the plant safety rules and regulations are observed at all times during maintenance procecdures. Note: The booster pump is an integral part of the pumpset. The following instructions should, therefore, be read in conjunction with those for the boiler feed pump and the associated equipment. 5.1 Equipment condition 5.1.1 Performance record Keep a written performance log for the equipment. An ongoing performance record will assist troubleshooting and future pump service decisions. Long shutdowns and unnecessary expense can then be avoided. Pressure indicators can be installed into tapped openings in the suction and discharge nozzles to provide much of the data required for performance analysis. Periodic trending vibration recordings are necessary to diagnose excessive vibration levels. 5.2 General overhaul information and advice Dismantling Check for toxic or otherwise harmful fluids before loosening bolted joints or pipe connections. Collect and dispose of toxic or otherwise harmful fluids in accordance with the current environmental regulations to prevent endangering people or the environment. -



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Before starting any maintenance activity, ensure that: - Electrical power breakers are locked in the OFF position. - The booster pump is at ambient temperature. - Booster pump system pressure has been isolated. - The booster pump is drained and vented (by removing drain plugs or opening valves as applicable). - Suction, discharge, and auxiliary piping valves are closed. Cap the ends of all disconnected pipework to prevent the entry of dirt. During any dismantling procedure, mark all removed parts to enable replacement in the same position. Protect all parts. Place larger parts in a protected area and wrap in cloth or plastic. Place smaller parts and bolting in bags or boxes, and identify with labels where components are for re-assembly. Protect screwed joints and threads. Refer to each dismantling / assembly section for information on specific requirements for special tools and equipment. Obtain any required items before starting maintenance activities. Check booster pump rotation. Note that certain threaded shaft



components may be tightened against rotation and may have a left-hand thread. Assembly When the supplied booster pump and pumpset equipment is classified as suitable for use in a Hazardous Area, the following conditions during maintenance procedures MAY invalidate the Hazardous Area classification and MUST be avoided: • failure to maintain correct casing / impeller / bearing clearances, as detailed in Booster Pump Data. • failure to use NEW O-ring seals, gaskets, seals or nut locking devices of the correct type and size at all appropriate stages during assembly procedures. • failure to maintain bearings correctly. • failure to re-connect main (suction and discharge) pipework correctly to the pump casing in accordance with manufacturer’s information and current regulations. • failure to re-connect auxiliary pipework correctly in accordance with manufacturer’s information and current regulations and to direct the vent and drain pipework to suitable safe locations / containers. • failure to re-connect electrical equipment power supply and control cables and instrument cables correctly in accordance with manufacturer’s information and current regulations. • failure to ensure correct direction of rotation for the driver in accordance with manufacturer’s information. • failure to install the coupling spacer and coupling guard correctly in accordance with manufacturer’s information and current regulations. - All parts must be absolutely clean and free of oil or dust. Technical grade acetone is recommended for cleaning machined surfaces immediately before assembly. Air dry (use filtered, dry air) cleaned parts in a dust-free area. The rust inhibitor on machined surfaces should be removed with a suitable solvent. Ensure that there is no paint on locating spigots or recesses. - Handle all parts carefully so that they are not dropped, or damaged in any other way. - Ensure any burrs or dirt on the faces of sleeves and impeller bores are removed. Anti-scuffing paste must be applied to sleeves and impeller bores to facilitate later dismantling. - New gaskets, seals and O-ring seals of the same material, type and size as originally supplied must be used for re-assembly operations. The O-rings must be fitted carefully to prevent the risk of damage. - Powdered molybdenum disulphide can be used as a shaft lubricant. CAUTION



At all stages during assembly of the pump, it is essential that the pump shaft is adequately supported to prevent bending and/or damage to the bearings.



5.3 Shipping from site All equipment must be completely drained and decontaminated before removal from site.



5.4 Completion of booster pump overhaul Re - commission the booster pump following every overhaul. 5.5 Scheduled maintenance



5.5.1



5.5.2



5.5.3



5.5.4



When the supplied pump and pumpset equipment is classified as suitable for use in a Hazardous Area, the following conditions during scheduled maintenance procedures MAY invalidate the Hazardous Area classification and MUST be avoided: • Failure to detect and rectify leaks from main (suction and discharge) pipework connections to the pump casing • Failure to detect and rectify leaks from auxiliary pipework and associated equipment (i.e. mechanical seal, seal system, coolers, instruments) connections • Failure to maintain ancillary equipment and systems in accordance with manufacturer’s information Refer to the General Arrangement drawing, the pump Longitudinal Section drawing, and other drawing or document in Drawings and Documents. Daily checks - Perform a ‘walk-around’ inspection of the pumpset, preferably while the pumpset is operating, and: - Carry out a visual check for leaks, or damage to components. Pay particular attention to main and auxiliary pipework connections. Repair or report any damage or leaks. Note: Except for a daily visual inspection to check for excessive external leakage. In this event the pump should be taken out of service and the seal repaired or replaced. - Check all indicating instruments for correct functioning and unusual readings. Report faults and investigate the cause of any unusual readings. - Check the oil level in the constant level oilers - replenish as required. Record the replenishment amount to identify excessive oil loss / consumption. - Check for unusual noises. - When applicable, check strainer / filter differential pressures. Weekly checks - Check the oil level in the constant level oilers - replenish as required. Record the replenishment amount to identify excessive oil loss / consumption. - Record readings for all indicating instruments (identifies gradual changes in readings over time and may help to identify a developing problem in pumpset operation). Monthly checks - Check the temperature and vibration levels etc. against the string test reference readings for normal expected values. (This information should be recorded and used as a bench mark for future readings). Six-monthly checks - Replace the lube oil in the bearing housing. - Check the alignment of the drive coupling.



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5.5.5



Check the pump performance against reference data. Inspect all parts for damage to paintwork, and repaint if necessary. If evidence of rust is found, affected areas must be cleaned, de-rusted and then repainted. - Bright metal parts should also be examined for rust, the surfaces cleaned, and a film of Shell Ensis fluid re-applied as necessary. Yearly checks - Check the security of all holding down bolts (or every 8000 operating hours )



5.6 Fault diagnoses Analyze the booster pump performance before carrying out disassembling. Some problems may be resolved without disassembly. Performance records are useful to reduce the problem and estimate if the problem is caused by machine, hydraulic choice or system. The system problems mostly result from the system of the booster pump suction. Obviate the improper adjust of the control system. Mechanical and hydraulic problem are always related, so the reason is difficult to find. Refer to Fault diagnoses.



Problem



Diagnoses



Measure



No discharge pressure. Failure to deliver liquid at start-up.



Driver out of service, speed too low



Refer to the driver manufacturer’s information.



Lack of downstream back-pressure.



Check control valve setting and adjust valve to increase pressure.



Direction of rotation wrong.



Check power supply cables to motor driver, remove and reconnect to the correct terminals.



Pump not primed.



Refer to Commissioning and Operation and prime system with product.



Impeller passages obstructed.



Replace / overhaul pump.



Downstream control valve opening too far.



Investigate valve actuator and control system operation. Adjust as necessary to maintain correct valve opening.



Air pocket in suction line.



Open all vents to eliminate air from pumping system.



Insufficient suction pressure causing product to vaporise in pump.



Check pump design requirements and proceed to make necessary changes or adjustments to system and create sufficient pressure.



Suction strainer clogged.



Remove and clean, or replace, suction strainer screen.



Pipe strain or coupling misalignment.



Refer to Installation and Coupling Alignment. Check alignment and pipe strain - adjust as necessary.



Pump base not grouted, or air pockets exist between grout and base plate top plate.



Locate voids by tapping on top plate. Fill voids completely with grout, drilling additional holes in top plate if necessary to evacuate air.



Cold offset not accounted for during final alignment.



Refer to Installation and Coupling Alignment. Check alignment taking cold offset into account.



Loss of discharge pressure after start-up.



Vibration and noise.



Reduced pump output flow.



Short seal life. Excessive seal leakage. Seal flush injection line hot.



Improperly balanced rotating element or coupling.



Contact with manufactory.



Impeller passages obstructed.



Replace / overhaul pump rotor.



Bent shaft.



Replace / overhaul pump rotor.



Minimum flow line open or partially open.



Review minimum flow circuit and make corrections to ensure proper operation.



Impeller passages obstructed.



Replace / overhaul pump rotor.



Pump internals worn on close running clearance surfaces.



Replace / overhaul pump rotor.



Seal flush flow rate insufficient.



Seal flush system not vented.



Refer to seal manufacturer’s information. Open seal flush line vents to remove all entrapped air from system.



Seal pumping ring not secure or rotating backwards.



Refer to Mechanical Seals and to seal manufacturer’s information. Remove and check mechanical seal assembly for loose parts and pumping ring orientation.



Excessive seal flush flow velocity.



Wrong orifice up-stream of seal.



Remove from line, check size against flow requirements and replace if necessary.



Particulates in seal flush.



Clogged seal springs lock up.



Refer to Mechanical Seals and to seal manufacturer’s information. Remove seal assembly and replace springs. Review seal application if problem persists.



Seal face materials inadequate for abrasive service.



Review application with seal vendor and replace parts according to recommendation.



Coupling misalignment.



Refer to Installation and Coupling Alignment. Check alignment and adjust as necessary.



Bent pump shaft.



Replace / overhaul pump rotor.



Coupling misalignment.



Refer to Installation and Coupling Alignment. Check alignment.



Oil level too low or high.



Refer to Lubrication for correct level, and adjust as necessary.



Oil viscosity too high.



Use oil of recommended grade.



Excessive pump thrust.



Replace / overhaul pump rotor.



Worn out bearings.



Refer to Bearing Assemblies. Replace bearings.



Incorrectly installed bearing.



Refer to Bearing Assemblies. Examine assembly and condition of bearing and associated parts. Adjust assembly and replace parts as necessary.



Pump overheating / seizure.



Pump operating below minimum flow.



Review pump operating parameters with a SPEM representative. Dismantle and repair unit and follow correct procedures during future operation.



Short term corrosion erosion



Materials of construction not compatible with product.



Review pump operating parameters with a SPEM representative and make necessary corrections to unit design.



High bearing temperature.



6



MAINTENCE PARTICULARS



6.1 Estimated weights Pump Pump baseplate Rotor Ring section Suction cover Bottom half bearing housing (non-drive end) Top half bearing housing (non-drive end) Bottom half bearing housing (drive end) Top half bearing housing (drive end) Pump shaft Impeller



Weight (kg) 1250 1200 70 500 150 30 12 22 8 23 25



6.2 Joints Joint between



Material



Size



Pump casing and suction guide



1Cr18Ni9Ti+ Graphite



Spiral round gasket φ455/φ 435×4.5



Cooling bush cover and suction cover



Fluorine rubber F275



O ringφ184/3.53



Fluorine rubber F275



O ringφ100/3.53



Nitrile rubber bunan



O ringφ85/3.53



Bearing housing cover and bearing housing



7 LUBRICANT Recommended lube: N32 or N46 turbine oil



8



ROUTINE MAINTENANCE



8.1 Preparation for maintenance Before commencing any maintenance procedures, the pumpset must be isolated as follows: (1) Isolate the electrical supply to the motor; (2) Isolate the electrical power supplies to all instruments; (3) Check the pumpset suction and discharge isolating valves and the leak-off isolating valves are shut; (4) Isolate the cooling water supply; (5) Close the pump tap stage isolating valve; (6) Open the drain and vent connections, and drain the pump casing; (7) Before proceeding with any maintenance on the pump, ensure that there is no pressure within the pump casing. 8.2 Examining the bearing The following instructions apply when the pump bearings are to be dismantled for examination and/or renewal in situation. 8.2.1 Journal bearing, D.E. 8.2.1.1



Dismantle (1) Prepare the pump for maintenance, as described in Section 8.1. (2) Remove the coupling guard. Remove the coupling flexible elements, spacer and pump-half coupling hub. (3) Disconnect and remove the instrumentations from the bearing housing, and store in a safe place. (4) Drain any remaining oil from the bearing housing into a suitable container. (5) Carefully disconnect and remove auxiliary pipework from the bearing housing. Plug pipework ends to prevent ingress of dirt. (6) Remove bolt and dowel pins of the bearing housing top half. (7) Lift the bearing housing top half carefully away from the bottom half and lower it onto a flat surface, padded with cloth to protect the machined surface. Remove the lifting equipment. (8) Verify match-marks for re-assembly, and then remove the top half of the journal bearing and oil guard. (9) Remove thrower away from the lower half of the journal bearing .Lift the shaft slightly (maximum 0.1 mm) using a suitable piece of wood, then rotate the lower half of the journal bearing around the shaft and remove it. Lower the shaft.



8.2.1.2



Examination of bearing Journal Bearing



Visually inspect the journal bearing surfaces for excessive scoring and heat damage. Check whether the running surfaces, the bearings and the oil guard wear or not. Renew them if excessive wear or damage is present. Measure the bearing clearance and checked against the details given in Section 9.6.5. If the clearance has reached the maximum permissible clearance, or is likely to do so before the next overhaul, the component should be renewed. Bearing Housing Check bearing housing fits, filing off any interference points. 8.2.1.3



Assembly



8.2.1.4



Note:Ensure that the DE mechanical seal is installed before re-assembling the DE bearing assembly.



CAUTION



Check taper pins / dowel pins for proper fit and seating (not "bottoming") before tightening the screws. Incorrect seating affects rotating element radial centring. (1) Wipe clean and then generously lubricate the bearing surface of the journal bearing bottom half and the shaft bearing surface. (2) Raise the shaft slightly (max 0.1 mm) using a suitable piece of wood and fit the bearing half and oil guard. Lower the shaft.Fit the thrower. (3) Wipe clean and then generously lubricate the bearing surface of the journal bearing top half and the shaft bearing surface. (4) Fit the journal bearing top half and oil guard. (5) Lift the bearing housing top half into position on the housing bottom half ,ensuring that oil guard and anti-rotation pin are in the correct place. (6) Insert the dowel pins through the flange joint between bearing housing halves to position the bearing housing top half.Fit the screws and tighten them. (7) Refit auxiliary pipework and refit and connect instrumentation as appropriate.



CAUTION



8.2.2 8.2.2.1



After both bearing assemblies have been fitted, turn the shaft manually and check that the rotating element rotates freely before completing labyrinth seal fit. Also check that the endplay of the pump rotor is correct. (8) Refit the pump-half coupling hub and coupling spacer as required. NDE bearing assembly Dismantling (1) Prepare the pump for maintenance, as described in Section 8.1. (2) Remove the coupling spacer. (3) Disconnect and remove the instrumentation from the bearing



housing, and store in a safe place. (4) Drain any remaining oil from the bearing housing into a suitable container. (5) Carefully disconnect and remove auxiliary pipework from the bearing housing. Plug pipework ends to prevent ingress of dirt. (6) Remove the cover mounting screws. Remove the bearing suction cover, complete with O-ring seal. (7) At the horizontal joint flanges of the bearing housing halves, remove the locating taper pins / dowel pins and screws. Note: If temperature detector wires are fitted, they must be guided carefully as the bearing housing top half is removed. (8) Lift the bearing housing top half carefully away from the bottom half and lower it onto a flat surface, padded with cloth to protect the machined surface. Remove the lifting equipment. (9) Verify match-marks for re-assembly, and then remove the top half of the journal bearing and oil guard. (10)Remove thrower away from the lower half of the journal bearing .Lift the shaft slightly (maxium 0.1 mm) using a suitable piece of wood, then rotate the lower half of the journal bearing around the shaft and remove it. Lower the shaft. (11)Loose the grub screws on the sleeve nuts. Remove the bearing sleeve nuts and thrower. (12)Insert the splitted adjusting ring for dismantling into the space between the bottom bearing housing and the angular contact ball bearings. (13)Remove dowel pins and screws securing bearing housing bottom half to suction cover. (14)Remove the angular contact ball bearings and the bearing housing bottom half. 8.2.2.2



Examination of bearing



Thrust Bearings Visually inspect the journal bearing surfaces for excessive scoring and heat damage. Check whether the running surfaces, the bearings and the oil guard wear or not. Renew them if excessive wear or damage is present. Measure the bearing clearance and checked against the details given in Section 9.6.5. If the clearance has reached the maximum permissible clearance, or is likely to do so before the next overhaul, the component should be renewed. Bearing Housing Check bearing housing fits, filing off any interference points. 8.2.2.3



Assembly Note: Ensure that the NDE mechanical seal is installed before re-assembling the NDE bearing assembly. (1) Fit two suitable eyebolts to the bearing housing bottom half, one on each side using suitable tapped screw holes in the joint flange. Lift the bearing housing bottom half into position on the suction casing, Insert the locating dowel pins and fit screws loosely to secure the bearing housing. Seat the dowel pins, then fully tighten the mounting screws.



CAUTION



CAUTION



Check the dowel pins before tightening the nuts. It may affects rotating element radial centring. Refer to Radial centring of rotating assembly. Renewing the bearing housing bottom half should ensure the rotating element radial centring. Refer to Radial centring of rotating assembly. (2) Install the angular contact ball bearings (a)The thrust bearing is a duplex angular contact bearing,mounted in a back-to-back configuration. Always purchase, store and use the pairs as a unit. Never replace only one bearing of a pair.



CAUTION



New bearing should be left in factory-sealedl packages and stored in a dry area until immediately before installation. Cleanliness during bearing assembly is required to avoid contamination and failure. (b)Bearings can be oven-heated(95~105°C, thermostatically controlled is recommended)or heated in an oil bath. Avoid overheating or prolonged heating to minmise potential distortion.



CAUTION



Use of induction heaters is discouraged. Torch heating of bearings is forbidden. (c)Apply straight pressure to inner race to avoid binding. Seat securely up to spacer sleeve.



(3) Refit sleeve nuts and thrower. (4) When the temperature of the bearing and the shaft falls to the environmental temperature, re-tighten the sleeve nuts. CAUTION



Correct tightening of a shaft nut is required to ensure that inner race faces are in correct contact. The nut should be tightened sufficiently to ensure no axial play exists between the shaft shoulder, axial adjusting ring, bearing inner race and sleeve nut, but no over-tighten. (5) Tighten the grub screws on the sleeve nuts. (6) Raise the shaft slightly (max 0.1 mm) using a suitable piece of wood and fit the bearing half and oil guard. Lower the shaft.Fit the thrower. (7) Fit the thrower to the bearing bottom half. (8) Wipe clean and then generously lubricate the bearing surface of the journal bearing bottom half and the shaft bearing surface. (9) Fit the journal bearing top half and oil guard. (10)Lift the bearing housing top half into position on the housing bottom half ,ensuring that oil guard and anti-rotation pin are in the correct place. (11)Insert the dowel pins through the flange joint between bearing housing halves to position the bearing housing top half.Fit the screws and tighten them. (12)Fit a new ‘O’ ring seal to the bearing suction cover. Fit bearing suction cover on bearing housing. Tighten bolts to locate bearing suction cover. Check the allowable clearance between suction cover and the locating surface of bearing housing.



CAUTION



After both bearing assemblies have been fitted, turn the shaft manually and check that the rotating element rotates freely before completing labyrinth seal fit. Also check that the endplay of the pump rotor is correct. (13)Refit the auxiliary pipes as required and connect instruments. (14)Reinstall plug and constant level oil .Refer lubrication and replenish the bearing housing oil level. (15)Refit the coupling spacer.



8.3 Check mechanical seal Note: A small leakage of the mechanical seal is normal. In case of leakage seal ring pairs may also leak. If so the damaged parts have to be replaced. Seals have to be replaced during each assembly. Rotating and stationary seal rings must be replaced together. 8.3.1



Mechanical seal D.E.



Note: The coupling hub and DE bearing assembly must be removed before removal and/or installation of the DE mechanical seal. 8.3.1.1



Disassembly (1) Refer to 8.2.1 - DE journal bearing and remove the DE journal bearing assembly. (2) Remove the dowel pins and nuts of bearing housing bottom half and suction cover and remove the bearing housing bottom half. Remove the thrower. (3) Remove auxiliary pipework to enable access to the mechanical seal. Plug pipework ends to prevent ingress of dirt. (4) Revolve and embed the mechanical seal plate to the trough of the mechanical seal sleeve (5) Loose the grub screws of mechanical seal sleeve and not scuff the shaft during disassembly. (6) Remove the bolts of the mechanical seal cover and the mechanical seal. Be careful to the discharge of survival.



8.3.1.2



Check mechanical seal Check mechanical seal according to mechanical seal instruction and assemble it.



8.3.1.3



Assembly (1) Fix the mechanical seal and tighten the bolts of suction cover. (2) Tighten the grup screws of seal sleeve. (3) Rotate the mechanical seal plate out of the trough of sleeve and tighten it. (4) Slide the thrower to the correct position of the shaft. (5) Fit two suitable eyebolts to the bearing housing bottom half, one on each side using suitable tapped screw holes in the joint flange. Lift the bearing housing bottom half into position on the suction casing, Insert the locating dowel pins and fit screws loosely to secure the bearing housing. Seat the dowel pins, then fully tighten the mounting screws. (6) Refit the auxiliary pipes as required. (7) Refer 8.2.1 - Journal bearing D.E and refit journal bearing D.E.



CAUTION



8.3.2



After both bearing assemblies have been fitted, turn the shaft manually and check that the rotating element rotates freely. Also check that the endplay of the pump rotor is correct. Mechanical seal N.D.E Note: .The NDE bearing assembly must be removed before removal and/or installation of the NDE labyrinth seal.



8.3.2.1



Disassembly (1) Refer 8.2.2- Journal bearing N.D.E., remove journal bearing N.D.E. (2) Remove the axial adjusting sleeve. (3) Slide the thrower from shaft. (4) Remove auxiliary pipework to enable access to the mechanical seal. Plug pipework ends to prevent ingress of dirt. (5) Revolve and embed the mechanical seal plate to the trough of the mechanical seal sleeve. (6) Loose the grub screws of mechanical seal sleeve and not scuff the shaft during disassembly. (7) Remove the bolts of the mechanical seal cover and the mechanical seal. Be careful to the discharge of survival.



8.3.2.2



Check mechanical seal Check mechanical seal according to mechanical seal instruction and assemble it.



8.3.2.3



Assembly (1) Fix the mechanical seal and tighten the bolts of suction cover. (2) Tighten the grup screws of seal sleeve. (3) Rotate the mechanical seal plate out of the trough of sleeve and tighten it. (4) Slide the thrower to the correct position of the shaft. (5) Fit the axial adjusting sleeve.



CAUTION



Adjust the length of axial adjusting sleeve, it affects the rotating element radial centring. Refer to- Axial centring of rotating assembly. (6) Refer 8.2.2- Journal bearing N.D.E. and refit journal bearing N.D.E. and angular contact ball bearing.



CAUTION



After both bearing assemblies have been fitted, turn the shaft manually and check that the rotating element rotates freely. Also check that the endplay of the pump rotor is correct.



9



OVERHAUL



9.1 Preparation Study the following procedures as well as the booster pump Longitudinal Section drawing, and other available drawings and documents, and be familiar with the design details and assembly sequence. Plan the operations and have withdrawal and assembly equipment, and other special tools available. This includes any required measuring devices. 9.2 Examination and cleanliness Unless the pump casing needs renovation, it will remain installed after the booster pump rotor has been removed. The pump casing must be protected from ingress of dirt and physical damage during the maintenance cycle. 9.3 Balancing marks Component parts of the rotating element are match-marked on their peripheries. These marks must be lined up on assembly with corresponding, similar marks stamped on the shoulders to preserve the balance of the pump rotor. 9.4 General information on dismantling and assembly 9.4.1 Dismantling Check for toxic or otherwise harmful fluids before loosening bolted joints or pipe connections. Collect and dispose of toxic or otherwise harmful fluids in accordance with the current environmental regulations to prevent endangering people or the environment. -



-



-



Before starting any maintenance activity, ensure that: - Electrical power breakers are locked in the OFF position. - The pump is at ambient temperature. - Pump system pressure has been isolated. - The pump is drained and vented (by removing drain plugs or opening valves as applicable). - Suction, discharge, and auxiliary piping valves are closed. Cap the ends of all disconnected pipework to prevent the entry of dirt. During any dismantling procedure, mark all removed parts to enable replacement in the same position. Protect all parts. Place larger parts in a protected area and wrap in cloth or plastic. Place smaller parts and bolting in bags or boxes, and identify with labels where components are for re-assembly. Protect screwed joints and threads. Refer to each dismantling / assembly section for information on specific requirements and equipment. Obtain any required items before starting maintenance activities.



9.4.2



Assembly All parts must be absolutely clean and free of oil or dust. Technical grade acetone is recommended for cleaning machined surfaces immediately before assembly. Air dry (use filtered, dry air) cleaned parts in a dust-free area. The rust inhibitor on machined surfaces should be removed with a suitable solvent. Ensure that there is no paint on locating spigots or recesses. Handle all parts carefully so that they are not dropped, or damaged in any other way. New gaskets, seals and O-ring seals of the same material, type and size as originally supplied must be used for re-assembly operations. The O-rings must be fitted carefully to prevent the risk of damage. Lubricate screwed joints and threads with glycerine or ’ polytetrafluoroethylene’. When applicable, re-assemble small bore pipework using new plugs in unions that have been disconnected.



9.5 Booster pump disassembly Refer to the Longitudinal Section drawing as applicable in Drawings and Documents. (1) Remove the D.E. bearing and the mechanical seal according to 8.2.1.1 and 8.3.1.1. (2) Remove the journal bearing N.D.E., rolling bearing and mechanical seal according to 8.2.2.1 and 8.3.1.1 CAUTION



Mark on the suction cover and pump casing. Refit at the same place. (3) Unscrew nuts fastening the casing cover(N.D.E). Loosen nuts crosswise and remove the nuts and discs. (4) Use a rope sling to lift the casing cover. Carefully pull casing cover away from pump casing.Take care not to damage the shaft during casing cover removal. Be careful: Remaining medium will flow out. (5) Use a rope sling to lift the rotor in two steps with the aid of a crane out of the pump casing. Use care to minimize shaft stress by placing the slings as close to the impeller as possible. First use a rope sling to lift the rotor from the D.E. and N.D.E. Carefully move it to N.D.E. until the impeller is out of the pump casing. (6) Position the dismantled rotor horizontally onto a flat wooden surface and support as required. (7) Unscrew nuts fastening the casing cover(D.E.). Loosen nuts crosswise and remove the nuts and discs. (8) Use a rope sling to lift the casing cover(D.E.). Carefully pull casing cover(D.E.) away from pump casing.



(9) Remove rotation element (a)Bend the lock washer tab out of the lock nut and remove the lock nut and the lock washer. (b)Slide the shaft sleeve out of the shaft and disengage the key. (c)The Impeller is transient fit. Using soft flame heater to heat up around of the impeller until the impeller can be removed. Remove the impeller key. (10)Remove the cooling bush housing of the suction cover(D.E. and N.D.E.) and discard the ‘o’ ring. 9.6 Inspection, renewal and repair procedures All components should be thoroughly cleaned and inspected for any signs of wear or damage. All diametrical running clearances between components should be measured, using internal and external micrometers, and compared with the values given in Section 9.6.5. If the clearance has reached the maximum permissible clearance, or is likely to do so before the next overhaul, the component should be renewed. The main consideration, however, is pump performance, i.e. an unacceptable decrease in pump discharge pressure, a significant increase in motor power consumption or an increase in vibration to an unacceptable level is noted and the pump should be overhauled. 9.6.1 Impeller and wear ring Inspect the impeller for wear and damage. Look for the cavitation mark in the suction area, erosion of vanes and cracks in the shroud. Examine the impeller bores and keyways for fretting or any damage which may have occurred during dismantling, and remove any burrs. Ensure that the impeller bores are perfectly smooth and free from distortion. Renew the impeller as necessary. If impeller shows wear, a balance check should be performed before use. Examine the impeller and casing wear rings, and measure the diametrical clearances between them. If the measured clearance exceeds the maximum permissible clearance, given in Section 9.6.5 , the wear rings must be renewed. Replace wear rings when pump performance drops below acceptance system standard or the recommended clearances have been reached of exceed. 9.6.2 Shaft Examine the shaft for any signs of damage or bowing, and check for concentricity: it should be within 0.025 mm full indicator movement. 9.6.3 Journal and thrust bearing (1) Thoroughly clean the journal bearings and examine them for signs of wear or damage. Measure the radial clearances. If the clearances exceed the values given in Section 9.6.5., renew them. (2) Thoroughly clean the rolling bearings and examine them for signs of wear or damage. Renew them as necessary. It is generally considered good practise to replace bearing during a major



overhaul. (3) Examine the oil guard for any signs of wear or damage and renew as necessary. 9.6.4



General (1) Examine all studs, nuts and bolts for any signs of damage or deterioration. Renew as necessary; (2) All joints and ‘O’ rings, anti-extrusion rings and Garlock seals should be renewed on assembling; (3) Examine the components of the coupling flexible elements assemblies and coupling bolts for wear or damage and renew as necessary.



9.6.5 Clearance The table gives the running clearances. Column 1 shows the new clearance and Column 2 the clearance at which the component(s) should be renewed. Clearance between(diameter) Ⅰ Ⅱ Journal bearing and pump shaft 0.05~0.09 0.11 Ring section wear rings and impeller 0.40~0.496 0.6 Oil guard 0.10~0.15 0.2 Total axial clearance (in rolling bearing) 0.02~0.05 Total axial clearance, rolling bearing removed 10±1 9.6.6 Dynamic balance If the impeller or half coupling is renewed, it should be noted that though the new components are balanced individually during manufacture, they may affect the dynamic balance of the complete assembly. Therefore, rotor must always be dynamic balanced when renewing or repairing and is strongly suggested to be done at works of manufacture. Where suitable workshop facilities are available, the recommended method of checking the dynamic balance is as follows: (1) Support the assembly at the bearing centre lines and check that it is balanced within quality grade G6.3 in GB9239.1-2006 (ISO 1940.1-2). (2) Dynamic balance is to be achieved by removing metal from the impeller shrouds, within the following limits: If the amount of metal to be removed exceeds the limits imposed by (a) and (c), SPEM should be consulted. (a) The thickness of impeller shroud must not be reduced by more than 2mm at any point. (b) Remove metals between the 380~420 mm diameters. (c) The weight of metal to be removed is to be calculated in the form of a segment, the arc of which does not exceed 0.1 of the circumference of the



impeller.



9.7 Assembling the booster pump All components must be perfectly clean and all bores and oil ways must be cleaned before the pump is assembled. Note: During assembly, it is recommended that colloidal graphite, or similar, is applied to the shaft and to the bores of the impellers and sleeves, allowed to dry and the surfaces then polished.



9.7.1



Assembly (1) Vertically put the pump shaft on the bracket and fit the impeller key. (2) The Impeller is transient fit. Using soft flame heater to heat up around of the impeller. Then fit the impeller over the shaft and key until it abuts the shoulders. (3) When the shaft and impeller have cooled, fit the shaft sleeve and lock washer and tighten the lock nut. Use the lock washer to lock the nut. (4) Clean the pump casing and examine all the seal faces in the pump casing. Any impress or groove is unallowable. (5) Clean the cooling housing and seal face of D.E. cover. Place new ‘O’ ring . Fit the cooling bush cover and tighten the bolts. (6) Fit the D.E. cover and use new seal ring. Carefully sling the suction cover to pump casing. Lubricate the face of thread and nut, tighten the nut crosswise and equably. (7) Use a rope sling to lift the rotor with the aid of a crane into the pump casing. Use care to minimize shaft stress by placing the slings as close to the impeller as possible. (8) Renew new seal ring on the N.D.E. suction cover. Use a rope sling to push the suction cover with the aid of a crane to the shaft and into the pump casing. Lubricate the face of thread and nut, tighten the nut crosswise and equably. (9) Fit the N.D.E. mechanical seal and journal bearing as 8.3.2.3. (10)Fit the D.E. mechanical seal and journal bearing as 8.3.2.3. (11)Fit the pipeline and instruments.



(12)Fit the coupling and guard. 9.7.2 Radial centring of rotating assembly If a replacement bearing housing is to be fitted to a suction cover, it is necessary to align the bearing housing before drilling and reaming two new holes for the locating dowel pins. To do this it is necessary for the mechanical seals to be removed to allow access to the bores of the suction covers. CAUTION



9.7.3



An incorrectly fitted replacement bearing housing, or inproper bearing housing to case taper pin seating, can affect radial centring of the rotating assembly, leading to damage. (1) Install the journal bearings and the bearing housings at both ends of the pump, without installing the mechanical seals. (2) Begin the following procedure at the end of the pump which has a new housing, or if both housing are new, begin at either end. (3) Attach a suitable small-sized dial indicator on the shaft, with the probe positioned on the inside surface of the bore in the suction cover. (4) Set the dial indicator to zero. (5) Rotate the shaft through 360°and take measurements of the runout between the shaft and the bore of the cover at 90°interval. (6) Move the bearing housing sufficiently to reduce the runout to less than, or equal to, 0.025mm. (7) Tighten the bearing housing securing screws and recheck all the measurements. (8) Repeat steps 3 to 7 for the other end of the pump. (9) When the runout at both ends of the pump is within the specified limits, either drill and ream holes for dowel pins or ream existing dowel pin holes to the next size. (10)Repeat the measuring procedur in order to ensure the alignment of two ends is correct. (11)Remove the bearing housing and bearings and re-install them and the mechanical seals.



9.7.3



Axial centring of rotating assembly (1) Install the journal bearings and bearing housings at both ends of the pump without installing the mechanical seals. (2) Alignment of journal direction is complete. (3) Mount a dial test indictor at the drive end with the probe tip in contact with the shaft end. (4) Push the shaft as far as it will go towards the NDE and set the dial indicator to zero. (5) Now move the shaft as far as it will go towards the DE and note the dial indicator reading, This is the total end play of the rotating assembly within the volute casing. (6) Move the shaft back towards the NDE by half the total end play. This sets the impeller centrally within the stationary wear rings.



10 LUBRICANTION 10.1.1 Initial filling of the bearing housings CAUTION



On a new unit, the oil should be changed 24 hours after the first start-up. (1) Remove the bearing housing filler and fill both the DE and NDE bearing housings with clean oil. Check the oil level plates fixed to the bearing housings and the oil level should be in the middle of oil indicator. Fill majority oil to bearing housing and others is completed by constant level oiler. (2) Refit the bearing housing filler.



(3) Check the finally level of oil in the constant level oiler resevoirs, which should be at least two-thirds full. 10.1.2 leakage Monitor the oil level, particularly during commissioning. A sudden oil level drop may indicate a leak. Stop operation and inspect the unit. 10.1.3 Oil changes After draining used oil, flush the housing with clean oil, refit the drain plug and refill with new oil.