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002 001 000

REV Project Title

8-Jul-12 18-Apr-12 6-Sep-11 DATE

W.O.P M.KIDO H.I BY

ISSUE FOR INFORMATION ISSUE FOR APPROVAL ISSUE FOR INFORMATION DESCRIPTION

W.O.P W.O.P D.AOKI CHKD.

J.B.K G.B.B

S.H.Y S.H.Y T.FUKIDA

CERT.

APPD.

CONVERSION OF QURAYYAH OPEN CYCLE POWER PLANT TO COMBINED CYCLE POWER PLANT PROJECT C

Client

Consultant

Contractor

Document Title

OPERATIONS MANUAL FOR CONDENSATE EXTRACTION PUMP (Vol-I)

CREATED BY: DATE STARTED: OPR'G. DEPT.:

CHECKED BY: DATE COMPLETED: ENG. DEPT.: APPROVAL/CERTIFICATION INFORMATION DOC. NO. REV. NO.

THIS DOCUMENT IS NOT TO BE USED FOR CONSTRUCTION OR FOR ORDERING MATERIAL UNTIL CERTIFIED AND DATED

QURAYYAH JOB ORDER NO.

SAUDI ARABIA

1-0923053.01
JOB NO. PROJECT SUBDIVISION DOCUMENT TYPE CODE DOCUMENT NUMBER REV. NO.

30621127

000

3DT

00007

002

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MESSRS. PROJECT

: Doosan Heavy Industries & Construction Co., LTD : Qurayyah Combined Cycle Project

Operations Manual

OPERATION AND MAINTENANCE MANUAL

PRODUCT No. TYPE & SIZE SERVICE

: AP9332019,27,35,43,51 : MMTV200/4 : Condensate Extraction Pump

) ) )

3 2 1
REV. No.

2012/04/16 2012/02/01

Revised Revised
DESCRIPTION

D.Aoki M.Kido T.Fukuda D.Aoki M.Kido


T.Fukuda

TORISHIMA PUMP MFG. CO., LTD.


1-1-8 Miyata Cho, Takatsuki City, Osaka, Japan
APPROVED CHECKED DRAWN DATE 10.Feb.2011
REV.

DATE

APP'D

CH'D

DR'N

DISTRIBUTION

1 1 1

T.Fukuda
DWG. No.

D.Aoki

M.Kido

G305751-1/147

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Table of Contents
Table of Contents

Table of Contents
1. Introduction ............................................................................................ 3 2. Safety Precautions ................................................................................. 5
2.1 Warning Signs ............................................................................................................................. 5 2.2 General Precautions .................................................................................................................... 6

3. Installation .............................................................................................. 7
3.1 Foundation ................................................................................................................................. 10 3.1.1 Installation Flow ........................................................................................................ 10 3.1.2 Lifting........................................................................................................................ 13 3.1.3 Foundation Work ...................................................................................................... 14 3.2 Equipment Installation ............................................................................................................... 20 3.2.1 Installation ................................................................................................................ 20 3.2.2 Alignment ................................................................................................................. 25 3.2.3 Installation of Accessories ........................................................................................ 29 3.2.4 Check Items at the Completion of Equipment Installation ......................................... 29 3.3 Piping and Wiring ...................................................................................................................... 31 3.3.1 Piping Installation ..................................................................................................... 31 3.3.2 Wiring ....................................................................................................................... 31 3.3.3 Check Items at the Completion of Piping and Wiring ................................................ 31

4. General Description and Structure of Equipment.................................. 32


4.1 General Description of Pump .................................................................................................... 32 4.1.1 General .................................................................................................................... 32 4.2 Structure of Pump ...................................................................................................................... 32 4.2.1 Casing ...................................................................................................................... 32 4.2.2 Impeller .................................................................................................................... 33 4.2.3 Shaft ......................................................................................................................... 33 4.2.4 Shaft Seal ................................................................................................................. 33 4.3 General Description of Motor .................................................................................................... 34 4.4 General Description of Auxiliary Equipments ............................................................................ 34 4.4.1 Rigid Coupling .......................................................................................................... 34 4.4.2 Suction Strainer ........................................................................................................ 34

5. Operation Procedure ............................................................................ 35


5.1 Operation Flow .......................................................................................................................... 36 5.1.1 Commissioning Flow ................................................................................................ 36 5.1.2 Normal Operation Flow ............................................................................................. 38 5.2 Operation Procedure ................................................................................................................. 39 5.2.1 Preparation and Check before Commissioning ......................................................... 39 5.2.2 Preparation before Priming ....................................................................................... 40 5.2.3 Priming and Venting ................................................................................................. 40 5.2.4 Check before Start-up ............................................................................................... 40 5.2.5 Start-up..................................................................................................................... 40 5.2.6 Check after Start-up (at the Minimum Flow Operation) ............................................. 40 5.2.7 Minimum Flow Operation .......................................................................................... 41 5.2.8 Putting the Pump from Minimum Flow Operation into Normal Operation .................. 41 5.2.9 Check during Normal Operation ............................................................................... 41 5.2.10 Shutdown (to Standby State) .................................................................................. 42 5.2.11 Emergency Shutdown (to Inspection and Maintenance) ......................................... 42

6. Maintenance, Disassembly and Assembly ........................................... 43


6.1 Maintenance .............................................................................................................................. 44 6.1.1 Periodic Inspection ................................................................................................... 44 6.2 Disassembly .............................................................................................................................. 44

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Table of Contents
Table of Contents 6.2.1 Disassembly Tools and Others ................................................................................. 44 6.2.2 Disassembly of Pump ............................................................................................... 45 6.3 Inspection .................................................................................................................................. 47 6.3.1 Clearance Check ...................................................................................................... 47 6.3.2 Checking Runout of Shaft ......................................................................................... 47 6.3.3 Mechanical Seal ....................................................................................................... 47 6.3.4 Impeller .................................................................................................................... 48 6.3.5 Casing ...................................................................................................................... 48 6.3.6 Replacing Casing Wearing Ring ............................................................................... 48 6.3.7 Dynamic Balance ..................................................................................................... 49 6.4 Assembly ................................................................................................................................... 51 6.4.1 Precautions for Assembly ......................................................................................... 51 6.4.2 Reassembly.............................................................................................................. 51

7. Troubleshooting.................................................................................... 55 8. Storage ................................................................................................ 58


8.1 Storage Area .............................................................................................................................. 58 8.2 Storage Management ................................................................................................................ 58 8.2.1 Management during Storage .................................................................................... 58 8.2.2 Installation in Storage Area ....................................................................................... 59 8.2.3 Protection during Storage ......................................................................................... 59 8.2.4 Maintenance during Storage ..................................................................................... 61 8.2.5 Maintenance during Long-Term Storage ................................................................... 61

Attachment ............................................................................................... 62 Service Network ......................................................................................143

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1. Introduction

1. Introduction
This manual describes the installation and operation methods for the vertical multistage pump in detail. To install the pump, please read and fully understand the descriptions given in Chapter 3 of this manual with enough reference to the relevant drawings beforehand. As for the operations of the pump, Chapter 5 describes the operation procedure and Chapter 6 describes the maintenance and disassembling/assembling of the pump. In order to use the pump safely for a long time, it is necessary to fully understand the structure of the pump and its operation/maintenance practice. This manual also describes the safety precautions and operations necessary for the operator. The operator shall read the manual thoroughly before starting the operation or maintenance of the pump. In addition, always keep this manual at hand so that anyone who uses or maintains the pump can read it at any time. Note that any failure caused by a deviation from the instructions of this manual or any trouble caused by the situations described below is not covered by the warranty of our company. 1) When the liquid which does not meet the ordered specifications (including quality, density, temperature, and impurity or foreign objects contamination) is pumped up, or when the pump is operated beyond its specified performance characteristics (e.g., when the pump is operated with excessively large or small flow rate of liquid, or with an inadequate suction condition). Damages or defects caused by not following the instructions given in this manual, in other words, improper use or operation, wrong installation, use of inappropriate materials (e.g. use of inappropriate type of lubricant agent), wrong or incomplete piping, etc. Disassembly and assembly given in Chapter 6 require enough knowledge about our pumps, judgments based on experience, and enough experience and practice about practical work. Thus we recommend that pump is disassembled and assembled in our factory or that our supervisor is dispatched for advice. Please understand that any failure of pump disassembled or assembled by the customer alone, even if based on this manual, can not be guaranteed by us.

2)

3)

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1. Introduction

If you have any question regarding our products, please give us the following information to ensure prompt attention: (1) Product No. (six-digit figure following AP, P, KP, etc.) (2) Type and Size (3) Item No. The information above is provided in the name plate attached to the pump body. When ordering spare parts, please also inform us of the part numbers and names of the parts. (Refer to the "Sectional Drawing" of the pump.)

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2. Safety Precautions / 2.1 Warning Signs

2. Safety Precautions
2.1 Warning Signs
The warning levels and signs used in this manual are described as follows.

Danger
This indicates a potential danger that may result in death or serious injury of the operator.

Warning
This indicates a potential danger that may result in serious injury of the operator or damage of the equipment.

Caution
This indicates a potential danger that may result in injury of the operator or malfunction and/or performance degradation of the equipment. Note: This provides important information for understanding and operating the equipment.

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2. Safety Precautions / 2.2 General Precautions

2.2 General Precautions


The general precautions for the equipment are given below. Read these precautions before actually starting work to ensure safe operation.

Danger
Never allow any person other than service engineers to engage in disassembly, repair or remodeling work. Never work alone. Make sure to put on helmet, safety goggles, earplugs, safety shoes and other protective items when working. Make sure that there are no dangers of fire and explosion hazards, before carrying out any work involving sparks such as welding. Make sure that the liquid in the casing has been discharged thoroughly when the pumped-up liquid is a chemical solution. A chemical solution may lead to injuries when get in touch with the human body. Make sure to conduct checking of crane and slinging equipment such as wire rope unfailingly, before starting of work. When lifting heavy objects, use chain blocks, hang ropes, etc. as specified in the manual. Never work under lifted objects. Make sure to turn off the motor switch and affix "Do not power on" tag to the switch in order not to turn it on by mistake before starting any work involving touching the rotor. Do not open the terminal cover of electric equipment such as a motor during power-on. Otherwise, the workers might be seriously injured due to an electric shock. Make sure that the power is off and take preventive measures for powering on by wrong operation. Select proper lifting tools depending on the weight of the object to lift.

Warning
Install a safety fence around the work area and ensure evacuation routes. When there is a risk of freezing, completely drain the pump.

Caution
If oil spills on the floor or passage, immediately wipe it off. Otherwise, it may lead to a slip and fall accident. Read the related documents and drawings carefully before starting work to understand the structure of the pump and make the necessary preparations. Note: Always observe all the appropriate rules and regulations for safe installation and operation of the pump. If there is a serious mechanical damage, please contact us for advice.

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3. Installation

3. Installation
Precautions for Installation 1) General

Danger
Never allow any person other than service engineers to engage in disassembly, repair or remodeling work. Never work alone for your safety. Work under the control of the safety manager on-site. And, make sure to put on helmet, safety goggles, earplugs, safety shoes and other protective items when working. Make sure that there are no dangers of fire and explosion hazards, before carrying out any work involving sparks such as welding. Make sure that the liquid in the pump has been discharged thoroughly when the pumped-up liquid is a chemical solution. A chemical solution may lead to injuries when get in touch with the human body. Make sure to conduct checking of crane and slinging equipment such as wire rope unfailingly, before starting of work. When lifting heavy objects, hang ropes as specified in the manual. Never work under lifted objects. Make sure to turn off the motor switch, and affix "Do not power on" tag to the switch or take other preventive measures in order not to turn it on by mistake before starting any work involving touching the rotor. Do not open the terminal cover of electric equipment such as a motor during power-on. Otherwise, the worker may get seriously injured due to an electric shock. Make sure that the power is off and take preventive measures for powering on by wrong operation. Select proper lifting tools depending on the parts mass and shape of the object to lift. In a pit or a manhole where toxic gas may be generated or hypoxia may occur, check the place for safety before starting work.

Warning
Before unpacking the pump or pump parts, check the unpacking area for any obstacle etc. that may lead to serious damage during unpacking. Remove such obstacle etc. beforehand, if any.

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3. Installation

2)

Before Installation

Caution
When unpacking, take care not to damage the pump and its accessories. Before unpacking after a long storage period, perform the following checks for each part and make sure that it is serviceable. If any defective parts are found, they need to be replaced with new ones or they may be used without replacement after consulting with our company. (a) Check the contents and the number of pieces in the package against the packing list. (b) Check that the equipment is not damaged during storage. (c) Check the painted surfaces of the equipment. After unpacking, take care to prevent rust on the equipment for the period from installation to starting operation. Especially, pay enough attention to couplings and bearings. Read the related drawings and this manual carefully before starting work to understand the structure of the pump and make the necessary preparations.

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3. Installation

3)

During Installation

Caution
Pump foundation and installation works shall be performed in view of ensuring smooth operation of the pump and preventing the shock and vibration caused by the pump operation from being transmitted to neighboring facilities. If you want to install the pump in a method other than that specified in this manual, please consult us before using such method. When lifting the product, take the following precautions. (a) When lifting heavy parts such as a pump, pay careful attention so that the wire rope does not slip. (b) When lifting a part with wire rope, place some soft pads between the part and the wire rope to protect the painted or machined surface from the wire rope. Do not raise or lower the parts rapidly with a crane. (c) When placing a part on the ground, put a protection support between the part and the ground. (d) When lifting a pump, take care not to bump it against the ground. Remove the cover from each pump part and remove antirust coating, which was applied for rust prevention during transportation, with industrial cleaning agent (or thinner) before assembly. Remove all foreign objects from tapped holes with compressed air. Check that there is no rust, dust or protuberance on the flange or mounting surface before assembling each part. Be careful not to drop tools and the parts into the pump and the barrel. If they are sucked into the pump, the rotating element, the casing and the impeller will be damaged. Check that all the bolts for flanges or other parts are fully and evenly tightened. Take care to prevent rust on each part before starting operation. Touch up the coated surface which has been damaged or coming off during assembly with refinish paint. Check that there are no foreign objects in the auxiliary piping. Clean it completely before connecting to the pump.

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3. Installation / 3.1 Foundation

3.1 Foundation
In this section, the foundation part to install the equipment is described in detail. A barrel and foundation bolts are installed over the foundation. The liners that are buried under the barrel support the mass of the pump, the barrel, the electric motor and the water in the pump and the barrel. Work after understanding this section enough to make satisfactory foundation.

3.1.1 Installation Flow


The installation flow is shown in the figure below. Also the referential sections are indicated in the lower right of boxes in the figure.
Check the dimensions of foundation from the datum line. (Floor level, dimension of foundation bolt holes, etc.) 3.1.3 Foundation Work 1) Preparation for Installation Chip the surface of foundation (concrete). 3.1.3 Foundation Work 2) Installation of Temporary Liners Mark the centerline of pump, the height of foundation and the position of foundation bolts. 3.1.3 Foundation Work 1) Preparation for Installation Set the temporary liners on the foundation. 3.1.3 Foundation Work 2) Installation of Temporary Liners Make a mortar wall. 3.1.3 Foundation Work 2) Installation of Temporary Liners Install the barrel temporarily. 3.2.1 3.2.1
Installation Installation

1) Installation of Barrel 2) Temporary Installation of Barrel, Setting of Foundation Bolt (The First Filling of Mortar)

Adjust temporarily the levelness of the barrel. 3.2.1


Installation

2) Temporary Installation of Barrel, Setting of Foundation Bolt (The First Filling of Mortar)

Fig. 3.1-1 Installation Flow (1/3)

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3. Installation / 3.1 Foundation

Is the level within the tolerance? Yes 3.2.1

No

Adjust with the taper liner.

Installation

2) Temporary Installation of Barrel, Setting of Foundation Bolt (The First Filling of Mortar)

Fill the foundation bolt hole with mortar. (First Filling with Mortar) 3.2.1
Installation

2) Temporary Installation of Barrel, Setting of Foundation Bolt (The First Filling of Mortar)

Once lift up the barrel and set the final liners. 3.2.1
Installation

3) Setting of Final Liners

Install finally the barrel and adjust its levelness. 3.2.1


Installation

4) Final Installation of Barrel

Is the level within the tolerance? Yes 3.2.1

No

Adjust with the taper liner. 3.2.1


Installation

4) Final Installation of Barrel

Installation

4) Final Installation of Barrel

Fasten the foundation bolts. 3.2.1


Installation

4) Final Installation of Barrel

Spot weld the flat liners and taper liners. 3.2.1 Assemble the frame. 3.2.1
Installation Installation

5) Fixing of Liners

6) The Second Filling of Mortar

Fig. 3.1-1 Installation Flow (2/3)

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3. Installation / 3.1 Foundation

Fill the foundation with mortar. (Second Filling of Mortar) 3.2.1 Remove the frame.
Installation

6) The Second Filling of Mortar

Install the pump and motor. 3.2.1 Installation 7) Installation of Pump Body 3.2.2 Alignment 2) Alignment of Coupling (temporary alignment) Make a preliminary alignment. 3.2.2 Alignment 2) Alignment of Coupling (temporary alignment)

Is the alignment within the tolerance? Yes

No Adjust with the motor liners.

3.2.2 Alignment 2) Alignment of Coupling (Temporary Alignment)

Install the main piping. 3.2.1 Installation 7) Installation of Pump Body 3.3.1 Piping Installation 1) General, 2) Main Piping Make final alignment. 3.2.2 Alignment 4) Coupling Alignment (Final Alignment)

Is the alignment within the tolerance? Yes

No Adjust with the motor liners.

3.2.2 Alignment 3) Allowable Value of Alignment

Check the fastening state of the foundation bolts again.

Install the auxiliary piping and the accessories. 3.2.3 Installation of Accessories / 3.3.1 Piping Installation 3) Auxiliary Piping / 3.3.3 Wiring

Fig. 3.1-1 Installation Flow (3/3)

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3. Installation / 3.1 Foundation

3.1.2 Lifting
Use a crane to lift and move the pump unit. Attach a wire rope or a sling belt to the pump unit as shown in Fig. 3.1-2. When using a wire rope, protect the painted surface of the pump unit with a soft cloth etc.

Warning
Surely, lift individually the electric motor, the motor stool, the pump body and the barrel. The lifting holes of each part are designed based on only each individual mass. Therefore, lifting these parts in a combined condition (e.g. the electric motor and motor stool, the motor stool and pump body, etc.) may cause the breakage of attaching bolts or the drop of lifted parts. Select appropriate lifting tools including a crane by considering pump mass and working space. Before each lifting operation, check that lifting tools are firmly attached to ensure safety.

Danger
Do not work under lifted objects. Refer to the following figures (Fig. 3.1-2) for lifting the pump unit and equipment. Also refer to the "G. A. Drawing" for the mass of equipment.

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3. Installation / 3.1 Foundation

Barrel

Electric Motor Fig. 3.1-2 Lifting Typical Parts of Pump System

Pump Body

3.1.3 Foundation Work


1) Preparation for Installation (1) Mark the datum line and bench marks for installation on a stable surface which does not sink or slide during the installation work. (2) Check that the levelness of pump floor and the dimensions of foundation bolt holes are as specified in the "G. A. Drawing". (3) Mark the centerline of pump, the height of foundation and the positions of foundation bolts according to the "G. A. Drawing". (4) Clean the concrete surface and foundation bolt holes to remove all foreign objects. (5) Degrease the concrete surface and the foundation bolt holes.

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3. Installation / 3.1 Foundation

2) Installation of Temporary Liners (1) Heap up mortar for temporarily-adjusting liners on the installation surface of the pump floor. Set up temporarily-adjusting liners at about four, evenly-distributed places. Note: The number of temporarily-adjusting liners may vary if the required levelness of the barrel is obtained. For a smaller pump, three temporary liners will do. Reversely, for a larger pump, use about six temporarily-adjusting liners for the temporary installation.

Set up the temporarily-adjusting liners at the in-between spaces of neighboring foundation bolt holes in order to put setting places aside for the final-adjusting liners, which will be set up later. Furthermore, adjust the edge position of each temporarily-adjusting liner so that the edge is a little sticking out of the barrel in order to make the adjustment by taper liners easy.

Caution
Avoid the temporarily-adjusting liner excessively sticking out of the barrel so as to get enough area to support the load of the barrel, and avoid the temporarily-adjusting liner which is excessively inside the barrel so as to hold an easy adjustment by taper liners. (Refer to Fig. 3.1-3)

Suction nozzle: Barrel

Suction nozzle: Top casing

Fig. 3.1-3 Installation Position of Temporary Flat liners

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3. Installation / 3.1 Foundation

Note:

The flat and taper liners used here shall be provided by the customer. The shapes of a flat liner and a taper liner are shown in Fig. 3.1-4, and the respective dimensions are given in Table 3.1-1 for reference.

Flat liner

Taper liner (Two plates make a set.)

Fig. 3.1-4 Shapes of Flat Liner and Taper Liner Dimensions of Flat Liner and Taper Liner (For reference) Unit [mm] Flat liner A 75 100 120 150 180 150 180 200 250 B 38 50 75 90 90 65 65 75 75 C 8 11 11 15 18 15 15 18 18 D 75 100 120 150 180 150 180 200 250 E 38 50 75 90 90 65 65 75 75 Taper liner F 15 20 19.2 26 30.8 26 24.8 30 28 G 6 8 7.2 10 11.8 10 8.8 11 9 H 9 12 12 16 19 16 16 19 19

(2) When installing flat liners, chip the concrete surface of the pump floor so that the mortar on which flat and taper liners are mounted adheres tightly to the concrete. Then, clean the pump floor and moisten it adequately. Furthermore, chip also the insides of foundation bolt holes at the same time as the concrete surface of the pump floor. (3) Heap up mortar on the chipped concrete surface. Ensure heaping up mortar at both sides of each foundation bolt hole. (4) Place flat liners on the mortar. Check the levelness of each flat liner in each direction with a level. The height differences between each flat liner shall be within 1mm. And set the height of the top surface of the flat liner as about 30mm lower than the installation level of the barrel. (Refer to Fig. 3.1-5)

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3. Installation / 3.1 Foundation

Fig. 3.1-5 Installation Level of Flat Liner Furthermore, the allowable tolerance shall be within 0.5mm for the set height and within 0.1mm/m for levelness when measured as a single liner. (Refer to Fig. 3.1-6)

Fig. 3.1-6 Height and Levelness Adjustment of Flat Liner (5) Make a mortar wall around the foundation hole. In this regard, put tubes in the top of the mortar wall to vent air when filling mortar. (Refer to Fig. 3.1-7)

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3. Installation / 3.1 Foundation

Suction nozzle: Barrel

Suction nozzle: Top casing

Fig. 3.1-7 Construction Area of Frame (6) If the mortar with the flat liners on it is completely cured, place taper liners on the already installed flat liners. The allowable tolerance shall be within 0.01mm/m for levelness between each taper liner. (Refer to the upper side of Fig. 3.1-8) Check the levelness with a level and adjust it, if necessary, by sliding the paired taper liners with each other along the slant face. (Refer to the lower side of Fig. 3.1-8)

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3. Installation / 3.1 Foundation

Levelness

Fig. 3.1-8 Levelness between Taper Liners on Both Sides of Foundation Bolt Hole and its Adjustment

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3. Installation / 3.2 Equipment Installation

3.2 Equipment Installation


Note: Check "G. A. Drawing" and "Sectional Drawing" sufficiently before starting actual installation.

3.2.1 Installation
1) Installation of Barrel Install the barrel as follows: (1) Mark the centerline of the barrel. (Refer to Fig. 3.2-1)

Suction nozzle: Barrel

Suction nozzle: Top casing

Fig. 3.2-1 Indications of Center Lines (2) Lift the barrel by using shackles and the crane, etc. While the barrel is being lifted, place some soft pads between the barrel and the wire rope to protect the barrel surface. (Refer to Fig. 3.2-2)

Caution
Damage on the barrel surface (painted surface) might cause a pit to the barrel due to corrosion by water after the installation. Be careful to protect the barrel surface because the barrel with the pitting must be removed again to repair it.

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3. Installation / 3.2 Equipment Installation

Fig. 3.2-2 Barrel Lifting -1 (3) Stand the barrel vertically and slowly with taking care not to slip the hooked wires out. After that, move it over the barrel pit. (Refer to Fig. 3.2.3)

Fig. 3.2-3 Barrel Lifting -2 (4) Lower the barrel into the foundation hole slowly and vertically with taking care not to bump it on the foundation. (5) Place the barrel on the flat liners. 2) Temporary Installation of Barrel, Setting of Foundation Bolt (The First Filling of Mortar) (1) Attach foundation bolts to the barrel and place it on the taper liners. When attaching a foundation bolt, make such a jig of a piece of wire etc. as shown in the following figure, and insert the jigs into a bolt hole to prevent the foundation bolt from inclining. The wire size (diameter) is given by the half of the difference between the diameter of the bolt hole and the bolt diameter. (Refer to Fig. 3.2-4)

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3. Installation / 3.2 Equipment Installation

Fig. 3.2-4 Foundation Bolt Setting (2) Adjust the center, height and levelness of the barrel. (Temporary adjustment to bury the foundation bolts.) The allowable tolerance shall be within 0.1mm/m for levelness of the upper surface of the barrel. (3) The First Filling of Mortar Fill the first mortar according to the following: (a) Check that each foundation bolt is vertical and positioned in the central portion of the foundation bolt hole for the barrel. (b) Fill the foundation bolt holes with mortar to fix the foundation bolts in the holes. (Refer to Fig. 3.2-5)

Fig. 3.2-5 The First Filling of Mortar

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3. Installation / 3.2 Equipment Installation

3) Setting of Final Liners (1) Remove the barrel temporarily after mortars in the foundation bolt holes are completely cured. (2) Set the flat liners for final adjustment on mortars heaped up at the both sides of each foundation bolt hole. (3) Adjust the heights of the flat liners in the same way as the temporary adjustment. (Refer to Fig. 3.2-6) 4) Final Installation of Barrel Place the barrel again on the final liners. Adjust the height and the levelness of the upper surface of the barrel by using the taper liners while the foundation bolts are being tightened. The allowable tolerance shall be within 0.1mm/m for levelness of the upper surface of the barrel. (Refer to Fig. 3.2-6)

Suction nozzle: Barrel

Suction nozzle: Top casing

Fig. 3.2-6 Installation with Final Liners and Adjustment for Levelness 5) Fixing of Liners After all position adjustments are completed, check that all foundation bolts are fully tightened, and then, fix all liners by spot welding. (Refer to Fig. 3.2-7)

Fig. 3.2-7 Spot Welding of Liners

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3. Installation / 3.2 Equipment Installation

6) The Second Filling of Mortar (1) Assemble the frame around the foundation, and then fill mortar inside the frame. (Refer to Fig. 3.2-8) (2) Cure mortar until it is hardened completely. (3) Remove the frame.

Fig. 3.2-8 The Second Filling of Mortar 7) Installation of Pump Body (1) Remove all covers attached on openings and rotor-fixing jig (channel steels which prevent the rotor from moving) for transportation. (2) Lift the pump laid horizontally, pull it up vertically in the same way as the barrel and move it over the barrel. (3) Insert the pump into the barrel and fasten it with hexagonal bolts. Remember to set an O-ring (4120.7) to the upper surface of the barrel.

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3. Installation / 3.2 Equipment Installation

3.2.2 Alignment
1) Position Adjustment of Rotor For this pump, the way to adjust the rotor position when the pump delivered (new pump) differs from the way in reassembling the pump which has been disassembled. To adjust the rotor position, refer to the suitable procedure as follows for each condition.

When the pump delivered:


(1) Attach a centering tool to the mechanical seal.

Fig. 3.2-9 Details of Shaft Seal (2) Lift up the rotor by the design value of the lifting up range, which is equal to 61mm.

Caution
Make sure not to lift up the rotor more than the design value (more than 7mm) because lifting over the value pushes the mechanical seal excessively and might damage it, which is also mentioned in the following section.

When the pump disassembled and reassembled:


(1) Adjust the position of the rotor with the mechanical seal not attached according to the following steps. (a) Measure the distance (L) between the end of the shaft and the top face of the top casing when the rotor is in its lowest position. (b) Next, measure the distance (L) between the end of the shaft and the top face of the top casing when the rotor is lifted up to the position where the rotor touches the stator side. The difference (L) between L and L in previous step is the moving range of the pump rotor. The pump lifting up range (S) is half the length of L. (Refer to Fig. 3.2-10.) (2) Attach the mechanical seal. (3) Attach a centering tool to the mechanical seal and start alignment work. (Refer to Fig. 3.2-9)

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3. Installation / 3.2 Equipment Installation

Caution
The design value of the lifting up range is given by 61mm. Make sure not to lift up the rotor more than the design value (more than 7mm) because lifting over the value pushes the mechanical seal excessively and might damage it.

S (Lifting Up Range) L / 2 (L = L L) Fig. 3.2-10 Adjustment of Lifting Up Range of Rotor 2) Alignment of Coupling (Temporary Alignment) (1) Attach the motor stool and electrical motor to the pump. (2) Adjust the clearance between the coupling on the electrical motor side and the spacer ring to the lifting up range (S) when the pump rotary assembly is lowered. (Refer to Fig. 3.2-11.) The clearance between the spacer ring and coupling can be adjusted by rotating the spacer ring because the spacer ring is attached on the shaft by threads.

Fig. 3.2-11 Alignment and Adjustment of Distance at Spacer Ring

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3. Installation / 3.2 Equipment Installation

3) Allowable Value of Alignment Measure the parallelism (camming) between the faces of the couplings by inserting a dial gauge (lever type). (If there is no lever type dial gauge, measure the parallelism by putting a normal dial gauge on the under side of the coupling hub of the pump side.) The runout of the coupling peripheral surface is measured by putting a dial gauge on the periphery of the coupling. Refer to Table 3.2-1 for the allowable values of the alignment. Table 3.2-1 Allowable values of Alignment Allowable value (For the value indicated on the dial gauge, etc.) Temporary alignment Final alignment Camming Within 0.1 mm Within 0.1 mm Runout of coupling peripheral surface Within 0.05 mm Within 0.05 mm (Note 2) Notes 1) The allowable values above are ones when the alignment is performed by rotating the motor coupling hub. 2) The allowable values of both the temporary and final alignment are within 0.025 mm when judging from the runout of the core axis. 3) Refer to Coupling Drawing for the details of the couplings.

Caution
Make sure to perform alignment while the pump is cold. 4) Coupling Alignment (Final Alignment) (1) Connect the suction and discharge piping. (At this time, make sure not to apply piping load or moment to the pump flange.) (2) Confirm that the lifting up range (S), the distance between the faces and alignment of the faces of the couplings are the set values or within the ranges of the allowable values in the previous section. If not, readjust referring the previous section. (3) Tighten the two nuts of the coupling bolts at diagonal positions, and lift up the pump rotor. Next, tighten the nuts of the remaining coupling bolts.

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3. Installation / 3.2 Equipment Installation

(4) Remove the centering tool.

Caution
Make sure to remove the centering tool. If operate the pump without removing the tool, the tool and the seal sleeve will rotate contacting with each other and they may damaged.

(5) After finishing the alignment, rotate the shaft by hand and confirm that there is no abnormality.

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3. Installation / 3.2 Equipment Installation

3.2.3 Installation of Accessories


The installation methods for the accessories are described below. 1) Suction Strainer Keep enough maintenance space for strainer installation. Clean the flange faces of a strainer and its mounting location before installing. When installing a strainer, pay attention to the direction of the strainer and do not leave out inserting a gasket. The clogging of a suction strainer is generally detected by a differential pressure gauge and it is recommended to install a differential pressure gauge for a strainer.

Caution
Install a strainer so that the distance between the connection flange faces is kept equal.

3)

Other Accessories Install the other accessories according to the P&ID (Piping and Instrumentation Diagram). Refer to the relevant instruction manual of each accessory.

3.2.4 Check Items at the Completion of Equipment Installation


The check items necessary for the completion of equipment installation are listed in 1. Check Items at the Completion of Equipment Installation of Attachment 2) Check List at the Completion of Installation.

3.2.5 Detuning of Pump


When the pump is operated at the site, the vibration might become large. One of the causes of the vibration is a resonance which is generated by the coherence of the natural frequency of the pump and the rotation frequency of the electric motor (*). In order to solve this problem, the detuning bolts can be attached to the sides of the electrical motor mounting bolts. If the detuning bolts are attached, the natural frequency of the pump is lowered and the resonance is avoided. Even if the descent of the rigidity of a foundation across the age could lead a resonance, it can be avoided by attaching the detuning bolts. If there is no problem of the vibration at the trial run at the site, the detuning bolts are not attached. (The holes for the bolts are made.) * The pump is designed and manufactured so that the natural frequency is isolated from a vibration frequency enough, and the natural frequency of the pump is measured at a trial run at our factory. However, the natural frequency might come close to the rotation frequency by the difference of the rigidity of the foundation or of the state of an installation between at your site and our factory.

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3. Installation / 3.2 Equipment Installation

Fig. 3.2-1 Detuning Bolt

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3. Installation / 3.3 Piping and Wiring

3.3 Piping and Wiring


3.3.1 Piping Installation
1) General Before starting piping installation, clean the inside of the piping and check that there is no scale or rust left in the piping. Install not only piping but also appropriate piping supports so that excessive piping load or moment is not applied to the pump. In this installation, be careful not to constrain the thermal expansion of the equipment, piping or its supports. The piping load applied to the pump flange shall not exceed the values specified in the "Outline Drawing. (Otherwise, the pump may be broken.) Main Piping Install the main piping after the second-filled mortar hardens and the frame is removed. When the main piping installation is completed, make the final alignment. Auxiliary Piping Install the auxiliary piping according to the G. A. Drawing (or auxiliary piping diagram) and the P&ID. Note: If Swagelok tube fittings are used, install them according to Attachment 6) Swagelok Tube Fitting Installation Instructions.

2)

3)

3.3.2 Wiring
Perform wiring in accordance with the wiring diagram.

3.3.3 Check Items at the Completion of Piping and Wiring


The check items necessary for the completion of piping and wiring are listed in 2. Check Items at the Completion of Piping and Wiring of Attachment 2) Check List at the Completion of Installation.

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4. General Description and Structure of Equipment / 4.1 General Description of Pump / 4.2 Structure of Pump

4. General Description and Structure of Equipment


4.1 General Description of Pump
4.1.1 General
This pump includes the water-injecting device for the shaft seal part and the equalizing pipe because it is used with the service water in high vacuum. The former prevents the atmosphere from leaking in the inside of the pump by always supplying external seal water to the shaft seal part, which is required because the inside of the pump is in vacuum when it is running or stops. The shaft-sealing water is supplied from the service water when this pump is running. When this pump stops, the shaft-sealing water is obtained from another pump which supplies pressured water. As for the latter, the air in the suction line side negatively affects the suction performance of this pump. Also, the inside air can not be exhausted into the atmosphere if it is attempted to fill the inside of the pump with the condensate water when the pump is vacuumed up by the condenser. To exhaust the inside air, therefore, the equalizing pipe is installed in the higher place of the suction side and it is connected to the upper part of the condenser. The air exhaust to the condenser through the equalizing pipe always keeps the degree of the vacuum inside the suction barrel the same as the condenser.

4.2 Structure of Pump


This pump is the vertical centrifugal multi-stage pump, and has the suction port in the pit barrel (or top casing) and the discharge port in the top casing. The rotor is driven directly by the motor. The motor bearing supports the pump thrust along the shaft and the mass of the rotor. Main components a pump consists of are outlined as follows:

4.2.1 Casing
The casing of this pump consists of the bellmouth, volute casing, intermediate casing and diffuser casing. The bellmouth is the driving channel of the suction part of the pump and is connected to the volute casing or diffuser casing. The volute casing is used to enclose the 1st stage impeller. The intermediate casing connects the volute casing and the diffuser casing, and functions as the suction opening for the double entry type of impeller. The diffuser casings enclose the second stage and the following impellers. The riser pipe is directly connected to the last diffuser casing. Each casing is fastened to the next stage casing with hex. bolts or stud bolts.

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4. General Description and Structure of Equipment / 4.2 Structure of Pump

4.2.2 Impeller
The closed type of impeller is used and all impellers are attached on the main shaft in the same direction. Keys are used to fix the impellers on the shaft against rotation. The double entry type of impeller is used as the first stage impeller. Each impeller except for the fist stage has balancing holes to reduce the thrust. The casing wearing ring is set between the sliding part of a diffuser casing and the one of an impeller to obtain an appropriate gap, which restricts the leakage of service water from the high-pressure side to the low-pressure side to the minimum.

4.2.3 Shaft
The shaft transmits the power transmitted from the motor to each machine element of the rotor while rotating at the required speed. Each machine element is fastened to the shaft by a key or fitting in the rotation direction, and by the contact surface of the stepped portion of the shaft, split rings or fitting in the axial direction to transmit the generating power or thrust.

4.2.4 Shaft Seal


Leakage of service water is restricted by the mechanical seal. The suction of the air is prevented by injecting external seal water to the seal part. The floating seat (4750) is in the stator side. The sealing washer (4720) and the spring (4770), etc. are fixed on the shaft and rotate with the rotor. The positions of the parts in the rotor side are adjusted so that the pushing range of the mechanical seal is appropriate when the rotor is pressed to the counter-motor side (lower side in installed condition). Then, the sealing edge is formed with the floating seat (4750) by lifting the rotor upwards. Therefore, the restriction of the leakage depends on the position adjustments of the parts in the rotating side and the lifting up range of the rotor. These works also affect the damage of the mechanical seal. For details, refer to the sections 3 and 6, and "Mechanical Seal Instruction Manual" separately attached.

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4. General Description and Structure of Equipment / 4.3 General Description of Motor

4.3 General Description of Motor


Refer to the accompanying instruction manual for details.

4.4 General Description of Auxiliary Equipments


4.4.1 Rigid Coupling
It consists of coupling hubs and reamer bolts, and no lubricant is required owing to its structure.

4.4.2 Suction Strainer


It is recommended to install a strainer in the suction side of the pump to prevent damages inside the pump due to dust, scale or welding slag that enter the supplied water from outside. When a strainer is installed, always check that the differential pressure does not exceed the one for cleaning and take care not to operate the pump with clogging in the strainer.

Caution
Above mentioned strainer is used to prevent relatively larger particles from damaging inside of the pump. However it is not efficient for smaller particles such as sand or iron powder. Please control such smaller particles not to mix in by the customer yourself.

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5. Operation Procedure

5. Operation Procedure
1) Precautions for Operation To ensure safe work, read the precautions given in "2.2 General Precautions" and also the precautions given below before starting the pump operation.

Danger
Immediately stop the pump if the pump makes abnormal sounds or vibrations, and make sure to inspect the pump before the resumption of operation. Please contact us in advance when disassembling the pump. Do not come closer to or touch the rotors such as the shaft and coupling during operation as they may be scattered due to breakage. When approaching to the pump in operating, please confirm in advance that there is no excess leakage from the piping. Do not touch hot sections of the pump during and right after the operation without checking the temperature of the pump in advance.

Warning
If the water filling is insufficient, the sudden breakage of the impeller, mechanical seal, submerged bearing and casing may be caused due to an idle rotation or an excess flow operation of the pump. Pump operation deviating from any specified conditions can become a cause to damage the pump.
2) Precautions for Operator

Warning
Any person other than the operator who is able to operate the pump shall not operate the pump.

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5. Operation Procedure

5.1 Operation Flow


5.1.1 Commissioning Flow
The commissioning flow is shown in Fig. 5.1-1. Also the referential sections are indicated in the lower right of some boxes in the figure.

Preparation before commissioning


5.2.1 Preparation and Check before Commissioning

Electrical system check (including motor) Loop check, valve check, etc. Apparatus check

Check before commissioning


5.2.1 Preparation and Check before Commissioning

Checking and cleaning suction line

Filling main line of suction side with water

Checking and cleaning discharge line

Preparation before priming


5.2.2 Preparation before Priming

Priming and venting


5.2.3 Priming and Venting

(1) to (4) in "Check before Start-up"


5.2.4 Check before Start-up

Checking the ratio of each valve opening


5.2.4 Check before Start-up

Fig. 5.1-1 Commissioning Flow (1/2)

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5. Operation Procedure / 5.1 Operation Flow

Starting the pump for a short time and shutting-down

Has the pump run smoothly?

No

Determine the causes and solve. (Please contact us if disassembling)

Yes Start-up
5.2.5 Start-up

Check after start-up (minimum flow)


5.2.6 Check after Start-up (at the Minimum Flow Operation)

Is the check OK?

No

Shut down the pump

Yes

Determine the causes and solve. (Please contact us if disassembling)

Is it possible to start checking continuous running?

No

Yes Start-up the pump

Checking continuous running

Shutdown (to Standby State)


5.2.10 Shutdown (to Standby State)

Fig. 5.1-1 Commissioning Flow (2/2)

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5. Operation Procedure / 5.1 Operation Flow

5.1.2 Normal Operation Flow


The normal operation flow is shown in Fig. 5.1-2. Also the referential sections are indicated in the lower right of some boxes in the figure.
Preparation before operation Electrical system check (including motor) Loop check, valve check, etc. Apparatus check Check before start-up
5.2.4 Check before Start-up

Start-up
5.2.5 Start-up

Check after start-up (minimum flow)


5.2.6 Check after Start-up (at the Minimum Flow Operation)

Is the check OK?

No

Yes Putting the pump from minimum flow operation into normal operation
5.2.8 Putting the Pump from Minimum Flow Operation into Normal Operation

Check during normal operation


5.2.9 Check during Normal Operation

Is the check OK? Yes Normal operation

No

Shut down the pump

Determine the causes and solve. (Please contact us if disassembling)

Shutdown (to standby state) or emergency shutdown (to inspection and maintenance)
5.2.10 Shutdown (to Standby State) 5.2.11 Emergency Shutdown (to Inspection and Maintenance)

Fig. 5.1-2 Normal Operation Flow

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5. Operation Procedure / 5.2 Operation Procedure

5.2 Operation Procedure


5.2.1 Preparation and Check before Commissioning
Check the following before commissioning the pump: (1) Check if all apparatus function properly. (2) Check the pump rotor assembly by rotating it manually. (3) Check the alignment of the pump and motor without connecting them (to confirm that the alignment is within the tolerance in "3.2.2 Alignment"). Adjust the alignment if necessary.

Warning
Entanglement hazard If operating the motor during the alignment work, serious injury to the worker and damage to the pump may be caused. Confirm that the motor has been turned off, and take measures to prevent the motor from running by wrong operation. (4) Let cooling water flow into its piping by opening the main and related valves of cooling water, if necessary. (5) Check the oil level of the thrust bearing is appropriate. (6) Check the rotation direction of the motor: a) b) c) Inch the motor (turn on, then off the motor quickly) before connecting it to the pump. Confirm the rotation direction by comparing to the marking. When the rotation direction is wrong, check if the power cables are connected properly. Reconnect the power cables by the electrician if necessary, and check others. If the rotation direction is correct, turn the power off.

d)

Danger
Do not open the terminal cover of electric equipment such as a motor during power-on. Otherwise, the worker may get seriously injured due to an electric shock. When opening the terminal cover, confirm that the power is off and take preventive measures against powering-on by wrong operation. (7) Operate the motor in unloaded condition and check if the motor is running normally. (8) After confirming that the motor is running normally, shut down the motor.

Warning
Entanglement hazard If operating the motor during the alignment work, serious injury to the worker and damage to the pump may be caused. Confirm that the motor has been turned off, and take measures to prevent the motor from running by wrong operation.

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5. Operation Procedure / 5.2 Operation Procedure

5.2.2 Preparation before Priming


Make the following preparation before priming: (1) Open the equalizing pipe and the air vent valve of the shaft seal part.

5.2.3 Priming and Venting


(1) Open gradually the gate valve of the suction line to its full opening. (2) Open the flow control valve. (3) At the valve manifolds, vent the air from pressure measurement instruments such as the pressure gauges. (4) Check the pump rotor assembly by rotating it manually.

5.2.4 Check before Start-up


(1) (2) (3) (4) Check that the gate valve of the suction line is in full opening. Check the water filling and suction pressure, and record them. Check that a centering tool for the mechanical seal has been removed. Check that water is injected into the seal water piping, the equalizing pipe is opened, and there is no water leakage from other piping etc. (5) Rotate the motor for a short time by inching operation. a) b) c) d) Start the pump (motor) and check that it runs smoothly. Operate the pump to the rated revolution and check that each pressure is in proper value. Rotate the motor for a short time to vent the residual air in the pump. Turn the pump (motor) off and check that it slows down smoothly and stops.

5.2.5 Start-up
(1) Start-up the pump (motor).

5.2.6 Check after Start-up (at the Minimum Flow Operation)


(1) Make sure that the flow rate of the pump does not become less than the Minimum-Flow during the operation. Especially, pay attention to the quick rise in the service water temperature. (2) Check the mechanical seal to see whether there is any leakage from the shaft seal part or not. (3) Check and record the suction pressure of the pump. (4) Check and record the discharge pressure of the pump. (5) Check and record the differential pressure of the suction strainer.

Caution
If the differential pressure exceeds the cleaning differential pressure, clean or replace the filter element.

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5. Operation Procedure / 5.2 Operation Procedure

5.2.7 Minimum Flow Operation


When the pump operates in the state of zero or extremely low discharge flow rate, the pump efficiency will drop significantly, so that a large portion of the power provided by the motor will convert to heat, which increases the service water temperature in the pump. Restricted operation of the pump in a flow rate less than a discharge flow rate will cause a sharp rise in temperature, which is very dangerous. The minimum discharge flow rate to avoid such a sharp temperature-rise during the pump operation is called as Minimum Flow.

Caution
The Minimum Flow operation is for avoiding the sharp rise in temperature in a short time and not for the continuous operation. Please contact us for flow rate where continuous operation is possible.

5.2.8 Putting the Pump from Minimum Flow Operation into Normal Operation
(1) Open the flow control valve and increase gradually the discharge flow to the rated flow.

Caution
If the discharge piping is empty, do not open rapidly the discharge valve to its full opening. Increase the discharge flow gradually. Adjust the flow into the discharge piping by the discharge valve.

5.2.9 Check during Normal Operation


(1) Check the mechanical seal to see whether there is any leakage from the shaft seal part or not. (2) Check the oil level of the oil level gauge and whether there is no oil leakage from the bearing or not. (3) Check and record the suction pressure of the pump. (4) Check and record the discharge pressure of the pump. (5) Check and record the differential pressure of the suction strainer.

Caution
If the differential pressure exceeds the cleaning differential pressure, clean or replace the filter element. (6) Check and record the vibration level.

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5. Operation Procedure / 5.2 Operation Procedure

5.2.10 Shutdown (to Standby State)


(1) Close the discharge valve gradually to make the flow of the pump approach to the Minimum Flow. (2) Turn the motor off. (3) Check that the pump slows down smoothly and stops: A) It is recommended to record the slowing-down time until the pump stops. B) If the pump stops suddenly, it is possible that some part of the pump rotor have interior contact with other parts due to a foreign object bitten in. After pump temperature becomes low enough, check the pump rotor by rotating it manually. Note: Except that the pump is stopped running for a long term and the water has been already drained, keep the suction valve in open.

5.2.11 Emergency Shutdown (to Inspection and Maintenance)


(1) (2) (3) (4) Turn the motor off. Check that the pump slows down smoothly and stops. Close the discharge valve. Close the suction valve

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