TORISHIMA

Boiler Circulation Pumps

HLAV
Contents

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


Training course 2
Installation & commissioning
3.1 Lifting Motor set
Do not remove temporary covers !
Motor assembly : Approx. 7,300 kg
Transport motor set as shown below
Prepare to lift and install motor set
Do not damage motor set !
Lift motor unit carefully
3. Motor Set Installation
Use Chain-block 10tons/2 sets for lifting up & down
Remove temporary cover before motor set
installation, use 1ton Chain Block
Inspect casing and heat barrier sealing
faces and set spiral wound gasket on heat
barrier before motor set installation
Pump casing
Motor set
Sealing face of Pump casing
Bolts
Bottom
3. Pump/Motor Set Installation
3.1 Lifting Motor set
Determine Initial Tightening Starting Position
Measure dimensions B & C at 4 points using
depth gauge and micrometer.
3.1 Lifting Motor set into Pump casing
Calculate starting distance between pump
casing and motor flange (A) by formula
Initial Tightening Starting Position A=C-B+1.6mm
Record dimensions (A, B, C)
Paint bolt numbers on both pump casing and
motor flange (1-16)
Strip paint from a suitable part for micrometer
head at 4 points on bolt pitch-circle ( shown by
arrows in fig. )
Paint bolt numbers
3. Motor Set Installation
3. Motor Set Installation
CAUTION While Lifting Motor set
3.1 Lifting Motor set into Pump casing
Stop Lifting Motor set at the position
Impeller approaches Wearing Ring . Fig1.
Measure 4 points of distance A and adjust
till value of A is same at all points
Lift Motor set slowly by measuring distance
A for the 4 points and carefully operating 2
chain blocks at the same time till Impeller is
positioned into Wearing Ring smoothly as in
Fig2. Initial tightening distance A shall be
followed in item 3.3.
Stop Lifting Motor set in case the Impeller
touches Wearing Ring during lifting, then lift
down Motor set and inspect Impeller & wearing
ring for damage. Repeat lifting and setting by
to properly.
Fig.2
A
Fig.1
A
Coat molybdenum sulfide on
threads of each stud bolt and
mating surface of each washer
Locate washers, and screw nuts onto stud bolts
The head of each stud bolt is to
protrude approx.170mm from motor
flange !
Pump casing
Stud bolt
3-2 Setting Nuts/Washers to Stud Bolts
170mm
3. Motor Set Installation
3.3 Tightening the Stud Bolts
Measure each distance (A) by inside micrometer and confirm the
tolerance is less than or equal to 0.05mm
Mark each nut and motor flange
Nut Scale Division
Mating Mark
3. Motor Set Installation
3.4 Tightening by Bolt Heaters
Confirm that power source is off, then
connect cable to switch box.
Insert a bolt heater into each of 16 stud bolts
Switch on every second bolt heater (1
st
group)
(8 heaters : No.1,3,5,7,9,11,13,15)
Confirm that every second stud bolt is heated
Surface temperature of stud bolts
should not exceed 300 deg.C !
Monitor temperature using a temperature
crayon or surface thermometer
Motor
flange
Stud
bolt
Be careful
of burns !!
3. Pump/Motor Set Installation
23 scale divisions
Switch on first set of 8 bolt heaters to heat up
first 8 stud bolts, then tighten respective nuts by
further 14 scale divisions for a total of 34 scale
divisions. (No.1,3,5,7,9,11,13,15)
3.4 Tightening by Bolt Heaters
Tighten 20 scale divisions first
Switch off bolt heaters and cool
down stud bolts to approx.60 deg. C
Switch on bolt heaters for remaining 8 stud bolts.
Tighten these 8 nuts by 34 scale divisions.
(2
nd
group : No. 2,4,6,8,10,12,14,16)
Switch off bolt heaters and cool
down stud bolts to approx.60 deg. C
After all stud bolts cool down to room temperature,
measure flange to flange distance A at 4 points within
0.05mm. Record the measurements.
20
34
0
Bolt layout
14
3. Motor Set Installation
3.5 Installation of HP Motor cooler
Clean Motor Cooler by water flushing and seal
face of each welded sockets before welding work
Carry proper socket welding to position:
after confirming Motor cooler & HP piping position
Inspect each welded HP connection by PT
Clean LP cooling water piping line to Motor
cooler and carry welding socket connections
Confirm final tightening of bolts (mark ) for
Motor cooler support.
Install the instruments for each position.
3. Motor Set Installation
In case of BHEL
design, these
should be welding
connection
Check water quality and filling rate; Max.5L/min.
Valve1
from BCP purge water cooler
4. Commissioning and Start up
Drain Valve
Fill the water until the quality is
clear and colorless
Close drain valve
Point !
Do not open the drain valve once start
the water filling to the motor
4.1 Priming and venting
Close valve1 and open drain valve fully
4.1 Priming and venting
Open valve 2&3, related air venting
valves fully and open valve1 slowly
Valve2
Valve1
from BCP purge water cooler
4. Commissioning and Start up
Point 2
Priming and Flushing must always be carried
out from the motor bottom to upwards
PI
Point 1
Air shall be removed from motor
Drain valves
shall be closed
Valve3
Check valve2 : Flow rate from
valve1 is max. 5L/min.
Priming Flushing
4.2 Pre Operational Check Items
Operational check items to be monitored
- Temperatures
- Cooling water flow
- Ammeters at switch gear room
- All Motor protection switches
Confirm water filling
Confirm correct direction
Measure insulation resistance
4. Commissioning and Start up
4.2 Pre Operational Check Items
To confirm quantity of LP cooling water
To confirm Motor Cavity temp is below 63 deg. C
To check water level in drum
To complete motor flushing cleaning
To assure pressure tight seals
Need to check Item , ,
in routine starts !
LP : Auxiliary cooling water
HP : High pressure cooling water
in Motor
4. Commissioning and Start up
(1) Drum water level
(2) Differential pressure
(3) Motor current at switch gear room Refer to Data sheet
(4) Motor Cavity temperature 63 deg.C
(5) LP Cooling water flow rate
- Cooler : 150L/min.
- Heat barrier : 30L/min.
(6) LP Cooling water temperature
generally 45 deg. C
(7) Smooth
running or
not
5. Supervision during operation
5.1 At operating
Refer to Data
sheet or P&ID
Maintain the following condition until the boiler water is below 63 deg. C !
(8) LP Cooling water flow
(9) LP Cooling water temperature
(10) Motor Cavity temp.
5. Supervision during operation
5.2 At stopping (after switched off)
1. Daily inspection check items
No.
Inspection point Inspect. Item Method Criteria Note
1 Suction tank Water level Level detector Min. Water
Level
Daily
2 Pump suc. & dis. pipes Pump differential press.
(During operation)
Pressure gauge Specified
head
Daily
3 Power supply Motor current Current meter Specified
current
Daily
4 Motor cavity HP cooling water temp. Temp. detector Below 63 deg.
C
Daily
5 Motor cooler
LP cooling water outlet
LP cooling water temp. Temp. detector Max. 45 deg.
C
Daily
LP cooling water quantity Flow switch Refer to Data
sheet
Daily
6 Heat barrier
LP cooling water outlet
LP cooling water temp. Temp. detector Max. 45 deg.
C
Daily
LP cooling water quantity Flow switch Refer to Data
sheet
Daily
7 Pump motor Abnormal noise or
vibration
- No
abnormality
Daily
8 HP cooling water lines Leak Visual No leak Daily
(Important)
9 LP cooling water lines Leak Visual No leak Weekly
Recommended inspection;
2. Annual or monthly inspection check items
No.
Inspection
point
Inspect. Item
Method Criteria Note
1 Motor terminal
box
Insulation
resistance
Megger meter
At cold water filling
(at approx. 20deg.C)
At hot stand-by
(at approx. 50deg.C)

200 Mega-
ohm or more.
4 Mega-ohm
or more.
Annual
stage
2 Stand-by pump Start up check Start up stand-by pump No
abnormality
Monthly
No.
Inspection
point
Inspect. Item
Method Criteria Note
1 Pump motor Overhaul Overhaul at
Torishima Works
Instruction
manual
First 1 year
and
thereafter
every 4-
5years
3. Overhaul inspection check items
Recommended inspection;
Disconnect the power cable