TORISHIMA Boiler Circulation Pumps HLAV

Training course 2 Installation & commissioning Contents

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

3. Motor Set Installation 3.1 Lifting Motor set

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 Do not remove temporary covers !

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

3. Pump/Motor Set Installation 3.1 Lifting Motor set

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
Bottom Bolts

Pump casing

Motor set

Sealing face of Pump casing

3. Motor Set Installation

3.1 Lifting Motor set into Pump casing

Paint bolt numbers

Determine Initial Tightening Starting Position Measure dimensions B & C at 4 points using depth gauge and micrometer. 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. )

3. Motor Set Installation 3.1 Lifting Motor set into Pump casing
CAUTION While Lifting Motor set 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.
A

Fig.1

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

3. Motor Set Installation

3-2 Setting Nuts/Washers to Stud Bolts
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

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

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

Mating Mark

Nut Scale Division

3. Pump/Motor Set Installation 3.4 Tightening by Bolt Heaters

Confirm that power source is off, then connect cable to switch box.

Motor flange

Stud bolt

Insert a bolt heater into each of 16 stud bolts Switch on every second bolt heater (1st 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

Be careful of burns !!

3. Motor Set Installation 3.4 Tightening by Bolt Heaters

Tighten 20 scale divisions first Bolt layout

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. (2nd group : No. 2,4,6,8,10,12,14,16) Switch off bolt heaters and cool down stud bolts to approx.60 deg. C 34 20 14 0

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

23 scale divisions

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.
In case of BHEL design, these should be welding connection

4. Commissioning and Start up

4.1 Priming and venting
Close valve1 and open drain valve fully
Check water quality and filling rate; Max.5L/min. Fill the water until the quality is clear and colorless Point !
Do not open the drain valve once start the water filling to the motor

Close drain valve

from BCP purge water cooler

Valve1

Drain Valve

4. Commissioning and Start up

4.1 Priming and venting
Open valve 2&3, related air venting valves fully and open valve1 slowly Check valve2 : Flow rate from valve1 is max. 5L/min.
Valve2

Point 1 Air shall be removed from motor Priming Flushing

PI
Valve3

Point 2 Priming and Flushing must always be carried out from the motor bottom to upwards
Valve1
from BCP purge water cooler

Drain valves shall be closed

4. Commissioning and Start up

4.2 Pre Operational Check Items
Confirm water filling Measure insulation resistance Confirm correct direction
Operational check items to be monitored - Temperatures - Cooling water flow - Ammeters at switch gear room - All Motor protection switches

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

5. Supervision during operation 5.1 At operating (4) Motor Cavity temperature 63 deg.C
(1) Drum water level (5) LP Cooling water flow rate - Cooler : Refer 150L/min. to Data - Heat barrier : 30L/min. sheet or P&ID

(2) Differential pressure

(6) LP Cooling water temperature generally 45 deg. C (7) Smooth running or not

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

5. Supervision during operation 5.2 At stopping (after switched off)

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.

Recommended inspection;

1. Daily inspection check items

No.
1 2 3 4 5

Inspection point
Suction tank Pump suc. & dis. pipes Power supply Motor cavity Motor cooler LP cooling water outlet

Inspect. Item
Water level Pump differential press. (During operation) Motor current HP cooling water temp. LP cooling water temp.

Method
Level detector Pressure gauge Current meter Temp. detector Temp. detector

Criteria
Min. Water Level Specified head Specified current Below 63 deg. C Max. 45 deg. C

Note
Daily Daily Daily Daily Daily

LP cooling water quantity

6 Heat barrier LP cooling water outlet LP cooling water temp. LP cooling water quantity 7 8 9 Pump motor HP cooling water lines LP cooling water lines Abnormal noise or vibration Leak Leak

Flow switch
Temp. detector Flow switch Visual Visual

Refer to Data sheet

Max. 45 deg. C Refer to Data sheet No abnormality No leak No leak

Daily
Daily Daily Daily Daily (Important) Weekly

Recommended inspection;

2. Annual or monthly inspection check items

No.

Inspection point
Motor terminal box

Inspect. Item
Insulation resistance

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

Criteria

Note
Annual stage

Disconnect the power cable

200 Megaohm or more. 4 Mega-ohm or more. No abnormality

Stand-by pump

Start up check

Monthly

3. Overhaul inspection check items

No.

Inspection point
Pump motor

Inspect. Item Overhaul

Method
Overhaul at Torishima Works

Criteria
Instruction manual

Note
First 1 year and thereafter every 45years