EP11030 & 11032 Hisar O & M Rev 0___June 2009

HISAR #1 & #2

OPERATING & MAINTENANCE

MANUAL

CLIENT : SHANGHAI ELECTRIC GROUP Co. Ltd

CUSTOMER ORDER No. : SEC/HS-JK-2007-005 & SEC/HS-JK-2007-006

HTEP REFERENCE : EP11030 & EP11032

SERVICE : 3 x 420kW BCP per order REVISION : 0, June 09

Rev 0, Jun 09 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD - i - Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401

FOREWORD 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 Table of Contents list shows that the manual is divided into sections. Paragraph references are consecutive throughout each section, and are preceded by the appropriate section number. For example 6.1. designates:- Section 6, Commissioning. 6.1. Pre-Start Check List. The major illustrations of the Pump and Motor are included at the rear of Section 8. Additional illustrations of particular features are incorporated in the text.

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. Revised manuals will not automatically be issued, however, should they be required, Hayward Tyler may be contacted and arrangements can be made.

REVISION HISTORY Rev 0 June 09

CONTACT DETAILS Hayward Tyler Ltd. 1 Kimpton Road Luton Bedfordshire ENGLAND LU1 3LD Telephone :- +44 (0) 1582 731144 Fax :- +44 (0) 1582 452198

Rev 0, Jun 09 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD - ii - Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401

WARRANTY The unit(s) is/are subject to a warranty as specified within the original sales contract. In the unlikely event of a unit ceasing to operate normally please refer in the first instance to the fault matrix included in this manual. If the issue still cannot be resolved then contact Hayward Tyler using the details below: HTS Customer Services Coordinator Hayward Tyler Ltd (Services) 1 Kimpton Road Luton Bedfordshire ENGLAND LU1 3LD Telephone: +44 1582 731144 Email: [email protected]

Hayward Tyler is committed to delivering excellent aftersales service. As part of the warranty process, all claims will be acknowledged within 1 working day and actioned within 5 working days from initial notification. In order to assist Hayward Tyler to address the claim effectively, please provide the following information when reporting a warranty issue: Unit Serial Number Primary contact details Details of the issue including the date issue was first observed Commissioning Date Last Service Date (Service Agency) Previous Warranty Claims Dependant on the nature of the fault, it may be necessary to strip and inspect the unit prior to issuing a report. Any work undertaken on a unit that has failed under circumstances not deemed to be covered under warranty will be chargeable to the unit end user.

mailto:[email protected]

Section 1 – Table of Contents

Rev 0, Jun 09 Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD - 1 - Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401

1 Table Of Contents

FOREWORD .....................................................................................................................................i REVISION HISTORY ........................................................................................................................i CONTACT DETAILS.........................................................................................................................i WARRANTY ..................................................................................................................................... ii 1 Table Of Contents................................................................................................................... 1 2 Technical Data ........................................................................................................................ 3

2.1 General........................................................................................................................... 3 2.2 Pump / Motor Design Characteristics............................................................................. 3 2.3 Operating Points............................................................................................................. 3 2.4 Clearances & Settings.................................................................................................... 4 2.5 Heat Exchanger.............................................................................................................. 4 2.6 Water Quality.................................................................................................................. 4 2.7 Instrumentation............................................................................................................... 4 2.8 Torque Loading .............................................................................................................. 4 2.9 Weights (Approximate)................................................................................................... 5 2.10 BCP Fill/Purge System................................................................................................... 5

3 Storage.................................................................................................................................. 10 3.1 Environment ................................................................................................................. 10 3.2 Storage – General ........................................................................................................ 10 3.3 Inhibitor......................................................................................................................... 10 3.4 Heat Exchanger............................................................................................................ 12 3.5 Exterior Surfaces.......................................................................................................... 12 3.6 Standard Storage Checks For Storage Up To 3 Years................................................ 12 3.7 Storage Periods Greater Than Three Years ................................................................ 13 3.8 Preparation For Storage After Use............................................................................... 14 3.9 Inspection Record Card ............................................................................................... 15

4 Description ............................................................................................................................ 17 4.1 General......................................................................................................................... 17 4.2 Pump ............................................................................................................................ 17 4.3 Motor ............................................................................................................................ 17 4.4 Terminal Box ................................................................................................................ 21 4.5 Heat Exchanger............................................................................................................ 21 4.6 Alarm Systems ............................................................................................................. 21 4.7 Strainer......................................................................................................................... 22 4.8 Cooler........................................................................................................................... 22

5 Installation............................................................................................................................. 23 5.1 General......................................................................................................................... 23 5.2 Pump Case Installation (Fig 5.1).................................................................................. 24 5.3 Preparation For Motor Installation................................................................................ 25 5.4 Motor Installation (Fig 5.2) ........................................................................................... 25 5.5 Fitting The Heat Exchanger ......................................................................................... 28 5.6 Purge System Installation ............................................................................................ 28 5.7 Filling The Circulator With Boiler Cold ......................................................................... 28 5.8 Hydrotesting Boiler With Circulator Installed................................................................ 29 5.9 Electrical Connections.................................................................................................. 31 5.10 Motor Protection........................................................................................................... 32

6 Commissioning ..................................................................................................................... 40 6.1 Pre-Start Check............................................................................................................ 40 6.2 Initial Starting – Cold Boiler Condition.......................................................................... 40 6.3 Stopping ....................................................................................................................... 42

Section 1 – Table of Contents


7 Operation .............................................................................................................................. 43

7.1 Starting The Circulator ................................................................................................. 43 7.2 Shutting Down The Circulator ...................................................................................... 45 7.3 Routine Checks And Operation Conditions ................................................................. 46 7.4 Fault Finding (Fig 7.1) .................................................................................................. 49

8 Maintenance ......................................................................................................................... 50 8.1 Motor Removal ............................................................................................................. 50 8.2 Disassembly ................................................................................................................. 52 8.3 Inspection Of Components........................................................................................... 53 8.4 Assembly Notes ........................................................................................................... 55 8.5 Re-Installation Of Motor ............................................................................................... 57 8.6 Parts Lists..................................................................................................................... 58

9 Stud Tensioning Equipment.................................................................................................. 69 9.1 Introduction................................................................................................................... 69 9.2 Application.................................................................................................................... 69 9.3 Description ................................................................................................................... 69 9.4 Assembling The Stud Tensioner (Fig. 9.3) .................................................................. 71 9.5 Replenishing The Pump Tank...................................................................................... 77 9.6 Indexing........................................................................................................................ 77 9.7 Safety Procedures........................................................................................................ 77 9.8 Tightening Flange Nuts ................................................................................................ 77 9.9 Releasing Flange Nuts................................................................................................. 78 9.10 Parts List (Fig 9.6) ........................................................................................................ 80

10 Purge Cooler and Strainer .................................................................................................... 81 10.1 Description ................................................................................................................... 81 10.2 Commissioning............................................................................................................. 81 10.3 Operation...................................................................................................................... 81 10.4 Maintenance................................................................................................................. 82

Section 2 - Technical Data


2 Technical Data

2.1 General

Unit Serial Nos: EP/07/11030/ A / B/ C EP/07/11032/ A / B/ C

Service: Boiler Water Circulating Pump with Motor below Pump

Number Supplied: 3 per order, 6 in total

Electrical: 3300V - 3 Phase - 50Hz

2.2 Pump / Motor Design Characteristics Pump Type: Single Suction, Double Discharge, Volute Pump size (2x13)x16x20H Design Pressure 20.16 MPa @365.3°C Hydrostatic test pressure 30.24 MPa Motor rated output 420 kW Motor service factor 1.0 Motor winding insulation XLP PE2+PA Motor electrical supply 3.3kV 3Ph 50Hz Nominal speed 1450 rpm Starting Current 473 A Full Load Current 100.7 A Locked Rotor Current 411 A Estimated Pump curve No. E94357/2 Estimated Motor curve No. EP2007-11660-1

2.3 Operating Points 1 2 3

Design

Duty (Hot)

Single Pump

Design Duty

(Cold) Quantity pumped m³/h 3904.0 4685.0 3904.0 Differential Head m 30.7 17.8 30.7 Differential pressure Pa 174.11 100.95 301.06 Pump temperature °C 353.3 353.3 20.0 Suction pressure MPa 19.05 19.05 Min. NPSH req. above vapour pressure (Cold) m 12.5 22.0 12.5 Specific Gravity at pump suction temperature T/m³ 0.5783 0.5783 1.0000 Pump efficiency % 84.0 79.4 84.0 Power absorbed by pump (mechanical) kW 224.77 204.50 388.68 Motor efficiency % 89.3 89.1 89.2 Electrical input to motor kW 251.70 229.52 435.74 Power factor 0.760 0.745 0.815 Combined efficiency % 75.0 70.7 74.9 Line current Amp 57.9 53.9 93.5



2.4 Clearances & Settings

(mm)

Impeller Setting (Dimension ‘Z’): 542-543 Initial Maximum Impeller Wear Ring Clearance : ∅ 1.15 - 1.26 1.82 Journal Bearing Clearance Pump End: ∅ 0.27 - 0.45 0.62 Journal Bearing Clearance Cover End: ∅ 0.27 - 0.45 0.62 Reverse Thrust Wear Ring Clearance : ∅ 0.36 - 0.46 0.70 Rotor End Float: 0.20 – 0.30 0.50

2.5 Heat Exchanger

Pressure Drop 0.7 bar Low Pressure Cooling Water Inlet Temperature 35°C max 38°C max 40°C max Low Pressure Cooling Water Flow (Boiler Hot) m3/hr 4.5 4.5 4.5 Low Pressure Cooling Water Flow (Boiler Cold) m3/hr 4.5 4.5 4.5

2.6 Water Quality

Heat Exchanger Quality of the water to be clear, clean filtered water, treated to eliminate fungal growth. Ph 7 up to ph 9 treated. Chlorides to be minimal possible.

Motor cavity water

To be demineralised water or condensate of normal boiler quality filtered to 50 microns and cooled to approx 30 °C. Normal ph 8 -9 as required by boiler. Magnetite will appear in the motor but in our experience this will not significantly affect operational reliability of the motor.

2.7 Instrumentation

RTD Probe PT100 Type – 4 wire

Temperature Indicator / Alarm HNL Series 80 Smartstat

Pump Thermocouple Type ‘KK’ Ungrounded

Thermometers – Motor and Heat Exchanger HP and LP pipework SSD Type MSS 150 Direct Mounted 0 -100°C

Heat Exchanger LP Pipework Flow Switch / Indicator

KDG Mowbrey : Model No M.12.S.LP.6EE.S.Ics.S1.D1 Flanged 1-1/2” ANSI 300

2.8 Torque Loading Refer to Figure 2.1, Schedule of Torque Loadings



2.9 Weights (Approximate)

Pump Case 3820 kg Complete Motor and Rotating Assembly 6900 kg Heat Exchanger 530 kg TOTAL 11250 kg

2.10 BCP Fill/Purge System

Service: Boiler water fill and purge line equipment for straining and cooling

Number Supplied: 1 Set per order comprising 1 Strainer & 1 Cooler

Cooler Characteristics HP Purge Side (Inner Pipe) Design pressure 20.2 Mpa g Design temperature 365.3 °C Hydrotest pressure 30.3 Mpa g Operating flowrate 11.4 litres/min Operating inlet temp. 175 °C Operating outlet temp. 49 °C LP Cooling Water Side (Outer Pipe Annulus) Design pressure 1 Mpa g Design temperature 175 °C Hydrotest pressure 1.5 Mpa g Operating flowrate 460 litres/min Operating inlet temp. 40 °C max Strainer Characteristics Design flow rate: 11.4 litres/min Strainer size: 160 mesh Design pressure: 202 bar Design temperature: 365.3°C Hydrotest pressure: 303 Mpa

Estimated Weights Strainer 16 kg Cooler 330 kg

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Figure 2.1 : Motor Assembly

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Figure 2.2 : Winding Resistance Diagram

Performance curves for a 4 pole motor rated at 420 kW on 3 phase, 3300V, 50Hz supply

EP2007-11030 & 32 Rev 0 HT-IM-BC-400420-30330050-E7SEG- Hisar - India 420 R 453 3300

Figure 2.3 : Motor Performance Curve -8-

150 200 250 300 350 400 45088.0

88.5

89.0

89.5

90.0

90.5

150 200 250 300 350 400 450

Effic

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150 200 250 300 350 400 4500.68

0.70

0.72

0.74

0.76

0.78

0.80

0.82

0.84

150 200 250 300 350 400 450

Pow

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150 200 250 300 350 400 45014401445

14501455

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14701475

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150 200 250 300 350 400 450

Spee

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150 200 250 300 350 400 45040

50

60

70

80

90

100

110

150 200 250 300 350 400 450

Line

Cur

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150 200 250 300 350 400 450150

200

250

300

350

400

450

500

150 200 250 300 350 400 450

Output Power kW

Inpu

t Pow

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Customer SEG Pump Size : (2x13)x16x20H

Project HISAR #1&#2 Curve No. : E94357/2

HT Order : EP 11030/11032 Speed 1450

Design Duty : 3904 m³/h @ 30.7 m

Estimated Pump Performance

0

10

20

30

40

50

60

70

80

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Head m

10

20

30

40

50

60

70

80

90

Efficiency %

0

50

100

150

200

250

300

350

400

450

500

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

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KW Absorbed (sg 1.0)

0

10

20

30

40

50

60

70

80

90

100

NPSHr m

KW Shaft Power (s.g. = 1.0)

Efficiency

Head/Quantity

Figure 2.4 : Pump Performance Curve -9-

Section 3 – Storage


3 Storage 3.1 Environment The storage area must have a hard standing floor that will be capable of supporting the weight of the units.

3.2 Storage – General 3.2.1 Pump Case (Fig. 3.1) 1) The pump case internal areas and all

machined faces must be cleaned and a suitable removable solvent rust preventative, with a minimum effective life of 6 months, applied. Recommended rust 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.

Figure 3.1 : Pump Case Storage Details

3.2.2 Motor (Fig. 3.2) 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. 2) The motor apertures must be blanked

off with flanges secured with studs, bolts and nuts.

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.

3.3 Inhibitor Inhibitor is to be produced from a pre-mixed concentration of mono-propylene glycol and distilled 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 20°C is as 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



Figure 3.2 : Motor Storage / Transit Details



3.4 Heat Exchanger The 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.

3.5 Exterior Surfaces All exterior surfaces of the motor must be maintained in a good painted condition. Scratched or damaged paintwork must be repainted.

3.6 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:-

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.

3.6.1 Motor 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.

4)

a) All studs, bolts and nuts are present and in sound condition.

b) The phosphate, or any other plating,

applied to these items has not deteriorated.

5) Measure and record the ambient

temperature of the storage area.

6) Check and record the insulation resistance of the stator windings as follows:

a) Remove the terminal box cover.

b) Check the insulation resistance at

the terminal stems using a l000V megger. Record the result.

IMPORTANT: - Motor insulation resistance falls with time and depends on storage and service conditions. Insulation resistance should not fall below 200 megohms at 20°C in less than 12 months. Insulation figures less than 5 megohms indicate that the motor winding has deteriorated to a level where maintenance is required. See Winding Resistance Diagram, Section 2, Figure 2.2.

c) Fit the terminal box cover.

7) Remove the inspection cover from the top of the transit canister (Fig.3.2).

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.

CAUTION: To rotate the assembly in a clockwise direction may damage the impeller nut locking screw. If the shaft cannot be rotated or is very difficult to turn, contact Hayward Tyler for advice.

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.

9) 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 3.3.



3.6.2 Pump Case and Transit Assemblies

10) Replace the transit inspection cover

when the inspection is satisfied. Inspect the pump assembly and check the following: - 3.6.1.1 Topping up/Draining Inhibitor

(Fig 3.3) 1) No extensive corrosion has occurred on

the internal pump machined areas. 1) Attach a hose leading from a pumping device to the hose tube of the inhibitor filling valve.

2) The protective coating is satisfactory.

Re-apply if necessary. 2) Unscrew the filling valve screw by two

turns. This action opens the valve to allow the pumped liquid to enter the motor.

3) Visually examine the assembly for

damage.

4) Check that the pump case protective flanges are correctly fitted and secure. 3) When the sufficient inhibitor has been

pumped in, turn screw to close the valve. 3.6.3 Stud Tensioning Equipment

1) After use, the stud tensioning components must be thoroughly cleaned, examined for damage and a rust preventative lubricant applied to all surfaces.

4) Remove the hose from the inhibitor filling valve.

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.

2) The components must be then wrapped

in suitable waterproofed material and stored in a clean, dry area.

3.7 Storage Periods Greater Than Three Years

Units that remain in store over three years require special consideration and Hayward Tyler Limited should be consulted for specialist advice. CAUTION: Precautions must be taken prior to use that the unit is pressure tight.

Figure 3.3 : Inhibitor Filling Valve



3.8 Preparation For Storage After Use

1) Remove the motor from the pump case and drain the motor as described in Section 8.

2) Disassemble the motor cover and clean

out any loose material, sediment etc. 3) Check all fittings and clearances and

general condition. Fit spare parts as necessary.

4) Using a socket wrench on the impeller

nut, check that the shaft rotates freely, approximately seven revolutions in an anti-clockwise direction.

5) Check the insulation resistance of the

winding and compare to the Winding Resistance Diagram in Section 2 Fig 2.2.

6) Fit the transit canister to the main flange

and stand the motor upright on the motor cover.

7) Seal off all apertures with appropriate

transit flanges and gaskets. 8) Fill the motor with a pre-mixed

concentration of inhibitor, in accordance with paragraph 3.2.6.2, through the filling connection in the transit flange, sealing the motor heat exchanger bottom outlet.

9) Fit the transit canister inspection cover. 10) Re-check the insulation resistance of

the motor windings. 11) Check that the storage conforms to Para

3.2.

Figure 3.4 : Rotating the Rotor Assembly



3.9 Inspection Record Card A typical inspection record card and check list is given on the following pages (Figs 3.5 and 3.6).

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Figure 3.5 : Inspection Record Card



SITE…………………………………………………

UNIT NO……………………………………………

DATE……………………………………………….

UNITS STOPPED AT……………………………..

Mot

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ase

& T

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it A

ssem

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Pum

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Ass

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Inte

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Pip

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Fill

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Val

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Ass

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ASSEMBLY IN STORAGE AREA STORED IN SAFE POSITION IDENTIFICATION LABELS ATTACHED PAINTWORK IN GOOD CONDITION ASSEMBLIES HAVE INCURRED NO PHYSICAL DAMAGE (SEE NOTE 1) STUDS, NUTS AND BOLTS ARE IN A SOUND CONDITION X X STUDS, NUTS AND BOLTS FITTED IN THE CORRECT NUMBER X X STUD PROTECTORS FITTED TO MAIN FLANGE STUDS X X X BLANK FLANGES FITTED SECURELY X X X X NO LEAKAGE OF THE INHIBITOR VISIBLE X ROTATING ASSEMBLY ROTATED 6-7 TIMES X X X X INHIBITOR LEVEL CORRECT X INHIBITOR COMPOSITION CORRECT X NO CORROSION ON PUMP CASE PROTECTED AREAS X X X X WOODEN COVERS SECURED TO PUMP CASE OPENINGS X X X X RUBBER BUNGS SECURELY FITTED X X HEAT EXCHANGER SECURELY FITTED TO WOODEN CRADLE X X X X

INSULATION RESISTANCE READING……………………………………………………..

AMBIENT TEMPERATURE OF STORAGE AREA…………………………………………

KEY : √ ACCEPTABLE

O REQUIRES ACTION

∗ REQUIRES IMMEDIATE ACTION

NOTE 1 : DETAILS OF OBESERVATIONS SHOULD BE NOTED ON THE REVERSE SIDE OF CHECK LIST

WITNESSED BY…………………………………………………… OF………………………………………....….

COMPILED BY……………………………………………………… OF…………………………………………….

Figure 3.6 : Check List

Section 4 – Description


4 Description 4.1 General 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 reactor power stations and similar applications. 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. 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: - 1) Thermal Conduction. Because the

pump temperature is so high, usually above 340°C and the motor temperature is limited to about 55°C, a simple restriction, in the form of a 'neck', is provided to minimise heat conduction.

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 restricts solids 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.

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 cold purge is to be used only as an emergency.

4.2 Pump 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 branch uppermost. 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 the impeller. The impeller wear ring is the harder component to prevent galling.

4.3 Motor The motor is a squirrel cage, wet stator, induction motor, the stator wound with a special 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. 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 labyrinth with 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. Lifting lugs are supplied to secure hoists when raising and lowering the motor.



4.3.1 Auxiliary Cooling Circuit (Fig. 4.1) The 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. When the motor is stationary, thermosyphon circulation takes place to remove conducted heat from the pump end of the motor.

Figure 4.1 : Auxiliary Cooling Circuit



4.3.2 Bearings 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.

4.3.2.1 Journal Bearings

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.

4.3.2.2 Thrust Bearing

A 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 thrust disc is also designed to operate as an auxiliary impeller to circulate the internal water content of the motor.

4.3.2.3 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.

4.3.3 Internal Filter 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.

4.3.4 Main Flange Joints 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 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. Stud tensioning equipment is supplied with each circulator order.

4.3.5 Terminal Gland (Fig 4.2) 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 gland blowout at high temperatures. However, if the motor is subjected to sustained overheating, a slight leakage may occur into the terminal box.



Figure 4.2 : Terminal Gland



4.4 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 must be sealed by a cable gland. Each phase notation is identified by the coding, Red, Yellow or Blue and IEC markings ‘U’, ‘V’& ‘W’. See Section 5 – Installation. 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.

4.5 Heat Exchanger A heat exchanger (cooler) is fitted to dissipate the heat generated by the motor and the heat transferred from the pump casing. Brackets are provided on the motor case to mount the heat exchanger. The heat exchanger is of the shell and tube type comprising two main components; the pressure vessel which houses the tube bundles, and the inlet and outlet covers. The high pressure water from the motor flows through the tubes whilst the low pressure cooling water flows through the shell. High pressure outlet and inlet flange connections are situated top and bottom of the motor case for connection to the high pressure mating flanges.

4.6 Alarm Systems Refer to drawings in Section 5.

4.6.1 Temperature Indicator / Switch

A temperature indicator/switch is provided and should be mounted in the pocket provided in the motor casing. This instrument houses the alarm and trip contacts and gives visual indication of the motor temperature. An alarm circuit should be arranged such that when temperature reaches 60°C an audible alarm is energised. Should the temperature continue to rise to 65°C, a second trip circuit should be activated, arranged to de-energise the motor.

4.6.2 Thermocouple A thermocouple is provided to monitor the pump case metal temperature.

4.6.3 Motor Case Cavity RTD A PT100 RTD probe is provided to monitor the motor case cavity temperature.

4.6.4 Dial Thermometers Temperature indicating dial thermometers are provided on the motor case, on the high pressure heat exchanger interconnecting pipe work and on the low pressure pipe work assembly (adjacent to the flow meter). These give local visual indication only.

4.6.5 Flow / Switch Indicator A flow/switch indicator is supplied for connecting into the low pressure cooling water circuit. An alarm circuit may be arranged to indicate low flow below the set point.

4.6.6 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.



4.7 Strainer A purge strainer is required at the inlet to the purge cooler to prevent large particles from entering the purge water fill line.

4.8 Cooler A purge cooler is required to limit the temperature of water entering the motor to 49°C to prevent damage to the electrical windings and shaft bearings.

Section 5 – Installation


5 Installation 5.1 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. When installing the circulators the following conditions MUST be observed. 1) The system pipe work should be

adequately supported to accept the weight of the circulator.

2) When mounted, the pump should

accommodate movement in the pipe work due to thermal expansion without imposing excessive loads on the casing and branches, associated pipework and cables.

3) Sufficient clearance should be allowed

beneath the motor to permit lowering of the motor from the pump case for maintenance. (See Section 8 for the General Arrangement drawing). 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.

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) The pump should be positioned so that

the nett positive suction head (N.P.S.H.) available exceeds the N.P.S.H. specified in the Technical Data - Section 2).

NOTE: When operating at temperature, sub cooling of the inlet water is normally present and this gives a considerable increase in the N.P.S.H. available. The worst condition is normally operating cold. 5) Fit a suitable gland (not supplied) to the

cable entry of the terminal box.

5.1.1 Installation Notes 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) Permanent insulation should be applied

only to the pump case. No insulating material must be applied to the motor case or to the main flange studs and nuts, as this will cause the motor to overheat.

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.



5.2 Pump Case Installation (Fig 5.1)

1) Remove the pump case flange and branch covers and clean the pump branches.

2) Attach shackles and slings to the casing

eyebolts. A plate on the pump case indicates the front of the pump.

3) Raise the case to meet the system pipe

work, with the suction branch uppermost.

4) Ensure that the main motor/case flange

is horizontal to within 1°. Tack weld to

the system pipe work and re-check the horizontal limits.

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.

Figure 5.1 : Pump Case Installation



5.3 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. We do not recommend motor installation on a Hot Boiler. 1) Hose down internally, the pump case,

the valves and adjacent piping, to ensure the removal of all loose debris.

2) Fully close the pump suction and

discharge valves.

5.4 Motor Installation (Fig 5.2) 1) Using a 1000V megger, check that the

insulation resistance to ground of the motor leads is above 200 megohms when measured at the terminal stems with the unit full of water below approximately 20°C, if possible, or at normal ambient temperature.

2) Stand the motor in a vertical position, on

the motor cover stand, and in the correct orientation to the pump.

3) Remove the pump case main flange

nuts and cover and ensure there is no debris in the pump pipe work system that could enter the pump case.

4) Clean and inspect the pump case

flange, remove any burrs. 5)

a) Remove the plug or inspection cover at the top of the transit canister.

b) Loosen the inhibitor filling valve

situated in the motor fill and drain transit flange, (Section 2 Fig. 2.1), and drain approximately 40-45 litres of inhibitor. Close the inhibitor filling valve.

6) Remove the transit canister from the

motor case. 7)

a) If the motor is to be operated immediately upon installation, completely drain then proceed as (8)

b) If motor operation is not imminent,

install the motor in the inhibited condition, proceed as 9), leaving 8) to be performed when fitting the heat exchanger.

8)

a) Connect a clean cold water supply to the motor cover fill and drain connection, and flush the motor until inhibitor-free water flows from the top of the motor.

b) Check that the shaft freely rotates, if

not, contact Hayward Tyler for advice.

9) Clean the overlay that provides the seat

for the gasket in the main flange of the motor. Inspect for burrs and surface discontinuity, dress if necessary with a fine grade stone. Fit a new gasket. NEVER apply any compound to the gasket and ensure that it is dry.

10) Ensure that the motor is in correct

orientation with the pump case. See General Arrangement Drawing in Section 8.

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. 11) Attach shackles and slings to the motor

casing lifting lugs and lift into position, taking care to avoid damage to the terminal box.



12) Fit the motor to the pump case as follows:

a) Using the chain type hoists, lift the

motor until the impeller is about to enter the pump case.

b) Measure the distance between the

pump case and the motor flanges at four 90° degree points on the flange periphery. If necessary, adjust the lay of the motor by the chain hoists to make the distances approximately equal.

c) Bring the gap between the flanges

equal all round. This is best achieved by using a spring-loaded 'inside' calliper, set to the gap directly in line with one of the chain hoists. The set calliper is then moved to the opposite side of the flange and the gap adjusted, using the chain hoist. Check the gaps at right angles to the first two and adjust the lay of the motor to make the gaps equal.

d) Check that the studs are centred in

the motor flange holes. Adjust the motor “lay” as required.

e) With the chain hoists working in

unison, slowly raise the motor. CAUTION. If any increase in effort is required on the chain hoists to raise the motor - stop raising it immediately as the impeller may be fouling the pump case wear ring. In which instance, fractionally lower the motor, check the gap and raise the motor again.

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 the hoists 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.

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 on the gasket to make it adhere to its recess.

h) Coat the stud threads with high temperature anti-seize compound or silicon grease and install the nuts by hand.

NOTE: Do not coat the exposed extended diameter threads of the studs as these threads are for the tensioner application.

i) Tighten the nuts, using the hydraulic stud tensioner in accordance with the instructions in Section 9. Remove the lifting tackle and removable lifting lugs.

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.

k) Install the heat exchanger, see

Section 5.5.

l) Install the instrumentation described in Section 4.6, referring to drawings at the end of this section.

m) Connect the power supply cables to

the motor terminals, see Section 5.9.

13) If, after fitting the heat exchanger:

a) running is not reasonably imminent, the motor and heat exchanger circuit must be refilled immediately with inhibitor.

b) sub-freezing temperatures are

envisaged the motor and heat exchanger circuit must be refilled immediately with inhibitor.



c) 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.

Figure 5.2 : Motor Installation



5.5 Fitting The Heat Exchanger

1) Remove the blank flanges from the motor high pressure outlet to cooler and fill and drain connection.

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 water

system until clear water is discharged. 4) Mount the heat exchanger onto the

motor case brackets and proceed.

a) Bring the heat exchanger parallel to the motor supporting the weight with the lifting tackle.

b) Loosely attach the heat exchanger,

by the mounting plates, to the mounting plates on the motor.

c) The heat exchanger should now

stand parallel to the motor.

d) Place the Flexitallic gasket at the top high pressure flange joint of the motor and coat the bolt threads with silicone grease, leave the gasket clean. Bolt the top high pressure connection together.

NOTE: On high pressure / temperature applications, guide ring type gaskets are used at the auxiliary flange joints; tighten the flanges about the guide ring, metal-to-metal.

e) Clamp the heat exchanger to the motor by tightening up the securing bolts, nuts and washers.

f) Ensure the motor / heat exchanger

interconnecting pipe work assembly is correct for the circulator. The correct pipe work is stamped with the serial number.

g) Place a Flexitallic gasket at each

joint at the bottom of the motor case and heat exchanger for the bottom high pressure connection. Coat the

flange fastener threads with silicone grease.

h) Offer up the interconnecting pipe

work to the heat exchanger and motor flanges and secure with bolts, nuts and washers.

5) Install gauges and recorders for

temperature and pressure. Connect the low pressure cooling systems to the heat exchanger and high pressure fill and purge system to the motor, at the motor cover.

6) Fit temporary strainers to the low

pressure cooling systems, and then check that circulation meets the heat exchanger specification.

7) Close the shut off valve in the high

pressure fill and purge line and blow down piping.

8) The motor and heat exchanger circuit

must now be refilled with inhibitor (See 5.4, Para. 13 (a) or (b) or with treated boiler water or condensate.

5.6 Purge System Installation

Check that the strainer and the associated valves have been correctly installed. (See Section 10)

5.7 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. 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. 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. 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. 1) Isolate the circulator from the boiler by

closing appropriate discharge valves, by-pass valves and drain valves.

2) Supply the low pressure side of the heat

exchanger as follows: -

a) Open the supply valves in the low pressure cooling water system.

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 through the blow down valve.

NOTE: The flushing must always be carried out before introducing any water through the lines to the motor and heat exchanger. 3) If the low pressure supply contains an

orifice, check that it is clean and that its flow rate is correct.

4) Adjust the flow rate to approximately 2

litres/min. 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.

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.

8) Isolate the now filled circulator. 9) Ensure that the terminal box is dry and

with the unit full of water below 20ºC 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.

IF NOT, CALL HAYWARD TYLER. DO NOT ATTEMPT TO RUN THE MOTOR.

5.8 Hydrotesting Boiler With Circulator Installed

1) Treated Water or Condensate available:- Should the customer wish to hydrotest

the circulator, the hydrostatic test pressure must not exceed the maximum specified in Section 2. 2) Treated Water Not Available: -

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.5.2.

5.8.1 Post Hydrostatic Test Procedure

1) Boiler circulators are not to be drained, but left filled to a level above the suction downcomer.

2) Freezing can be avoided by filling with

glycol in the concentration detailed in Section 3.



Figure 5.3 : Terminal Box



5.9 Electrical Connections 5.9.1 Power Supply to Motor Refer to the terminal box arrangement shown in Figure 5.3. 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 then

remove the terminal box cover using lifting gear, if necessary.

2) Remove the nuts and washers and take

off the cable entry gland plate. 3) Drill the cable entry plate as necessary

to suit the cable gland. 4) 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.

5) Earth the circulator adequately.

Grounding pads are provided on the motor casing adjacent to the terminal box.

6) Ensure that all electrical connections

particularly at the terminal box entry gland are secure.

7) 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 the installation of the motor.

a) Dismantle the bursting disc assembly and discard the cardboard sheet fitted in lieu of the disc.

8) Reassemble the bursting disc assembly

with the bursting disc in place, as depicted in Fig. 5.4.

9) Fit and secure the terminal box covers

using the nuts and washers previously removed.

Figure 5.4 : Bursting Disc Assembly

5.9.2 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 downcomer

temperature and pump case temperature. This is required to avoid thermal shocks when starting a pump on a hot boiler.

5.9.3 Alarm Circuits WARNING: Lethal voltage is present in the alarm system when the motor is inoperative. To make the circulator safe - open the isolator. Suitable alarm and trip devices should be fitted to protect the motor and arranged to provide: - 1) An alarm - as an indication of motor

overheat conditions. 2) Motor trip (shut down) - if the

temperature rise continues above the alarm setting.

The normally advised settings for the protection devices are: 60°C for alarm and 65°C for trip. In practice, the alarm setting should be reduced to 5°C above normal motor operating temperature.

5.10 Motor Protection The following protective devices must be provided for the motor: -

5.10.1 Continuous Overload Protection 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. 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. Maximum current at nominal voltage: See Technical Data, Section 2.

5.10.2 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 2.

5.10.3 Starting Period Protection 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 magnetic circuit. Motor Starting Current: See Technical Data, Section 2.

5.10.4 Earth Leakage Protection (Fig 5.5)

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. 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. 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. 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.



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. NOTE: It is important that no earth conductor is allowed to be enclosed by the current

transformer. The earth leakage sensitivity and 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.

Figure 5.5 : Earth Leakage Protection Circuit Diagram

Figure 5.6 : Temperature Indicator / Switch - Motor

-34-

Figure 5.7 : Temperature Indicator - Motor

-35-

Figure 5.8 : Temperature Indicator - HE HP & LP Pipework

-36-

Figure 5.9 : Thermocouple - Pump Case

-37-

Figure 5.10 : RTD - Motor Cavity

-38-

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-39-

Section 6 – Commissioning


6 Commissioning 6.1 Pre-Start Check The following pre-start checks must be satisfied before starting the motor. 1) Ensure that the circulator is completely

vented. 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.

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 7. 3) Ensure that the high pressure cold water

purge at 20°C maximum temperature is connected but isolated.

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 2, Fig. 2.2 when measured at the terminal stems with the unit full of water below approximately 20°C, if possible, or at normal local ambient temperature.

5) Check that the correct voltage is

connected to the circulator. 6) Check that the electrical supply is

available at the point of control selected and that the starting equipment is functioning correctly.

7) Test the operation of all instrumentation

and alarms. 8) Ensure that sufficient N.P.S.H. is

available for the pump to run without cavitation.

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.

6.2 Initial Starting – Cold Boiler Condition

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. When a boiler is started from cold, a minimum of two circulators must be operated. It is normal practice to simultaneously warm the standby circulators to permit immediate starting when required. CAUTION: Motors must not be energised if the motor cavity temperature is below 2°C. 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. The motor may be damaged if motor temperature exceeds 65°C. 1) Ensure that the motor has been vented

as detailed in Section 5, Para. 5.7. 2) Ensure that a flow of approximately 2

litres/min., is entering into the motor through the low pressure fill line.

3) Ensure that the pre-start checklist, as

described in Para. 6.1, 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)

a) Vent the pump by opening vent valves.

b) When air-free water is discharged

from vent valve to atmosphere, close valves.



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

NOTE: The by-pass valve should never be fully closed. It is normally throttled to provide a minimal flow between the pump suction and discharge system. 7) Switch on power to the starter. 8) Press the starter button on the control

console and energise the motor for 5 seconds only.

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 20 minutes. 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 the pressure stated in Section 2.

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 twenty minutes. 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 the secondary 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 and

differential 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 60°C, whichever is the lower. The trip setting must never exceed 65°C.

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 of increased 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.

6.3 Stopping 1) Press the stop button on the control

console. The run-down time is approximately 2.5 seconds.

2) Close the discharge valves. 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 Section 3.2.2.)

Section 7 – Operation


7 Operation Any of the following conditions may exist when putting a circulator into service. Follow the relevant procedures below and refer to 7.3 for routine checks and operational fault action.

7.1 Starting The Circulator 7.1.1 Boiler Cold - Circulator Cold

and Filled (Boiler Start-Up) 1) Ensure that the pre-start checklist, para

6.1 is satisfied. 2) Vent the motor as follows: -

a) Release any air trapped below the suction by opening the by-pass valves and the filling valves.

b) When air-free water is discharged

through the vent valve, close vent valve.

3) Vent the pump as follows: -

a) Open the vent valve. b) When air-free water is discharged

from vent valve, close vent valve and filling valves.

c) Open the stems of the discharge

valves. CAUTION: The pump must always be re-vented in this manner prior to starting when the drum pressure is below 3.5 bars. 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. 4)

a) On circulators that will not be energised, open the pump discharge by-pass valves. This ensures that as the boiler heats up, a flow passes from the discharge

legs to the pump case and impeller etc.

b) Check the motor temperature on the

alarm thermometer; this should not exceed 49°C or be less than 5°C.

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 given in Section 2.

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.7.3.

a) Amperage.

b) Motor cavity temperature on alarm thermometer.

c) Differential pressure.

d) Low pressure cooling flow and

temperature.

e) Vibration.

f) Drum level.

g) Valve and gland leakage. 8) Energising other motors: When the

boiler differential pressure parameters require the other circulators to be energised: -

a) Check that the differential

temperature, between the pump case and boiler water in the downcomers, is within 28°C.

b) Energise the other motors.

c) Close by-pass valves on the newly

energised pump(s).

d) Perform the operation checks on the newly energised pump as detailed in para.7.1.1(7).



7.1.2 Boiler Hot - Circulator Hot and Filled (Hot Standby)

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.

CAUTION: The differential temperature between the pump case and the boiler water in the downcomers must not exceed 28°C. Non-

adherence to this may cause thermal shocks and damage to occur. 2) Energise the motor. 3) Close by-pass valves. 4) Check circulator operation as detailed in

para.7.1.1 (7).

7.1.3 Installation on a Hot Boiler This is not recommended without suitable safety precautions in place.



7.2 Shutting Down The Circulator

CAUTION: Low pressure cooling water flow and motor temperatures must always be within the specified limits, whenever the circulator is on hot standby.

7.2.1 Boiler Hot - Circulator to go on Hot Standby

1) Press the stop button on the control console.

2) Ensure that the low-pressure cooling

line valves are open. 3) Open by-pass valves to provide

circulation of high temperature boiler water through the pump casing, suction and discharge lines.

7.2.2 Boiler Hot - Circulator to be Isolated for Maintenance

1) Press the stop button of the control console to de-energise the motor.

2) Close the stems on the discharge valves 3) Maintain the low pressure cooling

system to the heat exchanger, until the pump casing has fully cooled.

CAUTION: Keep a close watch on the motor cavity temperature, should the temperature increase, apply a high-pressure purge as described in para. 7.3.8. 4) Check the pump case temperature as

the pump case is cooling to ensure that the cooling rate does not exceed 60°C per hour. If necessary, correct the cooling rate as follows:

a) Cooling rate too fast: - If the pump case cooling rate is too fast, slow the cooling rate by partially opening the by-pass valves as necessary.

b) Cooling rate too slow: - If the pump

case cooling rate is too slow, increase the rate by injecting a high pressure purge as detailed in Para. 7.3.8.

5) When the pump case has cooled to

43°C de-pressurise the circulator as follows: -

a) Ensure the pump discharge by-pass

valves and shut-off valve are closed. b) Slowly depressurise the circulator

by cracking open vent valves.

c) Open shut-off valves and check the pressure on the motor cavity gauge. When the pressure has stabilised, close vent valves.

d) Re-check that the pressure does not

increase. Should it increase, check the following: -

i) Make sure that all valves

between the circulator and high-pressure system are closed.

ii) De-pressurise the circulator

again, if necessary.

6) On completion of depressurising, the motor is ready for removal.

7.2.3 Boiler Cold 1) Press the button on the control console. 2) Leave open the low pressure cooling

water line valves. 3) Pump discharge valves may be left

open.



7.3 Routine Checks And Operation Conditions

(Also see Fault list chart)

7.3.1 Supply Current 1) Check the motor running current each

shift. The current should be constant and comply with that specified in section 2.

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.

7.3.2 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 60°C and to de-energise the motor if the temperature reaches 65°C. 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 long enough to stabilise.

2) Immediately investigate the following

possible causes for high temperature alarm sounding: -

CAUTION : Do not stop the motor.

a) Check the low pressure cooling water supply for adequate flow, temperature vapour locks and leakage in piping (see 7.3.7.)

b) Check the circulator for leaks from

the 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.

c) Check that the cooling water

strainers are not obstructed.

d) Check for indication of bearing

damage (noise, vibration). 3) If temperature increase continues and

exceeds the 65°C trip setting and the cause cannot be detected or the condition corrected, refer to the relevant shutdown procedure in Section 7.2. If necessary, blow down the boiler system or apply a high-pressure purge to the motor, see Section 7.3.8.

4) Should the alarm sound whilst the

circulator is on stand-by, start the circulator to accelerate internal high pressure cooling water flow. Check possible causes for temperature increase as above. The circulator should be tripped if the temperature exceeds 65°C and the shutdown / purge procedure in para 7.2 carried out.

7.3.3 High Temperature Alarm and Trip Settings

At weekly intervals check that the motor high temperature alarm setting does not exceed 60°C or 5°C above normal operating Temperature (whichever is the lower) and that the trip setting does not exceed 65°C. Re-set if necessary.

7.3.4 Pump Head and Quantity 1) Check the total head generated by each

pump at weekly intervals. 2) Correct possible causes of decrease in

head and quantity as follows: -

a) The check valves in the circulating pump discharge lines are not fully open. Check and adjust the setting as necessary.

b) 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.

c) Vent the pipe system to remove

vapour locks.



d) Power supply and reverse rotation

checks are given in 6.2 (9).

e) Worn wear rings and a blocked or damaged impeller can be corrected only after removing the motor assembly from the pump case. Clearances are specified in section 2.

7.3.5 Insulation Condition Before initially energising the motor and thereafter at monthly intervals, check the following: - 1) The insulation resistance to ground of

the motor leads. 2) With the unit filled with water below

20°C or at normal local ambient temperature, the resistance measured at the terminal links, using a 1000V megger, must conform to the Winding Resistance curve in Section 2, Figure 2.2).

NOTE: The insulation resistance of the stator winding varies with temperature and must always be measured cold 20°C or at normal local ambient temperature. 3) Ensure that the interior of the terminal

box is dry, especially the insulation projecting over the gland stems.

7.3.6 Vibration 1) Check the circulators for excessive

noise or vibration, which can be either hydraulic or mechanical in origin.

2) 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: -

a) Cavitation due to low N.P.S.H., as

described in 7.3.4.

b) Unequal settings of the discharge valves. Check and re-set in the fully open position.

c) Incorrect directional rotation as

described in section 6.2, 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.

3) If the cause cannot be determined,

contact Hayward Tyler for advice. Other possible causes could be :

a) Damaged or unbalanced rotor or

impeller, worn bearings, excessive end float or incorrect impeller setting.

b) Electrically induced vibration also a

factor, i.e. Rotor bar breakage etc.

7.3.7 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 will be de-energised as soon as the motor temperature reaches the trip setting of 65°C by the temperature controller. Prior to this an alarm will be initiated by the low pressure cooling water flow monitor indicating that the low pressure cooling water supply has been lost and a further alarm will be initiated by the temperature controller when the motor temperature reaches 60°C. CAUTION : Damage to the windings may occur if the motor remains in operation after 5 minutes from the loss of cooling water. CAUTION : 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 the motor temperature rises above 65°C.



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 38°C.

7.3.8 High Pressure Purge Supply To Motor

Purge water applied to the motor through the high pressure fill line, in an emergency, will limit motor temperature, so protecting the motor until inspection and rectification are possible. The flow of purge water must be sufficient to stabilise the temperature of the motor to overcome any water loss due to leakage, etc., as follows: - NOTE: 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 and solids into the motor. 1) Flush down the fill and purge system to

ensure the line is clean. 2) Check that the low pressure cooling

water supply valves are open. 3) Introduce high pressure purge through

the filling valves. Check that the purge temperature does not exceed 49°C and that the purge pressure is above the boiler pressure.

7.3.9 Extended Shut-Down When the circulator remains shutdown for an extended period: - 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 3.2. 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 fill and vent procedure, as detailed in Section 5.7, must be followed.

7.3.10 Boiler Cleaning 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 of contaminated water into the bearing and motor components.



7.4 Fault Finding (Fig 7.1) Refer to the fault list chart that follows.

CONDITION/CAUSE

CIR

CU

LATO

R

SY

STE

M

ELE

CTR

ICA

L

CIR

CU

LATO

R

SY

STE

M

CIR

CU

LATO

R

SY

STE

M

ELE

CTR

ICA

L

CIR

CU

LATO

R

SY

STE

M

ELE

CTR

ICA

L

CIR

CU

LATO

R

SY

STE

M

SE

CO

ND

AR

Y C

OO

LING

W

ATE

R FA

ILUR

E

ACTION

● ● CHECK LOW PRESSURE COOLANT FLOW AND RATE

● ● ● ● ● ● CHECK TEMPORARY FILTER FOR BLOCKAGE

● ● ● CHECK ALIGNMENT & STRAIGHTNESS OF SHAFT

● ● CHECK HEAT EXCHNAGER IS CLEAN AND VENTED

● ●CHECK SYSTEM VALVES ARE CLOSED AND NOT LEAKING

● ●CHECK MOTOR HEAT EXCHANGER PIPEWORK & FLANGES ARE NOT LEAKING

● ● CHECK MOTOR COVER IS NOT LEAKING

● ●STOP, REMOVE MOTOR COVER & CHECK FILTER WATER PASSAGES

● ● ● ● ●CHECK DIRECTION OF ROTATION, IF INCORRECT REVERSE ANY TWO SUPPLY LEADS

● ● ● ●CHECK THAT FLOW VALVES ARE TOTALLY OPEN AND BYPASS VALVES ARE CLOSED.

● ● ● ● CHECK SYSTEM NOT VAPOUR LOCKED

● ● ●CHECK BOILER IS FILLED ACCORDING TO SPECIFICATION

● ● ● ● ● ●CHECK SYSTEM FOR BLOCKAGE OR CONSTRUCTIONAL CHANGE

● ● ● ● ● ● ● ● ● ● ● ●CHECK NAMEPLATE DUTY & VOLTAGE AGREE WITH ACTUAL SITE CONDITIONS

● ●CHECK & REPLACE IMPELLER & CASE WEAR RINGS IF WORN

● ● CHECK IMPELLER IS NOT BLOCKED OR DAMAGED

● ● CHECK NPSH AVAILABLE

● CHECK FOR UNBALANCED MOTOR ROTOR OR IMPELLER

● ● CHECK FOR WORN BEARINGS

● ● CHECK IMPELLER SETTING

● ●CHECK FOR EXCESSIVE PIPE STRAIN OR INADEQUATE CASING SUPPORT

● ● CHECK FOR EXCESSIVE END FLOAT

CHECK DISCHARGE VALVES EQUALLY OPEN

●

EXCESSIVE PO

WER

CO

NSU

MPTIO

N

NO

ISE AN

D VIB

RA

TION

RED

UC

ED Q

UA

NTITY

RED

UC

ED H

EAD

● ●

INC

REA

SED M

OTO

R TEM

PERA

TUR

E

CHECK FOR EXTERNAL LOADS ON MOTOR eg. SUPPORT EXPANSION

Figure 7.1 : Fault List Chart

Section 8 – Maintenance


8 Maintenance 8.1 Motor Removal Refer to Figure 5.2 in Section 5. WARNING: Before removing the motor, the circulator must be completely isolated from the system, depressurised and cooled as described below. 1) Isolate the electrical supply, disconnect

all instrument cables from the motor identifying the connections and leads.

2) Remove the terminal box cover and

disconnect the external power supply cables from the terminals, identifying each lead for reassembly.


insulation resistance to ground of the motor leads conforms to Winding Resistance Diagram, Section 2, Fig 2.2 when measured at the terminal stems with the unit full of water at 20°C or the normal ambient temperature. Record the reading.

4) If suction valves are not fitted, the boiler

system must be cooled, depressurised and drained before motor removal.

5) Check that the circulator is

depressurised. 6) Drain the pump casing using the drain

valves in the discharge pipework and /or the pump case drain valve where fitted.

WARNING: Never drain the pump casing through the motor fill & drain line as this could cause contamination of the motor. 7) Isolate and disconnect the low pressure

cooling water inlet and outlet flanges from the heat exchanger, top and bottom respectively.

8) Drain the motor through the fill and drain

valve. 9) Disconnect the fill and drain line.

Discard gasket.

10) Remove the heat exchanger from the

motor, as follows:

a) Disconnect and the remove the bottom outlet high pressure interconnecting pipework between the motor and heat exchanger by removing the flange nuts and washers from the flange bolts and/or studs. Discard the flange gaskets.

b) Disconnect the top inlet high

pressure connection between the motor and heat exchanger as above.

c) Take the weight of the heat

exchanger with adequate lifting gear and remove the nuts and bolts securing the heat exchanger to the motor brackets.

d) Remove the heat exchanger to an

inspection area. 11)

a) Fit the removable lifting lugs to the brackets on the motor casing. Set up two chain hoists and rigging, of sufficient capacity for each to take the full weight of the motor, and connect to the lifting lugs.

WARNING: Normally two hoists are used for removing the motor and because the load can shift from one hoist to the other during the removal, each hoist must be capable of taking the full weight of the motor.

b) Take the initial strain of the motor. 12) Loosen the pump/motor flange stud nuts

in accordance with the hydraulic stud tensioning instructions in Section 9.

13) Lower the motor evenly to the floor

level, supporting the base on suitable timber.

14) Lower the motor to the horizontal

position, (Figure 8.1), remove the lifting tackle and cover all joint faces and openings with clean rags.



15) If necessary, transport the motor to a working area where adequate facilities are available for disassembly, inspection and maintenance.

16) Seal off the pump case opening by fitting the blank off plate – refer to Section 5 for details.

Figure 8.1 : Laying Down The Motor



8.2 Disassembly CAUTION: 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.

8.2.1 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 six

screws securing the wear ring inside the pump casing. Carefully lower the wear ring from its location within the casing.

3) Lower to ground level and store in a

safe place for inspection.

8.2.2 Main Impeller (Fig 8.2) Remove the impeller from the rotor assembly as follows:- 1) Unlock the punch marks and remove the

impeller cap screw. 2) Remove the LEFT-HAND threaded

impeller nut using the special spanner and tommy bar provided 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 blows with a leadfaced hammer. If the nut shows any tendency to seize on the shaft, do not continue to exert force, but drill and split the nut to remove. 3) Carefully withdraw the impeller, then

remove the impeller washer and remove the impeller key.

4) Immediately refit a serviceable impeller

nut to permanently protect the shaft threads.

Figure 8.2 : Impeller removal

8.2.3 Motor Case Wear Ring Examine the motor case wear ring. If damaged, remove the socket headed cap screws and lock washers. Remove the wear ring for a fuller inspection or renewal.

8.2.4 Motor Disassembly must only be carried out by Hayward Tyler Service Personnel.



8.3 Inspection Of Components 8.3.1 Main Flange Stud

Inspection Stud inspection must be carried out in accordance with the inspection cycles indicated below.

8.3.1.1 Stud Inspection at each Flange Breakdown

Whenever either the pump case/ motor case or the motor case/motor cover flange joint is broken, the exposed portion of all the flange studs must be thoroughly inspected visually for indications of damage or corrosion, mainly in the form of pitting and cracks etc. Pitted or cracked studs must be renewed.

8.3.1.2 Stud inspection at Pump Overhaul

At each convenient circulator overhaul period, approximately 4 - 5 years, a percentage of the studs must be given a non-destructive examination, as follows: 1) Remove two random studs from both

the pump case/motor case joint and any one stud from the motor case/motor cover joint.

2) Clean up the studs, and using a liquid

dye penetrant and/or magnetic particle examination, examine for surface cracks, particularly in the stud threads and thread run out areas.

NOTE: If there has been a history of leakage in service from the joints and/or previous recorded damage, remove and inspect at least 10% of each flange’s studs. 3) Identify any corrosive deposits that may

be present, i.e. pitted areas etc., and if corrosion is evident, consider its stress corrosion influences. If any stud

condition raises doubts as to the stud's serviceability, renew all the studs in the flange.

4) If necessary renew the studs.

8.3.1.3 Studs on Extended Circulator Service Life

If at the end of the circulator nominal service life, or as otherwise defined, an extension of circulating pump life is proposed, it is recommended that all studs should be renewed. However, should a request be made for an extension to the life of the existing studs, then the following points must be satisfied:- 1) The general condition and surface

integrity of the studs must be satisfactory.

2) There should be adequate residual

fatigue life in the studs for the extended life proposed; this can be obtained by suitable fatigue tests carried out on a minimum of three studs selected at random from the pump case/motor case joint and motor case/motor cover joint.

8.3.2 Impeller and Case Wear Rings (Fig 8.3)

1) Clean the impeller and the case wear rings and check them for damage.

2) Subtract the impeller wear ring outer

diameter from the case wear ring bore, allowing for any temperature difference and compare with the clearance specified in Section 2, Technical Data.

3) If the pump case wear ring requires

renewal, fit the new ring and secure using the socket head cap screws and lock washers. Tighten the screws in accordance with the torque figures detailed in Section 2.



Figure 8.3 : Impeller and Case Wear Ring



8.4 Assembly Notes NOTE: In the event of new components being required refer to the Sectional Arrangement Drawing (Section 8) and quote the circulator Serial No.- stamped on the motor nameplate - in all correspondence with Hayward Tyler.

8.4.1 Assembly of Main Flange Studs (Fig 8.4)

Renew damaged or corroded studs, with reference to Fig. 8.4 and in accordance with the following instructions: 1) Thoroughly clean the threads in the

case with a suitable solvent and/or by wire brushing. Remove any very hard encrustation in the threads by running down a tap but this should be used only as a last resort.

2) Check the replacement studs for

damage to the threads or protective coating during transit. Renovate or reject damaged studs as necessary.

3) Apply high temperature anti-seize

compound or silicone grease to the casing end of the stud.

4) Assemble the stud as follows: -

a) Screw the stud into the case until dimension ‘L’ measures 285 mm in the pump case and 261mm in the motor case.

b) Maintain the ends of the studs on a

common plane to adjacent studs within 2 mm, this is essential to prevent fouling of the Hydraulic Stud Tensioner on the studs either side of the stud being tensioned.

NOTE: When fitting an individual stud to an assembled unit, screw the stud in until its protruded end is on the same plane as adjacent studs. 5) Check the length of the stud protruding

above the casing, the dimension should be long enough to accept the full depth of the nut.

6) When initially fitting the nut, prevent the

stud from turning by using a wrench (spanner) on the squared end.

Figure 8.4 : Assembly of Flange Studs

8.4.2 Motor Case Wear Ring If the motor case wear ring has been removed, refit by using the screws and washer. Torque tighten in accordance with figures given in Figure 2.1.

8.4.3 Main Impeller (Fig 8.5) Fit the impeller as follows: - 1) Remove the protective impeller nut and

fit the impeller key. 2) Fit the impeller washer with the internal

chamfer towards the shaft shoulder. NOTE: In some cases it may be necessary to fit the impeller washer prior to fitting the impeller key.



3) Coat the threads of the left-hand

threaded impeller screw with silicone grease, then re-fit the impeller and the impeller nut.

4) Check that the gap between the key and

the top of the impeller hub does not exceed 0.25mm.

5) Using the special impeller nut spanner

and tommy bar, supplied in the tool kit, and a lead-faced hammer, tighten the impeller nut.

NOTE: The impeller nut has a left handed thread. Do not use any leverage in the water passages of the impeller to oppose force exerted by the spanner, the weight of the rotor will oppose rotation if the spanner is given a few heavy blows with a lead-faced hammer. 6) Draw the impeller and rotor assembly

forwards until the thrust disc rests upon the thrust pads.

7) Measure the dimension between the top

of the impeller and the pump/motor case flange. (Dimension ‘Z’ on Figure 2.1).

Adjust the thickness of the impeller washer as necessary, to obtain the dimension given in Section 2 - Technical Data.

8) Renew the screw, torque tighten as per

motor assembly drawing in Fig 2.1 and punchlock.

9) If the unit is to be stored, fit the transit

canister and cover the flanges with blanks. Slowly fill the motor with inhibitor through the inhibitor filling valve.


insulation resistance to ground of the motor leads is above 200 megohms when measured at the terminal stems with the unit full of water below approximately 20°C, if possible, or at normal ambient temperature. Record Reading.

8.4.4 Heat Exchanger Ensure that the heat exchanger is serviceable and if removed, re-fit in accordance with installation procedures as described in Section 5.



Figure 8.5 : Impeller Setting

8.5 Re-Installation Of Motor The re-installation of the motor assembly to the pump case is carried out in accordance with the installation procedure described in Section 5. WARNING: Reinstallation is only possible with the boiler cold, de-pressurised and drained. Fit a temporary gauge to check the pressure inside the pump casing. Blow

down and cool as required before removing the casing blank. 1) Remove the casing blank and fit a new

flexitallic gasket to the motor flange. 2) Fit the motor, heat exchanger, inter-

connecting pipe work, fill and high pressure purge lines and the secondary cooling water pipe work.



8.6 Parts Lists

8.6.1 Sectional Arrangement

ITEM NO PART NO. DESCRIPTION QTY. 1 42900-2001 MOTOR CASE - FINAL M/C 1

2 42895-2030 BAFFLE WEAR RING 1

3 42577-212 M12 NORDLOCK WASHER 42

4 42900-2028 STUD - MOTOR/COVER 18

5 42751-1019 NUT 18

6 16801M12-35 HEX HD SCREW 6

7 42900-1901 MOTOR COVER - FINAL M/C 1

8 42900-013 MOTOR ROTOR ASSEMBLY 1

9 41778-148 IMPELLER WASHER 1

10 41341-135 IMPELLER KEY 1

11 42469-110 IMPELLER - INITIAL M/C 1

12 42538-1405 IMPELLER WEAR RING 1

13 38882-102 IMPELLER WEAR RING SCREW 3

14 42843-1501 THRUST DISC - FINAL M/C 1

15 42751-1202 IMPELLER NUT 1

16 16884M16-50 SKT. HD. CAP SCREW 1

17 41365-49 JOURNAL BEARING SLEEVE 2

18 39693-139 JOURNAL SLEEVE KEY 2

19 35557-117 JOURNAL LOCKING SCREW 2

20 42276-106 THRUST KEY 1

21 42774-1243 THRUST NUT 1

22 42560-1211 SPACER SLEEVE 1

23 167WBCNN10M0 SPLIT PIN 1

24 42900-1701 C.E. BEARING HSG. - FINAL M/C 1

25 42843-1804 BEARING RING 2

26 42845-1705 SECURING RING - COVER END. 1

27 41365-51T2 JOURNAL TILTING PAD ASSEMBLY 24

28 16884M10-55 M10 x 55mm SOCKET HEAD CAP SCREW 16

29 42577-210 NORDLOCK WASHER M10 22

30 42774-1710 ANTI ROTATION PEG 4

31 42774-1601 THRUST SEAT 2

32 38192-2 MICHELL THRUST PAD 12

33 38185-108 THRUST PAD STOP GMP UNIT 21

34 167WBDGJ62M0 SPLIT PIN 21

35 42843-2501 REVERSE THRUST HOUSING 1

36 42276-140T2 REVERSE THRUST WEAR RING 1

37 16884M6-30 SOCKET HEAD CAP SCREW M6 x 30mm 6

38 16526M6 PHILIDAS NUT M6 6

39 42665-1711 O' RING 1

40 17207M8 M8 SPRING WASHER 12



41 17207M10 M10 SPRING WASHER 90

42 16884M10-95 SKT HD. CAP SCREW 12

43 16884M8-30 SKT HD CAP SCREW 12

44 42900-1801 PUMP END BEARING HOUSING 1

45 42843-1805 SECURING RING - PUMP END 1

46 42777-003 TERMINAL BOX 3

47 42499-411 FLEXITALLIC GASKET 1

48 42900-2101 STATOR SHELL FINAL M/C 1

49 42665-2104 STATOR LAMINATION 1

50 42665-2105 STATOR ENDPLATE 2

51 41667-131 WINDING SUPPORT BRKT 8

52 42665-2108 SPLIT RING - STATOR SHELL 3

53 42900-2110 STATOR KEY 1

54 36810-185 SPLIT RING LOCKING PIECE 1

55 168YSBFG11M0 SCREW - LOCKING PIECE 1

56 42900-2111 BEARING HOUSING LOCK RING 2

57 168YSBFD11M0 1/4" UNC x 3/8" SHCS 7

58 42843-028 FILTER ASSEMBLY 1

59 42900-2904 STATOR LOCK RING 1

60 42665-2903 SPLIT RING - STATOR LOCK RING 1

61 41258-506 STATOR LOCKING SCREW 18

62 16201M10-35 HEX HEAD SCREW 6


64 42900-1003 PUMP CASE - FINAL M/C 1

65 42759-1010 CASE WEAR RING 1


67 42895-1018 STUD-PUMP 18

68 42751-1019 NUT 18

69 42499-335 GASKET - PUMP/MOTOR FLANGE 1

70 42900-006 THERMOCOUPLE-PUMP CASE 1

71 42900-007 RTD ASSEMBLY - MOTOR CASE 1

72 42900-2125 WINDING CABLE 3

73 38192-5 MITCHELL THRUST PAD R(T) 12



8.6.2 Other Items Supplied The following parts and assemblies are supplied by Hayward Tyler but may not be shown on the Sectional Arrangement Drg 42900/002.

PART NO DESCRIPTION QTY 42499/335 GASKET - PUMP/MOTOR FLANGE 1

42900/201 TEMPERATURE INDICATOR (DIAL) 1

42900/004 TEMPERATURE INDICATOR SWITCH 1

42876/006 THERMOCOUPLE – PUMP CASE 1

42900/007 RTD ASSEMBY - MOTOR 1

42554/200 DIRECT MOUNTED THERMOMETER - HE PIPE - HP/LP 2

42900/300 FLOW SWITCH/INDICATOR 1

SP42900/033 TOOL KIT 2 OFF TOTAL

SP42853/031 REMOVABLE LIFTING LUG ASSEMBLY 2 OFF TOTAL

SP42900/045 STUD TENSIONER KIT 2 OFF TOTAL

SP42900/040 HEAT EXCHANGER AND FITTINGS 1

SP42930/042 L.P. PIPEWORK ASSEMBLY 1

39930/209 GASKET - L.P. HEAT EX. CONNS 4

42930/5027 COMPANION FLANGE - LP CONNS 2

16508M16 NUT - L.P. CONNS & H.P. FILL/DRAIN 40

17201M16 WASHER - L.P. CONNS & H.P. FILL/DRAIN 40

42751/5091 STUD-BOLT - L.P CONN 16

42930/5027 COMPANION FLANGE – PURGE COOLER LP SIDE 4 OFF TOTAL

39930/209 GASKET - PURGE COOLER LP SIDE 4 OFF TOTAL

42751/5091 STUD-BOLT - PURGE COOLER LP SIDE 32 OFF TOTAL

16508M16 NUT – PURGE COOLER LP SIDE 64 OFF TOTAL

17201M16 WASHER – PURGE COOLER LP SIDE 64 OFF TOTAL

42754/1908 COMPANION FLANGE – FILL & DRAIN 3

39930/202 GASKET- FILL & DRAIN 3

42751/1921 STUD BOLT – FILL & DRAIN 8

42937/109 PURGE STRAINER 2 OFF - TOTAL

SP42444/035 H.P. DOUBLE FILLING VALVE ASSEMBLY 1

SP42900/060 PURGE COOLER 2 OFF - TOTAL

42900/1042 STUB PIPES 3



8.6.3 Terminal Box

PART NO DESCRIPTION QTY 42774/2701 TERMINAL BOX 1

42774/2707 TERMINAL BOX COVER 1

42774/2708 GASKET - TERM. BOX COVER 1

16012M10/25 STUD - TERM. BOX COVER 26

42774/2705 GASKET - TERM. BOX SUPPORT 1

16012M10/25 STUD - TERM. BOX SUPPORT 12

17207M10 WASHER –SHAKEPROOF 38

16501M10 NUT – M10 38

39988/125 PANEL DESSICATOR 1

42777/2741 GLAND PLATE 1

42774/2711 GASKET - CABLE ENTRY PLATE 1

16012M10/35 STUD - BLANK PLATE 4

17207M10 WASHER 4

16501M10 NUT 4

42777/2740 CABLE GLAND 1

37917/169 BURSTING DISC 1

37917/137 CLAMPING PLATE 2

42333/129 BODY 2

37917/136 GASKET - TOP 2

37917/139 GASKET - BOTTOM 2

37917/140 PROTECTION SHEET 2

16884M6/50 SKT. HD. CAP SCREW - BURSTING DISC 8

42774/2717 TERMINAL BLOCK ASSEMBLY 1

16884M12/55 SKT HD CAP SCREW – TERM BLOCK/BOX 4

189YDNBB53M0 CIBA ARALDITE TWIN PACK AS REQ

42333/131 TERMINAL LINK ASSEMBLY 1

42629/2719 WASHER – TERMINAL SCREW 8

42629/2720 NUT – TERMINAL SCREW 10

36816/126 WASHER – TERMINAL STEM 2

36816/146 NUT – TERMINAL STEM 3

189WPGDC81M0 HEAT SHRINK TUBE AS REQ

189WPGLC54M0 HEAT SHRINK TUBE AS REQ

189WCBJB81M0 SILICON THERMOSETTING TAPE AS REQ



8.6.4 Terminal Gland Terminal Gland Assembly – 3 off- each comprising

PART NO. DESCRIPTION QTY 37977/677 GLAND MOULDING & CABLE ASSEMBLY 1

37977/123 LEAD PROTECTION TUBE 2

37977/125 BACK UP SLEEVE 1

36810/146 BELLEVILLE WASHER 2

8.6.5 Commissioning Spares One set of spares per boiler supplied.

PART NO DESCRIPTION QTY 36823/127 ‘O’ SEAL – CABLE GLAND 8

37977/108 BACK UP RING – CABLE GLAND 18

37977/205 ‘O’ SEAL – STEM 18

42499/411 GASKET – MOTOR COVER 3

42499/335 GASKET – PUMP/MOTOR 9

39930/204 GASKET – HP HEAT EX. CONNS 9

39930/211 GASKET – FILLING VALVE 6

42891/101/4 GASKET – PURGE STRAINER 2

37917/169 BURSTING DISC 2

169XYNFB LOCKING WIRE 35 m ROLL 1

189YCHBB53M0 ARALDITE RESIN 2

189WBCDN54M0 TIE BACK TAPE 2

8.6.6 Drawing List The following drawings are provided for reference:

Figure 8.6 General Arrangement Figure 8.7 Sectional Arrangement Figure 8.8 Terminal Box Figure 8.9 Tool Kit List Figure 8.10 Double Filling Valve

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Section 9 – Stud Tensioning Equipment


9 Stud Tensioning Equipment

9.1 Introduction All items mentioned herein relate to the M56 Stud Tensioner Equipment supplied as a comprehensive kit. This must be used ONLY in conjunction with the circulator manual for the equipment supplied for the specific contract.

9.2 Application The physical dimensions of the pump case/motor case joint and the motor case/cover joint prevent adequate pressure sealing by hand-tightened nuts. For these applications, hydraulically operated stud tensioner heads are supplied with each contract. The tensioner heads stretch the studs and the nuts are then tightened down by hand. When the tension on the stud is released, the load is transferred to the nut to give the required tightness. When working on a circulator flange joint, all the heads are employed simultaneously, each being diametrically opposed. The heads are positioned on the studs in a prescribed sequence, and are pressurised to a specified limit in accordance with each of five consecutive stud tensioning programmes. As the studs are progressively tensioned, the mating flanges are drawn together, so allowing the circulator flange nuts to be tightened or released.

9.3 Description 9.3.1 General The Hydraulic Stud Tensioner Equipment comprises three principal components: - 1) Tensioner head assembly, including the

bridge, tensioner body and piston and threaded inserts (see Fig. 9.2).

2) Hand-pump - including oil reservoir. 3) High Pressure Couplings, hoses and

pressure gauge.

Four metal rods are provided in the kit. One end of the rod is used for tightening the threaded inserts when installing the heads. The other end is used for pulling down the flange nuts. Although each Stud Tensioner is operable by one engineer, this practice is not recommended due to weight and environmental criteria.

9.3.2 Hand Pump The stud tensioner equipment hydraulic pump is a hand operated, dual piston, high pressure unit. Initially, both low and high pressure flow is applied at each pump handle stroke until the tensioning head starts to take load, when the high pressure application continues and the low pressure is diverted back to the oil reservoir. Re-setting of the low and high pressure takes place automatically allowing the pump to operate with maximum efficiency at all times. Pressure limiting valves trip when the pressure exceeds the pump capacity. The pump body contains the oil reservoir, incorporating an oil filter plug and oil pressure return valve for variable pressure release, the pump handle, gauge and quick release high pressure hoses complete the assembly. All the pump components are easy to dismantle for servicing.

9.3.3 Stud Tensioner Heads The stud tensioner heads each comprise a bridge that fits over the stud and stud nut to seat on the flange and is retained by the bridge retainer. A tensioner body incorporating a seal, sits on the bridge and is held in position by the threaded insert, screwed on the stud. The head is hydraulically pressurised via a quick release coupling and high pressure hose. Three of the four heads have two connectors fitted. The fourth head has one connector and one blanking plug. The fourth head is always the last in line in the system, the other heads are interconnected.



9.3.4 Operation Having hand tightened the stud nut, the hydraulic pressure on the tensioning head piston is gradually released, via the hand pump oil return valve, and the load is transferred to the stud nut to give the required tightness. The threaded inserts are unscrewed from the studs and the heads are transferred to the next studs in the tightening sequence.

When the hydraulic pressure, in accordance with the stud tensioning program, is applied to the tensioner head, the body reacts against the threaded insert which in turn stretches the stud. While the stud is stretched, the stud nut is hand tightened, using the bar provided in the kit.

Figure 9.1 : Hydraulic Stud Tensioning Equipment



9.4 Assembling The Stud Tensioner (Fig. 9.3)

The hand pump and its accessory hoses are normally provided, in the toolbox, already assembled needing only to be connected to the tensioning heads. However for information purposes, the assembly of the stud tensioner kit is as follows: - 1)

a) Remove the hand pump, complete with pressure gauge, high pressure hoses and hose couplings from the hydraulic pump tool box.

b) Ensure that all studs are

scrupulously clean and that their threads are undamaged. Carefully examine that portion of each stud thread protruding beyond the flange nut after fitting. If the studs have been in service for some time, inspect as described in the Section 8.

c) When tensioning studs of the

circulators which have been in service, inspect all faces of each flange nut. Reject any damaged nuts. (Damaged faces of nuts can be re-ground for subsequent re-use).

CAUTION: Never lubricate the stud top threads, or those of the threaded insert. 2) Install and hand tighten all flange nuts.

Apply silicone grease or high temperature anti-seize compound to the threads and faces of each flange nut.

3) Connect the high pressure feed hose via

the quick release female connector to the gauge tee on the pump.

4) Assemble the load cell and bridge, over

the first set of bolts (diametrically opposed) to be tightened. The bridge window should be positioned so that access to the nut is obtained. It is normal for the bridge window to face

radially outwards from the centre of the circular flanged joint.

NOTE: The bridge base circumference should sit flatly against the surface against which it is being tensioned. 5) Attach each threaded insert into the bolt

tensioners by screwing onto the threads protruding above each nut. Screw down the inserts using the tommy bars supplied with the equipment, until contact with the load cells is achieved.

CAUTION: Body and piston seals will be damaged if the piston protrudes excessively from the tensioner body, observe the yellow maximum extension warning line. (Maximum extension 6mm) NOTE: If the seals need replacing, refer to the operator’s manual provided with the stud tensioning equipment. 6) Connect the end of the high pressure

feed hose to the first tensioner head. 7) Fit one of the inter-connecting hoses

between the first and second heads. 8) Connect up the second and third heads

and finally, using the one remaining hose. Connect the fourth head (i.e. with a blanking plug fitted) to complete the circuit.

9) Check the oil level in the hydraulic hand

pump, fill or top-up if necessary. NOTE. The quick release female connectors have a knurled security locking ring in the centre. This must be turned to lock the spring-loaded end of the coupling to eliminate the possibility of an accidental disconnection. CAUTION: Do not pressurise an un-connected male coupling.



Figure 9.2 : Single Piston Stud Tensioner - Exploded View



Figure 9.3 : Single Piston Stud Tensioner - General Arrangement



Figure 9.4 : Quick Release Coupling



Figure 9.5 : Nut Tightening Sequence (1)



Figure 9.5 : Nut Tightening Sequence (2)



9.5 Replenishing The Pump Tank

The pump is supplied already filled with oil but after repeated use the oil should be replenished as follows:- 1) Unscrew the oil filler plug from the top

pump tank. 2) Replenish the tank from the 5 litre

container of hydraulic fluid to the bottom of the level tube.

9.6 Indexing It is essential that the gasket is uniformly compressed and the studs evenly prestressed. To ensure this, diametrically opposed flange nuts are tightened simultaneously in accordance with a predetermined numbering sequence. Using any convenient nut as No. 1 and working in a clockwise direction, sequentially mark with chalk on the flange periphery, the appropriate nut tightening sequence. Refer to Fig.9.5 for Nut Tightening Sequences.

9.7 Safety Procedures 1) Eye protection and gloves should be

worn when working with high pressure hydraulics.

2) Pressurise slowly, do not exceed the

maximum working pressure stated in the manufacturer’s instructions supplied with the kit.

CAUTION Gauge pressure should be constantly monitored during pump operation. 3) Do not exceed the maximum piston

extension 6mm. indicated by a yellow line.

4) Do not leave a pressurised system

unattended, release pressure if leaving the working area.

5) Check the equipment:

a) Ensure that the hoses are undamaged.

b) Check that all hose couplings are

serviceable and tight on the hose ends and tensioning heads.

6) Check equipment is correctly

assembled:

a) Tensioning head components must be seated squarely within each other and with the motor cover face or motor pump flange.

b) The thread engagement between

the stud and the threaded insert must be 48 mm minimum.

c) Before pressurising, ensure hose

connector security by pulling on each locked connection.

7) Do not attempt to use stud tensioner if

unsure of the correct assembly and operation of the equipment.

8) Do not attempt any repairs on the

system when under pressure.

9.8 Tightening Flange Nuts 1) Fit the four tensioner bodies complete

with threaded inserts onto the studs and screw down on to each bridge. Attach the hydraulic link hoses.

2) Ensure that the insert is fully depressed

within the tensioner body. 3) Depress the hydraulic piston fully in the

tensioner body by:

a) Opening the oil return valve on the hydraulic hand pump using the winged control valve screw.

b) Fully tightening the threaded inserts

using the rod provided.

c) Closing the oil return valve on the hydraulic pump.

4) The pump, hoses and tensioner heads

are pre-filled and system venting should not be necessary. However, should venting of the system be required,



loosen the blanking plug from the last head in the circuit and operate the pump until air free fluid emerges from around the plug on completion of venting.

5) Using the hydraulic hand pump, obtain a

true pressure stipulated for the 1st pass of the 5 passes given in the following table.

CAUTION; The indicated gauge pressures are true operating pressures. Never exceed maximum working pressure for the head when tensioning, or damage to the tensioner or to the studs may occur. See the manufacturer’s instructions supplied with the kit for the maximum working pressure. 6) The piston stroke and pressure should

be continually monitored so that neither go above the corresponding working pressures. If the maximum piston stroke is reached before working pressure is achieved go straight to procedure (8).

Close the pump stop valve, then pressurise the system to the required pressure, when this is reached stop the pump to hold the pressure.

7) Check the pressure gauge to ensure the

pressure is holding constant. When satisfied that the pressure is stable, use the tommy bars to rotate the nuts, through the access windows, down towards the joint surface. Fit the appropriate rod (bar) to the flange nuts and fully hand tighten. Hand tighten adjacent loose nuts.

8) Remove the stud tensioner heads by:-

a) Screwing in the oil return valve on the pump to release the oil pressure (which transfers the load to the nuts).

b) Tightening, then releasing the

threaded insert.

c) Screwing out the oil return valve on the hand pump.

d) Removing the threaded insert complete with body.

e) Removing the bridge.

f) Disconnect the hydraulic hoses.

NOTE: If the required pressure is not reached, return to step 2. 9) Transfer the stud tensioners to studs

numbered 2 in the tightening sequence. Repeat operations 2) to 8).

10) Continue tightening progressively to the

numbered sequence until all the nuts are tightened to the 1st pass pressure i.e. nuts 2 in turn then nuts 3 followed by nuts 4, then 5 and so on.

11) Repeat the tightening sequence round

the flange of a 2nd, 3rd, 4th or 5th pass, at the stud tensioning pressure stipulated for the applicable pass.

12) If, on the 5th pass, the flange nuts can

be tightened further, additional passes at maximum pressure should be made until no further tightening is possible.

13) When all flange nuts are correctly

tightened, the gasket is fully compressed and the nuts pre-stressed.

14) Check at several equidistant points on

the flange periphery that the gap between the faces of the pump case and motor flanges is less than 1.5 mm.

9.9 Releasing Flange Nuts WARNING: Ensure that the motor is electrically isolated, adequately supported and de-pressurised, before any nuts are slackened. 1) Fit the tensioner heads to the studs and

connect the hoses and hand pump. If one head is used for this operation it must be the head with the blanking plug fitted.



2) Screw down the threaded insert fully, then release it one half (½) turn. Pressurise the system to the 5th pass pressure shown on the table in Section 2, Figure 2.1 and unscrew each flange nut one half (½) turn using the appropriate bar. Repeat for every stud on each pass.

3) Should the nuts fail to move, a slow

gradual increase in pressure should be made until the nut lifts of the flange face. At this stage, a further increase in pressure is un-necessary and will not assist in freeing a tight nut.

CAUTION: Never exceed the maximum system pressure when removing the nuts.

4) If the nuts are still in contact with the

flange and cannot be removed with the system at absolute pressure, consult Hayward Tyler for advice.

5) Repeat the stud tensioning and nut

unscrewing sequences diametrically until all flange nuts are released.

6) After use, thoroughly clean, examine for

damage and lubricate each component of the stud tensioner equipment. Wrap all components in suitable water-proof material then store in a clean, dry area in their respective tool boxes.



9.10 Parts List (Fig 9.6) See Figure 9.6 for assembly drawing.

ITEM DESCRIPTION QTY M56 stud tensioners 4

Consisting of

1 BODY 1

2 RAM 1

3 BRIDGE 1

4 M56 PULLER 1

5 ADAPTOR 1

6 BONDED SEAL 2

7 INNER SEAL SET 1

8 OUTER SEAL SET 1

9 SNAP NIPPLE 1

10 M56 SOCKET 1

Figure 9.6 : Stud Tensioner Assembly (Hose connection position may vary)

Also included: -

Hand Pump Complete With 1500 Bar Pressure Gauge

Hydraulic Harness Manufactured From Flexible Hose And Quick Release Couplings To Tension 4 Tools Simulteaneously.

Harness Consisting Of 5 Metre Lead Hose And 1.5 Metre Interconnecting Hoses

Tommy Bars, Oil Pack, Spare Seals, Storage Box For Tensioning Heads, Storage Box For Pump And Harnesses.Manuals For Tensioner And Hand Pump.

Section 10 – Purge Cooler and Strainer


10 Purge Cooler and Strainer

10.1 Description 10.1.1 ‘Y’ Type Strainer A strainer is required at the inlet to the purge cooler to prevent large particles from entering and thus reducing cooler efficiency and service life. This strainer consists of a simple pressure vessel, with a bolted cover and gasket containing a strainer screen. The strainer screen is 160-mesh stainless steel. Ensure that the strainer is installed with the fluid flow in the correct direction as shown by the arrow stamped on the strainer body. The strainer may be fitted vertically provided the flow is downwards.

10.1.2 Cooler A purge cooler is required to limit the temperature of water entering the motor to 49°C to prevent damage to the electrical windings and shaft bearings. It consists of a simple single ‘U’ tube, through which flows high pressure purge water, surrounded by an outer tube which forms an annulus for the passage of low pressure cooling water.

10.2 Commissioning Check that the purge strainer, cooler and the associated valves have been correctly installed. The strainer and cooler and the system pipework should have been flushed after installation. If in doubt flush the strainer, cooler and pipework. 1) Ensure that the strainer high pressure

supply valve is shut. 2) Open valves to establish a supply via

the cooler to the double filling valve, which should be closed.

3) Ensure the motor fill and purge valve

remains closed and check for pressure on fill & purge supply gauge. Open the pressure gauge shut-off valves.

4) Open any vent / drain valves and flush

the line through the blow down valves. When clear air-free water is discharged, close the valves.

5) Check that the pressure on gauge is

sufficient to enable motor filling to proceed. Also check the temperature on gauge. This should indicate cold water is present.

6) The motor may now be filled with cold

clean water from the condensing water pump supply by opening the double filling valves.

7) The motor filling rate should not exceed

2 litres/min and this should be controlled if necessary using the fill & purge double shut-off valve and noting the pressure on the fill & purge gauges.

Note: If possible the supply line should have a suitable flow restriction orifice correctly and cleanly installed.

10.3 Operation Initial operation of the system, is for low pressure filling of the motor, (see Para 10.6) thereafter, the system operates on the high pressure side of the supply.

10.3.1 Strainer 1) Connect the HP fill and purge system as

follows: -

a) Ensure the LP filling valves and are closed. Close the strainer shut-off valve (to the fill & purge cooler).

b) Pressurise the strainer by opening

the valves and from the boiler feed water pump and strainer inlet valve.



10.3.2 Cooler Operation of the cooler is in conjunction with the purge strainer. Purge water applied to the motor through the high pressure fill line, in an emergency, will limit motor temperature, so protecting the motor until inspection and rectification are possible. The flow of purge water must be sufficient to stabilise the temperature of the motor and overcome any water loss due to leakage, etc., as follows: - NOTE: 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 and solids into the motor.

1) Apply the High Pressure Purge supply

to the motor as follows: -

a) Check that the fill and purge cooler is supplied with secondary cooling water by opening the fill and purge L.P. coolant shut-off valves to and from the cooler.

b) Check that all HP double filling

valves are closed.

c) Admit high pressure purge water via the boiler feed water pump through the strainer by opening valve.

d) Crack open the drain blow down

valves to flush out any debris in the pipe.

e) When the flow rate is steady at

approx. 3.8 litres/minute check the temperature on the fill & purge thermometer. The water temperature should not exceed 49°C.

f) Close the blow down valves and

check that the pressure on the fill & purge supply pressure gauge exceeds the boiler circulation system pressure by approximately 7 bar.

g) Open the double filling valve to

admit purge water into the motor.

h) Check that the temperature does not exceed 49°C. Check that the flow rate and pressure gauges readings are satisfactory.

10.4 Maintenance The frequency of strainer cleaning and filter element replacement is dependent on the cleanliness of the supply. It is suggested that the strainer is inspected after six months and again after 12 months operation, and from these inspections, the station maintenance authority should be able to establish an inspection frequency to be performed thereafter, should this be required. Alternatively, since the purge system is normally used for initial commissioning only and thereafter infrequently. It is recommended that the strainer be cleaned on completion of commissioning and thereafter flushed out as described later in this section, after each usage. Cleaning should only be necessary when large amounts of sediment are evident during flushing.

10.4.1 Strainer Cleaning and removal of the strainer and basket can only be undertaken when purge supply to the motor is not required.

10.4.2 Cleaning 1) Check that the valves in the HP and LP

supply lines are closed. Close the strainer inlet and outlet valves.

2) Allow retained fluid to drain down by

removing the drain plug (where fitted). 3) Remove the cover and withdraw strainer

screen. 4) The strainer screen can be cleaned with

a suitable solvent. Ultrasonic cleaning is recommended to avoid damage to the filter media.



5) Always remove all traces of the cover gasket and refit the new one.

6) Reassembly is the reverse of the above

procedure however care must be taken to seat the filter screen properly before replacing the cover.

10.4.3 Filling and Venting Open any vent / drain valves and flush the line through the blow down valves. When clear air-free water is discharged, close the valves.

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-84-

Figure 10.2 : Purge Cooler

-85-

Documents

EP11030 & 11032 Hisar O & M Rev 0___June 2009