SECTION - C

CONDENSATE

EXTRACTION PUMP

TYPE : EN6J40/500
 PART – 4

EQUIPMENT DETAILS

SECTION - C

CONDENSATE EXTRACTION PUMP

LIST OF CONTENTS

CHAPTER TITLE

1 Description

2 Operating Instructions

3 Maintenance Instructions

4 Sub-vendor’s Drawings / Instructions

 SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 1

DESCRIPTION

LIST OF CONTENTS

1 General specification

2 General Description

3 Associated equipment

3.1 Canister and foundation ring

3.2 Discharge headpiece

3.3 Motor Stool

3.4 Stuffing box assembly

3.5 Combined thrust and journal

Bearing Assembly

3.6 Coupling

4 Driving motor
 CHAPTER – 1

DESCRIPTION

1. GENERAL SPECIFICATION

Pump Designation : EN6J40/500

Type : Vertical, canister

Number of Stages : 6

Number of Pump Set : 3

2. GENERAL DESCRIPTION

The condensate extraction pumps are of the vertical centrifugal canister type with the
driving motor supported on a fabricated motor stool. The motor stool is supported on
a fabricated head piece which is secured to a fabricated canister. The canister is
secured to a foundation ring which is held to the floor with nuts on foundation bolts.

The pump stage casings form an interconnected assembly which is attached to the
underside of the headpiece and is suspended within the canister.

The head piece is provided with a stuffing box which contains a mechanical seal to
prevent pump leakage. Small bore pipe work, for sealing purpose, is connected to
the stuffing box. The head piece also supports the water cooled oil lubricated thrust
and journal bearing.

The pump discharge branch and vent pipe are integral with the head piece and the
pump suction branch is integral with the canister.

The motor stool, secured to the top of the head piece, supports the driving motor.
Cooling water pipe work along with the oil filling/vent pipe and gauge glass extension
pipe are attached to the motor stool.

Apertures formed on the motor stood and head piece provide access to the coupling,
thrust bearing and mechanical seal.
 Each pump is driven by an electric motor mounted on the motor stool. The motor is
supplied by BHEL, Bhopal/Hardwar. The motor shaft is connected to a top shaft via a
flexible spacer coupling and the top shaft connects to the intermediate shaft via a
solid muff coupling. The intermediate shaft in turn is connected to a bottom shaft
through a muff coupling. The top shaft passes through the combined thrust and
journal bearing and stuffing box, and also carries the fourth to sixth stage rotating
assemblies. The intermediate shaft carries second and third stage rotating
assemblies. The bottom shaft carries the first stage rotating assembly. The shafts are
supported by two cutless rubber bearings at the first stage and by a single cutless
rubber bearing at the second to sixth stages. The thrust bearing absorbs the
downward axial thrust from the pump rotating assembly, and the white metal lined
journal bearing with in the thrust bearing assembly supports the shafts along with the
cutless rubber journal bearing within each intermediate stage assembly and element
assembly.

A snubber secured into the bottom of the canister engages the suction bell mouth
fitted to the first stage casing. This arrangement provides support to the bottom end
of the pump.

3. ASSOCIATED EQUIPMENT

3.1 Canister and Foundation Ring

The canister is a fabricated tubular chamber formed with a dished bottom end which
is closed by a snubber which is located and secured to the bottom of the canister by
screws, tab-washers and dowels. Leakage between the canister and snubber is
prevented by a joint, and a cylindrical extension of the snubber provides rigid support
to the first stage pump casing assembly.

A suction branch integral with the canister is positioned above floor level
and a flange provided below the suction branch accommodates screws for
securing the canister to the foundation ring. The canister top flange supports the
discharge head piece.
 The foundation ring is provided with holes for foundation bolts and
tapped holes for canister securing screws. The foundation bolts and foundation
ring are grouted to the floor.

3.2 Discharge Head piece

The fabricated head piece, secured to the pump canister with screws,
incorporates the discharge branch and supports the thrust bearing housing and
motor stool. The head piece is sealed where the shaft passes through by a stuffing
box which incorporates a mechanical seal.

Small bore pipe work connects to the stuffing box, for inlet and outlet
sealing water. The outlet pipe work, which returns the sealing water to the pump
suction, is provided with two orifice plates. A vent pipe provided with a spigot
flange is incorporated within the structure of the head piece for connecting to
condenser. A Valve is provided for installing between the vent pipe and
condenser.

Tapped holes on the inner flange situated on the underside of the head
piece provide location for the top rising main screws and holes drilled through the
outlet of the outer flange provide location for screws which secure the head piece
to the canister flange. Tapped holes provided on the inner flange situated
on the topside of the head piece, provide location for the stuffing box securing
screws. Tapped holes on the topside outer flange provide location for the motor
stool securing bolts.

Apertures formed on the head piece provide access to the stuffing box and
are closed by wire mesh guards.

Lugs are situated at the top of the headpiece for lifting purposes.
3.3 Motor Stool

The fabricated motor stool is dowelled to the head piece and secured by
bolts. A recess formed on the top flange of the motor stool locates the driving
motor, which is secured with screws to the motor stool.

Small bore pipe work is provided within the motor stool for thrust bearing
inlet and outlet oil cooling water. A combined oil filler and vent pipe extends
through the side of the motor stool. The thrust bearing oil level gauge glass is
secured to a pipe which also extends through the side of the motor stool.
Apertures formed on the motor stool provide access to the flexible spacer coupling
and thrust bearing, and are closed by wire mesh guards.

3.4 Stuffing Box Assembly

3.4.1 Mechanical Seal : The stuffing box is secured to the head piece with
screws, leakages being prevented by a joint.

The entry of pumped condensate at the underside of the stuffing box is

restricted by a gap between a restriction bush, secured with screws to the stuffing
box and a sleeve secured to the shaft with “Loctite”.

The stationary seal face of the mechanical seal is retained by an “O” ring
in the seal plate, and the rotating components of the mechanical seal are retained
on a sleeve held by a retaining collar. The retaining collar is secured to the sleeve
with grub screws and secured to the shaft with grub screws.

The seal is of 'cartridge' type and seal setting is done by seal manufacturer
at their works itself.

The seal plate is spigot located and secured to the stuffing box with
screws, leakage being prevented by an “O” ring. Tapped holes are provided on the
seal plate for jacking screws, to assist with dismantling. Small bore pipe work
connects to the seal plate to sealing water purposes.
 Two additional orifice plates are supplied for each pump to be installed in
client’s small bore pipe work which connects to the common discharge. This
feature enables an adequate flow of flushing water to be maintained at the stuffing
box, during the time the pump is on standby.

Further particulars for the mechanical seal are contained in Chapter – 4.

3.5 Combined Thrust and Journal Bearing Assembly

The combined thrust and journal, water cooled bearing assembly is

mounted on the head piece and absorbs the pump hydraulic downward thrust, and
takes the weight of the pump rotating assembly.

The casing base plate is spigot-located on to an adaptor plate which also

locates by spigot to the head piece. The casing base plate and adapter plate are
secured together with nuts on studs, and the adaptor plate is secured to the head
piece with screws.

The thrust collar which is a tight fit and keyed on the shaft is retained
against a shoulder on a shaft by the thrust collar nut. Tapped holes are provided
on the collar for fitting and removal purposes. The thrust is absorbed by the white
metal faced thrust pads fitted to the base plate, under the collar. White metal lined
journal pads are fitted in the casing and locate the collar radially.

The casing top is closed by a split cover secured to the casing with bolts,
the halves of the split cover being secured together with nuts on fitted studs and
nuts on bolts. Taped holes on the split covers facilitate eye-bolts for lifting and
removal purposes. Provisions is also available for a temperature probe. Leakage
between the split cover and casing is prevented by a joint. Leakage between the
sleeve and the underside of the base plate is prevented by a joint. The bearing
casing is supplied with inlet and outlet cooling water connections, an oil level
gauge, a combined air vent and oil filler and an oil drain plug on the base plate.
Tapped holes in the casing facilitate jacking screws for dismantling purposes.
 Leakage between the casing and base plate is prevented by an “O” ring fitted in a
groove machined in the base plate.

For further particulars refer to the bearing manufacturer’s instructions

contained in Chapter-4.

3.6 Couplings

The drive from the motor to the top shaft is transmitted via a spacer type
flexible coupling. Each half coupling is a tight fit and keyed to its respective shafts,
the halves being connected by means of a spacer which interconnects via flexible
membranes at each end.

The coupling is designed to accommodate a certain amount of both offset

and angular misalignment and also any free end float or vertical movement of the
shafts.

The top shaft half coupling abuts the thrust collar nut, and a recess
machined in the bore of the top shaft half coupling accommodates a thrust plate
which corresponds with the LEF button.

For further particulars refer to the spacer coupling manufacturer’s

instructions contained in chapter-4.

4.0 DRIVING MOTOR

The vertical driving motor is mounted and secured to a spigot flange

provided on the motor stool.

For further particulars and information for the driving motor, refer to the
motor manufacturer’s instructions not contained in this manual. The driving motor
is supplied by BHEL, Bhopal/Hardwar.
 SECTION - C

CONDENSATE EXTRACTION PUMP

CHAPTER – 2

OPERATING INSTRUCTIONS

LIST OF CONTENTS

1. Introduction

2. Pre-start checks

3. Start-up

4. Pump running checks

5. Normal shut-down

6. Preparing a pump for standby

7. Stud-down when the pump is to be isolated

8. Fault finding
 CHAPTER – 2

OPERATING INSTRUCTIONS

1 INTRODUCTION

The following operating instructions are applicable to the mentioned type

of condensate extraction pumps, and should be read in conjunction with those for
the operation of the pump driving motor and the station operating instructions.

The pump driving motor, pump suction and discharge pipe work, valves
and control equipment are not supplied by BHEL, Hyderabad therefore the
installation should include all the necessary ancillary equipment to facilitate
satisfactory operation and prevent any malfunction at an early stage.

The three condensate extraction pumps are designed as 50% duty pumps
and their normal mode of operation permits two pumps running, and one on
standby.

To obtain the maximum attainable working life, continuous running is

recommended.

2 PRE-START CHECKS

Following an overhaul or maintenance procedure, check that the following

steps have been carried out along with the motor manufacturer’s instructions.

(1) Ensure that the power supply is available to the driving motor.

(2) Check the oil level in the thrust bearing gauge glass. Top up the thrust
bearing, if necessary.
 (3) Ensure that the cooling water is available to the thrust bearing.

(4) Ensure that the sealing water is available to the stuffing box.

(5) Ensure that the pump discharge isolating valve is shut.

CAUTION : If the pump is to be started with the discharge valve open, it is

essential that the discharge line is full to prevent the pump running
out of its characteristic, and imposing an overload on the driving
motor.

(6) Ensure that the pump suction isolating valve is open.

(7) Ensure that the discharge pressure gauge isolating valve is open.

(8) Ensure that the valve on the air vent pipe to the condenser is open. The
valve should be locked in the “Open” position.

3 START - UP

(1) Ensure that the pre-start checks have been carried out.

CAUTION : (a) The pump must not be started unless the canister is full of
condensate.

(b) The suction isolating valve must not be used for throttling the
pump output: the discharge valve should be used for this
purpose.

(2) Refer to the motor manufacturer’s instructions and start the driving motor.
Ensure that the motor direction of rotation is correct.

CAUTION : The pump must not be run for an extended period with the discharge
valve closed.
 (3) Slowly open the discharge valve and fill the system pipe work with
condensate. When the system pressure stabilizes fully open the discharge
isolating valve.

(4) Check the following readings if the appropriate instruments are available.

(a) Pump suction pressure.

(b) Pump discharge pressure.

(c) Pump suction temperature.

(d) Motor current. Refer to the motor manufacturer’s instructions.

(5) Check the oil level in the thrust bearing gauge glass.

(6) Check the mechanical seal for leakage.

(7) Check all joints above floor level for leaks.

(8) Check for any undue noise or vibration.

4 PUMP RUNNING CHECKS

The following checks should be carried out at regular intervals :-

(1) Check that the following readings are normal if the appropriate
instruments are available.

(a) Suction pressure.

(b) Discharge pressure.

(c) Suction temperature.

(d) Motor current. Refer to the motor manufacturer’s instructions.

(2) Check the oil level in the thrust bearing gauge glass; top up if necessary.

(3) Check the mechanical seal for leakage.

 (4) Check all joints above floor level for leaks.

(5) Check the accessible fastenings for security.

(6) Check for any undue noise or vibration.

5 NORMAL SHUT-DOWN

(1) Stop the pump driving motor. Refer to the motor manufacturer’s
instructions.

(2) Shut the pump discharge isolating valve.

(3) Unlock and shut the valve on the air vent pipe to the condenser. Lock the
valve.

Note : Refer to the station operating instructions.

6 PREPARING A PUMP FOR STANDY

If a duty pump should fail or extra duty is required, the standby pump
should be ready for immediate start-up. To prepare a pump for standby, the
following procedures must be carried out in conjunction with the motor
manufacturer’s instructions and the station operating procedures.

(1) Check the oil level in the thrust bearing gauge glass; top up if necessary.

(2) Ensure that cooling water is available to the thrust bearing.

(3) Ensure that sealing water is available to the mechanical seal.

Note : Constant sealing water is supplied to the stuffing box mechanical seal on
each pump from the common discharge pipe work via small bore pipe
work, which prevents the ingress of air when a pump is stationery. Two
orifice plates are fitted in each set of small bore supply pipe work.

(4) Ensure that the pump discharge isolating valve is shut.

 CAUTION : If the pump is to be started with the discharge valve open, it is
essential that the discharge line is full to prevent the pump running
out of its characteristic and imposing an overload on the driving
motor.

(5) Ensure that the pump suction isolating valve is open.

(6) Ensure that the canister is full.

(7) Ensure that the discharge pressure gauge isolating valve is open.

(8) Unlock and open the valve on the air vent pipe to the condenser. Lock the
valve in the open position.

7 SHUT-DOWN WHEN THE PUNP IS TO BE ISOLATED :

(1) Stop the pump driving motor. Refer to the motor manufacturer’s
instructions.

(2) Shut the pump discharge isolating valve.

(3) Shut the pump suction isolating valve.

(4) Isolate the electrical power supply from the pump driving motor. Refer to
the motor manufacturer’s instructions.

(5) Isolate the cooling water supply to the thrust bearing.

(6) Isolate the sealing water supply to the mechanical seal.

(7) Unlock and shut the valve on the air vent pipe to the condenser. Lock the
valve.

Note : Refer to the station operating instructions.

(8) Evacuate the accumulated condensate from the canister.

8 FAULT FINDING

Symptom Possible Cause Action

(1) Pump fails to start (a) Electrical supply to Check the electrical supply.
the driving motor Refer to the motor
isolated or faulty. manufacturer’s instructions.
(b) Seizure of the pump Remove the pump set.
or motor. Disconnect the pump from
the motor to establish
locality and cause of
seizure. Dismantle and
renew the pump or motor
components as necessary.
(c) Thrust and journal Remove and examine thrust
bearing seized. and journal bearings. Refer
to Chapter 3.
(2) Pump (a) Motor power faulty. Check the motor and
performance electrical supply. Refer to
low motor manufacturer’s
instructions.
(b) Incorrect rotation. Check the motor terminals at
the starter. Refer to the
motor manufacturer’s
instructions.
(c) Discharge valve not Check the valve.
fully open.
(d) Excessive clearance Remove the pump set,
between the impeller dismantle the pump and
wear rings and renew components as
casing wear rings. necessary, Refer Chapter 3.
(3) Excessive (a) Pump or motor Dismantle the pump or
noise and/or rotating assembly motor and check
vibration out of balance. components for dynamic
balance. Refer to dynamic
balance, Section 8.11,
Chapter 3.
(b) Journal bearing, Dismantle the thrust bearing
thrust bearing, or and dismantle the pump and
bearing bushes on check the pump and shaft
the pump, or bottom bushes; renew as
shaft worn. necessary. Refer Chapter 3.
(c) Journal bearings on Refer to the motor
the motor worn. manufacturer’s instructions.
(d) Excessive wear of Dismantle the pump and
pump internals. check for wear. Renew
components as necessary.
Refer to Chapter 3.
(e) Excessive wear in Refer to the motor
motor internals. manufacturer’s instructions.
(f) Securing Ensure that all accessible
arrangements loose. fastenings and
corresponding pipe work are
secure.
 SECTION - C

CONDENSATE EXTRACTION PUMP

CHAPTER – 3

MAINTENANCE INSTRUCTIONS

LIST OF CONTENTS

1 Introduction
1.1 Periodic and preventive maintenance
1.2 Routine checks
2 Tools
3 Recommended lubricants
4 Weights
5 Maintenance procedures
5.1 Examining the combined thrust and journal
bearings
6 Removing the driving motor
7 Dismantling procedures
7.1 Preparation prior to removing the motor stool,
headpiece and pump
7.2 Removing the motor stool, headpiece and
pump.
7.3 Dismantling the headpiece and pump
8 Inspection and renewal
8.1 Clearances
8.2 Impellers
8.3 Shaft sleeves and bearings
8.4 Pump Shafts
8.5 Combined thrust and journal bearing
8.6 Mechanical seals
8.7 Flexible couplings
8.8 Keys
8.9 Nuts, Bolts & studs
8.10 Joints, “O” rings and locking device
8.11 Dynamic balancing
8.12 Cleanliness
9 Assembling procedure
9.1 Assembling the pump and head piece
10 Installing pump, head piece and motor stool
11 Installing the drive motor
12 Final assembling and connection
13 Parts identification
 CHAPTER – 3

MAINTENANCE INSTRUCTIONS

1 INTRODUCTION

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

established during which the condition of the various components in the pump set
can be determined and recorded for comparison with later inspections. Any
defects should be repaired or the components renewed at the earliest opportunity.

Certain inspections can only be made when the plant is shut down, but
others can be made under operating conditions.

It is essential that all lifting tackle and equipment is maintained in a

serviceable condition and that safety rules and regulations are observed at all
times.

A high degree of cleanliness of the equipment and surrounding area

should be maintained as this will assist in the detection of minor leaks and defects
which, if unnoticed, could lead to more serious defects.

1.1 Periodic and Preventive Maintenance

The following are the primary criteria for examination and renewal of wearing parts
and it is recommended that these aspects are checked regularly during every shift.

(1) Reduction in pump performance, ie., reduction in discharge pressure or a

sustained increase in motor power consumption.

(2) Excessive vibration.

(3) Excessive leakage at the pump mechanical seal plate.

1.2 Routine Checks

It is essential that the pump running check given in Chapter 2, Section 4,

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

(1) Check that the pump discharge pressure is normal.

(2) Check that the motor current is normal.

(3) Check the oil level in the thrust bearing gauge glass.

(4) Check the stuffing box for excessive leakage.

(5) Check the accessible joints for leaks.

(6) Check the accessible fastenings for security.

(7) Check for any undue noise or vibration.

2 TOOLS

The following tools and equipment are available for use on the pumps.
When not in use they should be safety stored. Any defects or shortages should be
remedied at the earliest opportunity, otherwise maintenance and overhaul may be
hindered.

No. off Tool and Purpose

1 “C” spanner for impeller nuts and muff coupling nuts.
1 set Withdrawal and fitting gear, thrust bearing.
1 set Withdrawal and fitting gear first stage.

3 RECOMMENDED LUBRICANTS
 Refer to the thrust bearing manufacturer’s instructions in Chapter 5 for the
recommended lubricant.

4 WEIGHTS

Item Weight, kg
Pump (less motor, canister and foundation ring) 5080
Rotating assembly 547
Canister 1920
Foundation ring 145
Head piece 1032
Shaft, bottom 109
Impeller, 1st stage 50
Impeller, 2nd to last stage 31
Ring main, top. 7 stage 93
Ring main bottom 145
Suction bell mouth 64
Casing, 1st stage 640
Casing, intermediate 2nd stage 235
Casing, last stage 191
Shaft, top / intermediate 171
Motor stool 417

5 MAINTENANCE PROCEDURES
5.1 Examining the combined thrust and journal bearing

Note : The following instructions should be read in conjunction with the thrust
bearing manufacturer’s instructions contained in Chapter-4.

(1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been
carried out.

(2) Remove the access covers from the motor stool and headpiece.

(3) Remove the nuts and bolts and remove the spacer and membranes from
the pump and motor half couplings.

Note : The flanges of the spacer and half couplings should be marked in relation
to each other for ease of assembling.

(4) Remove the drain plug from the base plate and drain the oil from the thrust
bearing.

(5) Remove the oil gauge glass and pipe extension to avoid any damage.

(6) Disconnect and remove the combined oil filler and vent pipe to avoid any
damage.

(7) Remove the bearing inlet and outlet cooling water pipe work.

(8) Remove the bearing cover securing screws and remove the halves of the
cover, with the cooler attached.

Note : Tapped holes are provided in the cover for lifting purposes.

(9) Unlock the lock-washers and remove the anti-vortex shroud securing
screws. Raise the shrouds to gain access to the journal pads.

(10) Remove the journal pads from the casing, by inserting a suitable screwed
rod into the tapped hole provided on each journal pad. Carefully slide each
pad around and out from the casing.

(11) Examine the journal bearings. Refer to the bearing manufacturer’s

instructions contained in Chapter-4.

(12) Apply a film of oil to each journal and install the pads into location in the
casing and around the shaft. Remove the temporary screwed rod from
each journal pad.
(13) Locate a temporary face plate on the pump shaft end and a similar
temporary face plate on the motor shaft end. Secure each face plate to its
respective shaft end with a center bolt.

(14) Locate temporary bolts and nuts between the motor and pump half
couplings.

Note : Do not tighten the temporary nuts and bolts between the half
couplings at this stage.

(15) Remove the nuts securing the bearing casing and base plate to the
adapter plate.

(16) Remove the access guards from the head piece.

(17) Disconnect the inlet and outlet mechanical seal sealing water pipe work.
This will avoid any unnecessary strain and protect the seal, during any
movement of the shaft, whilst examining the thrust pads.

(18) Remove the screws on the seal plate and slacken the grub screws which
lock the seal retaining collar and seal sleeve to the pump shaft.

Note : Check that the seal plate is free within its normal location.

(19) Insert starting screws into the tapped holes provided in the thrust bearing
casing and carefully break the seal between the casing and base plate.

(20) Tighten the nuts on the temporary bolts between the half couplings, and
raise the shaft assembly by 8 mm, to ensure that the thrust collar is clear
of the thrust pads.

(21) Lift the thrust casing from the base plate to gain access to the thrust pads.
Support the thrust casing on temporary supports placed between the base
plate and casing. Remove the starting screws from the casing.

CAUTION : Avoid any damage to the “O” ring provided in the base plate.

(22) With sufficient access available to the thrust pads, remove each pad from
the groove formed in the base plate.
(23) Examine the thrust pads. Refer to the bearing manufacturer’s instructions
contained in Chapter-4.

(24) Apply a film of oil to each thrust pad and install the pads into the place in
the groove formed in the bas plate.

Note : Ensure that the thrust pads are correctly fitted and prevented from
rotating by means of the thrust pad stop.

(25) Lift the thrust casing, remove the temporary supports and lower the casing
onto the base plate.

(26) Unscrew the nuts on the temporary bolts, between the half couplings and
carefully lower the shaft assembly to return to its original position. The
thrust collar will rest on the thrust pads.

(27) Locate and secure the seal plate with the screw to the stuffing box.

(28) Secure the thrust casing to the base plate with the nuts on the studs.

(29) Locate the anti-vortex should into the thrust casing and secure it with the
screws the new lock-washers to the casing. Lock the screws with their
lock-washers.

(30) Fit a new cover joint to the casing and locate and secure the cover halves,
with attached cooler, to the casing with screws.

(31) Install and connect the pipe extension and oil gauge glass to the casing
assembly.

(32) Fit the drain plug to the thrust bearing base plate

(33) Connect and secure the combined oil filler and vent pipe to the casing.

(34) Remove the combined air vent/oil filler and fill the bearing to the correct
level with the recommended lubricant. Replace the combined air vent/oil
filler.

(35) Connect and secure the bearing inlet and outlet cooling water pipe work.

(36) Remove the temporary nuts and bolts from the coupling halves and
remove each temporary face plate from the pump and motor shaft ends.
 (37) Check the coupling alignment. Refer to the information contained in
illustration P2424.

(38) Ensure that the seal assembly is secured with its screws to the stuffing
box. Refer to the instructions indicated on the seal drawing.

Note : The mechanical seal must be removed during the dismantling in Section
and renewed during the assembling in Section 9.

(39) Secure the inlet and outlet sealing water pipe work to the mechanical seal
plate.

(40) Secure the access guards to the headpiece.

(41) Install and secure the coupling spacer and membranes to the respective
pump and motor half couplings, with the nuts and bolts. Refer to the
coupling manufacturer’s instructions in Chapter-4.

(42) Secure the access guards to the motor stool.

(43) Prepare the pump for start-up. Refer to Chapter-2, Operating Instructions,
Section-2, Pre-Start Checks.

6 REMOVING THE DRIVING MOTOR

Note : The following instructions should be read in conjunction with the motor
manufacturer’s instructions.

(1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been
carried out.

(2) Isolate and remove the electrical supply cables from the driving motor.
Refer to the motor manufacturer’s instructions.

(3) Remove the access covers from the motor stool.

(4) Remove the nuts and bolts and remove the spacer and membranes from
the pump and motor half couplings. Refer to the coupling manufacturer’s
instructions in Chapter-4.

Note : The flanges of the spacer and half couplings should be marked in
relation to each other for ease of assembling.
 (5) Attach suitable lifting gear to the lifting lugs provided on the motor.
Unscrew and remove the screws securing the motor to the motor stool,
and carefully lift the motor from the motor stool with its half coupling
attached.

(6) Lower the motor onto suitable supports and remove the lifting gear.

7. DISMANTLING PROCEDURES

7.1 Preparation Prior to Removing the Motor Stool, Headpiece and Pump

(1) Ensure that the procedures for removing the driving motor in Section 6
have been carried out.

(2) Withdraw the half coupling from the pump top shaft with the withdrawal
gear provided. Remove the half coupling key from the shaft and retain it.
Refer to the coupling manufacturer’s instructions in Chapter-4.

(3) Remove the oil drain plug from the thrust bearing and drain the oil into a
suitable container. When the oil has drained replace the drain plug. Refer
to the thrust bearing manufacturer’s instructions in Chapter-4.

(4) Disconnect and remove the thrust bearing cooling water inlet and outlet
pipe work. Remove the combined air vent/oil filler pipe work, oil level
gauge associated pipe work and oil drain pipe work.

7.2 Remove the Motor Stool, Headpiece and Pump

Note : Ensure that the preparation procedures have been carried out in
Section 7.1.

(1) Attach suitable lifting gear to the motor stool, then remove the motor stool
securing screws and carefully remove the motor stool from the head piece.

(2) Remove the access covers from the headpiece.

(3) Disconnect and remove the inlet and outlet sealing water pipe work from
the stuffing box.

(4) Disconnect the seal assembly . Refer to the instructions given on the seal
drawing.
(5) Remove the thrust collar lock-nut from the shaft with the spanner provided.

Note : As the lock-nut is unscrewed, the rotating assembly will gradually drop
to its lowest position, with each impeller resting in its casing.

(6) Remove the bearing cover securing screws and lift and remove the cover,
with the cooler attached, to gain access to the internals of the thrust
bearing. Remove and discard the cover joint.

Note : Tapped holes are provided in the cover for lifting purposes.

(7) Unlock the lock-washers and remove the anti-vortex shroud securing
screws. Remove the shroud to gain access to the journal pads.

(8) Remove the journal pads from the casing, by inserting a suitable screwed
rod into the tapped hole provided on each pad. Carefully slide each pad
around and out from the casing.

(9) Attach suitable lifting gear to the thrust collar and with the withdrawal gear
supplied withdraw the thrust collar from the shaft. Remove and retain the
collar key. Lower the thrust collar onto supports and remove the lifting
gear.

Note : During removal of the thrust collar, ensure that the corresponding
bearing faces are not damaged.

(10) Remove the nuts from the studs securing the casing and base plate to the
adaptor plate. Attach suitable lifting gear to the casing and remove the
casing clear from the base plate and shaft.

(11) Lower the casing onto suitable supports and remove the lifting gear.

(12) Remove the thrust pads from the groove formed in the base plate.

(13) Refer to the bearing manufacturer’s instructions in Chapter-4. Insert

jacking screws into the tapped holes provided on the base plate. Screw in
the jacking screws to separate the base plate from the adaptor plate. Lift
the base plate away with the sleeve attached.
 (14) Remove the screw securing the sleeve to the base plate. Remove the
sleeve and remove and discard the joint. Remove and discard the “O” ring
from the base plate.

(15) Remove the seal assembly from the stuffing box. Refer to the mechanical
seal manufacturer's instructions on the seal drawing.

(16) Remove the seal nut from the shaft and remove the seal plate from the
stuffing box.

(17) Remove the stuffing box securing screws and screw in jacking screws into
the tapped holed provided. Attach suitable lifting gear and remove the
stuffing box from the headpiece and shaft. Lower the stuffing box onto
suitable supports and remove the lifting gear. Unlock-washers then
remove the screws from the underside of the stuffing box and remove the
restriction bush.

(18) Remove the nuts and bolts securing the discharge branch to the discharge
pipe work.

(19) Attach suitable lifting gear to the lugs provided on the head piece.

(20) Remove the screws securing the headpiece to the canister. With the lifting
gear attached, carefully raise the headpiece and pump assembly from the
canister. Remove and discard the joint. Cover the canister opening with a
suitable temporary cover.

(21) Transport the headpiece and pump assembly to a suitable maintenance

area. Carefully lower and support the headpiece and pump assembly in
the horizontal position.

CAUTION : The pump must not pivot on the first stage casing.

7.3 Dismantling the Head piece and pump:

CAUTION : (a) The head piece, pump casing and rising mains must be
supported on the horizontal position.
 (b) The pump top shaft must be suitably supported in the
horizontal position.

(c) Before dismantling the assembly, mark the headpiece, pump

casings, rising mains and bell mouth to ensure correct
assembly.

(1) Before proceeding any further check the total axial travel as follows:-

(a) Push the pump shaft until it abuts at the suction end. Lay a straight
edge across the face of the head piece, at the stuffing box adjoining
face, and with a pencil scribe a line on the top shaft.

(b) Pull the pump shaft until it abuts at the discharge end.

(c) Lay the straight edge across the face of the head piece and scribe a
second line on the top shaft.

(d) Measure the distance between the two scribe lines which indicate
the total axial travel of the rotating assembly.

Note : The correct total axial travel should measure 8 to10 mm.

CAUTION : The pump to shaft and casings must be supported.

(2) Attach suitable lifting gear to the suction bell mouth, unlock the tab
washers and remove the screws securing the bell mouth to the first stage
pump casing, then lift the bell mouth clear off the pump shaft. Discard the
tab-washers and the “O” ring. Lower the bell mouth on suitable supports
and remove the lifting gear.

Note : The bell mouth incorporates a casing wear ring and Cutless rubber
bearing.

(3) Release the lock-washer securing the shaft nut and using the special
spanner supplied, remove the nut from the shaft. Discard the lock-washer.

(4) Remove the first stage bottom sleeve from the shaft.

(5) Attach lifting gear to the first stage impeller and withdraw the impeller from
the pump shaft using the withdrawal gear supplied. Remove and retain the
 impeller key. Lower the impeller onto suitable supports and remove the
lifting gear.

(6) Attach lifting gear to the first stage pump casing, unlock the tab-washers
and remove the screws securing the first stage casing to the Element-I.
Insert starting screws into the tapped holes provided in the first stage
casing and tighten them to assist with removal of the casing. Move the
first stage casing along and clear from the shaft. Remove and discard the
“O” ring, and Lower the casing onto suitable supports. Remove the lifting
gear.

Note : The first stage casing incorporates a casing wear ring and a Cutless
rubber bearing.

(7) Remove the grub screws and remove the shaft tube from the first stage
casing. Discard the “O” ring.

(8) Remove the first stage top sleeve from the shaft.

Note : Support the shaft.

9) Attach lifting gear to Element-I, unlock the tab washers and remove the
screws securing the Element-I to Element-II. Insert starting screws into the
tapped holes provided in Element-I and tighten them to assist removal of
the Element. Move the Element-I along and clear from the shaft. Remove
and discard the 'O' ring and lower the casing onto suitable supports.
Remove the lifting gear.

Note : The Element -I incorporates a cutless rubber bearing.

10) Remove the grub screws and remove the shaft sleeve of Element-I.
Remove and retain the sleeve key.

11) Repeat step (9) to remove Element-II.

12) Attach separate lifting gear to the bottom shaft. Remove the lock washer
and slacken back the lock nut securing the bottom shaft to the muff
coupling. Screw the coupling nut clear off the coupling, and withdraw the
bottom shaft from the coupling and lift it away. Remove and retain the
coupling key and shear ring halves.
Note : Support the intermediate shaft prior to withdrawal of bottom shaft.

13) Repeat step (12) to withdraw the muff coupling from intermediate shaft.

14) Repeat step (9) and (10) t remove Element-III.

Note : Support the intermediate shaft. Element-III incorporates a cutless rubber

bearing.

15) Release the lock washer securing the second stage impeller nut, then
using the special spanner provided, remove the nut.

16) Pull the shaft sleeves from the bottom of second stage impeller, remove
and retain the sleeve keys.

Note : Support the shaft.

17) Using the withdrawal gear supplied, withdraw the second stage impeller
from the shaft, remove and retain the impeller key.

18) Attach lifting gear to the second stage pump casing, unlock the tab
washers and remove the screws securing the second stage casing to the
third stage casing, then remove the second stage casing from the shaft.
Discard the tab-washers and the “O” ring.

Note : The second stage casing incorporates a casing wear ring and a Cutless
rubber bearing.

19) Pull the intermediate sleeve from the shaft.

20) Repeat Steps (17 to 19) to remove the third stage impeller and pump
casing.

21) Attach lifting gear to the bottom rising main, unlock the tab-washers and
remove the screws securing the rising main to the fourth stage pump
casing. Lift the rising main clear off the shaft. Discard the tab-washers and
the “O” ring.

22) Attach separate lifting gear to the intermediate shaft. Release the lock-
washer and slacken back the lock-nut securing the bottom shaft to the muff
coupling. Screw the coupling nut clear of the coupling, and withdraw the
 intermediate shaft from the coupling and lift it away. Remove and retain the
coupling key and the shear ring halves.

23) Repeat step (22) to withdraw the muff coupling from the top shaft.

24) Repeat steps (17) to (19) to remove the fifth and sixth stage impellers and
pump casings.

Note : Continue to support the shaft.

25) Attach a suitable lifting sling to the top shaft and remove it from the head
piece. Lower the shaft onto suitable supports and remove the lifting sling.

Note : The head piece should remain supported in the horizontal position.

8. INSPECTION AND RENEWAL

8.1 Clearances

(1) Refer to the sectional arrangement for details of clearances. It is

recommended that when the pump internal diametrical clearances have
reached twice the mean of the figures quoted or are expected to before
the next overhaul, the component or components should be renewed. The
main considerations, however, are pump performance and motor power
consumption.

(2) Casing wear rings and impeller wear rings are normally supplied undersize
and oversize respectively on the wearing surfaces, so that they can be
machined to give the appropriate clearance.

Note : (a) The impeller wear rings are pressed on to the impellers and retained
by grub screws, and the casing wear rings are pressed into their
respective casings and also retained by grub screws.

(b) if the impeller or casing wear rings require to be renewed the wear
rings must be machined from the casing or impeller, and new wear
rings pressed on and secured by grub screws.

(4) A shaft sleeve fitted to the top shaft, in way of the mechanical seal, is held
by loctite. If the sleeve has to be renewed it must be machined from the
shaft and a new sleeve fitted and secured by loctite.
8.2 Impeller

(1) Examine the shaft sleeves for wear and damage. Renew as necessary.

(2) Ensure that the impeller wear rings are correctly fitted and secured.

8.3 Shaft Sleeves and Bearings

(1) Examine the shaft sleeves for wear and damage. Renew as necessary.

(2) Examine the journal bearings from wear and damage. Renew as
necessary. Refer to Section 8.1 Step (4).

8.4 Pump Shafts

Examine the shafts for damage or bowing and check for concentricity. Each shaft
must be within 0.05 mm full indicator movement.

8.5 Combined Thrust and Journal Bearing

Refer to the manufacturer’s instructions in Chapter 4.

8.6 Mechanical Seal

(1) Renew the mechanical seal. Refer to the seal manufacturer’s instructions
in Chapter-4.

(2) Check that the water passageways formed on the seal plate are clear.

(3) Examine the stuffing box restriction bush. Renew as necessary.

8.7 Flexible Coupling

Refer to the manufacturer’s instructions in Chapter-4.

8.8 Keys

All keys must be a good fit in their keyways and reference marks must be
clearly legible. They must be flat, parallel and free from burrs. Worn or damaged
keys must be renewed.

8.9 Nuts, Bolts and Studs

 Examine all studs, nuts and bolts for damage or deterioration. Renew as
necessary.

8.10 Joints, “O” Rings and Locking Devices

All joints “O” rings and locking devices must be renewed on assembly.

8.11 Dynamic Balance

If any of the impellers or the coupling hub are renewed, it should be noted
that the new components are dynamically balanced during manufacture. If,
however, the dynamic balance of any components is checked and is found to be
out with the limit of 2835 M/N g cm per plane of measurement, the following rules
must be adhered to when removing metal to effect the balance.

Note M = weight of the component (kg)

N = pump speed (rev/min)

CAUTION : (1) The thickness of the impeller shroud must not be reduced by
more than 1.6 mm at any point.

(2) No meal is to be removed from the impeller within 12.7 mm of

its periphery.

(3) The weight of metal to be removed is to be calculated in the

from of segment, the arc length of which does not exceed 0.1
of the circumstance of the impeller.

(4) If the amount of metal to be removed exceeds the limits

imposed by (1) and (3), BHEL, Hyderabad, should be
consulted.

8.12 Cleanliness

All components must be perfectly clean and free from burrs, and all water
passages must be cleaned out before the pump is assembled. Check that all small
bore pipe work is clear.

9 ASSEMBLING PROCEDURES

9.1 Assembling the Pump and Head piece

 During assembly, it is recommended that colloidal graphite or similar is
applied to the shaft and bores of the impeller and shaft sleeves, allowed to dry and
then polished.

CAUTION : The pump shaft and casings must be suitably supported in the
horizontal position whilst assembling the pump.

Note : (a) The following torque figures must be used when assembling the
pump:-

Sixth stage casing to head piece. 700 Nm

First to third and fourth to last stage castings, inclusive 1350 Nm

Bottom rising main to third and fourth stage casing 140 Nm

Bell mouth to first stage casing 50 Nm

Head piece to canister 290 Nm

Motor stool to head piece 220 Nm

(b) Observe the match marks made prior to dismantling to ensure

correct assembly.

(1) Ensure that the head piece is supported in the horizontal position.

(2) Install the last stage shaft sleeve on the top shaft, to abut the sleeve fitted
on the shaft by loctite.

(3) Attach lifting gear to the top shaft, and carefully install the shaft in the head
piece. Support the shaft and remove the lifting gear.

Note : When installing the sixth stage casing, adjust the top shaft supports to
the ensure that the shaft is supported at all times.

(4) Locate a new “O” ring on the spigot of the last stage pump casing, attach
lifting gear and install the casing on the top rising main. Secure the pump
casing to the rising main with the screws and new tab-washers.

Note : (a) Observe the note following Step (4).

 (b) When installing the pump casing, ensure that the Cutless
rubber journal bearing does not become damaged.

(c) Do not bend over the lock-washer tabs meantime.

(6) Install the sixth stage impeller key in the shaft, then install the impeller on
the shaft, to locate on the key and abut the last stage shaft sleeve.

(7) Repeat Steps (5) and (6) to install the fifth and fourth stage pump casing
and impellers.

(8) Screw the impeller nut onto the shaft and, using the special spanner
provided, tighten the nut against the hub of the fifth stage impeller.

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

(a) Push the pump shaft until it abuts at the suction end. Lay a straight
edge across the face of the head piece, at the stuffing box adjoining
face, and with a pencil scribe a line on the top shaft.

(b) Pull the pump shaft until it abuts at the discharge end. Lay the
straight edge across the face of the head piece and scribe a second
line on the top shaft.

(c) Measure the distance between the two scribed lines which indicate
the total axial travel to the rotating assembly.

(e) The total axial travel is 8 to 10 mm, and if this is not achieved, the
cause must be established and the fault must be corrected before
proceeding.

(10) Slide the muff coupling nut, lock-nut and a new lock-washer onto the top
shaft, beyond the shear ring groove in the shaft, then install the shear ring
halves in the groove, and the coupling key in the shaft.

(11) Slide the coupling sleeve onto the shaft, to abut the shear ring, then screw
the coupling nut into the bore of the sleeve. Tighten the nut to pull the
sleeve hard against the shear ring and secure it with the lock-nut and lock-
washer.
(12) Install the muff coupling nut, lock-nut, new lock-washer, shear ring halves
and coupling key on the bottom shaft as described in Step (8). Sling the
bottom shaft and install it in the muff coupling sleeve, ensuring that the
spigot on the shaft end engages in the recess in the end of the top shaft.
Tighten and lock the coupling nut as described in Step (9). Support the
bottom shaft and remove the lifting gear.

(13) Install the bottom rising main as described in step (4), then install the third
and second stage pump casings and impellers as described in Steps (6) to
(7). Continue to support the bottom shaft and the pump casings.

(14) Install the sleeve keys on the shaft, at the bottom of the second stage
impeller. Install the sleeves to locate on the keys and abut the second
stage impeller.

(15) Repeat steps (8), (9) and (5) to assemble impeller, nut, check total float
and assemble Element-IV.

(16) Install the sleeve keys of Element-III on the shaft. Install the sleeve to
locate on the key and abut the shoulder on the shaft. Lock the sleeve on
to the shaft with grub screws provided.

(17) Repeat steps (10,11 &12) to assemble the muff coupling and bottom shaft.

(18) With the total axial travel checked, and corrected as necessary, bend over
the tabs on the tab-washers on all the pump casing screws, stages 2 to 6.

(19) Ensure that the first stage shaft tube is in place in the first stage pump
casing, with new “O” rings, then locate a new “O” ring on the spigot of the
first stage casing.

(20) Sling the first stage pump casing and carefully install it over the shaft, to
locate on the second stage casing, and secure it with the screws and new
tab-washers. Do not bend over the washer tabs meantime.

(21) Install the first stage top sleeve on the shaft, to abut the shoulder on the
shaft, and locate the first stage impeller key in the keyway in the shaft.
 (22) Sling the first stage impeller and install it on the shaft, to abut the first
stage top sleeve.

Note : Ensure that the direction of rotation of the impeller is correct.

(23) Install the first stage bottom sleeve on the shaft and secure the assembly
with the shaft nut and new lock-washer.

(24) Install the bell mouth on the first stage casing, with a new “O” ring, and
secure it with the screws and new tab-washers.

(25) Check the total axial travel as described in Step (9) then bend over the
tabs on the lock-washers.

10 INSTALLING PUMP, HEAD PIECE AND MOTOR STOOL

(1) Attach suitable lifting gear to the lugs on the head piece. Carefully lift the
head piece and pump from the horizontal to the vertical position and use
adequate supports as necessary.

CAUTION : Care must be exercised to ensure that the pump does not pivot
on the first stage casing or attached bell mouth. Ensure that the
pump is supported thus avoiding the possibility of bowing.

(2) Remove the temporary cover from the canister.

(3) Lower the pump and head piece into the canister and ensure that the
pump discharge pipe is in line with the corresponding discharge pipe work.
Continue to lower the assembly until the head piece rests on the canister.
Ensure that the suction bell mouth is engaged on the snubber within the
canister and that the holes in the head piece correspond with the holes in
the canister.

(4) Secure the headpiece to the canister with the screws and remove the
lifting gear from the head piece.
(5) Secure the pump discharge pipe work to the pump discharge branch.

(6) Secure the restriction bush with screws and lock-washers to the underside
of the stuffing box or seal housing.

(7) Locate the seal sleeve key in the key way in the shaft, and secure it with
the countersunk screw.

(8) Install the mechanical seal. Refer seal manufacturer's instructions on the
seal drawing.

Note : The mechanical seal is of cartridge design.

CAUTION : Do not tighten the seal plate securing screws at this stage.

(a) Screw the seal sleeve nut and the lock-nut/thrower onto the shaft and
leave loose meantime.

(9) Locate and secure the adaptor plate with screw to the top of the head
piece.

Note : During manufacture of the pump set, the adapter plate is machined to
a specific thickness and locates between the thrust bearing base plate
and headpiece. The adaptor plate determines the position of the
rotating assembly when the thrust bearing is assembled.

(10) Fit a new joint to the sleeve and insert the sleeve into the thrust bearing
base plate. Secure the sleeve to the base plate with the screws and fit a
new “O” ring to the base plate. Refer to the bearing manufacturer’s
instructions.

(11) Lift the bearing base plate onto the adaptor plate studs.

Note : Ensure that the drain hole on the base plate is positioned to
accommodate the drain pipe work. When the motor stool is assembled.
(12) Apply a film of oil to the thrust pads and insert the thrust pads onto the
base plate and move the pads around the groove to abut the pad stop.
Refer to the bearing manufacturer’s instructions.

(13) Lift the bearing casing onto the base plate.

(14) Secure the bearing casing and base plate to the adaptor plate with nuts on
the adaptor plate studs.

Note : Ensure that the casing is located to accommodate the corresponding oil
level gauge pipe work.

(15) Fit the collar key to the shaft and attach suitable lifting gear to the thrust
collar. Engage the collar onto the shaft and with the use of the assembly
gear fit the collar to the shaft. Remove the assembly gear.

(16) Screw the thrust collar nut onto the haft, to abut the thrust collar, then
using the special spanner provided, tighten the nut to raise the pump shaft
into its corrected running position.

(17) Apply a film of oil to the journal pads and locate the journal pads, between
the casing and collar. Locate the journal pads by inserting a screwed rod
into the tapped hole provided in each pad. Remove the screwed rod.

(18) Locate and secure the anti-vortex shroud with lock-washers and screws to
the casing. Tighten the screws and secure the screws with the lock-
washers.

(19) Fit a new cover joint to the casing. Install the cover with attached cooler.
Secure the cover to the casing with screws. Refer to the bearing
manufacturer’s instructions.

Note : (a) Tapped holes are provided in the cover for lifting purposes.
 (b) Ensure that the cover is located in the casing to accommodate the
corresponding cooling water small bore pipe work.

(20) Fit the half coupling to the shaft. Attach suitable lifting gear to the half
coupling and lift the half coupling on the shaft to abut the thrust collar nut,
using the assembly gear supplied. Remove the assembly gear from the
half coupling.

(21) Tighten the seal plate securing screws. Tighten the grub screws in the seal
sleeve until they contact the shaft. Disengage the eccentric washers /
assembly fixture from the seal sleeve.

Mechanical seal is of cartridge design.

Refer to the seal manufacturer's drawings / instructions.

(22) Secure the inlet and outlet sealing water pipe work to the stuffing box.

(23) Attach suitable lifting gear to the motor stool and lift the motor stool onto
the spigot flange provided on the headpiece.

Note : Ensure that the motor stool is positioned on the headpiece to

accommodate cooling water, oil level, oil filling pipe work and oil drain
pipe work associated with the thrust and journal bearing.

(24) Secure the motor stool with the screws and remove the lifting gear from
the motor stool.

(25) Connect and secure the thrust bearing cooling water inlet and outlet pipe
work, oil filter and air vent pipe work, oil level pipe work and gauge. Fit the
oil drain pipe work to the thrust bearing and fit the drain plug.

(26) Fill the thrust bearing to the correct level with the recommended lubricant.
Refer to the thrust bearing manufacturer’s instructions.
11. INSTALLING THE DRIVING MOTOR

Note : The following instructions should be read in conjunction with the motor
manufacturer’s instructions.

(1) Ensure that the motor half coupling is fitted. Refer to the coupling
manufacturer’s drawings / instructions.

(2) Attach suitable lifting gear to the lifting hooks provided on the motor. Lift
the motor onto the motor stool.

Note : Ensure that the motor is positioned on the stool to accommodate the
associated supply cables and cooling water pipe work, etc.

(3) Secure the motor to the stool with the nuts and bolts, and remove the
lifting gear.

(4) Check the alignment between the pump and motor half couplings. Refer to
illustration for Checking coupling alignment.

(5) With the coupling alignment checked and satisfactory, assemble the
coupling spacer and membranes.

Note : The flanges of the spacer and half couplings were previously marked
in relation to each other for assembly purposes. Ensure that the marks
on the flanges coincide.

(6) Secure the half couplings, spacer and membranes with the nuts and bolts.
Refer to the coupling manufacturer’s drawings / instructions.

(7) Secure the access covers to the motor stool.

12 FINAL ASSEMBLING AND CONNECTION

 (1) Connect and secure the air vent pipe to the pump.

(2) Ensure that the cooling water is available to the thrust bearing.

(3) Ensure that the sealing water is available to the stuffing box.

(4) Connect and secure the electrical power supply cables to the driving
motor. Refer to the motor manufacturer’s instructions.

(5) Return all tools and lifting gear to their storage area. Refer to Chapter 2
and carry out the Pre-start checks.

13. PARTS IDENTIFICATION

When ordering spare parts reference must be made to the pump Serial or
Job Number, Nomenclature, the Sectional Arrangement Drawing, the Item
Number, and the Quantity of each components.
 SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB-VENDOR’S DRAWINGS / INSTRUCTIONS

1 Mechanical Seal

2 Connecting coupling

3 Thrust & Journal Bearing

4 Suction Strainer
 SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

1. MECHANICAL SEAL
 OPERATING MANUAL
NO.
OPERATING MANUAL
FOR
BURGMANN
MECHANICAL SEAL (M.S.)
10
9
8
7
6
5
4
3
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 OPERATING MANUAL
NO.

- TABLE OF CONTENTS PAGE

0 Foreword 1
1 General Information 2

2 Product Information 3-5

2.1 Manufacturer and country of origin 3
2.2 Declaration 3
10

2.3 Type Designation 3

2.4 Operating Conditions 3
2.5 Designated Use 4
9

2.6 Description and Function 4

2.7 Required Space, connecting dimensions 4
8

2.8 Drawings, Diagrams 4

7

3 Safety Notes 6
4. Transport, Storage and Installation 5- 9
4.1 Packing and Storage 6
6

4.2 Preparation for Assembly 6-7

4.3 Special Instructions 8
5

4.4 Installation 9
4.5 Directives in case of Failure 9
4

5. Servicing 10 - 13
5.1 Tungsten Carbide Designs 10
5.2 Circulation 10
3

5.3 Buffer Fluid 10

5.4 After Sales Service by BURGMANN 10-12
2

5.5 Disposal of Burgmann Mechanical Seal 12

6. Copyright 13
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 OPERATING MANUAL
NO.

- FOREWORD

Section
0 Dear Sir,

Page 1 of 13 Thank you for purchasing the Burgmann Mechanical Seal (M.S.).
We at Burgmann are confident that your new purchase will greatly
expand your working capacity and efficiency.
This Operating Manual shows you how to get the most out of your new
10

Burgmann Mechanical Seal (M.S.). Whether you are installing,

operating or servicing, this manual will show you how to do it - quickly
and easily.
9

Please take some time to go through this manual before installation. You
don't have to read it all at once. We just want you to know what a great
Mechanical Seal (M.S.). you have.
8

We've taken a great deal of care in preparing this manual so that you will
never be left wondering how to perform a certain function. Nevertheless,
even after reading this manual if you still aren't sure about something,
7

please feel free to contact your nearest sales or service center of

Burgmann or our HQ. We shall be too glad to answer your queries.
6
5

BURGMANN
4
3
2

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 OPERATING MANUAL
NO.

1. GENERAL INFORMATION
Section
1

SR. DESCRIPTION DETAILS

Page 2 of 13 NO.
I Customer Bharat Heavy Electricals Ltd
II Machine Manufacturer B.H.E.L
III Customer PO No. F6 04 D989
10

IV Drawing Nos. 09-H75N/100-E3

V Burgmann W.O. 14910
9
8
7
6
5
4
3
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 OPERATING MANUAL
NO.

- 2. PRODUCT INFORMATION

Section
2 2.1 MANUFACTURER AND COUNTRY OF ORIGIN

Page 3 of 13 BURGMANN INDIA PVT. LTD.

A. K. Industrial Estate, Veer Savarkar Flyover,
Goregaon (West),
Mumbai-400 062.
10

INDIA.

2.2 DECLARATION
9

within the meaning of the EC-directive >> MACHINERY <<

A mechanical seal does not function independently. It is intended
to be incorporated into or assembled with machinery.
8
7

2.3 TYPE DESIGNATION

6

MECHANICAL SEAL DRG. NO. : 09-H75N/100-E3

The materials of the mechanical seal depend on the application and

are fixed in the order. They may vary from those stated in the
5

drawing.
4

2.4 OPERATING CONDITIONS

3

MECHANICAL SEAL DRG. NO. : 09-H75N/100-E3

Kind of Machine : --
Medium to be sealed :-
2

Suction Pr. : FULL VACUUM

Discharge Pr. : 3 Kg/cm2
Temperature Max. : 200O C
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Speed : 1000 RPM

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 OPERATING MANUAL
NO.

- 2.5 DESIGNATED USE

Section This mechanical seal is exclusively designed for the use in the
specified machine. A different utilisation or a utilisation going
2 beyond the specification is considered contrary to its designated
use and excludes a liability by the manufacturer.

Page 4 of 13 Operation under conditions lying outside those limits stated in

paragraph >> operating data << is considered contrary to its
designated use.
10

Should the seal be operated under different conditions or at a

different application BURGMANN has to be asked for recognition as
safe in advance.
9

2.6 DESCRIPTION AND FUNCTION

8

The BURGMANN Mechanical Seal mentioned in clause 2.3 & 2.4

has been supplied in cartridge construction, in this, the seal can be
7

installed directly on the pump casing without any adjustment. The

seal forms a pre-mounted unit (seal cartridge), asembled at works,
ready to be installed without any adjustment.
6

Assembly Fixtures (24) are provided for holding the cartridge in one
piece during transport, storage, assembly and disassembly.
5

2.7 REQUIRED SPACE, CONNECTING DIMENSIONS

4

The connecting dimensions of the Mechanical Seal were checked

and approved by the customer on the main drawing.
3

The available mounting space given by the machine was decisive

for the design of the gland parts of Mechanical Seal. The
connecting dimension was checked before shipment with regard to
2

the BURGMANN drawing.

2.8 DRAWINGS, DIAGRAMS

Assembly drawing Nos. 09-H75N/100-E3
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The assembly drawing in the original scale and in its latest edition
SG
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(latest revision) only is decisive for the design and use.

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In the following description all figures in parentheses, e.g.(2) define

Revision

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the respective part item no. in the assembly drawing.

Date
 OPERATING MANUAL
NO.
- 3. SAFETY NOTES

Section
3 Any person at the user's shop being involved in assembly,
disassembly, operation and maintenance of the BURGMANN
Mechanical Seal must have read and understood this
Page 5 of 13 Instruction Manual and in particular the safety notes. We
recommend the user to have this confirmed.
10

BURGMANN Mechanical Seals are manufactured on a high

quality level (ISO 9001) and they keep a high working reliability.
Yet, if they are not operated within their intended purpose or
handled inexpertly by untrained personnel they may cause risks.
9

The user is asked to check as part of his security program what

8

effects a failure of the Mechanical Seal might have on the

environment and what additional safety measures have to be
taken to prevent personal injury.
7

Any operation mode that affects the operational safety of the

6

mechanical seal is not permitted.

5
4
3
2

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 OPERATING MANUAL
NO.
4. TRANSPORT / STORAGE / INSTALLATION
-
4.1 PACKING AND STORAGE
Section
If not specified differently in the order the BURGMANN standard
4 packaging is used, suited for dry transport by truck, train or plane.
The signs and notes for handling on the packaging have to be
observed.
Page 6 of 13 Notes for incoming inspection
- Check packaging for visible damages.
- Open packaging carefully. do not damage or lose parts -
supplied separately
10

- Check if consignment is complete (delivery note). Inform the

supplier immediately in writing if parts are damaged or
missing.
9

These recommendations apply to all BURGMANN mechanical seals

which have been supplied and stored in their undamaged original
packaging, as well as to seals which have been installed in a
component of a plant. (e.g. pump, compressor, etc.) but have not
8

yet been put into operation.

A preservation of the BURGMANN mechanical seals is not
7

necessary.
- Do not use corrosion protection agents.
- There is the risk of deposition or chemical attack of the
6

elastomeric secondary seals.

Check in case of a preservation of complete plants with

5

mechanical seals installed:

- the compatibility of the chosen preservation agent with the
seal materials and with the elastomers
- no impairment of the seal's axial movability by
4

conglutination or by gumming

Sliding materials and elastomers are subject to material-specific

3

and time-based alterations (distortion, ageing) which might reduce

the full efficiency of the seals. yet, this may be avoided by
observing the storage instructions.
2

Damages caused by improper storage may not be claimed on

the BURGMANN company with regard to their warranty.

Store the seal in the original packing lying on a flat surface.

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The mechanical seals have to be stored in dry, dustfree, moderately

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ventilated and tempered rooms. We recommend : relative air

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humidity below 65%, temperature between 15oC and 25oC.

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 OPERATING MANUAL
NO.

- 4.1 PACKING AND STORAGE ( cont....)

Section Direct exposure of the mechanical seal to heat (sun, heating) as

well as to ozone, present or produced by ultraviolet light
4 (halogen or fluorescent lamps), must be avoided because of the
risk of embrittlement of elastomeric materials.
Page 7 of 13
Check the mechanical seal:
- after a storage period of approximately 4 years
- after a damage of the packaging
- after a shock on the mechanical seal (e.g. by dropping
10

the packed seal)

- at the manufacturer's or at the nearest service centre.
9

4.2 PREPARATION FOR ASSEMBLY

General Instructions
8

Utmost care must be taken to ensure cleanliness during assembly;

it is especially important to avoid damage to the elastomers.
7

- Observe the assembly dimensions.

- Observe the axial run-out and concentricity tolerances as stated in
the valid design manual.
6
5
4
3
2

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 OPERATING MANUAL
NO.

Section
-
4

Page 8 of 13
- All the shoulders over which elastomers
- are to be pushed must be chamfered by 2mm x 30°. Their
surfaces must be free of any damages and their edges rounded
off.
10

- The shaft must show the following surface roughness values in the
vicinity of radial sealing elements :
(Dynamic sealing part (spring loaded unit of the seal) Ra 1.0µ.m.
9

Static seal part of Ra 2.5µ.m)

- For cartridge seals, the seal can be assembled directly after
taking precautions on the shaft.
- Profile rings of Statotherm® can only be deformed axially (radial
8

deformation results in destruction).

- To reduce frictional forces during assembly of the seal, the shaft
is thinly lubricated with oil or silicon grease in the zone of the seal
7

rings.

Warning : This does not apply to rubber bellows seals.

6

Warning : In the electric dip-painting range the O-rings must be

free from silicon grease and must be mounted free from silicon
grease.
Warning : Under no circumstances must O-rings made of
5

Ethylene Propylene rubber come into contact with mineral oil

or grease. It is recommended to use silicon grease.
4

- Never cover the sliding faces with a lubricant as they must be

assembled completely dry, clean and dust-free.
- When pressing in stationery seals, make sure that the pressure
3

distribution is uniform. The O-ring must be fitted using water or

alcohol only.
- For heat dissipation and lubrication of single-acting mechanical
seals, there should be a recirculation from pump discharge to
2

seal.
This measure prevents medium deposits in the sealing area.
- Thoroughly vent the stuffing box before starting and remove the
assembly fixture before start-up.
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In the event of any particular problems, please contact Burgmann

0

India, or one of our sales/service offices in your area.

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7
OPERATING MANUAL
NO.

- 4.3 SPECIAL INSTRUCTIONS

Section The Burgmann mechanical seals H75N are independent of the

direction of rotation. The set screws with cup points must be
4 renewed after every dismounting; they must be fastened with
Loctite Nr. 241 or a similar Product.
Page 9 of 13
4.4 INSTALLATION

All steps on (in) which the seal is to be mounted should have a 2 x

30° bevel and all sharp edges should be chamfered. The shaft
10

surface should be smooth machined and ground in the areas where

radial seal elements are to be located (R = 2.5µ.m.)
9

The nutation of the shaft should not exceed 100 µ.m. and although
the seal can absorb slight vibration, sources of vibration should be
eliminated. Extreme cleanliness must be observed during
installation, and damage to the seal faces and mounting rings must
8

be avoided. The O-rings may be oiled to reduce friction, during

installation of the seal. EP-rubber O-rings are an exception,
however, and should not come into contact with oil or grease;
7

In this case lubrication with glycerine or water is

recommended.
6

Special care must be taken when mounting O-rings of double-

PTFE-coated elastomers; apart from having a 2 x 30° mm bevel, all
edges should be deburred and rounded. When mounting O-rings
of double PTFE-coated elastomers care must be taken to
5

position the rings with the butt of the outer coating facing
away from the direction of installation, otherwise splitting or
stripping of the coating is possible.
4

Crowned drive pins must be replaced whenever the seal is

3

dismantled. During insertion of the stationary seats, especially

those of special carbon, care must be taken to exert pressure
evenly.
2

4.5 DIRECTIVES IN CASE OF FAILURE

Try to define the kind of failure and record it and immediately

contact Burgmann India or nearest BURGMANN Service Centre.
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During the warranty period the mechanical seal must only be

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disassembled or removed with BURGMANN's approval or when a

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BURGMANN representative is present.

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 OPERATING MANUAL
NO.
5 SERVICING
-
5.1 TUNGSTEN CARBIDE DESIGNS
Section
5 Are extremely wear resistant but have poor emergency running
properties. For this reason provisions must be made to ensure
lubrication.
Page 10of 13
5.2 CIRCULATION

To reduce frictional heat and prevent sedimentation in the seal

faces a circulation line from the discharge of the pump to the seal
10

stuffing-box necessary. Normally a ¼-inch pipe is sufficient.

9

5.3 BUFFER FLUID

When operating double mechanical seals care must be taken to

ensure circulation of the buffer fluid. The pressure of the buffer fluid
8

should be 1.5--2 bar higher than the internal pressure and the rate
of flow should be adjusted so that the outlet temperature dose not
exceed 60°C. The outlet must be located at the highest point of the
7

stuffing-box to prevent bubble formation.

6

If you have any special problems please contact BURGMANN Head

Quarters or the corresponding sales/service office in your area.
5

5.4 AFTER-SALES SERVICE BY BURGMANN

The range of services offered by Burgmann not only includes advice

4

during the planning stages but also technical support after

commissioning. This is support by a world comprehensive network of
subsidaries, field engineers and service centres.
3

MUMBAI (HEAD QUARTERS)

BURGMANN INDIA PVT. LTD.
2

A.K.INDUSTRIAL ESTATE,
VEER SAVARKAR FLYOVER,
GOREGAON(WEST)
MUMBAI-400 062.
TEL: 022-28741534
FAX: 022-28748810.
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 OPERATING MANUAL
NO.

- SERVICE CENTRES
BANGALORE BARODA
Section 3390/41,3rd Cross,5th Main, 17-A Nutan Bharat Society,
RPC Layout,Vijayanagar, Near Nutan Bharat Club,
5 Bangalore – 560 040. Alkapuri,
Tele Fax : 080-23305137 Baroda – 390 007.
Email : [email protected] Tel. : 0265 233 9151
Page 11of 13 Fax. : 0265 233 9149
Email: [email protected]
CHENNAI COCHIN
“N” Block, New No. 5,Old No.320, 34/749A, Thrikkovil Road,
10

25 Street, Anna Nagar (East), Edapally,Cochin – 682 024.

Chennai – 600 102. Kerala, India.
Telefax.: 044 2620 6968. Telefax. : 0484 2331 708
Touchtel : 52020649 Email : [email protected]
9

Email : [email protected]

DELHI HYDERABAD
40/55, 1st Floor, 5D, Dhruvatara Apartments,
8

Chittaranjan Park, Amruta Estate, Somajiguda,

New Delhi – 110 019. Hyderabad – 500 482.
Tel : 011 2642 2533, 011 2648 3347 Telefax : 040 2331 6577
7

Fax : 011 2648 3275 Email: [email protected]

Email : [email protected]

KOLKATA KOTA
6

903-Krishna, Ashirwad Pearl,10-F-12,

224 Acharya Jagdish Chandra Bose Flat No. S1,Parijat Scheme
Road, Mahaveer Nagar III,
Kolkata – 700 017. Kota, Rajasthan,
5

Tel. : 033 2240 9829 Kota – 324 005.

Fax : 033 2240 6480 Telefax : 0744 247 6537
Email : [email protected] Tele/Answering Machine 0744
4

3090472
Email : [email protected]

PUNE VISAKHAPATNAM
3

H– 198, Mantri Market, Flat No. 301, Eswar Homes,

Pune Solapur Road, 3rd Floor, 1st Lane,
Hadapsar, Dwarakanagar,
2

Pune – 411 028. Visakhapatnam – 530 016.

Telefax : 020 2682 1713 Telefax: 0891 254 0360
Email : [email protected] Tele : 0891 551 6503
Email : [email protected]
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 OPERATING MANUAL
NO.
SERVICE CENTRES
-
MUMBAI PANVEL
Section Excl Industrial Products Pvt. Ltd., Excl Industrial Products Pvt. Ltd.,
5 A.K. Industrial Estate, 1st Floor, Om – Hari Darshan Apts.,
Veer Savarkar Flyover, Plot No. 34, V. M. Road,
S.V.Road, Goregaon (W), Sector 1, Opp. CIDCO Office,
Mumbai – 400 062. New Panvel – 410 206.
Page 12of 13 Telefax: 022 2877 6896 Telefax : 022 2746 9152/3958 1948
Email : Email : [email protected]
[email protected]
10

PUNE SURAT
Excl Industrial Products Pvt. Ltd., Excl Industrial Products Pvt. Ltd.,
C – 2, Amar Enclave, B 1/14, Vishal Nagar,
Opp. A.S.P.T. Near Gujarat Gas Circle,
9

Wanowire, Above Vijay Dairy,

Pune – Solapur Road, Adajan Road,
Hadapsar, Surat – 395 009.
Pune – 411 013. Telefax: 0261 269 3538
8

Tel. : 020 2681 6646/4024366/2682 Email : exclsurat@ burgmannmail.com

1943
Fax. : 020 2687 7000
7

Email : info@ burgmannmail.com

5.7 DISPOSAL OF BURGMANN MECHANICAL SEAL

6

Usually, the BURGMANN mechanical seals can be easily disposed

after a thorough cleaning.
5

Metal parts (steels, stainless steels, non-ferrous heavy metals

divided into the different groups belong to scrap metal waste.
4

- Synthetic materials/ plastics ( elastomers, PTFE )special waste.

- Attention ! Material containing fluorine must not be burnt.
- Some synthetic materials divided into the different groups can
3

be recycled.
- Ceramic materials (synthetic carbons, ceramics, carbides ) belong
to waste products. They can be separated from their housing
2

materials, as they are physiologically recognised as safe.

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 OPERATING MANUAL
NO.
- 6. COPYRIGHT
BURGMANN has a copy right in this manual. Buyer, planner and
Section user of the product are authorised for use in connection with further
5 documentation.

We reserve the right to carry out technical modifications which

Page 13of 13 might become necessary to improve our products but are not
mentioned in this manual yet.
10
9
8
7
6
5
4
3
2

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 SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

2. CONNECTING COUPLING
INSTALLATION, OPERATION & MAINTENANCE

MANUAL OF CONNECTING COUPLINGS

(FOR CONDENSATE EXTRACTION PUMP)

COUPLING TYPE : 8GBL-200

PROJECT : 500 MW THERMAL POWER PLANTS

CONTENTS

GENERAL NOTES (DO’S & DON’TS)

DESCRIPTION OF COUPLINGS/OPERATING CONDITONS

INSTALLATION INSTRUCTIONS

MAINTENANCE INSTRUCTIONS

ALIGNMENT INSTRUCTIONS

COUPLING ASSEMBLY DRAWING

INSTALLATION, OPERATION & MAINTENANCE

MANUAL
 GENERAL NOTES

It is essential that all the instructions contained in the following documents be carried
out by a competent person. Should any problems be anticipated or encountered then
Euroflex Transmissions personnel are available for site visits or, alternatively, repairs
and overhauls can be undertaken in our works.

Prior to performing any maintenance work (including inspections) it is essential that the
power supply is isolated and that no accidental movement of rotating machinery is
possible.

This product is designed for a specific purpose. It is vital that it is not used for any
purpose other than that for which it is designed and supplied, and that the limits of it’s
capacities, as detailed here or in any other document, are not exceeded.

No liability will be accepted and any other warranty, either expressed or implied, will be
null and void should any component of whatever kind, including nuts, bolts and
washers, be used in the assembly, or modifications be made to all or part of the
product which are not supplied, specified or agreed by Euroflex Transmissions.

DO’S

The following instructions should be read and understood prior to starting any
assembly or maintenance work on the disc coupling.

Prior to filling any component, care should be taken to ensure that it is clean and free
from any dirt.

Where hub/shaft connections require a standard interference fit the hubs may be
heated in oil at 200-250 Celsius and rapidly positioned on the shaft. It is essential that
this heat is evenly applied over the whole hub and that spot heating is avoided.

DON’TS

Do not use any component that is not supplied or approved by Euroflex Transmissions
in the assembly of this product.

Do not attempt, where the weight of the unit is excessive, to lift the coupling without the
use of lifting equipment.

The inherent balance of these couplings could be disturbed if they are allowed to be
knocked either by striking or rolling. Care should be taken when transporting and fitting
to avoid such knocks. This particularly when a coupling is specifically balanced.
 DESCRIPTION OF COUPLING

The coupling is of the dry laminated diaphragm or disc type. Flexibility is obtained by the
deformation of the disc packs, within defined limits, which are separated by a tubular
spacer.

Individual laminations are of regular polygonal profiles which are assembled into a stack of
previously designated thickness and secured by bushing. Flexibility is accomplished by
connecting through the bushed holes, on a common pitch circle diameter, by means of
bolts, alternately, to driving and driven components.

The bolts, bushes and associated holes are machined to close limits associated with “fitted
bolts”. Due to the need for reasonable ease of assembly, interference fits are undesirable
and, consequently, tolerances are such as to allow for a close slide or slight transition fit.
To compensate for these clearances and to ensure the best possible concentricity
between components, the pitch circle diameter of the bolt holes in the flexible element is
made smaller that that of the mating holes in the adjacent components. On assembly, all
inherent clearances are, therefore, eliminated. Coupling bolts are sized such that they are
capable of including a load equivalent to 4 times the tensile load in the flexible element
laminations, between driving and driven bolt, when transmitting the full rated continuous
torque of the coupling. This assumes a coefficient of friction between the various
components of 0.25 but experience has shown that, due to the high loads induced, minute
compressive deformation is sufficient to raise this to about 0.3.

The reason for adopting this principle of using large, highly loaded, bolts is two-fold a (to
prevent interface slip, as already mentioned, and b) to eliminate any chance of bolt
bending due to the overhung radial loading imposed by the flexible element. Avoiding
either slip or bending helps to avoid fretting which occurs when bolts are designed only to
drive in shear.

In general, the design is identical to a large number of units already in operation.

OPERATING CONDITIONS

In operating the flexible elements are subjected to both tensile and bending stresses, each
having an influence on the allowable magnitude of the other. It is important, therefore, that
the operating limits of the various deflections for which the coupling is designed to
accommodate, are kept, as far as practicable, within those indicated on the “Allowable
Misalignment Curve” which was individually supplied with the final engineering data.

In practice, the initial alignment of the coupling should be as close as possible and within
the alignment limits given in the “Installation Instructions”. This will allow for changes
during operating to remain within allowable limits.

As the Euroflex units are designed to transmit the torque in friction between the driving and
driven bolts and the flexible elements, it is essential that, should the need arise, these
bolts should be correctly tightened to the torque indicated on the assembly drawing or in
the “Installation and Maintenance instructions”.
Torque and speed should remain within the originally specified conditions.
 INSTALLATION INSTRUCTIONS

GENERAL

No liability will be accepted, and any warranty, either expressed or implied, will be null and
void should any components of whatsoever kind, including nuts, bolts and washers, be
used in the assembly or any modifications be made to all or part of the unit which are not
supplied, specified or agreed by Euroflex Transmissions Ltd.

For general Safety, Alignment and Maintenance Instructions see other sections of this
manual.
IMPORTANT

When tightening any bolts or screws, this should be done evenly, i.e. cylinder head
fashion, to 50% torque then to 100% torque in the same sequence.

Threads should be lubricated with Molybdenum Disulphide grease or equivalent.

INSTALLATION INSTRUCTIONS

1. With the Motor Rotor in it’s central axial position, check the distance between the
machinery shaft ends is xxx +/-0.1mm (This gives a 0.7 mm pre-stretch when the
coupling is installed.

2. Check that the parallel & angular misalignment of shafts is within the limits defined on
the separate Alignment Instructions sheet.

3. Fit the Hubs (items 1 & 2) to their relevant shafts, ensuring that the Motor hub (item
1) face finishes flush with the motor shaft end.

4. Check the distance between the Hub faces is xxx mm +/-0.25 mm.

5. Insert the Spacer Assembly (item 3) between the Hubs and align Match Marks (or
Serial Numbers) by rotating the Spacer or machinery shafts.

6. Insert the Element Assemblies (item 4) between the Spacer & Hub flanges (item 1,2
& 3)

7. Fit Coupling Bolts, Overload Washers & Nuts (item 5/6/7) as indicated on the drawing
and torque tighten, cylinder head fashion, to the value shown on the drawing,
ensuring threads are correctly lubricated.
 MAINTENANCE INSTRUCTIONS

General maintenance of the coupling consists of an annual (or other agreed period) check
of the following :

Axial, Angular & Parallel misalignment to ensure these are still within acceptable
limits and that no major machinery movements have occurred.

All bolts to ensure they are correctly tightened.

The Flexible Elements, by visual inspection, for signs of fatigue cracking local to the
washer anchor points or general signs of fretting corrosion. Slight bowing or “S” like
distortion of the laminations is not detrimental to the unit operation.

NOTE : Any requirement for spare part should be made quoting the Original Purchaser,
Original Order Number & the Coupling Serial Number (this will be etched
on the major coupling flanges as BTLxxxx and should appear on all post
production Quality documents).
 ALIGNMENT INSTRUCTIONS

Euroflex Transmissions couplings will accept substantial amounts of misalignment, the

configuration of each individual unit defining the actual acceptable level. The allowable
misalignment is shown graphically on a curve produced uniquely for any unit. This curve
shows the maximum permitted level of misalignment for operation and is NOT intended to
define setup limits.

ALIGNMENT METHOD :

Each company ahs it’s own method for aligning machinery all of which well documented in
both internal and freely available documents and books. Hence it is not our intention to
describe methods for setting machines. Instead, the following gives guidelines for quick
checks for alignment suitable after initial installation and for general maintenance checks.

AXIAL :

The suggested limits for axial set-up distance between the machinery shafts will, generally,
be specified in the installation instructions unique for the coupling. However, as a general
rule, the following may be used.

4-bolt couplings:- +/- 0.4mm

6-bolt couplings:- +/- 0.3mm
8-bolt couplings:- +/- 0.2mm
12-bolt couplings:- +/- 0.2mm

These values may be exceeded in certain cases and, if no reference is made in the unique
installation instructions, reference should be made to Euroflex Transmissions.

PARALLEL/RADIAL/ANGULAR :

Having basically aligned the machinery shafts using one of the established techniques, the
coupling may be installed as per the instructions. It is then worth performing a check to
establish that the overall alignment is correct for the particular coupling. This may be
simply performed by one of the following two methods:

Attach a dial indicator securely to the back of one of the coupling flanges, with the
needle in contact with the flange face the other side of the flexible element as near
the outside periphery as possible. Rotate the machinery & coupling and locate the
minimum reading position. At this position, set the dial reading to zero. Rotate the
machinery again and record the maximum reading over 360 degrees. Divide this
maximum value by the coupling flange diameter to gain a value in mm/mm, which
should be no greater than that shown in the following list. (This should be repeated at
both flexible elements in a spacer coupling).

An alternative method is, where possible to accurately measure the distance across
the flanges which sandwich the flexible element to obtain a maximum and minimum
value. The difference between these two values should the be divided by the flange
outside diameter to obtain a value in mm/mm, which should be no greater than that
 shown in the following list. (This should be repeated at both flexible elements in a
spacer coupling).

4-bolt couplings:- +/- 0.004mm

6-bolt couplings:- +/- 0.003mm
8-bolt couplings:- +/- 0.002mm
10-bolt couplings:- +/- 0.015mm

NOTE : These values are intended as guides only and, in certain cases, may be
exceeded, IF IN DOUBT, CONTACT EUROFLEX TRANSMISSIONS.
 SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

3. THRUST CUM JOURNAL BEARING

 Michell Bearings

A Vickers company

Operations and Maintenance

Instructions for Standard Vertical Bearings

Customer: B.H.E.L - Hyderabad

Project : COND. EXTRN PUMP FOR 500MW TPS

Drawing Number: 58227

Bearing Model : 8 DNT

Version date – 14 December 1998

 Operation and Maintenance Instructions for
Standard Vertical Bearings.

1 PRELIMINARY NOTES.---------------------------------------------------------------------------- 2

.1 Introduction. ---------------------------------------------------------------------------------------- 2

.2 Safety. ----------------------------------------------------------------------------------------------- 3

2 DESCRIPTION. --------------------------------------------------------------------------------------- 5

.1 Introduction. ---------------------------------------------------------------------------------------- 5

3 HANDLING THE BEARING. ---------------------------------------------------------------------- 6

.1 Introduction. ---------------------------------------------------------------------------------------- 6

.2 Points on Handling.------------------------------------------------------------------------------- 6

4 INSTALLATION.-------------------------------------------------------------------------------------- 7

.1 Introduction. ---------------------------------------------------------------------------------------- 7

.2 Assembly of the Bearing. ----------------------------------------------------------------------- 8

.3 Points before use.------------------------------------------------------------------------------- 14

5 OPERATING.---------------------------------------------------------------------------------------- 15

.1 Introduction. -------------------------------------------------------------------------------------- 15

.2 Operating Risks.--------------------------------------------------------------------------------- 15

6 CARE AND MAINTENANCE.------------------------------------------------------------------- 16

.1 Introduction. -------------------------------------------------------------------------------------- 16

.2 Procedures.--------------------------------------------------------------------------------------- 16

.3 Maintenance Schedule. ----------------------------------------------------------------------- 17

.4 Dismantling. -------------------------------------------------------------------------------------- 18

.5 Maintenance.------------------------------------------------------------------------------------- 21

APPENDIX 1 (SPARES). --------------------------------------------------------------------------- 25

.1 Ordering. ------------------------------------------------------------------------------------------ 25

APPENDIX 2 (TABLE OF TORQUE’S).-------------------------------------------------------- 26

1
 Operation and Maintenance Instructions for Standard Vertical Bearings

1 PRELIMINARY NOTES.

.1 Introduction.

This manual is to be used by qualified engineers only. It contains information

that will familiarise the user with the machine and its safe operation. It is
recommended that the health and safety advice given in this manual is
followed and is kept in mind throughout all aspects of installation, storage,
operation, etc.

- General points on safety can be found in the first section.

- More specific points on safety can be found in each separate section.

* Make sure that all safety points are clearly understood and carefully noted. *

Warrantee.
Unless otherwise stated all warranty claims shall be dealt with in accordance
with Michell Bearings.
These warranty obligations will automatically become void if the product is:
1) Subjected to overloads.
2) Improperly handled.
3) Supplied with spare parts not approved by Michell Bearings.
4) Exceeding, or falling short of the technical characteristics specified.

Page 2
 Operation and Maintenance Instructions for Standard Vertical Bearings

.2 Safety.

When operating the machine danger may arise to the user, the product and
plant and/or other assets. Therefore when running the machine make sure
that all the safety procedures given in this manual are strictly adhered to.

The below procedures should be noted.

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

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

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

out on the bearing whilst the shaft is rotating or capable of movement.

4 Personnel that manipulate the product should be sufficiently trained.

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

Michell.

6 All users responsible for the operation of the machine must understand the
chapters fully and be familiar with the associated dangers described. These
are instructions that, if ignored, could result in death or injury.

Page 3
 Operation and Maintenance Instructions for Standard Vertical Bearings

Before working on the bearing the engineers should familiarise themselves

with the layout of the manual.
Attention is drawn to the following formats:

! This symbol signifies a warning. These are instructions that, if

ignored could result in death or injury.

This symbol signifies that attention should be made by the

operator. If ignored it could result in minor injury or failure to carry out a
particular process correctly.

This symbol signifies additional instructions. This is usually a

check. Missing out this stage could lead to an error going unnoticed.

Page 4
 Operation and Maintenance Instructions for Standard Vertical Bearings

2 DESCRIPTION.

.1 Introduction.

The bearing supplied is one of the Michell Standard Vertical Series, as

manufactured by Michell Bearings. The Standard Vertical Series are a
standard range of vertical bearings.
Within the series a range of types are catered for;
i) S Type: This is a single thrust and guide bearing. It is designed to absorb
lateral forces from a rotating shaft, as well as a force along the shaft in one
direction only.
ii) D Type: This is a double thrust and guide bearing, designed to absorb
lateral forces from a rotating shaft, as well as a force along the shaft in either
direction.

The standard S Type may also be supplied with a Surge ring, designed to
absorb a temporary upward force.

All types of bearing can be fitted with a variety of Resistance Temperature

Devices (RTDs) to measure the temperature of the lubricating oil or pads. The
Standard Vertical Series are usually self contained with water coolers, the
bearings can also be modified for different methods of cooling (i.e. natural air
cooled, fan cooled and circulated oil variations) with minimum modifications to
the basic casing.

The bearing can also be insulated as an option to protect against stray

currents whilst the machine is in operation.

Page 5
 Operation and Maintenance Instructions for Standard Vertical Bearings

3 HANDLING THE BEARING.

.1 Introduction.

This section points out the relevant information essential when handing the
bearing.
The bearing is supplied fully assembled (see arrangement drawing for mass
of complete bearing). Threaded holes are provided for the fitting of eyebolts
on the bearing casing and other components.
It is advisable to keep the bearing within any casing and packaging until it is
necessary to remove it for assembly.

.2 Points on Handling.

! Under no circumstances should the completed bearing be

handled manually.

! Before using any lifting equipment, ensure that it is certified to

carry a load greater than that of the bearing.

! When handling the bearing use only provided lifting points.

Make sure bearings are stored in the intended mounting position in a dry
room only.
Please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell straight
away.

Page 6
 Operation and Maintenance Instructions for Standard Vertical Bearings

4 INSTALLATION.

.1 Introduction.

Prior to installation the bearing should be dismantled into a series of sub-

assemblies.

! Do not touch moving parts.

Additionally the following sub-assemblies may also be present and can be

handled manually; Circular Cooler(s), Journal Pads, Oil level gauge, RTD
assembly, Air Vent, Lower Thrust Pads and Anti-Vortex Shroud or Upper
Surge face.

The bearing is also supplied with Curil T sealant.

Remove all packaging. All parts are coated in a rust preventative. This must
be removed and all parts thoroughly cleaned before installation begins. To
remove the rust preventative, white spirit or a strong spirit based cleaner
should be used.

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

Use a lint free cloth when cleaning the bearing.

Page 7
 Operation and Maintenance Instructions for Standard Vertical Bearings

.2 Assembly of the Bearing.

! The disassembling and reassembling of the equipment by an

individual who is inexperienced can cause danger. Michell will not take
on any liability for any damage resulting from non-compliance with
details given in this manual.

To assemble the bearing the below procedure should be followed which if

carried out correctly could increase the working life of the machine.

1. Coat all bearing surfaces in clean oil of the correct grade.

2. Place jointing on the sleeve.

Care should be taken when handling components to avoid the

risk of trapping hands when assembling.

3. Secure the sleeve to the baseplate with tapbolts.

If the bearing is fitted with dust seals, do not fit tapbolts.

4. Dust Seal Fitted Bearings:

Fit seal housing to the sleeve and secure it in place with screws.

Fit seal into housing.

Fit seal cover and secure with tapbolts

Page 8
 Operation and Maintenance Instructions for Standard Vertical Bearings

Dust seals require some time to bed in. Do not fully tighten the

securing bolts. For the first month operation, gradually tighten the

tapbolts.

5. Position the baseplate on to the studs located on the supporting structure

and set baseplate concentric with centreline of machine.

6. Fit thrust pad stop to baseplate.

Ensure that stop is fully tightened and locked in place with Loctite

222 or similar adhesive.

! Always follow instructions on adhesives.

7. Fit lower thrust pads and push well in.

Check that the clearance between the pads is correct. The

clearance is given on the arrangement drawing.

Ensure that RTD fitted pads are in the correct position, as shown

on the arrangement drawing.

8. Place O-Ring into the groove in the baseplate.

9. Fit collar to the shaft and ensure that it runs true.

10.Lower the collar until it rests on the lower thrust pads.

Page 9
 Operation and Maintenance Instructions for Standard Vertical Bearings

Check alignment. Follow the below procedure:

Check that no thrust pads are loose (i.e. all pads are firmly clamped by the

collar).

Use feeler gauges to check the clearances between the thrust pads pivots

and the baseplate. The clearances should be equal and no greater than

0.04mm.

When using feeler gauges, take care not to damage the

Whitemetal surfaces.

11.Fit the journal pad stop to the casing.

Ensure that stop is fully tightened and locked in place with Loctite

222 or similar adhesive.

! Always follow the instructions on adhesives.

12. Coat both the casing and baseplate mating surfaces with sealant.

! Always follow sealant manufacturers’ instructions.

13. Lower casing into position.

14. Secure casing and base plate to the supporting structure using studs and

nuts. Torque nuts to value indicated in Appendix 2.

Page 10
 Operation and Maintenance Instructions for Standard Vertical Bearings

This Appendix should be adhered to as over tightening could

damage the shell.

15. Fit journal pads.

Ensure that RTD fitted pads are in the correct position, as shown

on the arrangement drawing.

16.For bearings fitted with anti vortex shrouds, assemble the shroud, and bolt

on to the casing.

17.For double thrust (D type) bearings:

Assemble the upper thrust rings, pads and stops.

Ensure that stop is fully tightened and locked in place with Loctite

222 or similar adhesive.

! Always follow instructions on adhesives.

Fit thrust ring on top of the journal housing in the casing.

18. For Surge ring fitted bearings;

Assemble Surge ring.

Bolt Surge ring to the journal housing in the casing.

19.Place jointing in position on the casing.

Page 11
 Operation and Maintenance Instructions for Standard Vertical Bearings

20.For bearings fitted with internal cooler, fit cooler to cover.

Take care not to overtighten the securing bolts on the cooler.

Overtightening may damage the cooler.

21. Fit cover and cooler assembly to the casing. Secure the cover to the

casing. Torque cover securing bolts to value indicated in Appendix 2.

Check the cooler. Ensure that leakage from the cooler is not

possible.

22. Dust Seal Fitted Bearings:

Fit the dust seal into the top of the cover.

Fit seal cover and secure it in place with tapbolts.

23.Fan Cooled Bearings:

Assemble fan and fit it to the shaft.

Fit RTDs, pipework elbows and any extension pieces required to allow

connections to pass through fan shroud.

Fit fan shroud to bearing casing. Secure it in place with capscrews.

Ensure that fan shroud does not foul the fan.

24.Fit and seal in oil level gauge, blanking plugs and any thermometry or

detectors.

Page 12
 Operation and Maintenance Instructions for Standard Vertical Bearings

! Always follow sealant manufacturers’ instructions.

Ensure that RTD assembly is not damaged and is working

correctly before fitting it.

Ensure that all plugs, pipework joints and instruments are secure

and sealed.

25. Connect up external pipework.

26. Remove air vent and fill bearing with oil up to the standing oil level

marked on the oil level gauge.

For temperature probe fitted bearings; run the bearing and establish a steady

state operating temperature then set temperature alarm to 5 C above the

steady state operating temperature. Shut down temperature alarm is to be set

at 10 C above steady state operating temperature.

Page 13
 Operation and Maintenance Instructions for Standard Vertical Bearings

.3 Points before use.

The bearing is now complete, it must not be used until the items below

have been dealt with;

1. The entire machine has received a Declaration of Conformity, or has

been declared exempt from the Supply of Machinery (Safety

Regulations) Act 1992 and the Machinery Directive.

2. Lubricating oil has passed through the bearing and is at the proper

level.

Note!!

The lubricating oil must be a mineral based turbine oil inhibited against

oxidation, corrosion and foaming, with an ISO viscosity grade as

indicated on the arrangement drawing.

The use of any other oil should be referred to Michell Bearings.

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

3. Local safety regulations have been met.

Page 14
 Operation and Maintenance Instructions for Standard Vertical Bearings

5 OPERATING.

.1 Introduction.

This section points out the risks that can occur when operating the machine.

! Do not touch any moving parts.

.2 Operating Risks.

If the bearing has been correctly assembled, using the procedure already
given, there is only a marginal risk of the bearing failing which would be due to
the design conditions being exceeded. Examples of these conditions are;
overspeed, low lubrication levels and excess load. In order to avoid these
situations, it is suggested that;
i) Control panels are labelled with the bearing limitations.
ii) The shaft should be stopped immediately if;
a) Coolant circulation fails.
b) Bearing temperature exceeds normal operating temperature by
10 C.

The users’ attention is drawn to the fact that both the pipework and
bearing surface may be hot during operation.

Where bearings are fan cooled, the fan shroud must not be removed whilst
the bearing is operating.

In order to avoid leakage of lubricant, plugs, RTDs and seals must never be
removed while the bearing is operating.

Page 15
 Operation and Maintenance Instructions for Standard Vertical Bearings

6 CARE AND MAINTENANCE.

.1 Introduction.

This section demonstrates the care and maintenance needed for the smooth
operation of the machine.

! Do not touch any moving parts.

.2 Procedures.

Once the steady state operating temperature has been determined, the alarm
point should be set at 5 C above this. Shut down is to occur at 10 C above
the steady state operating temperature.

Regular inspection should be made of all seals and pipework. Any large
leakage of lubricant or coolant or sudden increase in leakage will indicate that
a seal or join is failing. Maintenance must then be carried out as soon as
possible.

If a bearing is fan cooled, the air inlet and outlets must be periodically
inspected in order to prevent the build up of dirt and waste material. Such a
build up will lead to there being insufficient air flow and overheating will occur.

Collect used oil and dispose of under the correct regulations.

Page 16
 Operation and Maintenance Instructions for Standard Vertical Bearings

.3 Maintenance Schedule.

Oil changes will be at differing periods depending on the frequency of bearing

operation and the conditions in which the bearing is operating. Approximate
oil change times are indicated below.

Conditions. Oil Change Period.

Constant Operation, dusty Three Months.
atmosphere.
Constant Operation. Six Months.
Periodic Operation. At routine maintenance.

For a bearing that is operating constantly, routine maintenance should take

place annually. If the user only operates the bearing periodically, maintenance
periods may be able to take place less frequently, this is however at the users’
discretion. An annual inspection is recommended as a minimum service
requirement.

Page 17
 Operation and Maintenance Instructions for Standard Vertical Bearings

.4 Dismantling.

The below procedure should be followed when dismantling the bearing.

1. Switch off machinery. Lock off controls. Secure and isolate shaft.

! Ensure control gear, barring gear and any other equipment

capable of moving the shaft is locked out and labelled “Not to be

used”.

! Beware hot oil. Allow machinery to cool off before proceeding

further.

2. Where a bearing is fitted with continuous circulation of oil, allow the

circulation to continue whilst the bearing is cooling.

3. Switch off, drain and disconnect cooling system.

4. Switch off and drain the oil supply.

! Do not disconnect the oil inlet and outlet pipework until the

bearing has been drained of oil.

5. Remove drain plug and fully drain oil from bearing.

Any oil spillage should be collected in suitable containers.

6. Disconnect and remove any thermometry and instrumentation. With fan

cooled bearings this may not be possible, see next stage.

Page 18
 Operation and Maintenance Instructions for Standard Vertical Bearings

7. Fan Cooled Bearings:

Remove any connections passing through the fan shroud.

Remove capscrews and lift off fan shroud.

Dismantle and remove the fan

Remove any instrumentation, pipework and thermometry now visible.

8. Remove the top dust seal.

9. Remove cover and cooler assembly.

! Before removing bolts, fit eye bolts and lifting gear to the cover.

Ensure that the eye bolts are tight and secure.

! Before using any lifting equipment, ensure that it is certified to

carry a load greater than the mass of the component or sub-

assembly.

When removing the cover and cooler, take care not to damage

any equipment.

10.Remove upper surge ring, upper thrust ring or vortex shroud.

11.Fit lifting bolts and remove the journal pads from the casing.

The surge ring and journal pads will be oily and may stick. They

will also be very slippery when handling. Take care to avoid dropping

and damaging the pads and ring.

Page 19
 Operation and Maintenance Instructions for Standard Vertical Bearings

12.Remove fasteners and lift off casing.

! Before removing bolts, fit eyebolts and lifting gear to the casing.

Ensure that the eyebolts are tight and secure.

! Before using any lifting equipment, ensure that it is certified to

carry a load greater than the mass of the component or sub-

assembly.

13.Jack up the shaft until there is a clearance between the collar and the

lower thrust pads.

! Ensure that jacking equipment is safely positioned and certified

to carry a load greater than the mass of the shaft.

! Once the shaft is raised, secure it in position using other

equipment. Do not rely on jacking equipment alone.

14.Remove thrust pads by sliding out.

The thrust pads will be oily and may stick to the casing. The
pads will also be slippery when handling. Take care to avoid dropping
and damaging pads.

Page 20
 Operation and Maintenance Instructions for Standard Vertical Bearings

.5 Maintenance.

With the bearing dismantled, (refer to assembly drawing with parts list)
examine the thrust pads, journal pads and surge ring. The appearance should
be that shown in Figure 1 and Figure 2 overleaf. There may be some scoring
and wear on the pads and ring, but provided wear is no greater than 0.125
mm the pads and ring are still serviceable. If there is any sign of the White
metal surface coming away from the pad or ring, they must be replaced.

Examine the jointing between the casing and cover and that between the
base plate and the sleeve. If the jointing has decayed so that it is either
disintegrating or leaking, it should be replaced.

Examine the O-Ring, if it has started to leak or decay, it should be replaced.

Inspect the collar surface for any sign of damage. If it is necessary to replace
the pads, the collar should also be replaced and repaired, otherwise the
replacement pads will have a short life.

Page 21
Operation and Maintenance Instructions for Standard Vertical Bearings

Figure 1 Thrust Pad Appearance

Figure 2 Journal Pad Appearance

Page 22
 Operation and Maintenance Instructions for Standard Vertical Bearings

Clean the cooler assembly, using the below routine;

1. Remove cooler assembly from bearing cover.

2. Clean the bore of the tubes using a high pressure water jet or steam

cleaning.

3. Any remaining deposits or blockages can be removed by using a cleaning

rod or hypochlorite based cleaning solution.

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

When using cleaning rods, take care not to damage the cooler
tubes.

Page 23
 Operation and Maintenance Instructions for Standard Vertical Bearings

If the bearing is air or fan cooled, the spaces between each of the cooling fins
must be cleaned. With fan cooled bearings, the fan and shroud should be
inspected for any signs of damage caused by the two fouling each other. If
there is any damage, the parts should be repaired and alignment of fan and
shroud checked on re-assembly.

Where dust seals are fitted, these should be removed from their housings and
inspected. If the seal has started to break up, or has become clogged up with
dust and oil, it should be replaced.

Prior to re-assembly, all the old sealant should be removed and fresh sealant

applied in the positions identified in the section on Installation (4.2).

Page 24
 Operation and Maintenance Instructions for Standard Vertical Bearings

Appendix 1 (Spares).

.1 Ordering.

As a minimum, replacements should be carried for all Whitemetal

components.

When replacing thrust and journal pads, please ensure that

these are the correct hand. The direction of rotation stamped on the
replacement pads must be the same as that on the old pads.

Consideration should also be given to holding the consumable parts listed

below:

O-Rings
Casing/Cover jointing
Sleeve/Baseplate jointing
RTD assemblies
Washers
Dust Seals

Page 25
 Operation and Maintenance Instructions for Standard Vertical Bearings

Appendix 2 (Table of Torque’s).

Bolt Size (mm) Tightening Torque (Nm)

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

Page 26
Michell Bearings
Scotswood Road
Newcastle Upon Tyne
NE15 6LL
Great Britain
Tel: (0191) 273 0291
Fax: (0191) 272 2787
Michell Bearings reserve the right to amend these instructions.
© Michell Bearings 1997.
 SECTION – C

CONDENSATE EXTRACTION PUMP

CHAPTER – 4

SUB – VENDOR’S DRAWINGS / INSTRUCTIONS

4. SUCTION STRAINER (BASKET)

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

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

Patra INFORMATION
Date: 2009.02.05 15:00:03
+05'30'
 PART - 5

SUB-DELIVERY ITEMS

BFP RECIRCULATION
CONTROL VALVE

(M/S. CONTROL COMPONENTS INC., USA)

 
 
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 
  
 
   
   
  
   
  
  
 
  

 
 
 
 
  
 
  
  

 
 
 
  
   
  
  

   
 
   
  
  
   
  
    
  
  
   
 
   

  
 
 
 
  
  
  
    
  
  
  
  
  
   

 

    
 
  
 
  
  
  
 
   
    
  
   
 
  
  
  
  
  
 
 
 

  


 
 
 












 




























 
 
 PART - 6

DRAWINGS / DOCUMENTS

INDEX

SECTION-A : BOILER FEED BOOSTER PUMP

SECTION-B : BOILER FEED PUMP

SECTION–C : CONDENSATE EXTRACTION PUMP

 SECTION – A

BOILER FEED BOOSTER PUMP

LIST OF DRAWINGS

Erection & Maintenance

S.No. Description of Drawing Drawing No.

01. Sectional Assembly of Booster Pump HY-DG-1-18000-56321

02. Outline Arrangement of MDBP HY-DG-1-18000-56311

03. Outline Arrangement of TDBP HY-DG-1-18000-56312

04. Key & Holding down bolts details for 3 189 005 4854
MDBP & TDBP

05. Spanner (Coupling Nut) 2 180 291 3317

06. Hook Spanner (Var. No. 9, 10, 11&12) FP90016

Informative Drawings

S.No. Description of Drawing Drawing No.

07. Estimated Performance Curves of HY-DG-3-18900-65322

MDBP

08. Estimated Performance Curves of HY-DG-3-18900-65324

TDBP

09. Estimated Performance Curves of HY-DC-4-18000-68804

BP-NPSHR
 REV. DATE ALTERED
250 REV. DATE ALTERED REV. DATE ALTERED

CHKD. & APPD. CHKD. & APPD. CHKD. & APPD.

240 MIN. RC FLOW

230

220
D
210 A NOTE : MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
B
C INDICATED ONLY FOR THE PURPOSE OF CALCULATING
200 BFP SET SHUT OFF PRESSURES AT RC FLOW.

190
PARAMETERS AT 50Hz:-
180
EMERGENCY
170 D
OPERATION 920 207.5 162.1 0.905 80.0 588 1495 4.15
160
C MCR WITH
150 U/F OPERATION 900 208 160.1 0.907 80.0 578 1495 4.05

950
AT 51.5Hz BEST
750 B EFFICIENCY
AT 50Hz 855 210 161.1 0.9070 80.0 554 1495 3.9
C POINT
A
550 D
B
DESIGN
350 A CONDITION 990 205 161.8 0.9054 81.5 614 1495 4.5

150
OPERATING FLOW HEAD TEMP. SP. GR. EFFICIENCY POWER SPEED NPSHR
REF (mlc)
CONDITION (m3/hr) (mlc) (0 C) (%) (kW) (RPM)
90
A
80

70
JOB NO. : 270
DAMODAR VALLEY CORPORATION
60 STATUS : CONTRACT KOLKATA
50 7 DRG. / REF. NO. MEJIA PHASE - II THERMAL POWER STATION
(INTERNAL) 2 x 500 MW - UNIT 1 & 2
40 6 3 189 005 5322
30 5 NAME SIGN. DATE
PUMPS ENGINEERING
A PRPD. D.K.Gupta -sd/- 26.04.08
20 1540 RPM D
4 BHARAT HEAVY ELECTRICALS LTD.
B C CHKD. M.M.R. -sd/- 26.04.08
HYDERABAD
10 1495 RPM 3 APPD. B.RAJKUMAR -sd/- 26.04.08
TITLE TEST CODE
0 2 PUMP TYPE : FA 1B 75
HIS
ESTIMATED PERFORMANCE CURVES DRG. NO. : REV.
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
OF MD BOOSTER PUMP HY-DG -3-18900-55322 00
SUCTION FLOW (m3/hr) SHEET NO. : 1 NO. OF SHEETS : 1
 REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED
270
CHKD. & APPD. CHKD. & APPD. CHKD. & APPD.

260

250

240
NOTE : MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
INDICATED ONLY FOR THE PURPOSE OF CALCULATING
230
BFP SET SHUT OFF PRESSURES AT RC FLOW.
D
220

210 C EMERGENCY 162.1 0.9050 80.5 637

A D 920 226 1550 4.3
OPERATION
200
MIN. RC FLOW B MCR WITH
C 900 216 160.1 0.9070 80.0 600 1518 4.1
U/F
190
BEST
180 B EFFICIENCY 855 193 161.1 0.9070 79.5 513 1439 3.9
POINT
170
DESIGN
1150 A 990 205 161.8 0.9054 81.5 614 1495 4.5
CAPACITY
950
OPERATING FLOW HEAD TEMP. SP. GR. EFFICIENCY POWER SPEED NPSHR
REF ( 0C) (%) (kW) (RPM) (mlc)
750 CONDITION (m3/hr) (mlc)
D
C
550 A
B
350

150
90
A

80

70
JOB NO. : 270 DAMODAR VALLEY CORPORATION
60 8 STATUS : CONTRACT KOLKATA

DRG. / REF. NO. (INTERNAL)

50 7 MEJIA PHASE -II THERMAL POWER STATION
3 189 005 5324 2 x 500 MW - UNIT 1 & 2
40 6

30 5 NAME SIGN. DATE

1644 RPM
D PUMPS ENGINEERING
1550 RPM A
20 4 PRPD. D.K.GUPTA -sd/- 28.04.08
C
B
BHARAT HEAVY ELECTRICALS LTD.
1495 RPM HYDERABAD CHKD. M.M.R -sd/- 28.04.08
10 3
APPD. B.RAJKUMAR -sd/- 28.04.08
0 2
PUMP TYPE : FA1B75 TESTHIS
CODE
TITLE
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 REV.
ESTIMATED PERFORMANCE CURVES DRG. NO.: HY-DG -3-18900-55324
SUCTION FLOW (m3/hr) OF TD BOOSTER PUMP SHEET NO.: 1 NO. OF SHEETS : 1
 ESTIMATED PERFORMANCE DRAWING NO: HY-DC-418000-58805 REV
CURVES OF BP - NPSHR 00
CUSTOMER DAMODAR VALLEY CORPORATION KOLKATA PUMP TYPE:
MEJIA PHASE - II THERMAL POWER STATION FA1B75
2 x 500 MW - UNIT 1 & 2

SHEET 2 OF 2

ALL CURVES AT BP SPEED 1495 RPM

16

15

14

13

12

11

10

9
NPSHR FOR
40000 HR LIFE
8

7
NPSHR
6
1 % Hd
NPSHR 0 % Hd
5
NPSHR 3 %Hd
4

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
FLOW (Cu.m / Hr)

BHEL PUMPS ENGINEERING

PREPARED BY: CHECKED BY: APPROVED BY: DATE:

HYDERABAD D.K.GUPTA M.M.R. B.RAJ KUMAR 16.05.08

 SECTION – B

BOILER FEED PUMP

CHAPTER – 5

LIST OF DRAWINGS

Erection & Maintenance

S.No. Description of Drawing Drawing No.

01. Sectional Assembly of TD&MDBFP HY-DG-1-18000-56314&13

02. Foundation Arrangement of MDBFP HY-DG-1-18000-56306
03. G.A. Drg. of TDBFP set HY-DG-1-18000-56307
04. G.A. Drg. of MDBFP set HY-DG-1-18000-56308
05. G.A. & Found. of MDBFP HC Coolers HY-DG-1-18000-56322
06. Outline Arrangement of TD&MDBFP HY-DG-1-18000-56310&09
07. Key & Holding down bolts details 3 180 00 5 5065
for TDBFP
08. Key & Holding down bolts details 3 180 00 5 5064
for MDBFP
09. Alignment Diagram of MDBFP set 3 180 00 5 4907
10. PID of Feed Water of MDBFP set HY-DG-1-18000-56315
11. PID of Sealing & Cooling water of HY-DG-1-18000-56316
MDBFP set

12. PID of Lube oil & Working oil system HY-DG-1-18000-56317

of MDBFP set

13. PID of Lube oil system of TDBFP set HY-DG-1-18000-56318

14. PID of Feed Water of TDBFP set HY-DG-1-18000-56319
15. PID of Sealing & Cooling water of HY-DG-1-18000-56320
TDBFP set
16. Instrument Schedule of MDBFP set HY-SC-4-18000-58794
17. Instrument Schedule of TDBFP set HY-SC-4-18000-58795
 S.No. Description of Drawing Drawing No.

18. Recommended list of Annunciation HY-DC-4-18000-58811

& Trips for MDBFP

19. Sequential Interlocking conditions HY-DC-4-18000-58812

of MDBFP

20. BFP & CEP utility requirements HY-DC-4-18000-58810

21. Lube oil requirement of BFP & CEP HY-DC-4-18000-58806
22. Cartridge withdrawal arrangement 1 180 005 5249
23. Method of checking coupling 3 180 00 5 4908
alignment
24. Thrust collar withdrawal plate 4 180 291 4277

25. Withdrawal plates of mech seal sleeves 4 180 291 4280 & 4285

26. Balance drum withdrawal plate 4 180 291 4283

27. Tube spanner, balance drum 2 180 291 3314

28. Tube spanner, shaft 2 180 291 3315

29. Tube spanner, coupling nut 2 180 291 3316

30. Recommended analog inputs to DDCMIS HY-DC-4-18000-58813

for MDBFP set

INFORMATIVE DRAWINGS

31. Estimated Performance Curves HY-DG-3-18000-65321

of MDBFP

. 32. Estimated Performance Curves HY-DG-3-18000-65323

of TDBFP

33. Estimated performance curve of HY-DG-4-18000-58800

Kicker stage impeller

34. Design characteristic curves of MD HY-DG-4-18000-68801

BFP set at various speeds
S.No. Description of Drawing Drawing No.

35. Design characteristic curves of TD HY-DG-4-18000-68802

BFP set at various speeds

36. Design characteristic curves of BFP HY-DG-4-18000-68649

Kicker stage at various speeds

37. Estimated Performance Curves of HY-DG-4-18000-68804

BFP-NPSHR

38. Special Tools & Tackles for BFP set HY-DG-249-139-0040

39. Schedule of Motors for BFP & CEP HY-SC-4-18000-58807

40. Schedule of solenoid valves of BFP&CEP HY-SC-4-18000-58808
41. Schedule of Actuators for BFP&CEP HY-SC-4-18000-58809
42. Technical data sheet of BFP set HY-DC-4-18000-58814
43. BFP inter stage characteristic curve for HY-DC-4-18000-68799
2nd stage tap off at design capacity

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

SP O = DVC, OU = Engineering
and Planning
Reason: I have reviewed
this document and approved

Patra under CAT I

Date: 2008.04.22 16:07:46
+05'30'
 Digitally signed by S P Patra
DN: CN = S P Patra, C = IN,

SP O = DVC, OU = Engineering
and Planning
Reason: I have reviewed this
document and approved

Patra under CAT I

Date: 2008.04.22 16:11:12
+05'30'
 Digitally signed by S P Patra
DN: CN = S P Patra, C = IN, O

SP = DVC, OU = Engineering and

Planning
Reason: I have reviewed this
document and approved under

Patra CAT I
Date: 2008.04.07 17:52:59
+05'30'
 Digitally signed by S P
Patra

SP DN: CN = S P Patra, C =
IN, O = DVC, OU =
Engineering and
Planning
Reason: I have reviewed

Patra this document and

approved under CAT I
Date: 2008.04.07
17:54:16 +05'30'
 Digitally signed by S P Patra
DN: CN = S P Patra, C = IN,

SP O = DVC, OU = Engineering
and Planning
Reason: I have reviewed this
document and approved

Patra under CAT I

Date: 2008.04.22 16:13:22
+05'30'
 HY-DC-4-18000-58813
Rev No. 5 PROJECT:
TD-106-1

DAMODAR VALLEY CORPORATION KOLKATA

Form No. MEJIA PHASE - II THERMAL POWER STATION
Rev. No.01
2 x 500 MW - UNIT 1 & 2
Page 2 of 4

LIST OF RECOMMENDED ANALOG INPUT TO DDCMIS

MOTOR DRIVEN BOILER FEED PUMP SET
---------------------------------------------------------------------------------------------------------------------------
SLNO DESCRIPTION OF INPUT INITIATING KKS TAG NO.
DEVICE
---------------------------------------------------------------------------------------------------------------------------
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,

1. BFP & BOOSTER PUMPS.

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

1. BFP BEARING (DE) METAL TEMP. RTD PT 100 LAC03 CT 103

2. BFP BEARING (NDE) METAL TEMP. RTD PT 100 LAC03 CT 104

3. BFP THRUST BEARING BEARING METAL TEMP. RTD PT 100 LAC03 CT 105 TO 108

4. . BOOSTER PUMP BEARING (DE) MEATL TEMP RTD PT 100 LAC13 CT 106
COPYRIGHT AND CONFIDENTIAL

5. BOOSTER PUMP BEARING (NDE) MEATL TEMP. RTD PT 100 LAC13 CT 105

6. BOOSTER PUMP THRUST BEARING MEATL TEMP RTD PT 100 LAC13 CT 101 TO 104

7. . BOOSTER PUMP THRUST & NDE BEARING DRAIN RTD PT 100 LAC13 CT 107

OIL TEMP.

8. BOOSTER PUMP DE BEARING DRAIN OIL TEMP. RTDPT 100 LAC13 CT 108

9. BFP BEARING (DE) DRAIN OIL TEMP. RTD PT 100 LAC03 CT 109

10. BFP THRUST & NDE DRAIN OIL TEMP. RTD PT 100 LAC03 CT 110

11. BFP SUCTION FEED WATER TEMP. RTD PT 100 LAB13 CT 103 TO 105

12. BFP DISCHARGE FEED WATER TEMP. RTD PT 100 LAB23 CT 101 TO 103

13. BFP BARREL TEMP. TOP RTD PT 100 LAC03 CT 101

14. BFP BARREL TEMP. BOTTOM RTD PT 100 LAC03 CT 102

15. BP MECH. SEAL COOLER NDE, S.W INLET TEMP. RTD PT 100 PGB41 CT 101

16. BP MECH. SEAL COOLER NDE, S.W OUTLET TEMP. RTD PT 100 PGB41 CT 102

17. BP MECH. SEAL COOLER DE, S.W INLET TEMP. RTD PT 100 PGB41 CT 103

18. BP MECH. SEAL COOLER DE, S.W OUTLET TEMP. RTD PT 100 PGB41 CT 104

19. BFP MECH. SEAL COOLER DE, S.W OUTLET TEMP. RTD PT 100 PGB41 CT 105

20. BFP MECH. SEAL COOLER DE, S.W INLET TEMP. RTD PT 100 PGB41 CT 107

21. BFP MECH. SEAL COOLER NDE, S.W OUTLET TEMP. RTD PT 100 PGB41 CT 106

22. BFP MECH. SEAL COOLER NDE, S.W INLET TEMP. RTD PT 100 PGB41 CT 108

23. BP MECH. SEAL COOLER NDE, C.W OUTLET TEMP. RTD PT 100 PGB41 CT 109
FP10957
Ref. Doc

24. BP MECH. SEAL COOLER DE, C.W OUTLET TEMP. RTD PT 100 PGB41 CT 110

25. BFP MECH. SEAL COOLER NDE, C.W OUTLET TEMP. RTD PT 100 PGB41 CT 111

26. BFP MECH. SEAL COOLER DE, C.W OUTLET TEMP. RTD PT 100 PGB41 CT 112
 HY-DC-4-18000-58813
PROJECT:
Rev No. 5
TD-106-2

DAMODAR VALLEY CORPORATION KOLKATA

Form No. MEJIA PHASE - II THERMAL POWER STATION
Rev No .01
2 x 500 MW - UNIT 1 & 2
Page 3 of 4
---------------------------------------------------------------------------------------------------------------------------
SLNO DESCRIPTION OF INPUT INITIATING KKS TAG NO.
DEVICE
---------------------------------------------------------------------------------------------------------------------------
27. DIFF. PR. ACROSS BP SUC. STRAINER DIFF.PR. TRANSMITTER LAB13CP103

28. DIFF. PR. ACROSS BFP SUC. STRAINER DIFF. PR. TRANSMITTER LAB13CP104

29. BFP DISCHARGE PRESSURE PR. TRANSMITTER LAB23CP102

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

30. BFP SUCTION PRESSURE PR. TRANSMITTER LAB13CP105

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

31. BFP DE (H&V) VIBRATION MONITORING VIB.TRANSDUSER LAC03 CY101, 102

32. BFP NDE (H&V) VIBRATION MONITORING VIB.TRANSDUSER LAC03 CY103, 104

33. KEY PHASER BFP KEY PHASER LAC03 CS101

2. MOTOR.

1. MOTOR BEARING(BP END) METAL TEMP. RTD PT 100 LAC03 CT 125

COPYRIGHT AND CONFIDENTIAL

2. MOTOR BEARING(HC END) METAL TEMP. RTD PT 100 LAC03 CT 126

3. MOTOR STATOR WINDING TEMP. RTD PT 100 LAC03 CT 111 TO 122

4. MOTOR BEARING(BP END) DRAIN OIL TEMP. RTD PT 100 LAC03 CT 123

5. MOTOR BEARING(HC END) DRAIN OIL TEMP. RTD PT 100 LAC03 CT 124

3. HYDRAULIC COUPLING.

1. H.C BEARING NO.1 METAL TEMP. RTD PT 100 LAC23 CT 101

2. H.C BEARING NO.2 METAL TEMP. RTD PT 100 LAC23 CT 102

3. H.C BEARING NO.3/4 OIL TEMP. RTD PT 100 LAC23 CT 103

4. H.C BEARING NO.5 METAL TEMP. RTD PT 100 LAC23 CT 104

5. H.C BEARING NO.6 METAL TEMP. RTD PT 100 LAC23 CT 105

6. H.C BEARING NO.7 METAL TEMP. RTD PT 100 LAC23 CT 106

7. H.C BEARING NO.8 METAL TEMP. RTD PT 100 LAC23 CT 107

8. H.C BEARING NO.9/10 OIL TEMP. RTD PT 100 LAC23 CT 108

9. H.C BEARING NO.11 METAL TEMP. RTD PT 100 LAC23 CT 109

10. H.C BEARING NO.12 METAL TEMP. RTD PT 100 LAC23 CT 110

11. BFP SPEED (4 - 20ma SIGNAL) SPEED LAC23 CS 101

TRANSDUCER

12. BFP SPEED (4 - 20ma SIGNAL) SPEED LAC23 CS 102

TRANSDUCER

13. H.C WORKING OIL TEMP.UP RTD PT 100 LAC23 CT 111 TO 113
UP STEAM OF COOLER
FP10957
Ref. Doc

14 . H.C WORKING OIL TEMP. RTD PT 100 LAC23 CT 114

DOWN STEAM OF COOLER
 HY-DC-4-18000-58813
PROJECT:
Rev No. 5
TD-106-2

DAMODAR VALLEY CORPORATION KOLKATA

Form No. MEJIA PHASE - II THERMAL POWER STATION
Rev No .01
2 x 500 MW - UNIT 1 & 2
Page 4 of 4

15. LUBE OIL TEMP. UP STEAM OF COOLER RTD PT 100 LAC23 CT 115

16. LUBE OIL TEMP. DOWN STEAM OF COOLER RTD PT 100 LAC23 CT 116 TO 118

17. WORKING OIL PRESSURE PRESSURE

TRANSMITTER LAC23 CP 101 TO 103

18. LUBE OIL PRESSURE PRESSURE

TRANSMITTER LAC23 CP 104 TO 106
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
It must not be used directly or indirectly in any way detrimental to the interest of the company.
COPYRIGHT AND CONFIDENTIAL

FP10957
Ref. Doc
 REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED
3200 CHKD. & APPD. CHKD. & APPD. CHKD. & APPD.

3000

2800

2600
NOTE :
2400 1. DISCHARGE FLOW AT THE FOLLOWING CONDITIONS
D
ARE WITH INTER STAGE & KICKER STAGE CLOSED.
2200 MIN. RECIRCULATION FLOW C
A

2000 PARAMETERS AT 50Hz

B

1800
EMERGENCY 5675 52
D 920 2313 161.1 0.9050 81.0 6475
OPERATION
1600
MCR WITH
1400 C 900 2227 160.1 0.907 81.0 6112 5565 51
U/F
BEST
1200 44
B EFFICIENCY 855 1985 161.1 0.907 80.0 5240 5260
POINT
7500
A DESIGN 990 2050 162.8 0.9054 81.0 6177 5465 50
D
6500 CAPACITY
A
C
5500 OPERATING FLOW HEAD TEMP. SP. GR. EFFICIENCY POWER SPEED NPSHR
REF (mlc)
CONDITION (m3/hr) (mlc) (0 C) (%) (kW) (RPM)
B
4500

3500
90
A

80

70 JOB NO. : 270 CUSTOMER - DAMODAR VALLEY CORPORATION

KOLKATA
60 STATUS : CONTRACT

50 80 DRG. / REF. NO. (INTERNAL)

MEJIA PHASE - II THERMAL POWER STATION
40 70 3 180 0055321 2 x 500 MW - UNIT 1 & 2
5775 RPM

30 60 PUMPS ENGINEERING NAME SIGN. DATE

D
C PRPD. D.K.GUPTA -sd/- 25.04.08
20 50 BHARAT HEAVY ELECTRICALS LTD.
A
HYDERABAD CHKD. M.M.R -sd/- 25.04.08
10 B 40 APPD. B.RAJKUMAR -sd/- 25.04.08

0 30 TITLE PUMP TYPE : FK 4E 36 TEST CODE

HIS
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 ESTIMATED PERFORMANCE CURVES DRG. NO. : REV.
OF MD BOILER FEED PUMP HY-DG -3-18000-55321
SUCTION FLOW (m3/hr) SHEET NO.: 1 NO. OF SHEETS : 1 00
 REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED

3400 CHKD. & APPD. CHKD. & APPD. CHKD. & APPD.

3200

3000

2800
NOTE :
2600
1. DISCHARGE FLOW AT THE FOLLOWING CONDITIONS
2400 ARE WITH INTERSTAGE & KICKER STAGE CLOSED.
D
2200 C
A

2000 EMERGENCY
B D 920 2294 162.1 0.9050 81.0 6422 5665 49.5
OPERATION
1800
MCR WITH U/F 81.0 49
C 900 2219 160.1 0.9070 6090 5550
1600
BEST
1400 B EFFICIENCY 855 2002 161.1 0.9070 80.0 5285 5260 43
POINT
7500
D A DESIGN 990 2050 161.8 0.9054 81.0 6178 5465 50
6500 C A CAPACITY

5500 OPERATING FLOW HEAD TEMP. SP. GR. EFFICIENCY POWER SPEED NPSHR
REF (mlc)
B CONDITION (m3/hr) (mlc) (0 C) (%) (kW) (RPM)
4500

3500

90
A
80

70 JOB NO. : 270 DAMODAR VALLEY CORPORATION

STATUS : CONTRACT KOLKATA

60
DRG. / REF. NO. (INTERNAL) MEJIA PHASE - II THERMAL POWER STATION
50 80 3 180 0055323 2 x 500 MW - UNIT 1 & 2

40 70
6012 RPM NAME SIGN. DATE
PUMPS ENGINEERING
30 60 PRPD. D.K.GUPTA -sd/- 28.04.08
D BHARAT HEAVY ELECTRICALS LTD. CHKD. M.M.R -sd/- 28.04.08
20 50 HYDERABAD
C A APPD. B.RAJKUMAR -sd/- 28.04.08
10 B 40 TEST CODE
PUMP TYPE : FK4E36
HIS
0 30 TITLE
DRG. NO. : REV.
ESTIMATED PERFORMANCE CURVES HY-DG -3-18000-55323 00
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
SUCTION FLOW (m3/hr) OF TD BOILER FEED PUMP SHEET NO. : 1 NO. OF SHEETS : 1
 Digitally signed by S P Patra
DN: CN = S P Patra, C = US,

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

Patra INFORMATION
Date: 2009.01.22 16:42:24
+05'30'
    
  

  

  


      

     
      

   



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





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

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             


 
















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













 Digitally signed by S P
Patra

SP DN: CN = S P Patra, C
= US, O = DVC, OU =
Engineering and
Planning

Patra Reason: I have

reviewed this document
Date: 2008.06.14
14:21:50 +05'30'
   
 
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 


    



 










 

 
 









 

 




 



              


 
 

 

   



























   
 Digitally signed by S P Patra
DN: CN = S P Patra, C =

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

Patra Date: 2008.06.14 14:39:19

+05'30'
   
 
                                       











                           
             












    













 


 


 

 










 


 





              


 

 

 

   



























   
 Digitally signed by S P Patra
DN: CN = S P Patra, C = US, O =

S P Patra DVC, OU = Engineering and Planning

Reason: I have reviewed this
document and approved under CAT I
Date: 2008.06.26 13:24:21 +05'30'
 






  


   
   
 
   
   
   
   
   
   
   
 
   
   
   
   
   
   
   
   
   
 
   
   
   
   
   
   
   
   

   
 
   
   
   
   

 
   
 





   

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   
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   
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   
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   
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   
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   
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 
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   
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   
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 
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        
     
   


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          
 

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   


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    
 
        

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 





 
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
    
   

    
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
    
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   
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 
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   
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      

   
   

      


   
   
     
 

   
   
   
 
 

   
   
   
   
   
   
   
   
   
      
 

  
   
  
 





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 
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   
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  

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   
 
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   
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  

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 
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   
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   
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   
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     
 

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   
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   
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   
  

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 
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   
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   
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   
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 





 
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   
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   

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   
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   
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   
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   
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   
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   
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   
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 
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   
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   
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   
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   
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   
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  
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   
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   
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   
   
          
 




        
 

   

    
   
        
 

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      


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   
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   
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       


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 
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   
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   

   

   
   
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        

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        


   

   
   
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   
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   

   

   
   
   
   
 




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   
   
       

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   
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   

   

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   
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   
        

   
   

   
   
   
  
 

   

   

    
   

    
   
   
   
   
  
 
   
   
   
   
   
   

   

   

 





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 
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   
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   
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   
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        
      

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   
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   
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   

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    
   
 
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   
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   
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   
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   
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   
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   
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 
  
  
  
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   
 




 
  
  
  

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   
   
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   
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   
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   
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   
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   
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   
   
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   
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   
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   
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   
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   
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   
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   
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   
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   
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   
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   
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   
 




   
   
   
   
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   
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   
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   
 
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   
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   
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   
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   
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   
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 
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   
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   
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   
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   
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 
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   
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   
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   
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 
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   
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   
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 




    

   
   
   
   
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   
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
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 
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   
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   
   
       

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   
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 
   
   
   
   
   
       

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 
   
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 
   
   
   
   
   
   
   
   
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   
   
 
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   
 




   
   
   
   
   
   
   
   
 Digitally signed by S P Patra
DN: CN = S P Patra, C = US, O

SP = DVC, OU = Engineering and

Planning
Reason: DVC have reviewed this
document and taken it for

Patra INFORMATION
Date: 2009.01.22 16:43:55
+05'30'
   

  

 

 


 













































       



 
 SECTION – C

CONDENSATE EXTRACTION PUMP

LIST OF DRAWINGS

Erection & Maintenance

S.No. Description of Drawing Drawing No.

01. Sectional Assembly of CEP HY-DG-1-18100-56323

02. General Arrangement of CEP HY-DG-1-18100-56324

03. Schematic diagram of Sealing and HY-DG-2-18100-54890

Cooling water for CEP

04. Instrumentation Scheme for CEP HY-DG-2-18100-54891

05. Instrumentation Schedule for CEP HY-SC-4-18100-58818

06. Recommended list of analog inputs HY-DC-4-18000-58819

to owner’s DDCMIS for CEP

07. Sequential Interlocking conditions of CEP HY-DC-4-18100-58824

08. Thrust bearing withdrawal & assy tools 1 181 231 3686

09. Impeller withdrawal & assy tools 2 181 231 3616

10. ‘C’ Spanner (Var.no. 12 & 13) FP 90016

Informative Drawings

11. Estimated Performance Curves of CEP HY-DG-4-18100-68817

NPSHR

12. Estimated Performance Curves of CEP HY-DG-3-18100-65325

13. Design characteristic curves of 2 CEPs HY-DG-4-18100-58821

in operation

14. Technical Data of CEP HY-DC-4-18100-58820

= # =
     
  

   
  
  
 Digitally signed by S P Patra
DN: CN = S P Patra, C = IN,

SP O = DVC, OU = Engineering
and Planning
Reason: I have reviewed
this document and approved

Patra under CAT I

Date: 2008.04.07 17:56:09
+05'30'
 Digitally signed by S P Patra
DN: CN = S P Patra, C =
SP US, O = DVC, OU =
Engineering and Planning
Reason: I have reviewed

Patra this document

Date: 2008.06.06 15:23:41
+05'30'
    
 

 


 


   

 




 
 




            

























 
 








  
 REV. DATE ALTERED : REV. DATE ALTERED : REV. DATE ALTERED :
500
APPD : APPD : APPD :
450

400 Min. Recirculation

Flow
350

300 D 745 235 46 0.9902 79.0 712 1486 3.4 280

A
250 D
B
C C 710 240 46 0.9902 80.5 637 1486 3.2 268
200
B 620 215 46 0.9902 80.0 633 1486 2.65 303
150

100
A 800 275 49.2 0.9899 81.0 732 1486 3.05 275
900
51.5 HZ
A CAPACITY HEAD TEMP SP. GR. EFFICIENCY POWER SPEED NPSHR ACTUAL
50 HZ REF (cu. m./ h r.) (mlc) ( C) (%) ( kw) ( RPM) (mlc) DEV.HEAD
700 FOR INFORMATION (mlc)
47.5 HZ

500 NOTE :
A - DESIGN CONDITION.
300 B - BEST EFFICIENCY POINT-MCR WITH 3% MU 1. SHUT OFF HEAD AT 50Hz = 350mlc.
C - VWO FLOW WITH 10% MARGIN 2. INPUT POWERS AT B,C &D ARE CALCULATED
D - MAX FLOW CONDITION BASED ON ACTUAL HEADS GENERATED
100 AT 50 Hz.

90
A
80

70
JOB NO. : 270 D A M O D A R V A L L E Y C O R P O R A T IO N
K O LKA TA
60 STATUS : CONTRACT

50 DRG. / REF. NO. (INTERNAL) MEJIA PHASE - II THERMAL POWER STATION

2 x 500 MW - UNIT 1 & 2
40 5 3 181 00 6 5325

30 4 PUMPS ENGINEERING
50 HZ NAME SIGN. DATE
A
20 3 BHARAT HEAVY ELECTRICALS LTD. PRPD REDDY Sd/- 14.05.08
HYDERABAD. 14.05.08
10 2 CHKD. M.M.R. Sd/-

APPD B.R.K. Sd/- 14.05.08

0 1 TEST CODE
PUMP TYPE : EN6J40/500
TITLE HIS
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 CEP DRG. NO. : REV.
ESTIMATED PERFORMANCE CURVES HY-DG -3-18100-65325 00
SUCTION FLOW (Cu.m/Hr)
SHEET NO. : 1 NO. OF SHEETS : 1
 Digitally signed by S P Patra
DN: CN = S P Patra, C = US, O =

S P Patra DVC, OU = Engineering and

Planning
Reason: I have reviewed this
document
Date: 2008.06.06 15:25:43 +05'30'
              
             
                                         
                               

                 

    

    

   































   
 Digitally signed by S P Patra
DN: CN = S P Patra, C = US, O =

SP DVC, OU = Engineering and

Planning
Reason: I have reviewed this
document and approved under

Patra CAT I
Date: 2008.06.06 15:20:44 +05'30'
 






  

   
   


   
 


   
   


   
   


   
   


   
    


   
    


   
    


   
          
 

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 
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   


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   


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   


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   


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 


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   


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   


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   
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   


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 





  

   
   


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   


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   


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        
 
 

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  
   

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   


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   


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   


   



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   


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   


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   


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   


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   


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        
  

   
   
   
   


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   


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    


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 





  


 
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   


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   


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   


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 
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   


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   


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   


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   


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   


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   


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   


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 


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   


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   


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   


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 


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   


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    


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   

 






  

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 
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   
   
   
   
   
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   


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 


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   


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   


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 


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   


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   


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   


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   


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 


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   
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   


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   


 

   



   


  
 
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