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BFBP MAINTENANCE
INSTRUCTION FOR
HZB200-430
Eyebolts at pump parts and other parts of the unit may not be used for
the lifting of the complete assembled pump or even the whole unit. The
eyebolts are only meant for the lifting of the loosened parts during assembly
and disassembly
3.3 Storage
Pump and accessories shall be provided with damp proof and rust preventive
means to ensure no rust and damage occurs within one year. If over twelve
months, it is necessary to disassemble single volute pump to check 、
spot-check core of barrel casing pump and re-carry out rust-proofing treatment.
Duration of validity of oil seal is twelve months, it shall be checked timely.
Centrifugal pumps which are not installed and commissioned immediately after
delivery can be stored for the period determined by the dispatch preservation.
The pump unit can be stored in a clean and dry warehouse without
maintenance measures up to the time given by the dispatch preservation.
To avoid the forming of condensate and consequently corrosion
ATTENTION
(especially in the gap areas), bearing damage and contamination,
a dry room, possibly with constant temperature as well as a clean,
shock- free storage space has to be selected.
ATTENTION If the bearing housing is only be filled with lubricating oil for
intermediate start-up. Turn pump rotor by hand at least 5
revolution in the proper direction every month.
Bearing: The bearing housings are screwed with the suction covers. After
assembly of the bearing housings and the rotating assembly to the pump casing,
the bearing housings are aligned by centring of the shaft within the bore of the
suction covers, and the bearing housings are positioned by dowel pins. Sleeve
bearings absorb the radial loads in the bearing housing of two sides. A duplex
angular contact ball roller bearings (back-to-back) are installed in the N.D.E.
bearing housing to assure freedom from interference with the radial bearing and
take up the residual axial forces.
Lubrication of each bearing is by means of a lubrication ring which rotates on a
sleeve. Each bearing housing is provided with an oil indicator, an oil constant level
oiler and an air breather. The lubrication oil is cooled by the oil cooler at the
bottom of bearing housing. The journal bearing depends on throwers to dip into
the oil reservoir and throw oil into troughs on the shaft. Oil flows through the
bearings and returns to the reservoir. The rolling bearing depends on lubricating
rings to dip into the oil reservoir and throw oil into troughs on the rolling bearing.
Oil flows through the bearings and returns to the reservoir.
5 SCOPE
This section contains general information and advice on booster pump
maintenance procedures for a horizontal pumpset. These general instructions are
provided as guidelines to aid and direct a safe and efficient maintenance project.
It also provides a general booster pump set maintenance schedule that can be
adapted and used as required when a specific site maintenance schedule is not
available.
It is essential that the plant safety rules and regulations are observed at all times
during maintenance procecdures.
Note: The booster pump is an integral part of the pumpset. The following
instructions should, therefore, be read in conjunction with those for the boiler feed
pump and the associated equipment.
5.1 Equipment condition
5.1.1 Performance record
Keep a written performance log for the equipment. An ongoing performance
record will assist troubleshooting and future pump service decisions. Long
shutdowns and unnecessary expense can then be avoided.
Pressure indicators can be installed into tapped openings in the suction and
discharge nozzles to provide much of the data required for performance analysis.
Periodic trending vibration recordings are necessary to diagnose excessive
vibration levels.
5.2 General overhaul information and advice
Dismantling
Check for toxic or otherwise harmful fluids before loosening bolted
joints or pipe connections.
Collect and dispose of toxic or otherwise harmful fluids in
accordance with the current environmental regulations to prevent
endangering people or the environment.
CAUTION At all stages during assembly of the pump, it is essential that the
pump shaft is adequately supported to prevent bending and/or
damage to the bearings.
5.3 Shipping from site
All equipment must be completely drained and decontaminated before removal
from site.
5.4 Completion of booster pump overhaul
Re - commission the booster pump following every overhaul.
5.5 Scheduled maintenance
When the supplied pump and pumpset equipment is classified as
suitable for use in a Hazardous Area, the following conditions
during scheduled maintenance procedures MAY invalidate the
Hazardous Area classification and MUST be avoided:
• Failure to detect and rectify leaks from main (suction and
discharge) pipework connections to the pump casing
• Failure to detect and rectify leaks from auxiliary pipework and
associated equipment (i.e. mechanical seal, seal system,
coolers, instruments) connections
• Failure to maintain ancillary equipment and systems in
accordance with manufacturer’s information
Refer to the General Arrangement drawing, the pump Longitudinal
Section drawing, and other drawing or document in Drawings and
Documents.
5.5.1 Daily checks
- Perform a ‘walk-around’ inspection of the pumpset, preferably while
the pumpset is operating, and:
- Carry out a visual check for leaks, or damage to components.
Pay particular attention to main and auxiliary pipework
connections. Repair or report any damage or leaks.
Note: Except for a daily visual inspection to check for excessive
external leakage. In this event the pump should be taken out of
service and the seal repaired or replaced.
- Check all indicating instruments for correct functioning and
unusual readings. Report faults and investigate the cause of any
unusual readings.
- Check the oil level in the constant level oilers - replenish as
required. Record the replenishment amount to identify excessive
oil loss / consumption.
- Check for unusual noises.
- When applicable, check strainer / filter differential pressures.
5.5.2 Weekly checks
- Check the oil level in the constant level oilers - replenish as
required. Record the replenishment amount to identify excessive
oil loss / consumption.
- Record readings for all indicating instruments (identifies gradual
changes in readings over time and may help to identify a
developing problem in pumpset operation).
5.5.3 Monthly checks
- Check the temperature and vibration levels etc. against the
string test reference readings for normal expected values. (This
information should be recorded and used as a bench mark for
future readings).
5.5.4 Six-monthly checks
- Replace the lube oil in the bearing housing.
- Check the alignment of the drive coupling.
- Check the pump performance against reference data.
- Inspect all parts for damage to paintwork, and repaint if
necessary. If evidence of rust is found, affected areas must be
cleaned, de-rusted and then repainted.
- Bright metal parts should also be examined for rust, the surfaces
cleaned, and a film of Shell Ensis fluid re-applied as necessary.
5.5.5 Yearly checks
- Check the security of all holding down bolts (or every 8000
operating hours )
5.6 Fault diagnoses
Analyze the booster pump performance before carrying out disassembling. Some
problems may be resolved without disassembly. Performance records are useful
to reduce the problem and estimate if the problem is caused by machine,
hydraulic choice or system.
The system problems mostly result from the system of the booster pump suction.
Obviate the improper adjust of the control system. Mechanical and hydraulic
problem are always related, so the reason is difficult to find. Refer to Fault
diagnoses.
Loss of discharge Downstream control valve opening Investigate valve actuator and control
pressure after too far. system operation. Adjust as necessary to
start-up. maintain correct valve opening.
Air pocket in suction line. Open all vents to eliminate air from
pumping system.
Insufficient suction pressure causing Check pump design requirements and
product to vaporise in pump. proceed to make necessary changes or
adjustments to system and create sufficient
pressure.
Suction strainer clogged. Remove and clean, or replace, suction
strainer screen.
Vibration and noise. Pipe strain or coupling misalignment. Refer to Installation and Coupling
Alignment. Check alignment and pipe
strain - adjust as necessary.
Pump base not grouted, or air pockets Locate voids by tapping on top plate. Fill
exist between grout and base plate voids completely with grout, drilling
top plate. additional holes in top plate if necessary to
evacuate air.
Cold offset not accounted for during Refer to Installation and Coupling
final alignment. Alignment. Check alignment taking cold
offset into account.
Improperly balanced rotating element Contact with manufactory.
or coupling.
Impeller passages obstructed. Replace / overhaul pump rotor.
Reduced pump Minimum flow line open or partially Review minimum flow circuit and make
output flow. open. corrections to ensure proper operation.
Impeller passages obstructed. Replace / overhaul pump rotor.
6.2 Joints
Joint between Material Size
Pump casing and suction 1Cr18Ni9Ti+ Graphite Spiral round gasket φ455/φ
guide 435×4.5
Cooling bush cover and Fluorine rubber F275 O ringφ184/3.53
suction cover
Fluorine rubber F275 O ringφ100/3.53
Bearing housing cover and Nitrile rubber bunan O ringφ85/3.53
bearing housing
7 LUBRICANT
Recommended lube: N32 or N46 turbine oil
8 ROUTINE MAINTENANCE
8.1 Preparation for maintenance
Before commencing any maintenance procedures, the pumpset must be
isolated as follows:
(1) Isolate the electrical supply to the motor;
(2) Isolate the electrical power supplies to all instruments;
(3) Check the pumpset suction and discharge isolating valves and the
leak-off isolating valves are shut;
(4) Isolate the cooling water supply;
(5) Close the pump tap stage isolating valve;
(6) Open the drain and vent connections, and drain the pump casing;
(7) Before proceeding with any maintenance on the pump, ensure that
there is no pressure within the pump casing.
8.2 Examining the bearing
The following instructions apply when the pump bearings are to be dismantled
for examination and/or renewal in situation.
8.2.1 Journal bearing, D.E.
8.2.1.1 Dismantle
(1) Prepare the pump for maintenance, as described in Section 8.1.
(2) Remove the coupling guard. Remove the coupling flexible
elements, spacer and pump-half coupling hub.
(3) Disconnect and remove the instrumentations from the bearing
housing, and store in a safe place.
(4) Drain any remaining oil from the bearing housing into a suitable
container.
(5) Carefully disconnect and remove auxiliary pipework from the
bearing housing. Plug pipework ends to prevent ingress of dirt.
(6) Remove bolt and dowel pins of the bearing housing top half.
(7) Lift the bearing housing top half carefully away from the bottom half
and lower it onto a flat surface, padded with cloth to protect the
machined surface. Remove the lifting equipment.
(8) Verify match-marks for re-assembly, and then remove the top half
of the journal bearing and oil guard.
(9) Remove thrower away from the lower half of the journal
bearing .Lift the shaft slightly (maximum 0.1 mm) using a suitable
piece of wood, then rotate the lower half of the journal bearing
around the shaft and remove it. Lower the shaft.
8.2.1.2 Examination of bearing
Journal Bearing
Visually inspect the journal bearing surfaces for excessive scoring and heat
damage. Check whether the running surfaces, the bearings and the oil guard
wear or not. Renew them if excessive wear or damage is present. Measure the
bearing clearance and checked against the details given in Section 9.6.5. If the
clearance has reached the maximum permissible clearance, or is likely to do
so before the next overhaul, the component should be renewed.
Bearing Housing
Check bearing housing fits, filing off any interference points.
8.2.1.3 Assembly
8.2.1.4 Note:Ensure that the DE mechanical seal is installed before
re-assembling the DE bearing assembly.
CAUTION Check taper pins / dowel pins for proper fit and seating (not
"bottoming") before tightening the screws. Incorrect seating
affects rotating element radial centring.
(1) Wipe clean and then generously lubricate the bearing surface of
the journal bearing bottom half and the shaft bearing surface.
(2) Raise the shaft slightly (max 0.1 mm) using a suitable piece of
wood and fit the bearing half and oil guard. Lower the shaft.Fit the
thrower.
(3) Wipe clean and then generously lubricate the bearing surface of
the journal bearing top half and the shaft bearing surface.
(4) Fit the journal bearing top half and oil guard.
(5) Lift the bearing housing top half into position on the housing bottom
half ,ensuring that oil guard and anti-rotation pin are in the correct
place.
(6) Insert the dowel pins through the flange joint between bearing
housing halves to position the bearing housing top half.Fit the
screws and tighten them.
(7) Refit auxiliary pipework and refit and connect instrumentation as
appropriate.
CAUTION
After both bearing assemblies have been fitted, turn the shaft
manually and check that the rotating element rotates freely
before completing labyrinth seal fit. Also check that the endplay
of the pump rotor is correct.
(8) Refit the pump-half coupling hub and coupling spacer as required.
8.2.2 NDE bearing assembly
8.2.2.1 Dismantling
(1) Prepare the pump for maintenance, as described in Section 8.1.
(2) Remove the coupling spacer.
(3) Disconnect and remove the instrumentation from the bearing
housing, and store in a safe place.
(4) Drain any remaining oil from the bearing housing into a suitable
container.
(5) Carefully disconnect and remove auxiliary pipework from the
bearing housing. Plug pipework ends to prevent ingress of dirt.
(6) Remove the cover mounting screws. Remove the bearing suction
cover, complete with O-ring seal.
(7) At the horizontal joint flanges of the bearing housing halves,
remove the locating taper pins / dowel pins and screws.
Note: If temperature detector wires are fitted, they must be guided
carefully as the bearing housing top half is removed.
(8) Lift the bearing housing top half carefully away from the bottom half
and lower it onto a flat surface, padded with cloth to protect the
machined surface.
Remove the lifting
equipment.
(9) Verify match-marks for
re-assembly, and then
remove the top half of
the journal bearing and
oil guard.
(10)Remove thrower away
from the lower half of
the journal bearing .Lift
the shaft slightly
(maxium 0.1 mm) using
a suitable piece of wood,
then rotate the lower
half of the journal
bearing around the
shaft and remove it. Lower the shaft.
(11)Loose the grub screws on the sleeve nuts. Remove the bearing
sleeve nuts and thrower.
(12)Insert the splitted adjusting ring for dismantling into the space
between the bottom bearing housing and the angular contact ball
bearings.
(13)Remove dowel pins and screws securing bearing housing bottom
half to suction cover.
(14)Remove the angular contact ball bearings and the bearing housing
bottom half.
8.2.2.2 Examination of bearing
Thrust Bearings
Visually inspect the journal bearing surfaces for excessive scoring
and heat damage. Check whether the running surfaces, the
bearings and the oil guard wear or not. Renew them if excessive
wear or damage is present. Measure the bearing clearance and
checked against the details given in Section 9.6.5. If the clearance
has reached the maximum permissible clearance, or is likely to do
so before the next overhaul, the component should be renewed.
Bearing Housing
Check bearing housing fits, filing off any interference points.
8.2.2.3 Assembly
Note: Ensure that the NDE mechanical seal is installed before
re-assembling the NDE bearing assembly.
(1) Fit two suitable eyebolts to the bearing housing bottom half, one on
each side using suitable tapped screw holes in the joint flange. Lift
the bearing housing bottom half into position on the suction casing,
Insert the locating dowel pins and fit screws loosely to secure the
bearing housing. Seat the dowel pins, then fully tighten the
mounting screws.
CAUTION Check the dowel pins before tightening the nuts. It may affects
rotating element radial centring. Refer to Radial centring of
rotating assembly.
Renewing the bearing housing bottom half should ensure the
CAUTION
rotating element radial centring. Refer to Radial centring of
rotating assembly.
(2) Install the angular contact ball bearings
(a)The thrust bearing is a duplex angular contact bearing,mounted in a
back-to-back configuration. Always purchase, store and use the pairs
as a unit. Never replace only one bearing of a pair.
CAUTION
New bearing should be left in factory-sealedl packages and
stored in a dry area until immediately before installation.
Cleanliness during bearing assembly is required to avoid
contamination and failure.
(b)Bearings can be oven-heated(95~105°C, thermostatically
controlled is recommended)or heated in an oil bath. Avoid
overheating or prolonged heating to minmise potential distortion.
CAUTION
After both bearing assemblies have been fitted, turn the shaft
manually and check that the rotating element rotates freely
before completing labyrinth seal fit. Also check that the endplay
of the pump rotor is correct.
(13)Refit the auxiliary pipes as required and connect instruments.
(14)Reinstall plug and constant level oil .Refer lubrication and
replenish the bearing housing oil level.
(15)Refit the coupling spacer.
8.3 Check mechanical seal
Note: A small leakage of the mechanical seal is normal. In case of
leakage seal ring pairs may also leak. If so the damaged parts have
to be replaced. Seals have to be replaced during each assembly.
Rotating and stationary seal rings must be replaced together.
8.3.1 Mechanical seal D.E.
Note: The coupling hub and DE bearing assembly must be removed
before removal and/or installation of the DE mechanical seal.
8.3.1.1 Disassembly
(1) Refer to 8.2.1 - DE journal bearing and remove the DE journal
bearing assembly.
(2) Remove the dowel pins and nuts of bearing housing bottom half
and suction cover and remove the bearing housing bottom half.
Remove the thrower.
(3) Remove auxiliary pipework to enable access to the mechanical
seal. Plug pipework ends to prevent ingress of dirt.
(4) Revolve and embed the mechanical seal plate to the trough of the
mechanical seal sleeve
(5) Loose the grub screws of mechanical seal sleeve and not scuff the
shaft during disassembly.
(6) Remove the bolts of the mechanical seal cover and the mechanical
seal. Be careful to the discharge of survival.
8.3.1.2 Check mechanical seal
Check mechanical seal according to mechanical seal instruction and
assemble it.
8.3.1.3 Assembly
(1) Fix the mechanical seal and tighten the bolts of suction cover.
(2) Tighten the grup screws of seal sleeve.
(3) Rotate the mechanical seal plate out of the trough of sleeve and
tighten it.
(4) Slide the thrower to the correct position of the shaft.
(5) Fit two suitable eyebolts to the bearing housing bottom half, one on
each side using suitable tapped screw holes in the joint flange. Lift
the bearing housing bottom half into position on the suction casing,
Insert the locating dowel pins and fit screws loosely to secure the
bearing housing. Seat the dowel pins, then fully tighten the
mounting screws.
(6) Refit the auxiliary pipes as required.
(7) Refer 8.2.1 - Journal bearing D.E and refit journal bearing D.E.
CAUTION After both bearing assemblies have been fitted, turn the shaft
manually and check that the rotating element rotates freely.
Also check that the endplay of the pump rotor is correct.
8.3.2 Mechanical seal N.D.E
Note: .The NDE bearing assembly must be removed before removal
and/or installation of the NDE labyrinth seal.
8.3.2.1 Disassembly
(1) Refer 8.2.2- Journal bearing N.D.E., remove journal bearing N.D.E.
(2) Remove the axial adjusting sleeve.
(3) Slide the thrower from shaft.
(4) Remove auxiliary pipework to enable access to the mechanical
seal. Plug pipework ends to prevent ingress of dirt.
(5) Revolve and embed the mechanical seal plate to the trough of the
mechanical seal sleeve.
(6) Loose the grub screws of mechanical seal sleeve and not scuff the
shaft during disassembly.
(7) Remove the bolts of the mechanical seal cover and the mechanical
seal. Be careful to the discharge of survival.
8.3.2.2 Check mechanical seal
Check mechanical seal according to mechanical seal instruction and
assemble it.
8.3.2.3 Assembly
(1) Fix the mechanical seal and tighten the bolts of suction cover.
(2) Tighten the grup screws of seal sleeve.
(3) Rotate the mechanical seal plate out of the trough of sleeve and
tighten it.
(4) Slide the thrower to the correct position of the shaft.
(5) Fit the axial adjusting sleeve.
CAUTION
Adjust the length of axial adjusting sleeve, it affects the rotating
element radial centring. Refer to- Axial centring of rotating
assembly.
(6) Refer 8.2.2- Journal bearing N.D.E. and refit journal bearing N.D.E.
and angular contact ball bearing.
After both bearing assemblies have been fitted, turn the shaft
CAUTION
manually and check that the rotating element rotates freely.
Also check that the endplay of the pump rotor is correct.
9 OVERHAUL
9.1 Preparation
Study the following procedures as well as the booster pump Longitudinal
Section drawing, and other available drawings and documents, and be familiar
with the design details and assembly sequence.
Plan the operations and have withdrawal and assembly equipment, and other
special tools available. This includes any required measuring devices.
9.2 Examination and cleanliness
Unless the pump casing needs renovation, it will remain installed after the
booster pump rotor has been removed.
The pump casing must be protected from ingress of dirt and physical damage
during the maintenance cycle.
9.3 Balancing marks
Component parts of the rotating element are match-marked on their peripheries.
These marks must be lined up on assembly with corresponding, similar marks
stamped on the shoulders to preserve the balance of the pump rotor.
9.4 General information on dismantling and assembly
9.4.1 Dismantling
Check for toxic or otherwise harmful fluids before loosening
bolted joints or pipe connections.
Collect and dispose of toxic or otherwise harmful fluids in
accordance with the current environmental regulations to
prevent endangering people or the environment.
9.7.1 Assembly
(1) Vertically put the pump shaft on the bracket and fit the impeller key.
(2) The Impeller is transient fit. Using soft flame heater to heat up
around of the impeller. Then fit the impeller over the shaft and key
until it abuts the shoulders.
(3) When the shaft and impeller have cooled, fit the shaft sleeve and
lock washer and tighten the lock nut. Use the lock washer to lock the
nut.
(4) Clean the pump casing and examine all the seal faces in the pump
casing. Any impress or groove is unallowable.
(5) Clean the cooling housing and seal face of D.E. cover. Place new
‘O’ ring . Fit the cooling bush cover and tighten the bolts.
(6) Fit the D.E. cover and use new seal ring. Carefully sling the suction
cover to pump casing. Lubricate the face of thread and nut, tighten
the nut crosswise and equably.
(7) Use a rope sling to lift the rotor with the aid of a crane into the pump
casing. Use care to minimize shaft stress by placing the slings as
close to the impeller as possible.
(8) Renew new seal ring on the N.D.E. suction cover. Use a rope sling
to push the suction cover with the aid of a crane to the shaft and into
the pump casing. Lubricate the face of thread and nut, tighten the
nut crosswise and equably.
(9) Fit the N.D.E. mechanical seal and journal bearing as 8.3.2.3.
(10)Fit the D.E. mechanical seal and journal bearing as 8.3.2.3.
(11)Fit the pipeline and instruments.
(12)Fit the coupling and guard.
9.7.2 Radial centring of rotating assembly
If a replacement bearing housing is to be fitted to a suction cover, it is
necessary to align the bearing housing before drilling and reaming two new
holes for the locating dowel pins. To do this it is necessary for the mechanical
seals to be removed to allow access to the bores of the suction covers.
CAUTION
9.7.3 An incorrectly fitted replacement bearing housing, or inproper
bearing housing to case taper pin seating, can affect radial
centring of the rotating assembly, leading to damage.
(1) Install the journal bearings and the bearing housings at both ends of
the pump, without installing the mechanical seals.
(2) Begin the following procedure at the end of the pump which has a
new housing, or if both housing are new, begin at either end.
(3) Attach a suitable small-sized dial indicator on the shaft, with the
probe positioned on the inside surface of the bore in the suction
cover.
(4) Set the dial indicator to zero.
(5) Rotate the shaft through 360°and take measurements of the
runout between the shaft and the bore of the cover at 90°interval.
(6) Move the bearing housing sufficiently to reduce the runout to less
than, or equal to, 0.025mm.
(7) Tighten the bearing housing securing screws and recheck all the
measurements.
(8) Repeat steps 3 to 7 for the other end of the pump.
(9) When the runout at both ends of the pump is within the specified
limits, either drill and ream holes for dowel pins or ream existing
dowel pin holes to the next size.
(10)Repeat the measuring procedur in order to ensure the alignment of
two ends is correct.
(11)Remove the bearing housing and bearings and re-install them and
the mechanical seals.
9.7.3 Axial centring of rotating assembly
(1) Install the journal bearings and bearing housings at both ends of the
pump without installing the mechanical seals.
(2) Alignment of journal direction is complete.
(3) Mount a dial test indictor at the drive end with the probe tip in
contact with the shaft end.
(4) Push the shaft as far as it will go towards the NDE and set the dial
indicator to zero.
(5) Now move the shaft as far as it will go towards the DE and note the
dial indicator reading, This is the total end play of the rotating
assembly within the volute casing.
(6) Move the shaft back towards the NDE by half the total end play.
This sets the impeller centrally within the stationary wear rings.
10 LUBRICANTION
10.1.1 Initial filling of the bearing housings
CAUTION On a new unit, the oil should be changed 24 hours after the first
start-up.
(1) Remove the bearing housing filler and fill both the DE and NDE
bearing housings with clean oil. Check the oil level plates fixed to
the bearing housings and the oil level should be in the middle of oil
indicator. Fill majority oil to bearing housing and others is
completed by constant level oiler.
(2) Refit the bearing housing filler.
(3) Check the finally level of oil in the constant level oiler resevoirs,
which should be at least two-thirds full.
10.1.2 leakage
Monitor the oil level, particularly during commissioning. A sudden oil level drop
may indicate a leak. Stop operation and inspect the unit.
10.1.3 Oil changes
After draining used oil, flush the housing with clean oil, refit the drain plug and
refill with new oil.