1. 1.Shipping

Before transporting and lifting the water pump, check the load limit of the load-bearing components, especially paying attention to the gravity bearing point. And strictly follow the lifting position on the water pump or packaging box for lifting. The lifting diagram is as follows:

It is best to use transportation tools with elastic pads or wooden boards during transportation. And the pump body and other components must be tightened to prevent falling and damage during transportation.

2 Temporary storage

The load-bearing capacity of the support plate must be greater than the weight of the stored object.

The seal on the pump body must be properly sealed before installation, and can only be opened during installation.

The components should be stored in a dry and stable environment; If the parts are stored outdoors, they should be protected against moisture and water.

When the pump body is stored for a long time, the rotor should be turned every half month to prevent jamming between the rotor and stator, and to prevent the pump shaft from bending and deformation.

Water pumps are generally stored for no more than 6 months. If the water pump is stored for a long time or if the rotor disc does not move, it needs to be disassembled and inspected under the guidance of relevant personnel, re polished, cleaned, and assembled.

1. Preparation before installation

1) Check the basic surface, which should be flat and solid. The surface around the anchor bolt hole should be flat to facilitate the placement of shims;

2) Review the foundation dimensions based on the pump installation foundation drawings;

3) Clean up debris and debris from the foundation surface, surroundings, anchor bolt holes, and pump pits to ensure the installation of the foundation plate and outer casing;

4) Use appropriate transportation tools and lifting equipment to transport the pump and its accessories to the site, and hang them in appropriate positions. Carefully remove the outer packaging to prevent damage to the internal equipment;

5) The components placed on site must be properly stored to prevent moisture, dirt, and damage.

2 Equipment installation

2.1 Pipeline installation

1) The suction pipeline diameter of the pump unit should have the most sufficient size, ensuring a flow rate of V=1~2m/s inside the pipeline to reduce resistance and ensure that the system has sufficient effective NPSHa;

2) The outlet pipeline should be equipped with a regulating valve, located as close as possible to the outlet of the water pump;

3) The outlet pipeline should be equipped with a check valve, which should be installed after the regulating valve;

4) The inlet and outlet pipes of the pump should have separate supports to minimize the load exerted by the pipes on the pump;

5) The determination of the installation height of the pump is based on the premise that the pump always operates under water level conditions, and the pump is not allowed to operate without water level;

6) Before installing the pump, a corresponding water pressure test should be conducted on the inlet pipeline to ensure the sealing of the inlet pipeline system.

2.2 Installation of pump unit

1) Check if the pump body, outer cylinder, motor and other components are damaged;

2) Place the sizing block on both sides of the foundation bolt hole, place the foundation plate on the sizing block, put on the foundation bolt, screw on the nut, make the foundation bolt located in the foundation bolt hole, adjust the length of the foundation bolt extending out of the foundation plate, adjust the alignment of the foundation plate and the pump pit hole, and grout into the foundation bolt hole after adjustment;

3) After the grouting in the anchor bolt hole is dry, adjust the sizing block to make the foundation plate level, with the levelness tolerance of 0.05mm/m, and tighten the anchor bolt;

Note. Basic level is crucial, and if the foundation is uneven, it may cause vibration of the pump or motor.

4) Perform secondary grouting, pay attention to the levelness during the grouting process, and recheck the levelness after 5-6 days of cement solidification;

5) Clean the inside of the outer casing, lift it into the pump pit hole and fix it on the foundation plate, measure its levelness, and after measurement, cover the simple opening of the outer casing with a lid to prevent foreign objects from falling into the casing, which may cause malfunctions during pump operation;

Note: During the lifting and measurement process, be careful not to drop foreign objects into the cylinder. If they fall into the cylinder, they should be cleaned up in a timely manner.

6) Lift the pump body into the outer cylinder, fix it to the cylinder, and check the levelness of the motor base. The allowable levelness should be 0.05 mm/m; The pump body is lifted using lifting holes, and the lifting method is shown in the following figure:

7) Lift the motor and adjust the coaxiality between the motor coupling and the pump coupling by adjusting the screws on the motor base. The outer circle deviation of the coupling is required to be ≤ 0.08mm. After adjustment, tighten the bolts between the motor and the motor base and install the coupling pin. Adjust the screws and measure the centricity of the coupling as shown in the following figure:

8) Install inlet and outlet pipelines, connect degassing hole pipes, cooling water pipes, sealing water pipes, and various instrument pipelines.

1. Preparation before startup and operation

1) Check the water level of the hot well, and its minimum water level should not be lower than the specified minimum water level;

2) Check if the installed instruments can work properly;

3) Add ISOVG30 (rolling bearing), ISOVg46 (sliding bearing) mechanical oil or turbine oil to the thrust bearing, and add them to the position indicated on the oil mark. For the lubrication method and maintenance of the thrust bearing, please refer to 8.4 Thrust Bearing Components;

4) Disconnect the elastic coupling and check if the motor direction is correct (counterclockwise when viewed from the side of the motor to the pump), then install the elastic pin of the coupling;

5) Fill the water pump with water, carefully check whether the filter screen, sealing water, and cooling water pipelines of the inlet pipeline are unobstructed, and pay attention to timely cleaning;

6) Manual turning and water pump rotor rotation should not be less than 3 revolutions, check for any abnormal rotation, and the turning should be flexible without jamming;

7) Close the pump outlet pipeline valve and pressure gauge plug;

8) Open the external seal water supply valve to ensure that the seal water pipeline is smooth, and then adjust the seal water pressure to maintain at 0.4~0.6MPa

0.3-0.6 m/h; If there is cooling water in the thrust bearing, the bearing cooling water valve should be opened to ensure the smoothness of the cooling water pipeline. The cooling water flow rate should be adjusted to 0.8~1.2m/h and the pressure should be 0.3~0.6MPa.

9) Adjust the positioning plate and clamping ring screws of the mechanical seal. For specific operations, please refer to 8.3.1 Mechanical Seal Components.

2. Start

1) Start the motor to the rated speed and open the pressure gauge plug;

2) Gradually open the valve of the pump outlet pipeline to the required working condition, check the readings of each instrument and the leakage of sealing water,

Note that under the condition of the outlet valve being closed, the operating time should not exceed 2 minutes.

3. Operation

1) Check if the valve on the pump outlet pipeline is open;

2) Verify whether the pump outlet pressure meets the specified requirements;

3) Check if the pump system runs smoothly and if the vibration meets the standard. The vibration of pumps is generally evaluated according to JB8097-1999 “Measurement and Evaluation Methods for Pump Vibration”, and a level of C or above is considered qualified. The condensate pump with a center height of over 225mm and a speed of 1480r/min is classified as the second category, and the corresponding C-level qualification standard is a vibration intensity level of 4.5mm/s. The vibration measurement points (1, 2, 3) are shown in the following figure:

4) Pay attention to the temperature monitoring instruments for the motor and pump thrust bearings;

The temperature control of the pump thrust bearing temperature measurement metal platinum resistance is: the bearing temperature rise does not exceed the ambient temperature of 40C, the bearing temperature alarms at 75C, shuts down at 80C, the oil temperature alarms at 65C, and shuts down at 70C; The temperature control of the stator winding temperature measurement resistance of the motor is: 130C alarm, 140C shutdown. The temperature control of the upper and lower bearings temperature measurement resistance of the motor is: 70C alarm, 80C shutdown (the alarm and shutdown values of the motor temperature measurement element are provided by the motor factory).

Attention: (1) The installation elevation of the pump is determined based on the condition that the pump is always at a water level. Therefore, during operation, the water level of the condenser hot well should not be lower than the minimum water level for any suitable working conditions of the generator set.

(2) The pump is absolutely prohibited from running below the minimum flow rate. Before and after starting the pump, it should pass through this area quickly and cannot run with the valve fully open to avoid vibration, noise, and possible cavitation.

5) When the pump unit adopts variable frequency operation, try to reduce the frequency of variable frequency operation as much as possible, and cooperate with adjusting the outlet valve for variable operating conditions to improve the service life of the pump shaft;

4. Shutdown

1) Turn off the power and observe if the water pump rotor stops smoothly;

2) Close the outlet valve and pressure gauge plug;

3) Close the inlet valve;

4) Close the cooling water valve;

5. Work after shutdown

1) The water level of the hot well should be above the lowest water level;

2) Close the outlet valve and pressure gauge plug;

3) When in standby mode, continue to supply external sealing water;

4) Electric motors are moisture-proof.

6. Operation of standby units

The standby unit should be put into operation regularly. It is recommended to rotate the two pumps used in the same unit every 30-40 days and keep the standby pumps in normal operation.

After the pump is transported to the site and properly stored, it is generally not allowed to disassemble and inspect within six months.

1.Pump disassembly

1) Remove the connecting bolts between the motor and the motor frame, lift out the motor and place it on a wooden pad;

2) Remove the pipe plug on the lower (or side) part of the thrust bearing component, and drain the lubricating oil of the thrust bearing component through a temporary connecting pipe;

3) Remove the instrument connections, sealing water, and cooling water connections. Remove the connecting bolts on the flange of the pump outlet pipeline and remove the sealing gasket at the joint;

4) Remove the connecting bolts between the pump and the outer casing, lift the pump body vertically, and place it on an assembly frame, assembly pit, or flat surface with a suitable height;

5) Remove the coupling (requiring tools such as pullers) and locking nuts in sequence, and the thrust bearing components can be directly disassembled and repaired separately

6) When the pump body is placed flat on a flat surface, remove the water blocking ring, mechanical seal (see 8.3.1 Mechanical Seal Components for disassembly and assembly of mechanical seal) or packing gland, packing, machine seal box or packing box in sequence

7) For condensate pumps with models KNL200-360 and above, use two M10 long bolts or round rods with M10 threads at the front end to pull out the throttling sleeve;

8) Then measure and disassemble the pump from the inlet to the outlet;

9) Remove the impeller nut, water inlet horn, first stage impeller, and key in sequence;

10) Remove the guide vane housing, impeller positioning sleeve, secondary impeller, key, etc. in sequence, and remove each level step by step according to this method. During the disassembly process, wooden blocks should be added to both the rotor and stator to maintain a relative level and prevent damage from rubbing and collision of the parts;

11) Remove the reducer housing, guide bearing components, and intermediate connecting pipe;

12) Remove the sleeve coupling connecting the two shafts, remove the pump shaft, and hang the pump shaft on a V-shaped wooden pad or rubber surface;

13) Then extract the transmission shaft from the water outlet housing and hang it on a V-shaped wooden pad or rubber surface;

14) The LDTN condensate water pump is dismantled from the outlet to the inlet side;

15) The entire dismantling process ends.

2.Pump assembly

The assembly process of the pump is basically the opposite of the disassembly process.

The adjustment of the axial clearance of the pump must be carried out independently in the following aspects:

1) Ensure the correct position of the impeller’s displacement in the guide vane housing. When adjusting, the movement of the rotor components is achieved by adding wooden blocks or rubber pads to the hydraulic jack to support the impeller nut. The final positioning of the axial displacement of the rotor components is adjusted by the adjusting nut on the thrust bearing body. The operation method is as follows:

When the water pump is in a vertical or flat position, loosen the bolt on the adjustment nut and take it out; Use an iron rod or hook wrench, and if necessary, turn the adjusting nut with an extended sleeve. Rotate counterclockwise to lift the adjusting nut, place the rotor at the bottom, and lightly tap the upper end of the transmission shaft to ensure that the rotor is at the bottom; Then use a jack or wooden stick to push the rotor towards the other end, record the total displacement of the rotor, and place the rotor below half of the total displacement. Finally, rotate the adjusting nut clockwise and tighten the bolt on the adjusting nut.

2) All parts must be cleaned thoroughly before assembly. Replace all O-ring seals or paper pads;

3) Appropriate lubricants should be used during the assembly process. When assembling rotor components, it is recommended to use a dense and thick velvet cloth to vigorously wipe the molybdenum dioxide powder onto the assembly surface of the shaft and the matching surface of the installed part holes. The relative friction surfaces between the rotor and stator are also treated similarly. When the above conditions are not met, 20 engine oil can be used as a substitute, but lithium based lubricating grease containing molybdenum dioxide powder should be used at the friction surface gap, and the oil coating should be uniform and thin.

4) Water lubricated bearings must not come into contact with grease or strong alkaline substances, and it is allowed to apply molybdenum dioxide powder on the surface of the corresponding shaft sleeve

5) The key issue to note during the disassembly and reassembly process of the pump is that the shaft should always be kept in a free state free from external forces throughout the entire process to prevent high-precision shaft bending and deformation.

1.Jumping and clearance inspection of rotor components

During the overhaul period of the pump, the jumping (or shaking) of the rotor components should be checked, which can be done using a horizontal lathe or a standard

The V-shaped iron supports the rotor and measures it with a dial gauge. When measuring, follow the requirements in the rotor component diagram and use the position of the guide bearing with the farthest distance between the two as the reference.

2.During major repairs, the following clearances should be checked

The clearance between the front and rear rings of the first stage impeller.

The clearance between the front and rear ring of the secondary and standard impeller.

Gap between throttle sleeves.

Clearance between guide bearings and interstage guide bearings.

The allowable values for the above gaps are listed below (diameter direction): (mm)

3.Sealing components

3.1 Mechanical seal components

The mechanical seal is a containerized mechanical seal, with two water systems, as shown in the following figure and its explanation. Q. D is the inlet and outlet of sealed water, Q needs to be connected to external water supply, with a flow rate of 20-30L/h and a pressure of 0.1-0.2MPa. The water quality is condensate or desalinated water, with a temperature less than 38 ° C. As long as there is dripping water flowing out, it can be recovered or discharged into the trench by the user; E is the sealed flushing water, which needs to be connected to an external water supply with a flow rate of 0.3-0.6m/h and a pressure of 0.4-0.6MPa. The water quality is condensate or desalinated water, with a temperature less than 38’C. F is the outlet of the machine seal exhaust and pressure relief water, which has been connected through pipelines and pump bodies, and users do not need to Install adapter pipe.

Note:

1) Before starting the pump, connect the sealing water pipeline to meet the water pressure and quantity. If there is water leakage from the upper part of the machine seal after the sealing water is connected but before starting, it indicates that the sealing water pressure or flow rate is too high and needs to be adjusted to allow dripping water to flow out of the OD.

2) Due to Q D sealing water needs to be recycled by the user themselves. If this condition is available on site, E sealing flushing water may not be connected. If the conditions for user’s self recycling are not available on site, only E sealing flushing water can be connected without the need for Q D Sealing water

Special reminder: Before starting or turning the pump, it is necessary to first tighten the mechanical seal clamping ring and the screws on it, then loosen the small screws on the circular or square positioning plate, move the positioning plate outward, and then tighten the small screws, or remove the positioning plate and the small screws for storage. When the pump unit is shut down for disassembly and maintenance, first loosen the small screws on the mechanical seal positioning plate, then move the positioning plate to the slot of the mechanical seal shaft sleeve, tighten the small screws, and then loosen the screws on the clamping ring to facilitate the overall disassembly and assembly of the mechanical seal.

3.2 Packing sealing components

The schematic diagram of the packing sealing interface is shown in the figure.

Requirements for water system parameters of packing sealing structure, external sealing water flow rate: 0.3~0.6 m/h, pressure: 0.4~0.6 MPa,

Temperature:<38C, water quality: desalinated water or condensate water; Cooling water flow rate: 0.8~1.2m */h, pressure: 0.3~0.6MPa,

Temperature:<38 ° C, water quality: pure industrial water.

4. Thrust bearing components

4.1 Rolling bearing thrust components

The thrust bearing adopts No. 30 mechanical oil or steam turbine, and the oil tank must be thoroughly cleaned before oil injection. The oil level should be maintained at the position indicated on the oil gauge. The temperature rise of lubricating oil in the oil tank shall not exceed the ambient temperature of 40 ° C. The bearing alarm oil temperature is 75 ° C, the shutdown oil temperature is 80 ° C, the oil temperature is 65 ° C, and the shutdown is 70 ° C. Lubricating oil should be sampled and tested regularly. The use of oil cups and the method of adding lubricating oil are shown in the following figure:

4.2 Sliding thrust bearing components

The thrust bearing is lubricated with ISOVG46 oil, and the oil tank must be thoroughly cleaned before oil injection. The oil level should be maintained at the position indicated on the oil gauge. The temperature rise of lubricating oil in the oil tank shall not exceed 40 ° C above the ambient temperature, with an alarm oil temperature of 65C and a shutdown oil temperature of 70 ° C. Lubricating oil should be sampled and tested regularly. The cooling water used for the built-in oil cooler is industrial purified water, with a temperature of t ≤ 38 ° C, a pressure of 0.4~0.6Mpa, and a flow rate of 0.8~1.2m/h, adjusted according to the ambient temperature. After the first 300 hours of operation, the lubricating oil must be replaced, and the oil change cycle is generally 8000 hours. When starting and stopping frequently, the oil temperature is too high, or the oil is dirty due to external factors, the oil change cycle should be shortened. The cooling water of the built-in oil cooler is industrial purified water.

Temperature control of thrust and guide pads: alarm temperature of 75 ° C, shutdown temperature. When the temperature is too high, the machine should be stopped immediately to analyze the cause. If necessary, the bearings should be opened for inspection, maintenance, or replacement of the tiles. Familiar technicians must guide the operation, and be careful not to damage the tile surface. The thrust bearing body is shown in the following figure:

5. Guide bearings and interstage bearings

This bearing is a water lubricated bearing with high sensitivity to foreign impurities and particles. When the condensate pump participates in the system flushing, a filter must be installed upstream of the pump inlet. After the flushing is completed and it is confirmed that there will be no more impurities and particles in the system water, the temporary inlet filter should be removed to ensure effective NPSHa. If a fixed filter is installed, the mesh size is usually 40 mesh.

1. Comply with local environmental regulations of the power station

2. Packaging parts should be handled by the recipient

3. After use, the remaining lubricants, cleaning agents, processing agents, and unused electrical equipment should be handled by the operators themselves.