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INSTRUCTION MANUAL
FOR
CARGO PUMPING SYSTEM

MESSRS.
HULL NO.

NAMURA SHIPBUILDING CO., LTD.

286

REV.

DA. TE

DESCRIPTION

CHECKED BY DRAWN BY APPROVED BY

ORDER NO.

APPROVED BY
MODEL ,
KV400,RX I ,etc.

DATE
D RAW.NO.

JAN. 09, 2007

TIF - 0701 09-6
REV. '

CHECKED BY

IL

DRAWN BY

!~c~

SHlnKO IN:D.LTD.
FAX : ( 082 ) 508 - 1020

5-7-21, Ohzu, Minami-ku, Hiroshima, Japan

TEL : ( 082 ) 508 - 1000

MESSRS. NAMURA SHIPBUILDING CO., LTD.

HULL NO.
286

INDEX
NO.
1

SERVICE NAME

MODEL
KV400
RX 1

PAGE
81 -1 -1 5

2
3

CARGO OIL PUMP CARGO OIL PUMP TURBINE

87-1 -28
82-1 -1 5
9 6A- I -8

BALL~sT PUMP
CARGO OIL STRIPPING PUMP

cV450

4
5

KPH200 REMOTE CONTROL SYSTEM FOR CARCO OIL STRIPPING PUMP KSC65

97-1 -7

SHmKO IIVo. L To.

INSTRUCTION MANUAL FOR CENTRIFUGAL PUMP (KV)

This instruction manual describes construction, operation, maintenance, disassembling, assembling, etc. of model KV pump.

CONTENTS
Page

CHAPTER I CONSTRUCTION . . . . . . 81-2

2. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Pump stuffingboxseal . . . . . . . . . . . . . . . . . . . . . . . 3

6. Bulkhead stuffing box and intermediate shaft . . . . . . . . 3

wlth gear coupling 7. Steam cleaning device . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 2 CAUTION FOR INSTALLATION AND PIPlNG . . . . . . . 8 1 4

l . Place of installation and foundation . . . . . . . . . . . . . . . . . 4

2. Finishingofpumpmounting seat . . . . . . . . . . . . . . . . . . . 4
3. Caution for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Suction piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Permissible deformation ofbellows . . . . . . . . . . . . . . . . . 5

7. Fitting offloating shaft complete . . . . . . . . . . . . . . . . . . 5

CHAPTER 3 OPERATION . . . . . . . . . . . . . . . 81-6 1 . Check before operation . . . . . . . . 6

2. Starting . . . . . . . . . . . . . . . . . . 6 3. Stopping . . . . . . . . . . . . . . . . . . 6

CHAPTER 4 MAlNTENANCE . . . . . . . . . . . . . . 81-7

1 . Caution during operation . . . . . . . . . 7
2. Ban bearing . . . . . . . . . . . . . . . . . . 7 3. Mechanical seal . . . . . . . . . . . . . . . 7 4. Gear coupling . . . . . . . . . . . . . . . . 8

5. Bulkhead stuffingbox . . . . . . . . . . . 8 6. Maintenance check list . . . . . . . . . . . 9

7. Lubricants . . . . . . . , . . . . . . . . . . . 9 8. Standstill . . . . . . . . . . . . . . . . . . . 9

CHAPTER 5 STANDARD CLEARANCE AND LIMIT OF USE . . . 81-10

CHAPTER 6 DISASSEMBLlNG AND ASSEMBLlNG . . . . . . 81-11

1 . Disassembling . . . . . . . . 1 1 2. Assembling . . . . . . . . . . 12

CHAPTER 7 TROUBLE SHOOTlNG AND REMEDIES . . . . . . 81-13

CHAPTER 8 REPLACEMENT PARTS . . . . . 81-15

C~!D I suINKomlo.LTo.

C)

1 CONSTRUCTION CHAPTER
1 . GENERAL
The model KV pump is of a vertical single-stage double-suction centrifugal type, and the pump and driver are connected with the flexible couplings through an intermediate shaft and a bulkhead stuffing box, the construction being simple for ease ofhandling,
overhauling and caretaking.

2. PUMP CASING
The volute casing is split into two halves along a vertical plane containing the axis. Since the volute casing is of double-volute type the radial thrust on the impeller is almost balanced. Also since the suction and discharge nozzles are provided on the rear half casing, the

Fig. I .1

34

20
9
3 53 3 54
7
ldj
l

54
1

48
27

rotating element can be taken out by removing the front half casing (2) without
disturbing the suction and discharge pipings.

38
2
\

A vent to be connected with the stripping

or priming line and an air valve are provided on the volute casing.
t l

L 1\

// ll
\

tL1 t L 1 1t lt , ,
/

3. IMPELLER
The impeller (16) is of the double-suction type and hydraulically balanced. It is so designed as to improve pump efficiency and

16
19
7

/
54
1le
2

18

372
57

suction performance. Moreover, the impeller is statically and dinamically balanced.

35
7

14

4. BEARING
The rotating element is supported by ball bearings on both sides of the pump casing. The 6300 type ball bearing is fitted in the solid inner case (14) with the split type bearing housing and can be taken out together with the rotating element if the cap
of the bearing housing (7) is removed.

10

REa. FOR IPUMP

AEa. FOR pUMP

PART NO.

NAME OF PART
VOLUTE CASING
1

PART NO.

NAME OF PART

38
48.1

MOUTH RING
FLINGEA
FLINGER
MECHAN ICAL SEAL

2
1

VOLUTE COVER
PUMP BED
BEAR ING HOUSING

48.2

(1) The ball bearing (34) at the coupling end is secured in the housing by pressing its

7-1

54A
54B
57
70- 1

1 SET

outer race by means of the cover (9).

This serves to support the weight of the rotating element.

7-2

BEARING HOUSING

MECHANICAL SEAL
PACK ING R ING

1 SET
1

9
10

8EARING COVER
BEARING COVER
BEARING INNER CASE BEARING INNER CASE

SNAP RING
SPLIT RING

(2) The ball bearing (35) at the bottom end

is not fixed axially in view of the thermal expansion of the shaft (1 8).

141
1 42

70-2 70-3
1 46-1

1 SET
1

SNAP RING

16 18

IMPELLER

MECHA. SEAL COVER MECHA. SEAL COVER

BEAA ING NUT

iMPELLER SHAFT
IMPELLER KEY

1 46-2

(3) Grease is used as lubricant for the ball

bearing.

19

353
11 1

20 27

COUPLING KEY
IMPELLER NUT

354
37 2

BEAR ING WASHER

PACK ING R ING

34
35

BALL BEARING
BALL BEARING

snINKO INO.LTO.

5. PUMP STUFFING BOX SEAL

The stuffing box is so designed as to furnish the mechanical seal exclusively. Therefore there is no leakage of the liquid pumped and no air leaks into the pump. Moreover, the operation is very simple since no adjustment for the stuffing box during operation
is required.

Fig. I .3

~~:~~~]

f
a25
a]6

~I~~'
,ZI

~T I

[
,08

128
a21

Mechanical seal

101

42c

Unbalanced type mechanical seal is fitted and

flushed by pressure liquid led through the clearance

111 l
lal

138 149

between the impeller and the mouth ring.

,t]

,04

DECX

lo?

Fig. I .2

tog

D~~Z~~l

a:9

MECHAN I CAL SEAL

F LUSH I NG

438 da5
131
aQI

WATER PIPE

1
IF

409 ,t5 al3

a,o

2 5
t

A]o
lodt2
,31

3
5

"I
'12

4
5 5 5

129

105 aa8
4lg ,],
lll A

~~@
,3]
lll I

6
7

Itl I

Close-up view of mechanical seal

.'= \~

421

4:o

5lh 1

F LOAT I NG SEAT

542 543
51 h4

PACKINC RING
PAC K I NG

CARBON RUBBER RUBBER

STA I N LESS STE E L
R EQ. FOR PUMP

SEAL R INC

REa. FOR PUMP

PART NO.

545 546
51 h7

PACKING RING
SPR I NG
STOPPER RING & SET SCREW

RUBBER
STA IN LESS STE E L
401

NAME OF PART
BEARING SUPPORT
1
1

PART NO.

NAME OF PART

423B
424
425 426
427

HUB

STAIN LESS STEE L

402 BEARING CASE 403 BEARING CASE

404

For upper mechanical seal, A is attached, e.g. 54A-1

BEARING COVER 405 STUFFING BOX

406

FLOATlNG SEAT, and for lower one, e,g, 54B-1,

GLAND

428

407 FLINGER 408 COVER & PACKING

1 SET
l

429 430
431

6. BULKHEAD STUFFING BOX & INTERMEDIATE

SHAFT WITH GEAR COUPLING (Standard)
A stuffing box is provided where the intermediate shaft passes through the bulkhead to prevent the gas in the pump room coming into the engine room. If non-standard arrangement is fitted, it will be
shown later.
7.
41 1

409 DISTANCE RING 410 DISTANCE RINC

432 433 434

435

BALL BEAR ING

41 2

BALL BEARINC
LANTERN R ING

COUPLING BOLT & NUT 1 PACKING RING 1 PACKING RING 2 PACKING RING 1 PACKING RING 2 PACKING RING COVER & PACKING 1 SET INTERMEDIATE SHAFT 1 F LOATING SHAFT 4 COUPLING KEY 1 SNAP RING
1

413 414 416

417

BELLOWS
SEAT PACK ,NG
SEAT PACK I NG

PACKING RING 415 GLAND PACK ING

436
437 438

2
1 1

SLEEVE SLEEVE

SPACER

43g DOUBLING PLATE 440

441

STEAM CLEANlNG DEVICE (Option)

The device is provided on the pump to clean the mechanical seal and the mouth ring for pumping
very high viscosity cargoes.

418A S LE EV E 418B SLEEVE

419

PLUG
BEAA ING NUT

1 1

420
421

COUPLING FLANGE COUPLING FLANGE

442

BEARING NUT
BEAA ING WASHE R BEAR INC WASHE R

1 1

1 1 1 1

443 444

HUB 422 HUB 423A HUB

cg SnINKO INIO.LTO.
C

IN STALLATION AND PIPING CHAPTER 2 CAUTION FOR

In order to prevent occurrence periods with best efficiency and
of installation and piping.

of vibration and noise and to operate the pump over long safety the following points must be observed at the time

4 SUCTION PIPING 1 . PLACE OF INSTALLATION & FOUNDATION

(1) Size of the place of installation must be chosen in view of the pump disassembly and inspection. A space necessary for disassembly is shown in the outside drawing.

The piping on the suction side affects pump effi-

ciency to a great degree and to avoid troubles arising there from the following points must be
noted.

(2) The foundation must be strong enough to absorb pump vibration and to resist deformation against
long use.

(1) No air pocket must be formed in the piping.

(2) A11 fittings in the piping must be perfectly
tightened to prevent air invasion.

(3) The pump is placed on its foundation. The

driver with its bed is placed on its foundation with the bearing support (401) complete fastened at the bottom of the driver's bed.

(3) Care must be taken to prevent air leakage through glands of all valves in piping.

(4) The suction piping must be thoroughly cleansed

In this case confirm that the drstance "E" shown in the outside drawing, between the end faces of

so that pipe scale, welding beads and other

foreign matter do not remain, otherwise seizure and other troubles may result.
5

the coupling halves on the pump shaft end and the intermediate shaft bottom end must be as shown in the drawing. The permissible error of this distance * ''',, is :t2mm. (Refer to Fig. 2.2).

ALIGNMENT
Table 2.1 and 2.2 show permissible errors in ali-

gnment when the pump and driver are connected

through the intermediate shaft.

2. FINISHING OF PUMP MOUNTING SEAT

Chockliners must be welded on the foundation
place just under the pump foundation bolt holes
and their faces must be planed so that they lie in

When installations of the pump and driver have

been finished it is necessary to check the alignment and if the errors exceed those shown in Tables 2.1

a perfect plane. When the foundation bolts are

tightened leaving gaps between the liner faces and

and 2.2 adjustment is needed. This work is also

necessary when pipings for them have been finished.

pump bed, deformation may be given to the pump

and besides vibration may result.

When the alignment has been completed set the

driver's bed and the pump bed on their foundation
by driving the dowel pins.
Table 2J Between driver & intermediate shaft

3. CAUTION FOR PIPING

Deformation given to the pump by outside force
due to incorrect piping causes not only vibration but also pump troubles. Therefore, the pipe flanges connecting with the suction and discharge nozzles must be correctly matched. Be sure to avoid the

Parallel misalignment A Angular misalignment B at coupling (mm) at coupling (mm) Below O . 2 Below 0.2 (Between centers)

cases shown in Fig. 2.1 otherwise the pump may receive unreasonable force. Nor must the pump be directly given deformation due to the total
weight of piping and thermal expansion.
Fig. 2.1

Table 2.2 Between intermediate shaft & pump

Parallel misalignment A

at coupling (mm)
(Between centers)

Angular misalignment B at coupling (mm)

Below 0.4

Below 0.4

PIPING PUMP

Angular misalignment

Parallel

Flange faces

misalignment

do not touch

St,lNKO IND.LTD.

5 .1 Between driver and intermediate shaft

5 .2 Between intermediate shaft and pump

(1) Measurement ofparallel misalignment As shown in Fig. 2.2, fix a dial indicator on the coupling at the intermediate shaft upper
end for the alignment so that its spindle rests on the periphery of the coupling on the driver.

(1) Measurement of parallel and angular misalignments

As shown in Fig. 2.2, fix dial indicators on the

temporary shaft to be provided for the alignment so that their spindles rest on the periphery and the face of the coupling half on the

Give one complete turn at the same time to both coupling halves on the driver and the intermediate shaft and read the difference

intermediateshaft. Give one complete turn at the same time to both coupling halves on
the pump and intermediate shaft and read the

between the maximum and minimum readings

on the indicator.

difference between the maxirnum and minimum readings on the indicators.

(2) Measurement of angular misalignment In the same way as above, give one complete turn to both coupling halves at the same time

measure the gap between the coupling faces

(e.g. at each 90 deg.) using a feeler gauge, and

6. PERMISSIBLE DEFORMATION OF BELLOWS WHEN FITTED

(1) Elongation or contract in vertical direction i 10 mm.
(2) Angle deviation (Refer to Fig. 2.3) 5 deg.

read the difference between the maximum

and minimum measurements.
Fig. 2.2

(3) Perpendicular deviation (Refer to Fig.2.4) :!:8mm,

Driver

Fig. 2.3 Fig. 2,4

50
it,
'll

~ ~
't~

~1:

~r

FEELER GAUGE
F Parallel m is~ m isa I ignment

t,l
l

tl

i8

A
1

7. FITTING OF FLOATING SHAFT

(LOWER INTERMEDIATE SHAFT)

It is strictly prohibited to fit the floating shaft

(432) upside-down due to an abnormal thrust

BE L LOWS
m i sa misalignment

force is given to the pump bearing. It is therefore

Angu A lar

special attention should be paid for that the floating

shaft with the coupling marked with "C" is to be

"~~

fitted up and the other side marked with "PC" down.

TEMPORARY SHAFT

Pump

SnINKO IND.LTO.
C )

3 O'PERATION CHAPTER
1

CHECK BEFORE OPERATION

When operating for the first time after installation or overhaul and assembly, it is necessary to do as follows.

(2) Close the discharge valve completely and open

the suction valve fully.

(a) When the liquid level in the cargo tank is

(1) Take off dust preventing tape placed on the part where the pump shaft passes through and
take care so that no foreign matter enters the
clearance around the shaft.

above the pump the liquid flows into the

pump casing by gravity, so open the air vent valve on top of the volute casing to draw the air in the pump and close it when the liquid
begins to flow out of it.

(2) Give some oil to the mechanical seal. (Refer

(b) When the liquid level in the tank is below the

to "MECHANICAL SEAL")
(3) Give a few turns to the coupling by a turning
bar and see if it turns normally.

pump draw the air in the pump and suction

line through the gas vent on the volute casing

by means of stripping pump or some other

extracting devices so that liquid can fill the

(4) Confirm if the rotation direction of the driver

is correct.

pump inside. In this case keep the air vent

valve closed so that no air can enter the pump casing. Never neglect priming the pump.

(5) Confirm if the grease in the bearing housing

and the oil in the gear coupling, if fitted, is within the specified amount.
(6) Confirm if the driver is ready for the operation.

(3) Start the driver gently and increase its speed

gradually .

2 . STARTlNG (1) If the steam cleaning device for high viscosity cargoes is provided for cleaning the mechanical seal and mouth ring and if the last cargo un-

(4) When the discharge pressure has risen reasonablly, open the discharge valve gradually and
fully .

3. STOPPING
(1) Close the discharge valve.

10aded by the pump was so, open the steam

inlet valve provided on the device to clear the

(2) Stop the driver.

said parts before starting the pump and keep the valve closed during the operation of the
pump. Refer to Fig. 3.1 .
Fi9. 3.1

STEAM
In case stop valve

(3) If the steam cleaning device is fitted and the liquid pumped was high viscosity cargo, open the steam inlet valve on the device and clean the mechanical seal and mouth ring for about 1 O minutes to prevent from sticking the said parts under normal temperature.

is opened

' r~- -~J

L --~-l IN LET STEAM I tr---~l
(Steam press.

C LEAN I NG
( Fitted on

STEAM

DEVICE

pump body)

CASING

PUMP

2-3kglcm2 g)

Liquid being handled

I n case stop valve is closed

Pl I I I I J

IL~

Fl - l-el

1'~~-

SHINKO INO.LTD.

CHAPTER 4 MAINTENANCE
In order to eliminate pump troubles, to minimize parts consumption and repair and to maintain best efficiency over long periods the operator must aim at perfect maintenance of the pump.

1 . CAUTION DURING OPERATION

(1) Never throttle the suction valve in any case during operation otherwise troubles may occur
due to dry operation.

(2) Never operate the pump for over 3 minutes

with discharge valve completely closed. When a centrifugal pump is operated without discharge, most of the power changes into heat
and as a result temperature of the liquid in the

(7) With lowering of the liquid level in the tank suction pressure approaches the vapor pressure of liquid and vapor develops in the suction line and pump suction and, moreover, air is sucked through the suction bell-mouth until punrping ability decreases to such extent that
discharge stops.

In order to prevent this, vapor and gas coming

into the pump inside must be drawn through

that vent on the casing by means of stripping
pump or some other extracting devices.

pump casing rises to the boiling point causing seizure of the interior of the pump and accident may occur, especially when dangerous liquids are pumped.

(8) When cavitation occurs even though the pump

speed becomes minimum, discharge mut be

decreased by throttling the discharge valve. If this remedy is ineffective stop the pump.

(3) Never operate the pump with dry condition.

(4) Except that the driver is with the constant speed like electric motor, keep the discharge
valve open in full and it is desirable to adjust discharge flow by changing speeds. The adjust-

2. BALL BEARING
(1) In consideration of lubricating ability of the

ment of discharge flow by the degree of dis-

charge valve opening is not recommendable

because of loss of driving energy.

grease and running clearance of the bearing due to thermal expansion and liquid temperature pumped, the bearing temperature is so
designed as to stand up to 90'C.

(5) When operating more than 2 pumps in parallel be sure to keep the discharge pressure of each pump always equal. If the speed of some pump decreases during operation and its shut-off pressure drops below the discharge pressure of the remaining pumps, it is operated with zero flow even though its discharge valve is opened and thus the result will be the same as
mentioned in (2) before in this chapter.

However from viewpoint of service life it is

desirable to keep it below 75'C.
(2) For the lubrication of ball bearing grease is used.

The recommendable grease and the interval of replacement grease are shown in Table 4,1 and 4.2.
(3) For supplying grease for the bottom ball bearing, take the grease drain plug away.

In such a case try to make the speed of the

pump in question same as those of the remaining pumps, and if this is impossible stop that pump immediately.

3. MECHANICAL SEAL
(1) Cautions before starting and during standstill

Care must be taken so that no dust enters part

(a) in Fig. 4.1 .

(6) When operating the pump at the rated speed

with the discharge valve open in full available NPSH decreases as the liquid level in the tank

Pouring lubricating oil in (a), when the pump is

at a standstill, wiD prevent dust from sticking.

lowers and finally discharge becomes zero

due to cavitation.

If dust accumulates here and sticks hard seal ring (54-4) may stick and sliding face (S) can not be tightened. When the pump is delivered,
a strip of cloth tape is put over the gap around

In such a case pumping ability can be restored if discharge is decreased, so for the reason

the impeller shaft to prevent foreign matter

from invading.

mentioned above lower the speed without

throttling the discharge valve as the liquid level
in the tank drops.

(2) Check of flushing

The mechanical seal may be considered to be working perfectly if there is no heating near
the sliding parts and no abnormal noise.

SuINKO INiD.LTO.
C )

Fig. 4.1

(a) ll
(s)

Q)

plug B Rernove/

~'1~
/

plug A

\~e move

I'
vl Q)

~o Lc~,

u OJ)V1
J=

-C

- to
Cl)~~ ::, o

:= I-

(b) Fill oil through an oil plug hole on the

coupling by using pistol oiler till the oil

- ,= LLY-

begins to fiow out from the other oil plug

hole on the opposite side.

(3) Leaking from mechanical seal

Under normal operational conditions there is no leakage, but in case there is a leakage of over 30cc/h there must be some trouble inside,
so a remedy Inust be taken as early as possible. (4) Heating of sliding parts and abnormal noise.

Coupl i ng
o- r
n

g
o

Air gaP

Dverflow

~ea r
(]so

vG4so-s80)

Insufficient flushing to the sliding face causes

abnormal wear down of the carbon due to

O-ring
Coup I i ng
(c) (c

heating and dry contact. If flushing

temperature rises to more than 10~C above the liquid temperature being pumped, it is
necessary to trace the cause and remove it.

After the oil, put twolu plugs back After filling fillin the oil ut two s back toto

the coupling with Teflon seal tape on them.

When operated under the condition of dry

contact, abnormal sliding noise may occur.

Apply several turns to the shaft so that

4. GEAR COUPLING (Standard)

(1) Misalignment between pump and driver Since the gear coupling has sel~alignment action to some extent, small misalignment within the permissible values shown in Table
2.1 and 2.2 can be absorbed.

the oil may reach the interior of the coupling. If too much oil is filled, excessive oil may leak from the key way
but this is acceptable because necessary
oil is kept in the coupling.

5. BULKHEAD STUFFING BOX (Standard) (1) When operating for the first time after
repacking the stuffing box tighten once the gland firmly before starting, then loosen the
gland nuts to such extent that the coupling can
be turned lightly by turning bar.

However the excessive misalignment causes

too much slip between the teeth and as a result

wear becolnes excessive, vibration occurs and the coupling may be damaged.

(2) Lubrication
Lubrication oil has a very important function in

(2) Supply grease to the gland packing for

lubricating and to keep gas-tightness between

reducing friction and wear and in hydraulically

distributing contact pressure on the gear

flanks by forming oil film in the gap between
the m .

the pump room and engine room. The recommendable greases and the interval of replacement grease are shown in Table 4.1 and
4.2.

The recommendable oils and the interval of replacement oil are shown in Tables 4.1 and
4.2.

(3) Start the pump and adjust the gland nuts

gradually and evenly. If the gland is tightened

suddenly or too much or unevenly there may be

a danger of seizure of overheating.

(3) Filling lubricant oil

(a) Remove two oil plugs.

(4) If the packing becomes deteriorated the

tightness can not be kept no matter how much
the gland is tightened.

In such case renew the packing.

St,lNKO IND.LTO.

6. MAINTENANCE CHECK LIST

Maintenance and check for the followings can extend a life of the pump.

Item
Suction pressure

Inspection procedure

Remedy in case of trouble

Check every time if there is any

abnormal pressure drop
Check and record every tilne.
Check oil in gear c'oupling every time
through oil hole on it.

Stop pump immediately and check suction

line .

In the case of above ambient temperature

Bearing temperature

plus 40~C or above 85~C, stop pump and

eliminate cause.

Lubricating oil

Supply oil if necessary.

Ball bearing

Check abnormal noise every time.

If abnormal noise or overheating occurs, stop pump and eliminate cause, and renew
ball bearing if necessary.

Mechanical seal

Check leakage, heating, noise every

time.

Stop pump and remove cause.

Check alignment.

Vibration

Check vibration every tilne.

7. LUBRICANTS
(1) Replacement of lubrication
Table 4.1

The replacement of the lubricants is based on

deterioration or contamination of the lubricants

Replacement
Location
After initial start

being used. However, Table 4.1 shows

recommendable replacement. (2) Lubricants

Normal o peration

Within 3 months

NLGI No. 2(National Lubricating Grease

Institute) for grease for the ball bearing on the

Ball bearing

Every year
Every 6 months

pump and intermediate shaft and for its stuffing

Gear Coupling
Bulkhead stuffing box.

,,
Every operation
Every o peration

box, and for the gear coupling, ISO VG 460680 gear oil are recommendable. The brand names of the lubricants equivalent to the recolnmendable ones are shown in Table 4.2. (3) Grease amount

Pump model
Pump upper side bearing (g)
Pump lower side bearing (g)
Intermediate shaft upper side bearing (g)

KV 300
70
50 70

KV 350
70 50 70 70

KV 400
110

KV 450-3
150 llO 150
150

KV 450-4
270
150

KV 500-2
330 210 330 330

70
110 110

270

Intermediate shaft lower side bearing (g)

70
Bulkhead stuffing box (g)

270 360

240

240

280

300

400

(4) Gear oil amount

Pump model
Turbine side gear coupling (cc)
Intermediate shaft side gear coupling (cc)

KV 300
180
130 130

KV 350
180 130 130

KV 400
270
170 170

KV 450-3
480
280

KV 450-4
550

KV 500-2
700

380 380

410
410

Pump side gear coupling (cc)

280

8. STANDSTILL
When there is a fear of freezing, drain the pump conrpletely after stopping.
In case of a long standstill, clean each

sliding part thoroughly and apply rust preventive where necessary.

cg SHINKO INb.Llb.
C )

Table 4.2
Gre85e (NLGI N0.2)
( ;ear Oi] (rso VG 680)

Name of Com pany

IDEMITSU KOSAN DAPHNE EPONEX EP2

DAPnNE SUPER GEAR OIL 680

SPARTAN EP 680

EXXON
R/!OBIL OIL

BEACON EP2 LISTAN EP2

MOBIL UX 2 MOBIL PLEX 47

MOBIL GEAR 634 OR 636

NIPPON OIL

EPINOC GREASE AP2

BONNOCK M 680
~IEROPA LUBRICANT 680
REDUCTLJS 68,I

CALTEX OIL

MULTIFAK EP2
LISONIX GREASE EP2

JOMO
MITSUBISHI OIL

DIAMOND MIJLTIPURPOS N0.2 D[AMOND GEAR LUBE SP 680

C.ULF CROWN GREASE N0.2
BP ENERCREASE MM-F.P-2
MULTIPA K NO.2

CULF OIL
BP OIL

GL!LF EP LUBRICANT HD680

BP ENERCOL GR-XP 680

TEXACO OIL

TEXACO MEROPA 68Q

CASTROL
COSMO OIL

CASTROL ALPflA SP 680 StHEEROL AP2 OR EPL2

COS*MO GEAR SE 680 COSMO CREASI~ DAINAMAX N0.2

ALVANIA GREASE N0.2 ALVANIA CREASE EP2

SHOWA SHELL OIL

OMALA OIL 680

GENERAL S P GEAROL 680

GENERAL OIL
ELF

GEMICO GREASE MP-2

EPEXA 2 = EPONA Z680

DURA-LITH GRF.ASE EP2 , NL GEAR COMPOUNl] 680 ** EP680

CHEVRON

CLEARANCE AND LIMIT USE OF CHAPTER 5 STANDARD

The bigger the clearance between impeller and mouth ring becomes, the more the counterflow from discharge side to suction side becomes, and consequently pump capacity decreases.

Unit :

Table 5.1

mm

New parts
Name of part

Limit of use

Model

Standard
clearance a

Length b
Upper seal
15.9
15.9

b
a
1

Lower seal
15.9
15.9

Upper seal

Lower seal
13

KV 300
Im p eller

O. 3
o. 3 3 o. 3 3

13 13 13

c3

and
mouth ring

~3

350

1 1

13 13
13

400
b
450-3
45 O-4

15.9 15.9
16.5

15.9
l 5. 9
1 5. 9

o. 3 8 o. 3 8 o. 3 8

1 1 1

Floating
seat of

13
13.5

13
13.5

m echanical
seal

500-2

35

16.5

32

SHINKO INO.LTD.

6 DISASSEMBLlNG AND ASSEMBLING CHAPTER

1 . DISASSEMBLING
In order to replace impeller, ball bearing, mouth ring, etc., disassembling of pump is carried out as folbws.
l .1 Removal ofvolute cover (1) Remove the sealing pipe for the mechanical seal.
Fig. 6.1

34
1

20
9
3 53

td
1

354
4

54
1

(2) Loosen the nut for the mechanical seal cover (146) until the mechanical seal cover moves
and touches the flinger (48).

27

3B
2
I// l' /

_'1~1'1

~\
L \ \ Ll

(3) Remove the volute cover nuts and move the volute cover (2) forward by using the two
lifting b olts.
16
l9

,l
t

j~
l

' l ll l'
l
L~

__.l
5dB

1.2 Removal ofrotating element (1) Remove the coupling bolts.

(2) Remove the bearing housing cap after removing
the nuts fastening the cap.

70
18
37 2
Id
2

57

2 3

35 70

(3) Take out the rotating elements together with the bearing inner case (14), bearing covers
(9 & I O), bali bearing, etc. with paying attention

14 2

10

to the mouth ring (38) and mechanical seal.

l .3 Removal ofball bearing

(1) For the upper bearing, remove the coupling

after removing the snap ring (70-1).

1 .4 Removal ofmechanical seal Since the mechanical seal for this pump has a large spring compression allowance and force, the special tool provided must be used for re-

moving the mechanical seal and ball bearing

from the shaft.

Remove the bearing cover (9).

Make straight the rotation preventing piece on the washer (354) which is bent into one of the slots along the bearing nut (353) periphery and remove the bearing nut.

(1) As shown in Fig. 6.2 hold the tool in such

a way that the spring force does not act upon the flinger (48), and maintain not to transmit directly to the mechanical seal the shock produced when the ball bearing is removed.

(2) For the lower bearing remove the bearing

cover (1 O) and the snap ring (70-3).

(2) Remove the ball bearing and flinger from

the shaft.

(3) Compress the mechanical seal spring by using the special tool provided as shown in Fig. 6.2

and also mentioned in "Removal of mechanical seal".

(3) Loosen the special tool bolts to reduce the spring force and remove the special tool as
shown in Fig. 6.3 .

(4) Since the ball bearing is pushed lightly onto the shaft, it can be removed with the inner
case by using puller.
Fi9. 6.2
SPECIAL TOO L ISUPPLIED)

(4) Remove the mechanical seal from the shaft.

Fig. 6.3

COVER~ 2-"5cm

BALL BEARING

SPR I NC
SET SCR EW SEAL RINC

STO PP E R RtNG

LOAT I NG SEAT

FLING R

gD SuINKO INlo.L70.
C

1.5 Removal ofimpeller

The impeller ~shaft _diameter where the impeller (16) is fitted is the largest and gets smaller toward either end. Fixing the impeller is by the impeller nut (27) at the upper side and by the split ring (70-2) at the lower side.

(2) Take care not to injure sliding face and "O"

ring by hitting or scoring.

(3) When fitting be sure to apply lubricating oil

to "O" ring .

(4) Referring to Fig. 6.2 the floating seat (54-1)

(carbon) must be inserted by hand until it

(1) Remove the setscrews on the impeller nut (27) and remove the impeller nut after removing the ball bearing, the flinger and the
mechanical seal.

touches bottom of the cover (146) firmly

taking care not to injure sliding face.

(5) Place the stopper ring (54-7) against the shaft shoulder which forms fitting base and tighten
it by the setscrew.

(2) Remove the impeller from the shaft. However, if it is difficult to remove the im-

(6) Confirm the winding direction of the spring

if it is suitable for the rotation direction of

peller from the shaft, warm the hub of the

impeller slightly to ease working.

the pump. Refer to Fig. 6.4.

(7) Fit rotating elements of the mechanical seal

2. ASSEMBLING
Assembling can be carried out by reversing order of disassembling and attention must be paid to
the followings.

and the cover (146) onto the shaft.

(8) Afterward, apply the special tool and compress

the spring evenly as shown in Fig. 6.2.

(1) Clean each part thoroughly to remove rust

and scale, and be sure there are not injury and
burr in fitting parts.

(9) Fit the flinger and the ball bearing onto the
shaft, Ieaving the special tool as it is as shown

in Fig. 6.2 to compress the spring until the

rotor is settled in the volute casing.

(2) Assemble fitting parts according to match

marks if any.

(10) After settling the rotor in the volute casing

remove the special tool.
Fi9. 6.4

(3) Turn nuts for rotating parts securely and fix

anti-rotation device without fail.

(4) Be sure to thoroughly cleanse the ball bearing

with pure kerosene taking care to keep off

dust and foreign matter.

STOPPER RING
SEAL R ING
/
l

STOPPER RING
SEAL RING
l

2.1 Alignment Alignment is to be confirmed if it is within

the specified limit shown in Tables 2.1 and 2.2

in "ALIGNMENT" .
2.2 Assembly ofmechanical seal Use the special tool for assembling the mechanical seal as shown in Fig. 6.2 and 6.3. (1) Sliding face, "O" ring and "O" ring groove

R ight-hand

Left-hand

winding

winding

IMPELLER SHAFT

IMPELLER

must be claned with leadless gasoline and wiped with soft cloth taking care to keep
off dust and other foreign matter.

SmNKO INO.LTD.
C

CHAPTER 7 SHOOTING AND REMEDIES TROUBLE

Pump can perform satisfactory function if properly handled and maintained.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest
causes of trouble and suggested remedies.

Table 7.1

Troubles
1.

Causes
Pump not completely or insufficiently
filled with liquid.
2.
1.

Remedies
Prime once more,
Check suction line. Check suction line, Check by suction gauge on suction side.

3.

Pump cannot discharge

4.
5.

6.

Much air leakage in suction line. Air pocket in suction line. Suction lift too high. Wrong direction of rotation. Suction strainer and suction line clogged.

2,

3.

4.
5.

Check,
Check interior of suction line,

6.

7. 8.

Speed too low.

Impeller clogged.
Air leakage.

7.

8.

Check by tachometer. Check pump interior.

Check suction line and stuffing box,

1.
2.

l.

3.

Speed too low. Discharge head too high.

Suction lift too high.

2. 3.

4.
5.

4.
5.

Suction pipe bell-mouth not sufficiently

Check by tachometer. Check by discharge gauge. Check by suction gauge. Check.

Check interior of suction line.

submerged.
Insufficient discharge
6. 7.
8.

Suction strainer and suction line clogged.

6,
7.
8,

Impeller clogged. Wrong direction of rotation.

9.

1 O.

Excessive clearance between impeller and mouth ring. Cavitation due to high liquid temperature or excessive viscosity of liquid.

9.

Check pump interior. Check. Replace mouth ring by new one.

Check design.

1 O.

Pump discharges liquid

after starting, but soon fails to discharge

1.

Pump not sufficiently fmed with liquid

Air pocket in suction line. Much air leaks into suction line. Air leaks through stuffing box .

1.

2,

2.

3.

3.

4.

4.

Prime sufficiently. Check piping and if wrong correct it, Check suction side. Check if mechanical seal is incorrectly fitted or carbon is broken,

1.

Speed too high (Power frequency too

high.)

1.

Lower speed. (Frequency)

Check state of installation and

2.

Impeller touches mouth ring,

2.

3.

Prime mover overload

4.

Rotating elements touch stationary element due to bent shaft. Casing deformed.
Liquid specific gravity or viscosity is

3.

alignment. Replace shaft by new one.

Check if undue force is given by piping. Check design.

4.

5.

5.

6.

greater than designed one. Voltage too low (Constant input, but
increase in current) in case of electric

6.

Check power source,

motor driven.

SuINKO INb.LTo.
C )

Troubles
1. 2. 3.

Causes
Grease is too little.
1. 2.

Remdeies
Supply grease up to specified level. Remove grease till specified level.

Grease is too much. Grease has improper consistency or

it is deteriorated.

3.

Replace old grease with specified

Overheating of bearing

4.
5.

Misalignment is great.
Shaft is bent.

4.
5.

6.

Injury or too much wear in ball

bearing.

6.

new grease, CorTect alignment of pump and driver. Replace with new shaft. Replace with new ball bearings.
Check if impeller is clogged and if

7.

Too much thrust force.

7.

clearance between mouth ring and impeller becomes too much, and
correct them if any.
1.

Injury in balls or rolling face.

Abnormal noise in
ball bearing

2.

Too much clearance due to abnormal

we ar .

Replace with new ball bearing.

3.

Abnormal wear in retainer.

1.

Misalignment.
Shaft bent. Impeller partially clogged with foreign

1.

2. 3.

2. 3.

Check alignment of pump and driver. Renew shaft. Check pump interior.
Check state of installation.

matter.
4.
5.

Incorrect installation.

4.
5.

Weak foundation.

Vibration in pump

Measure vibration up and down, right and left around pump's mounting on
foundation, if vibration is too great

reinforce foundation.
6.

Suction and discharge pipings not

sufficiently secured.

6.

Refer to "CAUTIONS FOR PIPING'*,

and give necessary support.

7.

Rotating elements touch stationary elements.

Injury or excessive wear down in rubbing faces. Foreign matter in rubbing faces. Insufficient tightening of mechanical
seal cover.

7.

Check pump alignment and bending of

shaft.

1.

1.

Remove mechanical seal cover and

check rubbing faces.
Ditto.

2.

2.
3.

3.

Leakage in mechanical
seal

4.

Break down of "O" ring.

Insufficient tightening of setscrew of stopper ring (54-7).

4.

Check if cover bolts are evenly tightened. Check "O" rings for stationary and
rotary rings.

5.

5.

Tighten sufficiently setscrew.

6.

Injury or wear down of part of shaft where rotary ring's "O" ring (54-5)
contacts. Scale sticks in groove for "O" rmg (54-5), causing rotary ring to stick

6.

Replace with new shaft.

7.

7.

Disassemble and remove scale completely.

and rubbing faces to open.

1.

Heating of mechanical seal (Sometimes

Flushing is insufficient.

1.

Check if flushing pipe is clogged.

accompanied by abnormal
noise)

2.

Pump operated dry.

2.

Stop pump immediately.

SHINKO INO.LTb.

PART S CHAPTER 8 REPLACEMENT

When ordering replacement parts, include the following information.
1 . Ship's name

2. Shipbuilder and hull number

3 . Service and model of the pump

4. Parts' numbers and names shown in this instruction manual

PART NO.

NAME OF PART PUMP SUCTION PUMP DISCHARGE

R EQ.
1
1

PREssuRE GAUGE

71 Io
71 1 1
UJ

tD :)
(g
UJ cc :)
Cl)

U) UJ
o: CL

7221
TH ER MO-SW I TCH
( If fitted,

PUMP CASING

1 set
1

7221 .1 1

INSTALL THREAD
PUMP BEARING COUP.

7222
7222-1 1

1 set SIDE
1

INSTALL THREAD

7223

PUMP BEARING END SIDE1 set

1 INSTALL THREAD 1 set BULKHEAD STUFFING BOX 1 INSTALL THREAD

7221 -1 1

7222.1 1

I o h ~ co o ~:
a: UJ

7223.1 1

7226
7226.1 1

7223-1 1 7226-1 1

I F

7221

7222 7223 7225

SHINKO INO.LTD.
C

TURBlNE INSTRUCTION MANUAL RX FOR

This instruction manual describes construction, caution for installation and piping, operation, maintenance, etc. As the life of turbine depends extremely on the correct installation and

handling and suitable maintenance, it is recommendable to carry out

them according to this manual.

CONTENTS
CHAPTER 1 CONSTRUCTION , . , . . . . . . . . . . .871 . General ,
2. Exhaust casing . . . . . , . . . . .

Page 2 2
2 2 2 2 3
3

3. Rotor disc . . . . . . .

4. Governorvalve . , . . . . . . . , ,
5. Gland seal . . . , , . . . . . . . . .

6. Speed regulating governor

7. Emergency trip device , . . , . .

8. Lubrication system .

CHAPTER 2CAUTION FOR INSTALLATION AND PIPlNG . . . . . , , .871 . Place ofinstallation and foundation . . .

2. Finishing ofturbine mounting seat . .

4. Alignment . . . , . , . . . . . . . ,

4 4 4 4 4
5 5 5

CHAPTER 3OPERATION . . . . , . , . . . . , . . . . . , . .87_

1. Check before operation . . . . . . .
2. Starting . . , . , . . . , . . . . , . .

3. Operation at various speeds

4, Stopping . , . , , . . , . , . . . . , . .

5. Emergency stopping . . . . . 6, Resetting of emergency trip , . .

6 6 6
.87. 7

CHAPTER 4MAlNTENANCE .
l . Maintenance check list for during operation .

2. Adjustment for accessories and emergency trip . . .

3 . Maintenance check list for regular inspection . . . . .
4. Lubricants . . . . . . . . . . . . . . . . . . . . . . .

... 9
. . 10

. 87-1 1 CHAPTER 5STANDARD CLEARANCE AND LIMIT OF USE

CHAPTER 6DISASSEMBLlNG AND ASSEMBLlNG .

1. Disassembling . . . . .

. 87-1 2

. . . 12
14
. 87-1 5

2. Assembling .

CHAPTER 7TROUBLE SHOOTlNG AND REMEDIES

CHAPTER 8REPLACEMENT PARTS

. 87-1 8

C~g I snINKolNb.LTo.

C)

CHAPTER 1 CONSTRUCTION
l . GENERAL
The model RX steam turbine is a vertical Curtis
single stage with a reduction gear unit. Its construction is simple, strong and compact and

4. GOVERNOR VALVE
The governor valve is double seat type to prevent unbalance by the effect of steam pressure and also acts as an emergency stop valve so that this valve closses to stop the turbine when emergency trip
devices work.

the safety device and the governing device are composed of simple mechanism.

2. EXHAUST CASING
The exhaust casing is solid construction with an axial flow exhaust steam bore to lead steam flow smoothly to the exhaust steam piping for saving steam consumption.

5. GLAND SEAL
The turbine gland is provided with labyrinth packing.

3. ROTOR DISC
The rotor disc is provided on the turbine shaft end

by shrinkage fit. The pinion and shaft are solid construction and teeth faces are grinded or shaved
in order to operate in good effrciency and silently.

The outer circumference of rotor disc is provided with blads in two raws, and shroud rings are provided on the blads to prevent steam leakage.

Fig. I ,1

Fig. I .2

WITH UG8 GOVERNOR

BLADE
TURBtNE SHAFT EXHAUST CASING ROTOR DISC LABYRINTH PACKING

f=
C

~- ~
ll
,

rl

Illl

~ ~1J

GOVERNOR VALVE
J

WITH PGD GOVERNOR

c~g
c
J

SHINKO IND.LTD.

6.

SPEED REGULATING COVERNOR Fig. I .3 For the speed regulating governor, Woodward governor
is adopted and installed on the top of the reduction gear
casing, driven by a gear at the output shaft end.

The speed regulations are as follows. SPEED GOVERNOR

Momentary
Steady state
7.
:!: 9%

~1%

EMERGENCY TRIP DEVICE

For the purpose of safe turbine operation, the following emergency trips are provided. They actuate automatically

thus turbine is stopped. Lo pUMP

Overspeed trip
1 13-1 1 5% of rated speed

the governor valve, which is directly closed by linkage, MAIN

Low L.O. pressure trip 0.5 kg/cm2g or below

High back pressure trip I .5 kg/cm2g r~:hr"~

Local hand trip

Manual
source

Remote stop

Electric or pneumatic ~~::

In case of driving pump, if the followings are provided .. _. __ their standard set values are as below to stop the turbine. ~~~r~'~., ~~~~~ _._
Pump bearing overheat trip 800C (900C box for cargo ~ oil pump) Bulkhead stuffing f ~" '
8 Oo C

C trip Pump overpressure 1 10%80 ofrated dis. Pump casing trip overheat opress, . ,, ' dl iL :

overheat trip
8.

LUBRICATION SYSTEM
Forced lubrication system by turbine driven L.O. pump is adopted. Namely, after L.O. pressure is adjusted at I .0-1.5 kg/cm2 g by adjusting valve, the L.O. is supplied to bearings, reduction gear, etc. through the L.O. cooler and strainer. And a part of L.O. is sent to solenoid valve, trip servomotor and actuates as control oil for various emergency trip devices. For the safe operation of turbine a motordriven priming L.O. pump is provided. Unless the pressure in the L.O. Iine reaches 0.2-0.3 kg/cm2g the interlock acts so that the turbine does not start even though the main steam valve is opened.
Fig. I .4

BEARINGS
OIL JET FOR RE-

To triP deviCe
t

P.S. FOR LOW LOP.S. FOR PRIM. LO PR ESS.

PRESS. TR IP
,,

LO PUMP
ll

GAUGE

DUCTION GEARING
O L JET FOR GO-

i jOLn~~:E~:~/D VALVE

~~

VERNOR DAIVING GEARING

OIL JET FOR MAIN LO PUMP DR IVING

GEARING

LO STRAINER
t

PRESS.
AD J U ST I N G

CHECK VALVE

PRIM.

L/'L~ ji~iE~~]

LO COOLER

VALVE

LO PUMP MAIN
CHECK VALVE

CO CHECK
VALVE
LO TANK

LO PUMP

COOLINGWATER J [Ill]

cg SHINKO INb.LTb.
C )

IN STALLATION AND PIPlNG CHAPTER 2 CAUTION FOR

In order to prevent occurence of vibration and noise and to operate the turbine over long periods with best efficiency and safety the following points must be
observed at the time of installation and piping.

(b) Use of bellows type expansion joint Bellows joint is used in many cases. On the exhaust piping, the amount of elongation is

small due to low temperature but outside

force acting on the turbine is very great due to large bore of piping. Therefore, be sure to provide supports where necessary.

1 . PLACE OF INSTALLATION & FOUNDATION

(1) Size of the place of installation must be chosen in view of the turbine disassembly and inspection.

A space necessary for disassembly is shown in

the outside drawing.

(2) Give consideration also to the movement of the steam inlet and exhaust flanges themselves on

(2) The foundation must be strong enough to absorb

vibration of the turbine and to resist deformation against long use.

the turbine under operation due to thermal

expansion of the turbine itself.

3.4 Drain separator, drain traps and drain valves

Special attention should be given not to send

2. FINISHING OF TURBINE MOUNTING SEAT

(1) Chockliners must be welded on the foundation plate just under foundation bolt holes of the
turbine baseplate and their faces must be planed by a surface plate so that the turbine lies on a
perfect plane.

drain to the turbine because most causes of

turbine troubles are by the drain.

(1) Drain separator with drain trap for saturated steam

In order to remove the drain in the inlet steam be sure to provide a sufficient drain separator as near as possible to the turbine, with a drain
trap.

(2) When the foundation bolts are tightened leaving

gaps between the liner faces and the turbine baseplate, deformation may be given to the
turbine and besides vibration may result.

(2) Drain trap for superheated steam and saturated

st e am

Provide drain traps at the low point of piping,

3. PIPING
Deformation given to the turbine by outside force due to incorrect piping causes not only vibration but also turbine troubles. Therefore the followings must be considered.
(a) Matching piping flanges to turbine flanges. (b) Fitting support to bear piping dead weight.

expansion joint, upright pipe and the piping

end to remove drain in inlet steam. (3) Drain valves

Provide a drain valve each above 1 5 mm of

bore just before the steam in]et valve and above 40 mm of bore just after the steam exhaust valve

respectively to remove drain from the piping

before starting the turbine.

(c) Avoiding effect of thermal expansion ofpipings.

(d) Prevention of drain in pipings to turbine.

3.1 Matching pipe flanges to turbine flanges The pipe flanges connecting with the steam inlet

3.5 Others (1) Branch from main steam pipe

Take the branch from the top of the main

steam pipe and avoid the drain collection in
case a bend is provided. In case drain collects in the piping be sure to provide a drain trap. (2) Flushing piping Before connecting the piping to the turbine be sure to do flushing so that no foreign matters such as dust, pipe scales, etc. do not enter the
turbine.

and exhaust flanges of the turbine must be correctly matched.

3.2 Fitting support and hanger Provide supports and hangers to bear piping dead weight so that no bad effect caused by the piping
dead weight will be given to the turbine.

3.3 Effect ofthermal expansion of piping

(1) Thermal stress occurs when the pipe expands and contracts due to change of steam temperature and thus outside force is given to the turbine flanges, disturbing the alignment. In order to absorb the expansion ofpiping and
decrease the outside force actingon the turbine, the following 2 methods are considered. (a) Use ofelasticity ofpipe

(3) Special attention should be given to that pipe scales, welding beads, etc. may clog the drain trap especially at the initial operation after installation or repair of the turbine or the
piping.

ALIGNMENT

Refer to "ALIGNMENT" shown in the instruction

Provide 90'-bends, U-bends and double

U-bends to absorb the thermal expansion of
the steam inlet piping.

manual for the driven machine.

snINKO INO.LTO.

3 OPERATION CHAPTER
1 . CHECK BEFORE OPERATION
(1) Confirm if the driven machine is ready for so much steam as to start the turbine.

(2) Check by opening the drain valve or removing govemor does not function and the governor
the plug if water is in the oil tank, Woodward valve remains closed. Moreover, unless L.O. pre-

starting. Unless pulling the starting lever, if fitted, the

governor, the L.O. cooler or the oil strainer. ssure is above 0.3 kg/cm2g by operating the
(3) Check the oil level in the oil tank and the gover- Priming L.O. pump, the L.O. interlock acts and

nor. the governor valve can not be opened.

(4) Check oil in the gear couplingbetween the turbine 2. STARTING and driven machine by removing the plugs on (1) Open the steam inlet valve gradually and start

the gear coupling. the turbine. Then keep its speed at 100 to 200
Supply of oil to the gear coupling is from the rpm to warm up the turbine for 25 minutes.
(5) Start the priming L.O, pump and confirm oil pre- noise or vibration in the turbine and the redu-

plugs. (2) During that time check if there is no abnormal

ssure reaches above 0.3 kg/cm2 g. ction gear.
In case any abnormal state is felt, stop the

(6) Pass cooling water to the L.O. cooler, turbine immediately and trace the cause.

(cooling water is adjusted by throttling the (3) Close each drain valve on making sure that the cooling water outlet valve so that temperature

of the L.o. supplied is kept between 20 and drain has been completely discharged from

45'C during operation of the turbine.) each portion.

(7) Confirm all relating equipments, such as con- (4) Trip the turbine by operating the hand trip denser cooling water pump, condensate pump, knob to confirm that the governor valve closes

etc. are ready for starting the turbine. immediately.

(8) Open fully the drain valves on the drain se- (5) After sufficient warm up, open the steam inlet parator, the governor valve, the exhaust casing valve further and gradually and raise the speed and the pipings and also on the pipings before up to the rated revolutions in about 5 minutes. the steam inlet valve and after the exhaust (6) When the governor is used t~or the first time,

(9) Open the exhaust valve fully. the needle valve on the governor and adjust
(10) Turn the turbine together with the driven ma- the needle valve as described in the manual chine several revolutions by the turning bar to ofWoodward Governor.
(11) Set all trips on reset condition by the reset knob actuates surely always at the time of starting.

valve. draw out air in the govemor oil by opening

confirm smooth turning. (7) Confirm if the emergency trip mechanism

on the trip casing. Refer to Fig. 3.1. Also at the first operation after inspection or
long standstill, confirm the actuation of over-

(12) Set the governor at the minimum speed by speed trip at the specifiedspeed.
turning the adjusting knob counterclockwise

(13) Supply the sealing steam to the turbine gland the pump must be disconnected and the test must
as follows ; (In case ofthe exlraust is vacuum). nning of mechanical seal fitted on the pump.
Open the sealing steam valve gradually till the be to the turbine only in order to avoid dry ru-

and fully. (8) When testing the overspeed trip for the turbi[]e,

sealing steam begins to slightly leak from the 3. OPERATION AT VARIOUS SPEEDS turbine gland where the turbine shaft pases (1) For remote control
through. (The sealing steam pressure as an idea In the control room, operate the speed control

is 0.1 - 0.8 kglcm2 g. ) switch.

(14) Open the steam inlet valve slightly to warm- For speed increase, turn the switch clockwise,

up the turbine. and vice versa.

Pull the starting lever, if fitted, (2) For local control
to open the governor valve to supply a just suffi- For speed increase, turn the manual adjusting cient steam to the turbine for its warm-up, not knob clockwise, and vice versa.

9 1 SHIN!KOIN!O.LTO.
C

4. STOPPING
(1) Decrease the turbine speed gradually.
(2) Close the steam inlet valve.

5. EMERGENCY STOPPING
(1) Local stopping

Also stopping is possible when the remote stop or the hand trip on the turbine is actuated.

(3) When speed decreases and oil pressure falls

below 0.45 kg/cm2g the priming L.O. pump

starts automatically, keeping oil pressure above 0.3 kg/crn2g.
(4) Stop the cooling water to the L.O. cooler.

Push the hand trip knob provided on the trip casing on the reduction grear casing so that the spindle moves downward and the governor valve closes through actuation of the trip mechanism and the turbine stops as shown in Fig.
3.1 and 3.2.

(2) Remote stopping Push the remote stop switch provided in the
remote control room so that the trip mechanism actuates to close the governor valve to stop the turbine as shown in Fig. 3.1 and 3.2.

(5) When the turbine has stopped, close the exhaust valve and open all drain valves on the turbine to discharge drain completely.

(6) Keep the priming L.O. pump is in operation for more than 5 minutes after stopping the
turbine. After stopping the priming L.O. pump, confrrm that the turbine bearing temperature
does not rise above 80'C.

6. RESETTING OF EMERGENCY TRIP

Before resetting emergency trip, be sure to make
the following conditions.

(a) The driven machine is at the minimum load,

e.g. the pump discharge valve is fully closed.

(b) The governor speed setting is at the minimum

speed.

(c) The turbine steam inlet valve is fully closed.

Fig. 3,1

Fig. 3.2

WITH UG 8

GOVERNOR SPEED O SWITCH

SETTE R

RUNNING CONDITiON

SPEED REIMOTE STOP ADJUST. MOTOR

LOCAL

TRIP CONDITION WITH UG 8 GOVERNOR

O o o

Gov. LEVER

GOV & EMERG

STOP VALVE
In et

TRIP

close I '

SERVOMOTOR =
To nozzle

CONT.PAN E L

stea m

TACHOMETER o ~] RECEIVER Oo Q O~~

~~!:
SOU RC E

ELECTRIC
P.S. FOR LO TR IP
P S. FOR

TRIP KNOB KNOB

HAND

R ESET

\'
Press. oil

PRIM LO PUMP
P.S. FOR

BACK PRESS. TRIP

SOL. VA LVE

To LO tank

(DE-ENERGIZED)

OVER SPEED~ TRIP LEVER

TRIP

~ TRANSMITTER TACHOMETER

-~
WITH PGD GOVERNOR

WITHPGDGOVERNOR

SuINKO INO.LTO.

CHAPTER 4 MAINTENANCE
In order to eliminate turbine troubles, to minimize parts consumption and repair and to maintain best efficiency over long periods the operator must aim at perfect maintenance
of the turbine.

1 . MAINTENANCE CHECK LIST FOR DURlNG OPERATION

Maintenance and check for the followings can extend a life of the turbine.

Item
Inlet steam pressure and temperature before governor valve

Inspection procedure
Kcep constant as much as possible and record periodically.

Remedy in case of trouble

Chcck everyday. 2 Keep between I and 1.5 kg/cm g and rccord periodically.

Refer tO"TROUBLE SHOOTlNG & REMEDIES ".

L.O. pressure

Chcck everyday. Keep between 20 and 45~C and record periodically.

L.O. temperature at L.O. cooler outlet

Discharge drain periodically by opening drain valve on drain separator and piping.

Drain in steam into turbine

Check everyday.
Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Vibration and noise

Check everyday.

Turn its handle several times once a week to clean filter plate.

Oil strainer

Air in L.O. cooler and strainer

Draw out by vent valve or plug.

Check everyday by oil level gauge tbr oil tank and by sight glass for governor, and oil leakage from gear coupling.

Supply oil. Refer to "LUBRICANTS".

Oil level in oil tank, governor and gear coupling

In case of high vacuum (more than 600mmHg) , reduce the cooling water (S.W.) flow or driving steam pressure of ejector to keep the exilaust vacuum between design pressure and 600mlnH~,
Check everyday and record periodically. (Exhaust pressure never exceeds 600mmHg-V)

Keep its switch in automatic operation always.

Priming L.O. pump

Conrrrm at every initial starting of turbine if they work surely and smoothly.
When testing the overspeed trip for the turbine, the pump must be disconnected and the test must be to the turbine only in order to avoid dry ru- ' nning of mechanical seal fitted on the pump.

All trip devices

Steam leakage from turbine gland

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Check everyday.

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Bearing temperature

Check everyday and record periodically.

Corrosion protective piece on L.O. cooler

Corrosion protective piece (if fitted, the piece is shown in the spare list as its spare) is to be checked every 3 months and replaced if any.

g I SHINKOINlb.LTO.
C
)

2. ADJUSTMENT FOR ACCESSORIES &

2.4 Electric tachometer

EMERGENCY TRIP
As all parts of the turbine have been adjusted at
the shop trial, it is important to avoid unnecessary

Turn the adjusting screw inside the adjusting nut at the back of the tachometer to adjust
the reading.

readjustment.

Clockwise turn of the adjusting screw increases

the reading and vice versa.

However, if readjustment is required proceed as

follows ;

The tachometer pointer must be at zero point

when the turbine is at a standstill. Otherwise,

2.1 Speed governor (Woodward governor) Refer to the separate instruction manual of Woodward governor.

adjust by means of the zero point adjusting screw in the center of the tachometer front.
2.5 Mechanical overspeed trip ( I ) Remove the trip casing on the reduction gear

However, the adjustment of the interior is

very complicated and, therefore, must be done
by expert.

Never open the sealed governor part for the

adjustment.
2.2 L.O. pressure adjusting valve (Refer to Fig. 4.1)

casing and remove from this opening the split pin for locking the trip ring and trip spindle
of the overspeed trip.

Then draw out the trip spindle and spring from

the trip ring by screw driver.

Remove the plug and turn the adjusting screw to adjust lubricating oil pressure between 1.0
and 1.5 kg/cm2 g.

The adjusting liner is provided at the back of the spring in order to change as desired its

Clockwise turne of the adjusting screw increases

L.O, pressure and vice versa.
Fig. 4.1

compressive load. By changing the thickness

of this liner the overspeed trip actuating revo-

lutions can be changed. Every increase of

0.5 mm in thickness of this liner means about

65rpm rise in revolutions of the overspeed

P LU G

trip and vice versa. Refer to Fig. 4.3.

AD JU ST I NG

SC R EW
i

~ SPR ING

ADJUSTING VALVE BODY

ADJUSTING

(2) When testing the overspeed trip for the turbine, the pump must be disconnected and the test n:lust be to the turbine only in order to avoid drv running of mechanical seal fitted on the pump.
Fig. 4.3

VALVE

2.3 Sentinel valve (Refer to Fig. 4.2)

TRIP CASI NG

Remove the cap and turn the adjusting screw

to adjust the valve actuating pressure specified in the drawing. Clockwise turn of the adjusting
i
l

screw increases the valve actuating pressure

and vice versa.
Fig. 4.2

GEAR CASING

R EDUCTION

ADJUSTING
SC R EW

LOCK NUT
SPR I NG
j':
I:

VALVE BODY
ADJUSTING RING

OVERSPEED
TRIP

VALVE SEAT

CLOSE-UP OVERSPEED TRIP

TRIP SPINDLE

TRIP WEIGHT

ADJUSTING LINER
SPR I NG

snINKO INO.LTO.

2.6 Electric overspeed trip

( I ) Adjust so that the actuating revolutions becomes 1 12 - 1 1 3% of the rated revolutions by tuming the
adjusting screw at the head of the overspeed trip relay contained in the relay box. Clockwise turn of the adjusting screw increases the revolutions and vice versa. The adjusting range is between -5 and +1% of the preset revolutions. (2) when testing the overspeed trip for the turbine, the pump must be disconnected and the test must be to the tuFbine only in oFder to avoid dry running of mechanical seal fitted on the pump,

2.7 Pressure switCh (Refer tO Fig. 4.4 and 4.5)

Remove the plug and turn the adjusting screw clockwlse to decrease the actuating pressure and vice versa. For differential pressure adjustment, clockwise turn of the differential pressure adjusting screw widens
pressure difference and vice versa.
Fig.

4.4
P LU G

Fig. 4.5

ADJUSTING
SCR EW

P R ESSU R E

DIFFERENTIAL

P LU G

ADJUSTING
SC R EW

SCREW

ADJUSTING

~
L ~

~~~_ _

2.8 Thermo-switch for overheat trip(If fitted)

An adjusting stem each for the contractor and the temperature reading is provided at the center of the
front face and on the side respectively.

3. MAINTENANCE CHECK LIST FOR REGUIAR INSPECTION

It is recommendable to perform the regular inspection to avoid accidental troubles.

3.1 Inspection every 3 months

Item
Emergency trip device

Procedure and inspection

Item
Labyrinth packing and steam guard

Procedure and inspection

Confirrn wear and damage on
labyrinth packing and steam guard. Suitable clearance between shaft and labyrinth packing is shown in
standard clearance table.

Clean cooler interior and cooling tubes.

L.O. cooler

Confirm wear and damage on

bearing. Suitable clearance is shown

3.2 Inspection every year

in clearance table.

Item

Procedure and inspection

Check blades and nozzles for erosion, corrosion, damage and sticking scale. (Scale on blades causes vibration,

Bearing metai

No adjustment is required for radial bearing when fitting as they are

machined fine. Thrust bearing clearance is adjusted

with adjusting liner and its relating position is subject to clearance

Turbine blade and nozzle

abnormal steam thrust and insufficient output)

between moving blades and nozzles.

Confirm wear and rust on teeth

Governor valve,
its seat and

parts

Check valve and valve seat for erosion, corrosion and wear. Check valve stem and guide bush for

Reduction gear

faces. Ifthere is any indication of

rust immediately find cause and take proper measure.

wear.

Dynamic balance
for turbine rotor

Dynamic balance to be carried

if rotor is damaged or repaired.

Main L.O. pump

Check clearance between casing and pumping gear and also axial
clearance.

cg snINKO INIO.LTO.
C

LUBRICANTS
4.1 Replacement of lubricating oil

4.2 Lubricants

ISO VG 68 (International Standard Organithe lubricating oil

The replacement interval of is based on deterioration or

L.O. being used.

contamination of

zation) for lubricating oil for the bearing, the reduction gear and the Woodward gover-

nor and ISO VG 460-VG680 for Gear

Oi] for the gear coupling are recommendable.

However Table 4.1 shows recommendable

interval of the replacement.

The brand names of the oils equivalent to the recommendable one are shown in Table
4.2.

Table 4.1

Replacement
Location
After initial start

Norm al operation
Every I year
,l

L.O. tank

Within 3 months
If

Woodward
governor
Gear coupling
ll

Every 6 months

Table 4.2

Lubricating oil Gear oil BP ENERGOL GR-XP680,GR-EP680 BP ENERGOL THB68,77 CASTROL ALPHA SP680 PERFECTO T68 CASTROL COSMO GEAR SE680 COSMO TURBINE SUPER68 COSMO OIL SPARTAN EP680 EXXON TERESS068 SUPER GEAR OIL680 IDEMITSU KOSAN DAPHNE TURBlNE OIL68 KYOSEKI ES GEAR G680,M680 RIX TURBINE OIL 68 KYODO OIL DIAMOND GEAR LUBE SP680 HITSUBISHI OIL TURBINE OIL68, DIAMOND MARINE68 MOBIL DTE OIL HEAVY MOBIL DTE OIL HEAVY MEDlUM MOB I L MOBIL GEAR636

Name of company
BP

NIPPON OIL CALTEX OIL

FBK68 REGAL OIL R & O 68

BONNOCK SP680 MEROPA LUBRICANT 680

TURBO OIL T68 SHELL OIL TURBO OIL T68,J-H OIL68 SHOWA SHELL OIL REGAL OIL R & O 68 TEXACO OIL

SHELL OMARA OIL680 OMARA OIL680 TEXACO MEROPA 680

SHINKO INO.LTO.

LIMIT OF USE CHAPTER 5 CLEARANCE AND STANDARD

Fig. 5.1

17
1C_6

15 13 ,. 14 L-A 11

A
13 B

13

o
~,,

(~)
l* F~ l l I

D ETAI L-A

(~)

DETA IL-B L-B

Table 5.l

Unit ru :
l

mm
9

NO.
RXO
Standard
clearance

2
o.

15-0.2
0.3-0.35
0.2-0.3
0.45-0.55

RX1

0.150.2

0.25-0.35

0.25-0.30

0.2~RX2-2 0.25

0.3-0.35
0.23

0.15-0.2

RXO
Limit of

use

RX1

0.23
0.38

0.38
0.23

0.4

0.65
t

0.45

0.4

RXZ-2 0.28

NO.
Standard
clearance
Limit of

lO

ll

12

13

14

15

16

17

Backlash
0.28-0.63 (0.22-0.5D

0.25-0.30
0.4

0.20-0.50
0.65

0.20-0.25
0.35

2.2~2.8
1.5-3.5

use

The figures shown in Table 5.1 are for RX O , RX I . RX 2-2 ."Backlash" for RX O.
And the figure in ( ) shows Backlash of Model RX O only.

SHlnKO InD.LTD.
C
)

CHAPTER 6 DISASSEMBLING ANDASSEMBLING

1 . DISASSEMBLING
1.1 General caution
l .2 Disassembling ofexhaust casing (1) Remove the lagging on the casing.

(1) Proceed with the work in good order by referring to the assembly drawing and thoroughly understanding the construction.

('_) Remove the piece provided on the exhaust

piping for disassembling.

(3) Remove the tightening bolts and taper bolts

on the casing fiange.

(2) When removina* the fixing or fitting faces use

lifting bolts provided on them.

(4) Separate the casing from the steam chest by

lifting bolts on the casing flange.

(3) When removing the rotating element, be careful

to avoid damage on,the sliding faces, the journals and machiried faces.

(5) Remove the casing vertically and axially from

the steam chest.

(4) When removing the rotating parts from the shaft, remove them carefully after removing
the rotation preventing device.

This removal of the casing should be done carefully otherwise the casing may hit and
damage the rotor.

(5) In order to avoid mistake in assembling, mark suitable match marks as much as possible when
disassembling.

Fig. 6.1

ADE ADE MOVING BLADE

~ EXHAUST CASING
_-- EXH Ncz / MAII Top

STATIONARY BLADE

NCZZLE
MAIN LO PUMP

r : :~=E,~ t

TOP COVER
G E,~ GEAR

STEAM CHEST
EST ING AFT EAR VER

WHEE L

LABYRINTH PACKING
TURBINE SHAFT
CASING
r~

REDUCTION GEAR

.J

BOTTOM COVER

OUTPUT SHAFT OUT

c~ SHINKO IND.LTD.
C J

1.3 Disassembling of steam chest

.6

Opening of governor valve (Refer to Fig. 6.2)

(1) Disassembling of the steam chest should be

carried out after disassembling of the exhaust casing mentioned before.

(1)

Remove the linkage betWeen the governor

valve and the governor.

(2)

(2) Remove the bolts and taper bolts tightening the front and rear halves of the steam chest.
(3) Separate the front half of the chest from the
rear half by lifting bolts on its vertical flange.

Put the "Governor valve spring holding tool" to the threaded holes on both sides of the valve stem passing through the governor valve
casing cover and screw down its nut so that the
spring coils touches closely.

(4) Remove the front half of the steam chest. This removing of the steam chest should be
done carefully otherwise the rotating element,

(3)

Remove the bearing holder at the rod end of the valve stem frorn the valve stem after removing the split pin on the side and securing
the valve stem.

the moving and the stationary blades may be damaged.

1 .4 Disassembling of reduction gear casing cover

(4 )

Remove the tightening bolts and taper bolts

from the governor valve casing flange.

(1) Remove the thermometers on the reduction

gear casing.

(5)

Remove the cover vertically without bending

or injuring the valve stem.

(2) Remove the reduction gear casing top cover

and the front half of the bottom cover.

(6)

Screw 2 jack bolts of the governor valve seat

pulling tool to the valve seat.

Fix the holding plate to the casing by the

jack bolts.

(3) Remove the piping, wiring, etc. disturbing

the disassembling.

Refer to Fig. 6.3.

(4) Remove a bolt joinning the front half of the L.O, pump casing flange and reduction gear
casing cover.

(7)

Tighten the nuts of the jack bolts as to pull

out the valve seat from the casing.

(8)

(5) Separate the reduction gear casing cover from its casing by using the lifting bolts on the
flange.

After removing the valve guide of the governor valve take out the governor valve toward the valve stem. (If the governor valve is an assembled one, remove the stop ring on the
valve after removing the strainer and disassemble the valve before taking it out.)

(6) Pull the cover horinzontally.

1.5 Opening of turbine rotor and reduction gear

(1) Disassemble the exhaust casing, the steam

chest and the reduction gear casing cover in
accordance with I .2, I .3 and 1.4 ofthis chapter.

(2) Using eyebolt into the hole on the turbine

shaft end, put wire rope from the crane.

(3) Just lift up the turbine rotor a little gently

and draw it forward while taking care so as to avoid contact between the moving blads
and nozzles, and labyrinth packing.

(4) Using eyebolt into the hole on the output

shaft end, put wire rope from the crane.

(5) Just lift up the gear wheel a little gently and

draw it forward while taking care so as to

avoid damage.

Gg snINKO INlb.LTo.
c )

Fig. 6.2

Fig. 6.3

WITH UG8 GOVERNOR BEARING COV E R HOLDER

e

VALVE
STEM

VALVE

i~
!!i,l
i,ij,1,
J

STEM

JACK BOL BOLT

VALVE
GUIDE

~Til,

VALVE
1

HOLDING PLATE

VALVE
SEAT

GOVERNOR VALVE
CASING

AC Kl PAC Kl NG NG

WITH PGD GOVERNOR

RAINER STRAINER

~:ii

~~

i:1 !il!
I

'J~'

J -~
~

r~

L*

ASSEMBLING Assembling can be carried out by reversing order (8) Clean thoroughly various bolts and nuts on the
of disassembling and attention must be paid to the Steam side and apply seizure preventive (e.g.
(1) Clean each part thoroughly with kerosene to (9) Before assembling apply seizure preventive (e.g. remove dust and foreign matter and correct if Graphite) on the sliding portion of the governor

follovving: Graphite) on them.

injury is found. valve and on the valve and on the valve stem.
(2) Turn nuts for rotating parts securely and fix (10) Assemble the positioning liners. split pins, set

anti-rotation device without fail. screws, spring washers, etc. of each part in the (3) Assemble fitting parts according to match same state as before. Never t~orget caulking
where necessary.

marks ifany. (1 1) Check the clearance of each part in accordance

(4) Before assembling apply sufficient lubricating with the clearance table. oil to the bearing portion and gear teeth. (12) Check the backlash of gear teeth.
(5) Be careful to avoid one-sided tightening of

(6) Before assembling confirm that no dust and reduction gear, the L.O. pump driving gear
and the speed governor driving gear.

bolts. (13) Confirm that the position ofthe oil spray for the

foreign matter exist inside the turbine casing, (14) Confirm alignment (Refer to "r:\;'STALLATION governor valve casing, reduction gear casing
(7) Clean all the joint faces and fitting faces and (15) Confirm the smooth turning ofthe rotor.
apply heat resisting liquid packing (e.g. Hermetic) (16) When testing the overspeed trip for the turbine,

and oil tank. AND PIPPING).

on the steam side and oil-proof liquid packing the pump must be disconnected and the test must

(e.g. Three Bond) on the oil side. be to the turbine only in order to avoid dry running of mechanical seal fitted on the pump.

Cg SHINKOIN!O LTO
C J

CHAPTER 7 SHOOTlNG AND TROUBLE REMEDIES

Turbines can perform satisfactory function if properly handled and maintened.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest
causes of trouble and suggested remedies.

Table 7.1

Troubles
l.

Causes
Incorrect assembly.
1.

Remed ies
Check axial parallelism between shaft and bearing and correct. Check taper land of oil groove of thrust bearing and correct or replace.
Correct it within permissible value.

2.

Abnormal misaJignment between

turbine and driven machine.

2.

(Refer to "INSTALLATION AND PIPING" and "ALIGNMENT".

3.
sup p ly Refer to "Insufficient L.O. and pressure ,, mentioned later in this Table 7.1.

3.

Air, water or foreign matter mixed in

oil.

Overheating of bearing

4.

Incorrect selection of oil in oil tank.

4.

Replace oil with correct one.

(Refer to "LUBRICANTS")

5.

Shortage of oil in oil tank and of oil supply and of oil pressure by main

5.

Refer to "Insufficient L.O. supply and ,, pressure mentioned later in this

Table 7. l.

L.O. pump.
6.

Vibratio n.

6.

Refer to "Vibration
in this Table 7.1.

,,

mentioned later

7.
8.

Deterioration or pollution of L.O.

7.

Replace oil.

High temperature of L.O. main L.O. pump.

supplied by

8.

mentioned later in this Table 7. 1.

Refer to "High temperature of L.O. ,, supplied by main L.O. pump

1.

Shortage of oil in oil tank.

1.

Add oil.

2.

Abnormai condition of main L.O.

2.

pump.

Check clearance between shaft and bearing of main L.O. pump and correct
it by replacing bearing if necessary.

Check axial thrust clearance between pumping gear and bearing of main L.O. pump and replace bearing if necessary.
Insufficient L.O.

supply
3.

and pressure

Abnormal oil escape from L.O.

pressure adjusting valve.

3.

Increase oil pressure by adjusting valve.

(Refer to "ADJUSTMENT FOR

ACCESSORIES AND EMERGENCY

TRIP")
4.

Air mixed in oil.

4.

Draw air from oil strainer and L.O. cooler by plug or vent valve. Repair part from where air invades
into oil.

gl

St,!lNKO INO.LTO.
C )

Troubles

Causes

Remedies
5.

5. Water mixed in oil.

Draw water from oil tank, oil strainer

and L.O. cooler by plug or drain valve. Check and repair cooling tube of L.O.
cooler if necessary.

Insufficient L.O.

sup ply

and pressure

Check steam leakage from turbine

gland into reduction gear casing and replace labyrinth packing if necessary.
6. Foreign matter in oil.
6.

Clean oil strainer by turning handle on

oil strainer.

1. Foulling ofcooling tube of L.O.

cooler.

1.

Clean cooling tube of L.O.

cooler.

2. Insufficient cooling water flow to L.O. cooler.

2.

Increase cooling water by openin*

cooling water inlet and outlet vaives for L.O. cooler and keep L.O.

High temperature of L.O. supplied by main L.O. pump

temperature between 20 and 45

suitable for correct bearing temperature.

3. Abnormal operation of L.O.

temperature control valve, if fitted.

3.

Repair to work correctly.

4. High temperature of coolmg water

to L.O. cooler.

4.

Decrease cooling water temperature.

1. Excess ofsealmg steam supply

(In case of exhaust steam is

1.

Adjust sealing steam adjusting valve provided on this line.

vacuum)
Steam leakage from turbine gland
2. Excess of clearance between shaft and labyrinth packing.
2.

Replace with new packing.

1. Damage of bearing.

1.

Check bearing and replace if necessary.

Correct it within permissible value.

2. Abnorrnalmisalignment between
turbine and generator.

2.

(Refer to "INSTALLATION AND PIPlNG" and "ALIGNMENT")

3.

3. Excess of bearing clearance.

Replace bearing.

4. Unbalance ofshaft due to damage

Vibration
of blades or shrouds or bending
of shaft.

4.

Check and correct or replace with great consideration and dinamically rebalance.
Correct or replace labyrinth packing.

5. Abnormal contact between shaft

and labyrinth packing.

5.

6. Thermal deformation of shaft or casing due to insufficient warming

up or turning or excessive outside
force, Iike incorrect piping.

6.

Check and correct. Warm-up sufficiently and turn turbine manually and sufficiently.

SHINKO INO.LTD.

Troubles

Causes
7. Accumlated drain in exhaust casing
and drain in inlet steam.
7.

Remedies
Discharge drain by drain valve or plug. Clean drain separator and drain trap.

Vibration

8. Abnormal teeth contact of reduction

gear and driving gear of main L.O.

8.

Check and correct.

pump and speed governor.

l. Abnormal contact or damage of teeth

of pinion and gear wheel, driving gear

l.

Check and correct parallel between pinion and gear wheel, and driving
gears.

of main L.O. pump and governor.

Noise
2. Insufficient oil spray to teeth of pinion, gear wheel or driving gear
2.

Correct teeth by shaving or grinding machine, etc.

Clean oil spray to teeth.

of main L.O. pump and governor.

1. Sticking in movement of governor

valve, valve stem and valve guide.

1.

Check and correct to move smoothly

or replace.

2. Wear or sticking ofjoints and

pins of linkage.

2.

Correct to move smoothly or replace.

Hunting in operation and

difficulty of speed control caused by turbine itself

3. Incorrectselection of oil in

3.

Replace with correct oil.

govemor.

(Refer to "LUBRICANTS")

4. Deterioration or pollution of L.O. in governor.

4.

Replace oil.

5. Incorrect operation ofgovernor.

5.

Refer to manual of Woodward

governor.

SuINKO INO.LTO.
C )

CHAPTER 8 REPLACEMENT PARTS

This chapter introduces replacement parts information for the turbine RX. When ordering replacement parts, include the following information:
1 . Ship's name

2. Shipbuilder and hull number

3. Service and model of the turbine
4. Parts' numbers and names shown in the parts lists

1414 \
1 402
1 461 ,

1 440 ~
1521 ~

/
L

l(

1 oo 1

7008-1 4. 7065-7
7008-1 . 7065-1

7008-2 7065-1
t~r, ~

~ 7008-3
231 7

1 089, 1 093

1 087 ~-~~~
1 460,

231 5

1 520 ll
1 050

// 1712

1 002 / 1 003 l~
1012
1 020

//~2115 _~/ 7128

2 1 08

2101
~.,

1015 "

2 1 07

2119
2 1 24
7 1 29

2113
7 1 26

=~~

21 1 6 2 1 20

1401
1 430

21 25

2117

// 7053-27

2114
7 1 27

L~:

2118
1 432

1433 /

SuINKO INO.LTO.

PART NO.
1 Ool

NAME OF PART
EXHAUST CASI NG

REQ.
1 set 1 set

PART NO.
2113
2114
21 1 5

NAME OF PART

REQ.
1 set

1 002

STEAM CHEST
PACKI NG CASE

1 003
1 ol 2 1 O1 5

1 set

LABYR INTH PACKI NG

2 sets
1 set

2116
2117

BEARING METAL BEARING METAL BEARING METAL BEARING METAL

TH RUST METAL
TH R UST M ETAL

1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set

1 set 1 set

STEAM GUARD
SPRING

1 020
1 050
1 087

8
1 or 2 1 or 2
1 set or 2 sets
1 set or 2 sets
1

2118

NOZZLE
STATIONARY B, SEAT

2119 2120 2124 2125

231 5
231 7

THRUST METAL
TH RUST M ETAL

1 089

STATIONARY BLADE

1 093
1 40 1

SHROUD
TURBINE SHAFT ROTOR DISC

OIL GUARD OIL GUARD

TACHOMETER ROTOR
TACHOMETE R TRANS. CAP SCREW CAP SCREW CAP SCREW CAP SCREW

1 402
1 41 4

1 1 1 1 1 1

KEY
TH R UST CO LLAR

7008-1

1 430 1 432
1 433

7008-2 7008-3
7 008- 1 4

BALANCE WEIGHT
TRIP SHAFT

1 440

NUT
Ist MOVING BLADE

7053-27
7065-1

KEY
SPRING WASH ER

1 460
1 461

1 set
1 set 1 set

2nd MOVING BLADE

7065-7
7 1 26

SPRING WASHER
TH E RM OM ETE R
TH E RM OM ETE R
1 1

1 520
1 521

SHROUD SHROUD
DRIVING GEAR REDC. GEAR CASING

1 set
1

7127
7 1 28

1712
2101

1 set
1 1

7 1 29

THERMOMETER THERMOMETER

1
1

2107
2 1 08

WHEEL
WHEEL SHAFT

SulNIKO INlb.L7b.
C

COVERNOR VALVE

1 340 7061-29, 7051 -16

1 337

----~__

'~\\'
\

1317
1 341 =-1 304

\\\\ 1 730 1 753 706 1 -32,

6101. 7055-22 \

\.

1302 \_ 1 305 __
1 306

\\

\\

7051-10

\\

\+

1 752

7074-1 O
1 331

1 330 ---

1301 -__
~~/~~~~ ___/ 7074-1 2 ~ _~_/-

1 333 1 335

__~~ 1 322
=.~ - 1203 =1 7074-2 /

\;
\\-.

/
7008-24 /

~'l
PART NO.
1 7 30

PART NO.
1 203
1 301

NAME OF PART
STE AM STRAINER

* R E O.
1

NAME OF PART

R EO.
1 1

1 302

1 304 1 305 1 306

V. CASING GOVERNOR V. COVER GOVERNOR lrl,,,,~~ SPRING ~ - ,~-1 1

1752
1 753

LEVER GOVERNOR HOLDER

BUSH

6101

BUSH STEM
SPR t NG HOLDER

7008-24
1 1
1

7051 -1 O
705 1 -1 6

1317
1 322

STUD CAP SCREW RtNG SNAP RING SNAP

2 2

VALVE GOVERNOR
P LU G

7055-22
7 06 1 -29

NUT
PIN PIN
1
1

1 330
1 331

V. LtNER 1 IL 1 GOVERNOR
GUtDE GUIDE BUSH BUSH 8USH BALL BEARING
LINER
1
1 1

706 1 -32

1 332

7074-2
7074- I O

GASKET PACKI NG

1 333

GASKET PACKtNG
GAS CET PACK,NC

1 334
1 335
1 337

7074-1 1

7074-1 2

GASKET PACKING

1
1

1 340

1341

SuINKO INO.LTO.

TR,P SERVO -MOTOR FOR UG 8 GOVERNOR

1721
7061-33, 7051 -6

PART NO.
1 721

NAME OF PART
LINK

RE(L
1 1

1 724
C 1 830

CONNECTiNG BAR
ASSEM B LY

1 set
1
1 1 1
1

1 830

CYLINDER
COV E R

1831

4750-2
1 7 24

> J m ~;
LU

1832
1 835 1 836
1 837
1 84 1

BUSH
PISTON

1 841

(1)

co a:

SPINDLE

4750-1

7061 -41 , 7051 -9

1 837

o H o ~:

ROD END NEEDLE BEARING

SPR I NG

1 1
1

1 836

3870-5
1 832
1 83 1

o > a:
UJ co
rL

1 842
1 843

SPR I NG

3870-5
7051 -9

OIL SEAL

a:

7072-1 8
1 830
n' li,i[,

7057-7
706 1 -4 1

SNAP RING U-NUT

PIN

2
1 1 1 1 1

7072- 1 8

1 835
li

4750-1

SEAT PACKI NG BALL JOINT (L-TYPE)

BALL JOtNT ( L-TYPE)

7057-7
l i,

47 50- 2
705 1 -6

li

1 843
1 842

SNAP RING
PIN

2
1

7061 -33

1 755

FOR PGD GOVERNOR

1 758
C 1 830

1 830
1 831
1 837~.
1 84 1 ,..

ROD END BALL BEARING ASSEMBLY CYLINDER

COV E R

1
1

1 set
1

1
1

7061 -41 , 7051 -9

:l
1 755
lll I~

> J oo
~~ UJ co co a:

1 832 1 835 1 836

1 837

BUSH
P I STON

1 1 1
1

1 836 \.

3870 5 \
1 832
1 83 1 l _JL\~::JJJl' ' 7072-1 8

SPINDLE

7061 -33,705 1 -1 7

1 758

o H o :~

1841
1 842

ROD END NEEDLE BEARING

SPRING SPRING
OIL SEAL

1 830 1 835

I ~~,rH
T[
I 1,Il l ll

o > a:
UJ co CL
:c

1 843

7057-7
1 843'

3870-5
7051 *9

1 842

.l

7057-7
7 061 -41

SNAP RING U-NUT

PIN

2
1
1

7 072-1 8

7051-17
7 06 1 -33

SEAT PACKtNG SNAP RING

PIN

2
1

SlllINKO INb.LTO.
C )

MAINL.O. PUMP

PART NO.
1 703 1 705

NAME OF PART

R EO.
1 1 1 1 1
1

~1~~ L'I~~~~Gd~ E RNOR COY~LING_

DRIVING SHAFT SPACER 1 709 BALL BEARING 1710 BALL BEARING

1 7 1:~ ;;~ijN~~n~bLLI~GGEAR

8001

2054
7057-9 3870-7

C2051 ASSEMBLY

set
1 1
1

2051 CASING~ ~~~~~

1 1

2053 DRIVING SHAFT

_ __ __2._054 FO L LOW_ I N G SHA FT

2064
2061 7057-8

2063
2051

>
1711
3530- 1
co
cl'

J co ~ UJ ~ D d J
z CL

2055 DRIVING GEAR 2057 FOLLOWING GEAR

2051}~91 BEA R I NG

set

set

2059 2055
7053-21

3540-1
1 709

- BEARING METAL 206,~__ 2060

2062 2063 2064
3870-7
3870- I o
7 05 3-2 1

1 set

BEARING METAL
BUSH BUSH

1 set
1
1 1 1

2057 2060 7053-22

3870- I o

1 703 1 705

-+

1710 2129
7053- 1 8

OIL SEAL
Ol L SEAL

2062 2053
2 1 30

1713

l. ~

7053-23
7057- 1 2

7053-22 7053-23 7057-8 7057-9

7057-1 2
21 29

2130
3530-1
3 540- 1

7053- 1 8

800 1

KEY KEY KEY U-NUT U-NUT U-NUT DRIVING GEAR FOLLOWING GEAR BEARING NUT BEARING WASHER KEY SPEED GOVERNOR

1
1

1 1
1 1

1 1 1 1 1 1

SuINKO INO.LTO.

TRIP DEVICE

PART NO.
1 434 1 436 1 450 1 605

NAME OF PART
O.S.T. WEIGHT
SPR I NG

R EO.
1 set
1 1 1 1

ADJUSTING LINER TRIP LEVER

SPR I NG

1911
1 922

1 608
1 91 o

C 1901
1 901

ASS EM B LY
CAS I N G

1 set
1 1 1
1 1

1921 ---

3870-6

1914
1 907 1 903

~ 1 902
1 91 2

1 902 1 903 1 905

COV E R COV E R

4020-2 1913
7057-15 -

1 905
1 90 1

1 906

1920 ~

3870-8
1 906

> J tD ~ UJ
co co UJ

1 907 1 908

1 909

BUSH BUSH BUSH SPINDLE SPINDLE

GRIP GRIP SPRING
SPR I NG

1
1

1910
1911

1
1

o
1 908 1 923 1 909 1 605 1 608 7061 -30, 7051 -1
ll ll
i

UJ
'L

> D
tC

1912 1913 1914

1 920

1
1 1

SPRING LINER

1 1 1
1 1 1

1434 \\

1 450 1 436

1921

~\

'!'f

l~

1922 3870-6 3870-8 4020-2

7057-1 5

LEVER FULCRUM BOLT

OI L SEAL

OtL SEAL
B E L LOWS

U-NUT

1
1

1923
7051-1
7061 -30

BRACKET
SNAP RING
PIN

2
1

cg SulNIKO INIO.LTb.
C

L . O.

COOLER
7301-6 l; 730 1 -5 / / 7301-9B ~~ 7301 -3

PART NO.
7 30 1

NAME OF PART
ASSEM B LY

R EO.
1

set
1

730 1 -2
730 1 -3

INLET HEAD

RETURN HEAD
TUBE SHEET TUBE SHEET COOLtNG TUBE

730 1 -4
730 1 -5

1
1

7301 -6

7301-9A
7301 -9B
7301 - 1 1

7301 -1 2

L.O. P R ESS. ADJUSTINC

V.

7801
7801 -1
780 1 -2 780 1 -3

GASKET GASKET STU D &NUT BOLT &NUT ASSEMBLY

CASING

set
1

VALVE
ADJUSTIN G SCR EW

7801 -4
7801 -5
780 1 -6

SPRING
P LU G

GASKET

781 1
L.O. +\ \

ASSEM8LY
FILTER

se t

781 1-3
781 1 -8

set
1

781 1 -6
781 1 -7

SPINDLE

HANDLE
PACKING AIR PLUG DRAIN PLUG
1

781 1 -8 781 1 -9

set
1

781 1-1 O

ll

PRIM. L.O. PUMP ( I f fitted ) _~_ 8301 _~~ 830 1 -~ 8301 ~_~= 8301 830 1 8301 83 o 1

8301
8301 -5 8301 -6

ASSEMBLY ROTOR
8ALL BEARING BALL BEARING

1 se t
1

set
11

8301 -7
8301 - 1 6 --8301 - 1 5

830 1 -9
8301 - 1 1

FAN
IMPELLER FAN COVER

8301 - 1 3

8301 - 1 5

CRIMP TERMtNAL
TERMINAL BOX OIL SEAL

3
1

8301 - 1 6
8301 - 1 8

cg SHINKO INO.LTO.
C J

PRIM. L.O, PUMP (If fitted)

PART NO.
8302
8302-1

NAME OF PART

R EQ.
1 set
1 1 1

ASSEMBLY
CAS I N G

CASING COVER DRIVING SHAFT 8302-4 FOLLOWtNG SHAFT

8302-2 8302-3

8302-5
8302'-6

PUMPING GEAR PUMPING GEAR

1 set

8302-7

1 set

8302-8 8302-9
8302- I O

BEARING METAL BEARING METAL

1 set

> J ao
8302-20 -___
8302-1
3 1 80-2
3 1 90*2
l,

8302-1 1
1 set
1

..,\.-

:~ UJ co co oL :~ :) o*

8302-1 2
8302- 1 3

7 053-32

8302-21
8302-1 8
8302-1 5

8302-1 9
7 008-62 // /~~/'/ 3530-3 l/'/ I l 8302-1 7

8302-3
l

8302-4
8302-1 O

8302-9 17053-33

BUSH 8302- 1 4 BUSH 8302- 1 5 SPACER d 8302-1 6 ADJUSTING LINER J ~ 8302-1 7 BALL BEARING oc tL 8302- 1 8 BEARING COVER 8302- 1 9 COUPLING 8302-20 COUPLING
8302*21
3 1 80-2 3 1 90-2

1 1 1 1 1 1 1 1

8302-7

8302-5 8302-6

OI L SEAL

7053-34

8302-1 2,// ~
8302-1 4
7057-1 7

8302-8

ll

8302-1 1
8302- 1 3

3530-3

COUPLING BOLT & NUT RING COUPLING BEARING NUT

BO LT

4 sets

4
1

\8302-1 6
7057-1 6

7008-62

2
1
1

7053-32 7053-33 7053-34

7057-1 6
7057-1 7

8302-2

KEY KEY KEY

U-NUT U-NUT KEY ON MOTOR SHAFT

1 1 1 1

MOTOR
ROTOR AXIAL MOV
. DETECT. (If fitted)

1 set
1 set
1

HEAD ASSEMBLY
> J :o
:~
~UJcl)
Ocod :~~

c 1 980

ASSEMBLY
CASING
E LEM E NT

1 980 1 984
1 998

BALANCE WEIGHT
1 984 1 980
I l

1 set
1

BRACKET

l I ~ Illi~L

f~ ~

Jo XI
Hh OUJ

J
l

- -- I ~~

l ~J - J-~

, PINt~ ~ll
/

QCo

-TJ
l

SET SCREW

__C. ~_~/

'LL
1 998

snl'VKO INb.LTb.
C )

SENTINEL VALVE
741 1 -10
741 1 -9

PART NO.

NAME OF PART
ASS E M B L Y

RE(l
1

J co ~ UJ
co co
UJ

>

741 1
741 1 -9
741 1 -1 o

set
1

SPRING CAP

li

li

> J > J uJ Z H z uJ
co

231 5

E LECTRIC TACHOMETER

R OTO R TACHOMETER

23 1 7

23 1 8

2325
{' !

TACHO. TRANSMITTER RECEIVER TACHOMETER TACHOM E TE RECEtVER R

S ETSC R EW

FOR CONTROL ROOM

23 1 5

701 0-37

701 0-37
23 1 8

2325

_ Jj

23 1 7

SOLENOID VALVE
745 1 -3 f' 7451-4 7451-10

7451
7451 -3

J Co ~ UJ
co co
uJ

>

7451 -4
745 1 -6

ASSEMBLY SLEEVE SPOOL

SPOOL SPR IN G
O- RING

set
1

7451 -7
745 1 -8

6
1

7451 -8
7451~7

7451.6

Tl

> J > D o z UJ J o U)

PUSH BUTTON
SOLENOID COI L

7451 -1 o

smNKO INO.LTO.

PREssuR E SWITCH

PART NO.
7161
7 1 63 7 1 74

NAME OF PART
LOW L O PRESS. TRIP

R EQ.
1 set 1 set

I o h ~ co
UJ oC :) co U) UJ oC

LOW L.O. PRESS. ALARM PUMP DIS. OVER PRESS. TRIP

1 set

7181

HIGH BACK PRESS.

1 set ALARM

~
7 1 78

PREssuRE SWITCH

ASSEM B LY

1 set 1 set 1 set 1 set

7178 1 7178 2 7178-3 7178

~~1 r~ --1 ~--l r~~~L----1 r --1 r--il I I t I : I I l i I

~ (D
(1)

o h

7 1 78-1

PRIM L.O.PUMP
L.O. PRESS. INTERLOCK

7 1 78.2

7 1 78.3

UJ oC

HIGH BACK PRESS. TRIP

D
CD uJ
oC 'L

LtM IT SWITCH

8454 I o H
Cl)

8458

OVERSPEED TRIP EMERGENCY TRIP

1 1

~r~1 ~
@
PR ESSURE GAUGE

~ H ~ J
7101
7 1 02
UJ

tN LET STEAM

1
1

7 1 04
7 1 05

o :) o
UJ oC :) (D
(1)

CHEST STEAM EXHAUST STEAM

1 1

GLAND STEAM
L.O.

7 1 08

1
1

7110
7111

UJ a: (L
l

PUMP SUCTION PUMP DISCHARGE

7 1 26

THERMOMETER

FOR L.O. COOLER FOR TURBINE

a: uJ

7127
7 1 28
7 1 29

TURBINE SHAFT LOWER SIDE WHEEL SHAFT UPPER SIDE WHEEL SHAFT
LOWER SI DE L.O. COOLER
L.O. INLET SIDE

TURBINE SHAFT UPPER SIDE

1 1
1

1 1 1

7 1 30

h UJ
:~

7131

L.O. COOLER L.O. OUTLET SIDE

O ~ CC
UJ

I h

SNINKO IND.LTO.
C )

TH E RMO-SWI TCH
( tf fitted,

PART NO.
7 230
7230-1 1

NAME OF PART
TURB,NF_ SHAFT UPPER StDE

R EO.
1 sot
1

7231
7231*1 1
:E

,NSTALL THREAD TURBINE SHAFT

LOWER SIDE

1 set
1

7230- 1 1
7231 -1 1 7232- 1 1 7233- 1 1

u h ~ U' O :~
a:

,NSTALL THREAO SHAFT 7232 WHEEL UPPER SIDE 7232- 1 1 ,NSTALL THREAD

1 set
1

1 set 7233 WHEEL SHAFT LOWER S,DE

7233- 1 1

tNSTALL THREAD

7230
7231

w I h

7232 7233

PART NO.

QUICK EXHAUST VALVE

74 1-7

NAME OF PART
BODY
VALVE BODY
DISC VALVE

REQ.
1 1
1

7481.1

7481-2
748 1 -3

7481-6 7481-2 7481-3

748 1 - 5
748 1 - 1

LU

748 , -9

748 1 -8
EXH .

> J
(o :D

7481-5

CHECK VALVE SEAT

1 1
1

7481~
748 1 -7 748 1 -8

IN

FROM 1~_L MAiN LO PUMP

TO OIL TANK

H ~ ~

CHECK VAKVE SPRING

VALVE SEAT

1 1

748 1 -9

VALVE SEAT GASKET

hl :, O

g D o

~'

TO TRIP SERVO-MOTOR

SHINKO INO.LTO.

INSTRUCTION MANUAL FOR DRAIN SEPARATOR FOR CARGO PUMP TURBINE

1 . Purpose for Drain Separator
(1 ) The Drain Separator is intended to remove the drain in the steam coming into the

Steam Turbine to prevent not only a decrease of the Steam Turbine's performance but also damages of the moving blades and the bearing metals.
(2) This Drain Sep~rator is so constructed that the steam coming, into the Drain Sep~rator circles in it and the Drain in the steam is gathered to the outer circle inside the Drain Separator and drained.

2. Installation of Drain Separator and Pipings A special attention is to be given for the installation of the Drain Separator and its

(1 ) The Drain S~parator is installed as low as possible to easily remove the Drain,and also near to the Steam Turbine. (2) The Drain Separator is securely fixed on its flat foundation with the bolts of M20, (3) The insulation is so constructed that the insulation is made thick enough to prevent as far as possible the steam in the Drain Separator becomes drain by radiation from the outside surrace of the Drain Separator. (4) The piping between the Drain Separator and the steam pipe is so connected that unreasonable force and moment do not effect as far as possible. (5) Special attention and consideration are sufriciently paid for the pipe supports and the hangers not to give bad efrect for,the pipings,

3. Opefation Manual
If the drain in the steam comes into the Steam Turbine it becomes th cause for several troubles. Therefore the drainage is to be carried out sutficiently before starting the Steam Turbine as follows;

(1 ) Warmihg up the steam pipings betwe~n the Boiler and the Drain Separator is
' sufficiently carried out by gradually opening the drain by - pass valve till no drain

comes out from the drain by - pass valve. ,

(2).After'confirming no drain coming out from the drain by - pass valve, the drain by pass valve is blosed and then the valve fitted on the Drain Trap Line is opened. (3) After sutficiently warming up th~ St~ani Turbine, the Steam Turbine is stared. (4) Dufing operating the Steam Turbine, no drain in the steam being supplied fs confirmed by opening the drain by - pa~s valve on the Drain Separator.

C~ I srnNKo IND. LTD.

c)

INSTRUCTION MANUAL FOR CENTRIFUGAL PUMP (CV)

This instruction manual describes construction, operation, maintenance, disassembling and assembling, etc. of model CV pump.

CONTENTS
Page

CHAPTER I CONSTRUCTION . . . . . . 82 - 2
2. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Pumpstuffingboxseal . . . . . . . . . . . . . . . . . . . . . . . . 3

6. Bulkhead stuffing box and intermediate shaft

with gear coupling . . . . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 2 CAUTION FOR INSTALLATION AND PIPlNG . . . . . . . 82 - 4

1. Place of installation and foundation . , . . , . . . . . 4 2. Finishing ofpump mounting seat . . . . . . . . . . . . 4
3. Caution for piping . . . . . . . . . . . . . . . . . . . . . 4 4. Suction piping . . . . . . . . . . . . . . . . . . . . . . . . 4 5. Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Permissible deformation ofbellows . . . . . . . . . . 5

7. Fitting offloating shaft . . . . . . . . . . . . . . . . . . 5

CHAPTER 3 OPERATION . . . . . . . . . . . . . . . 82 - 6
l . Check before operation . . . . . . . . . . 6
2. Starting . . . . . . . . . . . . . . . . . . . . 6 3. Stopping . . . . . . . . . . . . . . . . . . . . 6

CHAPTER 4 MAlNTENANCE . . . . . . . . . . . . . . 82 - 7
1 . Caution during operation . . . . . . . . . . 7
2. Ball bearing . . . . . . . . . . . . . . . . . . . 7

CHAPTER 5 STANDARD CLEARANCE AND LIMIT OF USE . . . . . 82 -10

CHAPTER 6 DISASSEMBLlNG AND ASSEMBLlNG . . . . . . . 82 -11

1 . Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 1 1

2. Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CHAPTER 7 TROUBLE SHOOTlNG AND REMEDIES . . . . 82 -13

CHAPTER 8 REPLACEMENT PARTS . . . 82 -15

9 1 SHINKOINb.LTO.

C)

CHAPTER 1 CONSTRUCTION
1 . GENERAL
The model CV pump is of a vertical single-stage double-suction centrifugal type, and the pump and driver are connected with the flexible couplings through an intermediate shaft and a bulkhead stuffing box, the construction being simple for ease of handling,
overhauling and caretaking.

2. PUMP CASING Fi9. I .1 The volute casing is split into two halves
along a vertical plane containing the axis.

Since the suction and discharge nozzles are provided on the rear half casing, the rotating element can be taken out by removing the front half casing (2) without
disturbing the suction and discharge pipings.

70
1

34

20
9
7
1

353 35d
4
1

ld,8
1

54A
1

A vent to be connected with the stripping

or priming line and an air valve are provided on the volute casing.

27 38
2
,
,

/
/
,~ ~

\\
/

lh

~LLI

3. IMPELLER
The impeller(16) is of the double-suction type and hydraulically balanced. It is so designed as to improve pump efficiency and
l

a , ,1 ll
,

1t
16
19

,, , / /
\

suction performance. Moreover, the impeller is statically and dinamically balanced.

~~ ll
/

,,

54B

t8

4. BEARING
The rotating element is supported by ball bearings on both sides of the pump casing. The 6300 type ball bearing is fitted in the solid inner case (14) with the split type bearing housing (7) and can be taken out together with the rotating element if the cap of the bearing housing (7) is removed.
(1) The ball bearing (34) at the coupling end
is secured in the housing by pressing its

L~~~
48
3
7

372
57 35

10

R EO. FOR PUMP

R EO. FOR PUMP

PAR T NO.

NAME OF PART
1

PART NO.

NAME OF PART

outer race by means of the cover(9).

This serves to support the weight of the
rotating element .

VOLUTE CASING

38
48-1

MOUTH RING
FLINGER FLINGER
MECHAN ICAL SEAL
PACK ING R ING

2
1

2 3
7- 1

VOLUTE COVER
PUMP BED

48.2

(2) The ball bearing(35) at the bottom end

is not fixed axially in view of the thermal expansion of the shaft (1 8).
7.2

BEARING HOUSING
BEARING HOUSING

54A MECHAN ICAL SEAL

54 B

1 SET 1 SET
1

9 10

BEARING COVER BEARING COVER

BEARING INNER CASE

57
70-1

(3) Grease is used as lubricant for the ball

bearing.

SNAP RING
SPLIT RING

141
1 42

70-2
70-3
1 46- 1

ISET
1

BEARiNG INNER CASE

SNAP RING

16
18

IMPELLER

MECHA. SEAL COVER MECHA. SEAL COVER

BEAR ING NUT
BEAR ING WASH ER
PACKING A ING

IMPELLER SHAFT IMPELLER KEY

1 46.2

19

353

20
27

COUPLING KEY
IMPELLER NUT

354
37 2

34 35

BALL BEARING
BALL BEAR ING

SNINKO INO.LTD.

5. PUMP STUFFING BOX SEAL

The stuffing box is so designed as to furnish the mechanical seal exclusively. Therefore there is no leakage of the liquid pumped and no air leaks into the pump. Moreover, the operation is very simple since no adjustment for the stuffing box during operation
is required.

Fig. 1.3

~~~~~!l

f
125
l

_:~~!=

'16

12e
IZ1

Mechanical seal Unblanced type mechanical seal is fitted and flushed by pressure liquid led from discharge side.
Fi9. I .2

401

426 I 411 l
'38 j
lo4 ,02 OHCX

441

a4:

,II

40,
13g a95 ,]s
1 31

t~Z~~]

52

,oT

5
1

~~

403

~)
Ito It2 14, 412
l05

lp

,15 4l9 lOO

13t

12g

5
5

1:3

~~@
1!a A

,T,
,8, ,1,

6
5
7
Close-up view of mechanical seai

139

7'
A

ll, l

(?1
lzo

,3a 430

541

F LOATING SEAT

542
5lh3

PACKING RING
PAC K I N G

CARBON RUBBER RUBBER

STA I N LESS STEE L
R Ea. FOR pUMP
REa. FOR PUM

544 545
546
5lh7

SEAL R ING

PART NO.

PACKING RING
SPR I NG
STOPPER R ING & SET SCREW

RUBBER
STA I N LESS STEE L STAI N LESS STE E L
401

NAME OF PAAT
BEARING SUFPORT
1

PART NO.

NAME OF PART

423B
424 425 426
427 428

HU8
COUPLING BOLT & NUT
PACK ING R ING

402 BEARING CASE

1 1

403 BEAR ING CASE 404 BEARING COVER 405 STUFFING BOX
4 06

PACKING R ING

For upper mechanical seal, A is attached, e.g. 54A-1

1
1

PACKING RING
PACKING R ING PACKING R ING

2
1

FLOATlNG SEAT, and tor lower one, e.g. 54B-1.

GL~ND
FLINGER COVER & PACKING DISTANCE RING DISTANCE RING BALL BEAAING BALL BEARfNG LANTERN RING PACKING RfNG
G LAND PACK ING

407 408

429
431

1 SET
1 1

430 COVER & PACKING

ISET
1 1

409 6. BULKHEAD STUFFING BOX & INTERMEDIATE 410 SHAFT WITH GEAR COUPLING (Standard)

A stuffimg box is provided where the intermediate shaft passes through the bulkhead to prevent the gas in the pump room coming into the engine room. If non-standard arrangement is fitted, it will be
shown later.

41 1

1
1

412

INTEAMEDIATE SHAFT 432 FLOATING SHAFT 433 COUPLtNG KEY 4 1 434 SNAP RING
435

413
414 415 416
417

BELLOWS
SEAT PACK ING
SEAT PACK I NG

436
437

2
1

SLEEVE SLEEVE 418A SLEEVE 418B SLEEVE 4l9 COUPLING FLANGE 4 20 COUPLiNG FLANGE

438
439
441

1 1

SPACER DOUBLING PLATE 440 PLUG

1 1 1

1
1 1

HUB HUB 423A HUB

42 1

BEAR ING NUT 442 BEAR ING NUT 443 BEAR ING WASHE R 444 BEAR ING WASHER

1 1

422

1 1

c!D

SuINKO INO.LTO.
C

2 CAUTION CHAPTER ANDPIPING FORIN STALLATION

In order to prevent occurrence periods with best efficiency and
of installation and piping.

of vibration and noise and to operate the pump over long safety the following points must be observed at the time

4 SUCTION PIPING l . PLACE OF INSTALLATION & FOUNDATION

(1) Size of the place of installation must be chosen in view of the pump disassembly and inspection. A space necessary for disassembly is shown in the outside drawing.

The piping on the suction side affects pump effi-

ciency to a great degree and to avoid troubles arising there from the following points must be
noted.

(2) The foundation must be strong enough to absorb pump vibration and to resist deformation against
10ng use.

(1) No air pocket must be formed in the piping.

(2) All fittings in the piping must be perfectly
tightened to prevent air invasion.

(3) The pump is placed on its foundation. The

driver with its bed is placed on its foundation with the bearing support ( 401 ) complete fastened at the bottom of the driver's bed.

(3) Care must be taken to prevent air leakage through glands of all valves in piping.

(4) The suction piping must be thoroughly cleansed

In this case, confirm that the distance "E" shown in the outside drawing, between the end faces of

so that pipe scale, welding beads and other

foreign matter do not remain, otherwise seizure and other troubles may result.
5

the coupling halves on the pump shaft end and the intermediate shaft bottom end must be as shown in the drawing. The permissible error of
this distance "E" is :t2mm. (Refer to Fig. 2.2).

ALIGNMENT

Tables 2.1 and 2.2 show permissible errors in alithrough the intermediate shaft.

gument when the pump and driver are connected

When installations of the pump and driver have
been finished it is necessary to check the alignment

2. FINISHING OF PUMP MOUNTING SEAT

Chockliners must be welded on the foundation
place just under the pump foundation bolt holes
and their faces must be planed so that they lie in

and if the errors exceed those shown in Tables 2.1

a perfect plane. When the foundation bolts are

tightened leaving gaps between the liner faces and

and 2.2 adjustment is needed. This work is also

necessary when pipings for them have been finished.

pump bed, deformation may be given to the pump

and besides vibration may result.

When the alignment has been completed set the

driver's bed and the pump bed on their foundation
by driving the dowel pins.
Table 2,1 Between driver & intermediate shatt

3. CAUTION FOR PIPING

Deformation given to the pump by outside force
due to incorrect piping causes not only vibration but also pump troubles. Therefore, the pipe flanges connecting with the suction and discharge nozzles must be correctly matched. Be sure to avoid the

Paranet misangnment A Angutar misalignrnent B at coupling (mm) at coupling (mm)

Below O . 2 (Between centers)

Below 0.2

cases shown in Fig. 2.1 otherwise the pump may receive unreasonable force. Nor must the pump be directly given deformation due to the total
weight of piping and thermal expansion.
Fig. 2.1

Table 2.2

Between intermediate shaft & pump

Parallel misalignment A

at coupling (mm)
(Between centers)

Angular misalignment B at coupling (mm)

Below 0.4

Below 0.4

PIPING PUMP

Angular misalignment

Parallel
m isa I ign ment

F Iange faces

do not touch

suINKO INO.LTO.

5.1

Between driver and intermediate shaft

5 .2 Between intermediate shaft and pump

(1)

Measurement of parallel misalignment As shown in Fig. 2.2, fix a dial indicator on the coupling at the intermediate shaft upper end for the alignment so that its spindle rests on the periphery of the coupling on the driver.

(1) Measurement of paranel and angular misalignments

As shown in Fig. 2.2, fix dial indicators on the

temporary shaft to be provided for the alignment so that their spindles rest on the periphery and the face of the coupling half on the

Give one complete turn at the same time to both coupling halves on the driver and the intermedaite shaft and read the difference

between the maximum and minimum readings

on the indicator.
(2)

intermediate shaft. Give one complete turn at the same time to both coupling halves on the pump and intermediate shaft and read the difference between the maximum and minimum readings on the indicators.

Measurement of angular misalignment In the same way as above, give one complete turn to both coupling halves at the same time

measure the gap between the coupling faces

(e.g. at each 90 deg.) using a feeler gauge, and

6. PERMISSIBLE DEFORMATION OF BELOWS WHEN FITTED

(1) Elongation or contract in vertical direction
:!:lO mm.

read the difference between the maximum and minimum measurements.

Fig. 2.2

(2) Angle deviation (Refer to Fig. 2.3) 5 deg.

(3) Perpendicular deviation (Refer to Fig. 2.4)

:!:8 mm.
Driver

Fi9. 2.3 Fi9. 2.4

50

~ ~
,,,

~]

~r

FEELER GAUGE
Parallel

'It,

li

ll

tl

mi: misalignment

~8

A
/
[

7. FITTING OF FLOATING SHAFT (LOWER INTERMEDIATE SHAFT)

It is strictly prohibited to fit the floating shaft

BE L LOWS
Angu I ar m i$ m isa I ignment

( 432 ) upside-down due to an abnormal thrust

force is given to the pump bearing. It is therefore
special attention should be paid for that the floating

shaft with the coupling marked with "C" is to be

B~c

fitted up and the other side marked with "PC" down.

TEMPORARY SHAFT

Pum p

SuINKO INO.LTD.
C )

CHAPTER 3 OPERATION
1 . CHECK BEFORE OPERATION
When operating for the first time after installation

2. STARTING
(1) Close the discharge valve completely and open
the suction valve fully.

or overhaul and assembly, it is necessary to do as

foilows.

(a) When the liquid level at the suction side is

(1) Take off dust preventing tape placed on the part where the pump shaft passes through and
take care so that no foreign matter enters the
clearance around the shaft.

above the pump the liquid flows into the

pump casing by gravity, so open the air vent valve on top of the volute casing to draw the air in the pump and close it when the liquid
begins to flow out of it.

(2) Give some oil to the mechanical seal. (Refer

to " MECHANICAL SEAL")

(3) Give a few turns to the coupling by a turning
bar and see if it turns normally.

(b) When the liquid level at the suction side is below the pump draw the air in the pump and
suction line through the gas vent on the volute

(4) Confirm if the rotation direction of the driver

is correct.

casing by means of stripping pump or some

other extracting devices so that liquid can fill the pump inside. In this case keep the air vent

(5) Confirm if the grease in the bearing housing

and the oil in the gear coupling, if fitted, is within the specified amount.
(6) Confirm if the driver is ready for the operation.

valve closed so that no air can enter the pump casing. Never neglect priming the pump.

(2) Start the driver gently and increase its speed

gradually .

(3) When the discharge pressure has risen reasonablly, open the discharge valve gradually and
fully .

3. STOPPING
(1) Close the discharge valve.

(2) Stop the driver.

SnINKO INo.LTb.

CHAPTER 4 MAINTENANCE
In order to eliminate pump troubles, to minimize parts consumption and repair and to maintain best efficiency over long periods the operator must aim at perfect maintenance
of the pump.

1 . CAUTION DURING OPERATION

(1) Never throttle the suction valve in any case during operation otherwise troubles may occur
due to dry operation.

(7) With lowering of the liquid level at suction side

suction pressure approaches the vapor pressure

(2) Never operate the pump for over 3 minutes

with discharge valve completely closed. When a centrifugal pump is operated without discharge, most of the power changes into heat
and as a result temperature of the liquid in the pump casing rises to the boiling point causing seizure of the interior of the pump and accident

of liquid and vapor develops in the suction line and pump suction inlet and, moreover, air is sucked through the suction bell-mouth
until pumping ability decreases to such extent
that discharge stops.

In order to prevent this, vapor and air coming

into the pump inside must be drawn through the vent on the casing by means of stipping
pump or some other extracting devices.

may occur.

(8) When cavitation occurs even though the pump

(3) Never operate the pump with dry condition.

(4) Except that the driver is with the constant speed like electric motor, keep the discharge
valve open in full and it is desirable to adjust discharge flow by changing speeds. The adjust-

speed becomes minimum, discharge must be

decreased by throttling the discharge valve. If this remedy is ineffective stop the pump.

2. BALL BEARING
(1) In consideration of lubricating ability of the

ment of discharge flow by the degree of dis-

charge valve opening is not recommendable

because of loss of driving energy.

grease and running clearance of the bearing due to thermal expansion and liquid temperature pumped, the bearing temperature is so
designed as to stand up to 900C.

(5) When operating more than 2 pumps in parallel be sure to keep the discharge pressure of each pump always equal. If the speed of some pump decreases during operation and its shut-off pressure drops below the discharge pressure of the remaining pumps, it is operated wlth zero flow even though its discharge valve is opened and thus the result will be the same as
mentioned in (2) before in this chapter.

However from viewpotnt 6f service life it is

desirable to keep it below 750C.
(2) For the lubrication of ball bearing grease is used.

The recommendable grease and the interval of replacement grease are shown in Tables 4.1 and
4.2.

In such a case try to make the speed of the pump in question same as those of the remaining pumps, and if this is impossible stop that pump immediately.

(3) For supplying grease for the bottom ball bearing, take the grease drain plug away.

3. MECHANICAL SEAL
(1) Cautions before starting and during standstill
Care must be taken so that no dust enters part(a)
in Fig. 4.1 .

(6) When operating the pump at the rated speed

and with the discharge valve open in full available NPSH decreases as the liquid level at the suction side lowers and finally discharge becomes
zero due to cavitation.

Pouring lubricating oil in (a), when the pump

is at a standstill , will prevent dust from sticking.

In such a case pumping ability can be restored if discharge is decreased, so for the reason

If dust accumulates here and sticks hard seal ring (544) may stick and sliding face (S) can not be tightened. When the pump is delivered,
a strip of cloth tape is put over the gap around

mentioned above lower the speed without

throttling the discharge valve as the liquid level
at the suction side drops.

the impeller shaft to prevent foreign matter

from invading.

SnINKO INlo.LTb.
C )

Fig. 4.1

(a)

(~)

[i)lug ~

~~~ ~~~~ T i J / ~ fjiUg A_

\:~emove~

11

~ e m o v el
Q) ci

>
r~

/ I LJ+- ---

L/~

ELo

U
t/~

T)
EL c]

(b) Fill oil through an oil plug hole on the

coupling by using pistol oiler till the oil

~)

Ll

begins to flow out from the other oil plug

hole on the opposite side.

(3) Leaking from mechanical seal

Co u i) I i ng

Under normal operational conditions there is no leakage, but in case there is a leakage of over 30cc/h there must be some trouble inside,
so a remedy must be taken as early as possible. (4) Heating of sliding parts and abnormal noise.
Insufficient flushing to the sliding face causes

A I ,' ga p
Ov e "' f t ow

O-ring
Gear oi
( so

vc}4so-~80)

abnormal wear down of the carbon due to

heating and dry contact. If flushing

temperature rises to more than 10~C above the liquid temperature being pumped, it is
necessary to trace the cause and remove it.
(C)

O rin~ CouJling
C

'i

After the oil, put twolu plugs back After filling fillin the oil ut two s back toto

the coupling with Teflon seal tape on them.

When operated under the condition of dry

contact, abnormal sliding noise may occur.

Apply several turns to the shaft so that

the oil may reach the interior of the coupling. If too much oil is filled,
excessive oil may leak from the key way but this is acceptable because necessary
oil is kept in the coupling.

4. GEAR COUPLING (Standard)

(1) Misalignment between pump and driver Since the gear coupling has sel~alignment action to some extent, small misalignment within the permissible values shown in Table
2.1 and 2.2 can be absorbed.

5. BULKHEAD STUFFING BOX (Standard) (1) When operating for the first time after
repacking the stuffimg box tighten once the gland firmly before starting, then loosen the
gland nuts to such extent that the coupling can
be turned lightly by turning bar.

However the excessive misalignment causes

t,oo much slip between the teeth and as a result

wear becomes excessive, vibration occurs and the coupling may be damaged. (2) Lubrication
Lubrication oil has a very important function in

(2) Supply grease to the gland packing for

lubricating and to keep gas-tightness between the pump room and engine room. The recommendable greases and the interval of replacement grease are shown in Table 4.1 and
4.2.

reducing friction and wear and in hydraulically

distributing contact pressure on the gear

flanks by forming oil film in the gap between them.

The recommendable oils and the interval of replacement oil are shown in Tables 4.1 and
4.2.

(3) Start the pump and adjust the gland nuts

gradually and evenly. If the gland is tightened suddenly or too much or unevenly there may be a danger of seizure of overheating.

(3) Filling lubricant oil

(a) Remove two oil plugs.

(4) If the packing becomes deteriorated the

tightness can not be kept no matter how much
the gland is tightened.

In such case renew the packing.

SuINKO INO.LTO.

6. MAINTENANCE CHECK LIST

Maintenance and check for the followings can extend a life of the pump.

Item
Suction pressure

Inspection procedure

Remedy in case of trouble

Check every tinre if there is any

abnormal pressure drop
Check and record every time.
Check oil in gear coupling every time
through oil hole on it.

Stop pump immediately and check suction

line .

In the case of above ambient temperature

Bearing temperature

plus 40~C or above 85~C, stop pump and

eliminate cause.

Lubricating oil

Supply oil if necessary.

Ball bearing

Check abnormal noise every time.

If abnormal noise or overheating occurs, stop pump and eliminate cause, and renew
ball bearing if necessary.

Mechanical seal

Check leakage, heating, noise every

t ilne .

Stop pump and remove cause.

Check alignment.

Vibration

Check vibration every time.

7. LUBRICANTS
(D Replacement oflubrication
The replacement of the lubricants is based on
deterioration or contamination of the lubricants

Table 4.1

Replacement
Location
After initial start

being used. However, Table 4.1 shows

recommendable replacement. (2) Lubricants

Normal o peration

Within 3 months

NLGI No. 2(National Lubricating Grease

Institute) for grease for the ball bearing on the

Ball bearing

Every year
Every 6 months

pump and intermediate shaft and for its stuffing

Gear Coupling
Bulkhead stuffing box.

,,
Every o peration

box, and for the gear coupling, ISO VG 460680 gear oil are recommendable. The brand names of the lubrjcants equivalent to the recornmendable ones are shown in Table 4.2.

Every o peration

(3) Grease amount

Pump model
Pump upper side bearing (g)
Pwnp lower side bearing (g)
Intermediate shaft upper side bearing(g)

cV 350
50 30 70

CV 400-2
50
30

Cv 450
110

cV 500-2
150 110

70
110

70

150 150

Intermediate shaft lower side bearing (g)

70
Bulkhead stuffing box (g)

70 240

110

240

280

300

(4) Gear oil amount

Pump model
Turbine side gear coupling (cc)
Intermediate shaft side gear cou pling(cc)

cV 350
180 130

CV 400-2
180
130

CV 450
180 130

CV 500-2
310
190

Pump side gear coupling (cc)

130

130

130

190
In case of a long standstill, clean each

8. STANDSTILL
When there is a fear of freezing, drain the pump completely after stopping.

sliding part thoroughly and apply rust preventive where necessary.

SHINKO INb.LTO.
c
)

Table 4.2
Crcase (*NLGI N0.2)

Gear Oil (fSO VC 680)

~lame of compan,_'

IDEMITSU KOSAN DAPHNE EPONEX EP2

BEACON EP2 LISTAN EP2

DAPtiNE SUPER CEAR O[L 680

SPARTAN EP 680

Dxxorl

MOBIL OIL
NIPPO~' O]L

MOBIL VX 2 MOBIL PLEX 47

MOBIL CBAR 634 OR 636

EPINOC GREASE AP2

MLfLTIFAK EP2
LISONIX GREAS!~ EP2

BONNOCK M 680
MEROPA LUBRICAr,T 680

CALTEX OIL

JoMo
MITSUB[SHI OIL

REDUCTUS 680

DIAMOND MULTIPURPOS N0.2l][AMOND GEAR LUBE SP 680

GULF OIL
BP OIL

CULF CROWN GREASE NO 2 CLILF EP LUBRICANT HD680

BP ENERGREASE MM-EP-2
MLfLTIFAK N0.2

BP ENERGOL CR-XP 680

TEXACO OIL

TEXACO MEROPA 6~O

CASTROL ALPtlA SP 680

CASTROL
COSMO OIL

SPHEEROL AP2 OR EPL2

COSMO CEAR SE 68(] COSMO CREASE DAINAMAX N0.2

ALVANIA GREASE N0.2 AL1/A*NIA CREASE EP2

SHOWA SHELL OIL

O~IALA OIL 680

GENERAL SP CEAROL 680

GENERAL OrL
ELF

GEMICO GREASE MP-2

EPEXA 2

EPONA Z680
~L GEAR COMPOUND 680 or EP680

CHEVRON

DURA-LITH GREASE EP2

AND LIMIT OFUSE 5 STANDARD CLEARANCE CHAPTER

The bigger the clearance between impeller and mouth ring becomes, the more the counterflow from discharge side to suction side becomes, and consequently pump capacity decreases.
Table 5.1
Unit :

mm

Name of parts

Model

New parts
S t and ard

Limit of use
a

clearance a
Im peller an d

Length b
15.9 15.9 15.9
15.9

el

d~~L

CV 350
400-2

0.35

1.5
1.5 1.5

13
13 13

mouth ring

0.35

Floating seat

of mechanical seal

rb

450
! 5 OO*2

0.40 0.40

1.5

13

SnINKO INO.LTD.

6 DISASSEMBLING AND AssEMBLING CHAPTER

1.

DISASSEMBLING
In order to replace impeller, ban bearing, ring, etc., disassembling of pump is carried
follows.

Fig. 6.1

mouth
out as

1 .1 Removal ofvolute cover (1) Remove the sealing pipe for the mechanical seal.

(2) Loosen the nut for the mechanical seal cover (146) until the mechanical seal cover moves
and touches the flinger (48).

(3) Remove the volute cover nuts and move the volute cover (2) forward by using the two
lifting bolts.
L1

I I \ \ \\

l .2 Removal ofrotating element (1) Remove the coupling bolts.

(2) Remove the bearing housing cap after removing

the nuts fastening the cap.

(3) Take out the rotating elements together with the bearing inner case (14), bearing covers
(9 & I O), ball bearing, etc. with paying attention

to the mouth ring (38) and mechanical seal.

l.3 Removal ofball bearing

(1) For the upper bearing, remove the coupling

after removing the snap ring (70-1).

1 .4 Removal ofmechanical seal Since the mechanical seal for this pump has a large spring compression allowance and force, the special tool provided must be used for re-

moving the mechanical seal and ball bearing

from the shaft.

Remove the bearing cover (9). Make straight the rotation preventing piece on the washer (354) which is bent into one of the slots along the bearing nut (353) periphery and remove the bearing nut.

(1) As shown in Fig. 6.2 hold the tool in such

a way that the spring force does not act upon the flinger (48), and maintain not to transmit directly to the mechanical seal the shock produced when the ball bearing is removed.

(2) For the lower bearing remove the bearing

cover (1 O) and the snap dng (70-3).

(2) Remove the ball bearing and flinger from

the shaft .

(3) Compress the mechanical seal spring by using the special tool provided as shown in Fig. 6.2

and also mentioned m "Removal of mecha

nical seal".

(3) Loosen the special tool bolts to reduce the spdng force and remove the special tool as
shown in Fig. 6.3 .

(4) Since the ball bearing is pushed lightly onto the shaft, it can be removed wlth the inner
case by using puller.
Fi9' 6,2
SPEC,AL TOOL ,SUPPL,ED,

(4) Remove the mechanical seal from the shaft.

Fig. 6.3
~ '."=" '
- 5cnl

BALL BEARINC

SPRINO
STOPPE R,NG
FLOATfNG SEAT ET SEAL SCREW RtNG

FLING R

snINKO INO.LTO.
C )

l .5 Removal ofimpeller The impeller shaft diameter where the impeller

(16) is fitted is the largest and gets smaller to-

(2) Take care not to injure sliding face and "O"

ring by hitting or scoring.

(3) When fitting be sure to apply lubricating oil

to "O" ring .

ward either end. Fixing the impeller is by the impeller nut (27) at the upper side and by the split ring (70-2) at
the lower side.

(4) Referring to Fig. 6.2 the floating seat (54-1)

(1) Remove the setscrews on the impeller nut (27) and remove the impeller nut after removing the ball bearing, the flinger and the
mechanical seal.

(carbon) must be inserted by hand until it touches bottom of the cover (146) firmly
taking care not to injure sliding face.

(5) Place the stopper ring (54-7) against the shaft

shoulder which forms fitting base and tighten

it by th*e setscrew.

(2) Remove the impeller from the shaft. However, if it is difficult to remove the im-

(6) Confirm the winding direction of the spring

if it is suitable for the rotation direction of

peller from the shaft, warm the hub of the

impeller slightly to ease working.

the pump. Refer to Fig. 6.4.

2. ASSEMBLING
Assembling can be carried out by reversing order of disassemblirrg and attention must be paid to
the followings.

(7) Fit rotating elements of the mechanical seal

and the cover (146) onto the shaft.

(8) Afterward, apply the special tool and compress

the spring evenly as shown in Fig. 6.2.

(1) Clean each part thoroughly to remove rust

and scale, and be sure there are not injury and
burr in fitting parts.

(9) Fit the flinger and the ball bearing onto the
shaft, Ieaving the special tool as it is as shown

in Fig. 6.2 to compress the spring until the

rotor is settled in the volute casing.

(2) Assemble fitting parts according to match

marks if any.

(lO) After settling the rotor in the volute casing

remove the special tool.
Fig. 6.4

(3) Turn nuts for rotating parts securely and fix

anti-rotation device without fail.

(4) Be sure to thoroughly cleanse the ball bearing

with pure kerosene taking care to keep off

dust and foreign matter.

STOPPER RING

STOPPER RING
SEAL R ING

2.1 Alignment Aligument is to be confirmed if it is within

the specified limit shown in Tables 2.1 and 2.2

SEAL RING
/
l
l

in " ALIGNMENT" .
Right-hand winding
L eft -ha nd

winding

2.2 Assembly of mechanical seal

Use the special tool for assembling the mechanical seal as shown in Fig. 6.2 and 6.3.

IMPELLER SHAFT

IMPELLER

(1) Slidmg face "O" rmg and "O" ring groove must be claned with leadless gasoline and wiped with soft cloth taking care to keep
off dust and other foreign matter.

SHINKO INO.LTO.

CHAPTER 7 REMEDIES SHOOTING AND TROUBLE

Pump can perform satisfactory function if properly handled and maintained.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest
causes of trouble and suggested remedies.

Table 7.1

Troubles
1.

Causes
Pump not completely or insufficiently
filled with liquid.
2.
3.
1.

Remedies
Prirne once more,
Check suction line. Check suction line. Check by suction gauge on suction side.

Much air leakage in suction line. Air pocket in suction line.

Suction lift too high.

2.

3.

4.

4,
5.

Pump cannot discharge

Wrong direction of rotation. 6. Suction strainer and suction line clogged. 7. Speed too low. 8. Impeller clogged,
5.
1,

Check.
Check interior of suction line.

6.

7.
8.

Check by tachometer. Check pump interior.

Check suction line and stuffing box,

Air leakage.

1. 2.

2.

3.

Speed too low. Discharge head too high.

Suction lift too high.

3.

4.
5,

4.
5.

Insufficient discharge

Suction pipe bell-mouth not sufficiently submerged , 6. Suction strainer and suction line clogged. 7. Impeller clogged. 8. Wrong direction of rotation. 9. Excessive clearance between impeller

Check by tachometer. Check by discharge gauge. Check by suction gauge. Check.

Check interior of suction line.

6.
7.
8.

9.

Check pump interior. Check. Replace mouth ring by new one.

and mouth ring.

Pump discharges liquid
after starting, but soon fails to discharge
1.

2. 3.

Pump not sufficiently filled with liquid Air pocket in suction line.
Much air leaks into suction line. Air leaks through stuffing box.

1.

2.

Prime sufficiently. Check piping and if wrong correct it.

3.

4.

4.

Check suction side. Check if mechanical seal is incorrectly fitted or carbon is broken.

1.

Speed too high (Power frequency too

high) Impeller touches mouth ring.

1.

Lower speed, (Frequency)

Check state of installation and

2.

2.

Prime mover overload

Rotating elements touch stationary element due to bent shaft. 4. Casing deformed. 5. Voltage too low (Constant input, but
3.

3.

alignment. Replace shaft by new one.

Check if undue force is given by piping.

4.
5.

Check power source,

increase in current) in case of electric

motor driven.

SHINKO INO.LTb.
C
j

Troubles
1.

C auses
Grease is too little.
1.

Remedies
Supply grease.

2. 3.

Grease is too much. Grease has improper consistency or

it is deteriorated.

2.

Remove grease.
Replace grease with specified new one.

3.

4.

Misalignment is great.
Shaft is bent.

4.
5.

Overheating of bearing

5.

6.
7.

Injury or too much wear in ball

bear ing.

6.

Correct alignment of pump and driver. Replace with new shaft. Replace with new ball bearings.
Check if impeller is clogged and if

Too much thrust force.

7.

clearance between mouth ring and impeller becomes too much, and
correct them if any.
1.

Injury in balls or rolling face.

Abnormal noise in
ball bearing

2.

Too much clearance due to abnormal

wear. Abnormal wear in retainer.

Replace with new ball bearing.

3.

1.

Misalignment.
Shaft bent. Impeller partially clogged with foreign

1.

2. 3.

2.

3.

Check alignment of pump and driver. Renew shaft. Check pump interior.
Check state of installation.

matter.
4.
5.

Incorrect installation.

4.
5.

Weak foundation.

Vibration in pump

Measure vibration up and down, right and lieft around pump's mounting on
foundation, if vibration is too great

reinforce foundation.
6.

Suction and discharge pipings not

sufficiently secured.

6.

Refer to "CAUTIONS FOR PIPING",

and give necessary support.

7.

Rotating elements touch stationary elements.

Injury or excessive wear down in
rubbing faces. Foreign matter in rubbing faces. Insufficient tightening of mechanical
seal cover.

7.

Check pump alignment and bending of

sh af t.

1.

1.

Remove mechanical seal cover and

check rubbing faces.
Ditto.

2.

2.

3.

3.

Check if cover bolts are evenly

tightened.

4.

Break down of "O" ring.

Insufficient tightening of setscrew for
stopper ring (54.7).

4.

Check "O" rings for stationary and

rotary rings.

Leakage in mechanical
seal
s.
5.

Tighten sufficiently setscrew.

6.

Injury or wear down of part of shaft

contacts. Scale sticks in groove for "O" rmg (54-5), causing rotary ring to stick and rubbing faces to open.
Flushing is insufficient.

6.

Replace with new shaft.

7.

7.

Disassemble and remove scale

com pletely.

Heating of mechanical seal (Sometimes

1.

1.

Check if flushing pipe is clogged.

2.

Pump operated dry.

2.

Stop pump immediately.

accompanied by abnormal
noise)

SuINKO INO.LTO.

PARTS CHAPTER 8 REPLACEMENT

When ordering replacement parts, include the following information.
1 . Ship's name

2 . Shipbuilder and hull number

3 . Service and model of the pump

4. Parts' numbers and names shown in this instruction manual

PREssuRE GAUGE
l

PART NO.
71 IO
71 1 1
UJ cg
::)

NAME OF PART
PUMP SUCTICN PUMP DISCHARGE

R EQ.
1 1

o
LU a:
:D

U' Q8 LU
c::

If
l

TH ERMO-SW,TCH
( tf fitted)

7 22 1

PUMP CASING

1 set
1

7221 .1 1

INSTALL THREAD INSTALL THREAD

PUMP BEARING END

1 set 7222 PUMP BEARING COUP. SIDE

7222- 1 1
ll
1

7223
!:

StDE 1 set
1

7221 -1 1

I 7222_1 1
7223.1 1 7225-1 1

o H ~ o 2 ~c
Cl]

7223.1 1

INSTALL THREAD
INSTALL THREAD

7226 BULKHEAD STU FFING

7226.1 1

1 set BCX
1

uJ :E

7221
7 222 7 223

7226
l

,~5l

SNINKO IND.LTD.
C )

PISTONPUMP (KPH ) STEAM DRIVEN MANUAL OF INSTRUCTION

This instruction manual describes construction, installation maintenance, disassembling, assembling and trouble shooting of model KPH pump.

, operation, and remedies

CONTENTS
Page

CHAPTER 1 CONSTRUCTION . . . . .
1. General . . . . . . .

96A- 2

2. Steam cylinder
3. Steam chest . . .

4. Liquid cylinder
5. Valve box . . . . . 6. Pump Valve . . . .

.2 .2 .2 .2 .2 .2
96A-3
3 3 4
9 6A- S

PIPING . . . CHAPTER 2 CAUTION FOR INSTALLATION AND

l. Place of installation and 2. Finishing of pump mounting

3. Cautions for piping . . . . . .
4. Suction piping . . . . . . . . . . .

foundat i on
seat . . . .

CHAPTER 3OPERATION . . .
1. Preparation 2. Starting and
3. Stopping . . .
4. Caution . . . .

for operation
running . . . .

.S .S
S

CHAPTER 4MAINTENANCE AND INSPECTION

l. Maintenance . . . . . . . . . . .

96A-6

2. Normal inspection . . . . . 3. Lubricating oil . . .. .. .

... 6 .... 6

... 6
. 96A-7
7 7

ASSEMBLlNG CHAPTER S DISASSEMBLlNG AND

l. Disassembling
2. Assembling .. .

ANDREMED I ES SHOOTING CHAPTER 6 TROUBLE

. 96A-8

SUPPLEMENTATION

, 96A-9 ADJUSTMENT OF PISTON STRO

Cg I snlNIKolNo.LTo.

C)

CHAPTER lCONSTRUCTION
l . GENERAL

The model KPH pump is a steam driven direct

t ype .

action

p u mp

of the

worthington

Fig. 1.l

2. STEAM CYLINDER The steam cylinder block has 2 cylinders.

3. STEAM CHEST The steam chest block has 2 cylinders and distributes steam to the steam cylinder.

'~~ (,1,

l 69

75

~)
20
' 24

4 8
32 35

76

74
T70

171

28

36

30

4. LIQUID CYLlNDER The liquid cylinder block has 2 cylinders which are provided
with liners(14) .
s.

43
210
191 204

47
45

48
26
171

2oe 207

77

VALVE BOX

/~~ ~/256 ~ 202

Ill

(1) The top and bottom valve boxes are cast separately and connect-

~'i~ 203
.J
.~ ~f",E ~,,1

73 70
.~/14 ~,~~ 11 ,

~~~20sA
201

ed together on both sides by connecting pieces. (2) Both boxes are identical in construction and dimensions, and each contains suction
chamber, suction valve chamber,,

208

\Jl

PART
NO.
l

l PAR NAME OF PARTFOP PUMP NO.

l

AEQ NO

NArnE OF PART

REQ NO
FOR I puedP

STEAM CYLINOER

76

and discharge valve chamber. (3) The suction valve chamber is divided into two chambers, each of which is open to the liquid cylinder.
(4) Of both connecting pieces, one

4 8
ll

l STEAM CHEST STEAM CHEST LINER 2

77
l 70

STEAM PtSTON ROD2SETS GLANO PACX,NG LIQU,O PISTON ROO GLANO PACXING 2SETS

LfQUID CYLtNOER

169 VALVE ROO TOP GLANO2 VALVE ROO 80TTOM 2

14 LIQUID CYLtNOER LINER 2

171

GLANO PISTou ROO GLANO

20 STEAM PtSTON 24
26

2SETS
191

23 STEAM P,STON R,NG 4

serves as suction passage and

the other as discharge passage,

STEAM PfSTOW ROD 2

LtQUIO PISTON ROO
2
l

VALVE BOX

8 201 SUCTION VALVE SEAT

with suction and discharge openings respectively.

6.

28 FRONT COLUMN 30 BACK COLUMN 32 PtSTON VALVE 35 PtSTON VALVE RING 3G VALVE ROO 45 ROCKING LEVER 47 CROSSHEAO 48 CROSSHEAO PIN 7o UQUID PISTOfl
73 UQU,O P,STON Rt~3

2
2

202 DELtVERY VALVE SEAT8 203 SUCTtON VALVE GUARD 8

8 204 DELIVERY VALVE GUARD

PUMP VALVE
Both suction and discharge valves are of the flat type. The suction valve is fixed by pulling from the bottom by means of setscrew stay(208) and the discharge valve is fixed by pressing from the valve box cover by means
of jack boltC210) .

8
2

205 VALVE

16

205A VALVE DISC

206 VALVE SPRING

16
16

2 43 ROCKtNG LEVER SPINOLE

2 2 2

8 207 VALVE STEM 208 YA~ VALVE SETSCREW 8

210 JACK 80LT

241

2SETS
4

ESCAPE VALVE OOX

l 1

RCO 80TTOM 74 VALVe 2 SETS 243 VALVE GLANO PACKI~3 VALVE aoO TOP 75 2SETS ~6 SPRt~G
GLANO PACXlrG

g I snINKOINO.LTD.
C )

CHAPTER 2 CAUTIONS FOR INSTALLATION AND PIPING

In order to prevent occurrence of vibration and noise and to operate the pump over long periods with best efficiency and safety the following points~ must be observed at the time of installation and piping.
l. PLACE OF INSTALLATIO\1 AND FOVNDATION

(1) Size of the place of installation must be chosen in view of the purnp's Space necessarY for disassembly is shown disassembly and inspection. in the outside drawing.

(2) The foundation must be strong enough to absorb pump's vibration and to resist deformation against long use.
2. FINISHING OF PUMP MOUNTING SEAT Chockliners must be welded on the foundation plate just under the puJnp'S foundation bolt holes and their faces must be planed using a surface plate so that they lie in a perfect plane. When the foundation bolts are tightened leaving gaps between the liner faces and liquid cylinder, deformation may be given to the pump and besides vibration may result. The same precaution is necessary in the case of fixing the steam cylinder to the bulkhead if any, for if fitted incorrectly pump alignment will be disturbed and premature wear of sliding faces and other trouble will occur.
3. CAUTIONS FOR PIPING

Deformation given to the pump bY outside force due to incorrect piping causes not only vibration but also pump troubles. Therefore, the pipe flanges connecting with the suction and discharge nozzles must be correctly matched. Be sure to avoid the cases shown in Fig. 2.l otherwise the pump may receive unreasonable force. Nor must the pump be directly given deformation due to the total weight of piping and thermal
expan s ion .

Fig. 2.1

P ip in g

P ump

Angular misalignment

Para I I e l

mi sa I i gnment

Flange faces do not touch

g I SHINKOINO.LTD.

c)

4.

SUCTION PIPING The piping on the suction side affects pump efficiency to a degree and to avoid troubles arising therefrom the following must be noted. (1) No air pocket must be formed in the piping.

great points

(2) All fittings in the piping must be perfectly tightened to prevent air
invas ion .

(3) Care must be taken to prevent air leakage through glands of all valves in the piping. (4) The suction piping must be thoroughly cleansed so that pipe scale, welding beads and other foreign matter do not remain, otherwise seizure and other troubles may result.

cg SHINKO INO.LTO.

C)

CHAPTER 3 OPERATION 1. PREPARATION FOR OPERATION (1) Open each drain valve, exhaust valve, suction and discharge valve. (2) Pour oil where required. (3) Keep bolts and nuts perfectly tight.

2. STARTING AND RUNNING (1) Warm up the steam cylinder by opening the steam valve a little. (2) The pump will begin starting if the steam valve is opened further
gradual I y .

(3) Wllen drain stops completely, close the drain valve. (4) Open the test valve provided on the valve box cover and expel air inside completely. (5) Open the steam valve gradually until the steam pressure reaches required pressure at required revolutions, and begin operation if no abnormal point is seen in the condition of running. (6) When steam or liquid leaks excessively from the glands, tighten the glands further and keep a tiny amount of liquid leaking from the pump
gl ands .

(7) In case the extent of steam valve opening is kept constant during the operation the revolutions will rise or fall in accordance with the variation of the liquid end pressure, but the operation must be carried out at the rated revolutions by adjusting the extent of steam valve opening. In case the speed exceeds 12S"', of the rated revolutions there will be a fear of abnormal wear in the steam cylinder and piston rings.
3. STOPPING (1) Close the steam valve. (2) Open the drain valve to draw out the drain. (3) After the pump stops, close the exhaust valve, suction and discharge
valves .

(4) Before stopping supply a small amount of oil and give attention to the means of preventing rust.
4. CAUTIONS

In case that the pump works as cargo oil stripping pump, a special attention is to be given to the followings; It may happen that discharge pressure of the pump is suddenly reduced due to an oil level in the cargo tank becomes lower and then gases and air come into the suction pipe, resulting that the pump speed becomes higher, the pump stroke length becomes shorter and shorter and finally the pump stops. Under the circumstances mentioned above, the pump does not work satisfactorily with its capability but also it cames abnormal wear out of the steam cylinder quickly. In case that gases and air mixtured in the cargo come into the pump, it is recomlnendable to operate the pump with a reduced speed, Iess than a half of the rated speed, and, if remote control devices are fitted, 10cal operation is preferable due to a difficulty of delicate control by the remote control devices.

SfJlINKO INO.LTO.
C

AN D INSPECTION 4 MAINTENANCE CHAPTER

1. MAINTENANCE

(1) Since the service life of the pump depends greatly upon whether maintenance is good or not, it is important to observe what this booklet explains and. not to make mistakes in handling. (2) When stopping the pump, keep each moving part in good condition, and where rusting is feared apply rust preventing oil. (3) When stopping over long periods, open the steam cylinder and steam chest and remove the drain completely, and apply mineral oil on the inner surfaces after cleaning the interior. However this oil must be wiped off cleanly before using the pump again. The same proceduse is also applicable to the liquid cylinder.
2. NORMAL INSPECTION (1) During operation it is necessary to inspect from time to time the status of lubrication and the bolts and nuts which tend to loosen, especially the cap nuts for the pump valve setscrew stay at the bottom of the valve box and lock nuts need attention so that they do not drop off during operation. (2) It is desirable to inspect at least once a year the parts invisible from outside such as steam piston, Iiquid piston and pump valves, even though no trouble occurs during operation. Too much time and cost will be needed when the cylinder walls are found to have been injured due to the unexpectedly great wear or breakdown of piston rings. (3) It is imperative to inspect the pump valves once a year after overhauling the valve box. Especially, the valve discs made of synthetic resin should be replaced by spare ones when they are enlarged or deparated by reason of the weardown of the central holes.

3. LUBRICATING OIL For the lubrication for the crossstand and crosshead pin, oil of ISO VG68 (International Standard Organization) is used. The brand names of oil which is equivalent to ISO VG68 are shown in the right table.

Table 4.l
NAJVIE OP COMPANY

LUBRICATING OIL

BRITISH PETROLEUVI
CASTRO L

BP ENERGOL THB68,77
PERFECTO T68

CO~dO OIL

COSMO TURBINE SUPER 68

TRESSO 68

ESSO STANDARD VACUUM

GULP OIL
IDEMITSU KOSAN
KYODO OIL
NITSUBISH:1 OIL

GULF HARMONY 68

DAPHNI TUEBINE OIL N0.68

RIX68 TUEBINE OIL
DIANOND MARINE68 TURBINE OIL68
MOBIL DTE OIL HEA~ MOBIL DTE OIL HEAVY MEDIUVl

MOBIL OIL

NIPPON OIL, CALTEX OIL

SHOWA SHELL OIL

PBK 68 REGAL OIL ReO 68

TURBO T OIL68

TEXACO OIL

REAGAL OIL E (R~O)

SHINKO INO.LTO.

CHAP TE R5

AN D ASSEMBLING DISASSEMBLING

l. DISASSEMBLING

Disassembling of the pump in case of replacing the parts with spares, maintenance and repair work will be done by following orders. (1) Remove all accessories.
(2) Disconnect valve rod from valve rod link and remove valve rod link.

(3) Remove lever spindle nut and take off each lever spindle and at the same time remove rocking lever. (4) After drawing out bolt on the crosshead, disconnect stearn piston rod from crosshead.
(S) Remove steam cylinder cover, Ioosen gland, and after fitting eye-bolt to top end of piston rod, Iift. piston rod together with piston.
(6) Remove crosshead from liquid piston rod by turning it. (7) Remove gland for liquid cylinder and then remove liquid cylinder cover.

(8) Fit eye-bolt to top of liquid piston rod and lift piston rod together with piston. (9) Loosen glands for steam chest. (10) Remove steam chest covers.
C11) Take out piston valve.

(12) After removing cotter, split pin and nut from piston rod, draw piston from piston rod.

(13) Remove cap nut from valve adjusting screw loosen screw remove valve box cover nuts, and remove cover.
(14) Take out discharge valve.

(lS) Remove cap nut from suction valve setscrew stay at valve box bottom and take out suction valve.
2. ASSEMBLING

Assembling can be carried out attention must be paid to the

Cl) The fitting parts should be marks if any.

by reversing
fo 1 Iowing .

order of

disassembling and

assembled in accordance with matching

taken so that
al l

(2) At assembling care should be fitting parts. (3) Care should be taken so that securely fixed.

no undue

f o rce

is given to

bolts,

nut s ,

screws and pins are

SHINKO INO.LTD.

C)

CHAPTER 6TROUBLE SHOOTrNG AND REMEDI'*S

Shou I d

can perform satisfactory function if properly handled trouble occur speedy remedies must be found for it. shows commonest causes of trouble and suggested remedies.
Pump s
Table 6.l
Troub I e s

and maintained. Table 6.l

Caus e s

Remidies

(1) Ste~tm too muc~h.

(1) Jump at start ot~ stroke is mostly

cCluscd b), tOo much s~te(Im, so trace

and eliminate caus~e.

Too much vibra tion ~ noise

(2) Liquid temperature too high.

(~) 11'hen liquid temperature it;_- too

high, jump and noise will re_sult, so it must be reduced.

(3) Air leak~~ge.

(3) Examine gland, pipe fitting etc. , and make them t;~ompletely airtight.
In reL:lproc~tlng pumps, increas.~e in

Speed too high.

Piston strikes
cylinder covers

spGed tends to caus~e long stroking and as a result piston strikes~ cylinder covers, so decrease spced by throttling steam valve.

(1) Foreign matter lodges in valve.

Decrease in pump discharge
(2) Piston ring LYorn or damaged.

(1) Remove valve box cover and examine valve and put it in good ordcr.

C2) Dismantle and examine. Renew rlng if necessary.

(1) Tighten gland properly. (2) Renew packlng
(3) Renew piston rod.

Too much leak

from stut~fing box

(1) Gland not enough tightened. (2) Packing deteriorated.

(3) Pis~ton rod worn.

Damage by over
heat

(1) Incorrect alignment.

(1) Correct alignment.

(2) Invasion of foreign matter.

(2) Prevent invasion of dust and sand.

Slide valve adjustment is not

Both stroke lengths are not
equa l
correc t .

Dlsconnect valve rod and link, then adjust valve position by turning valve rod. However, adjustmcnt of righthand stroke length is adJusted by left-hand valve rod. too closely, sliding resistance Increases, causing often vibratio.n,

Steam or/and liquid piston rings are not in good condition.

Small vibration

especially at low speed. In such

case, remove piston rings and examine
them.

SHINKO INO.LIO.

AD JU STMENT OFPISTON SUPPLEMENTATION STROKE

The adjustment of the piston stroke is made as follows in case of that the cylinder top or bottom is knocked under
the rated operation (the rated discharge pressure, the rated suction head, the rated exhaust steam pressure and the

rated number of stroke).

A) For "H" and lost motion

The pump was adjusted and set at the shop
test so that the pistons move in the middle of
whole stroke under the rated operation.

Therefore if something happens on board the

ship, Iike that the piston knocks the steam

l,

VALVEROb

cylinder top or bottom under the rated

operation, it is necessary to confirm first as

LOCK NUT
AD JUST I NG

follows that the adjusted value marked at the

shop test is being kept as it was.

NUT~
LOST MOTloN L = 3~m
AD JUST I NG

~~
I

::r ~

1) To confirm "H" between the valve rod

and the valve rod joint is correct and
same as that set at the shop test.

NUTC
SPLIT PIN
VALVE ROD
Jo I NT

~~~

("H" was adjusted at the shop test and has

been marked on the side of front column

P,No. 28)

If "H" is incorrect compared with one

marked on the front column, it is adjusted

by moving the adjusting nuts.

(When reassembling after overhauling,

"H" is to be adjusted and set the original

one which has been marked on the front

column.)
2) To confirm the lost Motion L=3mm is being kept.
the adjusting nut (A) and set by the lock nut.

If L of 3mm is not being kept, it is adjusted by moving

B) For adjustment for piston stroke

If the piston stroke in operation is unsuitable even though the A) mentioned before is confirmed corrrect, the
adjustment is carried out as follows;

1 ) Relation between piston and piston valve

a) To change the left side piston stroke is made by moving the right side piston valve up or down. b) To change the right side piston stroke is made by moving the left side piston valve up or down.

!~c~

SHlnKO InD.LTb.

SW~~'uSSrui;::~:i:S,:::~S' , > * *, ;#="+. * + * ' ' ' "' '*** '* ' cl

2 ) Adjustment for piston stroke

A necessity for the adjustment to get a suitable piston stroke is confirmed under the rated operation
otherwise the piston stroke under other operation conditions is different.

a) In case of the left side piston moves partially up and down at lower position (like the piston knocks
the cylinder bottom) : It is so adjusted that the lock nut on the right side valve rod is loosened and

the adJustlng nuts (A)(B) are screwed In to make "H" small, resulting that the piston stroke range is

moved upwards as a whole.

However, the lost motion L=3mm is to be still kept.

b) In case of the left side piston moves partially up and down at upper position (like the piston knocks
the cylinder top) : It is so adjusted that "H" becomes big.

However, the lost motion L=3mm is to be still kept.

c) In case of the right side piston moves partially up and down at lower position (like the piston knocks
the cylinder bottom) : It is so adjusted that the lock nut on the left side valve rod is loosened and the

adJustlng nuts (A)(B) are loosened to make "H" big, resulting that the piston stroke range is moved

upwards as a whole.
However, the lost motion L=3mm is to be still kept.

d) In case of the right side piston moves partially up and down at upper position (like the piston knocks
the cylinder top) : It is so adjusted that "H" becomes small.

However the lost motlon L=3mm is to be still kept.

e) After the adjustment the "H" is to be set with the lock nut and the split pin.

C) References
l) In operation on board the ship, the piston knocks the cylinder top or bottom sometimes.

However, almost of these abnormal operations are caused by too low discharge pressure or too low
exhaust sieam pressure or the both, which makes too small reaction power to stop the piston at dead
points of the top and the bottom of the piston stroke.

Therefore , it is absolutely necessry to confirm a necessity for the adjustment of the piston stroke before
hand at the rated operation.

2) It is impossible, for example, to only adjust the piston stroke shortened towards downwards in case of
the piston knocks the cylinder bottom.
Therefore, in this case, do not shorten the piston stroke towards downwards but adjust the piston stroke

moving wholly upwards.

c~~

C]

SHIN!KO IN:D.LTD.

CONTROL SYSTEM REMOTE INSTRUCTION MANUAL OF FOR STEAM DRIVEN PISTON PUMP (KSC 65-lOO)
This Instruction service of each

Manual describes the construction , equipment of KSC 65 - lOO .

operation and type of

CONTENTS
Page
CHAPTER 1GENERAL

''e'''O
, e
, e

CHAPTER 2CONSTRUCTION INSTALLATION ANDPLACE OF

o t 97~2
, ,
,

CHAPTER 3OPERATION
1. 2.

Stroke number control Stroke counter

3 3

CHAPTER 4TYPE OF EACH SERVICE OF EQUIPMENT

l. 2. 3.

Stroke transmi tter Stroke converter .

S troke

' e ' ' ' ' , 97-4 4

e e

counter .
o
,

4 4

A ND REMEDIES CHAPTER 5TROUBLE SHOOTING

e 97~6
, e

~~ 1 sHINIKOlnD.a:~i~!' ' '

C)

CHAPTER l GENERAL

KSC 65 - 100 is a system which controls the (hereinaf ter called ffstroke number") of the "pump") from the cargo control after called of the tanker and at the same control room

reciprocating stroke number reciprocating pump (hereinconsole provided in the cargo time monitors pump operation.
with a
speed setter to

Generally, the control stroke

cargo control console is provided number and a stroke counter.

(Refer to CHAPTER ANDPLACE OF INSTALLATION 2 CONSTRUCTION

Fig .

3.1)

l . Steam
Th i s

Control Valve (1)

is installed
supply .

on the

s t eam

inlet

pipe in the

pump room and regulates

s t eam

2 . Stroke This is

Transmitter (7)

mounted on the pump and counts pump stroke number .

3. Stroke Converter (8) This is installed in counter

4 . S troke

the englne room an d outputs signals

to the

stroke

Counter (9)
on the cargo control

This is installed stroke number .

console and indicates

pump

5. Speed Setter (5)

Thi s
s t eam

is installed on control valve

the cargo control console, and operates and regulates pump stoke number

t^h.e

c~ Sl~NKO IHD.LTO.

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CHAPTER 3 OPERATION (Refer to Fig. 3 . I )

l . Regulating the stroke number

The steam supply is controlled by adjusting the opening of the steam control valve provided in the pump room, which can be done by changing pneumatic signals within the range of 0.2 to I .O kg/cm2 by the speed setter provided in the cargo control console.
2. Indicating the pump stroke number

2.1 The stroke transmitter provided on the pump counts the punrp stroke number, and supplies air to the stroke converter or dischargeS the air out. By repeating these actions, the transmitter outputs a pneumatic signal to the stroke converter provided in the englne room.

2.2 Pneumatic signal from the stroke transmitter is converted into an electric signal by the stroke converter provided in the engine room and then the electric signal is outputted to the stroke counter
2.3 An electric signal from the stroke converter is converted into stroke number by the stroke counter provided on the cargo control console and then the stroke number is digital-indicated on the stroke counter.

Flg. 3.l
CONTROL ROOM CARCO
AIR
(6~7 kg/cm2]

5
RUN. tN D.

ELEC SOURCE LA"IP C=_ J,-_D_PY_C_!!1_.2_5_W2 .(AC ,COINOV Of 2001~~fl

Cd~O

_j~~~~~l
l I I

.. - --1
5;*l

l t

O~2k TO 1.0k
-t

I t

l
l

t,,CNl

r!;TIT7r;~ITl

PUMP ROOM

r;~T;~Tr!~;;:71

~] ENGINE ROOM xt
>,Ll

Ul

Ai F~

!,I

Pl
I I

te~7 ~glcm2,

STEAM
EXHAUST
1 4k

6A
AtR
(6N7 k9/cm2]
i

8
l
l

l
, l

-J
STR I PPING

PUMP

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SHINKOiN:Bl.E:T~l. ~i~~~~~~~
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EQUIPMENT ANDADJUSTMENT OF EACH CHAPTER 4 TYPEOF SERVICE

l . Stroke

Transmitter

The three-way air valve is employed as the stroke transmitter. Vertical movements of the pumpfs valve rod changes over the air passage in the stroke transmitter. When the valve rod is in the the upward stroke, air pressure is outputted to the stroke converter. When the valve rod is in the downward stroke, air is discharged through the exhaust port of stroke transmitter, and air pressure is removed. Thus, the stroke transmitter ,repeats the above actions corresponding to the pump stroke number, by which a pneumatic *-ignal is made and outputted to the stroke converter.
2 . Stroke
Converter

The stroke converter converts air pressure signals outputted from the stroke transmitter into an electric signal and outputs it to the stroke counter on the cargo control console. The pressure switch is preset to be ON when air pressure reaches 1.1 kglcm2 When confirming the preset value, set the supply air pressure through the filter regulator(6A) (pressure reducing valve) mounted on the pump to 1.1 kglcm2 Then force the roller of the stroke transmitter in and confirm that the operation indicating lamp provided on the head of the stroke converter goes ON. If not, adjust the setting by the pressure setting screw on the head of the stroke converter until the lamp goes ON. After confirmation, regulate supply air pressure to I .4 kg/cm through the filter regulator.
3 . Stroke
3.l

Counter (Refer to

Fig. 4.1)

The stroke counter calculates a value per minute inversely in the signals outputted from the stroke converter and cycle of electric digital-indicates the results on the stroke counter.
Confirm as foll ows
and adjust if
(5) .

3.2
(1) (2)

necessary .

Press the power switch

While pressing the push button indicates 30 rpm. When adjustuent is necessary, (9), adjust the volume (8) by

(9), confirm that

the meter (1)

while pressing the push button uslng a screw driver .

c~ SHINKO IND.LTD.

c)

(3) While pressing the push button (ll) to confirm operating indication, confirm that the meter indicates 5 rpm. If adjustment is necessary, while pressing the push button (ll), adjust the volume (6) by using a screw driver. (4) When the optional overstroke indicator is provided, while pressing the push button (lO)p confirm that the meter (1) indicates 40 rpm. If adjustment is necessary9 while pressing the push button (10), adjust the volume (7) by using a screw driver. (5) After the above adjustment (3) or (4), press the push button
( 12) .

3 . 3 Others

(1) The stroke number counting operation of the stroke transmitter installed on the pump can be confirmed by the flickering lamp
( 13) .

(2)standard Theone. external terminal to indicate operation

ON/OFF of the contact to indicate operation can be confirmed by the lamp (2). (3) The external ternrinal to indicate overstroke (14) is optional.

On the unitcan with thisby device, overstroke operation be confirmed the lamp (3). ONIOFF of the

3.4 Stopping the Pump and Stroke Counter For twenty (20) s~conds after the pump stops, the stroke counter indicates the stroke number which have been made before the punrp stops, and after that, it indicates O rpm which means the pump is
not running .

When no signals from the stroke converter are outputted to the stroke counter for more than twent~ (20) seconds,' the stroke counter indicates O rpm to show that the pump is not running. As the circuit of the stoke counter has been designed not to indicate 3 rpm or less, the pump is in a waiting state for twenty (20) seconds (3rpm), and during this period if no signals are inputted by the stroke converter tihe stoke number is judged to be less than 3 rpm and the circuit is reset and O ~pm is indicated.
Fig .

4.l
STRtPPING PUMP

~>

rl~~I str::::1:lTrt: ~r I COINT o L l

~ig. 4.2
stroke converter

ELECTRIC WtRtNG DiAGRA,R

STROKE COUNTER

STROJ'~ couNTLn

L~IIFI-O

I,1 PUT

+1 2V

13

6
N'~s

+ o UT

12
11

UI-

'uNO e l 1 Au~ e ~~~

3
7
e l o "'Tn

10 18
f-CJIJL-~

a2av ~
t lav S :

C @ 4 @A z GND @B~ @c @ @A C @ 8~J PUT @ @ C C ~ @ o C C Ov @

,:

15

1tt I r'
P2taND' - It"I ll" I l

T1 Wl~~'1

INPuT P,

,~

Il PD"'iaV' II:

GND P2
tlav p3
OIJTPUTf t,

OulrpuTt~,

zo

ACa~~V
Act ta,lOOv F

o --

8
,aJIN

lI

@ @

8 n uN
:Olb,

g199alql ,uco,uu

D ALM :Ol

: ELECT,NC WIRE FOR $troke CaRVerter

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CHAPTER 5TROUBLE ANDREMEDIES SHOOTING

This system can perform satisfactory function maintained. In case any trouble should occur, at once. The following table shows the conunonest causes
remedies .

if
it

properl y

handled and should be remedied

and suggested

of trouble

Trouble
Stroke counter does not indicate
l
e

Possible Causes
Power wlrlng is not connected
,

Remedies
l
,

Connect wiring to terminal (18) at t he back of stroke counter Switch ON power switch (5) of stroke counter
,

2,

Power is not ON
e

2,

3 o Wrong wlrlng

stroke converter and counter ,

connection between stroke

3 , Correct the connection

between terminal codes P2 and P3 or Pl and P3, Ref er to Fig . 4 2 e

e

During
o peration ,

Pressure setting
is impro per .

of strokeconverter

indication of stroke counter is always O

Set pressure switch sO that it wi I l be ON at l 1 kg/cm e Ref er to 2 Chapter 4

, , ,

2,

Stroke transmitter is not operating properly .

2,

Check the operation . Ref er tO l Chapter 4

,

3 e Air pressure of stroke transmitter is insuf f icient

3 e Adjust air pressure so as to be more than l , 4 kg/cm with f ilter

regulator
4 , Wrong wiring

( 6A )
,

stroke converter and counter ,

connection between stroke

4 , Correct the connections of terminal codes Pl an

P2

Ref er to Fig .

4 2
,

c~ SHm,(O INBl.LTD.

C)

Trouble

Possible Causes
l.

Remedies
l.

During
o per.ation ~

Push but.ton (12) is not pressed .

l

f or

measurement

Press the push button

indication of stroke counter is always 5

Operation indicating l amp does not goes ON

1 -e

Pumpstroke number is less than 5 rpm.

l.

Make pump stroke number more than 5 rpm.

2.

Stroke counter setting

proper .

is . not

2. Set stroke counter to 5 rpm . Ref er to 3.2 (3) Chapter 4.

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C~

Back to Top Page

SHIN:XiOlno. L70.
Head Office & Factory

5-7-21, Ohzu, Minami-ku, Hiroshima, Japan

TokyQ Office
3-1 9-37, Takanawa, Minato-ku, Tokyo, Japan
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1 181 JC Amstelveen, The Netherlands.

TEL 31-20-6477053 TLX 15242 FAX 3 1 -20-6475633

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c/o M.A. Narong Enterprise (1982) Co.Ltd.
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