maintenance bfp

PLTU 1 JAWA BARAT（INDRAMAYU） 3×330MW POWER PLANT

FK6D32M

BOILER FEED PUMP

MAINTENANCE INSTRUCTIONS

SHANGHAI POWER EQUIPMENT MANUFACTURE CO.,LTD.

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TABLE OF CONTENTS

1 INTRODUCTION...............................................................................................................3

2 PERIODIC AND PREVENTIVE MAINTENANCE.............................................................3

2.1 ROUTINE CHECKS......................................................................................................................3

3 MAINTENANCE PARTICULARS.....................................................................................4

3.1 SPECIAL TOOLS.........................................................................................................................4

3.2 ESTIMATED WEIGHTS (FOR LIFTING PURPOSES)........................................................................4

3.3 JOINTS........................................................................................................................................5

3.4 RECOMMENDED LUBRICANTS...................................................................................................6

4 ROUTINE MAINTENANCE...............................................................................................6

4.1 PREPARATION FOR MAINTENANCE............................................................................................6

4.2 EXAMINING THE BEARINGS.......................................................................................................6

4.3 EXAMINING THE MECHANICAL SEALS....................................................................................11

4.4 CHECKING THE AXIAL RUNNING POSITION & THRUST BEARING CLEARANCE......................14

5 OVERHAUL.................................................................................................................... 16

5.1 PREPARATION FOR OVERHAUL................................................................................................16

5.2 WITHDRAWING THE PUMP CARTRIDGE...................................................................................16

5.3 DISMANTLING THE PUMP CARTRIDGE.....................................................................................17

5.4 INSPECTION, RENEWAL AND REPAIR PROCEDURES.................................................................19

5.5 ASSEMBLING THE PUMP CARTRIDGE.......................................................................................21

5.6 INSTALLING THE PUMP CARTRIDGE.........................................................................................24

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1 INTRODUCTION

It is recommended that a system of routine inspection and maintenance is

established during which the condition of the various units in the plant 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 the 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 maintenance problems.

2 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 every shift.

(1) Reduction in pump performance, i.e. reduction in head or flow.

(2) Excessive vibration.

(3) Excessive leakage from the mechanical seals.

2.1 Routine Checks

2.1.1 Every Shift

(1) Check the suction and discharge pressures.

(4) Check the pump bearing lubricating oil pressure and temperature.

(5) Check for excessive leakage from the mechanical seals.

(6) Check all joints and glands for leakage.

(7) Check for any undue noise and/or vibration.

(8) Check the temperature of the motor's air cooler;

(9) Check the cooling water for positive circulation in the operationg oil cooler,

lubricating oil cooler, motor; air cooler and mechanical seal.

(10) Check the lubricating oil flow at the sight flow indicators．2.1.2 Monthly

(1) Check the security of all accessible holding-down bolts and fastenings and

tighten as necessary.

(11) Check the condition of the lubricating oil.

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2.1.3 Six Monthly

(1) Check the security of all accessible holding-down bolts and fastenings and

tighten as necessary.

(12) Examine the flexible coupling bolts for wear or fretting and check the torque

loading of the bolts. Visually examine the element laminations for signs of

fatigue cracks local to the anchoring points.

(13) Examine the pump journal and thrust bearings.

(14) Examine the mechanical seals.

2.1.4 Yearly

It is recommended that the lubricating oil be changed, but this may be

amended depending on running experience and oil sampling results.

2.1.5 Three-Yearly

The interval between pump overhauls will be determined by the deterioration in

pumpset performance to an unacceptable level, or by excessive noise and/or

vibration. It is recommended however, that the interval between overhauls

should not exceed three years.

3 MAINTENANCE PARTICULARS

3.1 Special Tools

The following special tools are required for use on the pressure stage pump.

When not in use they should be safely stored. Any defects or shortages should

be remedied at the earliest opportunity otherwise maintenance and overhaul

may be hindered.

Tools Number Purpose

Cartridge withdrawal equipment INDRAMAYU-J1-3A-00 Pump cartridge

Cartridge tansportation equipment INDRAMAYU-J2-3A-00Pump cartridge store and

transport

Thrust Collar Withdrawal INDRAMAYU-J3-3A-00 Thrust collar

Balance Drum Withdrawal INDRAMAYU-J4-3C-00 Balance drum

StudHydraulicTensioning

Equipment

INDRAMAYU-J8-3B-00Discharge cover

3.2 Estimated Weights (for lifting purposes)

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Item Weight (kg)

Cartridge assembly 2200

Discharge cover 691

Bottom half bearing housing(non-drive end) 117

Top half bearing housing(non-drive end) 82

Top half bearing housing(drive end) 38

Bottom half bearing housing(drive end) 48

Suction guide 393

Ring sections (each) 80

Ring section (2nd) 91

Pump shaft 160

Interstage impellers(each) 14.8

Diffusers(each) 28

Diffuser(last) 19.5

Balance drum 26

3.3 Joints

Note An asterisk (*) denotes that a PTFE anti-extrusion ring is fitted with the ‘O’

ring.

Joint between Material Size

Pump casing and discharge cover Fluorocarbon F275 φ544.82(i/d)×φ6.99

Pump casing and suction guide Fluorocarbon F275 * φ506.72(i/d)×φ6.99

Pump casing and suction guide 1Cr18Ni9Ti φ500/φ459.5×3

Pump casing and insert ring Fluorocarbon F275 * φ443.36(i/d)×φ6.99

Ring section and ring section Fluorocarbon F275 * φ443.36(i/d)×φ6.99

Pump casing and ring

section(2nd)

Fluorocarbon F275 φ532.26(i/d)×φ6.99

Ring section(3rd) and ring section

(2nd)

Fluorocarbon F275 * φ486.2(i/d)×φ6.99

Oil thrower and pump shaft Fluorocarbon F275 φ94.54(i/d)×φ3.53

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Mechanical seal chamber, drive

end and non-drive end


Water cooling jacket, outer, drive

end


Water cooling jacket, inner, drive

end


Water cooling jacket, inner, non-

drive end


End cover and N.D.E bearing

housing


End cover and thrust bearing

housing


Mechanical seal assembly Refer to the manufacturer’s instructions

3.4 Recommended Lubricants

The lubricating oil for the journal and thrust bearings of the pressure stage

pump is supplied from the turbo coupling lubricating oil system and should be

as follows:

Grade: I.S.O. Grade 32

4 ROUTINE MAINTENANCE

WARNING: IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND

REGULATIONS ARE OBSERVED AT ALL TIMES DURING

MAINTENANCE PROCEDURES.

Note: The boiler feed pump is an integral part of the pumpset. The

following instructions should, therefore, be read in conjunction with

those for the booster pump and the associated equipment.

4.1 Preparation for Maintenance

(1) Isolate the electrical supply to the motor.

(15) Isolate the electrical power supplies to all instruments.

(16) Close the pumpset suction and discharge isolating valves and the minimum

flow valve. Refer to the manufacturers instructions.

(17) Isolate the lubricating oil supply to the pump bearings.

(18) Isolate the cooling water supply.

(19) Close the pump tap stage isolating valve.

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(20) Open the casing drain valve and drain the pump.

WARNING: BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE

PUMP, ENSURE THAT THERE IS NO PRESSURE WITHIN THE

PUMP.

4.2 Examining the Bearings

(Drg. No. INDRAMAYU-FK6D32M-00(1/2) & (2/2))

The following instructions apply when the pump bearings are to be dismantled

for examination and/or renewal in situation, without disturbing the pump

cartridge. It is recommended that the drive and non-drive end bearings are

examined at the same time.

4.2.1 Drive End Journal Bearing

(1) Prepare the pump for maintenance, as described in Section 4.1.

(21) Disconnect and remove all instrumentation. Mark and tape the ends of the

cables to facilitate to facilitate assembly.

(22) Remove any small bore pipework which may interfere with the dismantling.

(23) Remove the coupling guard. Disconnect the pump by removing the coupling

flexible elements and spacer.

(24) Remove the hexagon head screws and nuts securing the bearing housing top

half to the suction guide.

(25) Remove the nuts from the studs securing the bearing housing top half to the

bottom half and remove the dowel pins.

(26) Locate an eye-bolt in the tapped hole provided on the journal bearing top half

and, using suitable lifting slings and jacking screws in the tapped holes

provided, carefully lift off the the journal bearing top half, taking care to avoid

damage to the oil guard at each end of the housing.

(27) Withdraw the dowel pins and remove the nuts from the studs securing the

journal bearing keep to the journal bearing housing . Locate jacking screws in

the tapped holes provided and remove the bearing keep.

(28) Lift off the top halves of the journal bearing and the oil guard. Remove and

retain the anti-rotation pins.

CAUTION: Care must be taken when lifting the shaft that it is only lifted

by the amount necessary to release the weight from the

journal bearing bush.

(29) Take the weight of the shaft then carefully rotate the bottom halves of the

bearing bush and the oil guard around the shaft and remove them.

Note: Neither the journal bearing nor the oil guards are interchangeable

and the halves should be clearly marked for identification on

assembling.

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(30) Examine the journal bearing and the shaft journal for any signs of wear,

damage or deterioration. Examine the oil guard for wear or damage. Renew as

necessary. Measure the bearing clearance and compare it with the details

given in the clearance table in Section 5.4.6. If the measured clearance

exceeds the renewal clearance, or is likely to do so before the next

examination, the bearing should be renew.

Note: Lightly smear the shaft journal and the journal bearing bush

surfaces with oil before final assembly.

(31) Locate the bottom halves of the oil guard and journal bearing on the shaft and

rotate them into position in the bearing housing bottom half. Release the

weight of the shaft.

(32) Locate the top halves of the journal bearing and oil guard on the bottom

halves, ensuring that the anti-rotation pins are in place. Ensuring that the

indentification marks on each half coincide.

(33) Locate the journal bearing keep cover into position, ensuring that the anti-

rotation pins are correctly engaged. Locate and secure the keep cover to the

bearing housing with its dowel pins and nuts.

(34) Lift the journal bearing top half into position, ensuring that the oil guards are

correctly located, than locate and secure the journal bearing top half to the

bottom half with its dowel pins and nuts. Remove the lifting sling and eye-bolt.

(35) Secure the bearing housing top half to the suction guide with the hexagon

head screws.

(36) Connect all small bore pipework removed prior to dismantling, and install and

connect all instruments.

(37) Replace the coupling flexible elements and spacer, then install the coupling

guard.

4.2.2 Non-Drive End Journal Bearing And Thrust Bearing

(1) Prepare the pump for maintenance, as described in Section 4.1.

(38) Disconnect and remove all instrumentation. Mark and tape the ends of the

cables to facilitate to facilitate assembly.

(39) Remove any small bore pipework which may interfere with the dismantling.

(40) Remove the coupling guard. Disconnect the pump by removing the coupling

flexible elements and spacer.

(41) Remove the hexagon head screws securing the end cover to the bearing

housing, then remove the end cover. Discard the ‘O’ring .

(42) Remove the the hexagon head screws and dowels securing and locating the

bearing housing top half to the bottom half and remove dowel pins.

(43) Remove the bolts and nuts securing the bearing housing top half to the

discharge cover.

(44) Locate an eye-bolt in the tapped hole provided on the journal bearing top half

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and, using suitable lifting slings and jacking screws in the tapped holes

provided, carefully lift off the the journal bearing top half, taking care not to

damage to the oil guarde .

(45) Remove the nuts from the studs scewing the journal bearing keep cover to the

jounal bearing housing . Lift the journal bearing keep cover away.

(46) Lift off the top halves of the journal bearing and the oil guard,

(47) Remove the dowel pins and cap screws securing the thrust bearing cover to

the bottom half bearing housing. Insert starting screws to release the thrust

bearing cover and remove the cover.

Note: Care must be taken to prevent damage to the journal bearing bush

and oil guard when removing the top half housing and journal

bearing cover.

(48) Take the weight of the shaft then carefully rotate the bottom halves of the

bearing bush and the oil guard around the shaft and remove them.

(49) Unclip the spring and remove the split oil seal from the bottom half bearing

housing.

(50) Remove the socket head cap screws, then lift the retaining plate from the

bearing housing end cover and remove the split oil seal and spring from the

recess in the end cover.

(51) Remove each thrust carrier ring in turn, as follows:

CAUTION: The thrust bearing resistance temperature detectors (RTD)

elements are inserted in the thrust pads and clipped to thrust

carrier rings . The lead wires are routed out through the

bottom half bearing housing and into a terminal box head.

Before removing the thrust carrier rings from the bottom half

bearing housing, the element lead wires must be

disconnected from the terminal box head .

Rotate a 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 and lift it

clear. Repeat to remove the second carrier ring on the other side of the thrust

collar.

CAUTION: Care must be taken when lifting the shaft that it is only lifted

by the amount necessary to release the weight from the

journal bearing bush.

(52) Examine the journal bearing, shaft journal, and the thrust pads ， thrust

collar ， split oil seals and oil guard for any signs of wear, damage or

deterioration. Renew as necessary.

Note:

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（a） Under normal operating conditions it is not expected that any

measurable wear will take place on the pads other that a dulling of the white metal

surface. It is recommended that when this dulling has spread to more than half the

surface area of the pads they should be renewed.

（b） Measure the bearing clearance and compare it with the details given

in the clearance table in Section 5.4.6. If the measured clearance exceeds the

renewal clearance, or is expected to do so before the next examination, the bearing

should be renewed.

Note Lightly smear the shaft journal and the journal bearing bush surfaces with oil

before final assembly.

(53) 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 inner split oil seal on the pump shaft with the

spring. Release the weight of the shaft.

(54) Install each thrust carrier ring in turn, as follows:

CAUTION: The thrust bearing resistance temperature detectors (RTD) are

inserted in the thrust pads and clipped to the thrust carrier rings. When installing

the carrier rings, the elements must be fitted in position and the excess lead

wires fed back through the bottom half bearing housing.

The thrust carrier ring split line is at 90º to the bearing housing horizontal surface

and the stop pin locates in a slot in the thrust bearing cover. Place the half

carrier ring without the stop pin over the shaft, with the thrust pads touching the

face of the thrust collar, and rotate it into the bearing housing bottom half. Place

the other half carrier ring, with the stop pin, on the first half and rotate the

complete carrier ring around the shaft until the stop pin rests on the bearing

housing bottom half. Repeat with the second carrier ring on the other side of the

thrust collar.

CAUTION: Do not insert feeler between the thrust collar and the thrust

pads to check the axial clearance: this may given an

inaccurate reading, and cause damage to the white metal pad

surface.

(55) Secure the end cover to the bearing housing bottom half with the hexagon

head screws, and 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, cleck the clearance. Refer to the clearance table

in Section 5.4.6 for the original axial clearance: any measurable variation

should be investigated. Remove the end cover.

Note: Ensure that the thrust pad resistance temperature detector bungs

are inserted in the thrust pad holes, and that the excess lead wires

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fed back through the bottom half bearing housing before installing

the thrust bearing housing cover.

(56) Locte the thrust bearing cover onto the bottom half bearing housing， then

locate and secure the cover to the bottom half bearing housing with the dowel

pin and cap screws.

(57) Locate the top halves of the journal bearing.

(58) Place the bearing keep over the journal bearing, ensuring that the anti-rotation

dowel is correctly engaged, then locate and secure the keep to the bottom half

housing with the dowel pins and the nuts.

(59) Place the top half of the oil guard in position on the bottom half housing.

(60) Locate the bearing housing top half on the bottom half with the dowel pins and

secure it with the bolts and nuts. Secure the bearing housing top half to the

discharge cover with the hexagon head screws. Remove the lifting slings and

eye-bolt.

(61) Locate the split oil seal and spring in the recess in the end cover and retain

them with the retaining plate secured to the end cover with the socket head

cap screws

(62) Install the end cover on the bearing housing, with two new ‘O’ rings, and

secure it with the hexagon head screws, Tighten the screws to a torque

loading of 130Nm.


guard.

(64) Connect all small bore pipework removed prior to dismantling, and install and

connect all instruments.

4.3 Examining the Mechanical Seals

Refer to Drg. No. INDRAMAYU-FK6D32M-00(1/2)

The following instructions apply when the pump mechanical seals are to be

dismantled for examination and/or renewal in situation, without disturbing the

pump rotating assembly, and assumes that the drive and non-drive end seals

will be examined at the same time.

It is recommended that the examination of the mechanical seals is carried out

at the same time as the examination of the bearing, unless it is necessary to

rectify a specific fault.

4.3.1 Drive End Mechanical Seal

(1) Remove the drive end journal bearing as described in Section 4.2.1, Steps (1)

to (10).

(65) Remove the cap screw securing the coupling nut. Using the special spanner,

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unscrew and remove the coupling nut.

(66) Remove the pump half coupling from the shaft. Remove and retain the

coupling key from the keyway in the shaft.

(67) Suitably support the bearing housing bottom half. Remove the screws and

dowel pins securing and locating the bearing housing bottom half to the

suction guide and remove the housing.

(68) Mark the positions of the inboard and outboard oil throwers on the shaft, then

slacken the grub screws and slide the oil throwers from the shaft.

(69) Remove the mechanical seal flushing water pipes, the seal vent adaptor and

the breather.

Note: The seal chamber and water cooling jacket should only be

removed if it is thought necessary to renew the “O” rings.

(70) Refer to the seal manufacture’s instructions, and remove the seal assembly.

Remove the seal sleeve key from the keyway in the shaft.

(71) Remove the socket head screws securing the seal chamber to the suction

guide and remove the seal chamber and the water cooling jacket. Discard the

“O” rings from the seal chamber and the water cooling jacket.

(72) Refer to the seal manufacturer’s instructions and proceed as follows:

(a) Dismantle the seal cartridge

(b) Examine the seal components and renew as necessary

(c) Assemble the seal cartridge ready for installation

(73) Locate new “O” rings in the grooves in the water cooling jacket and install the

jacket in the suction guide ensuring the dowel pin locates correctly.

(74) Locate new “O” ring in the groove in the seal chamber and install the chamber

on the water cooling jacket

(75) Secure the seal chamber and the water cooling jacket to the suction guide with

the socket head screws.

(76) Refer to the seal manufacturer’s instructions, and install the seal key ,

cartridge and sleeve nut.

(77) Slide the oil throwers onto the shaft, into the positions determined during

dismantling, and secure them with the grub screws.

(78) Install the mechanical seal flushing water pipes and air breather and vent

adaptor.

(79) Locate the bearing housing bottom half to the suction guide with the dowel

pins and secure it with the screws and nuts.

(80) Install the drive end journal bearing as described in Section 4.2.1,

Staps(12)~(18).

(81) Locate the coupling key in the keyway in the shaft, then install the pump half

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coupling on the shaft.

(82) Screw the coupling nut onto the shaft and tighten it using the special spanner

provided. Lock the coupling nut with the cap screw.

(83) install the coupling flexible elements and spacer.

(84) Install the coupling guard.

(85) Install the lubricating oil supply and drain pipework, together with any other

small bore pipework and instrumentation removed prior to dismantling.

4.3.2 Non-drive End Mechanical seal

(1) Remove the non-drive end journal bearing and the thrust bearing as described

in Section 4.2.2, Spets (1)~(15).

(86) Suitably support the bearing housing bottom half. Remove the screws, nuts

and dowel pins securing the bearing housing bottom half to the discharge

cover and remove the housing.

(87) Bend up the tabs on the thrust collar lock-washer and remove the thrust collar

nut. Discard the lock washer.

(88) Using a ring burner, apply heat evenly to the thrust collar hub, then using

withdrawal gear, withdraw the thrust collar from the shaft. Remove and retain

the thrust collar key.

(89) Mark the position of the oil thrower on the shaft, then slacken the grub screw

and slide the oil thrower from the shaft.

(90) Remove the mechanical seal flushing water pipes, the seal vent adaptor and

breather.

Note: The seal chamber and water cooling jacket should only be

removed if it thought necessary to renew the ‘O’ rings.

(91) Refer to the seal manufacturer’s instruction, and remove the seal assembly.

Remove the seal sleeve key from the keyway in the shaft.

(92) Remove the cap screws securing the seal chamber to the discharge cover and

remove the seal chamber and the water cooling jacket. Discard the ‘O’ rings

from the seal chamber and the water cooling jacket.

(93) Refer to the seal manufacturer’s instructions and proceed as follows:

（a） Dismantle the seal cartridge

（b） Examine the seal components and renew as necessary

（c） Assemble the seal cartridge ready for installation

(94) Locate a new ’O’ ring in the groove in the water cooling jacket and install the

jacket in the discharge cover ensuring the dowel pin locates correctly.

(95) Locate a new ‘O’ ring in the grooves in the seal chamber then install the

chamber on the water cooling jacket.

(96) Secure the seal chamber and the water cooling jacket to the discharge cover

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with the socket head screws.

(97) Refer to the seal manufacturer’s instructions, and install the seal key, cartridge

and sleeve nut.

(98) Slide the oil thrower onto the shaft and into the position determined during

dismantling and secure it to the shaft with the grub screw.

(99) Locate the thrust collar key in the keyway in the shaft, than heat the hub of the

thrust collar and slide it into position on the shaft. Screw the thrust collar nut

onto the shaft, and tighten it against the thrust collar.

(100) When the assembly has cooled, remove the thrust collar nut, place a new

lock-washer against the hub of the thrust collar and screw the thrust collar nut

on to the shaft. Tighten the nut and lock it in place with the lock-washer.

(101) Locate the bearing housing bottom half to the discharge cover with the

dowel pins and secure it with the screws and nuts.

(102) Install the non-drive end journal and thrust bearings as described in Section

4.2.2，Spets(17)~(28).

4.4 Checking the Axial Running Position & Thrust Bearing Clearance

Note: The following checks must be carried out with the pump cartridge

installed in the pump casing and the drive end and non-drive end

bearing housings and mechanial seal disassembled. The drive

coupling guard and coupling assembly must also be removed.

CAUTION: The rotating assembly must be suitably supported at each end

of the pump at all times.

(1) The drive end of the pump should be assembled with the following

components installed:

(a) Water cooling jacket and seal chamber.

(b) Bottom half bearing housing.

(c) Bottom half journal bearing.

(103) The non-drive end of the pump should be assembled with the following

components installed:

(a) Water cooling jacket and seal chamber.

(b) Bottom half bearing housing, bottom half journal bearing.

(c) Thrust collar, key, thrust collar nut and lock-washer, and bearing

housing end cover.

(104) 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. Using the outer face of the thrust collar as a datum, scribe a

line on the horizontal surface of the bottom half bearing housing.

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(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.

(c) Position the inner halves of the thrust bearing carrier rings, thrust

pads and spacers in the 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 approximately midway between the two previous lines.

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

(a) Position the outer halves of the thrust bearing carrier rings, thrust

pads and spacers in the bottom half housing.

CAUTION: Do not insert feeler gauges between the thrust collar and the

thrust pads to check the axial clearance: this may give an

inaccurate reading and cause damage to the white metal pad

surface.

(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 thrust bearing

housing wall. The total axial clearance was originally as shown on Drawing No.

INDRAMAYU-FK6D32M-00(1/3) and any measurable variation should be

investigated.

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

Note: The spare inner and outer spacers are supplied oversize in

thickness for machining as necessary.

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(a) With the rotating assembly in the axial running position, accurately measure

the distance between the bottom half thrust bearing housing wall and the

inner thrust collar face and record the reading. Repeat the procedure

between the outer thrust collar face and thrust bearing housing end cover

wall and record the reading.

(b) The spacers should now be removed from 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 assembly thickness.

(II) Outer thrust ring spacer thickness = Measured distance between

housing wall and outer collar face minus(thrust ring assembly thickness plus

axial bearing clearance).

(c) Secure the spacers to the thrust carrier ring halves and repeat step (4) as

previously described.

(107) With the rotating assembly in its axial running position, check the drive end

and non-drive end mechanical seal setting dimension. If necessary, machine

or renew the seal setting distance piece achieve the required dimension.

5 OVERHAUL

WARNING: IT IS ESSENTIAL THAT THE PLANT SAFETY RULES

AND REGULATIONS ARE OBSERVED AT ALL TIMES DURING

MAINTENANCE PROCEDURES.

The following instructions apply when a 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 5.6 before proceeding to

dismantle and repair the worn cartridge(Sections 5.3 to 5.5

inclusive).

5.1 Preparation for Overhaul

(1) Prepare the pump for maintenance as described in Section 4.1.

(108) Remove all instruments and small bore pipework from the drive end and

non-drive end bearing housings and mechanical seals that may interfere with

the dismantling procedures.

(109) Disconnect and remove the two balance return pipes.

(110) Disconnect and remove the lubricating oil pipework to and from the pump

bearings.

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(111) Check that all lifting equipment and special tools are in good condition.

Note: The shaft nuts at the drive end have left hand threads: those at the

non-drive end have right hand threads. Reference numbers on

components should be re-marked as necessary to facilitate

assembling.

5.2 Withdrawing the Pump Cartridge

(1) Prepare the pump for overhaul as described in Section 5.1.

(112) Remove the coupling guard , then unscrew and remove the flexible

coupling elements and spacer.

(113) Remove the grab screw locking the pump half coupling nut, than using

special spanner, unscrew and remove the coupling nut in the shaft.

(114) Withdraw the pump half coupling from the shaft. Remove the coupling key

from the keyway in the shaft and retain it.

(115) Remove the screws securing the split pull-up ring to the pump casing and

remove the pull-up ring. Discard the ‘O’ ring and joint.

Refer to Drg. INDRAMAYU-J1-3A-00 & INDRAMAYU-J8-3B-00

(116) Secure the wiithdrawal tube to the drive end bearing housing and secure

the roller jack assembly to the pump baseplate.(Refer to Drg. INDRAMAYU-

J1-3A-00).

(117) Unscrew the stud caps from the discharge cover studs and remove the nuts

from the discharge cover studs, as the procedure show on Drg. INDRAMAYU-

J8-3B-00.

(118) Continue to withdrew the pump cartridge slowly from the pump casing

according next procedure show on Drg. INDRAMAYU-J1-3A-00.

5.3 Dismantling the Pump Cartridge

5.3.1 Preparation for Dismantling

Note: 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. At no time should the weight of the cartridge

be carried by the shaft.

(1) Withdraw the pump cartridge from the pump casing as described in Section

5.2.

(119) With the cartridge in the horizontal position in the maintenance area,

remove the lifting bracket from the suction guide and the jacking screws and

the eyebolt from the discharge cover.

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5.3.2 Removing the Drive End Bearing Housing and Mechanical seal

Remove the drive end bearing housing and mechanical seal as described in

Section 4.3.1, Step (1)~(8).

5.3.3 Removing the Non-Drive End Bearing Housing and Mechanical seal

Remove the non-drive end bearing housing and mechanical seal as described in

Section 4.3.2, Step (1)~(8).

5.3.4 Dismantling the Pump Internals

(Refer to Drg. Nos. INDRAMAYU-FK6D32M-00(1/2)&(2/2))

(1) Remove the drive end and non-drive end bearings and mechanical seals as

described in Sections 5.3.2 and 5.3.3.

(2) Set the rotationg assembly in the mid position and secure it with the clamping

plate and stud and nuts.

(120) Attach lifting gear to the cartridge lifting lug, and raise the cartridge into a

vertical pasition on the assembly support trestle.

CAUTION: When raising the assembly, care must be taken to ensure that

at no time is the weight of the assembly carried by the

protruding ends of the pump shaft.

(121) Remove the nuts from the tie rods securing the discharge cover and

remove the spacers and the tie rods.

(122) Attach lifting gear to the discharge cover, take the weight and carefully lift

the cover up and over the end of the shaft and clear of the assembly.

CAUTION: When removing the discharge cover, ensure that a straight lift

is obtained and that no damage is caused to the balance drum

and restriction bush.

(123) Bend down the tab on the balance drum lock-washer, then unscrew and

remove the balance drum nut and lock-washer. Remove the impacted ring.

Discard the seal ring.

(124) Using the withdrawal gear supplied, refer to INDRAMAYU-J4-3C-00, then

apply heat evenly around the balance drum until enough expansion take place

to enable removal of the balance drum. Lift the balance drum clear of the

shaft. Remove and retain the balance drum key from the keyway in the shaft.

Note Force must not be used to remove the balance drum. If the drum does not

remove completely, allow the assembly to cool, and repeat step (７).

(125) Lift the disc spring from the last stage diffuser.

(126) Remove the cap screws securing the last stage diffuser to the last stage

ring section. Lift off the diffuser.

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(127) Apply heat evenly to the hub of the last stage impeller until enough

expansion take place to enable removal of the impeller. Lift the impeller clear

of the shaft and mark it to facilitate assembing. Remove and retain the impeller

key and the impeller split ring.

Note: Force must not be used to remove the impeller. if the impeller does

not withdraw completely, allow the assembly to cool, and repeat

step (10).

(128) Remove the cap screws securing the fifth stage ring section to the fourth

stage ring section. Remove and discard the “O” ring and anti-extrusion ring.

(129) Attach the lifting gear lift off the fifth stage ring section and diffuser.

(130) Apply heat evenly to the hub of the fifth impeller until enough expansion

take place to enable removal of the impeller. Lift the impeller clear of the shaft

and mark it to facilitate assembing. Remove and retain the impeller key and

the impeller split ring.

(131) Repeat the above steps (12) and (13) until only the first stage impeller

remains on the shaft. Remove and discard the “O” rings and the Garlock seals

from the second stage ring section.

Note: The cap screws securing the third stage ring section to the second

stage are locked by locking strips which must be removed before

removing the screws.

(132) Screw the shaft lifting lug onto the end of the shaft and carefully raise the

pump shaft through the suction guide and clear of the assembly.

(133) Support the shaft in a horizontal position and heat evenly to the hub of first

stage impeller and slide impeller from the shaft. Remove and retain the

impeller key.

(134) Using suitable lifting gear lift the suction guide from the support frame.

5.4 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 5.4.6. 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, the

pump should be overhauled.

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5.4.1 Impellers and Wear Rings

(1) Examine the impellers for any signs of erosion, particularly at the blade tips.

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.

(135) 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 5.4.6 or is likely to do so before the

next examination, the wear rings must be renewed. Proceed as follows:

（a） Lightly machine the impeller wear ring diameters to remove any

marks and to restore concentricity with the impeller bore.

（b） Machine the worn wear rings from the suction guide and ring

sections/diffusers.

（c） Ensure that the wear ring location is clean, then shrink the new wear

rings into place by immersing them in liquid nitrogen for a few minutes.

CAUTION: After removal from the liquid nitrogen, the wear rings must

not be handled without suitable protection.

（d） Lock the wear ring in place with the point welding.

（e） Machine the bore of the new wear rings to restore concentricity and

the new clearance as shown as shown in Section 5.4.6.

5.4.2 Shaft

(1) Examine the shaft for any signs of damage or bowing, and check for

concentricity: it should be within 0.02 mm full indicator movement.

(136) Check that all threads are in good condition and that all keyways are free

from burrs.

5.4.3 Mechanical Seals

Examine the seals for signs of damage or wear. Renew as necessary. Refer to the

seal manufacturer’s instructions.

5.4.4 Journal and Thrust Bearings

(1) Thoroughly clean the journal bearings and examine them for signs of wear or

damage. Measure the bearing clearances and compare them with the values

given in Section 5.4.6. Renew as necessary.

(137) Thoroughly clean the thrust pads and examine them for signs of wear or

damage.

Note: 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

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spread to more than half the surface area of the pads, they should

be renewed.

(138) Examine the thrust collar for signs of wear or damage, and renew as

necessary.

(139) Examine the oil seals for wear or deterioration and renew as necessary.

5.4.5 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.

(140) All dowel pins must be clean and free from damage. Worn or damaged

dowels must be renewed.

(141) All keys must be a good fit in their keyways. worn or damaged keys must

be renewed.

(142) Examine the components of the coupling flexible elements assemblies and

coupling bolts for wear or damage and renew as necessary.

5.4.6 Clearances

(Drg. No. INDRAMAYU-FK6D32M-00(1/2))

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. All

clearances are given in millimetres and, unless stated otherwise, are diametrical.

Clearance between Column 1 Column 2

journal bearing and pump shaft 0.140/0.215 0.26

Oil throwers and oil guards 0.350/0.410 0.47

Ring section wear rings and

impeller 0.410/0.490 0.675

Diffuser wear rings and impeller 0.410/0.490 0.675

Balance drum and balance drum

bush0.410/0.490 0.675

Last stage diffuser and discharge

cover(axial)1.23/2.27 --

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Total axial clearance in thrust

bearing0.4 By inspection

Ring section and impeller (axial) 4 --

Diffuser and impeller (axial) 4 --

total axial clearance, thrust pads

removed8 --

5.4.7 Dynamic Balance

Rotor must always be dynamic balanced when renewing or repairing individual

parts.

When suitable workshop facilities are available the recommended method of

checking the dynamic balance of the rotating assembly is as follows:-

(1) Support the assembly at the bearing centre lines and check that it is

dynamically balanced within quality grade G2.5 in GB9239-1988(ISO 1940/1-

1986(E)).

(143) Dynamic balance is to be achieved by removing metal from the impeller

shrouds within the following limits.

Note: If the amount of metal to be removed exceeds the limits imposed

by (a) and (C), SPEM Ltd. should be consulted.

（a） The thickness of the impeller shroud must not be reduced to less than

6.5 mm at any point.

（b） No metal is to be removed from the impeller outwith the 260~290mm

diameter band.

（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.

5.5 Assembling the Pump Cartridge

All components must be perfectly clean and all bores and oilways 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,

sleeves and balance drum, allowed to dry and the surfaces then

polished.

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5.5.1 Assembling the Pump Internals

Refer to Drg. No. INDRAMAYU-FK6D32M-00(1/2)

(1) Support the shaft on tresles in a horizontal postion, than locate the first stage

impeller key in the keyway in the shaft.

(144) Apply heat evenly around the rear hub of the first stage impeller using the

ring burner, than slide the impeller over the shaft and key until it abuts the

shoulder on the shaft.

CAUTION: Force should not be used when fitting the impeller. If the

impeller fails to butt against the shaft shoulder, remove the

impeller and check for any burrs or dirt which may have

been overlooked during inspection. Clean up as necessary,

then repeat step (2). Do not attempt to fit the impeller if the

temperature of the shaft is above ambient.

(145) Attach the lifting gear and lift the suction guide onto the support trestles

ensuring that it locates correctly on the assembly support plate, then remove

the lifting gear.

(146) When the shaft/first stage impeller assembly has cooled, screw the lifting

lug onto the non-drive end of the shaft and raise the shaft and impeller into a

vertical position above the suction guide.

(147) Carefully lower the assembly into the suction guide until the impeller enters

the first stage impeller eye bush in the suction guide. Remove the lifting gear

and the shaft lifting lug.

(148) Fit new ‘O’ ring, anti-extrusion rings and Garlock seals in the ring section

groove.

(149) Locate the anti-rotation dowel pin is in place in the first stage diffuser,

attach lifting gear to the ring section /diffuser and install it over the first stage

impeller, ensureing that it is correctly located on the suction guide. Remove

the lifting gear.

(150) Scure the frist stage ring section to the suction guide with the socket head

screws, ensuring that the screw heads do not protrude above the upper

surface of the ring section.

(151) Before proceeding further, check the total axial travel as follows:-

（a） Screw the lifting lug onto the non-drive end of the punp shaft and

suitably sling,

（b） Take The weight of the pump shaft and allow the first stage impeller

to rest on the suction guide.

（c） Lay a straight edge across the upper face of the first stage ring

section, and lightly mark a line on the shaft.

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（d） Using the jack, carefully raise the shaft as far as it will go without

disturbing the first stage ring section and, using the same datum as before,

mark a second line on the shaft. Lower the shaft.

（e） Measure the distance between the lines. The total axial travel is

8.0mm, and if this is not achieved, the cause must be identified .

CAUTION: The minimum acceptable total shaft travel is 6 mm.

(152) Locate the second stage impeller split ring in the groove in the shaft and

install the impeller key in the keyway in the shaft.

(153) Install the second stage impeller by proceeding as described in Step (2)

above.

(154) Install the remaining diffusers, rign sections and impellers as described

above, Steps (7) to (13), checking that the total axial travel remains unatered,

as described in Step(9).

Note: The socket head cap screws securing the second and third stage

ring section must be locked using new locking strips.

(155) Locate the last stage diffuser on the last stage ring section and secure it

with the cap screws.

(156) Install the balance drum key in the keyway in the shaft, then heat the

balance drum and slide it into position on the shaft, ensuring that it butts

against the shoulder on the shaft and locates on the balance drum key. Screw

the balance drum nut onto the shaft and tighten it against the balance drum.

(157) Allow the assembly to cool, then remove the balance drum nut. install a

new seal ring and impacted ring and lock-washer position into against the

balance drum then screw on and tighten the balance drum nut. Bend over the

lock-washer tab.

(158) Fit the disc spring in position.

(159) Screw nuts onto the tie rods supplied, screw the tie rods into the tapped

holes in the assembly support plate and tighten the nuts against the plate.

(160) Lower the discharge cover over the shaft and tie rods carefully, then insert

the jacks between the last stage diffuser and discharge cover.

(161) Adjust the jacks until the dimension between the support plate face and the

face of the discharge cover is 752±0.10mm.

(162) Locate the spacer supplied over the tie rods and into the discharge cover

stud holes, then screw on and tighten the nuts against the spacers. Remove

the lifting gear.

(163) Install the drive end locating assembly.

(164) Secure the lifting gear to the lifting lug, then lower the cartridge into a

horizontal position on the support trestles and remove the locating assembly .

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CAUTION: When lowering the cartridge assembly into the horizontal

position, it is essential to ensure that at no time is the weight

of the assembly carried by the pump shaft.

5.5.2 Installing the Mechanical Seals

CAUTION: The rotating assembly must be supported on wooden trestles

during assembly.

Note: The following instructions apply equally to the drive and non-drive

end mechanical seals.

(1) Locate new “O” rings in the grooves in each water cooling jacket and install

the jackets in the suction guide and discharge cover.

(2) Locate a new “O” ring in the groove in each chamber and install the seal

chambers on the water cooling jackets.

(165) Secure the seal chamber and the water cooling jacket to the suction guide

and the dishcharge cover with the cap screws.

(166) Refer to the seal manufacturer’s instructions, and install the seal key and

cartridge.

5.5.3 Assembling the Drive End Bearing

Install the drive end bearing as Described in Section 4.2.1, Steps (12) to (16).

5.5.4 Assembling the Non-Drive End Bearing

Install the non-drive end bearing as Described in Section 4.2.2, Steps (17) to (26).

5.6 Installing the Pump Cartridge

Drg. No. INDRAMAYU-J1-3B-00

(1) Secure the withdrawal tube plate to the drive end bearing housing with the

hexagon head screws. Secure the first withdrawal tube to the withdrawal tube

plate.

(2) Remove the nut, spacers and the tid rods securing the ring section assembly

together, then withdraw the support plate from the suction guide.

(3) Install a new “O” ring on the discharge cover, a new “O” ring in the groove in

the periphery of the second stage ring section and a new “O” ring in the

groove in the periphery of the suction guide. Install a new joint against the

suction guide joint face.

Note: The anti-extrusion ring must be located on the suctiion port side of

the suction guide “O” ring.

(167) Screw an eye-bolt to the discharge cover and lifting bracket to the suction

guide.

(168) Fit the roller Jack assembly to baseplate.

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(169) Fit all withdrawal tubes. Push the withdrawal tubes assembly into the pump

casing until the withdrawal tubes contacts the roller jack. Fit a suitable

sling/rope over the main casing stud and under the withdrawal tubes

assembly.

(170) Carefully lift the pump cartridge into the pump casing, and lower it until the

first stage withdrawal tube can be screwed into the withdrawal tubes assembly

supported by the sling and the tubes rest on the roller. Remove the withdrawal

tube support sling form the casing studs.

(171) Remove the lifting gear and lifting bracket to the suction guide.

CAUTION: When installing the pump cartridge ensure that the suction

guide is radially central with the casing bore by adjusting the

drive end roller jack assembly.

(172) Carefully push the pump cartridge into the pump casing, removing each

withdrawal tube as it clears the roller jack, until the discharge cover is engaged

on the pump casing studs.

Note: When installing the pump cartridge in the casing, great care must

be taken to ensure that the “O” ring and the Garlock seals do not

becom damaged and that the cartridge/casing alignment is not

disturbed.

(173) Continue to push the cartridge into the pump casing, until the suction guide

and discharge cover are properly located in the pump casing.

(174) With the discharge cover firmly against the pump casing, remove the sling

and eye-bolt from the discharge cover.

(175) Remove the roller jack assembly from the baseplate and remove the

withdrawal tube plate from the drive end bearing housing.

(176) Install the nuts on the casing studs and screw the nuts onto the studs hand-

tight against the discharge cover.

(177) Using the hydraulic stud tensioning equipment tighten the pump casing

discharge cover nuts as procedure in the Drg. INDRAMAYU-J8-3B-00.

(178) Install the stud caps over the casing studs.

(179) Install a new joint, a new “O” ring and the anti-extrusion ring in the suction

guide/pump casing recess.

(180) Locate the pull-up ring on the suction guide/pump casing and secure it in

position with the screws.

(181) Insert the coupling keys in their keyways in the shaft, then install the pump

half coupling on the shaft.

(182) Using the special spanner, tighten the coupling nut against the coupling

hub, and lock it in place with the grub screw.

(183) Turn the pump by hand, at the coupling, to ensure freedom of rotation.

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(184) Check the coupling alignment.


guard.

(186) Install all instrumentation and the seal cooling and lubrication oil pipework,

using new joints, together with any other small bore pipework removed prior to

the withdrawal of the pump cartridge.

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maintenance bfp

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