3. BCP Dismantling & OH With Trouble Shooting

8/12/2019 3. BCP Dismantling & OH With Trouble Shooting

1/24

TORISHIMA

Boiler Circulation PumpsHLAV

Contents

6. Disassembling procedure

7. Overhaul Inspection8. Trouble shooting

Training course 3Disassembling and Inspection


2/24

6. Disassembling Procedure

6.0 Flushing and cleaning of pump motor set before disassembling

Open Casing drain valve2 slowly till full open and drain

Boiler water from pump casing completely.

Close Suction & Discharge Main valves fully and confirmBoiler water temp is less than 63 deg. C.

Open purge water valve1 slowly and confirm purge waterflow to be max. 5L/min.for flushing and cleaning of Motor .

After confirming the drained waterfrom valve2 is clean and the color is

same as drinking water, close valve1

and open drain valve3 for whole drain

from pump/motor set afterflushing/cleaning.

Valve2

Valve1

Valve3


3/24

Disconnect the main cables

Remove the motor cooler


Disconnect LP cooling water pipingfrom motor cooler and heat barrier

Disconnect the HP cooling waterpiping from motor and HP cooler

LP : auxiliary cooling water

HP : cooling water inside motor

Remove the instruments

6.1 Dismantling motor unit

from pump casing


4/24


from pump casing

Install the chain/sling on the motorlifting lugs to lift by chain blocks

Insert the bolt heater into each ofthe 16 stud bolts

Heat all stud boltsand unscrewall nuts

Do not exceed 300 deg.C surface

temperature of the stud bolts!

Remove all nuts and protectthe stud bolt threads

Be careful of burns !!



5/24


6.1 Dismantling motor unit from pump casing

CAUTION while Lifting down Pump/Motor set

After removing Stud bolts Nuts, lift downpump/motor set slowly by operating both chain

block at same time as in fig.1 till pump/motor set

becomes free from pump casing as shown infig.2. when pump/motor set is lowered down by

approx. 100mm.

Lift down pump/motor set to Floor Level fortransport to Workshop.

Fig.2

Chain

Block 1

Chain

Block 2

Fig.1

While lifting down motor unit,take care not to damage any

parts

Lower

100 mm


6/24

Attach the temporary cover toimpeller

While lifting down motor unit,take care not to damage any

parts

Lay motor unit on the carrierand transport it to workshop for

OH inspection & maintenance


from pump casing

Carrier



7/24

Disassembling section of Motor unit

6.2.1

6.2.2

6.2.3


6.2 Disassembling of motor unit

6.2.4


8/24

HEAT BARRIER

DIFFUSER

PLAIN BEARING

(UPPER)

IMPELLER

SHAFT

Part name of Pump/Motor unit 1


9/24

6.2.1 Disassembling Impeller and the Heat Barrier

Hex. Bolt

(Lock washer)

Impeller

Hex. nut

Plain

bearing

(2) Remove hex. bolt (first bend back lock washer) then remove impeller

(3) Support the heat barrier by chain block then remove heat barrierand upper plain bearing

(1) Remove hex. nut (first bend back lock washer) then remove diffuser

Hex. Nut

(Lock washer)

Diffuser

Heat barrier


10/24

SHAFT

THRUST BEARING CASETHRUST BEARING

SEGMENT(LOWER)

THRUST BEARING

PLATE



11/24

6.2.2 Disassembling Lower Bearing Assembly and Rotor

Hex. nut

Thrust

bearing

case

Lower half ofthrust

bearing

Thrust bearing

plate

Shaft

(1) Remove the thrust bearing case with lower half of thrust bearing

(2) Remove hex. Bolt and pull the thrust bearing plate from shaft

Hex. Bolt

Lock washer


12/24

MOTOR CASING

THRUST BEARINGSEGMENT(UPPER)

PLAIN BEARING

(LOWER)

BEARING BRACKET



13/24

Upper thrust

bearing

Motor casing

Plain bearing

Bearing bracketSocket head

cap screw

(3) Remove the upper half of thrust bearing, bearing bracket,

and complete bottom plain bearing


14/24

Rotor

Motor winding

Extension

Pipe

soft sheet soft sheet

SlingSling

Boom

6.2.3 Pull out the rotor

Prevent damage to the motor windings and coil ends by using soft

(e.g. rubber) sheet

Attach a temporary pipe and withdraw the rotor by the crane


15/24

FILTER



16/24

6.2.4 Disassembling of the Filter Set

Socket head cap

screw

Filter with insert ring

Remove the socket head cap screw and filter set with insert ring


17/24

(1) Inspect all parts for wear

- Replace new parts, if clearance is over the

stated maximum clearances as follows

Bearing section-1

Bearing section-2Thrust bearing section

c

ed

a=0

T

bh

f

d1

g

d2

Impeller section

7. Overhaul Inspection


18/24

7. Overhaul Inspection: To record all data


19/24

A - A

A

A

Dial gauge

Dial gauge Dial gauge

Lathe

Magnet base

(2) Measurement of insulation resistance

(4) Run out check of Rotor

Max. permissible out-of-round:0.08mm

Motor winding

(3) Cleaning of winding setMotor winding ends :

Rinsed with water lightly !

Not chemical or mechanical clean up !

Need Dynamic balance test in caseof new Impeller


Support


20/24

(5) Check Flow conditions in heat barrier

(6) Clean out LP cooling water side of motor cooler.Hydrostatic test of HP cooling water side.

Heat barrier

cooling waterinlet / outlet

HP CW side

LP CW side

- Clean out, if necessary-Pressure drop of heat barrier

at nominal flow rate: 0.05 MPa

or less



21/24

(7) Cleaning the filter

(8) Visual examination of motor windings

Motor

winding

Filter



22/24

Life time (Estimated)Impeller 20

Case wearing 5-10

Radial bearings 5-10

Metal sleeves 5-10

Thrust bearing segment 5-10

Thrust bearing plate 5-10

Stator coil 10-15

Gaskets, O-rings, Washers After dismantlingthese parts, newones should be

installed.

*These life times are dependent on operational condition of BCPor plant condition. Also these life time is not guaranteed life but

estimated/expected life.

(Unit: year)


23/24

8. Trouble shooting: Cavity temp high

No. Cause Research Remedy

1 Insufficient LP

cooling water

Examine LP cooling

water flow rate. Cooler &

HB:

Refer to Data sheet

Open valve fully.

Engage LP coolingwater flow.

2 LP cooling

water temp.

high

Examine LP cooling

water temp.

Outlet temp.: max. 45

deg C

Engage LP cooling

water temp.

3 Leakage fromflange

Visual inspection Tighten stud bolts.

Exchange gasket if

necessary.

4* Leakage from

HP cooling

piping

Visual and liquid dye

penetrate examination.

Repair by welding.

5* Malfunction ofHP cooling

water circuit

Examine HP coolingwater inlet / motor cavity

temperature

Flushing andcleaning of HP

cooling water

piping and filter.

6* Fouling of

motor cooler

tube

Examine motor cooler

inlet / motor cavity

temperature

Inspect shell inside viahand-hole.

Cleaning of motor

cooler tube.

No.1, 2No. 4, 5

No. 6

No. 4, 5

No. 3


24/24

Thank you for your kind attention

Documents

3. BCP Dismantling & OH With Trouble Shooting