CC Pump Manual-Full (Original)

5/26/2018 CC Pump Manual-Full (Original)

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HAYWARD TYLER

ENGINEERED PRODUCTS

BHARAT HEAVY ELECTRICALS LTD

(BHEL)

Kahalgaon Power Station

SERIAL NUMBERS

EP/03/10757A,B,C,D,E & F

EP/04/10794A,B & C

3 X 500 MW BOILER CIRCULATING PUMPS


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FOREWORD

Each section contains an itemised Contents List.

The major illustrations of the Pump and Motor are

included at the rear of Section 7. Additional

illustrations of particular features are incorporated

in the text.

This instruction manual provides comprehensive

installation, operating and maintenance information

of a Hayward Tyler Glandless, Wet Stator, Motor

Pump Unit, referred to in the text as the circulator.

The General Contents list shows that the manual is

divided into eight main sections. Paragraph

references are consecutive throughout each section,

and are preceded by the appropriate section

number. For example 5.1. designates:-

Note! Where a customer boiler layout drawing is

shown, this is used in good faith. However,

Hayward Tyler can accept no responsibility for any

errors or consequences that may result.

Hayward Tyler Manuals are for guidance only and

we reserve the right to update, revise and modify

this manual in accordance with our continuous

research and development programme.

Section 5, Commissioning.

5.1. Pre-Start Check List.

Hayward Tyler Engineered Products Ltd.

1 Kimpton RoadRevised manuals will not automatically be issued,

however, should they be required, Hayward Tylermay be contacted and arrangements can be made.

Luton

BedfordshireENGLAND

LU1 3LD

Telephone: +44 (0) 1582 731144

Email: [email protected]

Fax: +44 (0) 1582 452198

i


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GENERAL CONTENTS

BOILER CIRCULATING PUMP INSTRUCTION AND MAINTENANCE MANUAL

SECTION 1 TECHNICAL DATA

SECTION 2 STORAGE

SECTION 3 DESCRIPTION

SECTION 4 INSTALLATION

SECTION 5 COMMISSIONING

SECTION 6 OPERATION

SECTION 7 MAINTENANCE

SECTION 8 STUD TENSIONING

ii


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SECTION 1

TECHNICAL DATA

1. 0

CONTENTS

PARAGRAPH PAGE

1.1 GENERAL 1.1

1.2 CHARACTERISTICS 1.1

1.3 MOTOR CHARACTERISTICS 1.2

1.4 CLEARANCES AND SETTINGS 1.2

1.5 HEAT EXCHANGER 1.3

1.6 INSTRUMENTATION 1.3

1.7 TORQUE LOADINGS 1.3

1.8 WEIGHTS (APPROXIMATE) 1.3

ILLUSTRATIONS

FIGURE 1/1 MOTOR ASSEMBLY 1.4

FIGURE 1/2 WINDING RESISTANCE DIAGRAM 1.5

FIGURE 1/3 PUMP PERFORMANCE CURVE 1.6

FIGURE 1/4 MOTOR PERFORMANCE CURVE 1.7


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SECTION 1

TECHNICAL DATA

1. 1

1.1 GENERAL

Unit Serial Nos: EP/03/10757 A B C D E F & EP/04/10794 A B

Customer Order No: 0130645 & 0140593

Service: Boiler Water Circulating Pump with

Motor below Pump.

Number Supplied: 9

Electrical: 3300V - 3 Phase - 50Hz

1.2 CHARACTERISTICS

Type: Single Suction - Double Discharge

Size: (2 x 13) x 16 x 19H Volute

Design Pressure: 214 kg/cm2

Design Temperature: 370C

Hydrostatic Test pressure: 321 kg/cm2

Suction Pressure: 197.4 kg/cm2

Specific Gravity at pump suction 0.542

N.P.S.H. required: 15 m (3% head drop)

Quantity Pumped: 3135 m3/hr

Differential Head: 32.37 m

Pump Efficiency: 83 % Cold 83 % Hot

kW Absorbed: 333.1 Cold 180.5 Hot

1.3 MOTOR CHARACTERISTICS

Type: Wet Stator Squirrel Cage Induction

Output: 360 kW

Service Factor: 1.0

Winding Insulation: XLP

Motor Case Design Pressure 214 kg/cm2

Motor Case Design Temperature 368oC

Speed: 1450 RPM.

Hot Duty Cold Test

Motor Efficiency: 89.5 % 89.5 %

kW Input: 201.7 372.2

Power Factor: 74.0 82.5

Overall Efficiency: 74.3 % 74.3 %

Full Load Current: 85 amps

Motor Starting Current: 410 amps


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SECTION 1

TECHNICAL DATA

1. 2

1.4 CLEARANCES & SETTINGS (mm)

Initial Maximum

Impeller Wear Ring Clearance : 1.46 1.58 2.03

Journal Bearing Clearance : 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

Impeller Setting (Dimension Z): 572.5 571.5 mm

1.5 INSTRUMENTATION:

Temperature Switches: Ashcroft Model T.461-T20-030-69C-XNH:

20-950C with 6096 mm capillary. 15amp. 125 to 250 Volt AC.

Alarm Setting 60C Trip Setting at 65C

Thermometer:Ashcroft Model 600A-03-C41-B01-A1-L07-BS-

XNG

0-1200C CD1

Pressure Gauge:Ashcroft Model 60-1379SSL-04L-XNH-XNG

0-250 Kg/cm2 CD1.

Flowmeter:KDG Mobrey Series 250 Rotameter

Model 250-50-CX-M12-TO-S6-Z6

Relay Mains supply: 220V 50/60 Hz

Contact Cut Off Capacity: Max 250V/4A/500VA

Thermocouples: Type K Dual Element Ungrounded

1.6 TORQUE LOADINGS:- Refer to Figure 1/1, Schedule of Torque Loadings

1.7 WEIGHTS (Approximate)

Pump Case 3425 kg

Motor Complete 6020 kg

Heat Exchanger 410 kg


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SECTION 1

TECHNICAL DATA

1. 3

TOTAL 9855 kg


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SECTION 1

TECHNICAL DATA

1. 4

Figure 1/1 Motor Assembly


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SECTION 1

TECHNICAL DATA

1. 6

Fi ure 1/3 Pum Performance Curve


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12/109

SECTION 2

STORAGE

CONTENTS

PARAGRAPH PAGE

2.1 ENVIRONMENT 2.2

2.2 STORAGE - GENERAL 2.2

2.3 INHIBITOR 2.2

2.4 HEAT EXCHANGER 2.2

2.5 EXTERIOR SURFACES 2.2

2.6 STANDARD STORAGE CHECKS FOR STORAGE UP TO 3 YEARS 2.3

2.7 STORAGE PERIODS GREATER THAN 3 YEARS 2.4

2.8 PREPARATION FOR STORAGE AFTER USE 2.4

2.9 INSPECTION RECORD CARDS 2.4

ILLUSTRATIONS

FIGURE 2/1 MOTOR STORAGE / TRANSIT DETAILS 2.1

FIGURE 2/2 PUMP CASE STORAGE DETAILS 2.2

FIGURE 2/3 INHIBITOR FILLING VALVE 2.3

FIGURE 2/4 ROTATING THE ROTOR ASSEMBLY 2.5

FIGURE 2/5 INSPECTION RECORD CARD 2.6

FIGURE 2/6 CHECK LIST 2.7

2.0


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SECTION 2

STORAGE

Figure 2/1 Typical Motor Transit/Storage Details

2.1


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SECTION 2

STORAGE

2.1 ENVIRONMENT

The storage area must have a hard standing

floor that will be capable of supporting the

weight of the units.

2.2 STORAGE GENERAL

2.2.1 Pump Case (Fig. 2/2)

1) The pump case internal cast areas and all

machined faces must be cleaned and a

suitable removable solvent rust

preventative, with a minimum effective

life of 6 months, applied. Recommendedrust preventatives are, Jenolac J400 or

Shell Ensis Fluid 264, or their

equivalents.

2) All pump case openings must be closed

with covers. These covers to be secured

to the weld preparations with steel

banding and the pump case main flange

with the existing studs and nuts supplied

on the pump flange.

2.2.2 Motors (Fig. 2/1)

1) The motor and transit assembly must be

stored in a vertical position standing on

the motor cover end.

NOTE:

When the terminal box protrudes

below the motor cover stand, rest the

motor cover on balks of timber of

sufficient height to keep the terminal

box clear off the ground (Fig. 2/1)

2) The motor apertures must be blanked off

with flanges secured with studs, bolts andnuts (Fig. 2/1).

3) The motor and transit assembly must be

filled to the top of the transit canister with

inhibitor of the appropriate concentration,

through the filling connector located in

the temporary transit flange, sealing off

the motor heat exchanger bottom outlet.

2.3 INHIBITOR

Inhibitor is to be produced from a pre-mixed

concentration of mono-propylene glycol anddistilled 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 isas follows:-

Mixture by%Volume Specific Gravity

45% MPG /55% Water 1.036

50% MPG /50% Water 1.038

55% MPG /45% Water 1.040

MPG = Mono-propylene Glycol

2.4 HEAT EXCHANGERFigure 2/2 Pump Case Storage DetailsThe heat exchanger should be stored as

instructed by the manufacturers.

The heat exchanger interconnecting pipe work

and the fill and drain assemblies must also be

filled with the same inhibitor as the motor,

blank flanges being used to seal both ends.

2.5 EXTERIOR SURFACES

All exterior surfaces of the motor must be

maintained in a good painted condition.

Scratched or damaged paintwork must berepainted.

2.2


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SECTION 2

STORAGE

CAUTION:

To rotate the assembly in a clockwise

direction may damage the impeller nut

locking screw.

2.6 STANDARD STORAGE CHECKS FOR

STORAGE UP TO 3 YEARS

A visual examination and inspection of the

motor and transit assembly must be made at

least every three months as follows:-

b) If the shaft cannot be rotated or is

very difficult to turn, the motor mustbe stripped down and inspected as

outlined in Section 7.NOTE:

When stored by the contractor, or by an

agency, a record card should be kept of the

intervals between inspections and the results

of the following inspection checks recorded.

8) Check the inhibitor level in the motor and

transit assembly. The level of inhibitor

must not fall below the level of the

impeller. Top up if necessary.

2.6.1 MOTOR9) Check the glycol/water concentration by

measuring the specific gravity of the

inhibitor. The inhibitor is considered

acceptable if it conforms to the

concentration and tolerance given in

paragraph 2.3.

1) The motor is stored vertically resting on

the motor cover - not horizontally.

2) The exterior paintwork is in good

condition. Repaint where necessary.3) All flanges and joints are tightly secured

and no leakage of the inhibitor has taken

place.

10) Replace the transit inspection cover

when the inspection is satisfied.

2.6.1.2 Topping up/Draining Inhibitor (Fig 2/3)4)

1) Remove the access cover plug.a) All studs, bolts and nuts are present

and in sound condition. 2) Attach a hose leading from a pumping

device to the hose tube of the inhibitor

filling valve.b) The phosphate, or any other plating,

applied to these items has not

deteriorated.3) Unscrew the filling valve screw by two

turns. This action opens the valve to allow

the pumped liquid to enter the motor.

5) Measure and record the ambient

temperature of the storage area.

4) When the sufficient inhibitor has been

pumped in, turn screw to close the valve.6) Check and record the insulation resistance

of the stator windings as follows:

a) Remove the terminal box cover. 5) Remove the hose from the inhibitor

filling valve.b) Check the insulation resistance at the

terminal stems using a l000V megger.

Record the result.NOTE:

If the motor is to be drained, allow the

liquid to flow out of the valve hose tube.

Ensure disposal of inhibitor is carried

out in accordance with local

regulations.

IMPORTANT: -

If any insulation resistance value falls below

200 megohms at 20C this, and any previous

readings, with dates, must be reported to

Hayward Tyler for comment.

c) Fit the terminal box cover.

7)

a) Remove the inspection cover from the

top of the transit canister (Fig.2/1).

Fit impeller wrench onto the impeller

nut and rotate the rotating assembly

seven complete revolutions in an anti-

clockwise direction when viewed from

the pump-end.

Fi ure 2/3 Inhibitor Fillin Valve

2.3


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SECTION 2

STORAGE

2.6.1.3 Pump Case and Transit Assemblies

2.8 PREPARATION FOR STORAGE

AFTER USE.Inspect the pump assembly and check the

following: -

1) Remove the motor from the pump caseand drain the motor as described in

Section 7.

1) No extensive corrosion has occurred on

the internal pump cast or machined areas.

2) The protective coating is satisfactory.

Re-apply if necessary. 2) Disassemble the motor cover and clean

out any loose material, sediment etc.3) Visually examine the assembly for

damage. 3) Disassemble the motor as described in

Section 7.4) Check that the pump case protective

flanges are correctly fitted and secure. 4) Check all fittings and clearances and

general condition (Section 1). Fit spare

parts as necessary.2.6.2 Stud Tensioning Equipment

After use, the stud tensioning componentsmust be thoroughly cleaned, examined for

damage and a rust preventative lubricant

applied to all surfaces.

5) Reassemble the motor as described inSection 7.

6) Using special wrench provided on the

impeller nut, check that the shaft rotates

freely, approximately seven revolutions in

an anti-clockwisedirection.

The components must be then wrapped in

suitable waterproofed material and stored in

a clean, dry area.7) Check the insulation resistance of the

winding. This should not be below 200

megohms.2.7 STORAGE PERIODS GREATER

THAN THREE YEARS8) Fit the transit canister to the main flange

and stand the motor upright on the motor

cover.

Units that remain in store over three years

require special consideration and HaywardTyler Limited should be consulted for

specialist advice.9) Seal off all apertures with appropriate

transit flanges and gaskets.

Motor assemblies that are stripped must be

reassembled using new gaskets, the details

recorded on the storage record card stating that

it has been stripped and listing any relevant

findings.

10) Fill the motor with a pre-mixed

concentration of inhibitor, in accordance

with paragraph 3, through the filling

connection in the transit flange, sealing

the motor heat exchanger bottom outlet.

CAUTION: 11) Fit the transit canister inspection cover.Precautions must be taken prior to use that

the unit is pressure tight. 12) Re-check the insulation resistance of the

motor windings.

13) Check that the storage conforms to Para

2.2.

2.9 INSPECTION RECORD CARD

(Fig. 2/5 and Fig 2/6)

A typical inspection record card and check list

is given on the following pages.

2.4


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SECTION 2

STORAGE

Fi ure 2/4 Rotatin the Rotor Assembl

2.5


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SECTION 2

STORAGE

Fi ure 2/5 Ins ection Record Card

2.6


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SECTION 2

STORAGE

2.7

Fi ure 2/6 Check List


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21/109

SECTION 3

DESCRIPTION

3.1 GENERAL 3.2 PUMP

The Hayward Tyler Glandless Motor

Circulator Pump is designed for recirculating

boiler water through the boiler water systems

of fossil fuel or liquid cooled nuclear reactorpower stations and similar applications.

The pump comprises a single suction and

double discharge branch casing, welded into

the boiler system pipe work at the suction and

discharge branches with the suction branchuppermost.

The circulators consist of a single stage

centrifugal pump and a wet stator induction

motor, which are mounted within a common

pressure vessel. The vessel consists of three

main parts, a pump casing, motor housing and

motor cover.

Within the pump cavity rotates a key driven,

mixed flow type impeller, mounted on the end

of the extended motor shaft. 'Renewable wear

rings are fitted to both the impeller and pump

case. The impeller wear ring is the harder

component to prevent galling

The motor is suspended beneath the pump

casing and is filled with cold boiler water at

full system pressure. No seal exists between

the pump and motor, but provision is made to

thermally isolate the pump from the motor in

the following respect: -

3.3 MOTOR

The motor is a squirrel cage, wet stator,

induction motor, the stator wound with aspecial water tight insulated cable. The phase

joints and lead connections are also moulded in

an insulated material. The motor is joined to

the pump casing by a pressure tight flange joint

and a motor cover completes the pressure tight

shell.

1) Thermal Conduction. Because the pump

temperature is so high, usually above 340C

and the motor temperature is limited to

about 55C, a simple restriction, in the form

of a 'neck', is provided to minimise heat

conduction. The motor shell contains all the moving parts,

except for the impeller. Below the impeller is

situated an integral heat baffle which reduces

the heat flow, a combination of convection and

conduction, down the unit. A baffle wear ring-

cum-sleeve above the baffle forms a labyrinthwith the underside of the impeller to limit

sediment penetration into the motor. Should

foreign matter manage to pass the labyrinth

device into the motor enclosure, a filter located

at the base of the cover end bearing housing

strains it out.

2) Hot Water Diffusion. To minimise

diffusion of boiler water, a narrow annulus

surrounds the rotor shaft, between the hot

and cold regions. A baffle ring restrictssolids entering the annulus.

3) Motor Cooling. The motor cavity is

maintained at a low temperature by a heat

exchanger in a closed loop water circulation

system, thus extracting the heat conducted

from the pump.

The motor design is such that for ease of

maintenance, the stator shell, complete with the

stator pack, the rotor shaft, the journal bearing

housings and the thrust assembly, can be

withdrawn from the motor case in sequence.

Lifting lugs are supplied to secure hoists whenraising and lowering the motor.

In addition, this water circulates through the

stator and bearings, extracting the heat

generated in the windings and providing

bearing lubrication. An internal filter is

incorporated in the circulating system.

4) In emergency conditions, if low pressure

coolant to the heat exchanger fails, or is

inadequate to cope with heat flow from the

pump case, a cold purge can be applied to

the bottom of the motor to limit the

temperature rise.

NOTE:

A high pressure cold purge is to be used

only as an emergency. (para 6.3.8)

3.1


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SECTION 3

DESCRIPTION

Figure 3/1 Auxiliary Cooling Circuit

3.2


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SECTION 3

DESCRIPTION

3.3.1 Auxiliary Cooling Circuit (Fig. 3/1)

3.3.3 Internal FilterThe motor is provided with its own auxiliary

closed circuit, which besides cooling the motor

lubricates the bearings. The water is

continuously circulated through the bearings,

motor windings and an external heat exchanger(cooler), by an auxiliary impeller at the thrust

bearing end of the motor shaft.

A stainless steel woven wire strainer, fitted at the

base of the reverse thrust seat, filters the liquid in

the motor before it is circulated through the

bearings after passing through the heat exchanger

(cooler).

The filter should be cleaned at normal

maintenance periods, removing any accumulation

of foreign matter in the motor cover.

When the motor is stationary, thermosyphon

circulation takes place to remove conducted heat

from the pump end of the motor.

3.3.4 Main Flange Joints3.3.2 Bearings

The pressure joints at the pump and motor cover

flanges employ spiral edge wound gaskets,

specially designed for very high pressure and

temperature. The main pump/motor flange

gasket is housed in stainless steel overlay,

recessed into the joint face.

The motor rotor shaft is supported by water

lubricated tilting pad type radial and thrust

bearings mounted on the stator shell, thus making

the motor internals into a separate construction

independent of the motor pressure vessel.

3.3.2.1 Journal BearingsThe studs and nuts securing the flanges are made

from special high tensile steel and, because

torque tightening these nuts is inadequate, the

studs are hydraulically stretched and the nuts

tightened down by hand. When the hydraulic

tension in the stud is released, the load is

transferred to the nut giving the required

tightness.

The journal bearings of the circulator are

the water lubricated Michell type located at

the ends of the motor shaft, i.e. pump-end

and cover-end. Each bearing comprises a

hardened steel sleeve on the shaft running

in six radially located tilting pads whose

bearing surfaces are lined with a composite

material. The bearing surfaces must never

be allowed to operate in a dry condition.Stud tensioning equipment is supplied with each

circulator order.

3.3.2.2 Thrust Bearing 3.3.5 Terminal GlandA main thrust bearing is situated below the

cover-end journal bearing and takes the full

hydraulic thrust of the pump. This bearing,

also of the Michell water lubricated type, is

formed by a steel thrust disc, with a

composite bearing surface, on the bottom of

the rotor shaft running on stationary

hardened steel tilting pads.

The electrical supply to the motor is taken

through special high pressure single lead cable

terminal glands of the high temperature, safety

type.

The seal is effected by a terminal gland

moulding, together with o-rings located between

an insulating sleeve and an inner casing, and

between the inner casing and the motor case.

The addition of a cone-shaped collar within the

terminal moulding, plus the design of the inner

casing, prevents any possibility of a glandblowout at high temperatures. However, if the

motor is subjected to sustained overheating, a

slight leakage may occur into the terminal box.

The thrust disc is also designed to operate

as an auxiliary impeller to circulate the

internal water content of the motor.

3.3.2.3 Reverse Thrust Bearing

The weight of the rotating assembly, as well

as the down thrust imposed at start-up and

shut-down, are taken by a reverse thrust

bearing located on a reverse thrust housing

which forms the bottom of the cover

housing cylinder.

The reverse thrust housing also includes a

composites reverse thrust wear ring and is

the mounting for the internal filter.

3.3


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SECTION 3

DESCRIPTION

Fi ure 3/2 Terminal Gland

3.4


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SECTION 3

DESCRIPTION

3.4 TERMINAL BOX

Robust fabricated steel terminal boxes are

provided on the side of the motor casing for

connecting the power supply to the motor.

Each phase supply cable for the motor enters a

box at its base and should be sealed by a cable

gland. Each phase notation is identified by a

colour coding, Red, Yellow or Blue.

Bursting discs are fitted to the wall of the

terminal boxes to relieve excessive pressure

build up within the box should a flash over

occur at the terminals.

Desiccators are fitted to absorb atmospheric

moisture that may decrease the electrical

resistance to ground. Each assembly is

completely enclosed by a bolted on cover.

3.5 HEAT EXCHANGER

A heat exchanger (cooler) must be fitted to

dissipate the heat generated by the motor and

the heat transferred from the pump casing.

High pressure outlet and inlet raised facings are

situated at the bottom and top of the motor case

respectively for connection to high pressure

heat exchanger / motor case stub pipes.

Interconnecting pipework must be short and

direct with the heat exchanger mounted as high

as possible to promote good thermosyphon

circulation when the unit is on hot standby.

3.6 ALARM SYSTEMS

3.6.1 Thermometer

The thermometer instrument is mounted adjacent

to the motor, and gives visual indication of the

motor temperature.

3.6.2 Temperature Switches

Two temperature switches, remotely mounted,

are provided for actuating the alarm. When a

pre-set temperature is reached, the alarm circuit

is energised via one of the switches. Should the

motor temperature continue to rise, the second

switch is activated to de-energise the motor.

3.6.3 Thermocouples

A thermocouple is provided for measuring motor

cavity temperature. Two thermocouples are also

supplied with weld on pads for measuring the

skin temperature of the pump case and suction

manifold. These are to be installed on site by the

user.

3.6.4 Instrument Pockets

Temperature switch, thermometer and

thermocouple pockets are provided where

required.

3.6.5 Differential Pressure Transmitter with

manifold

These are to be connected to the process

connections in the pump case by the user.

(Customer supply)

3.6.6 Pressure Gauge

A pressure gauge is remotely mounted to the

motor case.

3.6.7 Flow Meter

A flow meter is supplied to be fitted in the low

pressure cooling water return line by the user.

3.6.8 Ground Detection Relays

The motor windings should be protected by

ground detection relays, sufficiently sensitive to

detect the development of a pinhole or minor

crack in the stator winding insulation.

3.5


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SECTION 4

INSTALLATION

CONTENTS

PARAGRAPH PAGE

4.1 GENERAL 4.2

4.2 PUMP CASE INSTALLATION 4.2

4.3 PREPARATION FOR MOTOR INSTALLATION 4.2

4.4 MOTOR INSTALLATION 4.4

4.5 FITTING THE HEAT EXCHANGER 4.5

4.6 FILLING THE CIRCULATOR WITH BOILER COLD 4.6

4.7 HYDROTESTING BOILER WITH CIRCULATOR INSTALLED 4.6

4.8 ELECTRICAL CONNECTIONS 4.8

4.9 MOTOR PROTECTION 4.9

ILLUSTRATIONS

FIGURE 4/1 PUMP CASE INSTALLATION 4.1

FIGURE 4/2 MOTOR INSTALLATION 4.3

FIGURE 4/3 TERMINAL BOX 4.7

FIGURE 4/4 BURSTING DISC ASSEMBLY 4.8

FIGURE 4/5 EARTH LEAKAGE PROTECTION CIRCUIT DIAGRAM 4.10

4.0


27/109

SECTION 4

INSTALLATION

Fi ure 4/1 Pum Case Installation

4.1


28/109

SECTION 4

INSTALLATION

3) The cables, leading to the motor, should be

flexible and looped immediately prior to

entering the terminal boxes. The looping

should be sufficient to accommodate unit

movement caused by expansion and

contraction of the boiler pipe work.

4.1 GENERAL

WARNING

The Hayward Tyler boiler circulating pump is

a precision piece of heavy machinery.

It should only be installed under the

supervision of a qualified professional engineer

who should ensure that the staff directly

concerned are adequately trained and have

read and understood this manual.

4.2 PUMP CASE INSTALLATION (FIG 4/1)

1) Remove the pump case flange and branch

covers and clean the pump branches.

When installing the circulators the following

conditions MUST be observed.2) Attach shackles and slings to the casing

eyebolts. A plate on the pump case

indicates the front of the pump.1) The system pipe work should be adequately

supported to accept the weight of the

circulator.3) Raise the case to meet the system pipe

work, with the suction branch uppermost.

2) When mounted, the pump should

accommodate movement in the pipe work

due to thermal expansion without imposingexcessive loads on the casing and branches.

4) Ensure that the main motor/case flange is

horizontal to within 1. Tack weld to thesystem pipe work and re-check the

horizontal limits.

3) Sufficient clearance should be allowed

beneath the motor to permit lowering of the

motor from the pump case for maintenance.

(See Section 7 Fig. 7/35.). If removable

floors or girders etc. are fitted after the

motor is installed, ensure that the terminal

boxes or low pressure cooling water supply

lines will not foul them when the boiler is on

load and the circulator moves downwards

due to thermal expansion.

5) Complete the weld to the procedure

approved by the boiler manufacturer and test

radiographically for flaws.

6) On completion of a satisfactory

radiographic test, fit any pressure

differential transmitters using the stub pipes

on the pump case branches.

7) Fit the blanking off plate until the motor is

installed.NOTE:

Two long lift hoists should be used to

raise the pump or motor, each hoist being

capable of taking the full weight of the

pump or motor

4.3 PREPARATION FOR MOTOR

INSTALLATION

CAUTION:

The motor should be stored, topped-up with

inhibitor for as long as possible. If it is

necessary to install the motor before boiler

water is available, install in the inhibited

condition to provide additional protection for

the motor internal components. However,

the inhibitor must then be drained

immediately before mounting the heat

exchanger.

4) The pump should be positioned so that the

N.P.S.H. available exceeds the N.P.S.H.

specified in the Technical Data - Section 1).

NOTE:

When operating at temperature, sub

cooling of the inlet water is normally

present and this gives a considerableincrease in the N.P.S.H. available. The

worst condition is normally operating

cold. We do not recommend motor installation on

a Hot Boiler.4.1.2 Installation Notes

1) Hose down internally, the pump case, the

valves and adjacent-piping, to ensure the

removal of all loose debris.

The following conditions must be observed

when installing the circulator:

1) Ensure that the main system is free from

solids before mounting the circulators.2) Fully close the pump suction and discharge

valves.2) Permanent insulation should be applied

only to the pump case. No insulatingmaterial must be applied to the motor case

or to the main flange studs and nuts, as this

will cause the motor to overheat.

4.2


29/109

SECTION 4

INSTALLATION

Fi ure 4/2 Motor Installation

4.3


30/109


31/109

SECTION 4

INSTALLATION

c) If, after fitting of the heat exchanger,

running the motor is reasonably

imminent, and sub-freezing

temperatures are not envisaged, the

motor and heat exchanger must be filled

with treated boiler water or condensate

within 3 hours of fitting.

f) Check the gaps every 10 mm, or less,

during the last 100 mm of the motor

raising sequence to ensure that the motor

does not 'cock' or rotate as it is raised.

Adjust the gap as necessary.

g) Continue raising the motor until an

increase in the effort required on thehoists indicates that the gasket is in

contact with the pump case face. At this

stage, the gap between the flange faces

should be approximately 2.5mm and

should be equal all round the flange.

4.5 FITTING THE HEAT EXCHANGER

(CUSTOMER SUPPLY)

1) Remove the blank flanges from the motor

high pressure outlet to cooler and fill and

drain connection.CAUTION:

If the gap is unequal, the gasket may

have come out of its recess. If the gap

is unequal, lower the motor

sufficiently to check the condition of

the gasket. If the gasket is damaged -

renew. Never use any substance onthe gasket to make it adhere to its

recess.

2) Ensure that the motor, the heat exchanger

and the high pressure pipe work and high

pressure purge lines, have been flushed free

from all obstructions and foreign matter.

3) Flush out the secondary cooling watersystem until clear water is discharged.

4) Mount the heat exchanger onto the motor

case brackets and proceed.h) Coat the stud threads with high

temperature anti-seize compound or

silicon grease and install the nuts by

hand.

a) Bring the heat exchanger parallel to the

motor supporting the weight with the

lifting tackle.NOTE:

b) Clamp the heat exchanger to the motor

by tightening up the securing bolts, nuts

and washers.

Do not coat the exposed extended

diameter threads of the studs as these

threads are for the tensioner

application. c) Ensure the motor / heat exchanger

interconnecting pipe work assembly is

correct for the circulator.i) Tighten the nuts, using the hydraulic studtensioner in accordance with the

instructions in Section 8. Remove the

lifting tackle and removable lifting lugs.

d) Offer up the interconnecting pipe work

to the heat exchanger and motor flanges

and complete all pipe welds and NDE in

accordance with site approved

procedures.

j) Thoroughly flush out the fill and drain

system piping, to the motor cover and

when satisfied that the piping is clean,

connect to the motor cover. 5) Install gauges and recorders for temperature

and pressure. Connect the low pressure

cooling systems to the heat exchanger.k) Install the heat exchanger: see Para. 4.5

l) Install the appropriate thermocouples,

the thermometer, pressure guage and

temperature alarm switches.

6) Fit temporary strainers to the low pressure

cooling systems, and then check that

circulation meets the heat exchangerspecification.

m) Connect the power supply cables to the

motor terminals, See 4.8.

7) Close the shut off valve in the high pressure

fill and purge line and blow down piping.n) Install the vibration pick up probes if

permanent vibration monitoring is

required.The motor and heat exchanger circuit must

now be refilled with inhibitor (See 4.4, Para.

13 (a) or (b) or with treated boiler water or

condensate.

13)

a) If, after fitting the heat exchanger,

running is not reasonably imminent, the

motor and heat exchanger circuit must

be refilled immediately with inhibitor.

b) If, after fitting the heat exchanger, sub-

freezing temperatures are envisaged themotor and heat exchanger circuit must

be refilled immediately with inhibitor.

4.5


32/109

SECTION 4

INSTALLATION

5) After connecting the supply, open the heat

exchanger vent on the high pressure side, fill

the motor from the bottom and vent air from

the top, until clean air free water is

discharged from the vents.

4.6 FILLING THE CIRCULATOR WITH

BOILER COLD

Filling the circulator correctly is a prerequisite to

ensure satisfactory operation. If air is present in

the motor it could affect bearing lubrication and

precipitate bearing failure.

6) Close the vent on the high pressure side of

the heat exchanger.

7) Continue to fill the motor and vent any air

via the vent connections in the boiler system

pipe work.

If air pockets are present in the stator this would

affect dissipation of heat generated in the

windings, creating hot spots and consequent

degrading of the insulating material, and

ultimately cause winding failure.8) Isolate the now filled circulator.

9) Ensure that the terminal box is dry and with

the unit full of water below 20C or at

normal ambient temperature, using a 1,000

Volt Megger, check winding resistance to

ground at the terminals. The resistance

should exceed 200 megohms.

Due to the complexity of the passages in the

motor through which water must flow to displace

all air, it is necessary to fill the motor very slowly.

If air pockets are present in the stator this would

affect dissipation of heat generated in the

windings, creating hot spots and consequentdegrading of the insulating material, and

ultimately cause winding failure.

IF NOT, CALL HAYWARD TYLER.

DO NOT ATTEMPT TO RUN THE

MOTOR.The maximum filling rate is 2 litres /min.

The motor must NOT be filled via the pump

casing, but only through the filling connector

located at the motor cover.

4.7 HYDROTESTING BOILER WITH

CIRCULATOR INSTALLED

Treated Water or Condensate Available: -1) Isolate the circulator from the boiler by

closing appropriate discharge valves. Should the customer wish to hydrotest the

circulator, the hydrostatic test pressure must not

exceed the maximum specified in Section 1.2) Supply the low pressure side of the heat

exchanger as follows: -

Treated Water Not Available: -a) Open the supply valves in the low

pressure cooling water system. If the boiler is to be hydrotested at an early state

of construction, the pump casing can be pressure

tested without the motor once the blank off plate

is installed refer to para.4.2.

b) Flush out the piping for the supply of

low pressure treated boiler water, or

condensate, for filling the motor, until

clean air free water is discharged.4.7.1 Post Hydrostatic Test Procedure

NOTE:1) Boiler circulators are not to be drained, but

left filled to a level above the suction

downcomer.

The flushing must always be carried out

before introducing any water through the

lines to the motor and heat exchanger.

2) Freezing can be avoided by filling with

glycol in the concentration detailed inSection 2.

3) If the low pressure supply contains an

orifice, check that it is clean and that its flowrate is correct.

4) Adjust the flow rate to approximately 2

litres/min.

4.6


33/109

SECTION 4

INSTALLATION

Fi ure 4/3 Terminal Box

4.7


34/109

SECTION 4

INSTALLATION

4.8 ELECTRICAL CONNECTIONS

4.8.1 Power Supply to Motor

Refer to the terminal box arrangement shown in

Fig. 4/3.

WARNING:

Disconnect the power supply and the starter

before commencing any work.

CAUTION:

Ensure that the cable length will

accommodate expansion and removal of the

circulator.

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 thenremove the terminal box cover using lifting

gear, if necessary.

2) 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.

3) Earth the circulator adequately. Earthing

studs are provided on the motor casingadjacent to the terminal box.

4) Ensure that all electrical connections

particularly at the terminal box entry gland

are secure.

5) Fit the bursting discs to the terminal box as

follows: -

NOTE:

The bursting discs are supplied as loose

items and are packed separately to

prevent damage in transit. They are

fitted to the terminal box on theinstallation of the motor.

a) Dismantle the bursting disc assembly

and discard the cardboard sheet fitted in

lieu of the disc.

b) Reassemble the bursting disc assembly

with the bursting disc in place, as

depicted in Fig. 4/4.

6) Fit the desiccators, also supplied as loose

equipment, as follows:-

a) Check that the desiccator crystals are

coloured blue.b) If pink, reactivate by placing the

desiccator in a well ventilated oven

where it should be maintained at a

temperature of 110oC until the colour

reverts to blue. The re-activating time is

between 1 and 2 hours.

c) Screw the desiccators into the terminal

box covers taking precautions not to

damage the desiccators.

7) Fit and secure the terminal box covers using

the nuts and washers previously removed.

Fi ure 4/4 Burstin Disc Assembl

4.8.2 Recommended Instrumentation

It is recommended that the following be

provided: -

1) Pump suction and discharge pressure

gauges.

2) Continuous record of motor voltage.

3) Continuous record of motor current.

4) Ground leakage relay to warn of very low

winding resistance in order to prevent

winding insulation failure.

5) Indication and record of downcomertemperature and pump case temperature.

This is required to avoid thermal shocks

when starting a pump on a hot boiler.

4.8


35/109

SECTION 4

INSTALLATION

4.8.3 Alarm Circuits (Fig.4/5)

4.9.3 Starting Period ProtectionWARNING:Lethal voltage is present in the alarm system

when the motor is inoperative. To make the

circulator safe - open the isolator.

If the motor fails to start, trip out after a period

of approximately 5 seconds. The starting

current is based on a locked rotor test with an

allowance made for saturation of the magneticcircuit.

Suitable alarm and trip devices should be fittedto protect the motor and arranged to provide: -

Motor Starting Current: See Technical Data,

Section 1.

1) An alarm - as an indication of motor

overheat conditions.

4.9.4 Earth Leakage Protection (Fig. 4/5)2) Motor trip (shut down) - if the temperaturerise continues above the alarm setting.

Ground detection relays are recommended,

sufficiently sensitive to sound an alarm if a pin-

hole or minor crack should develop in the stator

winding. This protection is arranged in either of

the ways shown in Scheme A, Scheme B or

Scheme C.

The normally advised settings for the protection

devices are: 57C for alarm and 60C for trip. In

practice, the alarm setting should be reduced to

5C above normal motor operating temperature.

If the neutral point of the supply transformer is

grounded, a current transformer (CT) is inserted

into the ground lead, and a relay connected

across the current transformer secondary, see

Scheme A.

4.9 MOTOR PROTECTION

The following protective devices must be

provided for the motor: -

4.9.1 Continuous Overload Protection

Experience indicates that in the event of a fine

crack in the stator winding, the resistance to

ground drops to between 20,000 and 30,000

ohms. The relay should not trip the motors but

initiate an alarm.

The overload trip setting should be 10% above

the maximum current requirements which could

occur with the pump running on cold water at

some other point than the specified duty,

assuming nominal specified supply voltage. If

voltage variation can occur, then the trip setting

should be increased to 15% above maximum

current value.

If the neutral point of the supply transformer is

not grounded, three potential transformers (PT)are connected to the motor leads, with the

secondaries connected in an open delta, closed

by the relay winding, see Scheme B. The relay

should not trip the motors but initiate an alarm.

NOTE

Overload relays are now typically calibrated

in motor full load current (FLC) where the

relay trips with a current 10% above the

FLC setting point. Hence the overload relay

of this type should have a setting point of the

cold duty current.

Scheme C shows a core balance earth leakage

relay system where a core balance current

transformer encloses supply lines L1, L2 & L3

supplying the motor.

Maximum current at nominal voltage: NOTE

It is important that no earth conductor is

allowed to be enclosed by the current

transformer. The earth leakage sensitivityand trip time can generally be selected to

prevent nuisance tripping. Typical setting

points are 300 mA and 1 second. This may

require adjustment depending on supply

conditions.

See Technical Data, Section 1.

4.9.2 Instantaneous Trip Setting

To allow for transients during the first cycles of

the starting period, the instantaneous trip should

be set at 12 times the motor full load current.

Full Load current: See Technical Data, Section

1.

4.9


36/109

SECTION 4

INSTALLATION

4.10

Figure 4/5 Earth Leakage Protection Circuit Diagram


37/109

SECTION 5

COMMISSIONING

CONTENTS

PARAGRAP

HPAGE

5.1 PRE-START CHECK LIST 5.1

5.2 INITIAL STARTING-COLD BOILER CONDITION 5.1

5.3 STOPPING 5.3

5. 0


38/109

SECTION 5

COMMISSIONING

5.1 PRE-START CHECK When a boiler is started from cold, a minimumof two circulators must be operated. It is

normal practice to simultaneously warm the

standby circulators to permit immediate staring

when required.

The following pre-start checks must be

satisfied before starting the motor.

1) Ensure that the circulator is completely

vented. CAUTION:

1. Motors must not be energised if the

motor cavity temperature is below 2C.

2) Ensure that the low pressure cooling

water valves are open and the cooling

water flow rate agrees with that specified

in the heat exchanger manufacturer's

specification. All other valves must be

closed.

2. There should be at least ten-minute

intervals between two repetitive starts.

This must never be exceeded;

otherwise the motor winding

temperature will rise and could

damage the winding insulation.NOTE:

If the circulator is to be started on hot

standby, the pump delivery by-pass

valves must be open. Refer to the hot

standby procedure in Section 6.

3. The motor may be damaged if motor

temperature exceeds 65C.

1) Ensure that the motor has been vented asdetailed in Section 4, Para. 4.7.3) Ensure that the high pressure cold water

purge at 20C maximum temperature is

connected but isolated. 2) Ensure that a flow of approximately 2

litres/min., is entering into the motor

through the low pressure fill line.4) Using a 1000V megger, check that the

insulation resistance to ground of the

motor leads conforms to the Winding

Resistance curve shown in Section 1,

Fig. 1/2 when measured at the terminal

stems with the unit full of water below

approximately 20C, if possible, or at

normal local ambient temperature.

3) Ensure that the pre-start checklist, as

described in Para. 5.1, has been satisfied.

4)

a) Release any air trapped below the

discharge valves by opening valves.

b) When air-free water is discharged to

atmosphere, close valves.5) Check that the correct voltage isconnected to the circulator.

5)6) Check that the electrical supply is

available at the point of control selected

and that the starting equipment is

functioning correctly.

a) Vent the pump by opening vent

valves.

b) When air-free water is discharged

from vent valve to atmosphere, close

valves.7) Test the operation of all instrumentation

and alarms.6) Make sure that the boiler is full and open

the discharge valves.8) Ensure that sufficient N.P.S.H. is

available for the pump to run without

cavitation. NOTE:

The by-pass valve should never befully closed. It is normally throttled to

provide a minimal flow between the

pump suction and discharge system

9) Start parallel operating boiler circulating

pumps with the stems of the discharge

valves withdrawn to prevent overheating

of the boiler water in the pump case.7) Switch on power to the starter.

5.2 INITIAL STARTING-COLD BOILER

CONDITION8) Press the starter button on the control

console and energise the motor for 5

seconds only.In systems where the circulators are arranged

in parallel, to avoid cavitation, sufficient

circulators must be operated to limit the

capacity per pump to a value where the

N.P.S.H. required is less than the amount of

N.P.S.H. available.

5. 1


39/109

SECTION 5

COMMISSIONING

5. 2

CAUTION:

The motor runs up to full R.P.M. in

appropriately one second. If the

motor fails to start after five seconds,

press the stop button and do not

attempt to restart the circulator for 20minutes.

9) After ten minutes pause, run the

circulator for a further (2nd) five

seconds. During this run, check the

following:-

a) Motor Current (after ammeter has

come off initial surge of current)

b) Differential pressure - when the

check valves open, the differential

pressure should rise immediately to

approximately 3 bars.

NOTE:

If the differential pressure does not

rise, stop the motor immediately; it

may be an indication that the motor is

running in reverse. Reverse rotation

will result in approximately 30% less

head generated and about 10% more

power absorbed than specified.

10) After a further (3rd) ten-minute pause,

repeat operation (9).

11) After another (4th) ten-minute pause,

energise the motor and run for twentyminutes. During this running period,

carry out the following checks:-

a) Check the motor for vibration, using

a vibration detector, several times and

record reading for future comparison.

b) Check for rubbing or excess bearing

noise by holding a listening rod

against the pump and motor case.

c) Check the motor operating

temperature at regular intervals.

Initially it should rise several degrees

then stabilise. If necessary, adjust thesecondary cooling water flow after

checking that the strainers are not

obstructed.

d) Check, as the motor warms, that the

high pressure circulation pipe entering

the heat exchanger from the top of the

motor becomes warmer than the high

pressure circulation pipe from the

bottom of the heat exchanger to the

motor case. This indicates correct

functioning of the heat exchanger.

e) Check that motor current anddifferential pressure readings several

times and record the readings.

12) When the motor temperature has

stabilised: -

a) Adjust the high temperature alarm

setting to 10% above this point, or to

57C, whichever is the lower. Thetrip setting must never exceed 60C.

b) Make adjustment to other

instrumentation as necessary.

c) Check all flanges, glands and valves

for leaks.

d) As the boiler water temperature

increase, its specific gravity decreases

and the amount of N.P.S.H., available

increases. The temperature of the

high pressure water to the heat

exchanger may alter due to lower

losses in the motor, or because ofincreased heat flow from the pump.

NOTE:

It is normal procedure to commission

circulators separately, but if required,

before the last circulator is stopped,

the others may be energised and their

recordings taken after each one is

brought on-line.

5.3 STOPPING

1) Press the stop button on the control

console. The run-down time isapproximately 2.5 seconds.

2) Close the discharge valves.

3) Maintain the low pressure cooling water

supply to the heat exchanger.

NOTE 1:

If the circulator is to stand idle for

some considerable time with the boiler

cold, the low pressure cooling water to

the heat exchanger may be turned off,

especially on systems where the

cooling water runs to waste.

NOTE 2:

On hot boilers, and whenever the

circulator is run, the low pressure

cooling water to the heat exchanger

must always be on.

CAUTION:

If the circulator is to be idle for an

extended period, and be subjected to

freezing temperatures, make sure that

provision is made to protect the

motors from freezing (see Section2.2.2.)


40/109

SECTION 6

OPERATION

CONTENTS

PARAGRAP

HPAGE

6.1 STARTING THE CIRCULATOR 6.1

6.2 SHUTTING DOWN THE CIRCULATOR 6.2

6.3 ROUTINE CHECKS AND OPERATIONAL CONDITIONS 6.3

6.4 FAULT FINDING 6.5

ILLUSTRATIONS

Figure 6/1 FAULT LIST CHART 6.6

6.0


41/109

SECTION 6

OPERATION

Any of the following conditions may exist

when putting a circulator into service. Follow

the relevant procedures below and refer to 6.3

for routine checks and operational fault action.

6) Ensuring the boiler is still full, energise

the second duty circulator on line and run

up to speed.

7) Perform the operational checks below.

Refer also to Para. 6.3.

6.1 STARTING THE CIRCULATOR a) Amperage.

b) Motor cavity temperature on alarm

thermometer.6.1.1 Boiler Cold - Circulator Cold and

Filled (Boiler Start-Up).c) Differential pressure.

1) Ensure that the pre-start checklist, 5.1 is

satisfied. d) Low pressure cooling flow and

temperature.2) Vent the motor as follows: -

e) Vibration.a) Release any air trapped below the

suction by opening the by-pass valves

and the filling valves.

f) Drum level.

g) Valve and gland leakage.

8) Energising other motors: When the

boiler differential pressure parametersrequire the other circulators to be

energised: -


through the vent valve, close ventvalve.

3) Vent the pump as follows: -a) Check that the differential

temperature, between the pump case

and boiler water in the downcomers,

is within 28C.

a) Open the vent valve.


from vent valve, close vent valve and

filling valves.b) Energise the other motors.

c) Open the stems of the discharge

valves.c) Close by-pass valves on the newly

energised pump(s).

CAUTION: d) Perform the operation checks on the

newly energised pump as detailed in

para.6.1.1 (7).

The pump must always be re-vented in

this manner prior to starting when thedrum pressure is below 3.5 kg/cm

2.

6.1.2 Boiler Hot - Circulator Hot and

Filled (Hot Standby)NOTE:The motor starting procedure following

is based on a normal boiler starting

procedure where usually two circulators

are initially operated with the remainder

brought-on line as required.

NOTE:

The low-pressure coolant to the heat

exchanger must be on.

1) Check the differential temperature

between the pump case and the boiler

water in the downcomers.4)

a) On circulators that will not be

energised, open the pump discharge

by-pass valves. This ensures that asthe boiler heats up, a flow passes

from the discharge legs to the pump

case and impeller etc.

CAUTION:

The differential temperature between thepump case and the boiler water in the

downcomers must not exceed 28C. Non-

adherence to this may cause thermal

shocks and damage to occur.b) Check the motor temperature on the

alarm thermometer; this should not

exceed 49C or be less than 5C.2) Energise the motor.

3) Close by-pass valves.5) Energise the first motor. The current will

drop from full starting current after a few

seconds to approximately the value

corresponding to the operating point on

the makers test curve.

4) Check circulator operation as detailed in

para.6.1.1 (7).

6.1


42/109

SECTION 6

OPERATION

6.1.3 Installation on a Hot Boiler 6) Check the pump case temperature as thepump case is cooling to ensure that the

cooling rate does not exceed 120C per

hour. If necessary, correct the cooling rate

as follows:

NOTE:

Not recommended for safety reasons but

not possible on this installation since no

suction valves are fitted and hence pumps

cannot be isolated. a) Cooling rate too fast: - If the pumpcase cooling rate is too fast, slow the

cooling rate by partially opening the

by-pass valves as necessary.6.2 SHUTTING DOWN THE

CIRCULATOR b) Cooling rate too slow: - If the pumpcase cooling rate is too slow, increase

the rate by injecting a high pressure

purge as detailed in Para. 6.3.8.

CAUTION

Low pressure cooling water flow and motor

temperatures must always be within the

specified limits, whenever the circulator is

on hot standby.7) When the pump case has cooled to 45C

de-pressurise the circulator as follows: -

a) Ensure the pump discharge by-pass

valves and shut-off valve are closed.6.2.1 Boiler Hot - Circulator to go on Hot

Standbyb) Slowly depressurise the circulator by

closing the pump suction by-pass

valve and partially opening the pump

and suction leg vent valve.

1) Press the stop button on the control

console.

2) Ensure that the low-pressure cooling line

valves are open. c) Open the motor cavity pressure

gauge shut-off valves and check the

pressure on the motor cavity gauge.

When the pressure has stabilised,

close the pump suction leg vent valve.

3) Open by-pass valves to provide

circulation of high temperature boiler

water through the pump casing, suction

and discharge lines.d) Re-check that the pressure does not

increase. Should it increase, check the

following: -

6.2.2 Boiler Hot - Circulator to be Isolated

for Maintenance

i) Make sure that all valves between

the circulator and high-pressure

system are closed.

1) Press the stop button of the control

console to de-energise the motor.

2) Close the stems on the discharge valves.ii) De-pressurise the circulator

again, if necessary.3) Close the pump jumper line service

valves.8) On completion of depressurising, the

motor is ready for removal.4) Crack open the pump suction bypass

valves to prevent a vacuum forming in the

pump case during the circulator cooling

process.

CAUTION

The low pressure cooling water must

be maintained until the motor has been

separated from a hot pump case.5) Maintain the low pressure cooling

system to the heat exchanger, via the lowpressure flowrator valves in the cooling

pipes open until the motor has been

separated from the pump.

6.2.3 Boiler Cold

1) Press the button on the control console.

2) Leave open the low pressure cooling

water line valves.CAUTION:

Keep a close watch on the motor cavity

temperature, should the temperature

increase, apply a high-pressure purge as

described in para. 6.3.8.

3) Pump discharge valves may be left open.

6.2


43/109

SECTION 6

OPERATION

3) If temperature increase continues and

exceeds the 60C - trip setting - and the

cause cannot be detected or the condition

corrected, refer to the relevant shutdown

procedure in Para. 6.2. If necessary, blowdown the boiler system or apply a high-

pressure purge to the motor. See 6.3.8.

6.3 ROUTINE CHECKS AND

OPERATION CONDITIONS

(Also see fault list chart)

6.3.1 Supply Current

1) Check the motor running current each

shift. The current should be constant and

comply with that specified in section 1. a) After cooling and draining, removeand disassemble the motor andexamine for worn bearings, blocked

internal strainer, motor passages,

auxiliary impeller and fouled cooling

surfaces. In addition, leaks in the heat

exchanger.

NOTE:

High amperage readings or fluctuating

motor currents indicate wear or partial

seizure at the bearing or wear ring

surfaces. This condition can cause

vibration necessitating motor removal

strip and re-installation.4) Should the alarm sound whilst the

circulator is on stand-by, start the

circulator to accelerate internal highpressure cooling water flow. Check

possible causes for temperature increase

as above. The circulator should be tripped

if the temperature exceeds 60C and the

shutdown / purge procedure 6.2 carried

out.

6.3.2 Motor Temperature

1) During normal operation, the motor

temperature should be checked at weekly

intervals. The thermometer is originally

set to initiate an alarm if the motor cavity

temperature reaches 57C and to de-

energise the motor if the temperature

reaches 60C. If desired, the

aforementioned alarm temperature

settings may be lowered, on the

temperature alarm thermometer, to suit

normal operation but only after the boiler

and circulator has been operated longenough to stabilise.

6.3.3 High Temperature Alarm and Trip

Settings

At weekly intervals check that the motor

high temperature alarm setting does not

exceed 57C or 5C above normal operating

Temperature (whichever is the lower) andthat the trip setting does not exceed 60C.

Re-set if necessary.2) Immediately investigate the following

possible causes for high temperature

alarm sounding: - 6.3.4 Pump Head and Quantity1) Check the total head generated by each

pump at weekly intervals.CAUTION

Do not stop the motor.

2) Correct possible causes of decrease in

head and quantity as follows: -a) Check the low pressure cooling water

supply for adequate flow, temperature

vapour locks and leakage in piping

(see 6.3.7.).a) The gate valve in the circulating

pump suction line and the check valve

in the circulating pump discharge

lines are not fully open. Check and

adjust the setting as necessary.

b) Check the circulator for leaks fromthe motor casing, high pressure fill

and drain cooling water connections,

particularly the motor fill and purge

line shut-off valves and the motor

drain valves.

b) Discharge through the pump and

suction leg vent or the pump casing

and suction leg drain valves. Ensure

both are closed.c) Check that the cooling water strainers

are not obstructed. c) Low N.P.S.H., available due to

reduced water level in the steam

drum, changes in system pipework or

system blockage. Check and adjust

the number of circulators operating to

suit until the fault can be corrected.

d) Check for indication of bearing

damage (noise, vibration).

6.3


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SECTION 6

OPERATION

d) Vent the pipe system to remove

vapour locks.

f) Electrically induced vibration also a

factor, i.e. Rotor bar breakage etc.e) Power supply and reverse rotation

checks are given in 5.5.1 (5) and 5.2

(9).

NOTE:

When (e) is the cause, the motor must be

removed, as detailed in section 7.2,

before repairs can be undertaken.f) Worn wear rings and a blocked ordamaged impeller can be corrected

only after removing the motor

assembly from the pump case.

Clearances are specified in section 1.

6.3.7 Low Pressure Cooling Water Supply

Failure.

If the cooling water to the heat exchanger is

lost while the circulator is at operating

temperature, the motor must be de-energised

within five minutes and the suction and

delivery valves closed as soon as possible.

6.3.5 Insulation Condition

Before initially energising the motor and

thereafter at monthly intervals, check the

following: -CAUTION

1) The insulation resistance to ground of the

motor leads.Damage to the windings may occur if:

a) the motor remains in operation after 5

minutes from the loss of cooling water.a) With the unit filled with water below20C or at normal local ambient

temperature, the resistance measured

at the terminal links, using a 1000V

megger, must exceed 200 megohms.

Or

b) if the cooling water is not

restored before the motor

temperature rises above 60C.

NOTE:CAUTIONThe insulation resistance of the stator

winding varies with temperature and

must always be measured cold 20C or at

normal local ambient temperature.

Do not attempt to operate the motor by

overriding the temperature controller trip

mechanism and restore the low pressure

cooling water as quickly as possible.

Damage to the windings may occur if the

cooling water is not restored before themotor temperature rises above 60C.

2) Ensure that the interior of the terminal

box is dry, especially the insulation

projecting over the gland stems.

6.3.6 Vibration NOTE:Before re-starting a circulator after an

emergency shutdown, low pressure cooling

water must be supplied to the pump to

reduce the motor temperature to at least

38C.

Check the circulators for excessive noise or

vibration, which can be either hydraulic or

mechanical in origin.

Vibration should be monitored and recorded

daily. If a permanent vibration transducer is

not installed, check at weekly intervals

using temporary pick-ups. If the reading

increases, check for the following causes: -

6.3.8 High Pressure Purge Supply To

Motor.

On some boiler installations the motor fill

and drain connection may be connected to ahigh pressure cold purge system which can

be used for emergency motor cooling and to

protect the motor during boiler cleaning.

During normal operation this purge supply

must be isolated with a double isolation

valve fitted to the motor, as any leakage or

reverse flow from this point can result in

motor overheating, winding and / or bearing

damage. (Reverse flow totalling no more

than 2 3 litres is sufficient to cause

damage).

a) Cavitation due to low N.P.S.H., asdescribed in 6.3.4.

b) Unequal settings of the discharge

valves. Check and re-set in the fully

open position.

c) Incorrect directional rotation as

described in section 5.2, para. 9.

d) Excessive pipe strain on the pump

casing due to expansion or inadequate

support of pipes. Eliminate any strain

by providing adequate support.

e) Damaged or unbalanced rotor or

impeller, worn bearings, excessiveend float or incorrect impeller setting.

6.4


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SECTION 6

OPERATION

NOTE:If the boiler is laid-up under a nitrogen

blanket, take necessary precautions to

prevent damage to the motor through

gaseous water. Any pump start-up, when

the boiler is in this condition, must be

undertaken and initial start and the full filland vent procedure, as detailed in section

4.7, must be followed.

Continuous purging of the motor during

operation is recommended only during

boiling-out and acid cleaning. A purge rate

of 3.8 litres / min., is normally sufficient to

prevent the ingress of harmful fluids andsolids into the motor.

1) Flush down the fill and purge system to

ensure the line is clean.6.3.10 Boiler Cleaning

2) Check that the low pressure cooling

water supply valves are open.During any boiling-out or acid cleaning

operation of the boiler, the de-energised

circulators must be isolated completely prior

to introducing any chemicals to the boiler.

The circulators must be continuously purged

with clean cool water at a pressure of

approximately 7 bar, in excess of the existing

drum pressure to eliminate infiltration ofcontaminated water into the bearing and

motor components.

3) Introduce high pressure purge through

the filling valves. Check that the purge

temperature does not exceed 49C and

that the purge pressure is above the boiler

pressure.

6.3.9 Extended Shut-Down

When the circulator remains shutdown for

an extended period: -CAUTION

Severe damage can be caused if acid is

allowed to enter the motor. If

contamination from acid cleaning is

suspected, motor must be purged

immediately with clean water and

inspected for damage.

1) Check regularly that it remains full of

water.

2) Run the circulator for a minimum of ten

minutes every two months.

CAUTION

If the motor is to be subjected to extreme

low temperature, the motor must be

prevented from freezing, see section 2.2. (5)6.4 FAULT FINDING

Refer to the fault list chart that follows.

6.5


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OPERATION

Fi ure 6/1 Fault List Chart

6.6


47/109

SECTION 7

MAINTENANCE

7.0

CONTENTS

PARAGRAPH

PAGE

7.1 INTERNAL INSPECTION 7.3

7.2 MOTOR REMOVAL 7.3

7.3 DISASSEMBLY 7.4

7.4 INSPECTION OF COMPONENTS 7.16

7.5 ASSEMBLY NOTES 7.27

7.6 ASSEMBLY 7.29

7.7 RE-INSTALLATION OF MOTOR 7.42

PARTS LIST GENERAL 7.43

ILLUSTRATIONS

FIGURE 7/1 MOTOR REMOVAL 7.2

FIGURE 7/2 MAIN IMPELLER REMOVAL 7.5


FIGURE 7/4 UP - ENDING THE MOTOR 7.7

FIGURE 7/5 TYPICAL WORKING PLATFORM 7.8

FIGURE 7/6 MOTOR COVER AND FILTER REMOVAL 7.9

FIGURE 7/7 THRUST BEARING 7.10

FIGURE 7/8 COVER END JOURNAL BEARING ASSEMBLY - REMOVAL 7.11

FIGURE 7/9 ROTOR ASSEMBLY - REMOVAL 7.12

FIGURE 7/10 TERMINAL GLAND REMOVAL 7.13

FIGURE 7/11 STATOR ASSEMBLY - REMOVAL 7.14

FIGURE 7/12 JOURNAL BEARING TILTING PADS - REMOVAL 7.15

FIGURE 7/13 JOURNAL BEARING CLEARANCE 7.16


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MAINTENANCE

7.1

FIGURE 7/14 JOURNAL BEARING SLEEVE - REMOVAL 7.17

FIGURE 7/15 THRUST BEARING CLEARANCE 7.18

FIGURE 7/16 IMPELLER AND CASE WEAR RING 7.19

FIGURE 7/17 DETAILS OF TAPING HOOK 7.22

FIGURE 7/18 DETAILS OF TAPING NEEDLE 7.22

FIGURE 7/19 OUTER COIL TAPING 7.23

FIGURE 7/20 INNER COIL TAPING 7.24

FIGURE 7/21 TYPICAL KNOT SEALING 7.26

FIGURE 7/22 ASSEMBLY OF FLANGE STUDS 7.27

FIGURE 7/23 WIRE LOCKING 7.28

FIGURE 7/24 JOURNAL BEARING - ASSEMBLY 7.29

FIGURE 7/25 STATOR ASSEMBLY 7.30

FIGURE 7/26 JOURNAL SLEEVE 7.31

FIGURE 7/27 TERMINAL GLAND ASSEMBLY 7.32

FIGURE 7/28A COVER END BEARING ASSEMBLY 7.33

FIGURE 7/28B COVER END BEARING ASSEMBLY 7.33

FIGURE 7/28C COVER END BEARING ASSEMBLY 7.34

FIGURE 7/29 END FLOAT CHECK 7.35

FIGURE 7/30 MOTOR COVER AND FILTER ASSEMBLY 7.37


FIGURE 7/32 TERMINAL LINK INSULATION 7.39

FIGURE 7/33 BURSTING DISC DETAILS 7.40

FIGURE 7/34 IMPELLER SETTING 7.41

FIGURE 7/35 GENERAL ARRANGEMENT 7.47

FIGURE 7/36 SECTIONAL ARRANGEMENT 7.48

FIGURE 7/37 TERMINAL BOX ARRANGEMENT 7.49

FIGURE 7/38 TOOL KIT LIST 7.50


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SECTION 7

MAINTENANCE

7.2

Fi ure 7/1 Motor Removal


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SECTION 7

MAINTENANCE

7.3

NOTE 1:

Some of the illustrations shown are typical

only and not necessarily specific to the

circulator described, i.e. motor proportions

and number of studs etc., but indicate

generally the basis of the unit breakdown.

NOTE 2:

For items not annotated on the drawingswithin the text refer to the Main Sectional

Arrangement at the rear of the Section.

NOTE 3:

A tool kit is supplied with each circulator

contract, containing specialised tools

necessary for the disassembly and assembly of

the motor.

7.1 INTERNAL INSPECTION

Internal inspection of the circulator should becarried out to the recommendation of the station

maintenance authority.

Partial inspection of the internal filter and thrustbearing is possible in-situ after removal of themotor cover.

WARNING:

Inspection must only be carried out with the

circulator isolated from the electrical supply,

depressurised and the motor cover removed

as in Section 7.3.4.

A full inspection requires the motor assembly tobe removed as described below.

7.2 MOTOR REMOVAL (FIG. 7/1)

WARNING:

Before removing the motor, the circulator

must be completely isolated from the system,

depressurised and cooled as described below.

7.2.1 Motor Removal

1) Isolate the electrical supply; disconnect allinstrument cables from the motor identifyingthe connections and leads.

2) Remove the terminal box covers anddisconnect the external power supply cables

from the terminal box as described in 7.3.4,identifying each lead for reassembly.

3) If hoses are not fitted in the low pressurecooling system, adjacent to the heatexchanger, with sufficient slack to allow themotor to be separated from the pump case, fittemporary hoses as follows:-

a) Close the low pressure cooling watershut-off valves.

b) Immediately secure temporary coolingwater hoses to the inlet and outletconnections of the heat exchanger tomaintain a low pressure cooling waterflow within the heat exchanger.

c) Maintain cooling water until the motor isseparated from the pump.

CAUTION:The low pressure cooling water flow, and

motor temperature must be maintained

within the specified limits, whenever the

motor is in contact with the pump case.

4) Check the pressure gauges to ensure that thecirculator is depressurised.

5) Make sure that the discharge valves, thesuction valve, the by-pass valves and theshut-off valves are closed to isolate thecirculator from the boiler and fill system.

6) Drain the pump casing.

WARNING:Never drain the pump casing through the

motor fill & drain line as this could cause

contamination of the motor.

7) Fit the removable lifting lugs to the weldedbrackets on the motor case.

8) Set up two chain hoists and rigging, ofsufficient capacity for each to take the fullweight of the motor, and connect to thelifting lugs.

WARNING:

Normally two hoists are used for removing

the motor and because the load can shiftfrom one hoist to the other during the

removal, each hoist must be capable of

taking the full weight of the motor.

9) Take the initial strain of the motor.

CAUTION:

The motor must be removed from the

pump casing without a break in the

sequence (9) and (11).

10) Loosen the pump/motor flange stud nuts inaccordance with the hydraulic studtensioning instructions - section 8.

CAUTIONAlways double check that the motor and

pump case are cooled and depressurized

before loosening the studs nuts.

11) Disconnect the fill and drain line upstreamof shut-off valve if there is not sufficient playin the line to permit motor removal.


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SECTION 7

MAINTENANCE

7.4

12) Remove the flange stud nuts and lower themotor clear of the pump casing, keeping theflange faces parallel until the impeller isclear of the pump casing.

13) When the impeller is clear of the pump case,check the motor cavity temperature. Whenthe temperature falls below 54

oC remove all

instruments and store safely.14) Lower the motor to the floor.

15) Drain the motor via the drain valve andremove the valve and pipework

16) Remove the heat exchanger from the motor,in accordance with site procedures, asdescribed in 7.2.1.

CAUTION:

To prevent damage never stand or turn

the motor on either the drain valves or

terminal box.

17) Lower the motor to the horizontal positionto give access to the terminal box, removethe lifting tackle and cover all joint faces andopenings with clean rags.

18) If necessary, transport the motor to aworking area where adequate facilities areavailable for disassembly, inspection andmaintenance.

7.2.1 Heat Exchanger Removal

NOTE:

As the heat exchanger is welded to the motor

case via the interconnecting pipework,

removal of the heat exchanger is at the

discretion of, and the procedure will bedetermined by, the senior station engineer.

Check the heat exchanger during the firstmotor maintenance removal for build up ofsediment in the shell base; this will provide aguide to any future attention that may berequired.

7.3 DISASSEMBLYCAUTION:

Lifting tackle must not be attached to the

protruding rotor shaft nor must the shaft be

subject to any shock loads.The motor must be adequately supported

before and during any disassembly.

7.3.1 Case Wear Ring

1) The case wear ring can be left in place,bolted inside the pump case.

2) To remove the wear ring, remove the sixscrews securing the wear ring inside thepump casing. Carefully lower the wear ringfrom its location within the casing.

Lower to ground level, and store in a safeplace for inspection.

7.3.2 Impeller (Fig. 7/2)

1) Unlock the punch marks and remove theimpeller cap screw.

2) Remove the LEFT-HAND threaded impellernut using the special spanner and tommy barprovided in the tool kit.NOTE:

Do not use any leverage in the water

passages of the impeller to oppose force

exerted on the special spanner; the weight

of the rotor will oppose rotation if the

tommy-bar is given a few heavy blowswith a lead faced hammer.

If the nut shows any tendency to seize onthe shaft, do not continue to exert force,

but drill and split the nut to remove.

3) Fit the puller, provided in the tool kit, to thetapped holes in the top of the impeller boss,using the applicable studs and nuts in the toolkit. Withdraw the impeller from the motorshaft.

4) Withdraw the impeller washer and removethe impeller key.

5) Immediately refit a serviceable impeller nutto permanently protect the shaft threads.

7.3.3 Baffle Wear Ring

Examine the baffle wear ring. If damaged,remove the socket headed cap screws and lockwashers. Remove the wear ring for a fullerinspection or renewal

7.3.4 Terminal Boxes (Fig. 7/3)

1) Remove the nuts and washers from the studsand remove the terminal box cover.

2) Remove the nuts and washers from theterminal studs.

3) Identify the motor supply cable links for

reconnection.

4) Carefully cut the insulation from around thecable connections and links.

CAUTION:

Do not damage the link insulation.

5) Remove the washers and the nuts from theterminal stem as the link is removed.


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SECTION 7

MAINTENANCE

7.5

6) Remove the nuts and washers from theterminal box support studs. Using liftingtackle, lift off the terminal boxes and removethe gaskets.

NOTE:

A small metal cover should be fabricated

and placed over the terminal stems to

protect them during motor repair.

Fi ure 7/2 Im eller Removal


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SECTION 7

MAINTENANCE

7.6

Fi ure 7/3 Terminal Box


54/109

SECTION 7

MAINTENANCE

7.7

Fi ure 7/4 U -Endin the Motor


55/109

SECTION 7

MAINTENANCE

7.8

7.3.5 Motor Cover and Filter (Fig. 7/6)

1) Using two cranes and lifting tackle attach onewith shackles to the motor cover and theother via a sling around the motor flangeneck. Lift and up-end the unit as depictedFig. 7/4 until the motor is vertical, with themotor cover uppermost. Lower the motorpump flange on to a suitable building stand;a typical building stand is shownin Fig. 7/5.Support the rotor shaft beneath the standusing a screw or hydraulic jack. Care must betaken to avoid damaging the shaft or flangefaces. If a pit is not available, erect a suitableworking platform, similar to that depicted inFig. 7/5.CAUTION:

Firmly support the impeller end of therotor shaft on a suitable wooden block

when placing the motor on the stand and

jack so that when the thrust nut is

removed during a subsequent operation,

the rotor will be adequately supported.

2) Mark the cover relative to the motor case toensure correct alignment on reassembly.

3) Using the stud tensioning equipment (Section8), release the tension of the motor cover nutsand remove the nuts.

4) Attach the lifting tackle and carefully remove

the motor cover from the motor case.5) Remove the flexitallic spiral wound gasket

and before discarding, inspect the gasket forany unusual markings or depressions thatindicate a seat dressing is required.

6) Remove the filter by removing the hexagon-headed screws and lock washers.

Figure 7/5 Typical Working Platform


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SECTION 7

MAINTENANCE

7.9

Fi ure 7/6 Motor Cover and Filter Removal


57/109


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SECTION 7

MAINTENANCE

7.11

7.3.7 Cover End Journal Bearing

Assembly (Fig. 7/8)

1)

a) Remove the locking wire and the stator

lock ring hexagon headed screws.b) Push down the stator lock ring sufficiently

to permit split ring to be prised out of itsgroove.

c) Remove the split ring from its casinggroove, using screwdrivers as levers.

d) Withdraw the stator lock ring, usingscrews as lifters, from the motor case.

2) Match-mark the cover end bearing housingand the motor case to ensure that they are re-fitted in their original radial location.

3) Remove the bearing housing securing screws

and lock washers.4) Attach eyebolts and lifting tackle to the cover

end bearing housing and lift the housing,complete with the journal bearing assembly,to just above the motor casing.

5) Lower the bearing housing and remove anddiscard the `O` ring.

6) Place the housing in a clean and safe placefor subsequent disassembly.

Fi ure 7/8 Cover End Journal Bearin Assembl - Removal


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SECTION 7

MAINTENANCE

7.12

7.3.8 Motor Shaft (Fig. 7/9)

1) Fit an eyebolt, supplied in the tool kit, andlifting tackle to the rotor shaft as indicated.With an exact vertical lift, slowly lift therotor out of the stator, taking particular carenot to damage the cable ends whilst doing so.

2) Lower the rotor into the horizontal positionand position it carefully on to wooden 'V'blocks at floor level. Fit suitable protection,i.e. clean rags, over the journal sleeves. Refitthe thrust nut to protect the threads.

7.3.9 Terminal Gland Removal (Fig. 7/10)

1) To facilitate re-assembly, identify eachterminal stem body and its respectiveposition.

CAUTION

Make sure that the gland moulding doesnot turn with the gland nut by holding the

moulding stationary using a clamp

connector and the connecting link.

2) Remove the nuts and link from the terminalblock. Unscrew the gland nut and tap theconnector lightly until the gland assemblycan be carefully drawn out of the motor case.

3) Remove the gland nuts from two of the stemsand placed on the third stem.

4) Replace the clamp connector over this stemand undo the cable gland nut. This actionwill draw the gland assembly from the motorcase.

5) Remove the inner casing & the C shapedsupport ring. The two belleville washers andback up sleeve remain on the cable.

NOTE:

The terminal gland stems are

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CC Pump Manual-Full (Original)