TORISHIMATORISHIMABoiler Circulation PumpsBoiler Circulation Pumps

HLAVHLAV

ContentsContents

3. Motor set installation 4. Commissioning and Start-Up5. Supervision during operation

Training course 2Installation & commissioning

3.1 Lifting Motor set

Do not remove temporary covers !

Motor assembly : Approx. 7,300 kg

① Transport motor set as shown below

② Prepare to lift and install motor set

Do not damage motor set !

③ Lift motor unit carefully

3. Motor Set Installation

Use Chain-block 10tons/2 sets for lifting up & down

⑤ Remove temporary cover before motor set installation, use 1ton Chain Block

⑥ Inspect casing and heat barrier sealing faces and set spiral wound gasket on heat barrier before motor set installation

Pump casing

Motor set

Sealing face of Pump casing

Bolts

Bottom

3. Pump/Motor Set Installation3.1 Lifting Motor set

① Determine Initial Tightening Starting Position Measure dimensions B & C at 4 points using

depth gauge and micrometer.

3.1 Lifting Motor set into Pump casing

② Calculate starting distance between pump casing and motor flange (A) by formulaInitial Tightening Starting Position A=C-B+1.6mm

③ Record dimensions (A, B, C)

④ Paint bolt numbers on both pump casing and motor flange (1-16)

⑤ Strip paint from a suitable part for micrometer head at 4 points on bolt pitch-circle ( shown by arrows in fig. )

Paint bolt numbers3. Motor Set Installation

3. Motor Set Installation

CAUTION While Lifting Motor set3.1 Lifting Motor set into Pump casing

① Stop Lifting Motor set at the position Impeller approaches Wearing Ring . Fig1.

② Measure 4 points of distance A and adjust till value of A is same at all points

③ Lift Motor set slowly by measuring distance A for the 4 points and carefully operating 2 chain blocks at the same time till Impeller is positioned into Wearing Ring smoothly as in Fig2. Initial tightening distance A shall be followed in item 3.3.

④ Stop Lifting Motor set in case the Impeller touches Wearing Ring during lifting, then lift down Motor set and inspect Impeller & wearing ring for damage. Repeat lifting and setting by

to properly.① ③

Fig.2

A

Fig.1

A

② Coat molybdenum sulfide on threads of each stud bolt and mating surface of each washer

① Locate washers, and screw nuts onto stud bolts

The head of each stud bolt is to protrude approx.170mm from motor flange !

Pump casing

Stud bolt

3-2 Setting Nuts/Washers to Stud Bolts

170mm

3. Motor Set Installation

3.3 Tightening the Stud Bolts ⑥ Measure each distance (A) by inside micrometer and confirm the

tolerance is less than or equal to 0.05mm

⑦ Mark each nut and motor flange

Nut Scale Division

Mating Mark

3. Motor Set Installation

3.4 Tightening by Bolt Heaters① Confirm that power source is off, then connect cable to switch box.

② Insert a bolt heater into each of 16 stud bolts

③ Switch on every second bolt heater (1st group) (8 heaters : No.1,3,5,7,9,11,13,15)

④ Confirm that every second stud bolt is heated

Surface temperature of stud bolts should not exceed 300 deg.C !

⑤ Monitor temperature using a temperature crayon or surface thermometer

Motor flange

Stud bolt

Be careful of burns !!

3. Pump/Motor Set Installation

⑩ Switch on first set of 8 bolt heaters to heat up first 8 stud bolts, then tighten respective nuts by further 14 scale divisions for a total of 34 scale divisions. (No.1,3,5,7,9,11,13,15)

3.4 Tightening by Bolt Heaters⑥ Tighten 20 scale divisions first

⑦ Switch off bolt heaters and cool down stud bolts to approx.60 deg. C

⑧ Switch on bolt heaters for remaining 8 stud bolts. Tighten these 8 nuts by 34 scale divisions. (2nd group : No. 2,4,6,8,10,12,14,16)

⑨ Switch off bolt heaters and cool down stud bolts to approx.60 deg. C

⑪ After all stud bolts cool down to room temperature, measure flange to flange distance A’ at 4 points within 0.05mm. Record the measurements.

2034

0

Bolt layout

14

3. Motor Set Installation

3.5 Installation of HP Motor cooler① Clean Motor Cooler by water flushing and seal face of each welded sockets before welding work

② Carry proper socket welding to position:① ＆② after confirming Motor cooler & HP piping position

③ Inspect each welded HP connection by PT

④ Clean LP cooling water piping line to Motor cooler and carry welding socket connections

⑤ Confirm final tightening of bolts (mark ＊ ) for Motor cooler support.

⑥ Install the instruments for each position.

3. Motor Set InstallationIn case of BHEL

design, these should be welding

connection

② Check water quality and filling rate; Max.5L/min.

Valve1

from BCP purge water cooler

4. Commissioning and Start up

Drain Valve

③ Fill the water until the quality is

clear and colorless

④ Close drain valvePoint !Do not open the drain valve once start

the water filling to the motor

4.1 Priming and venting① Close valve1 and open drain valve fully

4.1 Priming and venting ① Open valve 2&3, related air venting 　　 valves fully and open valve1 slowly

Valve2

Valve1 from BCP purge water cooler

4. Commissioning and Start up

★Point 2Priming and Flushing must always be carried out from the motor bottom to upwards

PI

★Point 1Air shall be removed from motor

Drain valvesshall be closed

Valve3

② Check valve2 : Flow rate from valve1 is max. 5L/min.

Priming 　 →　 Flushing

4.2 Pre Operational Check Items

④ Operational check items to be monitored - Temperatures - Cooling water flow - Ammeters at switch gear room - All Motor protection switches

① Confirm water filling

③ Confirm correct direction

② Measure insulation resistance

4. Commissioning and Start up

4.2 Pre Operational Check Items ⑤ To confirm quantity of LP cooling water

⑥ To confirm Motor Cavity temp is below 63 deg. C ⑦ To check water level in drum

⑧To complete motor flushing cleaning⑨To assure pressure tight seals

Need to check Item , , ⑤ ⑥ ⑦ in routine starts !

LP : Auxiliary cooling water

HP : High pressure cooling water in Motor

4. Commissioning and Start up

(1) Drum water level

(2) Differential pressure

(3) Motor current at switch gear room Refer to Data sheet≦

(4) Motor Cavity temperature ＜ 63 deg.C

(5) LP Cooling water flow rate - Cooler : 150L/min.≧ - Heat barrier : 30L/min.≧

(6) LP Cooling water temperature ≦ generally 45 deg. C

(7) Smooth running or not

5. Supervision during operation5.1 At operating

Refer to Datasheet or P&ID

Maintain the following condition until the boiler water is below 63 deg. C !

(8) LP Cooling water flow

(9) LP Cooling water temperature

(10) Motor Cavity temp.

5. Supervision during operation5.2 At stopping (after switched off)

1. Daily inspection check itemsNo.

Inspection point Inspect. Item Method Criteria Note

1 Suction tank Water level Level detector Min. Water Level

Daily

2 Pump suc. & dis. pipes Pump differential press.(During operation)

Pressure gauge Specified head

Daily

3 Power supply Motor current Current meter Specified current

Daily

4 Motor cavity HP cooling water temp. Temp. detector Below 63 deg. C

Daily

5 Motor coolerLP cooling water outlet

LP cooling water temp. Temp. detector Max. 45 deg. C

Daily

LP cooling water quantity Flow switch Refer to Data sheet

Daily

6 Heat barrierLP cooling water outlet

LP cooling water temp. Temp. detector Max. 45 deg. C

Daily

LP cooling water quantity Flow switch Refer to Data sheet

Daily

7 Pump motor Abnormal noise or vibration

- No abnormality

Daily

8 HP cooling water lines Leak Visual No leak Daily (Important)

9 LP cooling water lines Leak Visual No leak Weekly

Recommended inspection;

2. Annual or monthly inspection check itemsNo.

Inspection point

Inspect. Item Method Criteria Note

1 Motor terminal box

Insulation resistance

Megger meter At cold water filling(at approx. 20deg.C) At hot stand-by (at approx. 50deg.C)

200 Mega-ohm or more.4 Mega-ohm or more.

Annual stage

2 Stand-by pump Start up check Start up stand-by pump No abnormality

Monthly

No.

Inspection point

Inspect. Item Method Criteria Note

1 Pump motor Overhaul Overhaul at Torishima Works

Instruction manual

First 1 year and thereafter every 4-5years

3. Overhaul inspection check items

Recommended inspection;

Disconnect the power cable