BCWP Manual

DURGAPUR #1 & #2
OPERATING & MAINTENANCE
MANUAL
CLIENT : BHARAT HEAVY ELECTRICALS Ltd.

CLIENT ORDER No. : FB-180-7700001566
HTEP REFERENCE : EP11104/5

6 x 380 kW BCP with motor
SERVICE :
(3 per order)
REVISION : 0, September 2010
FOREWORD
This instruction manual provides Note! Where a customer boiler layout
comprehensive installation, operating and drawing is shown, this is used in good faith.
maintenance information of a Hayward Tyler However, Hayward Tyler can accept no
Glandless, Wet Stator, Motor Pump Unit, responsibility for any errors or
referred to in the text as the circulator. consequences that may result.
The Table of Contents list shows that the Hayward Tyler Manuals are for guidance
manual is divided into sections. Paragraph only and we reserve the right to update,
references are consecutive throughout each revise and modify this manual in accordance
section, and are preceded by the with our continuous research and
appropriate section number. For example development programme.
6.1. designates:-
Revised manuals will not automatically be
Section 6, Commissioning. issued, however, should they be required,
6.1. Pre-Start Check List. Hayward Tyler may be contacted and
arrangements can be made.
The major illustrations of the Pump and
Motor are included at the rear of Section 8.
Additional illustrations of particular features
are incorporated in the text.
REVISION HISTORY
Revision Date Reason

0 September 2010 First Issue
CONTACT DETAILS
Hayward Tyler Ltd.
1 Kimpton Road
Luton
Bedfordshire
ENGLAND
LU1 3LD
Telephone :-
+44 (0) 1582 731144
Fax :-
+44 (0) 1582 452198
Rev 0 Sep 10 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD -i-
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
WARRANTY Hayward Tyler is committed to delivering
The unit(s) is/are subject to a warranty as excellent aftersales service. As part of the
specified within the original sales contract. warranty process, all claims will be
The unit warranty does not cover motor acknowledged within 1 working day and
burnouts due to internal dry running, actioned within 5 working days from initial
insufficient cooling, lightening strikes, notification. In order to assist Hayward Tyler
improper installation, control or operation. In to address the claim effectively, please
the unlikely event of a unit ceasing to provide the following information when
operate normally please refer in the first reporting a warranty issue:
instance to the fault matrix included in this
manual. If the issue still cannot be resolved Unit Serial Number
then contact Hayward Tyler using the details Primary contact details
below: Details of the issue including the date issue
was first observed
HTS Customer Services Coordinator Commissioning Date
Hayward Tyler Ltd (Services) Last Service Date (Service Agency)
1 Kimpton Road Previous Warranty Claims
Luton
Bedfordshire Dependant on the nature of the fault, it may
ENGLAND be necessary to strip and inspect the unit
LU1 3LD prior to issuing a report. Any work
undertaken on a unit that has failed under
Telephone: +44 1582 731144 circumstances not deemed to be covered
Email: warranty@haywardtyler.com under warranty will be chargeable to the unit
end user.
Rev 0 Sep 10 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD - ii -
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 1 Table of Contents
1 Table Of Contents
FOREWORD ..................................................................................................................................... i
REVISION HISTORY ........................................................................................................................ i
CONTACT DETAILS ......................................................................................................................... i
WARRANTY ..................................................................................................................................... ii
1 Table Of Contents ................................................................................................................... 1
2 Technical Data ........................................................................................................................ 3
2.1 General........................................................................................................................... 3
2.2 Pump / Motor Design Characteristics............................................................................. 3
2.3 Operating Points............................................................................................................. 3
2.4 Clearances & Settings .................................................................................................... 4
2.5 Instrumentation............................................................................................................... 4
2.6 Torque Loading .............................................................................................................. 4
2.7 Weights (Approximate) ................................................................................................... 4
3 Storage.................................................................................................................................... 9
3.1 Environment ................................................................................................................... 9
3.2 Storage General .......................................................................................................... 9
3.3 Inhibitor........................................................................................................................... 9
3.4 Heat Exchanger............................................................................................................ 11
3.5 Exterior Surfaces .......................................................................................................... 11
3.6 Standard Storage Checks For Storage Up To 3 Years................................................ 11
3.7 Storage Periods Greater Than Three Years ................................................................ 12
3.8 Preparation For Storage After Use............................................................................... 12
3.9 Inspection Record Card ............................................................................................... 14
4 Description ............................................................................................................................ 16
4.1 General......................................................................................................................... 16
4.2 Pump ............................................................................................................................ 16
4.3 Motor ............................................................................................................................ 16
4.4 Terminal Boxes ............................................................................................................ 20
4.5 Heat Exchanger............................................................................................................ 20
4.6 Alarm Systems ............................................................................................................. 20
5 Installation ............................................................................................................................. 21
5.1 General......................................................................................................................... 21
5.2 Pump Case Installation (Fig 5.1) .................................................................................. 22
5.3 Preparation For Motor Installation ................................................................................ 23
5.4 Motor Installation (Fig 5.2) ........................................................................................... 23
5.5 Fitting The Heat Exchanger (Customer supplied) ........................................................ 27
5.6 Filling The Circulator With Boiler Cold ......................................................................... 27
5.7 Hydrotesting Boiler With Circulator Installed ................................................................ 28
5.8 Electrical Connections .................................................................................................. 30
5.9 Motor Protection ........................................................................................................... 31
6 Commissioning ..................................................................................................................... 33
6.1 Pre-Start Check ............................................................................................................ 33
6.2 Initial Starting - Cold Boiler Condition .......................................................................... 33
6.3 Stopping ....................................................................................................................... 35
7 Operation .............................................................................................................................. 36
7.1 Starting The Circulator ................................................................................................. 36
7.2 Shutting Down The Circulator ...................................................................................... 37
7.3 Routine Checks And Operation Conditions ................................................................. 38
7.4 Fault Finding (Fig 7.1) .................................................................................................. 41
Rev 0 Sep 10 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD -1-
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 1 Table of Contents
8 Maintenance ......................................................................................................................... 42
8.1 Motor Removal ............................................................................................................. 42
8.2 Disassembly ................................................................................................................. 45
8.3 Inspection Of Components........................................................................................... 45
8.4 Assembly Notes ........................................................................................................... 48
8.5 Re-Installation Of Motor ............................................................................................... 50
8.6 Parts Lists..................................................................................................................... 52
8.7 Drawing List.................................................................................................................. 56
9 Stud Tensioning Equipment .................................................................................................. 66
9.1 Introduction................................................................................................................... 66
9.2 Application .................................................................................................................... 66
9.3 Description (Fig. 9.1) .................................................................................................... 66
9.4 Assembling The Stud Tensioner (Fig. 9.3) ................................................................. 68
9.5 Replenishing The Pump Tank ...................................................................................... 74
9.6 Indexing ........................................................................................................................ 74
9.7 Safety Procedures ........................................................................................................ 74
9.8 Tightening Flange Nuts ................................................................................................ 74
9.9 Releasing Flange Nuts ................................................................................................. 75
9.10 Parts List ...................................................................................................................... 77
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 2 - Technical Data
2 Technical Data
2.1 General
EP/09/11104 A, B, C
Unit Serial Nos:
EP/09/11105 A, B, C
Service: Boiler Water Circulating Pump with Motor below Pump
Number Supplied: 3 per order
Electrical: 3300V - 3 Phase - 50Hz
2.2 Pump / Motor Design Characteristics
Type: Single Suction, Double Discharge

Pump size (2x13) x 16 x 19N
Design Pressure/Temp 214 kg/cm2 @ 370C
Hydrostatic test pressure 321 kg/cm2
Motor rated output 380 kW
Motor service factor 1
Motor winding insulation XLP PE2+PA
Motor electrical supply 3300V 3Ph 50Hz
Full Load Current 91.2 A
Max Starting Current 451 A
Locked Rotor Current 393 A
Nominal speed 1458 rpm
Estimated Pump Curve No. E94460B Rev 1
Estimated Motor Curve No. cEP11104_P Rev 0
60% 50 % 50%
BMCR
2.3 Operating Points BMCR TMCR TMCR
GUARANTEED [SAT W]
Quantity m/hr 2975 3872 4072 4072
Differential Head [actual] m(g) 31.48 22.9 20.4 20.4
Differential Pressure kg/cm2(g) 1.76 1.39 1.42 1.42
Calculated Mixed Water Temperature C 356.6 343.7 306.6 308.6
Suction Pressure kg/cm2(g) 197.35 181.33 100.40 100.38
Min. NPSH req above vapour pressure [cold] m 16.3 14.3 14.7 14.7
Specific Gravity at pump suction temperature t/m 0.559 0.611 0.699 0.693
Pump Efficiency % 81.4 80.9 77.7 77.7
Power Absorbed by Pump (mechanical) kw 175.21 182.44 203.59 201.84
Motor Efficiency % 89.70 89.3 89.70 89.70
Electrical Input to Motor kW 196.43 204.21 226.93 225.05
Power Factor 0.707 0.716 0.739 0.737
Combined Efficiency % 72.6 72.2 69.7 69.7
Line Current Amp 48.6 49.9 53.7 53.4
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2.4 Clearances & Settings (mm)
Impeller Setting (Dimension Z): 544-543
As New Max when worn
Impeller Wear Ring Clearance : 1.465 1.588 2.03

Journal Bearing Clearance Pump End: 0.20 0.38 0.55
Journal Bearing Clearance Cover End: 0.20 0.38 0.55
Reverse Thrust Wear Ring Clearance : 0.42 0.52 0.76
Rotor End Float: 0.50 0.80 1.50
2.5 Instrumentation (See Sections 4.6 and 8.7 for more detail)
Instrument No. Located Type
Thermocouple 1 Pump Case Type KK Ungrounded
Thermocouple 1 Suction Branch Type KK Ungrounded
Thermocouple 3 Motor Case Cavity Type KK Ungrounded
Flow Switch/Indicator 1 HE LP pipework Flotech Flowrate meter
Visual Indicator 1 Motor Case Dresser/Ashcroft Duratemp Dial Thermometer
Pressure Gauge 1 Pump Case Dresser/Ashcroft Pressure Gauge
2.6 Torque Loading

Refer to Figure 2.1, Schedule of Torque Loadings
2.7 Weights (Approximate)
Pump Case 6430 kg

Complete Motor and Rotating Assembly 7650 kg
TOTAL 14080 kg
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Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401

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Section 3 Storage
3 Storage 3.2.2 Motor (Fig 3.2)

1) The motor and transit assembly must be
3.1 Environment stored in a vertical position standing on
The storage area must have a hard standing the motor cover end.
floor that will be capable of supporting the
NOTE:
weight of the units.
When the terminal boxes protrude below the
motor cover stand, rest the motor cover on
3.2 Storage General balks of timber of sufficient height to keep
3.2.1 Pump Case (Fig. 3.1) the terminal boxes clear off the ground.
1) The pump case internal surfaces and all 2) The motor apertures must be blanked
machined faces must be cleaned and a off with flanges secured with studs, bolts
suitable removable solvent rust and nuts.
preventative, with a minimum effective
life of 6 months, applied. 3) The motor and transit assembly must be
Recommended rust preventatives are, filled to the top of the transit canister
Jenolac J400 or Shell Ensis Fluid 264, with inhibitor of the appropriate
or their equivalents. concentration, through the filling
connector located in the temporary
2) All pump case openings must be closed transit flange, sealing off the motor heat
with covers. These covers to be exchanger bottom outlet.
secured to the weld preparations with
steel banding and the pump case main 3.3 Inhibitor
flange with the existing studs and nuts
supplied on the pump flange. Inhibitor is to be produced from a pre-mixed
concentration of mono-propylene glycol and
distilled water in a 50/50 solution by volume.
The mono-propylene glycol must contain
corrosion inhibitors and meet BS6580 or
equivalent. A tolerance of 5% on the
normal glycol/water mix may be applied.
The distilled water used must have a

conductivity of less than 10 reciprocal
megohms (microsiemens) per centimetre.
Check the specific gravity of the inhibitor to
ensure the correct concentration.
The specific gravity of the mixture at 20C is

as follows:-
Mixture by % Volume Specific

Gravity
45% MPG /55% Water 1.036
50% MPG /50% Water 1.038
Figure 3.1 : Pump Case Storage Details 55% MPG /45% Water 1.040
MPG = Mono-propylene Glycol
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 3 Storage
Figure 3.2 : Motor Storage / Transit Details
Rev 0 Sep 10 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD - 10 -
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 3 Storage
3.4 Heat Exchanger 6) Check and record the insulation

resistance of the stator windings as
The heat exchanger is supplied by the follows:
customer and should be stored as instructed
by their manufacturers. The heat exchanger a) Remove the terminal box covers.
interconnecting pipe work and the fill and
drain assemblies must also be filled with the b) Check the insulation resistance at
same inhibitor as the motor, blank flanges the terminal stems using a l000V
being used to seal both ends. megger. Record the result.
3.5 Exterior Surfaces IMPORTANT: -

Motor insulation resistance falls with
All exterior surfaces of the motor must be time and depends on storage and service
maintained in a good painted condition. conditions. Insulation resistance should
Scratched or damaged paintwork must be not fall below 200 megohms at 20C in
repainted. less than 12 months.
3.6 Standard Storage Insulation figures less than 5 megohms

indicate that the motor winding has
Checks For Storage Up deteriorated to a level where
To 3 Years maintenance is required.
A visual examination and inspection of the See Winding Resistance Diagram,
motor and transit assembly must be made at Section 2, Figure 2.2.
least every three months as follows:-
NOTE: c) Fit the terminal box covers.
When stored by the contractor, or by an
agency, a record card should be kept of the 7) Remove the inspection cover from the
intervals between inspections and the top of the transit canister (Fig.3.2).
results of the following inspection checks Fit impeller wrench onto the impeller nut
recorded. and rotate the rotating assembly seven
complete revolutions in an anti-
3.6.1 Motor clockwise direction when viewed from
1) The motor is stored vertically resting on the pump-end.
the motor cover - not horizontally.
CAUTION:
2) The exterior paintwork is in good To rotate the assembly in a clockwise
condition. Repaint where necessary. direction may damage the impeller nut
locking screw.
3) All flanges and joints are tightly secured
and no leakage of the inhibitor has If the shaft cannot be rotated or is very
taken place. difficult to turn, contact Hayward Tyler
for advice.
4)
a) All studs, bolts and nuts are present 8) Check the inhibitor level in the motor
and in sound condition. and transit assembly. The level of
inhibitor must not fall below the level of
b) The phosphate, or any other plating, the impeller. Top up if necessary.
applied to these items has not
deteriorated. 9) Check the glycol/water concentration by
measuring the specific gravity of the
5) Measure and record the ambient inhibitor. The inhibitor is considered
temperature of the storage area. acceptable if it conforms to the
concentration and tolerance given in
paragraph 3.2.3.
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Section 3 Storage
3) Visually examine the assembly for

10) Replace the transit inspection cover damage.
when the inspection is satisfied.
4) Check that the pump case protective
3.6.1.1 Topping up/Draining Inhibitor flanges are correctly fitted and secure.
(Fig 3.3)
1) Attach a hose leading from a pumping 3.6.3 Stud Tensioning Equipment
device to the hose tube of the inhibitor 1) After use, the stud tensioning
filling valve. components must be thoroughly
cleaned, examined for damage and a
2) Unscrew the filling valve screw by two rust preventative lubricant applied to all
turns. This action opens the valve to surfaces.
allow the pumped liquid to enter the
motor. 2) The components must be then wrapped
in suitable waterproofed material and
3) When the sufficient inhibitor has been stored in a clean, dry area.
pumped in, turn screw to close the
valve.
3.7 Storage Periods Greater
4) Remove the hose from the inhibitor Than Three Years
filling valve.
Units that remain in store over three years
require special consideration and Hayward
NOTE:
Tyler Limited should be consulted for
If the motor is to be drained, allow the liquid
specialist advice.
to flow out of the valve hose tube. Ensure
disposal of inhibitor is carried out in
accordance with local regulations. CAUTION:
Precautions must be taken prior to use
that the unit is pressure tight.
3.8 Preparation For Storage

After Use
1) Remove the motor from the pump case
and drain the motor as described in
Section 8.
2) Disassemble the motor cover and clean

out any loose material, sediment etc.
Figure 3.3 : Inhibitor Filling Valve 3) Check all fittings and clearances and
general condition. Fit spare parts as
necessary.
3.6.2 Pump Case and Transit
Assemblies 4) Reassemble the motor as described in
Section 8.
Inspect the pump assembly and check the
following: - 5) Using a socket wrench on the impeller
nut, check that the shaft rotates freely,
1) No extensive corrosion has occurred on approximately seven revolutions in an
the internal pump machined areas. anti-clockwise direction.
2) The protective coating is satisfactory. 6) Check the insulation resistance of the

Re-apply if necessary. winding and compare to the Winding
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 3 Storage
Resistance Diagram in Section 2 Fig with paragraph 3.2.6.2, through the

2.2. filling connection in the transit flange,
sealing the motor heat exchanger
7) Fit the transit canister to the main flange bottom outlet.
and stand the motor upright on the
motor cover. 10) Fit the transit canister inspection cover.
8) Seal off all apertures with appropriate 11) Re-check the insulation resistance of
transit flanges and gaskets. the motor windings.
9) Fill the motor with a pre-mixed 12) Check that the storage conforms to Para
concentration of inhibitor, in accordance 3.2.
Figure 3.4 : Rotating the Rotor Assembly
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Section 3 Storage
3.9 Inspection Record Card

A typical inspection record card and check list is given on the following pages (Figs 3.5 and 3.6).
Customer
Signed
Fourth Check
Date
Signed
Third Check
Date
Signed
Second Check
Order No ..
Date
Signed
First Check
W.S.U Storage Record
Date
Date put
in store
Check Requirements
Exchanger
Unit Nos
Others
Heat
Figure 3.5 : Inspection Record Card
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Section 3 Storage
SITE
UNIT NO
DATE.
UNITS STOPPED AT..
Pump Case Assembly

Motor Case & Transit
Fill & Drain Valve

Heat Exchanger
Interconnection
Assembly
Assembly
Pipework
ASSEMBLY IN STORAGE AREA
STORED IN SAFE POSITION
IDENTIFICATION LABELS ATTACHED
PAINTWORK IN GOOD CONDITION
ASSEMBLIES HAVE INCURRED NO PHYSICAL DAMAGE (SEE NOTE 1)
STUDS, NUTS AND BOLTS ARE IN A SOUND CONDITION X X
STUDS, NUTS AND BOLTS FITTED IN THE CORRECT NUMBER X X
STUD PROTECTORS FITTED TO MAIN FLANGE STUDS X X X
BLANK FLANGES FITTED SECURELY X X X X
NO LEAKAGE OF THE INHIBITOR VISIBLE X
ROTATING ASSEMBLY ROTATED 6-7 TIMES X X X X
INHIBITOR LEVEL CORRECT X
INHIBITOR COMPOSITION CORRECT X
NO CORROSION ON PUMP CASE PROTECTED AREAS X X X X
WOODEN COVERS SECURED TO PUMP CASE OPENINGS X X X X
RUBBER BUNGS SECURELY FITTED X X
HEAT EXCHANGER SECURELY FITTED TO WOODEN CRADLE X X X X
INSULATION RESISTANCE READING..

AMBIENT TEMPERATURE OF STORAGE AREA
KEY : ACCEPTABLE
O REQUIRES ACTION
REQUIRES IMMEDIATE ACTION
NOTE 1 : DETAILS OF OBESERVATIONS SHOULD BE NOTED ON THE REVERSE SIDE OF CHECK LIST
WITNESSED BY OF.....
COMPILED BY OF.
Figure 3.6 : Check List
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Section 4 Description
the pump case, a cold purge can be

4 Description applied to the bottom of the motor to
4.1 General limit the temperature rise.
The Hayward Tyler Glandless Motor NOTE:

Circulator Pump is designed for recirculating A cold purge is to be used only as an
boiler water through the boiler water emergency.
systems of fossil fuel or liquid cooled nuclear
reactor power stations and similar
applications. 4.2 Pump
The pump comprises a single suction and
The circulators consist of a single stage double discharge branch casing, welded into
centrifugal pump and a wet stator induction the boiler system pipe work at the suction
motor, which are mounted within a common and discharge branches with the suction
pressure vessel. The vessel consists of branch uppermost. The diffuser is
three main parts, a pump casing, motor permanently fixed into the pump case and
housing and motor cover. should not be removed.
The motor is suspended beneath the pump Within the pump cavity rotates a key driven,
casing and is filled with cold boiler water at mixed flow type impeller, mounted on the
full system pressure. No seal exists end of the extended motor shaft.
between the pump and motor, but provision
is made to thermally isolate the pump from 'Renewable wear rings are fitted to both the
the motor in the following respect: - impeller and the diffuser. The impeller wear
ring is the harder component to prevent
1) Thermal Conduction. Because the galling.
pump temperature is so high, usually
above 340C and the motor temperature
is limited to about 55C, a simple
4.3 Motor
restriction, in the form of a 'neck', is The motor is a squirrel cage, wet stator,
provided to minimise heat conduction. induction motor, the stator wound with a
special water tight insulated cable. The
2) Hot Water Diffusion. To minimise phase joints and lead connections are also
diffusion of boiler water, a narrow moulded in an insulated material. The motor
annulus surrounds the rotor shaft, is joined to the pump casing by a pressure
between the hot and cold regions. A tight flange joint and a motor cover
baffle ring restricts solids entering the completes the pressure tight shell.
annulus.
The motor shell contains all the moving
3) Motor Cooling. The motor cavity is parts, except for the impeller. Below the
maintained at a low temperature by a impeller is situated an integral heat baffle
heat exchanger in a closed loop water which reduces the heat flow, a combination
circulation system, thus extracting the of convection and conduction, down the unit.
heat conducted from the pump. A baffle wear ring-cum-sleeve above the
baffle forms a labyrinth with the underside of
In addition, this water circulates through the impeller to limit sediment penetration
the stator and bearings, extracting the into the motor. Should foreign matter
heat generated in the windings and manage to pass the labyrinth device into the
providing bearing lubrication. An motor enclosure, a filter located at the base
internal filter is incorporated in the of the cover end bearing housing strains it
circulating system. out.
4) In emergency conditions, if low pressure Lifting lugs are supplied to secure hoists
coolant to the heat exchanger fails, or is when raising and lowering the motor.
inadequate to cope with heat flow from
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4.3.1 Auxiliary Cooling Circuit supplied external heat exchanger (cooler),

(Fig. 4.1) by an auxiliary impeller at the thrust bearing
end of the motor shaft.
The motor is provided with its own auxiliary
closed circuit, which besides cooling the When the motor is stationary, thermosyphon
motor lubricates the bearings. The water is circulation takes place to remove conducted
continuously circulated through the heat from the pump end of the motor.
bearings, motor windings and a customer
Figure 4.1 : Typical Auxiliary Cooling Circuit Arrangement
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4.3.2 Bearings liquid in the motor before it is circulated

through the bearings after passing
The motor rotor shaft is supported by water through the heat exchanger (cooler).
lubricated tilting pad type radial and thrust
bearings mounted on the stator shell, thus The filter should be cleaned at normal
making the motor internals into a separate maintenance periods, removing any
construction independent of the motor accumulation of foreign matter in the
pressure vessel. motor cover.
4.3.2.1 Journal Bearings

4.3.4 Main Flange Joints
The journal bearings of the circulator are the The pressure joints at the pump and
water lubricated Michell type located at the motor cover flanges employ spiral edge
ends of the motor shaft, i.e. pump-end and wound gaskets, specially designed for
cover-end. Each bearing comprises a very high pressure and temperature. The
hardened steel sleeve on the shaft running in main pump/motor flange gasket is housed
six radially located tilting pads whose bearing in stainless steel overlay, recessed into
surfaces are lined with a composite material. the joint face.
The bearing surfaces must never be allowed
to operate in a dry condition. The studs and nuts securing the flanges
are made from special high tensile steel
4.3.2.2 Thrust Bearing and, because torque tightening these nuts
A main thrust bearing is situated below the is inadequate, the studs are hydraulically
cover-end journal bearing and takes the full stretched and the nuts tightened down by
hydraulic thrust of the pump. This bearing, hand. When the hydraulic tension in the
also of the Michell water lubricated type, is stud is released, the load is transferred to
formed by a steel thrust disc, with a composite the nut giving the required tightness.
bearing surface, on the bottom of the rotor
shaft running on stationary hardened steel Stud tensioning equipment is supplied
tilting pads. with each circulator order, .
The thrust disc is also designed to operate as 4.3.5 Terminal Gland (Fig 4.2)
an auxiliary impeller to circulate the internal The electrical supply to the motor is taken
water content of the motor. through special high pressure single lead
cable terminal glands of the high
4.3.2.3 Reverse Thrust Bearing temperature, safety type.
The weight of the rotating assembly, as well as
the down thrust imposed at start-up and shut- The seal is effected by a terminal gland
down, are taken by a reverse thrust bearing moulding, together with o-rings located
located on a reverse thrust housing which between an insulating sleeve and an inner
forms the bottom of the cover housing casing, and between the inner casing and
cylinder. the motor case. The addition of a cone-
shaped collar within the terminal
The reverse thrust housing also includes a moulding, plus the design of the inner
composite reverse thrust wear ring and is the casing, prevents any possibility of a gland
mounting for the internal filter. blowout at high temperatures. However, if
the motor is subjected to sustained
4.3.3 Internal Filter overheating, a slight leakage may occur
into the terminal boxes.
A stainless steel woven wire strainer, fitted at
the base of the reverse thrust seat, filters the
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Figure 4.2 : Terminal Gland
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4.4 Terminal Boxes 4.6.1 Thermocouples

Two thermocouples are provided to monitor
Robust fabricated steel terminal boxes are
the temperatures of the pump case metal
provided on the side of the motor casing for
and the suction branch.
connecting the power supply to the motor.
Three thermocouples are provided to
Each phase supply cable for the motor
monitor motor case cavity temperature. An
enters a box at the bottom and must be
alarm circuit should be arranged such that
sealed by a cable gland. Each phase
notation is identified by the coding, Red, when temperature reaches 60C an audible
Yellow or Blue and IEC markings U, V& alarm is energised. Should the temperature
W. See Section 5 Installation. continue to rise to 65C, a second trip circuit
should be activated, arranged to de-
Bursting discs are fitted to the wall of the energise the motor. (These figures are the
terminal box to relieve excessive pressure recommended figures for alarm and trip
build within the box should a flash over which could be marginally altered according
occur. to local conditions, See Section 5.8.3).
Dessicators are also fitted to absorb 4.6.2 Dial Thermometers

atmospheric pressure that may decrease the A temperature indicating dial thermometer is
electrical resistance to ground. provided on the motor case. This gives local
visual indication only.
Each assembly is completely enclosed by a
bolted on cover.
4.6.3 Flow / Switch Indicator
4.5 Heat Exchanger A flow/switch indicator is supplied for
connecting into the low pressure cooling
A heat exchanger (cooler) should be fitted to
water circuit. An alarm circuit may be
dissipate the heat generated by the motor
arranged to indicate low flow before the set
and the heat transferred from the pump
point.
casing. The heat exchanger is customer
supplied.
4.6.4 Pressure Gauge
Brackets are provided on the motor case to A pressure gauge is provided to monitor
mount the heat exchanger. motor case cavity pressure.
4.6 Alarm Systems 4.6.5 Ground Detection Relays

Refer to the Instrumentation Schedule in The motor windings should be protected by
Section 8 for more details. ground detection relays, sufficiently sensitive
to detect the development of a pinhole or
minor crack in the stator winding insulation.
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Section 5 Installation
NOTE:
5 Installation Two long lift hoists should be used to raise
5.1 General the pump or motor, each hoist being capable
of taking the full weight of the pump or motor
WARNING:
The Hayward Tyler boiler circulating 4) The pump should be positioned so that
pump is a precision piece of heavy the nett positive suction head (N.P.S.H.)
machinery. available exceeds the N.P.S.H.
specified in the Technical Data - Section
It should only be installed under the 2).
supervision of a qualified professional
engineer who should ensure that the NOTE:
staff directly concerned are adequately When operating at temperature, sub cooling
trained and have read and understood of the inlet water is normally present and this
this manual. gives a considerable increase in the
N.P.S.H. available. The worst condition is
When installing the circulators the following normally operating cold.
conditions MUST be observed.
5) Fit a suitable gland (not supplied) to the
1) The system pipe work should be cable entry of each terminal box.
adequately supported to accept the
weight of the circulator. 5.1.1 Installation Notes
2) When mounted, the pump should The following conditions must be observed
accommodate movement in the pipe when installing the circulator:
work due to thermal expansion without
imposing excessive loads on the casing 1) Ensure that the main system is free from
and branches, associated pipework and solids before mounting the circulators.
cables.
2) Permanent insulation should be applied
3) Sufficient clearance should be allowed only to the pump case. No insulating
beneath the motor to permit lowering of material must be applied to the motor
the motor from the pump case for case or to the main flange studs and
maintenance. (See Section 8 for the nuts, as this will cause the motor to
General Arrangement drawing). If overheat.
removable floors or girders etc. are fitted
after the motor is installed, ensure that 3) The cables leading to the motor, should
the terminal boxes or low pressure be flexible and looped immediately prior
cooling water supply lines will not foul to entering the terminal boxes. The
them when the boiler is on load and the looping should be sufficient to
circulator moves downwards due to accommodate unit movement caused by
thermal expansion. expansion and contraction of the boiler
pipe work.
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5.2 Pump Case Installation the system pipe work and re-check the
(Fig 5.1) horizontal limits.
1) Remove the pump case flange and 5) Complete the weld to the procedure
branch covers and clean the pump approved by the boiler manufacturer
branches. and test radiographically for flaws.
2) Attach shackles and slings to the casing 6) On completion of a satisfactory

eyebolts. A plate on the pump case radiographic test, fit any pressure
indicates the front of the pump. differential transmitters using the stub
pipes on the pump case branches.
3) Raise the case to meet the system pipe
work, with the suction branch 7) Fit the blanking off plate until the motor
uppermost. is installed.
4) Ensure that the main motor/case flange

is horizontal to within 1. Tack weld to
Figure 5.1 : Pump Case Installation
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5.3 Preparation For Motor litres of inhibitor. Close the

inhibitor filling valve.
Installation
CAUTION: 6) Remove the transit canister from the
The motor should be stored, topped-up motor case.
with inhibitor for as long as possible. If it
is necessary to install the motor before 7)
boiler water is available, install in the a) If the motor is to be operated
inhibited condition to provide additional immediately upon installation,
protection for the motor internal completely drain then proceed as
components. However, the inhibitor (8)
must then be drained immediately before
mounting the heat exchanger. b) If motor operation is not imminent,
install the motor in the inhibited
We do not recommend motor installation condition, proceed as 9), leaving 8)
on a Hot Boiler. to be performed when fitting the
heat exchanger.
1) Hose down internally, the pump case,
the valves and adjacent piping, to 8)
ensure the removal of all loose debris. a) Connect a clean cold water supply
to the motor cover fill and drain
2) Fully close the pump suction and connection, and flush the motor until
discharge valves where fitted. inhibitor-free water flows from the
top of the motor.
5.4 Motor Installation (Fig 5.2) b) Check that the shaft freely rotates, if
1) Using a 1000V megger, check that the not, contact Hayward Tyler for
insulation resistance to ground of the advice.
motor leads is above 200 megohms
when measured at the terminal stems 9) Clean the overlay that provides the seat
with the unit full of water below for the gasket in the main flange of the
approximately 20C, if possible, or at motor. Inspect for burrs and surface
normal ambient temperature. discontinuity, dress if necessary with a
fine grade stone. Fit a new gasket.
2) Stand the motor in a vertical position, on NEVER apply any compound to the
the motor cover stand, and in the correct gasket and ensure that it is dry.
orientation to the pump.
10) Ensure that the motor is in correct
3) Remove the pump case main flange orientation with the pump case. (See
nuts and cover and ensure there is no General Arrangement Drawing in
debris in the pump pipe work system Section 8)
that could enter the pump case.
WARNING:
4) Clean and inspect the pump case The Hayward Tyler boiler circulating
flange, remove any burrs. pump is a precision piece of heavy
machinery.
5)
a) Remove the plug or inspection It should only be installed under the
cover at the top of the transit supervision of a qualified professional
canister. engineer who should ensure that the
staff directly concerned are adequately
b) Loosen the inhibitor filling valve trained and have read and understood
situated in the motor fill and drain this manual.
transit flange, (Section 2 Fig. 2.1),
and drain approximately 40-45 11) Attach shackles and slings to the motor
casing lifting lugs and lift into position,
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taking care to avoid damage to the contact with the pump case face. At
terminal boxes. this stage, the gap between the
flange faces should be
12) Fit the motor to the pump case as approximately 2.5mm and should be
follows: equal all round the flange.
a) Using the chain type hoists, lift the CAUTION:

motor until the impeller is about to If the gap is unequal, the gasket may
enter the pump case. have come out of its recess. If the gap is
unequal, lower the motor sufficiently to
b) Measure the distance between the check the condition of the gasket. If the
pump case and the motor flanges at gasket is damaged - renew. Never use
four 90 degree points on the flange any substance on the gasket to make it
periphery. If necessary, adjust the adhere to its recess.
lay of the motor by the chain hoists
to make the distances h) Coat the stud threads with high
approximately equal. temperature anti-seize compound or
silicon grease and install the nuts by
c) Bring the gap between the flanges hand.
equal all round. This is best
achieved by using a spring-loaded NOTE:
'inside' calliper, set to the gap Do not coat the exposed extended diameter
directly in line with one of the chain threads of the studs as these threads are for
hoists. The set calliper is then the tensioner application.
moved to the opposite side of the
flange and the gap adjusted, using i) Tighten the nuts, using the hydraulic
the chain hoist. Check the gaps at stud tensioner in accordance with
right angles to the first two and the instructions in Section 9 and the
adjust the lay of the motor to make Motor Assembly drawing in Figure
the gaps equal. 2.1. Remove the lifting tackle and
removable lifting lugs.
d) Check that the studs are centred in
the motor flange holes. Adjust the j) Thoroughly flush out the fill and
motor lay as required. drain system piping, to the motor
cover and when satisfied that the
e) With the chain hoists working in piping is clean, connect to the motor
unison, slowly raise the motor. cover.
CAUTION: k) Install the heat exchanger: see

If any increase in effort is required on the Section 5.5.
chain hoists to raise the motor - stop
raising it immediately as the impeller may l) Install the instrumentation detailed
be fouling the diffuser wear ring. In in Section 2.7.
which instance, fractionally lower the
motor, check the gap and raise the motor m) Connect the power supply cables to
again. the motor terminals, See 5.9.
f) Check the gaps every 10 mm, or 13) If, after fitting the heat exchanger:
less, during the last 100 mm of the
motor raising sequence to ensure a) running is not reasonably imminent,
that the motor does not 'cock' or the motor and heat exchanger
rotate as it is raised. Adjust the gap circuit must be refilled immediately
as necessary. with inhibitor.
g) Continue raising the motor until an b) sub-freezing temperatures are

increase in the effort required on the envisaged the motor and heat
hoists indicates that the gasket is in
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exchanger circuit must be refilled temperatures are not envisaged, the

immediately with inhibitor. motor and heat exchanger must be
filled with treated boiler water or
c) running the motor is reasonably condensate within 3 hours of fitting.
imminent, and sub-freezing
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THIS DISTANCE MUST BE EQUAL TO

WITHIN 3.5mm ALL ROUND FLANGE
THROUGHOUT LIFT
LONG LIFT HOIST EACH HOIST MUST BE SUSPENDED

FROM AN ADEQUATE LIFTING POINT
SUFFICIENT TO TAKE THE FULL
SHACKLE WEIGHT OF THE MOTOR. HOIST
FALLS TO BE PERPENDICULAR
REMOVABLE LIFTING LUG WITH LIFTING LUG SHACKLE HOLES
MOTOR ASSEMBLY
TERMINAL BOXES 3 OFF
TERMINAL BOX CABLE GLAND

KEEP AREA BENEATH MOTOR CLEAR OF (CUSTOMER SUPPLY)
ANCILLIARY EQUIPMENT TO PERMIT
SUBSEQUENT MOTOR REMOVAL
LOOP CABLES TO ALLOW FOR
MOTOR EXPANSION
Figure 5.2 : Motor Installation
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5.5 Fitting The Heat

g) Offer up the interconnecting pipe
Exchanger (Customer work to the heat exchanger and
supplied) motor flanges and secure with bolts,
nuts and washers.
1) Remove the blank flanges from the
motor high pressure outlet to cooler and h) Clamp the heat exchanger to the
fill and drain connection. motor by tightening up the securing
bolts, nuts and washers.
2) Ensure that the motor, the heat
exchanger and the high pressure pipe 5) Install gauges and recorders for
work and high pressure purge lines, temperature and pressure. Connect the
have been flushed free from all low pressure cooling systems to the heat
obstructions and foreign matter. exchanger and high pressure fill and
purge system to the motor, at the motor
3) Flush out the secondary cooling water cover.
system until clear water is discharged.
6) Fit temporary strainers to the low
4) Mount the heat exchanger onto the pressure cooling systems, and then
motor case brackets and proceed. check that circulation meets the heat
exchanger specification.
a) Bring the heat exchanger parallel to
the motor supporting the weight with 7) Close the shut off valve in the high
the lifting tackle. pressure fill and purge line and blow
down piping.
b) Loosely attach the heat exchanger,
by the mounting plates, to the 8) The motor and heat exchanger circuit
mounting plates on the motor. must now be refilled with inhibitor (See
5.4, Para. 13 (a) or (b) or with treated
c) The heat exchanger should now boiler water or condensate.
stand parallel to the motor.
d) Place the Flexitallic gasket at the top 5.6 Filling The Circulator
high pressure flange joint of the With Boiler Cold
motor and coat the bolt threads with
silicone grease, leave the gasket Filling the circulator correctly is a
clean. Bolt the top high pressure prerequisite to ensure satisfactory operation.
connection together. If air is present in the motor it could affect
bearing lubrication and precipitate bearing
NOTE: failure.
On high pressure / temperature applications,
guide ring type gaskets are used at the If air pockets are present in the stator this
auxiliary flange joints; tighten the flanges would affect dissipation of heat generated in
about the guide ring, metal-to-metal. the windings, creating hot spots and
consequent degrading of the insulating
e) Ensure the motor / heat exchanger material, and ultimately cause winding
interconnecting pipe work assembly failure.
is correct for the circulator. The
correct pipe work is stamped with Due to the complexity of the passages in the
the serial number. motor through which water must flow to
displace all air, it is necessary to fill the
f) Place a Flexitallic gasket at each motor very slowly. The maximum filling rate
joint at the bottom of the motor case is 2 litres /min.
and heat exchanger for the bottom
high pressure connection. Coat the The motor must NOT be filled via the pump
flange fastener threads with silicone casing, but only through the filling connector
grease. located at the motor cover.
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8) Isolate the now filled circulator.

1) Isolate the circulator from the boiler by
closing appropriate discharge valves, by- 9) Ensure that the terminal boxes are dry
pass valves and drain valves. and with the unit full of water below 20C
or at normal ambient temperature, using
2) Supply the low pressure side of the heat a 1,000 Volt Megger, check winding
exchanger as follows: - resistance to ground at the terminals.
The resistance should exceed 200
a) Open the supply valves in the low megohms.
pressure cooling water system.
IF NOT, CALL HAYWARD TYLER. DO
b) Flush out the piping for the supply of NOT ATTEMPT TO RUN THE MOTOR.
low pressure treated boiler water, or
condensate, for filling the motor, 5.7 Hydrotesting Boiler
until clean air free water is
discharged. With Circulator Installed
1) Treated Water or Condensate available:-
NOTE:
The flushing must always be carried out Should the customer wish to hydrotest
before introducing any water through the the circulator, the hydrostatic test pressure
lines to the motor and heat exchanger. must not exceed the maximum specified in
Section 2.
3) If the low pressure supply contains an
orifice, check that it is clean and that its 2) Treated Water Not Available: -
flow rate is correct.
If the boiler is to be hydrotested at an
4) Adjust the flow rate to approximately 2 early state of construction, the pump casing
litres/min. can be pressure tested without the motor
once the blank off plate is installed refer to
5) After connecting the supply, open the para.5.2.
heat exchanger vents and the vent in the
interconnecting pipework. Fill the motor
from the bottom and vent air from the
5.7.1 Post Hydrostatic Test
top, until clean air free water is Procedure
discharged from the vents. 1) Boiler circulators are not to be drained,
but left filled to a level above the suction
6) Close the vents on the heat exchanger downcomer.
and interconnecting pipework.
2) Freezing can be avoided by filling with
7) Continue to fill the motor and vent any glycol in the concentration detailed in
air via the vent connections in the boiler Section 3.
system pipe work.
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Figure 5.3 : Terminal Box
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5.8 Electrical Connections damage in transit. They are fitted to the

terminal boxes on the installation of the
5.8.1 Power Supply to Motor motor.
Refer to the terminal box arrangement
shown in Figure 5.3. a) Dismantle the bursting disc
assembly and discard the cardboard
WARNING: sheet fitted in lieu of the disc.
Disconnect the power supply and the
starter before commencing any work. b) Reassemble the bursting disc
assembly with the bursting disc in
CAUTION: place, as depicted in Fig. 5.4.
Ensure that the cable length will
accommodate expansion and removal of 8) Fit and secure the terminal box covers
the circulator. using the nuts and washers previously
removed.
Ensure that the voltage connected to the
circulator is the correct operating voltage
as stamped on the motor nameplate
situated on the bottom of the motor case.
1) Remove the nuts and washers, and then

remove each terminal box cover using
lifting gear, if necessary.
2) Remove the nuts and washers and take

off the cable entry gland plate.
3) Drill the cable entry plate as necessary

to suit the cable gland.
4) Feed the cable through the conduit entry

gland and connect to the terminals in
the phase rotation RED, YELLOW,
BLUE (U, V or W). When so
connected the unit will operate in the
designed direction, i.e. clockwise when
viewed from above. All connecting
cables and links are marked with
appropriate phase colours.
5) Earth the circulator adequately.

Earthing studs are provided on the Figure 5.4 : Bursting Disc Assembly
motor casing adjacent to the terminal
boxes.
5.8.2 Recommended
6) Ensure that all electrical connections Instrumentation
particularly at each terminal box entry It is recommended that the following be
gland are secure. provided: -
7) Fit the bursting discs to the terminal 1) Pump suction and discharge pressure
boxes as follows: - gauges.
NOTE: 2) Continuous record of motor voltage.

The bursting discs are supplied as loose
items and are packed separately to prevent 3) Continuous record of motor current.
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NOTE:
4) Ground leakage relay to warn of very Overload relays are now typically calibrated
low winding resistance in order to in motor full load current (FLC) where the
prevent winding insulation failure. relay trips with a current 10% above the FLC
setting point. Hence the overload relay of
5) Indication and record of downcomer this type should have a setting point of the
temperature and pump case cold duty current.
temperature. This is required to avoid
thermal shocks when starting a pump on Maximum current at nominal voltage:
a hot boiler. See Technical Data, Section 2.
5.8.3 Alarm Circuits (Fig 5.5) 5.9.2 Instantaneous Trip Setting

WARNING: To allow for transients during the first cycles
Lethal voltage is present in the alarm of the starting period, the instantaneous trip
system when the motor is inoperative. To should be set at 12 times the motor full load
make the circulator safe - open the current.
isolator.
Full Load current:
Suitable alarm and trip devices should be See Technical Data, Section 2.
fitted to protect the motor and arranged to
provide: - 5.9.3 Starting Period Protection
1) An alarm - as an indication of motor If the motor fails to start, trip out after a
overheat conditions. period of approximately 5 seconds. The
starting current is based on a locked rotor
2) Motor trip (shut down) - if the test with an allowance made for saturation of
temperature rise continues above the the magnetic circuit.
alarm setting.
Motor Starting Current:
The normally advised settings for the See Technical Data, Section 2.
protection devices are: 60C for alarm and
65C for trip. In practice, the alarm setting 5.9.4 Earth Leakage Protection
should be reduced to 5C above normal (Fig 5.5)
motor operating temperature. Ground detection relays are recommended,
sufficiently sensitive to sound an alarm if a
5.9 Motor Protection pin-hole or minor crack should develop in
the stator winding. This protection is
The following protective devices must be arranged in either of the ways shown in
provided for the motor: - Scheme A, Scheme B or Scheme C.
5.9.1 Continuous Overload If the neutral point of the supply transformer

Protection is grounded, a current transformer (CT) is
inserted into the ground lead, and a relay
The overload trip setting should be 10% connected across the current transformer
above the maximum current requirements secondary, see Scheme A.
which could occur with the pump running on
cold water at some other point than the Experience indicates that in the event of a
specified duty, assuming nominal specified fine crack in the stator winding, the
supply voltage. If voltage variation can resistance to ground drops to between
occur, then the trip setting should be 20,000 and 30,000 ohms. The relay should
increased to 15% above maximum current not trip the motors but initiate an alarm.
value.
If the neutral point of the supply transformer
is not grounded, three potential transformers
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(PT) are connected to the motor leads, with NOTE:

the secondaries connected in an open delta, It is important that no earth conductor is
closed by the relay winding, see Scheme B. allowed to be enclosed by the current
The relay should not trip the motors but transformer. The earth leakage sensitivity
initiate an alarm. and trip time can generally be selected to
Scheme C shows a core balance earth prevent nuisance tripping. Typical setting
leakage relay system where a core balance points are 300 mA and 1 second. This may
current transformer encloses supply lines require adjustment depending on supply
L1, L2 & L3 supplying the motor. conditions.
Figure 5.5 : Earth Leakage Protection Circuit Diagram
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Section 6 Commissioning
6 Commissioning 6.2 Initial Starting - Cold

6.1 Pre-Start Check Boiler Condition
In systems where the circulators are
The following pre-start checks must be
arranged in parallel, to avoid cavitation,
satisfied before starting the motor.
sufficient circulators must be operated to
limit the capacity per pump to a value where
1) Ensure that the circulator is completely
the N.P.S.H. required is less than the
vented.
amount of N.P.S.H. available.
2) Ensure that the low pressure cooling
When a boiler is started from cold, a
water valves are open and the cooling
minimum of two circulators must be
water flow rate agrees with that
operated. It is normal practice to
specified in the heat exchanger
simultaneously warm the standby circulators
manufacturer's specification. All other
to permit immediate starting when required.
valves must be closed.
CAUTION:
NOTE:
Motors must not be energised if the
If the circulator is to be started on hot
motor cavity temperature is below 2C.
standby, the pump delivery by-pass valves
must be open. Refer to the hot standby
There should be at least ten-minute
procedure in Section 7.
intervals between two repetitive starts.
This must never be exceeded; otherwise
3) Ensure that the high pressure cold water
the motor winding temperature will rise
purge at 20C maximum temperature is
and could damage the winding
connected but isolated.
insulation.
4) Using a 1000V megger, check that the
The motor may be damaged if motor
insulation resistance to ground of the
temperature exceeds 70C.
motor leads conforms to the Winding
Resistance curve shown in Section 2,
1) Ensure that the motor has been vented
Fig. 2.2 when measured at the terminal
as detailed in Section 5, Para. 5.6.
stems with the unit full of water below
approximately 20C, if possible, or at
2) Ensure that a flow of approximately 2
normal local ambient temperature.
litres/min. is entering into the motor
through the fill line.
5) Check that the correct voltage is
connected to the circulator.
3) Ensure that the pre-start checklist, as
described in Para. 6.1, has been
6) Check that the electrical supply is
satisfied.
available at the point of control selected
and that the starting equipment is
4)
functioning correctly.
a) Release any air trapped below the
discharge valves by opening valves.
7) Test the operation of all instrumentation
and alarms.
b) When air-free water is discharged to
atmosphere, close valves.
8) Ensure that sufficient N.P.S.H. is
available for the pump to run without
5)
cavitation.
a) Vent the pump by opening vent
valves.
9) Start parallel operating boiler circulating
pumps with the stems of the discharge
b) When air-free water is discharged
valves withdrawn to prevent overheating
from vent valve to atmosphere,
of the boiler water in the pump case.
close valves.
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approximately 30% less head generated and

6) Close the high pressure filling line at the about 10% more power absorbed than
motor with a suitable double isolation specified.
valve.
12) After a further (3rd) ten-minute pause,
CAUTION: repeat operation (9).
This valve must remain closed at all
times unless the purge system is in use, 13) After another (4th) ten-minute pause,
for example during chemical cleaning or energise the motor and run for twenty
for emergency motor cooling. minutes. During this running period,
carry out the following checks:-
7) Vent the low pressure side of the heat
exchanger. a) Check the motor for vibration, using
a vibration detector, several times
8) Make sure that the boiler is full and and record reading for future
open the suction valve and discharge comparison.
valves, if fitted.
b) Check for rubbing or excess bearing
NOTE: noise by holding a listening rod
The by-pass valve should never be fully against the pump and motor case.
closed. It is normally throttled to provide a
minimal flow between the pump suction and c) Check the motor operating
discharge system. temperature at regular intervals.
Initially it should rise several
9) Switch on power to the starter. degrees then stabilise. If
necessary, adjust the secondary
10) Press the starter button on the control cooling water flow after checking
console and energise the motor for 5 that the strainers are not obstructed.
seconds only.
d) Check, as the motor warms, that the
CAUTION: high pressure circulation pipe
The motor runs up to full R.P.M. in entering the heat exchanger from
appropriately one second. If the motor the top of the motor becomes
fails to start after five seconds, press the warmer than the high pressure
stop button and do not attempt to restart circulation pipe from the bottom of
the circulator for 20 minutes. the heat exchanger to the motor
case. This indicates correct
11) After ten minutes pause, run the functioning of the heat exchanger.
circulator for a further (2nd) five
seconds. During this run, check the e) Check that motor current and
following :- differential pressure readings
several times and record the
a) Motor Current (after ammeter has readings.
come off initial surge of current)
14) When the motor temperature has
b) Differential pressure - when the stabilised: -
check valves open, the differential
pressure should rise immediately to a) Adjust the high temperature alarm
the figures specified in Section 2. setting to 10% above this point, or to
60C, whichever is the lower. The
NOTE: trip setting must never exceed 65C.
If the differential pressure does not rise, stop
the motor immediately; it may be an b) Make adjustment to other
indication that the motor is running in instrumentation as necessary.
reverse. Reverse rotation will result in
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c) Check all flanges, glands and valves 2) Close the discharge valves.
for leaks.
3) Maintain the low pressure cooling water
d) As the boiler water temperature supply to the heat exchanger.
increase, its specific gravity
decreases and the amount of NOTE 1:
N.P.S.H., available increases. The If the circulator is to stand idle for some
temperature of the high pressure considerable time with the boiler cold, the
water to the heat exchanger may low pressure cooling water to the heat
alter due to lower losses in the exchanger may be turned off, especially on
motor, or because of increased heat systems where the cooling water runs to
flow from the pump. waste.
NOTE: NOTE 2:
It is normal procedure to commission On hot boilers, and whenever the circulator
circulators separately, but if required, before is run, the low pressure cooling water to the
the last circulator is stopped, the others may heat exchanger must always be on.
be energised and their recordings taken
after each one is brought on-line. CAUTION:
If the circulator is to be idle for an
6.3 Stopping extended period, and be subjected to
freezing temperatures, make sure that
1) Press the stop button on the control provision is made to protect the motors
console. The run-down time is from freezing (see Section 3.2.2.)
approximately 2.5 seconds.
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Section 7 Operation
legs to the pump case and impeller

7 Operation etc.
Any of the following conditions may exist
when putting a circulator into service. Follow b) Check the motor temperature on the
the relevant procedures below and refer to alarm thermometer; this should not
7.3 for routine checks and operational fault exceed 49C or be less than 5C.
action.
5) Energise the first motor: The current
will drop from full starting current after a
7.1 Starting The Circulator few seconds to that stated in Section 2.
7.1.1 Boiler Cold - Circulator Cold
and Filled (Boiler Start-Up) 6) Ensuring the boiler is still full, energise
the second duty circulator on line and
1) Ensure that the pre-start checklist, para run up to speed.
6.1 is satisfied.
7) Perform the operational checks below.
2) Vent the motor as follows: - Refer also to Para.7.3.
a) Release any air trapped below the a) Amperage.
suction by opening the by-pass
valves and the filling valves. b) Motor cavity temperature on alarm
thermometer.
b) When air-free water is discharged
through the vent valve, close vent c) Differential pressure.
valve.
d) Low pressure cooling flow and
3) Vent the pump as follows: - temperature.
a) Open the vent valve. e) Vibration.
b) When air-free water is discharged f) Drum level.
from vent valve, close vent valve
and filling valves. g) Valve and gland leakage.
c) Open the stems of the discharge 8) Energising other motors: When the
valves. boiler differential pressure parameters
require the other circulators to be
CAUTION: energised: -
The pump must always be re-vented in
this manner prior to starting when the a) Check that the differential
drum pressure is below 3.5 bars. temperature, between the pump
case and boiler water in the
NOTE: downcomers, is within 28C.
The motor starting procedure following is
based on a normal boiler starting procedure b) Energise the other motors.
where usually two circulators are initially
operated with the remainder brought-on line c) Close by-pass valves on the newly
as required. energised pump(s).
4) d) Perform the operation checks on the
a) On circulators that will not be newly energised pump as detailed in
energised, open the pump para.7.1.1.(7).
discharge by-pass valves. This
ensures that as the boiler heats up,
a flow passes from the discharge
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Section 7 Operation
7.1.2 Boiler Hot - Circulator Hot 7.2.2 Boiler Hot - Circulator to be

and Filled (Hot Standby) Isolated for Maintenance
NOTE: NOTE:
The low-pressure coolant to the heat If no suction valves are fitted, pumps cannot
exchanger must be on. be isolated. The complete boiler system
must first be isolated and depressurised.
1) Check the differential temperature
between the pump case and the boiler 1) Press the stop button of the control
water in the downcomers. console to de-energise the motor.
CAUTION: 2) Close the stems on the suction and

The differential temperature between the discharge valves, if fitted.
pump case and the boiler water in the
downcomers must not exceed 28C. Non- 3) Maintain the low pressure cooling
adherence to this may cause thermal shocks system to the heat exchanger, until the
and damage to occur. pump casing has fully cooled.
2) Energise the motor. CAUTION:

Keep a close watch on the motor cavity
3) Close by-pass valves. temperature, should the temperature
increase, apply a high-pressure purge as
4) Check circulator operation as detailed in described in para. 7.3.8.
para.7.1.1 (7).
4) Check the pump case temperature as
7.1.3 Installation on a Hot Boiler the pump case is cooling to ensure that
the cooling rate does not exceed 60C
This is not recommended without suitable per hour. If necessary, correct the
safety precautions in place. cooling rate as follows:
7.2 Shutting Down The a) Cooling rate too fast: - If the pump
case cooling rate is too fast, slow
Circulator the cooling rate by partially opening
CAUTION: the by-pass valves as necessary.
Low pressure cooling water flow and
motor temperatures must always be b) Cooling rate too slow: - If the pump
within the specified limits, whenever the case cooling rate is too slow,
circulator is on hot standby. increase the rate by injecting a high
pressure purge as detailed in Para.
7.2.1 Boiler Hot - Circulator to go 7.3.8.
on Hot Standby 5) When the pump case has cooled to
1) Press the stop button on the control 43C de-pressurise the circulator as
console. follows: -
2) Ensure that the low-pressure cooling a) Ensure the pump discharge by-pass
line valves are open. valves and shut-off valve are closed.
3) Open by-pass valves to provide b) Slowly depressurise the circulator

circulation of high temperature boiler by cracking open vent valves.
water through the pump casing, suction
and discharge lines. c) Open shut-off valves and check the
pressure on the motor cavity gauge.
When the pressure has stabilised,
close vent valves.
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Section 7 Operation
d) Re-check that the pressure does not temperature reaches 65C. If desired,
increase. Should it increase, check the aforementioned alarm temperature
the following: - settings may be lowered, on the
temperature alarm thermometer, to suit
i) Make sure that all valves normal operation but only after the boiler
between the circulator and high- and circulator has been operated long
pressure system are closed. enough to stabilise.
ii) De-pressurise the circulator 2) Immediately investigate the following

again, if necessary. possible causes for high temperature
alarm sounding: -
6) On completion of depressurising, the
motor is ready for removal. CAUTION :
Do not stop the motor.
7.2.3 Boiler Cold
a) Check the low pressure cooling
1) Press the button on the control console. water supply for adequate flow,
temperature vapour locks and
2) Leave open the low pressure cooling leakage in piping (see 7.3.7.)
water line valves.
b) Check the circulator for leaks from
3) Pump discharge valves may be left the motor casing, high pressure fill
open. and drain cooling water
connections, particularly the motor
7.3 Routine Checks And fill and purge line shut-off valves
and the motor drain valves.
Operation Conditions
(Also see Fault list chart) c) Check that the cooling water
strainers are not obstructed.
7.3.1 Supply Current
d) Check for indication of bearing
1) Check the motor running current each damage (noise, vibration).
shift. The current should be constant
and comply with that specified in section 3) If temperature increase continues and
2. exceeds the 65C trip setting and the
cause cannot be detected or the
NOTE: condition corrected, refer to the relevant
High amperage readings or fluctuating motor shutdown procedure in Section 7.2. If
currents indicate wear or partial seizure at necessary, blow down the boiler system
the bearing or wear ring surfaces. This or apply a high-pressure purge to the
condition can cause vibration necessitating motor, See Section 7.3.8.
motor removal strip and re-installation. Low
fluctuating amps indicates cavitation. 4) Should the alarm sound whilst the
circulator is on stand-by, start the
7.3.2 Motor Temperature circulator to accelerate internal high
pressure cooling water flow. Check
1) During normal operation, the motor possible causes for temperature
temperature should be checked at increase as above. The circulator should
weekly intervals. The thermometer is be tripped if the temperature exceeds
originally set to initiate an alarm if the 65C and the shutdown / purge
motor cavity temperature reaches 60C procedure in para 7.2 carried out.
and to de-energise the motor if the
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Section 7 Operation
7.3.3 High Temperature Alarm Winding Resistance curve in Section 2,

and Trip Settings Figure 2.2).
At weekly intervals check that the motor high NOTE:

temperature alarm setting does not exceed The insulation resistance of the stator
60C or 5C above normal operating winding varies with temperature and must
temperature (whichever is the lower) and always be measured cold 20C or at normal
that the trip setting does not exceed 65C. local ambient temperature.
Re-set if necessary.
2) Ensure that the interior of each terminal
7.3.4 Pump Head and Quantity box is dry, especially the insulation
projecting over the gland stems.
1) Check the total head generated by each
pump at weekly intervals. 3) Check that the terminal box bursting
discs are intact.
2) Correct possible causes of decrease in
head and quantity as follows: -
7.3.6 Vibration
a) The check valves in the circulating 1) Check the circulators for excessive
pump discharge lines are not fully noise or vibration, which can be either
open. Check and adjust the setting hydraulic or mechanical in origin.
as necessary.
2) Vibration should be monitored and
b) Low N.P.S.H., available due to recorded daily. If a permanent vibration
reduced water level in the steam transducer is not installed, check at
drum, changes in system pipework weekly intervals using temporary pick-
or system blockage. Check and ups. If the reading increases, check for
adjust the number of circulators the following causes: -
operating to suit until the fault can
be corrected. a) Cavitation due to low N.P.S.H., as
described in 7.3.4.
c) Vent the pipe system to remove
vapour locks. b) Unequal settings of the discharge
valves. Check and re-set in the fully
d) Power supply and reverse rotation open position.
checks are given in 6.2 (9).
c) Incorrect directional rotation as
e) Worn wear rings and a blocked or described in section 6.2, para. 9.
damaged impeller can be corrected
only after removing the motor d) Excessive pipe strain on the pump
assembly from the pump case. casing due to expansion or
Clearances are specified in section inadequate support of pipes.
2. Eliminate any strain by providing
adequate support.
7.3.5 Insulation Condition
3) If the cause cannot be determined,
Before initially energising the motor and contact Hayward Tyler for advice. Other
thereafter at monthly intervals, check the possible causes could be:
following: -
a) Damaged or unbalanced rotor or
1) The insulation resistance to ground of impeller, worn bearings, excessive
the motor leads. With the unit filled with end float or incorrect impeller
water below 20C or at normal local setting.
ambient temperature, the resistance
measured at the terminal links, using a b) Electrically induced vibration also a
1000V megger, must conform to the factor, i.e. Rotor bar breakage etc.
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Section 7 Operation
7.3.7 Low Pressure Cooling prevent the ingress of harmful fluids and
Water Supply Failure solids into the motor.
If the cooling water to the heat exchanger is 1) Flush down the fill and purge system to
lost while the circulator is at operating ensure the line is clean.
temperature, the motor will be de-energised
as soon as the motor temperature reaches 2) Check that the low pressure cooling
the trip setting of 65C by the temperature water supply valves are open.
controller. Prior to this an alarm will be
initiated by the low pressure cooling water 3) Introduce high pressure purge through
flow monitor indicating that the low pressure the filling valves. Check that the purge
cooling water supply has been lost and a temperature does not exceed 49C and
further alarm will be initiated by the that the purge pressure is above the
temperature controller when the motor boiler pressure.
temperature reaches 60C.
7.3.9 Extended Shut-Down
CAUTION :
Damage to the windings may occur if the When the circulator remains shutdown for
motor remains in operation after 5 an extended period: -
minutes from the loss of cooling water.
1) Check regularly that it remains full of
CAUTION : water.
Do not attempt to operate the motor by
overriding the temperature controller trip 2) Run the circulator for a minimum of ten
mechanism and restore the low pressure minutes every two months.
cooling water as quickly as possible.
Damage to the windings may occur if the CAUTION
cooling water is not restored before the If the motor is to be subjected to extreme
motor temperature rises above 70C. low temperature, the motor must be
prevented from freezing, see section 3.2.
NOTE:
Before re-starting a circulator after an If the boiler is laid-up under a nitrogen
emergency shutdown, low pressure cooling blanket, take necessary precautions to
water must be supplied to the pump to prevent damage to the motor through
reduce the motor temperature to at least gaseous water. Any pump start-up, when
38C. the boiler is in this condition, must be
undertaken and initial start and the full
fill and vent procedure, as detailed in
7.3.8 High Pressure Purge section 5.6, must be followed.
Supply To Motor
Purge water applied to the motor through 7.3.10 Boiler Cleaning
the high pressure fill line, in an emergency,
During any boiling-out or acid cleaning
will limit motor temperature, so protecting
operation of the boiler, the de-energised
the motor until inspection and rectification
circulators must be isolated completely prior
are possible. The flow of purge water must
to introducing any chemicals to the boiler.
be sufficient to stabilise the temperature of
The circulators must be continuously purged
the motor to overcome any water loss due to
with clean cool water at a pressure of
leakage, etc., as follows: -
approximately 7 bar in excess of the existing
drum pressure to eliminate infiltration of
NOTE:
contaminated water into the bearing and
Continuous purging of the motor during
motor components. . A purge rate of 3.8
operation is recommended only during
litres / min., is normally sufficient to prevent
boiling-out and acid cleaning. A purge rate
the ingress of harmful fluids and solids into
of 3.8 litres / min., is normally sufficient to
the motor.
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Section 7 Operation
7.4 Fault Finding (Fig 7.1)

Refer to the fault list chart that follows.
NOISE AND VIBRATION
REDUCED QUANTITY
EXCESSIVE POWER CONSUMPTION
REDUCED HEAD
INCREASED MOTOR TEMPERATURE

CONDITION/CAUSE
CIRCULATOR
SYSTEM
ELECTRICAL
CIRCULATOR
SYSTEM
CIRCULATOR
SYSTEM
ELECTRICAL
CIRCULATOR
SYSTEM
ELECTRICAL
CIRCULATOR
SYSTEM
SECONDARY COOLING
WATER FAILURE
ACTION
CHECK LOW PRESSURE

COOLANT FLOW AND RATE
CHECK TEMPORARY
FILTER FOR BLOCKAGE
CHECK ALIGNMENT &

STRAIGHTNESS OF SHAFT
CHECK HEAT EXCHNAGER

IS CLEAN AND VENTED
CHECK SYSTEM VALVES
ARE CLOSED AND NOT
LEAKING
CHECK MOTOR HEAT
EXCHANGER PIPEWORK &

FLANGES ARE NOT
LEAKING
CHECK MOTOR COVER IS

NOT LEAKING
STOP, REMOVE MOTOR

COVER & CHECK FILTER
WATER PASSAGES
CHECK DIRECTION OF
ROTATION, IF INCORRECT
REVERSE ANY TWO
SUPPLY LEADS
CHECK THAT FLOW VALVES
ARE TOTALLY OPEN AND

BYPASS VALVES ARE
CLOSED.
CHECK SYSTEM NOT

VAPOUR LOCKED
CHECK BOILER IS FILLED

ACCORDING TO
SPECIFICATION
CHECK SYSTEM FOR
BLOCKAGE OR
CONSTRUCTIONAL
CHANGE
CHECK NAMEPLATE DUTY &

VOLTAGE AGREE WITH
ACTUAL SITE CONDITIONS
CHECK & REPLACE

IMPELLER & CASE WEAR
RINGS IF WORN
CHECK IMPELLER IS NOT

BLOCKED OR DAMAGED
CHECK NPSH AVAILABLE
CHECK FOR UNBALANCED

MOTOR ROTOR OR
IMPELLER
CHECK FOR WORN

BEARINGS
CHECK IMPELLER SETTING
CHECK FOR EXCESSIVE
PIPE STRAIN OR
INADEQUATE CASING
SUPPORT
CHECK FOR EXCESSIVE

END FLOAT
CHECK DISCHARGE
VALVES EQUALLY OPEN
CHECK FOR EXTERNAL

LOADS ON MOTOR eg.
SUPPORT EXPANSION
Figure 7.1 : Fault List Chart
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Section 8 Maintenance
from the heat exchanger, top and

8 Maintenance bottom respectively.
8.1 Motor Removal
8) Drain the motor through the fill and drain
(Refer to figure 5.2) valve.
WARNING: 9) Disconnect the fill and drain line.

Before removing the motor, the circulator Discard gasket.
must be completely isolated from the
system, depressurised and cooled as 10) Remove the heat exchanger from the
described below. motor, as follows:
1) Isolate the electrical supply; disconnect a) Disconnect and the remove the
all instrument cables from the motor bottom outlet high pressure
identifying the connections and leads. interconnecting pipework between
the motor and heat exchanger by
2) Remove the terminal box covers and removing the flange nuts and
disconnect the external power supply washers from the flange bolts and/or
cables from each terminal box, studs. Discard the flange gaskets.
identifying each lead for reassembly.
b) Disconnect the top inlet high
3) Using a 1000v megger, check that the pressure connection between the
insulation resistance to ground of the motor and heat exchanger as
motor leads conforms to Winding above.
Resistance Diagram, Section 2, Fig 2.2
when measured at the terminal stems c) Take the weight of the heat
with the unit full of water at 20C or the exchanger with adequate lifting gear
normal ambient temperature. Record and remove the nuts and bolts
the reading. securing the heat exchanger to the
motor brackets.
4) If suction valves are not fitted, the boiler
system must be cooled, depressurised d) Remove the heat exchanger to an
and drained before motor removal. inspection area.
CAUTION: 11)
The low pressure cooling water flow and a) Fit the removable lifting lugs to the
motor temperature must be maintained brackets on the motor casing. Set
within the specified limits whenever the up two chain hoists and rigging, of
motor is in contact with a hot pump case. sufficient capacity for each to take
the full weight of the motor, and
5) Check that the circulator is connect to the lifting lugs.
depressurised and isolated from the
boiler and fill system. WARNING:
Normally two hoists are used for
6) Drain the pump casing using the drain removing the motor and because the
valves in the discharge pipework and /or load can shift from one hoist to the other
the pump case drain valve. during the removal, each hoist must be
capable of taking the full weight of the
WARNING: motor.
Never drain the pump casing through the
motor fill & drain line as this could cause b) Take the initial strain of the motor.
contamination of the motor.
12) Loosen the pump/motor flange stud nuts
7) When the pump case has cooled. in accordance with the hydraulic stud
isolate and disconnect the low pressure tensioning instructions in Section 9.
cooling water inlet and outlet flanges
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15) If necessary, transport the motor to a

13) Lower the motor evenly to the floor working area where adequate facilities
level, supporting the base on suitable are available for disassembly, inspection
timber. and maintenance.
14) Lower the motor to the horizontal 16) Seal off the pump case opening by
position, (Figure 8.2), remove the lifting fitting the blank off plate refer to
tackle and cover all joint faces and Section 5 for details.
openings with clean rags.
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Figure 8.1 : Laying Down The Motor
Figure 8.2 : Impeller Removal
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8.2 Disassembly 8.2.3 Baffle Wear Ring

CAUTION: Examine the baffle wear ring. If damaged,
Lifting tackle must not be attached to the remove the socket headed cap screws and
protruding rotor shaft nor must the shaft lock washers. Remove the wear ring for a
be subject to any shock loads. fuller inspection or renewal.
The motor must be adequately supported 8.2.4 Motor

before and during any disassembly.
Disassembly must only be carried out by
Hayward Tyler Service Personnel.
8.2.1 Diffuser
1) The diffuser wear ring can be left in 8.3 Inspection Of
place, bolted inside the pump case.
Components
2) To inspect the wear ring and piston ring, 8.3.1 Main Flange Stud
carefully remove the suction tube from
inside the pump case.
Inspection
Stud inspection must be carried out in
3) Lower to ground level, dismantle and accordance with the inspection cycles
store in a safe place. indicated below.
8.2.2 Main Impeller (Fig 8.2) 8.3.1.1 Stud Inspection at each Flange
Breakdown
Remove the impeller from the rotor
assembly as follows:- Whenever either the pump case/ motor case
or the motor case/motor cover flange joint is
4) Unlock the punch marks and remove the broken, the exposed portion of all the flange
impeller cap screw. studs must be thoroughly inspected visually
for indications of damage or corrosion,
5) Remove the LEFT-HAND threaded mainly in the form of pitting and cracks etc.
impeller nut using the special spanner Pitted or cracked studs must be renewed.
and tommy bar provided in the tool kit.
8.3.1.2 Stud inspection at Pump
NOTE: Overhaul
Do not use any leverage in the water At each convenient circulator overhaul
passages of the impeller to oppose force period, approximately 4 - 5 years, a
exerted on the special spanner; the weight percentage of the studs must be given a
of the rotor will oppose rotation if the tommy- non-destructive examination, as follows:
bar is given a few heavy blows with a
leadfaced hammer. 1) Remove two random studs from both
the pump case/motor case joint and any
If the nut shows any tendency to seize on one stud from the motor case/motor
the shaft, do not continue to exert force, but cover joint.
drill and split the nut to remove.
2) Clean up the studs, and using a liquid
6) Carefully withdraw the impeller, then dye penetrant and/or magnetic particle
remove the impeller washer and remove examination, examine for surface
the impeller key. cracks, particularly in the stud threads
and thread run out areas.
7) Immediately refit a serviceable impeller
nut to permanently protect the shaft NOTE:
threads. If there has been a history of leakage in
service from the joints and/or previous
recorded damage, remove and inspect at
least 10% of each flanges studs.
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suitable fatigue tests carried out on a

3) Identify any corrosive deposits that may minimum of three studs selected at
be present, i.e. pitted areas etc., and if random from the pump case/motor case
corrosion is evident, consider its stress joint and motor case/motor cover joint.
corrosion influences. If any stud
condition raises doubts as to the stud's 8.3.2 Impeller and Diffuser Wear
serviceability, renew all the studs in the Rings (Fig 8.3)
flange.
1) Clean the impeller and the diffuser wear
4) If necessary renew the studs. rings and check them for damage.
8.3.1.3 Studs on Extended Circulator 2) Subtract the impeller wear ring outer
Service Life diameter from the diffuser wear ring
bore, allowing for any temperature
If at the end of the circulator nominal service difference and compare with the
life, or as otherwise defined, an extension of clearance specified in Section 2,
circulating pump life is proposed, it is Technical Data.
recommended that all studs should be
renewed. However, should a request be 3) Check the hardened surface of the
made for an extension to the life of the impeller wear ring.
existing studs, then the following points must
be satisfied:- 4) If the diffuser wear ring requires
renewal, fit the new ring and secure
1) The general condition and surface using the socket head cap screws and
integrity of the studs must be lock washers. Tighten the screws in
satisfactory. accordance with the torque figures
detailed in Section 2.
2) There should be adequate residual
fatigue life in the studs for the extended
life proposed; this can be obtained by
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Figure 8.3 : Impeller and Diffuser Wear Ring
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8.4 Assembly Notes NOTE:

When fitting an individual stud to an
NOTE: assembled unit, screw the stud in until its
In the event of new components being protruded end is on the same plane as
required refer to the 'Parts List' on Sectional adjacent studs.
Arrangement Drawing (Section 8) and quote
the circulator Serial No.- stamped on the 4) Check the length of the stud protruding
motor nameplate - in all correspondence above the casing, the dimension should
with Hayward Tyler. be long enough to accept the full depth
of the nut.
8.4.1 Assembly of Main Flange
Studs 5) When initially fitting the nut, prevent the
stud from turning by using a wrench
Renew damaged or corroded studs, with (spanner) on the squared end.
reference to Figures 8.4 and 8.5 and in
accordance with the following instructions:
1) Thoroughly clean the threads in the

case with a suitable solvent and/or by
wire brushing. Remove any very hard
encrustation in the threads by running
down a tap but this should be used only
as a last resort.
2) Check the replacement studs for

damage to the threads or protective
coating during transit. Renovate or
reject damaged studs as necessary.
3) Apply high temperature anti-seize

compound or silicone grease to the
casing end of the stud.
8.4.1.1 Pump/Motor Case Studs

1) Assemble the pump /motor case studs
as follows:
a) Screw the stud into the case, until Figure 8.4 : Assembly of Flange Studs
the last thread of the stud is (Pump /Motor Case)
recessed within the tapped hole
5mm nominal, that is, one full casing 8.4.1.2 Motor Case/Cover Studs
thread left exposed above the stud
1) Assemble the motor case/ cover studs
metal end as shown in Figure 8.4.
as follows:
b) In conjunction with the stud
a) Screw the stud into the case, until
recessing, maintain the squared end
dimension L measures 236 mm in
of the stud on a common plane to
the motor case.
adjacent studs within 3mm. This is
essential to prevent fouling of the
b) Maintain the ends of the stud on a
Hydraulic Stud Tensioner on the
common plane to adjacent studs
studs either side of the stud being
within 2mm. This is essential to
tensioned.
prevent fouling of the Hydraulic Stud
Tensioner on the studs either side of
the stud being tensioned.
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6) Check the length of the stud protruding

above the casing, the dimension should 2) Fit the impeller washer with the internal
be long enough to accept the full depth chamfer towards the shaft shoulder.
of the nut.
NOTE:
NOTE: In some cases it may be necessary to fit the
When fitting an individual stud to an impeller washer prior to fitting the impeller
assembled unit, screw the stud in until its key.
protruded end is on the same plane as
adjacent studs. 3) Coat the threads of the left-hand
threaded impeller screw with silicone
7) When initially fitting the nut, prevent the grease, then re-fit the impeller and the
stud from turning by using a wrench impeller nut.
(spanner) on the squared end.
4) Check that the gap between the key and
the top of the impeller hub does not
exceed 0.25mm.
5) Using the special impeller nut spanner

and tommy bar, supplied in the tool kit,
and a lead-faced hammer, tighten the
impeller nut.
NOTE:
The impeller nut has a left handed thread.
Do not use any leverage in the water
passages of the impeller to oppose force
exerted by the spanner, the weight of the
rotor will oppose rotation if the spanner is
given a few heavy blows with a lead-faced
hammer.
6) Draw the impeller and rotor assembly

forwards until the thrust disc rests upon
the thrust pads.
7) Measure the dimension between the top

of the impeller and the pump/motor case
flange. (Dimension Z on Figure 2.1).
Figure 8.5 : Assembly of Flange Studs Adjust the thickness of the impeller
(Motor Case / Cover) washer as necessary, to obtain the
dimension given in Section 2 - Technical
Data.
8.4.2 Baffle Wear Ring
If the baffle wear ring has been removed, 8) Renew the screw, torque tighten as per
refit by using the screws and washer. motor assembly drawing in Fig 2.1 and
Torque tighten in accordance with figures punchlock.
given in Figure 2.1.
9) If the unit is to be stored, cover the
impeller with the transit canister and
8.4.3 Main Impeller (Fig 8.6) flanges with blanks. Slowly fill the motor
Fit the impeller as follows: - with inhibitor through the inhibitor filling
valve.
1) Remove the protective impeller nut and
fit the impeller key.
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
10) Using a 1000V megger, check that the with the installation procedure described in
insulation resistance to ground of the Section 5.
motor leads is above 200 megohms
when measured at the terminal stems WARNING:
with the unit full of water below Reinstallation is only possible with the
approximately 20C, if possible, or at boiler cold, de-pressurised and drained.
normal ambient temperature. Record Fit a temporary gauge to check the
Reading. pressure inside the pump casing. Blow
down and cool as required before
8.4.4 Heat Exchanger removing the casing blank.
Ensure that the heat exchanger is 1) Remove the casing blank and fit a new
serviceable and if removed, re-fit in flexitallic gasket to the motor flange.
accordance with installation procedures as
described in Section 5. 2) Fit the motor, heat exchanger, inter-
connecting pipe work, fill and high
8.5 Re-Installation Of Motor pressure purge lines and the secondary
cooling water pipe work.
The re-installation of the motor assembly to
the pump case is carried out in accordance
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
Figure 8.6 : Impeller Setting
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
8.6 Parts Lists

8.6.1 Sectional Arrangement
ITEM NO. PART NUMBER DESCRIPTION QTY.

1 16885M8-20 SOCKET HEAD CAP SCREW M8 x 20mm 12
2 42577-208 M8 NORDLOCK WASHER 12
3 42938-1020 INSERT - PISTON RING 1
4 42806-1202 IMPELLER NUT 1
5 42938-2416 DIFFUSER SUPPORT RING 1
6 42806-1405 IMPELLER WEAR RING - INIT M/C 1
7 38882-102 IMPELLER WEAR RING SCREW 3
8 42938-2407 DIFFUSER WEAR RING 1
9 42938-1401 IMPELLER - FINAL MACHINE 1
10 42938-1003 PUMP CASE - FINAL MACHINE 1
11 42938-135 IMPELLER KEY 1
12 42938-2030 BAFFLE WEAR RING 1
13 16884M12-35 M12 x 35mm SOCKET HEAD CAP SCREW 6
14 42938-1201 IMPELLER WASHER 1
15 42938-2401 DIFFUSER - FINAL MACHINE 1
16 16801M16-35 HEX HEAD BOLT M16 x 35mm 21
18 42499-460 FLEXITALLIC GASKET 1
19 42910-1019 NUT - PUMP/MOTOR/COVER 18
20 42938-1018 STUD - PUMP / MOTOR 18
21 41779-115 JOURNAL BEARING SLEEVE 2
22 42808-1706 JOURNAL TILTING PAD ASSEMBLY 2
23 16884M12-55 M12 x 55mm SHCS 12
25 42774-2111 BEARING HOUSING LOCK RING 2
27 39693-139 JOURNAL SLEEVE KEY 2
28 39982-140 TEMPERATURE INDICATING STRIP 4
29 42658-2108 SPLIT RING - STATOR SHELL 2
STATOR INITIAL ASSEMBLY AND FINAL
30 42938-2101 1
MACHINE
31 42938-013 MOTOR ROTOR ASSEMBLY 1
34 17207M8 M8 SPRING WASHER 6
35 42808-1711 O' RING SEAL 1
36 16884M12-80 SHCS M12 x 80mm 12
37 42276-106 THRUST KEY 1
38 42808-2904 STATOR LOCK RING 1
39 42808-1501 THRUST DISC - FINAL M/C 1
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
40 42560-1211 SPACER SLEEVE 1

41 42759-2502T2 REVERSE THRUST PLATE 1
42 42938-2001 MOTOR CASE - FINAL M/C 1
43 42751-1019 NUT-MAIN FLANGES 16
44 42774-1018 STUD - MOTOR FLANGE 16
45 16201M10-35 HEX HEAD SCREW 6
46 16884M6-45 SKT. HD. CAP SCEW 6
47 16526M6 PHILIDAS NUT M6 6
48 167WBCNN10M0 SPLIT PIN 1
49 42808-028 FILTER ASSEMBLY 1
50 42774-1243 THRUST NUT 1
51 42808-019 MOTOR COVER ASSEMBLY 1
52 16884M12-120 SOCKET HEAD CAP SCREW M12 x 120mm 12
53 42488-431 FLEXITALLIC GASKET 1
54 42808-2501 REVERSE THRUST HOUSING 1
55 42808-2910 STATOR LOCKING SCREW 12
56 42938-027 TERMINAL BOX ARRANGEMENT 3
57 42808-2903 SPLIT RING - STATOR LOCK RING 1
58 42808-1603 THRUST PAD-FINAL MACHINE 12
59 167WBDGJ62M0 SPLIT PIN 12
60 42808-1601 THRUST SEAT 1
61 42777-023 GLAND MOULDING & CABLE ASSY 3
62 42808-1701 COVER END BEARING HOUSING 1
63 42808-1710 ANTI-ROTATION PEG 4
64 42808-1705 SECURING RING - COVER END 1
65 42808-1704 BEARING RING 2
66 42938-2125 WINDING CABLE - 3.3kV 2
67 42808-1805 SECURING RING 1
68 42808-1801 PUMP END BEARING HOUSING 1
69 35557-117 JOURNAL LOCKING SCREW 2
70 PreviewCfg M6 x 40mm SOCKET HEAD CAP SCREW 18
72 16884M16-50 SKT. HD. CAP SCREW 1
75 42938-2408 SUCTION TUBE - FINAL MACHINE 1
75 42808-1605 THRUST PAD - STOP 12
76 42653-2406 PISTON RING - LATCHED GAP 1
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
8.6.2 Other Items Supplied

The following parts and assemblies are supplied by Hayward Tyler but not shown on the
Sectional Arrangement Drg 42939/002.
PART NO DESCRIPTION QTY

42708/1042 DP STUD PIPES 3
42938/007 DUPLEX THERMOCOUPLE (MOTOR CAVITY) 3
42845/006 DUPLEX THERMOCOUPLE (PUMP CASE) 2
42401/201 FLOW SWITCH/INDICATOR 1
42401/205 TEMPERATURE INDICATOR 1
42401/207 PRESSURE GAUGE (MOTOR CAVITY) 1
42499/460 GASKET (PUMP/MOTOR) 1
42488/431 GASKET (MOTOR COVER) 6 TOTAL
39930/207 GASKET (FILLING VALVE) 1
SP42938/031 REMOVABLE LIFTING LUG 4 TOTAL
SP42938/033 TOOL KIT 2 TOTAL
SP42938/045 STUD TENSIONING KIT 2 TOTAL
42499/460 GASKETS (PUMP CASE/BLIND FLANGE) 6 TOTAL
8.6.3 Terminal Gland
PART NO. DESCRIPTION QTY

42777/023 GLAND MOULDING & CABLE ASSEMBLY 3
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
8.6.4 Terminal Box
PART NO. DESCRIPTION QTY

42774/2701 TERMINAL BOX 1
42938/2707 TERMINAL BOX COVER ASSEMBLY 1
42774/2708 GASKET - TERM. BOX COVER 1
16012M10/25 STUD - TERM. BOX COVER M10 x 25 26
42774/2705 GASKET - TERM. BOX SUPPORT 1
16012M10/25 STUD - TERM. BOX SUPPORT M10 x 25 12
17207M10 WASHER SHAKEPROOF 38
16501M10 NUT M10 38
39988/125 PANEL DESSICATOR 1
42816/2711 CABLE ENTRY PLATE 1
42774/2711 GASKET - CABLE ENTRY PLATE 1
16012M10/45 STUD - BLANK PLATE 4
17207M10 WASHER SHAKEPROOF 4
16501M10 NUT M10 4
37917/169 BURSTING DISC 2
37917/137 CLAMPING PLATE 2
42333/129 BODY - BURSTING DISC 2
37917/136 GASKET - TOP 2
37917/139 GASKET - BOTTOM 2
37917/140 PROTECTION SHEET 2
16884M6/50 SKT. HD. CAP SCREW - BURSTING DISC 8
42774/2717 TERMINAL BLOCK ASSEMBLY 1
16884M12/55 SKT HD CAP SCREW TERM BLOCK/BOX 4
189YDNBB53M0 CIBA ARALDITE TWIN PACK AS REQ
42938/131 TERMINAL LINK ASSMEBLY 1
42943/214 TUBULAR LUG SOCKET 1
42629/2719 WASHER TERMINAL SCREW 8
42629/2720 NUT TERMINAL SCREW M16 x 2.0 10
36816/126 WASHER TERMINAL STEM 2
36816/146 NUT TERMINAL STEM 5/8 UNC 3
189WPGGC81M0 HEAT SHRINK TUBE AS REQ
189WCBJB81M0 SILICON THERMOSETTING TAPE AS REQ
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
8.6.5 Spare Parts Commissioning

One set supplied per unit. See Figure 8.12 Drawing 42939/202 in Section 8.
8.6.6 Spare Parts

One set supplied in total. See Figure 8.13 Drawing 42939/203 in Section 8.
8.7 Drawing List

The following drawings are provided for reference
Figure 8.7 General Arrangement

Figure 8.8 Sectional Arrangement
Figure 8.9 Terminal Box
Figure 8.10 Tool Kit List
Figure 8.11 Instrumentation Schedule
Figure 8.12 Spare Parts Commissioning
Figure 8.13 Spares Kit
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401

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Figure 8.8 : Sectional Arrangement (2) -60-

THIRD ANGLE PROJECTION
SECTION A-A A3
409.25 344
26
3 2 24 25
105 105
28
A
13
14
4
15
88.5
5
1
X
23 7
9 10 11
10 9 6
12
22 20 16 17 18 19 21 8
152
28 42938-131 TERMINAL LINK ASSEMBLY 1
27 189YDBB53MO CIBA ARALDITE TWIN PACK AS REQ.
NOTES:- 26 42938-2707 TERMINAL BOX COVER ASSEMBLY 1
25 39988-125 DESICCATOR-MAIN TERMINAL BOX 1

1. THIS TERMINAL BOX IS CAPABLE OF WITHSTANDING SYSTEM FAULT CURRENTS UP TO 44kA 24 42774-2721 TUBULAR LUG SOCKET 1
AT 6.6kV FOR A DURATION OF 0.5 SEC.
9 23 42777-023 GLAND MOULDING & CABLE ASSY 1
22 42774-2717 TERMINAL BLOCK ASSEMBLY 1

2. APPLY 3 HALF LAP LAYERS OF 0.3mm X 25mm 3M TYPE 70 SELF FUSING SILICON TAPE OVER
21 37917-137 CLAMPING PLATE - BURSTING DISC 2
THE TERMINAL GLAND CONNECTION & CABLE LINK AS FOLLOWS:- OVERLAP THE NYLON
SLEEVE OF THE GLAND AND LINK CABLE BY AT LEAST THE TAPE WIDTH. EACH SUCCESSIVE 20 37917-136 TOP GASKET - BURSTING DISC 2
WRAPPED LAYER TO BE OFFSET BY HALF THE TAPE WIDTH. 19 37917-169 BURSTING DISC 2
15 18 37917-139 BOTTOM GASKET - BURSTING DISC 2

3. COVER THE TERMINAL GLAND CONNECTION WITH FLAME RETARDED POLYOLEFIN HEAT 17 42333-129 BODY - BURSTING DISC 2
SHRINK SLEEVING FROM THE NYLON SLEEVE ON THE TERMINAL GLAND TO 30mm ALONG THE 152 16 37917-140 PROTECTION SHEET 2
CABLE LINK SHEATH. FIT SLEEVING IN ACCORDANCE WITH PROCESS 36613/171. 15 42816-2711 CABLE ENTRY PLATE 1
14 42774-2711 GASKET - CABLE ENTRY PLATE 1

4. PAINTING INSTRUCTIONS:-
4.1. PAINT TERMINAL BOX AND COVER TO PROCESS SPECIFICATION 36613/108 13 42774-2708 GASKET - TERMINAL BOX COVER 1
4.2. PHASE MARKING TO PROCESS SPECIFICATION 36613/111 12 42774-2705 GASKET - TERMINAL BOX SUPPORT 1
11 16012M10-45 M10 x 45mm STUD 4
5. BILL OF MATERIAL INDICATED FOR ONE PHASE TERMINAL BOX ONLY, TYPICAL FOR 10 17207M10 M10 SPRING WASHER 42
REMAINING TWO PHASES 9 16501M10 M10 FULL NUT 42
8 M6 x 50mm SOCKET HEAD CAP

16884M6-50 8
SCREW
6. ALUMINIUM BURSTING DISCS, ITEM 20, BURSTING PRESSURE 0.352kg/cm 7 16884M12-55 M12 x 55mm SHCS 4
6 16012M10-25 M10 x 25mm STUD 38

7. FILL TERMINAL BLOCK HOLES WITH ARALDITE (189YNDNBB53M0) AS REQUIRED.
5 36816-126 TERMINAL SCREW WASHER 2
4 36816-146 TERMINAL SCREW NUT 3
3 42629-2719 WASHER- TERMINAL SCREW 8

VIEW ON ARROW 'X' 2 42629-2720 HEX NUT - TERMINAL SCREW 10
1 42774-2701 TERMINAL BOX - FAB & M/C 1

ITEM
PART NUMBER DESCRIPTION Default/QTY.
NO.
CONTRACT No. .................................................... 7700001565, 7700001565, 7700001565 TOLERANCE FOR POSITION EXCEPT WHERE OTHERWISE STATED SURFACE FINISH Ra MICROMETRES
www.haywardtyler.com
MATERIAL MASS kg 4856.8
CUSTOMER ............................................................ BHARAT HEAVY ELECTRICALS LTD
6.3 0.4
Pitch Dimensions 0.5mm Normal machine Grind
info@haywardtyler.com THIS DRAWING AND THE COPYRIGHT CONTAINED THERIN ARE THE PROPERTY OF
3.2 0.05
2009
SITE ...................................... KODERMA #1 & #2 DURGAPUR #1 & #2 ANPARA #1 & #2
Pitch Circle Diameter 0.5mm Machine Super finish HAYWARD TYLER ENGINEERED PRODUCTS LTD., LUTON, BEDS., LU1 3LD, ENGLAND.
1.6
* Angular Dimensions 30' Fine Machine
USE .......................................... BOILER WATER CIRCULATING PUMPS WITH MOTORS * Not Applicable for Pitching Holes
GEOMETRIC TOLERANCE SYMBOLS
HAYWARD TYLER
TEL. +441582 731144
FAX. +441582 452198
TITLE:
HAYWARD TYLER ENGINEERED PRODUCTS LTD 6.6 KV FAULT RATED TERMINAL BOX
MACHINING TOLERANCES EXCEPT WHERE OTHERWISE STATED mm
Straightness Parallelism
Over 0 50 150 300 600 1200 Flatness Squareness
SIZE
To 50 150 300 600 1200
Roundness Angularity NAME DATE
380-P-453-3300-210 GMP UNIT
Cylindricity Position
Outside
B 9822 CHANGE TO DRAWING NOTE AND TITLE. K. JONES 05/05/10 A. JONES 05/05/10 Diameter 0.12 0.25 0.50 0.75 1.25 1.50 Profile of a line Concentricity DRAWN T. BOLTON 30/03/2010
Profile of a surface Symmetry
A
Inside
Diameter
0.12 0.25 0.50 0.75 1.25 1.50 Run out M Maximum - CHECKED A.S. JONES 31/03/2010 DRG NO. ISSUE
42938-003 Sheet 1 of 1 B
* Boxed dimension - Metal Condition
MODIFIED APPROVAL APPROVED A.S. JONES 31/03/2010
REV. ECR CHANGE DESCRIPTION MODIFIED BY APPROVED BY Length 0.25 0.50 0.50 1.00 1.00 1.00 *Dimm. which defines true position
DATE DATE
Figure 8.9 : Terminal Box Arrangement -61-

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Figure 8.10 : Commissioning Spares -62-
INSTRUMENTATION SCHEDULE FOR KODERMA EP11101/02, DURGAPUR EP11104/5, ANPARA EP 11107/8
The following list of instruments is supplied with each pump/motor unit
Process Electrical Alarm

Instrument Where Used No. Supplied Part no Make Model Range Accuracy Alarm Contacts
Connection Connection Set Point
Tolerance to Recommended
0-800 deg C
Thermocouple Motor Cavity 3 42938/007 TC Ltd 12-K-289-118-8.0-2ID-3P11/IP67-165MM IEC60584.2:1993 3/4" NPT 3/4" NPT N/A 60 deg C alarm,
Class 2 65 deg C trip
Pump Case Tolerance to Must be less

0-800 deg C
Thermocouple Surface & Suction 2 42845/006 TC Ltd 12-K-241-116-6.0-2ID-3P11/IP67-165MM IEC60584.2:1993 3/4" NPT 3/4" NPT N/A than the Design
Branch Class 2 Temperature
2 Adjustable
Flow Switch / LP Cooling Water 1 1/2" ANSI /
1 42401/201 Flotech Solutions Ltd M16SSMP3EE3EESL1cS12F300S1D1 0-100% of 16m3/hr +/- 2% of full scale 20 mm conduit SPDT 0-100%
Indicator Pipework 300#RF
(3 wire) switches
Temperature
Motor Case 1 42401/205 Dresser/Ashcroft 600A-02-C27-B01-A1-L07-BS-XNG 0-120 deg C 1% FSD 1/2" NPT N/A N/A N/A
Indicator
60-1379SSL-04L-XNH-XNG with diaphragm seal model

Pressure Gauge Motor Cavity 1 42401/207 Dresser/Ashcroft 0-250 kg/cm2 0.5% FSD 1/2" NPT Lower N/A N/A N/A
50-100SS
InstrumentScheduleRev027Oct2010
Figure 8.11 : Instrumentation Schedule -63-

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Figure 8.13 : Tool Kit List -65-
Section 9 Stud Tensioning Equipment
Four metal rods are provided in the kit. One

9 Stud Tensioning end of the rod is used for tightening the
Equipment threaded inserts when installing the heads.
The other end is used for pulling down the
9.1 Introduction flange nuts.
All items mentioned herein relate to the M72 Although each Stud Tensioner is operable
and M56 Stud Tensioner Equipment by one engineer, this practice is not
supplied as comprehensive kits. This must recommended due to weight and
be used ONLY in conjunction with the environmental criteria.
circulator manual for the equipment supplied
for the specific contract.
9.3.2 Hand Pump
9.2 Application The stud tensioner equipment hydraulic
pump is a hand operated, dual piston, high
The physical dimensions of the pump pressure unit. Initially, both low and high
case/motor case joint and the motor pressure flow is applied at each pump
case/cover joint prevent adequate pressure handle stroke until the tensioning head
sealing by hand-tightened nuts. For these starts to take load, when the high pressure
applications, hydraulically operated stud application continues and the low pressure
tensioner heads are supplied with each is diverted back to the oil reservoir. Re-
contract. The tensioner heads stretch the setting of the low and high pressure takes
studs and the nuts are then tightened down place automatically allowing the pump to
by hand. When the tension on the stud is operate with maximum efficiency at all
released, the load is transferred to the nut to times. Pressure limiting valves trip when the
give the required tightness. pressure exceeds the pump capacity.
When working on a circulator flange joint, all The pump body contains the oil reservoir,
the heads are employed simultaneously, incorporating an oil filter plug and oil
each being diametrically opposed. The pressure return valve for variable pressure
heads are positioned on the studs in a release, the pump handle, gauge and quick
prescribed sequence, and are pressurised to release high pressure hoses complete the
a specified limit in accordance with each of assembly. All the pump components are
five consecutive stud tensioning easy to dismantle for servicing.
programmes. As the studs are
progressively tensioned, the mating flanges 9.3.3 Stud Tensioner Heads
are drawn together, so allowing the
circulator flange nuts to be tightened or The stud tensioner heads each comprise a
released. bridge that fits over the stud and stud nut to
seat on the flange and is retained by the
bridge retainer. A tensioner body
9.3 Description (Fig. 9.1) incorporating a seal, sits on the bridge and
9.3.1 General is held in position by the threaded insert,
The Hydraulic Stud Tensioner Equipment screwed on the stud. The head is
comprises three principal components: - hydraulically pressurised via a quick release
coupling and high pressure hose.
1) Tensioner head assembly, including the
bridge, tensioner body and piston and Three of the four heads have two
threaded inserts (see Fig. 9.2). connectors fitted. The fourth head has one
connector and one blanking plug. The
2) Hand-pump - including oil reservoir. fourth head is always the last in line in the
system, the other heads are interconnected.
3) High Pressure Couplings, hoses and
pressure gauge.
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9.3.4 Operation Having hand tightened the stud nut, the

hydraulic pressure on the tensioning head
When the hydraulic pressure, in accordance piston is gradually released, via the hand
with the stud tensioning program, is applied pump oil return valve, and the load is
to the tensioner head, the body reacts transferred to the stud nut to give the
against the threaded insert which in turn required tightness. The threaded inserts are
stretches the stud. While the stud is unscrewed from the studs and the heads are
stretched, the stud nut is hand tightened, transferred to the next studs in the tightening
using the bar provided in the kit. sequence.
Figure 9.1 : Hydraulic Stud Tensioning Equipment
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9.4 Assembling The Stud normal for the bridge window to face
radially outwards from the centre of the
Tensioner (Fig. 9.3) circular flanged joint.
The hand pump and its accessory hoses are
normally provided, in the toolbox, already NOTE:
assembled needing only to be connected to The bridge base circumference should sit
the tensioning heads. However for flatly against the surface against which it is
information purposes, the assembly of the being tensioned.
stud tensioner kit is as follows: -
5) Attach each threaded insert into the bolt
1) tensioners by screwing onto the threads
a) Remove the hand pump, complete protruding above each nut. Screw down
with pressure gauge, high pressure the inserts using the tommy bars
hoses and hose couplings from the supplied with the equipment, until
hydraulic pump tool box. contact with the load cells is achieved.
b) Ensure that all studs are CAUTION:

scrupulously clean and that their Body and piston seals will be damaged if
threads are undamaged. Carefully the piston protrudes excessively from
examine that portion of each stud the tensioner body, observe the yellow
thread protruding beyond the flange maximum extension warning line.
nut after fitting. If the studs have (Maximum extension 6mm)
been in service for some time,
inspect as described in the NOTE:
Circulator Instruction and If the seals need replacing, refer to the
Maintenance Manual. operators manual provided with the stud
tensioning equipment.
c) When tensioning studs of the
circulators which have been in 6) Connect the end of the high pressure
service, inspect all faces of each feed hose to the first tensioner head.
flange nut. Reject any damaged
nuts. (Damaged faces of nuts can 7) Fit one of the inter-connecting hoses
be re-ground for subsequent re- between the first and second heads.
use).
8) Connect up the second and third heads
CAUTION: and finally, using the one remaining
Never lubricate the stud top threads, or hose. Connect the fourth head (i.e. with
those of the threaded insert. a blanking plug fitted) to complete the
circuit.
2) Install and hand tighten all flange nuts.
Apply silicone grease or high 9) Check the oil level in the hydraulic hand
temperature anti-seize compound to the pump, fill or top-up if necessary.
threads and faces of each flange nut.
NOTE.
3) Connect the high pressure feed hose via The quick release female connectors have a
the quick release female connector to knurled security locking ring in the centre.
the gauge tee on the pump. This must be turned to lock the spring-
loaded end of the coupling to eliminate the
4) Assemble the load cell and bridge, over possibility of an accidental disconnection.
the first set of bolts (diametrically
opposed) to be tightened. The bridge CAUTION:
window should be positioned so that Do not pressurise an un-connected male
access to the nut is obtained. It is coupling.
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Figure 9.2 : Single Piston Stud Tensioner - Exploded View
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Figure 9.3 : Single Piston Stud Tensioner - General Arrangement
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Figure 9.4 : Quick Release Coupling
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Figure 9.5 : Nut Tightening Sequence (1)
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Figure 9.5 : Nut Tightening Sequence (2)
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9.5 Replenishing The Pump

b) Check that all hose couplings are
Tank serviceable and tight on the hose
The pump is supplied already filled with oil ends and tensioning heads.
but after repeated use the oil should be
replenished as follows:- 6) Check equipment is correctly assembled;
a) Tensioning head components must
1) Unscrew the oil filler plug from the top be seated squarely within each other
pump tank. and with the motor cover face or
motor pump flange.
2) Replenish the tank from the 5 litre
container of hydraulic fluid to the bottom b) The thread engagement between the
of the level tube. stud and the threaded insert must be
48 mm minimum.
9.6 Indexing c) Before pressurising, ensure hose
It is essential that the gasket is uniformly connector security by pulling on each
compressed and the studs evenly locked connection.
prestressed. To ensure this, diametrically
opposed flange nuts are tightened 7) Do not attempt to use stud tensioner if
simultaneously in accordance with a unsure of the correct assembly and
predetermined numbering sequence. operation of the equipment.
Using any convenient nut as No. 1 and
working in a clockwise direction, sequentially 8) Do not attempt any repairs on the system
mark with chalk on the flange periphery, the when under pressure.
appropriate nut tightening sequence. Refer
to Fig.9.5 for Nut Tightening Sequences. 9.8 Tightening Flange Nuts
1) Fit the four tensioner bodies complete
9.7 Safety Procedures with threaded inserts onto the studs and
1) Eye protection and gloves should be screw down on to each bridge. Attach the
worn when working with high pressure hydraulic link hoses.
hydraulics.
2) Ensure that the insert is fully depressed
2) Pressurise slowly, do not exceed the within the tensioner body.
maximum working pressure stated in the
manufacturers instructions supplied with 3) Depress the hydraulic piston fully in the
the kit. tensioner body by: -
a) Opening the oil return valve on the
CAUTION hydraulic hand pump using the
Gauge pressure should be constantly winged control valve screw.
monitored during pump operation.
b) Fully tightening the threaded inserts
3) Do not exceed the maximum piston using the rod provided.
extension 6mm. indicated by a yellow
line. c) Closing the oil return valve on the
hydraulic pump.
4) Do not leave a pressurised system
unattended, release pressure if leaving 4) The pump, hoses and tensioner heads
the working area. are pre-filled and system venting should
not be necessary. However, should
5) Check the equipment: venting of the system be required, loosen
the blanking plug from the last head in
a) Ensure that the hoses are the circuit and operate the pump until air
undamaged.
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free fluid emerges from around the plug

on completion of venting. f) Disconnect the hydraulic hoses.
5) Using the hydraulic hand pump, obtain a NOTE:

true pressure stipulated for the 1st pass If the required pressure is not reached, return
of the 5 passes given in the following to step 2.
table.
9) Transfer the stud tensioners to studs
CAUTION; numbered 2 in the tightening sequence.
The indicated gauge pressures are true Repeat operations 2) to 8).
operating pressures. Never exceed
maximum working pressure for the head 10) Continue tightening progressively to the
when tensioning, or damage to the numbered sequence until all the nuts are
tensioner or to the studs may occur. See tightened to the 1st pass pressure i.e.
the manufacturers instructions supplied nuts 2 in turn then nuts 3 followed by
with the kit for the maximum working nuts 4, then 5 and so on.
pressure.
11) Repeat the tightening sequence round
6) The piston stroke and pressure should be the flange of a 2nd, 3rd, 4th or 5th pass,
continually monitored so that neither go at the stud tensioning pressure stipulated
above the corresponding working for the applicable pass.
pressures. If the maximum piston stroke
is reached before working pressure is 12) If, on the 5th pass, the flange nuts can be
achieved go straight to procedure (8). tightened further, additional passes at
maximum pressure should be made until
Close the pump stop valve, then no further tightening is possible.
pressurise the system to the required
pressure, when this is reached stop the 13) When all flange nuts are correctly
pump to hold the pressure. tightened, the gasket is fully compressed
and the nuts pre-stressed.
7) Check the pressure gauge to ensure the
pressure is holding constant. When 14) Check at several equidistant points on
satisfied that the pressure is stable, use the flange periphery that the gap
the tommy bars to rotate the nuts, between the faces of the pump case and
through the access windows, down motor flanges is less than 1.5 mm.
towards the joint surface. Fit the
appropriate rod (bar) to the flange nuts 9.9 Releasing Flange Nuts
and fully hand tighten. Hand tighten
adjacent loose nuts. WARNING:
Ensure that the motor is electrically
8) Remove the stud tensioner heads by:- isolated, adequately supported and de-
a) Screwing in the oil return valve on pressurised, before any nuts are
the pump to release the oil pressure slackened.
(which transfers the load to the nuts).
1) Fit the tensioner heads to the studs and
b) Tightening, then releasing the connect the hoses and hand pump. If one
threaded insert. head is used for this operation it must be
the head with the blanking plug fitted.
c) Screwing out the oil return valve on
the hand pump. 2) Screw down the threaded insert fully,
then release it one half () turn.
th
d) Removing the threaded insert Pressurise the system to the 5 pass
complete with body. pressure shown on the table in Section 2,
Figure 2.1 and unscrew each flange nut
e) Removing the bridge.
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one half () turn using the appropriate 4) If the nuts are still in contact with the
bar. Repeat for every stud on each pass. flange and cannot be removed with the
system at absolute pressure, consult
3) Should the nuts fail to move, a slow Hayward Tyler for advice.
gradual increase in pressure should be
made until the nut lifts of the flange face. 5) Repeat the stud tensioning and nut
At this stage, a further increase in unscrewing sequences diametrically until
pressure is un-necessary and will not all flange nuts are released.
assist in freeing a tight nut.
6) After use, thoroughly clean, examine for
CAUTION: damage and lubricate each component of
Never exceed the maximum system the stud tensioner equipment. Wrap all
pressure when removing the nuts. components in suitable water-proof
material then store in a clean, dry area in
their respective tool boxes.
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
9.10 Parts List

M72 Stud Tensioner for use on Pump / M56 Stud Tensioner for use on Motor
Motor flange. Case/Cover flange.
ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY

M72 STUD TENSIONER 1 M56 STUD TENSIONER 1
Comprising: Comprising:
TENSIONERS 4 TENSIONERS 4
Comprising Comprising
1 BODY 1 1 BODY 1
2 RAM 1 2 RAM 1
3 BRIDGE 1 3 BRIDGE 1
4 M72 PULLER 1 4 M56 PULLER 1
5 ADAPTOR 1 5 ADAPTOR 1
6 BONDED SEAL 2 6 BONDED SEAL 2
7 INNER SEAL SET 1 7 INNER SEAL SET 1
8 OUTER SEAL SET 1 8 OUTER SEAL SET 1
9 SNAP NIPPLE 1 9 SNAP NIPPLE 1
10 SOCKET M72 1 10 SOCKET M56 1
Figure 9.6 : Stud Tensioner Assembly (Hose connection position may vary)
Also included: - Hand Pump complete with 1500 bar Pressure Gauge
Hydraulic Harness manufactured from flexible hose and quick release couplings to tension 4 tools
simultaneously.
Harness consisting of 5m Lead Hose and 1.5m Interconnecting Hoses
Tommy Bars, Oil Pack, Spare Seals, Storage Box for Tensioning Heads, Storage Box for Pump
and Harnesses, Manuals for Tensioner and Hand Pump.
Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401

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DURGAPUR #1 & #2

OPERATING & MAINTENANCE

CLIENT : BHARAT HEAVY ELECTRICALS Ltd.

HTEP REFERENCE : EP11104/5

Revision Date Reason

Service: Boiler Water Circulating Pump with Motor below Pump

Number Supplied: 3 per order

Electrical: 3300V - 3 Phase - 50Hz

2.2 Pump / Motor Design Characteristics

Type: Single Suction, Double Discharge

2.4 Clearances & Settings (mm)

Impeller Setting (Dimension Z): 544-543

As New Max when worn

Impeller Wear Ring Clearance : 1.465 1.588 2.03

Thermocouple 1 Pump Case Type KK Ungrounded

Thermocouple 1 Suction Branch Type KK Ungrounded

Thermocouple 3 Motor Case Cavity Type KK Ungrounded

Flow Switch/Indicator 1 HE LP pipework Flotech Flowrate meter

Visual Indicator 1 Motor Case Dresser/Ashcroft Duratemp Dial Thermometer

Pressure Gauge 1 Pump Case Dresser/Ashcroft Pressure Gauge

2.6 Torque Loading

2.7 Weights (Approximate)

Pump Case 6430 kg

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Figure 2.1 : Motor Assembly -5-

Figure 2.2 : Winding Resistance Diagram

Figure 2.3 : Motor Performance Curve -7-

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Figure 2.4 : Estimated Pump Performance Curve -8-

3 Storage 3.2.2 Motor (Fig 3.2)

The distilled water used must have a

The specific gravity of the mixture at 20C is

Mixture by % Volume Specific

Figure 3.2 : Motor Storage / Transit Details

3.4 Heat Exchanger 6) Check and record the insulation

3.5 Exterior Surfaces IMPORTANT: -

3.6 Standard Storage Insulation figures less than 5 megohms

3) Visually examine the assembly for

3.8 Preparation For Storage

2) Disassemble the motor cover and clean

2) The protective coating is satisfactory. 6) Check the insulation resistance of the

Resistance Diagram in Section 2 Fig with paragraph 3.2.6.2, through the

Figure 3.4 : Rotating the Rotor Assembly

3.9 Inspection Record Card

Figure 3.5 : Inspection Record Card

Pump Case Assembly

Fill & Drain Valve

INSULATION RESISTANCE READING..

REQUIRES IMMEDIATE ACTION

Figure 3.6 : Check List

the pump case, a cold purge can be

The Hayward Tyler Glandless Motor NOTE:

4.3.1 Auxiliary Cooling Circuit supplied external heat exchanger (cooler),

Figure 4.1 : Typical Auxiliary Cooling Circuit Arrangement

4.3.2 Bearings liquid in the motor before it is circulated

4.3.2.1 Journal Bearings

Figure 4.2 : Terminal Gland

4.4 Terminal Boxes 4.6.1 Thermocouples

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