30621127-000-3DT-00007-002

8/12/2019 30621127-000-3DT-00007-002

1/44

Project Title

Client

Consultant

Contractor

REV DATE BY DESCRIPTION CHKD. CERT. APPD.

CONVERSION OF QURAYYAH OPEN CYCLE POWER

PLANT TO COMBINED CYCLE POWER PLANT

PROJECT C

S.H.Y

000 6-Sep-11 H.I ISSUE FOR INFORMATION D.AOKI T.FUKIDA

001 18-Apr-12 M.KIDO ISSUE FOR APPROVAL W.O.P G.B.B

002 8-Jul-12 W.O.P ISSUE FOR INFORMATION W.O.P J.B.K S.H.Y

Document Title

CREATED BY: CHECKED BY:

DATE STARTED: DATE COMPLETED:

OPR'G. DEPT.: ENG. DEPT.:

DOC. NO. REV. NO.

QURAYYAH SAUDI ARABIA

THIS DOCUMENT IS NOT TO BE USED FOR

CONSTRUCTION OR FOR ORDERING

MATERIAL UNTIL CERTIFIED AND DATED

APPROVAL/CERTIFICATION INFORMATION

JOB ORDER NO.

30621127 000 3DT 00007 002

JOB NO. PROJECT SUBDIVISION DOCUMENT TYPE CODE DOCUMENT NUMBER REV. NO.

1-0923053.01

OPERATIONS MANUAL FOR CONDENSATE EXTRACTION PUMP (Vol-I)

30621127-000-3DT-00007-002_1 of 44

8/12/2019 30621127-000-3DT-00007-002

2/44

MESSRS. :

PROJECT :

PRODUCT No. : )

TYPE & SIZE : )

SERVICE : )

3

2 2012/04/16 D.Aoki M.Kido

1 2012/02/01 D.Aoki M.KidoREV.No. DATE CH'D DR'N APPROVED CHECKED DRAWN

1

1 DWG. No.REV.

1 2G305751-1/147

T.Fukuda

D.Aoki M.Kido 10.Feb.2011

D

ISTRI-

B

UTION

Revised T.Fukuda 1-1-8 Miyata Cho, Takatsuki City, Osaka, Japan

DESCRIPTION APP'D DATE

MMTV200/4

Condensate Extraction Pump

TORISHIMA PUMP MFG. CO. LTD.Revised T.Fukuda

Doosan Heavy Industries & Construction Co., LTD

Qurayyah Combined Cycle Project

AP9332019,27,35,43,51

OPERATION AND MAINTENANCE MANUAL

30621127-000-3DT-00007-002_2 of 44

Operations Manual

8/12/2019 30621127-000-3DT-00007-002

3/44

Table of Contents

Table of Contents

MESSRS DRAWING NO.

DRAWING NO. G305751-2/147

1. Introduction ............................................................................................ 32. Safety Precautions ................................................................................. 5

2.1 Warning Signs ............................................................................................................................. 52.2 General Precautions .................................................................................................................... 6

3. Installation .............................................................................................. 73.1 Foundation ................................................................................................................................. 10

3.1.1 Installation Flow ........................................................................................................ 103.1.2 Lifting ........................................................................................................................ 133.1.3 Foundation Work ...................................................................................................... 14

3.2 Equipment Installation ............................................................................................................... 20

3.2.1 Installation ................................................................................................................ 203.2.2 Alignment ................................................................................................................. 253.2.3 Installation of Accessories ........................................................................................ 293.2.4 Check Items at the Completion of Equipment Installation ......................................... 29

3.3 Piping and Wiring ...................................................................................................................... 31

3.3.1 Piping Installation ..................................................................................................... 313.3.2 Wiring ....................................................................................................................... 313.3.3 Check Items at the Completion of Piping and Wiring ................................................ 31

4. General Description and Structure of Equipment .................................. 324.1 General Description of Pump .................................................................................................... 32

4.1.1 General .................................................................................................................... 324.2 Structure of Pump ...................................................................................................................... 32

4.2.1 Casing ...................................................................................................................... 324.2.2 Impeller .................................................................................................................... 334.2.3 Shaft ......................................................................................................................... 33

4.2.4 Shaft Seal ................................................................................................................. 334.3 General Description of Motor .................................................................................................... 344.4 General Description of Auxiliary Equipments ............................................................................ 34

4.4.1 Rigid Coupling .......................................................................................................... 344.4.2 Suction Strainer ........................................................................................................ 34

5. Operation Procedure ............................................................................ 355.1 Operation Flow .......................................................................................................................... 36

5.1.1 Commissioning Flow ................................................................................................ 365.1.2 Normal Operation Flow ............................................................................................. 38

5.2 Operation Procedure ................................................................................................................. 395.2.1 Preparation and Check before Commissioning ......................................................... 395.2.2 Preparation before Priming ....................................................................................... 40

5.2.3 Priming and Venting ................................................................................................. 405.2.4 Check before Start-up ............................................................................................... 405.2.5 Start-up ..................................................................................................................... 405.2.6 Check after Start-up (at the Minimum Flow Operation) ............................................. 405.2.7 Minimum Flow Operation .......................................................................................... 415.2.8 Putting the Pump from Minimum Flow Operation into Normal Operation .................. 415.2.9 Check during Normal Operation ............................................................................... 415.2.10 Shutdown (to Standby State) .................................................................................. 425.2.11 Emergency Shutdown (to Inspection and Maintenance) ......................................... 42

6. Maintenance, Disassembly and Assembly ........................................... 436.1 Maintenance .............................................................................................................................. 44

6.1.1 Periodic Inspection ................................................................................................... 446.2 Disassembly .............................................................................................................................. 44

30621127-000-3DT-00007-002_3 of 44

8/12/2019 30621127-000-3DT-00007-002

4/44

Table of Contents

Table of Contents

MESSRS DRAWING NO.


6.2.1 Disassembly Tools and Others ................................................................................. 446.2.2 Disassembly of Pump ............................................................................................... 45

6.3 Inspection .................................................................................................................................. 47

6.3.1 Clearance Check ...................................................................................................... 476.3.2 Checking Runout of Shaft ......................................................................................... 47

6.3.3 Mechanical Seal ....................................................................................................... 476.3.4 Impeller .................................................................................................................... 486.3.5 Casing ...................................................................................................................... 486.3.6 Replacing Casing Wearing Ring ............................................................................... 486.3.7 Dynamic Balance ..................................................................................................... 49

6.4 Assembly ................................................................................................................................... 51

6.4.1 Precautions for Assembly ......................................................................................... 516.4.2 Reassembly.............................................................................................................. 51

7. Troubleshooting.................................................................................... 558. Storage ................................................................................................ 58

8.1 Storage Area .............................................................................................................................. 58

8.2 Storage Management ................................................................................................................ 588.2.1 Management during Storage .................................................................................... 588.2.2 Installation in Storage Area ....................................................................................... 598.2.3 Protection during Storage ......................................................................................... 598.2.4 Maintenance during Storage ..................................................................................... 618.2.5 Maintenance during Long-Term Storage ................................................................... 61

Attachment ............................................................................................... 62Service Network ......................................................................................143

30621127-000-3DT-00007-002_4 of 44

8/12/2019 30621127-000-3DT-00007-002

5/44

1. Introduction

MESSRS DRAWING NO.


1. Introduction

This manual describes the installation and operation methods for the vertical multistagepump in detail.

To install the pump, please read and fully understand the descriptions given in Chapter 3of this manual with enough reference to the relevant drawings beforehand.

As for the operations of the pump, Chapter 5 describes the operation procedure andChapter 6 describes the maintenance and disassembling/assembling of the pump. Inorder to use the pump safely for a long time, it is necessary to fully understand thestructure of the pump and its operation/maintenance practice.

This manual also describes the safety precautions and operations necessary for theoperator. The operator shall read the manual thoroughly before starting the operation ormaintenance of the pump.

In addition, always keep this manual at hand so that anyone who uses or maintains thepump can read it at any time.

Note that any failure caused by a deviation from the instructions of this manual or anytrouble caused by the situations described below is not covered by the warranty of ourcompany.

1) When the liquid which does not meet the ordered specifications (including quality,

density, temperature, and impurity or foreign objects contamination) is pumped up, or

when the pump is operated beyond its specified performance characteristics (e.g.,

when the pump is operated with excessively large or small flow rate of liquid, or with

an inadequate suction condition).

2) Damages or defects caused by not following the instructions given in this manual, in

other words, improper use or operation, wrong installation, use of inappropriate

materials (e.g. use of inappropriate type of lubricant agent), wrong or incomplete

piping, etc.

3) Disassembly and assembly given in Chapter 6 require enough knowledge about our

pumps, judgments based on experience, and enough experience and practice about

practical work. Thus we recommend that pump is disassembled and assembled in

our factory or that our supervisor is dispatched for advice.Please understand that any failure of pump disassembled or assembled by the

customer alone, even if based on this manual, can not be guaranteed by us.

30621127-000-3DT-00007-002_5 of 44

8/12/2019 30621127-000-3DT-00007-002

6/44

1. Introduction

MESSRS DRAWING NO.


If you have any question regarding our products, please give us the following informationto ensure prompt attention:

(1) Product No. (six-digit figure following AP, P, KP, etc.)

(2) Type and Size

(3) Item No.

The information above is provided in the name plate attached to the pump body.When ordering spare parts, please also inform us of the part numbers and names of theparts. (Refer to the "Sectional Drawing" of the pump.)

30621127-000-3DT-00007-002_6 of 44

8/12/2019 30621127-000-3DT-00007-002

7/44

2. Safety Precautions / 2.1 Warning Signs

MESSRS DRAWING NO.


2. Safety Precautions

2.1 Warning Signs

The warning levels and signs used in this manual are described as follows.

DangerThis indicates a potential danger that may result in death or serious injury of theoperator.

WarningThis indicates a potential danger that may result in serious injury of the operator ordamage of the equipment.

CautionThis indicates a potential danger that may result in injury of the operator or malfunctionand/or performance degradation of the equipment.

Note: This provides important information for understanding and operating theequipment.

30621127-000-3DT-00007-002_7 of 44

8/12/2019 30621127-000-3DT-00007-002

8/44

2. Safety Precautions / 2.2 General Precautions

MESSRS DRAWING NO.


2.2 General Precautions

The general precautions for the equipment are given below. Read these precautionsbefore actually starting work to ensure safe operation.

Danger

Never allow any person other than service engineers to engage in disassembly, repairor remodeling work.

Never work alone.

Make sure to put on helmet, safety goggles, earplugs, safety shoes and otherprotective items when working.

Make sure that there are no dangers of fire and explosion hazards, before carrying outany work involving sparks such as welding.

Make sure that the liquid in the casing has been discharged thoroughly when thepumped-up liquid is a chemical solution. A chemical solution may lead to injuries whenget in touch with the human body.

Make sure to conduct checking of crane and slinging equipment such as wire ropeunfailingly, before starting of work.

When lifting heavy objects, use chain blocks, hang ropes, etc. as specified in themanual.

Never work under lifted objects.

Make sure to turn off the motor switch and affix "Do not power on" tag to the switch inorder not to turn it on by mistake before starting any work involving touching the rotor.

Do not open the terminal cover of electric equipment such as a motor during

power-on. Otherwise, the workers might be seriously injured due to an electric shock.Make sure that the power is off and take preventive measures for powering on bywrong operation.

Select proper lifting tools depending on the weight of the object to lift.

Warning

Install a safety fence around the work area and ensure evacuation routes.

When there is a risk of freezing, completely drain the pump.

CautionIf oil spills on the floor or passage, immediately wipe it off. Otherwise, it may lead to a

slip and fall accident.

Read the related documents and drawings carefully before starting work tounderstand the structure of the pump and make the necessary preparations.

Note: Always observe all the appropriate rules and regulations for safe installationand operation of the pump.

If there is a serious mechanical damage, please contact us for advice.

30621127-000-3DT-00007-002_8 of 44

8/12/2019 30621127-000-3DT-00007-002

9/44

3. Installation

MESSRS DRAWING NO.


3. Installation

Precautions for Installation

1) General

DangerNever allow any person other than service engineers to engage in disassembly, repair

or remodeling work.

Never work alone for your safety.

Work under the control of the safety manager on-site.And, make sure to put on helmet, safety goggles, earplugs, safety shoes and otherprotective items when working.

Make sure that there are no dangers of fire and explosion hazards, before carrying outany work involving sparks such as welding.

Make sure that the liquid in the pump has been discharged thoroughly when thepumped-up liquid is a chemical solution. A chemical solution may lead to injuries whenget in touch with the human body.

Make sure to conduct checking of crane and slinging equipment such as wire ropeunfailingly, before starting of work.

When lifting heavy objects, hang ropes as specified in the manual.

Never work under lifted objects.

Make sure to turn off the motor switch, and affix "Do not power on" tag to the switch ortake other preventive measures in order not to turn it on by mistake before starting

any work involving touching the rotor.Do not open the terminal cover of electric equipment such as a motor during

power-on. Otherwise, the worker may get seriously injured due to an electric shock.Make sure that the power is off and take preventive measures for powering on bywrong operation.

Select proper lifting tools depending on the parts mass and shape of the object to lift.

In a pit or a manhole where toxic gas may be generated or hypoxia may occur, checkthe place for safety before starting work.

Warning

Before unpacking the pump or pump parts, check the unpacking area for any obstacleetc. that may lead to serious damage during unpacking. Remove such obstacle etc.beforehand, if any.

30621127-000-3DT-00007-002_9 of 44

8/12/2019 30621127-000-3DT-00007-002

10/44

3. Installation

MESSRS DRAWING NO.


2) Before Installation

Caution

When unpacking, take care not to damage the pump and its accessories.

Before unpacking after a long storage period, perform the following checks for eachpart and make sure that it is serviceable. If any defective parts are found, they need tobe replaced with new ones or they may be used without replacement after consultingwith our company.

(a) Check the contents and the number of pieces in the package against thepacking list.

(b) Check that the equipment is not damaged during storage.(c) Check the painted surfaces of the equipment.

After unpacking, take care to prevent rust on the equipment for the period frominstallation to starting operation. Especially, pay enough attention to couplings andbearings.

Read the related drawings and this manual carefully before starting work tounderstand the structure of the pump and make the necessary preparations.

30621127-000-3DT-00007-002_10 of 44

8/12/2019 30621127-000-3DT-00007-002

11/44

3. Installation

MESSRS DRAWING NO.

DRAWING NO. G305751-10/147

3) During Installation

Caution

Pump foundation and installation works shall be performed in view of ensuringsmooth operation of the pump and preventing the shock and vibration caused by thepump operation from being transmitted to neighboring facilities.

If you want to install the pump in a method other than that specified in this manual,please consult us before using such method.

When lifting the product, take the following precautions.

(a) When lifting heavy parts such as a pump, pay careful attention so that thewire rope does not slip.

(b) When lifting a part with wire rope, place some soft pads between the partand the wire rope to protect the painted or machined surface from the wirerope. Do not raise or lower the parts rapidly with a crane.

(c) When placing a part on the ground, put a protection support between the

part and the ground.(d) When lifting a pump, take care not to bump it against the ground.

Remove the cover from each pump part and remove antirust coating, which wasapplied for rust prevention during transportation, with industrial cleaning agent (orthinner) before assembly. Remove all foreign objects from tapped holes withcompressed air.

Check that there is no rust, dust or protuberance on the flange or mounting surfacebefore assembling each part.

Be careful not to drop tools and the parts into the pump and the barrel. If they aresucked into the pump, the rotating element, the casing and the impeller will bedamaged.

Check that all the bolts for flanges or other parts are fully and evenly tightened.

Take care to prevent rust on each part before starting operation.

Touch up the coated surface which has been damaged or coming off during assemblywith refinish paint.

Check that there are no foreign objects in the auxiliary piping. Clean it completelybefore connecting to the pump.

30621127-000-3DT-00007-002_11 of 44

8/12/2019 30621127-000-3DT-00007-002

12/44

3. Installation / 3.1 Foundation

MESSRS DRAWING NO.

DRAWING NO. G305751-11/147

3.1 Foundation

In this section, the foundation part to install the equipment is described in detail. A barreland foundation bolts are installed over the foundation. The liners that are buried under the

barrel support the mass of the pump, the barrel, the electric motor and the water in thepump and the barrel. Work after understanding this section enough to make satisfactoryfoundation.

3.1.1 Installation Flow

The installation flow is shown in the figure below. Also the referential sections areindicated in the lower right of boxes in the figure.

Fig. 3.1-1 Installation Flow (1/3)

Check the dimensions of foundation from the datum line.(Floor level, dimension of foundation bolt holes, etc.)

3.1.3 Foundation Work 1) Preparation for Installation

Chip the surface of foundation(concrete).

3.1.3 Foundation Work 2) Installation of Temporary Liners

Mark the centerline of pump, the height of foundationand the position of foundation bolts.

3.1.3 Foundation Work 1) Preparation for Installation

Set the temporary liners on thefoundation.


3.2.1

1) Installation of Barrel

3.2.1 2) Temporary Installation of Barrel, Setting ofFoundation Bolt (The First Filling of Mortar)

Install the barrel temporarily.

Adjust temporarily the levelnessof the barrel.

3.2.1

2) Temporary Installation of Barrel, Setting ofFoundation Bolt (The First Filling of Mortar)

A

Make a mortar wall.


30621127-000-3DT-00007-002_12 of 44

8/12/2019 30621127-000-3DT-00007-002

13/44


MESSRS DRAWING NO.

DRAWING NO. G305751-12/147


Is the level withinthe tolerance?

Yes

Adjust with the taper liner.No

3.2.1

2) Temporary Installation of Barrel, Setting of

Foundation Bolt (The First Filling of Mortar)

Once lift up the barrel andset the final liners.

3.2.1

3) Setting of Final Liners

Fill the foundation bolt hole withmortar. (First Filling with Mortar)

3.2.1

2) Temporary Installation of Barrel, Setting ofFoundation Bolt (The First Filling of Mortar)

Install finally the barrel and adjust itslevelness.

3.2.1 4) Final Installation of Barrel

Is the level withinthe tolerance?

Yes

Adjust with the taper liner.No

A

3.2.1 4) Final Installation of Barrel

3.2.1

4) Final Installation of Barrel

Fasten the foundation bolts.

3.2.1


Spot weld the flat liners andtaper liners.

3.2.1

5) Fixing of Liners

Assemble theframe.

3.2.1

6) The Second Filling of Mortar

B

30621127-000-3DT-00007-002_13 of 44

8/12/2019 30621127-000-3DT-00007-002

14/44


MESSRS DRAWING NO.

DRAWING NO. G305751-13/147


Fill the foundation with mortar.(Second Filling of Mortar)

3.2.1 6) The Second Filling of Mortar

Remove theframe.

Install the pump and motor.

3.2.1

7) Installation of Pump Body

3.2.2 Alignment 2) Alignment of Coupling (temporary alignment)

Make a preliminary alignment.3.2.2 Alignment 2) Alignment of Coupling (temporary alignment)

Is the alignmentwithin the tolerance?

Yes

NoAdjust with the motor liners.

3.2.2 Alignment 2) Alignment of Coupling (Temporary Alignment)

Install the main piping.

3.2.1 7) Installation of Pump Body

3.3.1 1) General, 2) Main Piping

Make final alignment.

3.2.2 Alignment 4) Coupling Alignment (Final Alignment)

Is the alignmentwithin the tolerance?

Yes

NoAdjust with the motor liners.

3.2.2 Alignment 3) Allowable Value of Alignment

Check the fastening state of the foundation bolts again.

Install the auxiliary piping and the accessories.

3.2.3 Installation of Accessories /3.3.1 Piping Installation 3) Auxiliary Piping / 3.3.3 Wiring

B

30621127-000-3DT-00007-002_14 of 44

8/12/2019 30621127-000-3DT-00007-002

15/44


MESSRS DRAWING NO.

DRAWING NO. G305751-14/147

3.1.2 Lifting

Use a crane to lift and move the pump unit. Attach a wire rope or a sling belt to the pumpunit as shown in Fig. 3.1-2. When using a wire rope, protect the painted surface of the

pump unit with a soft cloth etc.

WarningSurely, lift individually the electric motor, the motor stool, the pump body and the barrel.The lifting holes of each part are designed based on only each individual mass.Therefore, lifting these parts in a combined condition (e.g. the electric motor and motorstool, the motor stool and pump body, etc.) may cause the breakage of attaching boltsor the drop of lifted parts.

Select appropriate lifting tools including a crane by considering pump mass and workingspace. Before each lifting operation, check that lifting tools are firmly attached to ensure

safety.

DangerDo not work under lifted objects.

Refer to the following figures (Fig. 3.1-2) for lifting the pump unit and equipment.Also refer to the "G. A. Drawing" for the mass of equipment.

30621127-000-3DT-00007-002_15 of 44

8/12/2019 30621127-000-3DT-00007-002

16/44


MESSRS DRAWING NO.

DRAWING NO. G305751-15/147

Fig. 3.1-2 Lifting Typical Parts of Pump System

3.1.3 Foundation Work

1) Preparation for Installation

(1) Mark the datum line and bench marks for installation on a stable surface which does

not sink or slide during the installation work.

(2) Check that the levelness of pump floor and the dimensions of foundation bolt holes are

as specified in the "G. A. Drawing".

(3) Mark the centerline of pump, the height of foundation and the positions of foundation

bolts according to the "G. A. Drawing".

(4) Clean the concrete surface and foundation bolt holes to remove all foreign objects.(5) Degrease the concrete surface and the foundation bolt holes.

Barrel

Pump BodyElectric Motor

30621127-000-3DT-00007-002_16 of 44

8/12/2019 30621127-000-3DT-00007-002

17/44


MESSRS DRAWING NO.

DRAWING NO. G305751-16/147

2) Installation of Temporary Liners

(1) Heap up mortar for temporarily-adjusting liners on the installation surface of the pump

floor. Set up temporarily-adjusting liners at about four, evenly-distributed places.

Note: The number of temporarily-adjusting liners may vary if the required levelnessof the barrel is obtained.For a smaller pump, three temporary liners will do. Reversely, for a largerpump, use about six temporarily-adjusting liners for the temporary installation.

Set up the temporarily-adjusting liners at the in-between spaces of neighboring foundationbolt holes in order to put setting places aside for the final-adjusting liners, which will be setup later. Furthermore, adjust the edge position of each temporarily-adjusting liner so thatthe edge is a little sticking out of the barrel in order to make the adjustment by taper linerseasy.

CautionAvoid the temporarily-adjusting liner excessively sticking out of the barrel so as to getenough area to support the load of the barrel, and avoid the temporarily-adjusting linerwhich is excessively inside the barrel so as to hold an easy adjustment by taper liners.(Refer to Fig. 3.1-3)

Fig. 3.1-3 Installation Position of Temporary Flat liners

Suction nozzle: Barrel Suction nozzle: Top casing

30621127-000-3DT-00007-002_17 of 44

8/12/2019 30621127-000-3DT-00007-002

18/44


MESSRS DRAWING NO.

DRAWING NO. G305751-17/147

Note: The flat and taper liners used here shall be provided by the customer.The shapes of a flat liner and a taper liner are shown in Fig. 3.1-4, and therespective dimensions are given in Table 3.1-1 for reference.

Flat liner Taper liner(Two plates make a set.)

Fig. 3.1-4 Shapes of Flat Liner and Taper Liner

Dimensions of Flat Liner and Taper Liner (For reference)

Unit [mm]

Flat liner Taper liner

A B C D E F G H75 38 8 75 38 15 6 9

100 50 11 100 50 20 8 12120 75 11 120 75 19.2 7.2 12150 90 15 150 90 26 10 16180 90 18 180 90 30.8 11.8 19150 65 15 150 65 26 10 16180 65 15 180 65 24.8 8.8 16200 75 18 200 75 30 11 19250 75 18 250 75 28 9 19

(2) When installing flat liners, chip the concrete surface of the pump floor so that the

mortar on which flat and taper liners are mounted adheres tightly to the concrete.

Then, clean the pump floor and moisten it adequately. Furthermore, chip also the

insides of foundation bolt holes at the same time as the concrete surface of the pump

floor.

(3) Heap up mortar on the chipped concrete surface. Ensure heaping up mortar at bothsides of each foundation bolt hole.

(4) Place flat liners on the mortar. Check the levelness of each flat liner in each direction

with a level. The height differences between each flat liner shall be within 1mm. And

set the height of the top surface of the flat liner as about 30mm lower than the

installation level of the barrel. (Refer to Fig. 3.1-5)

30621127-000-3DT-00007-002_18 of 44

8/12/2019 30621127-000-3DT-00007-002

19/44


MESSRS DRAWING NO.

DRAWING NO. G305751-18/147

Fig. 3.1-5 Installation Level of Flat Liner

Furthermore, the allowable tolerance shall be within 0.5mm for the set height and

within 0.1mm/m for levelness when measured as a single liner. (Refer to Fig. 3.1-6)

Fig. 3.1-6 Height and Levelness Adjustment of Flat Liner

(5) Make a mortar wall around the foundation hole. In this regard, put tubes in the top of

the mortar wall to vent air when filling mortar. (Refer to Fig. 3.1-7)

30621127-000-3DT-00007-002_19 of 44

8/12/2019 30621127-000-3DT-00007-002

20/44


MESSRS DRAWING NO.

DRAWING NO. G305751-19/147

Fig. 3.1-7 Construction Area of Frame

(6) If the mortar with the flat liners on it is completely cured, place taper liners on the

already installed flat liners. The allowable tolerance shall be within 0.01mm/m for

levelness between each taper liner. (Refer to the upper side of Fig. 3.1-8)

Check the levelness with a level and adjust it, if necessary, by sliding the paired taper

liners with each other along the slant face. (Refer to the lower side of Fig. 3.1-8)


30621127-000-3DT-00007-002_20 of 44

8/12/2019 30621127-000-3DT-00007-002

21/44


MESSRS DRAWING NO.

DRAWING NO. G305751-20/147

Fig. 3.1-8 Levelness between Taper Liners on Both Sides

of Foundation Bolt Hole and its Adjustment

30621127-000-3DT-00007-002_21 of 44

8/12/2019 30621127-000-3DT-00007-002

22/44

3. Installation / 3.2 Equipment Installation

MESSRS DRAWING NO.

DRAWING NO. G305751-21/147

3.2 Equipment Installation

Note: Check "G. A. Drawing" and "Sectional Drawing" sufficiently before startingactual installation.

3.2.1 Installation

1) Installation of Barrel

Install the barrel as follows:

(1) Mark the centerline of the barrel. (Refer to Fig. 3.2-1)

Fig. 3.2-1 Indications of Center Lines

(2) Lift the barrel by using shackles and the crane, etc. While the barrel is being lifted,

place some soft pads between the barrel and the wire rope to protect the barrel

surface. (Refer to Fig. 3.2-2)

CautionDamage on the barrel surface (painted surface) might cause a pit to the barrel due to

corrosion by water after the installation. Be careful to protect the barrel surface becausethe barrel with the pitting must be removed again to repair it.


30621127-000-3DT-00007-002_22 of 44

8/12/2019 30621127-000-3DT-00007-002

23/44


MESSRS DRAWING NO.

DRAWING NO. G305751-22/147

Fig. 3.2-2 Barrel Lifting -1

(3) Stand the barrel vertically and slowly with taking care not to slip the hooked wires out.

After that, move it over the barrel pit. (Refer to Fig. 3.2.3)

Fig. 3.2-3 Barrel Lifting -2

(4) Lower the barrel into the foundation hole slowly and vertically with taking care not to

bump it on the foundation.

(5) Place the barrel on the flat liners.

2) Temporary Installation of Barrel, Setting of Foundation Bolt (The First Filling of Mortar)

(1) Attach foundation bolts to the barrel and place it on the taper liners. When attaching

a foundation bolt, make such a jig of a piece of wire etc. as shown in the following

figure, and insert the jigs into a bolt hole to prevent the foundation bolt from

inclining.

The wire size (diameter) is given by the half of the difference between the diameter

of the bolt hole and the bolt diameter. (Refer to Fig. 3.2-4)

30621127-000-3DT-00007-002_23 of 44

8/12/2019 30621127-000-3DT-00007-002

24/44


MESSRS DRAWING NO.

DRAWING NO. G305751-23/147

Fig. 3.2-4 Foundation Bolt Setting

(2) Adjust the center, height and levelness of the barrel. (Temporary adjustment to bury

the foundation bolts.) The allowable tolerance shall be within 0.1mm/m for levelness

of the upper surface of the barrel.

(3) The First Filling of Mortar

Fill the first mortar according to the following:

(a) Check that each foundation bolt is vertical and positioned in the central portion of

the foundation bolt hole for the barrel.

(b) Fill the foundation bolt holes with mortar to fix the foundation bolts in the holes.(Refer to Fig. 3.2-5)

Fig. 3.2-5 The First Filling of Mortar

30621127-000-3DT-00007-002_24 of 44

8/12/2019 30621127-000-3DT-00007-002

25/44


MESSRS DRAWING NO.

DRAWING NO. G305751-24/147

3) Setting of Final Liners

(1) Remove the barrel temporarily after mortars in the foundation bolt holes are

completely cured.

(2) Set the flat liners for final adjustment on mortars heaped up at the both sides of each

foundation bolt hole.(3) Adjust the heights of the flat liners in the same way as the temporary adjustment.

(Refer to Fig. 3.2-6)


Place the barrel again on the final liners. Adjust the height and the levelness of the

upper surface of the barrel by using the taper liners while the foundation bolts are

being tightened. The allowable tolerance shall be within 0.1mm/m for levelness of the

upper surface of the barrel. (Refer to Fig. 3.2-6)

Fig. 3.2-6 Installation with Final Liners and Adjustment for Levelness

5) Fixing of Liners

After all position adjustments are completed, check that all foundation bolts are fully

tightened, and then, fix all liners by spot welding. (Refer to Fig. 3.2-7)

Fig. 3.2-7 Spot Welding of Liners


30621127-000-3DT-00007-002_25 of 44

8/12/2019 30621127-000-3DT-00007-002

26/44


MESSRS DRAWING NO.

DRAWING NO. G305751-25/147

6) The Second Filling of Mortar

(1) Assemble the frame around the foundation, and then fill mortar inside the frame.


(2) Cure mortar until it is hardened completely.

(3) Remove the frame.

Fig. 3.2-8 The Second Filling of Mortar

7) Installation of Pump Body

(1) Remove all covers attached on openings and rotor-fixing jig (channel steels which

prevent the rotor from moving) for transportation.

(2) Lift the pump laid horizontally, pull it up vertically in the same way as the barrel and

move it over the barrel.(3) Insert the pump into the barrel and fasten it with hexagonal bolts.

Remember to set an O-ring (4120.7) to the upper surface of the barrel.

30621127-000-3DT-00007-002_26 of 44

8/12/2019 30621127-000-3DT-00007-002

27/44


MESSRS DRAWING NO.

DRAWING NO. G305751-26/147

3.2.2 Alignment

1) Position Adjustment of Rotor

For this pump, the way to adjust the rotor position when the pump delivered (new pump)

differs from the way in reassembling the pump which has been disassembled. To adjustthe rotor position, refer to the suitable procedure as follows for each condition.

When the pump delivered:

(1) Attach a centering tool to the mechanical seal.

Fig. 3.2-9 Details of Shaft Seal

(2) Lift up the rotor by the design value of the lifting up range, which is equal to 61mm.

CautionMake sure not to lift up the rotor more than the design value (more than 7mm) becauselifting over the value pushes the mechanical seal excessively and might damage it,which is also mentioned in the following section.

When the pump disassembled and reassembled:

(1) Adjust the position of the rotor with the mechanical seal not attached according to the

following steps.(a) Measure the distance (L) between the end of the shaft and the top face of the top

casing when the rotor is in its lowest position.

(b) Next, measure the distance (L) between the end of the shaft and the top face of

the top casing when the rotor is lifted up to the position where the rotor touches the

stator side. The difference (L) between L and L in previous step is the moving

range of the pump rotor. The pump lifting up range (S) is half the length of L.

(Refer to Fig. 3.2-10.)(2) Attach the mechanical seal.

(3) Attach a centering tool to the mechanical seal and start alignment work.


30621127-000-3DT-00007-002_27 of 44

8/12/2019 30621127-000-3DT-00007-002

28/44


MESSRS DRAWING NO.

DRAWING NO. G305751-27/147

CautionThe design value of the lifting up range is given by 61mm. Make sure not to lift up therotor more than the design value (more than 7mm) because lifting over the value

pushes the mechanical seal excessively and might damage it.

S (Lifting Up Range) L / 2 (L = L L)

Fig. 3.2-10 Adjustment of Lifting Up Range of Rotor

2) Alignment of Coupling (Temporary Alignment)

(1) Attach the motor stool and electrical motor to the pump.

(2) Adjust the clearance between the coupling on the electrical motor side and the spacer

ring to the lifting up range (S) when the pump rotary assembly is lowered. (Refer to Fig.

3.2-11.)

The clearance between the spacer ring and coupling can be adjusted by rotating the

spacer ring because the spacer ring is attached on the shaft by threads.

Fig. 3.2-11 Alignment and Adjustment of Distance at Spacer Ring

L

L

L

30621127-000-3DT-00007-002_28 of 44

8/12/2019 30621127-000-3DT-00007-002

29/44


MESSRS DRAWING NO.

DRAWING NO. G305751-28/147

3) Allowable Value of Alignment

Measure the parallelism (camming) between the faces of the couplings by inserting a dialgauge (lever type). (If there is no lever type dial gauge, measure the parallelism by puttinga normal dial gauge on the under side of the coupling hub of the pump side.)The runout of the coupling peripheral surface is measured by putting a dial gauge on the

periphery of the coupling. Refer to Table 3.2-1 for the allowable values of the alignment.

Table 3.2-1 Allowable values of Alignment

Allowable value(For the value indicated on the dial gauge, etc.)

Temporary alignment Final alignment

Camming Within 0.1 mm Within 0.1 mm

Runout of couplingperipheral surface(Note 2)

Within 0.05 mm Within 0.05 mm

Notes1) The allowable values above are ones when the alignment is

performed by rotating the motor coupling hub.2) The allowable values of both the temporary and final alignment are

within 0.025 mm when judging from the runout of the core axis.3) Refer to Coupling Drawing for the details of the couplings.

CautionMake sure to perform alignment while the pump is cold.

4) Coupling Alignment (Final Alignment)

(1) Connect the suction and discharge piping. (At this time, make sure not to apply piping

load or moment to the pump flange.)

(2) Confirm that the lifting up range (S), the distance between the faces and alignment of

the faces of the couplings are the set values or within the ranges of the allowable

values in the previous section. If not, readjust referring the previous section.

(3) Tighten the two nuts of the coupling bolts at diagonal positions, and lift up the pump

rotor. Next, tighten the nuts of the remaining coupling bolts.

30621127-000-3DT-00007-002_29 of 44

8/12/2019 30621127-000-3DT-00007-002

30/44


MESSRS DRAWING NO.

DRAWING NO. G305751-29/147

(4) Remove the centering tool.

Caution

Make sure to remove the centering tool. If operate the pump without removing the tool,the tool and the seal sleeve will rotate contacting with each other and they maydamaged.

(5) After finishing the alignment, rotate the shaft by hand and confirm that there is no

abnormality.

30621127-000-3DT-00007-002_30 of 44

8/12/2019 30621127-000-3DT-00007-002

31/44


MESSRS DRAWING NO.

DRAWING NO. G305751-30/147

3.2.3 Installation of Accessories

The installation methods for the accessories are described below.

1) Suction StrainerKeep enough maintenance space for strainer installation.

Clean the flange faces of a strainer and its mounting location before installing.

When installing a strainer, pay attention to the direction of the strainer and do not

leave out inserting a gasket.

The clogging of a suction strainer is generally detected by a differential pressure

gauge and it is recommended to install a differential pressure gauge for a strainer.

Caution

Install a strainer so that the distance between the connection flange faces is kept equal.

3) Other Accessories

Install the other accessories according to the P&ID (Piping and Instrumentation

Diagram). Refer to the relevant instruction manual of each accessory.

3.2.4 Check Items at the Completion of Equipment Installation

The check items necessary for the completion of equipment installation are listed in 1.Check Items at the Completion of Equipment Installation of Attachment 2) Check List at

the Completion of Installation.

3.2.5 Detuning of Pump

When the pump is operated at the site, the vibration might become large. One of thecauses of the vibration is a resonance which is generated by the coherence of the naturalfrequency of the pump and the rotation frequency of the electric motor (*).In order to solve this problem, the detuning bolts can be attached to the sides of theelectrical motor mounting bolts. If the detuning bolts are attached, the natural frequencyof the pump is lowered and the resonance is avoided.Even if the descent of the rigidity of a foundation across the age could lead a resonance,it can be avoided by attaching the detuning bolts.

If there is no problem of the vibration at the trial run at the site, the detuning bolts are notattached. (The holes for the bolts are made.)

* The pump is designed and manufactured so that the natural frequency is isolated from a

vibration frequency enough, and the natural frequency of the pump is measured at a

trial run at our factory. However, the natural frequency might come close to the rotation

frequency by the difference of the rigidity of the foundation or of the state of an

installation between at your site and our factory.

30621127-000-3DT-00007-002_31 of 44

8/12/2019 30621127-000-3DT-00007-002

32/44


MESSRS DRAWING NO.

DRAWING NO. G305751-31/147

Fig. 3.2-1 Detuning Bolt

30621127-000-3DT-00007-002_32 of 44

8/12/2019 30621127-000-3DT-00007-002

33/44

3. Installation / 3.3 Piping and Wiring

MESSRS DRAWING NO.

DRAWING NO. G305751-32/147

3.3 Piping and Wiring

3.3.1 Piping Installation

1) GeneralBefore starting piping installation, clean the inside of the piping and check that there

is no scale or rust left in the piping.

Install not only piping but also appropriate piping supports so that excessive piping

load or moment is not applied to the pump. In this installation, be careful not to

constrain the thermal expansion of the equipment, piping or its supports. The piping

load applied to the pump flange shall not exceed the values specified in the "Outline

Drawing. (Otherwise, the pump may be broken.)

2) Main Piping

Install the main piping after the second-filled mortar hardens and the frame is

removed. When the main piping installation is completed, make the final alignment.

3) Auxiliary Piping

Install the auxiliary piping according to the G. A. Drawing (or auxiliary piping

diagram) and the P&ID.

Note: If Swagelok tube fittings are used, install them according to Attachment 6)Swagelok Tube Fitting Installation Instructions.

3.3.2 Wiring

Perform wiring in accordance with the wiring diagram.

3.3.3 Check Items at the Completion of Piping and Wiring

The check items necessary for the completion of piping and wiring are listed in 2. CheckItems at the Completion of Piping and Wiring of Attachment 2) Check List at theCompletion of Installation.

30621127-000-3DT-00007-002_33 of 44

8/12/2019 30621127-000-3DT-00007-002

34/44

4. General Description and Structure of Equipment /4.1 General Description of Pump / 4.2 Structure of Pump

MESSRS DRAWING NO.

DRAWING NO. G305751-33/147

4. General Description and Structure of Equipment

4.1 General Description of Pump

4.1.1 General

This pump includes the water-injecting device for the shaft seal part and the equalizingpipe because it is used with the service water in high vacuum.

The former prevents the atmosphere from leaking in the inside of the pump by alwayssupplying external seal water to the shaft seal part, which is required because the insideof the pump is in vacuum when it is running or stops. The shaft-sealing water is suppliedfrom the service water when this pump is running. When this pump stops, theshaft-sealing water is obtained from another pump which supplies pressured water.

As for the latter, the air in the suction line side negatively affects the suction performanceof this pump. Also, the inside air can not be exhausted into the atmosphere if it isattempted to fill the inside of the pump with the condensate water when the pump isvacuumed up by the condenser.To exhaust the inside air, therefore, the equalizing pipe is installed in the higher place ofthe suction side and it is connected to the upper part of the condenser. The air exhaust tothe condenser through the equalizing pipe always keeps the degree of the vacuum insidethe suction barrel the same as the condenser.

4.2 Structure of Pump

This pump is the vertical centrifugal multi-stage pump, and has the suction port in the pit

barrel (or top casing) and the discharge port in the top casing. The rotor is driven directlyby the motor.The motor bearing supports the pump thrust along the shaft and the mass of the rotor.

Main components a pump consists of are outlined as follows:

4.2.1 Casing

The casing of this pump consists of the bellmouth, volute casing, intermediate casing anddiffuser casing.The bellmouth is the driving channel of the suction part of the pump and is connected tothe volute casing or diffuser casing.

The volute casing is used to enclose the 1st stage impeller.The intermediate casing connects the volute casing and the diffuser casing, and functionsas the suction opening for the double entry type of impeller.The diffuser casings enclose the second stage and the following impellers. The riser pipeis directly connected to the last diffuser casing.

Each casing is fastened to the next stage casing with hex. bolts or stud bolts.

30621127-000-3DT-00007-002_34 of 44

8/12/2019 30621127-000-3DT-00007-002

35/44

4. General Description and Structure of Equipment /4.2 Structure of Pump

MESSRS DRAWING NO.

DRAWING NO. G305751-34/147

4.2.2 Impeller

The closed type of impeller is used and all impellers are attached on the main shaft in thesame direction. Keys are used to fix the impellers on the shaft against rotation.

The double entry type of impeller is used as the first stage impeller.Each impeller except for the fist stage has balancing holes to reduce the thrust.The casing wearing ring is set between the sliding part of a diffuser casing and the one ofan impeller to obtain an appropriate gap, which restricts the leakage of service water fromthe high-pressure side to the low-pressure side to the minimum.

4.2.3 Shaft

The shaft transmits the power transmitted from the motor to each machine element of therotor while rotating at the required speed. Each machine element is fastened to the shaftby a key or fitting in the rotation direction, and by the contact surface of the steppedportion of the shaft, split rings or fitting in the axial direction to transmit the generating

power or thrust.

4.2.4 Shaft Seal

Leakage of service water is restricted by the mechanical seal.The suction of the air is prevented by injecting external seal water to the seal part.

The floating seat (4750) is in the stator side. The sealing washer (4720) and the spring(4770), etc. are fixed on the shaft and rotate with the rotor.The positions of the parts in the rotor side are adjusted so that the pushing range of themechanical seal is appropriate when the rotor is pressed to the counter-motor side (lowerside in installed condition). Then, the sealing edge is formed with the floating seat (4750)

by lifting the rotor upwards.

Therefore, the restriction of the leakage depends on the position adjustments of the partsin the rotating side and the lifting up range of the rotor. These works also affect thedamage of the mechanical seal.

For details, refer to the sections 3 and 6, and "Mechanical Seal Instruction Manual"separately attached.

30621127-000-3DT-00007-002_35 of 44

8/12/2019 30621127-000-3DT-00007-002

36/44

4. General Description and Structure of Equipment /4.3 General Description of Motor

MESSRS DRAWING NO.

DRAWING NO. G305751-35/147

4.3 General Description of Motor

Refer to the accompanying instruction manual for details.

4.4 General Description of Auxiliary Equipments

4.4.1 Rigid Coupling

It consists of coupling hubs and reamer bolts, and no lubricant is required owing to itsstructure.

4.4.2 Suction Strainer

It is recommended to install a strainer in the suction side of the pump to prevent damagesinside the pump due to dust, scale or welding slag that enter the supplied water fromoutside.

When a strainer is installed, always check that the differential pressure does not exceedthe one for cleaning and take care not to operate the pump with clogging in the strainer.

CautionAbove mentioned strainer is used to prevent relatively larger particles from damaginginside of the pump. However it is not efficient for smaller particles such as sand or ironpowder. Please control such smaller particles not to mix in by the customer yourself.

30621127-000-3DT-00007-002_36 of 44

8/12/2019 30621127-000-3DT-00007-002

37/44

5. Operation Procedure

MESSRS DRAWING NO.

DRAWING NO. G305751-36/147


1) Precautions for Operation

To ensure safe work, read the precautions given in "2.2 General Precautions" andalso the precautions given below before starting the pump operation.

Danger Immediately stop the pump if the pump makes abnormal sounds or vibrations, and

make sure to inspect the pump before the resumption of operation.

Please contact us in advance when disassembling the pump.

Do not come closer to or touch the rotors such as the shaft and coupling during

operation as they may be scattered due to breakage.

When approaching to the pump in operating, please confirm in advance that there is

no excess leakage from the piping.

Do not touch hot sections of the pump during and right after the operation without

checking the temperature of the pump in advance.

Warning If the water filling is insufficient, the sudden breakage of the impeller, mechanical seal,

submerged bearing and casing may be caused due to an idle rotation or an excessflow operation of the pump.

Pump operation deviating from any specified conditions can become a cause to

damage the pump.

2) Precautions for Operator

WarningAny person other than the operator who is able to operate the pump shall not operatethe pump.

30621127-000-3DT-00007-002_37 of 44

8/12/2019 30621127-000-3DT-00007-002

38/44


MESSRS DRAWING NO.

DRAWING NO. G305751-37/147

5.1 Operation Flow

5.1.1 Commissioning Flow

The commissioning flow is shown in Fig. 5.1-1. Also the referential sections are indicatedin the lower right of some boxes in the figure.

Fig. 5.1-1 Commissioning Flow (1/2)

Electrical system check

(including motor)

Loop check, valve check, etc.

Apparatus check

Preparation before commissioning

5.2.1 Preparation and Check before Commissioning

Checking and cleaning suction line

5.2.1 Preparation and

Check before

Commissioning

Preparation before priming

5.2.2 Preparation before Priming

A

5.2.3 Priming and Venting

(1) to (4) in "Check before Start-up"

5.2.4 Check before Start-up


Check before commissioning

Checking and cleaning discharge line

Priming and venting

Filling main line of suction side

with water

Checking the ratio of

each valve opening

30621127-000-3DT-00007-002_38 of 44

8/12/2019 30621127-000-3DT-00007-002

39/44

5. Operation Procedure / 5.1 Operation Flow

MESSRS DRAWING NO.

DRAWING NO. G305751-38/147

Fig. 5.1-1 Commissioning Flow (2/2)

Starting the pump for a short time

and shutting-down

A

Start-up

No

5.2.5 Start-up

Check after start-up (minimum flow)

Is the check OK?

Yes

No

Shutdown (to Standby State)

Shut down the pump

5.2.10 Shutdown (to Standby State)

5.2.6 Check after Start-up (at the Minimum Flow Operation)

Has the pump run

smoothly?

Yes

Determine the causes and solve.(Please contact us if disassembling)


Checking continuous running

Start-up the pump

Yes

Is it possible to start

checking continuous

running?

No

30621127-000-3DT-00007-002_39 of 44

8/12/2019 30621127-000-3DT-00007-002

40/44

5. Operation Procedure / 5.1 Operation Flow

MESSRS DRAWING NO.

DRAWING NO. G305751-39/147

5.1.2 Normal Operation Flow

The normal operation flow is shown in Fig. 5.1-2. Also the referential sections areindicated in the lower right of some boxes in the figure.

Fig. 5.1-2 Normal Operation Flow

Check before start-up


Start-up

5.2.5 Start-up

Yes

No


Putting the pump from minimum flowoperation into normal operation

5.2.8 Putting the Pump from Minimum FlowOperation into Normal Operation


Check during normal operation

5.2.9 Check during Normal Operation

Yes

No

5.2.10 Shutdown (to Standby State)5.2.11 Emergency Shutdown (to Inspection and Maintenance)

Electrical system check(including motor)

Loop check, valve check, etc.

Apparatus check

Preparation before operation

Is the check OK?

Check after start-up (minimum flow)

Shut down the pump

Normal operation

Shutdown (to standby state) oremergency shutdown

(to inspection and maintenance)

Is the check OK?

30621127-000-3DT-00007-002_40 of 44

8/12/2019 30621127-000-3DT-00007-002

41/44

5. Operation Procedure / 5.2 Operation Procedure

MESSRS DRAWING NO.

DRAWING NO. G305751-40/147

5.2 Operation Procedure

5.2.1 Preparation and Check before Commissioning

Check the following before commissioning the pump:(1) Check if all apparatus function properly.

(2) Check the pump rotor assembly by rotating it manually.

(3) Check the alignment of the pump and motor without connecting them (to confirm

that the alignment is within the tolerance in "3.2.2 Alignment"). Adjust the

alignment if necessary.

WarningEntanglement hazardIf operating the motor during the alignment work, serious injury to the worker and

damage to the pump may be caused. Confirm that the motor has been turned off, andtake measures to prevent the motor from running by wrong operation.

(4) Let cooling water flow into its piping by opening the main and related valves of

cooling water, if necessary.

(5) Check the oil level of the thrust bearing is appropriate.

(6) Check the rotation direction of the motor:

a) Inch the motor (turn on, then off the motor quickly) before connecting it tothe pump.

b) Confirm the rotation direction by comparing to the marking.

c) When the rotation direction is wrong, check if the power cables areconnected properly. Reconnect the power cables by the electrician ifnecessary, and check others.

d) If the rotation direction is correct, turn the power off.

DangerDo not open the terminal cover of electric equipment such as a motor during power-on.Otherwise, the worker may get seriously injured due to an electric shock. Whenopening the terminal cover, confirm that the power is off and take preventive measuresagainst powering-on by wrong operation.

(7) Operate the motor in unloaded condition and check if the motor is running

normally.

(8) After confirming that the motor is running normally, shut down the motor.

WarningEntanglement hazardIf operating the motor during the alignment work, serious injury to the worker anddamage to the pump may be caused. Confirm that the motor has been turned off, andtake measures to prevent the motor from running by wrong operation.

30621127-000-3DT-00007-002_41 of 44

8/12/2019 30621127-000-3DT-00007-002

42/44


MESSRS DRAWING NO.

DRAWING NO. G305751-41/147

5.2.2 Preparation before Priming

Make the following preparation before priming:(1) Open the equalizing pipe and the air vent valve of the shaft seal part.

5.2.3 Priming and Venting

(1) Open gradually the gate valve of the suction line to its full opening.

(2) Open the flow control valve.

(3) At the valve manifolds, vent the air from pressure measurement instruments

such as the pressure gauges.

(4) Check the pump rotor assembly by rotating it manually.


(1) Check that the gate valve of the suction line is in full opening.(2) Check the water filling and suction pressure, and record them.

(3) Check that a centering tool for the mechanical seal has been removed.

(4) Check that water is injected into the seal water piping, the equalizing pipe is

opened, and there is no water leakage from other piping etc.

(5) Rotate the motor for a short time by inching operation.

a) Start the pump (motor) and check that it runs smoothly.

b) Operate the pump to the rated revolution and check that each pressure is inproper value.

c) Rotate the motor for a short time to vent the residual air in the pump.

d) Turn the pump (motor) off and check that it slows down smoothly and stops.

5.2.5 Start-up

(1) Start-up the pump (motor).


(1) Make sure that the flow rate of the pump does not become less than the

Minimum-Flow during the operation. Especially, pay attention to the quick rise in

the service water temperature.

(2) Check the mechanical seal to see whether there is any leakage from the shaftseal part or not.

(3) Check and record the suction pressure of the pump.

(4) Check and record the discharge pressure of the pump.

(5) Check and record the differential pressure of the suction strainer.

CautionIf the differential pressure exceeds the cleaning differential pressure, clean or replacethe filter element.

30621127-000-3DT-00007-002_42 of 44

8/12/2019 30621127-000-3DT-00007-002

43/44


MESSRS DRAWING NO.

DRAWING NO. G305751-42/147

5.2.7 Minimum Flow Operation

When the pump operates in the state of zero or extremely low discharge flow rate, thepump efficiency will drop significantly, so that a large portion of the power provided by the

motor will convert to heat, which increases the service water temperature in the pump.Restricted operation of the pump in a flow rate less than a discharge flow rate will cause asharp rise in temperature, which is very dangerous. The minimum discharge flow rate toavoid such a sharp temperature-rise during the pump operation is called as MinimumFlow.

CautionThe Minimum Flow operation is for avoiding the sharp rise in temperature in a shorttime and not for the continuous operation. Please contact us for flow rate wherecontinuous operation is possible.

5.2.8 Putting the Pump from Minimum Flow Operation into Normal Operation

(1) Open the flow control valve and increase gradually the discharge flow to the

rated flow.

CautionIf the discharge piping is empty, do not open rapidly the discharge valve to its fullopening. Increase the discharge flow gradually. Adjust the flow into the discharge pipingby the discharge valve.

5.2.9 Check during Normal Operation

(1) Check the mechanical seal to see whether there is any leakage from the shaft

seal part or not.

(2) Check the oil level of the oil level gauge and whether there is no oil leakage from

the bearing or not.

(3) Check and record the suction pressure of the pump.

(4) Check and record the discharge pressure of the pump.

(5) Check and record the differential pressure of the suction strainer.

CautionIf the differential pressure exceeds the cleaning differential pressure, clean or replacethe filter element.

(6) Check and record the vibration level.

30621127-000-3DT-00007-002_43 of 44

8/12/2019 30621127-000-3DT-00007-002

44/44


5.2.10 Shutdown (to Standby State)

(1) Close the discharge valve gradually to make the flow of the pump approach to

the Minimum Flow.

(2) Turn the motor off.(3) Check that the pump slows down smoothly and stops:

A) It is recommended to record the slowing-down time until the pump stops.

B) If the pump stops suddenly, it is possible that some part of the pump rotorhave interior contact with other parts due to a foreign object bitten in. Afterpump temperature becomes low enough, check the pump rotor by rotating itmanually.

Note: Except that the pump is stopped running for a long term and the water hasbeen already drained, keep the suction valve in open.

5.2.11 Emergency Shutdown (to Inspection and Maintenance)

(1) Turn the motor off.

(2) Check that the pump slows down smoothly and stops.

(3) Close the discharge valve.

(4) Close the suction valve

Documents

30621127-000-3DT-00007-002