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PLTU 1 JAWA BARATINDRAMAYU 3330MW POWER PLANT

FK6D32M BOILER FEED PUMP MAINTENANCE INSTRUCTIONS

SHANGHAI POWER EQUIPMENT MANUFACTURE CO.,LTD.

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TABLE OF CONTENTS 1 INTRODUCTION................................................................................................................... 3 2 PERIODIC AND PREVENTIVE MAINTENANCE..................................................................3 2.1 ROUTINE CHECKS............................................................................................................................3 3 MAINTENANCE PARTICULARS.......................................................................................... 4 3.1 SPECIAL TOOLS...............................................................................................................................4 3.2 ESTIMATED WEIGHTS (FOR LIFTING PURPOSES)..............................................................................4 3.3 JOINTS............................................................................................................................................. 3.4 RECOMMENDED LU!RICANTS........................................................................................................." 4 ROUTINE MAINTENANCE................................................................................................... 6 4.1 PREPARATION FOR MAINTENANCE.................................................................................................." 4.2 E#AMINING THE !EARINGS ............................................................................................................$ 4.3 E#AMINING THE MECHANICAL SEALS .........................................................................................11 4.4 CHECKING THE A#IAL RUNNING POSITION % THRUST !EARING CLEARANCE............................14 5 OVERHAUL......................................................................................................................... 16 .1 PREPARATION FOR O&ERHAUL......................................................................................................1$ .2 WITHDRAWING THE PUMP CARTRIDGE.........................................................................................1$ .3 DISMANTLING THE PUMP CARTRIDGE...........................................................................................18 .4 INSPECTION' RENEWAL AND REPAIR PROCEDURES.......................................................................2( . ASSEM!LING THE PUMP CARTRIDGE.............................................................................................23 ." INSTALLING THE PUMP CARTRIDGE .............................................................................................2"

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INTRODUCTION

It is recommended that a system of routine inspection and maintenance is established during which the condition of the various units in the plant can be determined and recorded for comparison with later inspections. Any defects should be repaired or the components renewed at the earliest opportunity. Certain inspections can only be made when the plant is shut down, but others can be made under operating conditions. It is essential that all lifting tackle and equipment is maintained in a serviceable condition and that safety rules and regulations are observed at all times. A high degree of cleanliness of the equipment and the surrounding area should be maintained, as this will assist in the detection of minor leaks and defects, which, if unnoticed, could lead to more serious maintenance problems.
2 PERIODIC AND PREVENTIVE MAINTENANCE

The following are the primary criteria for examination and renewal of wearing parts and it is recommended that these aspects are checked every shift.
a) b) c) 2.1 1.1.1 Reduction in pump performance, i.e. reduction in head or flow. Excessive vibration. Excessive leakage from the mechanical seals.

Routin C! "#$ Every Shift 1) !heck the suction and discharge pressures. d) e) f) g) h) i) !heck the pump bearing lubricating oil pressure and temperature. !heck for excessive leakage from the mechanical seals. !heck all "oints and glands for leakage. !heck for any undue noise and#or vibration. !heck the temperature of the motor$s air cooler% !heck the cooling water for positive circulation in the operationg oil cooler, lubricating oil cooler, motor% air cooler and mechanical seal. !heck the lubricating oil flow at the sight flow indicators

") 1.1.& 'onthly

1) !heck the security of all accessible holding(down bolts and fastenings and tighten as necessary. k) !heck the condition of the lubricating oil.
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1.1.)

Six 'onthly 1) !heck the security of all accessible holding(down bolts and fastenings and tighten as necessary. l) Examine the flexible coupling bolts for wear or fretting and check the tor*ue loading of the bolts. +isually examine the element laminations for signs of fatigue cracks local to the anchoring points. Examine the mechanical seals.

m) Examine the pump "ournal and thrust bearings. n) 1.1., -early

It is recommended that the lubricating oil be changed, but this may be amended depending on running experience and oil sampling results.
1.1.. /hree(-early

The interval between pump overhauls will be determined by the deterioration in pumpset performance to an unacceptable level, or by excessive noise and/or vibration. It is recommended however, that the interval between overhauls should not exceed three years.
3 3.1 MAINTENANCE PARTICULARS S% "i&' Too'$

The following special tools are required for use on the pressure stage pump. When not in use they should be safely stored. Any defects or shortages should be remedied at the earliest opportunity otherwise maintenance and overhaul may be hindered.
/ools !artridge withdrawal e*uipment !artridge tansportation e*uipment 0umber 203R4'4-5(61()4(77 203R4'4-5(6&()4(77 1urpose 1ump cartridge 1ump cartridge store and transport /hrust collar 9alance drum 3ischarge cover

/hrust !ollar 8ithdrawal 9alance 3rum 8ithdrawal Stud:ydraulic/ensioning E*uipment

203R4'4-5(6)()4(77 203R4'4-5(6,()!(77 203R4'4-5(6;()9(77

3.2

E$ti(&t ) * i+!t$ ,-o. 'i-tin+ %u.%o$ $/


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2tem !artridge assembly 3ischarge cover 9ottom half bearing housing non(drive end) /op half bearing housing non(drive end) /op half bearing housing drive end) 9ottom half bearing housing drive end) Suction guide Ring sections each) Ring section &nd) 1ump shaft 2nterstage impellers each) 3iffusers each) 3iffuser last) 9alance drum 3.3 0oint$

8eight kg) &&77 <=1 11> ;& ); ,; )=) ;7 =1 1<7 1,.; &; 1=.. &<

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6oint between

4n asterisk ?) denotes that a 1/@E anti(extrusion ring is fitted with the 1O2 .in+. 'aterial @luorocarbon @&>. @luorocarbon @&>. ? 1!r1;0i=/i @luorocarbon @&>. ? @luorocarbon @&>. ? @luorocarbon @&>. SiAe B.,,.;& i#d)CB<.== B.7<.>& i#d)CB<.== B.77#B,.=..C) B,,).)< i#d)CB<.== B,,).)< i#d)CB<.== B.)&.&< i#d)CB<.==

1ump casing and discharge cover 1ump casing and suction guide 1ump casing and suction guide 1ump casing and insert ring Ring section and ring section 1ump casing and ring section &nd) Ring section )rd) and ring section &nd) Dil thrower and pump shaft

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B,;<.& i#d)CB<.==

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B=,.., i#d)CB)..)

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'echanical seal chamber, drive end and non(drive end 8ater cooling "acket, outer, drive end 8ater cooling "acket, inner, drive end 8ater cooling "acket, inner, non( drive end End cover and 0.3.E bearing housing End cover and thrust bearing housing 'echanical seal assembly 3.4 R "o(( n) ) Lu3.i"&nt$

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B&>=., i#d)CB<.==

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B&<..> i#d)CB<.==

Refer to the manufacturerEs instructions

The lubricating oil for the journal and thrust bearings of the pressure stage pump is supplied from the turbo coupling lubricating oil system and should be as follows: Grade:
4

I.S.O. Grade 32

ROUTINE MAINTENANCE *ARNIN45 IT IS ESSENTIAL THAT THE PLANT SAFET6 RULES AND RE4ULATIONS ARE OBSERVED AT ALL TIMES DURIN4 MAINTENANCE PROCEDURES. Not 5 /he boiler feed pump is an integral part of the pumpset. /he following instructions should, therefore, be read in con"unction with those for the booster pump and the associated e*uipment.

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P. %&.&tion -o. M&int n&n" 1) 2solate the electrical supply to the motor. o) p) *) r) s) 2solate the electrical power supplies to all instruments. !lose the pumpset suction and discharge isolating valves and the minimum flow valve. Refer to the manufacturers instructions. 2solate the lubricating oil supply to the pump bearings. 2solate the cooling water supply. !lose the pump tap stage isolating valve.

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t)

Dpen the casing drain valve and drain the pump.

*ARNIN45 BEFORE PROCEEDIN4 *ITH AN6 MAINTENANCE ON THE PUMP7 ENSURE THAT THERE IS NO PRESSURE *ITHIN THE PUMP. 4.2 E8&(inin+ t! B &.in+$

(Drg. No. INDRAMAYU-FK6D32M-00(1/2) & (2/2)) The following instructions apply when the pump bearings are to be dismantled for examination and/or renewal in situation, without disturbing the pump cartridge. It is recommended that the drive and non-drive end bearings are examined at the same time.
1.1.< 3rive End 6ournal 9earing 1) 1repare the pump for maintenance, as described in Section ,.1. u) v) 3isconnect and remove all instrumentation. 'ark and tape the ends of the cables to facilitate to facilitate assembly. Remove any small bore pipework which may interfere with the dismantling.

w) Remove the coupling guard. 3isconnect the pump by removing the coupling flexible elements and spacer. x) y) A) Remove the hexagon head screws and nuts securing the bearing housing top half to the suction guide. Remove the nuts from the studs securing the bearing housing top half to the bottom half and remove the dowel pins. Focate an eye(bolt in the tapped hole provided on the "ournal bearing top half and, using suitable lifting slings and "acking screws in the tapped holes provided, carefully lift off the the "ournal bearing top half, taking care to avoid damage to the oil guard at each end of the housing.

aa) 8ithdraw the dowel pins and remove the nuts from the studs securing the "ournal bearing keep to the "ournal bearing housing . Focate "acking screws in the tapped holes provided and remove the bearing keep. bb) Fift off the top halves of the "ournal bearing and the oil guard. Remove and retain the anti(rotation pins. C&. (u$t 3 t&# n 9! n 'i-tin+ t! $!&-t t!&t it i$ on': 'i-t ) 3: t! &(ount n " $$&.: to . ' &$ t! 9 i+!t -.o( t! ;ou.n&' 3 &.in+ 3u$!. cc) /ake the weight of the shaft then carefully rotate the bottom halves of the bearing bush and the oil guard around the shaft and remove
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.)

them. Not 5 0either the "ournal bearing nor the oil guards are interchangeable and the halves should be clearly marked for identification on assembling. dd) Examine the "ournal bearing and the shaft "ournal for any signs of wear, damage or deterioration. Examine the oil guard for wear or damage. Renew as necessary. 'easure the bearing clearance and compare it with the details given in the clearance table in Section ..,.<. 2f the measured clearance exceeds the renewal clearance, or is likely to do so before the next examination, the bearing should be renew. Not 5 Fightly smear the shaft "ournal and the "ournal bearing bush surfaces with oil before final assembly. ee) Focate the bottom halves of the oil guard and "ournal bearing on the shaft and rotate them into position in the bearing housing bottom half. Release the weight of the shaft. ff) Focate the top halves of the "ournal bearing and oil guard on the bottom halves, ensuring that the anti(rotation pins are in place. Ensuring that the indentification marks on each half coincide.

gg) Focate the "ournal bearing keep cover into position, ensuring that the anti(rotation pins are correctly engaged. Focate and secure the keep cover to the bearing housing with its dowel pins and nuts. hh) Fift the "ournal bearing top half into position, ensuring that the oil guards are correctly located, than locate and secure the "ournal bearing top half to the bottom half with its dowel pins and nuts. Remove the lifting sling and eye(bolt. ii) "") Secure the bearing housing top half to the suction guide with the hexagon head screws. !onnect all small bore pipework removed prior to dismantling, and install and connect all instruments.

kk) Replace the coupling flexible elements and spacer, then install the coupling guard. 1.1.> 0on(3rive End 6ournal 9earing 4nd /hrust 9earing 1) 1repare the pump for maintenance, as described in Section ,.1. ll) 3isconnect and remove all instrumentation. 'ark and tape the ends of the cables to facilitate to facilitate assembly.

mm)Remove any small bore pipework which may interfere with the dismantling. nn) Remove the coupling guard. 3isconnect the pump by removing the coupling flexible elements and spacer.
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oo) Remove the hexagon head screws securing the end cover to the bearing housing, then remove the end cover. 3iscard the GDEring . pp) Remove the the hexagon head screws and dowels securing and locating the bearing housing top half to the bottom half and remove dowel pins. **) Remove the bolts and nuts securing the bearing housing top half to the discharge cover. rr) Focate an eye(bolt in the tapped hole provided on the "ournal bearing top half and, using suitable lifting slings and "acking screws in the tapped holes provided, carefully lift off the the "ournal bearing top half, taking care not to damage to the oil guarde .

ss) Remove the nuts from the studs scewing the "ournal bearing keep cover to the "ounal bearing housing . Fift the "ournal bearing keep cover away. tt) Fift off the top halves of the "ournal bearing and the oil guard, uu) Remove the dowel pins and cap screws securing the thrust bearing cover to the bottom half bearing housing. 2nsert starting screws to release the thrust bearing cover and remove the cover. Not 5 !are must be taken to prevent damage to the "ournal bearing bush and oil guard when removing the top half housing &n) ;ou.n&' 3 &.in+ "o< .. vv) /ake the weight of the shaft then carefully rotate the bottom halves of the bearing bush and the oil guard around the shaft and remove them. ww) 5nclip the spring and remove the split oil seal from the bottom half bearing housing. xx) Remove the socket head cap screws, then lift the retaining plate from the bearing housing end cover and remove the split oil seal and spring from the recess in the end cover. yy) Remove each thrust carrier ring in turn, as followsH .)) T! t!.u$t 3 &.in+ . $i$t&n" t (% .&tu. ) t "to.$ ,RTD/ ' ( nt$ &. in$ .t ) in t! t!.u$t %&)$ &n) "'i%% ) to t!.u$t "&..i . .in+$ . T! ' &) 9i. $ &. .out ) out t!.ou+! t! 3otto( !&'- 3 &.in+ !ou$in+ &n) into & t .(in&' 3o8 ! &). B -o. . (o<in+ t! t!.u$t "&..i . .in+$ -.o( t! 3otto( !&'3 &.in+ !ou$in+7 t! ' ( nt ' &) 9i. $ (u$t 3 )i$"onn "t ) -.o( t! t .(in&' 3o8 ! &) . Rotate a complete carrier ring around the shaft until the half ring with the stop pin can be removed, then rotate the other half ring around the shaft and lift it clear. Repeat to remove the second carrier ring on the other side of the thrust collar.
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.)))

C&. (u$t 3 t&# n 9! n 'i-tin+ t! $!&-t t!&t it i$ on': 'i-t ) 3: t! &(ount n " $$&.: to . ' &$ t! 9 i+!t -.o( t! ;ou.n&' 3 &.in+ 3u$!. AA) Examine the "ournal bearing, shaft "ournal, and the thrust pads thrust collar split oil seals and oil guard for any signs of wear, damage or deterioration. Renew as necessary.

0oteH a 5nder normal operating conditions it is not expected that any measurable wear will take place on the pads other that a dulling of the white metal surface. 2t is recommended that when this dulling has spread to more than half the surface area of the pads they should be renewed. b 'easure the bearing clearance and compare it with the details given in the clearance table in Section ..,.<. 2f the measured clearance exceeds the renewal clearance, or is expected to do so before the next examination, the bearing should be renewed.

.1.1.1.1.1.1.2

Fightly smear the shaft "ournal and the "ournal bearing bush surfaces with oil before final assembly. aaa)/ake the weight of the pump shaft and rotate the bottom halves of the "ournal bearing and oil guard around the shaft and into position in the bottom half bearing housing. 2nstall the inner split oil seal on the pump shaft with the spring. Release the weight of the shaft. bbb)2nstall each thrust carrier ring in turn, as followsH

!45/2D0H /he thrust bearing resistance temperature detectors R/3) are inserted in the thrust pads and clipped to the thrust carrier rings. 8hen installing the carrier rings, the elements must be fitted in position and the excess lead wires fed back through the bottom half bearing housing. /he thrust carrier ring split line is at =7I to the bearing housing horiAontal surface and the stop pin locates in a slot in the thrust bearing cover. 1lace the half carrier ring without the stop pin over the shaft, with the thrust pads touching the face of the thrust collar, and rotate it into the bearing housing bottom half. 1lace the other half carrier ring, with the stop pin, on the first half and rotate the complete carrier ring around the shaft until the stop pin rests on the bearing housing bottom half. Repeat with the second carrier ring on the other side of the thrust collar.
.)+

Do not in$ .t - ' . 3 t9 n t! t!.u$t "o''&. &n) t! t!.u$t %&)$ to "! "# t! &8i&' "' &.&n" 5 t!i$ (&: +i< n &n in&""u.&t . &)in+7 &n) "&u$ )&(&+ to t! 9!it ( t&' %&) $u.-&" . ccc) Secure the end cover to the bearing housing bottom half with the

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hexagon head screws, and check the axial clearance by moving the pump shaft towards the drive end so that the thrust collar is hard against the inner thrust pads then, using feeler gauges between the outer thrust bearing spacer and the thrust housing inner wall, cleck the clearance. Refer to the clearance table in Section ..,.< for the original axial clearanceH any measurable variation should be investigated. Remove the end cover. Not 5 Ensure that the thrust pad resistance temperature detector 3un+$ &. in$ .t ) in t! t!.u$t %&) !o' $7 &n) t!&t t! 8" $$ ' &) 9i. $ - ) 3&"# t!.ou+! t! 3otto( !&'- 3 &.in+ !ou$in+ 3 -o. in$t&''in+ t! t!.u$t 3 &.in+ !ou$in+ "o< .. ddd)Focte the thrust bearing cover onto the bottom half bearing housing then locate and secure the cover to the bottom half bearing housing with the dowel pin and cap screws. eee)Focate the top halves of the "ournal bearing. fff) 1lace the bearing keep over the "ournal bearing, ensuring that the anti(rotation dowel is correctly engaged, then locate and secure the keep to the bottom half housing with the dowel pins and the nuts. ggg)1lace the top half of the oil guard in position on the bottom half housing. hhh)Focate the bearing housing top half on the bottom half with the dowel pins and secure it with the bolts and nuts. Secure the bearing housing top half to the discharge cover with the hexagon head screws. Remove the lifting slings and eye(bolt. iii) Focate the split oil seal and spring in the recess in the end cover and retain them with the retaining plate secured to the end cover with the socket head cap screws 2nstall the end cover on the bearing housing, with two new GDE rings, and secure it with the hexagon head screws, /ighten the screws to a tor*ue loading of 1)70m.

""")

kkk) Replace the coupling flexible elements and spacer, then install the coupling guard. lll) 4.3 !onnect all small bore pipework removed prior to dismantling, and install and connect all instruments.

E8&(inin+ t! M "!&ni"&' S &'$

Refer to Drg. No. INDRAMAYU-FK6D32M-00(1/2) The following instructions apply when the pump mechanical seals are to be dismantled for examination and/or renewal in situation, without disturbing the

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pump rotating assembly, and assumes that the drive and non-drive end seals will be examined at the same time. It is recommended that the examination of the mechanical seals is carried out at the same time as the examination of the bearing, unless it is necessary to rectify a specific fault.
1.1.; 3rive End 'echanical Seal 1) Remove the drive end "ournal bearing as described in Section ,.&.1, Steps 1) to 17). mmm) Remove the cap screw securing the coupling nut. 5sing the special spanner, unscrew and remove the coupling nut. nnn)Remove the pump half coupling from the shaft. Remove and retain the coupling key from the keyway in the shaft. ooo)Suitably support the bearing housing bottom half. Remove the screws and dowel pins securing and locating the bearing housing bottom half to the suction guide and remove the housing. ppp)'ark the positions of the inboard and outboard oil throwers on the shaft, then slacken the grub screws and slide the oil throwers from the shaft. ***)Remove the mechanical seal flushing water pipes, the seal vent adaptor and the breather. Not 5 /he seal chamber and water cooling "acket should only be removed if it is thought necessary to renew the =O> .in+$. rrr) Refer to the seal manufactureEs instructions, and remove the seal assembly. Remove the seal sleeve key from the keyway in the shaft. sss) Remove the socket head screws securing the seal chamber to the suction guide and remove the seal chamber and the water cooling "acket. 3iscard the JDK rings from the seal chamber and the water cooling "acket. ttt) Refer to the seal manufacturerEs instructions and proceed as followsH a) 3ismantle the seal cartridge b) Examine the seal components and renew as necessary c) 4ssemble the seal cartridge ready for installation uuu)Focate new JDK rings in the grooves in the water cooling "acket and install the "acket in the suction guide ensuring the dowel pin locates correctly.
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vvv) Focate new JDK ring in the groove in the seal chamber and install the chamber on the water cooling "acket www) Secure the seal chamber and the water cooling "acket to the suction guide with the socket head screws. xxx) Refer to the seal manufacturerEs instructions, and install the seal key , cartridge and sleeve nut. yyy) Slide the oil throwers onto the shaft, into the positions determined during dismantling, and secure them with the grub screws. AAA) 2nstall the mechanical seal flushing water pipes and air breather and vent adaptor. aaaa) Focate the bearing housing bottom half to the suction guide with the dowel pins and secure it with the screws and nuts. bbbb) 2nstall the drive end "ournal bearing as described in Section ,.&.1, Staps 1&)L 1;). cccc) Focate the coupling key in the keyway in the shaft, then install the pump half coupling on the shaft. dddd) Screw the coupling nut onto the shaft and tighten it using the special spanner provided. Fock the coupling nut with the cap screw. eeee) install the coupling flexible elements and spacer. ffff) 2nstall the coupling guard. gggg) 2nstall the lubricating oil supply and drain pipework, together with any other small bore pipework and instrumentation removed prior to dismantling. 1.1.= 0on(drive End 'echanical seal 1) Remove the non(drive end "ournal bearing and the thrust bearing as described in Section ,.&.&, Spets 1)L 1.). hhhh) Suitably support the bearing housing bottom half. Remove the screws, nuts and dowel pins securing the bearing housing bottom half to the discharge cover and remove the housing. iiii) 9end up the tabs on the thrust collar lock(washer and remove the thrust collar nut. 3iscard the lock washer. """") 5sing a ring burner, apply heat evenly to the thrust collar hub, then using withdrawal gear, withdraw the thrust collar from the shaft. Remove and retain the thrust collar key. kkkk) 'ark the position of the oil thrower on the shaft, then slacken the grub screw and slide the oil thrower from the shaft. llll) Remove the mechanical seal flushing water pipes, the seal vent adaptor and breather.

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Not 5

/he seal chamber and water cooling "acket should only be removed if it thought necessary to renew the 1O2 .in+$. mmmm) Refer to the seal manufacturerEs instruction, and remove the seal assembly. Remove the seal sleeve key from the keyway in the shaft. nnnn) Remove the cap screws securing the seal chamber to the discharge cover and remove the seal chamber and the water cooling "acket. 3iscard the GDE rings from the seal chamber and the water cooling "acket. oooo) Refer to the seal manufacturerEs instructions and proceed as followsH

a b c

3ismantle the seal cartridge Examine the seal components and renew as necessary 4ssemble the seal cartridge ready for installation pppp) Focate a new EDE ring in the groove in the water cooling "acket and install the "acket in the discharge cover ensuring the dowel pin locates correctly. ****) Focate a new GDE ring in the grooves in the seal chamber then install the chamber on the water cooling "acket. rrrr) Secure the seal chamber and the water cooling "acket to the discharge cover with the socket head screws. ssss) Refer to the seal manufacturerEs instructions, and install the seal key, cartridge and sleeve nut. tttt) Slide the oil thrower onto the shaft and into the position determined during dismantling and secure it to the shaft with the grub screw. uuuu) Focate the thrust collar key in the keyway in the shaft, than heat the hub of the thrust collar and slide it into position on the shaft. Screw the thrust collar nut onto the shaft, and tighten it against the thrust collar. vvvv) 8hen the assembly has cooled, remove the thrust collar nut, place a new lock(washer against the hub of the thrust collar and screw the thrust collar nut on to the shaft. /ighten the nut and lock it in place with the lock(washer. wwww) Focate the bearing housing bottom half to the discharge cover with the dowel pins and secure it with the screws and nuts. xxxx) 2nstall the non(drive end "ournal and thrust bearings as described in Section ,.&.&Spets 1>)L &;).

4.4

C! "#in+ t! A8i&' Runnin+ Po$ition ? T!.u$t B &.in+ C' &.&n"


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Not 5

/he following checks must be carried out with the pump cartridge installed in the pump casing and the drive end and non(drive end bearing housings and ( "!&ni&' $ &' )i$&$$ (3' ). T! ).i< "ou%'in+ +u&.) &n) "ou%'in+ &$$ (3': (u$t &'$o 3 . (o< ). T! .ot&tin+ &$$ (3': (u$t 3 $uit&3': $u%%o.t ) &t &"! n) o- t! %u(% &t &'' ti( $.

.+

1) /he drive end of the pump should be assembled with the following components installedH a) b) c) 8ater cooling "acket and seal chamber. 9ottom half bearing housing. 9ottom half "ournal bearing. yyyy) /he non(drive end of the pump should be assembled with the following components installedH a) b) 8ater cooling "acket and seal chamber. 9ottom half bearing housing, bottom half "ournal bearing.

c) /hrust collar, key, thrust collar nut and lock(washer, and bearing housing end cover. AAAA) !heck the axial running position of the rotating assembly as followsH a) 'ove the rotating assembly as far as possible towards the drive end of the pump. 5sing the outer face of the thrust collar as a datum, scribe a line on the horiAontal surface of the bottom half bearing housing. b) 'ove the rotating assembly as far as possible towards the non( drive end of the pump and, using the same datum, scribe a second line on the bottom half bearing housing. 'easure the distance between the two linesH this should be approximately ; mm. c) 1osition the inner halves of the thrust bearing carrier rings, thrust pads and spacers in the bottom half housing and move the rotating assembly as far as possible towards the drive end of the pump. Scribe a third line on the surface of the bottom half bearing housing, using the same datum as beforeH this line should be approximately midway between the two previous lines. aaaaa) !heck the thrust bearing axial clearance as followsH

a) 1osition the outer halves of the thrust bearing carrier rings, thrust pads and spacers in the bottom half housing.
.+)

Do not in$ .t - ' . +&u+ $ 3 t9 n t! t!.u$t "o''&. &n) t! t!.u$t %&)$ to "! "# t! &8i&' "' &.&n" 5 t!i$ (&: +i< &n in&""u.&t . &)in+ &n) "&u$ )&(&+ to t! 9!it ( t&' %&)
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$u.-&" . b) check the axial clearance by moving the pump shaft as before and carefully measuring the differenceH alternatively, move the pump shaft so that the thrust collar is hard against one set of thrust pads and use feeler gauges between the opposite thrust bearing spacer and the thrust bearing housing wall. /he total axial clearance was originally as shown on 3rawing 0o. 203R4'4-5(@M<3)&'(77 1#)) and any measurable variation should be investigated. bbbbb) 2f spare thrust bearing assemblies are fitted, proceed as followsH Not 5 /he spare inner and outer spacers are supplied oversiAe in thickness for machining as necessary.

a) 8ith the rotating assembly in the axial running position, accurately measure the distance between the bottom half thrust bearing housing wall and the inner thrust collar face and record the reading. Repeat the procedure between the outer thrust collar face and thrust bearing housing end cover wall and record the reading. b) /he spacers should now be removed from the inner and outer thrust carrier ring halves and machined accurately to give the correct thickness as followsH 2) 2nner thrust ring spacer thickness N 'easured distance between housing wall and inner collar face minus thrust ring assembly thickness. 22) Duter thrust ring spacer thickness N 'easured distance between housing wall and outer collar face minus thrust ring assembly thickness plus axial bearing clearance). c) Secure the spacers to the thrust carrier ring halves and repeat step ,) as previously described. ccccc) 8ith the rotating assembly in its axial running position, check the drive end and non(drive end mechanical seal setting dimension. 2f necessary, machine or renew the seal setting distance piece achieve the re*uired dimension. 5 OVERHAUL IT IS ESSENTIAL THAT THE PLANT SAFET6 RULES AND RE4ULATIONS ARE OBSERVED AT ALL TIMES DURIN4 MAINTENANCE PROCEDURES.

*ARNIN45

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

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Not 5

2f a replacement cartridge is available, this should be prepared and installed as described in Section ..< before proceeding to dismantle and repair the worn cartridge Sections ..) to ... inclusive).

5.1

P. %&.&tion -o. O< .!&u' 1) 1repare the pump for maintenance as described in Section ,.1. ddddd) Remove all instruments and small bore pipework from the drive end and non(drive end bearing housings and mechanical seals that may interfere with the dismantling procedures. eeeee) 3isconnect and remove the two balance return pipes. fffff) 3isconnect and remove the lubricating oil pipework to and from the pump bearings. ggggg) !heck that all lifting e*uipment and special tools are in good condition. Not 5 /he shaft nuts at the drive end have left hand threadsH those at the non(drive end have right hand threads. Reference numbers on components should be re(marked as necessary to facilitate assembling.

5.2

*it!).&9in+ t! Pu(% C&.t.i)+ 1) 1repare the pump for overhaul as described in Section ..1. hhhhh) Remove the coupling guard , then unscrew and remove the flexible coupling elements and spacer. iiiii) Remove the grab screw locking the pump half coupling nut, than using special spanner, unscrew and remove the coupling nut in the shaft. """"") 8ithdraw the pump half coupling from the shaft. Remove the coupling key from the keyway in the shaft and retain it. kkkkk) Remove the screws securing the split pull(up ring to the pump casing and remove the pull(up ring. 3iscard the GDE ring and "oint.

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


lllll) Secure the wiithdrawal tube to the drive end bearing housing and secure the roller "ack assembly to the pump baseplate. Refer to 3rg. 203R4'4-5(61()4(77). mmmmm) 5nscrew the stud caps from the discharge cover studs and remove the nuts from the discharge cover studs, as the procedure show on 3rg. 203R4'4-5(6;()9(77. nnnnn) !ontinue to withdrew the pump cartridge slowly from the pump casing according next procedure show on 3rg.
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203R4'4-5(61()4(77. 5.3 Di$(&nt'in+ t! Pu(% C&.t.i)+ 1reparation for 3ismantling Not 5 3uring dismantling of the pump cartridge, it is essential that the cartridge be firmly supported. /he initial dismantling is carried out in the horiAontal position, and the final stages with the cartridge supported vertically. 4t no time should the weight of the cartridge be carried by the shaft.

1.1.17

1) 8ithdraw the pump cartridge from the pump casing as described in Section ..&. ooooo) 8ith the cartridge in the horiAontal position in the maintenance area, remove the lifting bracket from the suction guide and the "acking screws and the eyebolt from the discharge cover. 1.1.11 Removing the 3rive End 9earing :ousing and 'echanical seal

Remove the drive end bearing housing and mechanical seal as described in Section ,.).1, Step 1)L ;). 1.1.1& Removing the 0on(3rive End 9earing :ousing and 'echanical seal

Remove the non(drive end bearing housing and mechanical seal as described in Section ,.).&, Step 1)L ;). 1.1.1) 3ismantling the 1ump 2nternals Refer to 3rg. 0os. 203R4'4-5(@M<3)&'(77 1#&)O &#&)) 1) Remove the drive end and non(drive end bearings and mechanical seals as described in Sections ..).& and ..).). &) Set the rotationg assembly in the mid position and secure it with the clamping plate and stud and nuts. ppppp) 4ttach lifting gear to the cartridge lifting lug, and raise the cartridge into a vertical pasition on the assembly support trestle. *! n .&i$in+ t! &$$ (3':7 "&. (u$t 3 t&# n to n$u. t!&t &t no ti( i$ t! 9 i+!t o- t! &$$ (3': "&..i ) 3: t! %.ot.u)in+ n)$ o- t! %u(% $!&-t. *****) Remove the nuts from the tie rods securing the discharge cover and remove the spacers and the tie rods. rrrrr)4ttach lifting gear to the discharge cover, take the weight and carefully lift the cover up and over the end of the shaft and clear of the assembly. *! n . (o<in+ t! )i$"!&.+ "o< .7 n$u. t!&t & $t.&i+!t 'i-t
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.+))

.+)))

i$ o3t&in ) &n) t!&t no )&(&+ i$ "&u$ ) to t! 3&'&n" ).u( &n) . $t.i"tion 3u$!. sssss) 9end down the tab on the balance drum lock(washer, then unscrew and remove the balance drum nut and lock(washer. Remove the impacted ring. 3iscard the seal ring. ttttt) 5sing the withdrawal gear supplied, refer to 203R4'4-5(6,()!( 77, then apply heat evenly around the balance drum until enough expansion take place to enable removal of the balance drum. Fift the balance drum clear of the shaft. Remove and retain the balance drum key from the keyway in the shaft.

.1.1.1.1.1.1.3

@orce must not be used to remove the 3&'&n" ).u(. I- t! ).u( )o $ not . (o< "o(%' t ':7 &''o9 t! &$$ (3': to "oo'7 &n) . % &t $t % , /. uuuuu) Fift the disc spring from the last stage diffuser.

vvvvv) Remove the cap screws securing the last stage diffuser to the last stage ring section. Fift off the diffuser. wwwww) 4pply heat evenly to the hub of the last stage impeller until enough expansion take place to enable removal of the impeller. Fift the impeller clear of the shaft and mark it to facilitate assembing. Remove and retain the impeller key and the impeller split ring. Not 5 @orce must not be used to remove the impeller. if the impeller does not withdraw completely, allow the assembly to cool, and repeat step 1@/. xxxxx) Remove the cap screws securing the fifth stage ring section to the fourth stage ring section. Remove and discard the JDK ring and anti(extrusion ring. yyyyy) 4ttach the lifting gear lift off the fifth stage ring section and diffuser. AAAAA) 4pply heat evenly to the hub of the fifth impeller until enough expansion take place to enable removal of the impeller. Fift the impeller clear of the shaft and mark it to facilitate assembing. Remove and retain the impeller key and the impeller split ring. aaaaaa) Repeat the above steps 1&) and 1)) until only the first stage impeller remains on the shaft. Remove and discard the JDK rings and the Parlock seals from the second stage ring section. Not 5 /he cap screws securing the third stage ring section to the second stage are locked by locking strips which must be removed before removing the screws. bbbbbb) Screw the shaft lifting lug onto the end of the shaft and
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carefully raise the pump shaft through the suction guide and clear of the assembly. cccccc) Support the shaft in a horiAontal position and heat evenly to the hub of first stage impeller and slide impeller from the shaft. Remove and retain the impeller key. dddddd) 5sing suitable lifting gear lift the suction guide from the support frame. 5.4 In$% "tion7 R n 9&' &n) R %&i. P.o" )u. $ 4ll components should be thoroughly cleaned and inspected for any signs of wear or damage. 4ll diametrical running clearances between components should be measured, using internal and external micrometers, and compared with the values given in Section ..,.<. 2f the clearance has reached the maximum permissible clearance, or is likely to do so before the next overhaul, the component should be renewed. /he main consideration, however, is pump performance, i.e. an unacceptable decrease in pump discharge pressure, a significant increase in motor power consumption or an increase in vibration to an unacceptable level is noted, the pump should be overhauled. 1.1.1, 2mpellers and 8ear Rings 1) Examine the impellers for any signs of erosion, particularly at the blade tips. Examine the impeller bores and keyways for fretting or any damage which may have occurred during dismantling, and remove any burrs. Ensure that the impeller bores are perfectly smooth and free from distortion. eeeeee) Examine the impeller and casing wear rings, and measure the diametrical clearances between them. 2f the measured clearance exceeds the maximum permissible clearance, given in Section ..,.< or is likely to do so before the next examination, the wear rings must be renewed. 1roceed as followsH a Fightly machine the impeller wear ring diameters to remove any marks and to restore concentricity with the impeller bore. b 'achine the worn wear rings from the suction guide and ring sections#diffusers. c Ensure that the wear ring location is clean, then shrink the new wear rings into place by immersing them in li*uid nitrogen for a few minutes.
.),

A-t . . (o<&' -.o( t! 'iAui) nit.o+ n7 t! 9 &. .in+$ (u$t not 3 !&n)' ) 9it!out $uit&3' %.ot "tion.

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d e

Fock the wear ring in place with the point welding.

'achine the bore of the new wear rings to restore concentricity and the new clearance as shown as shown in Section ..,.<. 1.1.1. Shaft 1) Examine the shaft for any signs of damage or bowing, and check for concentricityH it should be within 7.7& mm full indicator movement. ffffff)!heck that all threads are in good condition and that all keyways are free from burrs. 1.1.1< 'echanical Seals

Examine the seals for signs of damage or wear. Renew as necessary. Refer to the seal manufacturerEs instructions. 1.1.1> 6ournal and /hrust 9earings 1) /horoughly clean the "ournal bearings and examine them for signs of wear or damage. 'easure the bearing clearances and compare them with the values given in Section ..,.<. Renew as necessary. gggggg) /horoughly clean the thrust pads and examine them for signs of wear or damage. Not 5 normal operating conditions, it is not expected that any measurable wear will take place on the thrust pads other than a dulling of the white(metal surfaces. 2t is recommended that when this dulling has spread to more than half the surface area of the pads, they should be renewed. hhhhhh) Examine the thrust collar for signs of wear or damage, and renew as necessary. iiiiii) Examine the oil seals for wear or deterioration and renew as necessary. 1.1.1; Peneral 1) Examine all studs, nuts and bolts for any signs of damage or deterioration. Renew as necessary. &) 4ll "oints and GDE rings, anti(extrusion rings and Parlock seals should be renewed on assembling. """""") 4ll dowel pins must be clean and free from damage. 8orn or damaged dowels must be renewed. kkkkkk) 4ll keys must be a good fit in their keyways. worn or damaged keys must be renewed. llllll) Examine the components of the coupling flexible elements assemblies and coupling bolts for wear or damage and renew as
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necessary. 1.1.1= !learances 3rg. 0o. 203R4'4-5(@M<3)&'(77 1#&)) /he table gives the running clearances. !olumn 1 shows the new clearance, and !olumn & the clearance at which the component s) should be renewed. 4ll clearances are given in millimetres and, unless stated otherwise, are diametrical.

Clearance between "ournal bearing and pump shaft Dil throwers and oil guards Ring section wear rings and impeller 3iffuser wear rings and impeller 9alance drum and balance drum bush Fast stage diffuser and discharge cover axial) /otal axial clearance in thrust bearing Ring section and impeller axial) 3iffuser and impeller axial) total axial clearance, thrust pads removed

Column 1 7.1,7#7.&1. 7.).7#7.,17 7.,17#7.,=7

Column 2 7.&< 7.,> 7.<>.

7.,17#7.,=7 7.,17#7.,=7

7.<>. 7.<>.

1.&)#&.&>

((

7.,

9y inspection

, , ;

(( (( ((

1.1.&7

3ynamic 9alance

Rotor must always be dynamic balanced when renewing or repairing individual parts. 8hen suitable workshop facilities are available the recommended method of checking the dynamic balance of the rotating assembly is as followsH(

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1) Support the assembly at the bearing centre lines and check that it is dynamically balanced within *uality grade P&.. in P9=&)=(1=;; 2SD 1=,7#1( 1=;< E)). mmmmmm) 3ynamic balance is to be achieved by removing metal from the impeller shrouds within the following limits. Not 5 2f the amount of metal to be removed exceeds the limits imposed by a) and C/7 SPEM Lt). $!ou') 3 "on$u't ).

/he thickness of the impeller shroud must not be reduced to less than <.. mm at any point. g 0o metal is to be removed from the impeller outwith the &<7L&=7mm diameter band. h /he weight of metal to be removed is to be calculated in the form of a segment, the arc length of which does not exceed 7.1 of the circumference of the impeller. 5.5 A$$ (3'in+ t! Pu(% C&.t.i)+ 4ll components must be perfectly clean and all bores and oilways must be cleaned before the pump is assembled. Not 5 3uring assembly, it is recommended that colloidal graphite, or similar, is applied to the shaft and to the bores of the impellers, sleeves and balance drum, allowed to dry and the surfaces then polished.

1.1.&1

4ssembling the 1ump 2nternals

Refer to 3rg. 0o. 203R4'4-5(@M<3)&'(77 1#&) 1) Support the shaft on tresles in a horiAontal postion, than locate the first stage impeller key in the keyway in the shaft. nnnnnn) 4pply heat evenly around the rear hub of the first stage impeller using the ring burner, than slide the impeller over the shaft and key until it abuts the shoulder on the shaft. Fo." $!ou') not 3 u$ ) 9! n -ittin+ t! i(% '' .. I- t! i(% '' . -&i'$ to 3utt &+&in$t t! $!&-t $!ou') .7 . (o< t! i(% '' . &n) "! "# -o. &n: 3u..$ o. )i.t 9!i"! (&: !&< 3 n o< .'oo# ) )u.in+ in$% "tion. C' &n u% &$ n " $$&.:7 t! n . % &t $t % ,2/. Do not &tt (%t to -it t! i(% '' . i- t! t (% .&tu. o- t! $!&-t i$ &3o< &(3i nt. oooooo) 4ttach the lifting gear and lift the suction guide onto the support trestles ensuring that it locates correctly on the assembly support plate, then remove the lifting gear.

.,

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pppppp) 8hen the shaft#first stage impeller assembly has cooled, screw the lifting lug onto the non(drive end of the shaft and raise the shaft and impeller into a vertical position above the suction guide. ******) !arefully lower the assembly into the suction guide until the impeller enters the first stage impeller eye bush in the suction guide. Remove the lifting gear and the shaft lifting lug. rrrrrr) @it new GDE ring, anti(extrusion rings and Parlock seals in the ring section groove. ssssss) Focate the anti(rotation dowel pin is in place in the first stage diffuser, attach lifting gear to the ring section #diffuser and install it over the first stage impeller, ensureing that it is correctly located on the suction guide. Remove the lifting gear. tttttt)Scure the frist stage ring section to the suction guide with the socket head screws, ensuring that the screw heads do not protrude above the upper surface of the ring section. uuuuuu) 9efore proceeding further, check the total axial travel as followsH( a Screw the lifting lug onto the non(drive end of the punp shaft and suitably sling, b /ake /he weight of the pump shaft and allow the first stage impeller to rest on the suction guide. c Fay a straight edge across the upper face of the first stage ring section, and lightly mark a line on the shaft. d 5sing the "ack, carefully raise the shaft as far as it will go without disturbing the first stage ring section and, using the same datum as before, mark a second line on the shaft. Fower the shaft. e 'easure the distance between the lines. /he total axial travel is ;.7mm, and if this is not achieved, the cause must be identified .
.,)

T! (ini(u( &"" %t&3' tot&' $!&-t t.&< ' i$ 6 ((. vvvvvv) Focate the second stage impeller split ring in the groove in the shaft and install the impeller key in the keyway in the shaft. wwwwww) 2nstall the second stage impeller by proceeding as described in Step &) above. xxxxxx) 2nstall the remaining diffusers, rign sections and impellers as described above, Steps >) to 1)), checking that the total axial travel remains unatered, as described in Step =). Not 5 /he socket head cap screws securing the second and third stage ring section must be locked u$in+ n 9 'o"#in+ $t.i%$.
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yyyyyy) Focate the last stage diffuser on the last stage ring section and secure it with the cap screws. AAAAAA) 2nstall the balance drum key in the keyway in the shaft, then heat the balance drum and slide it into position on the shaft, ensuring that it butts against the shoulder on the shaft and locates on the balance drum key. Screw the balance drum nut onto the shaft and tighten it against the balance drum. aaaaaaa) 4llow the assembly to cool, then remove the balance drum nut. install a new seal ring and impacted ring and lock( washer position into against the balance drum then screw on and tighten the balance drum nut. 9end over the lock(washer tab. bbbbbbb) @it the disc spring in position. ccccccc) Screw nuts onto the tie rods supplied, screw the tie rods into the tapped holes in the assembly support plate and tighten the nuts against the plate. ddddddd) Fower the discharge cover over the shaft and tie rods carefully, then insert the "acks between the last stage diffuser and discharge cover. eeeeeee) 4d"ust the "acks until the dimension between the support plate face and the face of the discharge cover is >.&Q7.17mm. fffffff) Focate the spacer supplied over the tie rods and into the discharge cover stud holes, then screw on and tighten the nuts against the spacers. Remove the lifting gear. ggggggg) 2nstall the drive end locating assembly. hhhhhhh) Secure the lifting gear to the lifting lug, then lower the cartridge into a horiAontal position on the support trestles and remove the locating assembly .
.,))

*! n 'o9 .in+ t! "&.t.i)+ &$$ (3': into t! !o.iBont&' %o$ition7 it i$ $$ nti&' to n$u. t!&t &t no ti( i$ t! 9 i+!t o- t! &$$ (3': "&..i ) 3: t! %u(% $!&-t. 2nstalling the 'echanical Seals T! .ot&tin+ &$$ (3': (u$t 3 $u%%o.t ) on 9oo) n t. $t' $ )u.in+ &$$ (3':. Not 5 /he following instructions apply e*ually to the drive and non(drive end mechanical seals.

1.1.&&
.,)))

1) Focate new JDK rings in the grooves in each water cooling "acket and install the "ackets in the suction guide and discharge cover. &) Focate a new JDK ring in the groove in each chamber and install the seal chambers on the water cooling "ackets.

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iiiiiii) Secure the seal chamber and the water cooling "acket to the suction guide and the dishcharge cover with the cap screws. """"""") Refer to the seal manufacturerEs instructions, and install the seal key and cartridge. 1.1.&) 4ssembling the 3rive End 9earing

2nstall the drive end bearing as 3escribed in Section ,.&.1, Steps 1&) to 1<). 1.1.&, 4ssembling the 0on(3rive End 9earing

2nstall the non(drive end bearing as 3escribed in Section ,.&.&, Steps 1>) to &<). 5.6 In$t&''in+ t! Pu(% C&.t.i)+ 3rg. 0o. 203R4'4-5(61()9(77 1) Secure the withdrawal tube plate to the drive end bearing housing with the hexagon head screws. Secure the first withdrawal tube to the withdrawal tube plate. &) Remove the nut, spacers and the tid rods securing the ring section assembly together, then withdraw the support plate from the suction guide. )) 2nstall a new JDK ring on the discharge cover, a new JDK ring in the groove in the periphery of the second stage ring section and a new JDK ring in the groove in the periphery of the suction guide. 2nstall a new "oint against the suction guide "oint face. Not 5 /he anti(extrusion ring must be located on the suctiion port side of the suction guide =O> .in+. kkkkkkk) Screw an eye(bolt to the discharge cover and lifting bracket to the suction guide. lllllll) @it the roller 6ack assembly to baseplate. mmmmmmm) @it all withdrawal tubes. 1ush the withdrawal tubes assembly into the pump casing until the withdrawal tubes contacts the roller "ack. @it a suitable sling#rope over the main casing stud and under the withdrawal tubes assembly. nnnnnnn) !arefully lift the pump cartridge into the pump casing, and lower it until the first stage withdrawal tube can be screwed into the withdrawal tubes assembly supported by the sling and the tubes rest on the roller. Remove the withdrawal tube support sling form the casing studs. ooooooo) guide.
.,)+

Remove the lifting gear and lifting bracket to the suction

*! n in$t&''in+ t! %u(% "&.t.i)+ n$u. t!&t t! $u"tion +ui) i$ .&)i&'': " nt.&' 9it! t! "&$in+ 3o. 3: &);u$tin+ t!

2" of 28

).i<

n) .o'' . ;&"# &$$ (3':.

ppppppp) !arefully push the pump cartridge into the pump casing, removing each withdrawal tube as it clears the roller "ack, until the discharge cover is engaged on the pump casing studs. Not 5 8hen installing the pump cartridge in t! "&$in+7 +. &t "&. (u$t 3 t&# n to n$u. t!&t t! =O> .in+ &n) t! 4&.'o"# $ &'$ )o not 3 "o( )&(&+ ) &n) t!&t t! "&.t.i)+ C"&$in+ &'i+n( nt i$ not )i$tu.3 ). *******) !ontinue to push the cartridge into the pump casing, until the suction guide and discharge cover are properly located in the pump casing. rrrrrrr) 8ith the discharge cover firmly against the pump casing, remove the sling and eye(bolt from the discharge cover. sssssss) Remove the roller "ack assembly from the baseplate and remove the withdrawal tube plate from the drive end bearing housing. ttttttt) 2nstall the nuts on the casing studs and screw the nuts onto the studs hand(tight against the discharge cover. uuuuuuu) 5sing the hydraulic stud tensioning e*uipment tighten the pump casing discharge cover nuts as procedure in the 3rg. 203R4'4-5(6;()9(77. vvvvvvv) 2nstall the stud caps over the casing studs. wwwwwww) 2nstall a new "oint, a new JDK ring and the anti(extrusion ring in the suction guide#pump casing recess. xxxxxxx) Focate the pull(up ring on the suction guide#pump casing and secure it in position with the screws. yyyyyyy) 2nsert the coupling keys in their keyways in the shaft, then install the pump half coupling on the shaft. AAAAAAA) 5sing the special spanner, tighten the coupling nut against the coupling hub, and lock it in place with the grub screw. aaaaaaaa) /urn the pump by hand, at the coupling, to ensure freedom of rotation. bbbbbbbb) !heck the coupling alignment. cccccccc) Replace the coupling flexible elements and spacer, then install the coupling guard. dddddddd) 2nstall all instrumentation and the seal cooling and lubrication oil pipework, using new "oints, together with any other small bore pipework removed prior to the withdrawal of the pump cartridge.

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