Copt Manual 5w10x

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INSTRUCTION MANUAL FOR CARGO PUMPING SYSTEM

REV.

MESSRS.

NAMURA SHIPBUILDING CO., LTD.

HULL NO.

286

DA. TE

CHECKED BY DRAWN BY APPROVED BY

DESCRIPTION

ORDER NO.

APPROVED BY MODEL ,

KV400,RX I ,etc.

DATE

JAN. 09, 2007

D RAW.NO.

TIF - 0701 09-6

!~c~

CHECKED BY REV. '

DRAWN BY

SHlnKO IN:D.LTD.

5-7-21, Ohzu, Minami-ku, Hiroshima, Japan TEL : ( 082 ) 508 - 1000

FAX : ( 082 ) 508 - 1020

IL

MESSRS. NAMURA SHIPBUILDING CO., LTD. HULL NO.

286

INDEX SERVICE NAME

NO.

MODEL

PAGE

KV400

2

CARGO OIL PUMP CARGO OIL PUMP TURBINE

RX 1

87-1 -28

3

BALL~sT PUMP

cV450

82-1 -1 5

4

CARGO OIL STRIPPING PUMP

1

5

KPH200 REMOTE CONTROL SYSTEM FOR CARCO OIL STRIPPING PUMP KSC65

SHmKO IIVo. L To.

81 -1 -1 5

9 6A- I -8

97-1 -7

INSTRUCTION MANUAL FOR CENTRIFUGAL PUMP (KV) This instruction manual describes construction, operation, maintenance, disassembling, assembling, etc. of model KV pump.

CONTENTS Page

CHAPTER I CONSTRUCTION . . . . . . 81-2 2. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Pump stuffingboxseal . . . . . . . . . . . . . . . . . . . . . . . 3

6. Bulkhead stuffing box and intermediate shaft . . . . . . . . 3 wlth gear coupling 7. Steam cleaning device . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 2 CAUTION FOR INSTALLATION AND PIPlNG . . . . . . . 8 1 4 l . Place of installation and foundation . . . . . . . . . . . . . . . . . 4

2. Finishingofpumpmounting seat . . . . . . . . . . . . . . . . . . . 4 3. Caution for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4. Suction piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Permissible deformation ofbellows . . . . . . . . . . . . . . . . . 5 7. Fitting offloating shaft complete . . . . . . . . . . . . . . . . . . 5

CHAPTER 3 OPERATION . . . . . . . . . . . . . . . 81-6 1 . Check before operation . . . . . . . . 6 2. Starting . . . . . . . . . . . . . . . . . . 6 3. Stopping . . . . . . . . . . . . . . . . . . 6

CHAPTER 4 MAlNTENANCE . . . . . . . . . . . . . . 81-7 1 . Caution during operation . . . . . . . . . 7 2. Ban bearing . . . . . . . . . . . . . . . . . . 7 3. Mechanical seal . . . . . . . . . . . . . . . 7 4. Gear coupling . . . . . . . . . . . . . . . . 8

5. Bulkhead stuffingbox . . . . . . . . . . . 8 6. Maintenance check list . . . . . . . . . . . 9 7. Lubricants . . . . . . . , . . . . . . . . . . . 9 8. Standstill . . . . . . . . . . . . . . . . . . . 9

CHAPTER 5 STANDARD CLEARANCE AND LIMIT OF USE . . . 81-10

CHAPTER 6 DISASSEMBLlNG AND ASSEMBLlNG . . . . . . 81-11

1 . Disassembling . . . . . . . . 1 1 2. Assembling . . . . . . . . . . 12

CHAPTER 7 TROUBLE SHOOTlNG AND REMEDIES . . . . . . 81-13

CHAPTER 8 REPLACEMENT PARTS . . . . . 81-15

C~!D I suINKomlo.LTo.

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1 CONSTRUCTION CHAPTER 1 . GENERAL The model KV pump is of a vertical single-stage double-suction centrifugal type, and the pump and driver are connected with the flexible couplings through an intermediate shaft and a bulkhead stuffing box, the construction being simple for ease ofhandling, overhauling and caretaking. Fig. I .1

2. PUMP CASING The volute casing is split into two halves along a vertical plane containing the axis. Since the volute casing is of double-volute type the radial thrust on the impeller is almost balanced. Also since the suction and discharge nozzles are provided on the rear half casing, the

o

34

20 9

7

3 53

ldj

3 54

54

l

48

rotating element can be taken out by removing the front half casing (2) without

27

disturbing the suction and discharge pipings.

2

1

38 \

A vent to be connected with the stripping or priming line and an air valve are provided on the volute casing.

Lt L 11t 1t ,l t,

t

l

/

// ll

L 1\

3. IMPELLER

/

\

16

/

19

The impeller (16) is of the double-suction type and hydraulically balanced. It is so designed as to improve pump efficiency and

7

54 18

1le 2

372

suction performance. Moreover, the im-

57

peller is statically and dinamically balanced.

35

2

3 7

7

14

4. BEARING

10

The rotating element is ed by ball bearings on both sides of the pump casing. The 6300 type ball bearing is fitted in the solid inner case (14) with the split type bearing housing and can be taken out together with the rotating element if the cap

REa. FOR IPUMP

PART NO.

of the bearing housing (7) is removed.

(1) The ball bearing (34) at the coupling end is secured in the housing by pressing its

outer race by means of the cover (9). This serves to the weight of the rotating element.

(2) The ball bearing (35) at the bottom end is not fixed axially in view of the thermal expansion of the shaft (1 8).

(3) Grease is used as lubricant for the ball bearing.

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AEa. FOR pUMP

PART NO.

NAME OF PART

NAME OF PART

1

VOLUTE CASING

1

2

VOLUTE COVER

1

48.1

FLINGEA

1

3

48.2

FLINGER

1

38

MOUTH RING

2

PUMP BED

1

7-1

BEAR ING HOUSING

1

54A

MECHAN ICAL SEAL

1 SET

7-2

BEARING HOUSING

1

54B

MECHANICAL SEAL

1 SET

9

8EARING COVER

1

10

BEARING COVER

1

70- 1

SNAP RING

141

BEARING INNER CASE

1

70-2

SPLIT RING

1 42

BEARING INNER CASE

1

70-3

16

IMPELLER

18

iMPELLER SHAFT

19

IMPELLER KEY

1

20

COUPLING KEY

27

IMPELLER NUT

34

BALL BEARING

1

35

BALL BEARING

1

snINKO INO.LTO.

11 1

57

PACK ING R ING

1

1

1 SET

SNAP RING

1

1 46-1

MECHA. SEAL COVER

1

1 46-2

MECHA. SEAL COVER

1

353

BEAA ING NUT

1

354

BEAR ING WASHER

1

37 2

PACK ING R ING

1

5. PUMP STUFFING BOX SEAL

Fig. I .3

The stuffing box is so designed as to furnish the mechanical seal exclusively. Therefore there is no leakage of the liquid pumped and no air leaks into the pump. Moreover, the operation is very simple since no adjustment for the stuffing box during operation

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f

~I~~'

r

~T I

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a25

[ ,08

a]6

is required.

128 a21

Mechanical seal

42c

101

111 l

Unbalanced type mechanical seal is fitted and

lal

138

flushed by pressure liquid led through the clearance

149

between the impeller and the mouth ring. ,04

,t]

lo?

Fig. I .2

tog

DECX

D~~Z~~l

a:9 438

MECHAN I CAL SEAL

da5 131

F LUSH I NG

WATER PIPE

aQI

409

1 IF

,t5

a,o

2

al3

A]o

5

lodt2

3

t

,31

"I

5

4

'12

5 5

105

129

~~@

aa8

5

4lg

6

,3]

,],

lll I

lll A

Itl I

7 .'= \~

Close-up view of mechanical seal

5lh 1

F LOAT I NG SEAT

542 543

PACKINC RING PAC K I NG

51 h4

SEAL R INC

545 546

PACKING RING

421

4:o

CARBON RUBBER RUBBER STA I N LESS STE E L

R EQ. FOR PUMP

PART NO.

RUBBER

BEARING

1

423B

402 BEARING CASE 403 BEARING CASE

1

424

1

425

1

426

For upper mechanical seal, A is attached, e.g. 54A-1

BEARING COVER 405 STUFFING BOX

1

427

FLOATlNG SEAT, and for lower one, e,g, 54B-1,

406

51 h7

SPR I NG

STA IN LESS STE E L

STOPPER RING & SET SCREW

STAIN LESS STEE L

401

shown later.

431

432 433 434

1

435

BELLOWS

1

436

SEAT PACK ,NG

1

2

437

SEAT PACK I NG

1

SLEEVE SLEEVE

1

438

SPACER

1

1

43g DOUBLING PLATE

418A S LE EV E 418B SLEEVE

1

440

PLUG

1

1

441

BEAA ING NUT

1

The device is provided on the pump to clean the mechanical seal and the mouth ring for pumping very high viscosity cargoes.

1

428

1

429 430

1 SET

41 1

BALL BEAR ING

1

41 2

BALL BEARINC

1

413

LANTERN R ING

PACKING RING 415 GLAND PACK ING 414 416 417

STEAM CLEANlNG DEVICE (Option)

1

l

409 DISTANCE RING 410 DISTANCE RINC

6. BULKHEAD STUFFING BOX & INTERMEDIATE A stuffing box is provided where the intermediate shaft es through the bulkhead to prevent the gas in the pump room coming into the engine room. If non-standard arrangement is fitted, it will be

HUB

1

GLAND

407 FLINGER 408 COVER & PACKING

SHAFT WITH GEAR COUPLING (Standard)

NAME OF PART COUPLING BOLT & NUT 1 PACKING RING 1 PACKING RING 2 PACKING RING 1 PACKING RING 2 PACKING RING COVER & PACKING 1 SET INTERMEDIATE SHAFT 1 F LOATING SHAFT 4 COUPLING KEY 1 SNAP RING

404

7.

REa. FOR PUMP

PART NO.

NAME OF PART

419

420

COUPLING FLANGE COUPLING FLANGE

HUB 422 HUB 423A HUB 421

1

1

1

1

442

BEARING NUT

1

1

443

BEAA ING WASHE R

1

1

444

BEAR INC WASHE R

1

1 1

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IN STALLATIONAND PIPING CHAPTER 2 CAUTION FOR In order to prevent occurrence periods with best efficiency and

of vibration and noise and to operate the pump over long safety the following points must be observed at the time

of installation and piping.

1 . PLACE OF INSTALLATION & FOUNDATION4 SUCTION PIPING (1) Size of the place of installation must be chosen in view of the pump disassembly and inspection. A space necessary for disassembly is shown in the outside drawing.

The piping on the suction side affects pump effi-

ciency to a great degree and to avoid troubles arising there from the following points must be noted.

(1) No air pocket must be formed in the piping.

(2) The foundation must be strong enough to absorb pump vibration and to resist deformation against

(2) A11 fittings in the piping must be perfectly

long use.

tightened to prevent air invasion.

(3) The pump is placed on its foundation. The

(3) Care must be taken to prevent air leakage th-

driver with its bed is placed on its foundation with the bearing (401) complete fast-

rough glands of all valves in piping.

(4) The suction piping must be thoroughly cleansed

ened at the bottom of the driver's bed.

so that pipe scale, welding beads and other

In this case confirm that the drstance "E" shown in the outside drawing, between the end faces of

the coupling halves on the pump shaft end and the intermediate shaft bottom end must be as shown in the drawing. The permissible error of this distance * ''',, is :t2mm. (Refer to Fig. 2.2).

2. FINISHING OF PUMP MOUNTING SEAT Chockliners must be welded on the foundation place just under the pump foundation bolt holes and their faces must be planed so that they lie in

a perfect plane. When the foundation bolts are tightened leaving gaps between the liner faces and

pump bed, deformation may be given to the pump and besides vibration may result.

foreign matter do not remain, otherwise seizure and other troubles may result. 5

ALIGNMENT Table 2.1 and 2.2 show permissible errors in ali-

gnment when the pump and driver are connected through the intermediate shaft.

When installations of the pump and driver have been finished it is necessary to check the alignment and if the errors exceed those shown in Tables 2.1

and 2.2 adjustment is needed. This work is also necessary when pipings for them have been finished.

When the alignment has been completed set the driver's bed and the pump bed on their foundation by driving the dowel pins.

3. CAUTION FOR PIPING

Table 2J Between driver & intermediate shaft

Deformation given to the pump by outside force due to incorrect piping causes not only vibration but also pump troubles. Therefore, the pipe flanges connecting with the suction and discharge nozzles must be correctly matched. Be sure to avoid the

cases shown in Fig. 2.1 otherwise the pump may receive unreasonable force. Nor must the pump be directly given deformation due to the total weight of piping and thermal expansion.

Parallel misalignment A Angular misalignment B at coupling (mm) at coupling (mm) Below O . 2 Below 0.2 (Between centers)

Table 2.2 Between intermediate shaft & pump Parallel misalignment A

at coupling (mm)

Angular misalignment B at coupling (mm)

Below 0.4

Below 0.4

(Between centers)

Fig. 2.1

PIPING PUMP

Angular misalignment

C

J

Parallel

misalignment

Flange faces

do not touch

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St,lNKO IND.LTD.

5 .1 Between driver and intermediate shaft

5 .2 Between intermediate shaft and pump

(1) Measurement ofparallel misalignment As shown in Fig. 2.2, fix a dial indicator on the coupling at the intermediate shaft upper

(1) Measurement of parallel and angular misalignments As shown in Fig. 2.2, fix dial indicators on the

temporary shaft to be provided for the ali-

end for the alignment so that its spindle rests on the periphery of the coupling on the driver.

gnment so that their spindles rest on the periphery and the face of the coupling half on the

Give one complete turn at the same time to both coupling halves on the driver and the intermediate shaft and read the difference

intermediateshaft. Give one complete turn at the same time to both coupling halves on

between the maximum and minimum readings

the pump and intermediate shaft and read the

difference between the maxirnum and mini-

on the indicator.

(2) Measurement of angular misalignment In the same way as above, give one complete turn to both coupling halves at the same time

measure the gap between the coupling faces (e.g. at each 90 deg.) using a feeler gauge, and

read the difference between the maximum

mum readings on the indicators.

6. PERMISSIBLE DEFORMATION OF BELLOWS WHEN FITTED (1) Elongation or contract in vertical direction i 10 mm. (2) Angle deviation (Refer to Fig. 2.3) 5 deg.

and minimum measurements.

(3) Perpendicular deviation (Refer to Fig.2.4) :!:8mm, Fig. 2.2

Fig. 2.3 Fig. 2,4

Driver

~ ~

50

't~

it,

~1:

~r

FEELER GAUGE

t,l

'll

tl

l

I

F Parallel m is~ m isa I ignment

i8

A 1

7. FITTING OF FLOATING SHAFT

(LOWER INTERMEDIATE SHAFT) It is strictly prohibited to fit the floating shaft

(432) upside-down due to an abnormal thrust BE L LOWS

force is given to the pump bearing. It is therefore Angu A lar

m i sa misalignment

shaft with the coupling marked with "C" is to be

fitted up and the other side marked with "PC" down.

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E

special attention should be paid for that the floating

TEMPORARY SHAFT

Pump

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SnINKO IND.LTO. C

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3 O'PERATION CHAPTER 1

(2) Close the discharge valve completely and open

CHECK BEFORE OPERATION

the suction valve fully.

When operating for the first time after installation or overhaul and assembly, it is necessary to do as follows.

(a) When the liquid level in the cargo tank is

(1) Take off dust preventing tape placed on the part where the pump shaft es through and

above the pump the liquid flows into the

take care so that no foreign matter enters the

pump casing by gravity, so open the air vent valve on top of the volute casing to draw the air in the pump and close it when the liquid

clearance around the shaft.

begins to flow out of it.

(2) Give some oil to the mechanical seal. (Refer

(b) When the liquid level in the tank is below the

to "MECHANICAL SEAL")

pump draw the air in the pump and suction

(3) Give a few turns to the coupling by a turning

line through the gas vent on the volute casing

by means of stripping pump or some other

bar and see if it turns normally.

extracting devices so that liquid can fill the

(4) Confirm if the rotation direction of the driver

pump inside. In this case keep the air vent

is correct.

valve closed so that no air can enter the pump casing. Never neglect priming the pump.

(5) Confirm if the grease in the bearing housing and the oil in the gear coupling, if fitted, is within the specified amount.

(3) Start the driver gently and increase its speed gradually .

(6) Confirm if the driver is ready for the operation.

2 . STARTlNG (1) If the steam cleaning device for high viscosity cargoes is provided for cleaning the mechanical seal and mouth ring and if the last cargo un-

10aded by the pump was so, open the steam

(4) When the discharge pressure has risen reasonablly, open the discharge valve gradually and fully .

3. STOPPING (1) Close the discharge valve.

inlet valve provided on the device to clear the

(2) Stop the driver.

said parts before starting the pump and keep the valve closed during the operation of the

(3) If the steam cleaning device is fitted and the liquid pumped was high viscosity cargo, open the steam inlet valve on the device and clean the mechanical seal and mouth ring for about 1 O minutes to prevent from sticking the said parts under normal temperature.

pump. Refer to Fig. 3.1 . Fi9. 3.1

STEAM In case stop valve

is opened

STEAM

' r~- -~J L--~-l IN LET STEAM Itr---~l

C LEAN I NG

DEVICE

( Fitted on

pump body)

PUMP

CASING

(Steam press.

2-3kglcm2 g)

Liquid being handled

I n case stop valve is closed

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SHINKO INO.LTD.

CHAPTER 4 MAINTENANCE In order to eliminate pump troubles, to minimize parts consumption and repair and to maintain best efficiency over long periods the operator must aim at perfect maintenance of the pump.

1 . CAUTION DURING OPERATION (1) Never throttle the suction valve in any case during operation otherwise troubles may occur due to dry operation.

(2) Never operate the pump for over 3 minutes with discharge valve completely closed. When a centrifugal pump is operated without discharge, most of the power changes into heat

(7) With lowering of the liquid level in the tank suction pressure approaches the vapor pressure of liquid and vapor develops in the suction line and pump suction and, moreover, air is sucked through the suction bell-mouth until punrping ability decreases to such extent that discharge stops.

In order to prevent this, vapor and gas coming

and as a result temperature of the liquid in the

into the pump inside must be drawn through

pump casing rises to the boiling point causing seizure of the interior of the pump and accident may occur, especially when dangerous liquids are pumped.

that vent on the casing by means of stripping

(3) Never operate the pump with dry condition. (4) Except that the driver is with the constant speed like electric motor, keep the discharge valve open in full and it is desirable to adjust discharge flow by changing speeds. The adjust-

ment of discharge flow by the degree of dis-

charge valve opening is not recommendable because of loss of driving energy.

pump or some other extracting devices.

(8) When cavitation occurs even though the pump

speed becomes minimum, discharge mut be decreased by throttling the discharge valve. If this remedy is ineffective stop the pump.

2. BALL BEARING (1) In consideration of lubricating ability of the

grease and running clearance of the bearing due to thermal expansion and liquid temperature pumped, the bearing temperature is so designed as to stand up to 90'C.

(5) When operating more than 2 pumps in parallel be sure to keep the discharge pressure of each pump always equal. If the speed of some pump decreases during operation and its shut-off pressure drops below the discharge pressure of the remaining pumps, it is operated with zero flow even though its discharge valve is opened and thus the result will be the same as

However from viewpoint of service life it is desirable to keep it below 75'C. (2) For the lubrication of ball bearing grease is used.

The recommendable grease and the interval of replacement grease are shown in Table 4,1 and 4.2. (3) For supplying grease for the bottom ball bearing, take the grease drain plug away.

mentioned in (2) before in this chapter.

In such a case try to make the speed of the pump in question same as those of the remaining pumps, and if this is impossible stop that pump immediately.

(6) When operating the pump at the rated speed with the discharge valve open in full available NPSH decreases as the liquid level in the tank

lowers and finally discharge becomes zero due to cavitation.

3. MECHANICAL SEAL (1) Cautions before starting and during standstill

Care must be taken so that no dust enters part (a) in Fig. 4.1 .

Pouring lubricating oil in (a), when the pump is at a standstill, wiD prevent dust from sticking.

If dust accumulates here and sticks hard seal ring (54-4) may stick and sliding face (S) can not be tightened. When the pump is delivered, a strip of cloth tape is put over the gap around

In such a case pumping ability can be restored if discharge is decreased, so for the reason

mentioned above lower the speed without throttling the discharge valve as the liquid level

the impeller shaft to prevent foreign matter from invading.

(2) Check of flushing

The mechanical seal may be considered to be working perfectly if there is no heating near

in the tank drops.

the sliding parts and no abnormal noise.

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SuINKO INiD.LTO. C

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Fig. 4.1

(a) ll (s)

plug A

plug B Rernove/

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Q)

I'

\~e move

/

vl

~

Q)

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-C

u OJ)V1

(b) Fill oil through an oil plug hole on the

:= I-

•- to

J=

coupling by using pistol oiler till the oil

- ,= LLY-

begins to fiow out from the other oil plug

Cl)~~ ::, o

hole on the opposite side.

(3) Leaking from mechanical seal

Coupl i ng

Under normal operational conditions there is no leakage, but in case there is a leakage of over 30cc/h there must be some trouble inside,

o- r

n

g

Air gaP

Dverflow

so a remedy Inust be taken as early as possible. (4) Heating of sliding parts and abnormal noise.

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o

vG4so-s80)

Insufficient flushing to the sliding face causes

O-ring

abnormal wear down of the carbon due to

Coup I i ng

heating and dry . If flushing temperature rises to more than 10~C above the liquid temperature being pumped, it is

(c) (c

o

e

After the oil, puttwo twoluplugs back After filling fillin the oil ut s back toto

necessary to trace the cause and remove it.

the coupling with Teflon seal tape on them.

When operated under the condition of dry

Apply several turns to the shaft so that

, abnormal sliding noise may occur.

the oil may reach the interior of the coupling. If too much oil is filled, excessive oil may leak from the key way

4. GEAR COUPLING (Standard) (1) Misalignment between pump and driver Since the gear coupling has sel~alignment action to some extent, small misalignment within the permissible values shown in Table 2.1 and 2.2 can be absorbed.

but this is acceptable because necessary oil is kept in the coupling.

5. BULKHEAD STUFFING BOX (Standard) (1) When operating for the first time after

too much slip between the teeth and as a result

repacking the stuffing box tighten once the gland firmly before starting, then loosen the

wear becolnes excessive, vibration occurs and the coupling may be damaged.

be turned lightly by turning bar.

However the excessive misalignment causes

(2) Lubrication

gland nuts to such extent that the coupling can

(2) Supply grease to the gland packing for

Lubrication oil has a very important function in

lubricating and to keep gas-tightness between

reducing friction and wear and in hydraulically

the pump room and engine room. The recommendable greases and the interval of replacement grease are shown in Table 4.1 and

distributing pressure on the gear flanks by forming oil film in the gap between

4.2.

the m .

The recommendable oils and the interval of replacement oil are shown in Tables 4.1 and

(3) Start the pump and adjust the gland nuts gradually and evenly. If the gland is tightened

suddenly or too much or unevenly there may be

4.2.

(3) Filling lubricant oil

a danger of seizure of overheating.

(4) If the packing becomes deteriorated the

(a) Remove two oil plugs.

tightness can not be kept no matter how much the gland is tightened.

In such case renew the packing.

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St,lNKO IND.LTO.

6. MAINTENANCE CHECK LIST Maintenance and check for the followings can extend a life of the pump.

Inspection procedure

Item Suction pressure

Remedy in case of trouble

Check every time if there is any

Stop pump immediately and check suction

abnormal pressure drop

line .

In the case of above ambient temperature Bearing temperature

plus 40~C or above 85~C, stop pump and

Check and record every tilne.

eliminate cause. Lubricating oil

Ball bearing

Check oil in gear c'oupling every time

Supply oil if necessary.

through oil hole on it.

If abnormal noise or overheating occurs, stop pump and eliminate cause, and renew

Check abnormal noise every time.

ball bearing if necessary.

Mechanical seal

Vibration

Check leakage, heating, noise every

Stop pump and remove cause.

time.

Check alignment.

Check vibration every tilne.

7. LUBRICANTS (1) Replacement of lubrication

Table 4.1

The replacement of the lubricants is based on deterioration or contamination of the lubricants

Replacement

being used. However, Table 4.1 shows

Location

Normal o peration

After initial start

recommendable replacement. (2) Lubricants

Within 3 months

Ball bearing

NLGI No. 2(National Lubricating Grease

Every year

Institute) for grease for the ball bearing on the

Every 6 months

Gear Coupling

pump and intermediate shaft and for its stuffing

box, and for the gear coupling, ISO VG 460680 gear oil are recommendable. The brand names of the lubricants equivalent to the recolnmendable ones are shown in Table 4.2. (3) Grease amount

,, Every operation

Every o peration

Bulkhead stuffing box.

KV 300

KV 350

KV 400

KV 450-3

KV 450-4

KV 500-2

Pump upper side bearing (g)

70

70

110

150

270

330

Pump lower side bearing (g)

50

50

70

llO

150

210

70

70

110

150

270

330

70

70

110

150

270

330

240

240

280

300

360

400

KV 300

KV 350

KV 400

KV 450-3

KV 450-4

KV 500-2

Turbine side gear coupling (cc)

180

180

270

480

550

700

Intermediate shaft side gear coupling (cc)

130

130

170

280

380

410

Pump side gear coupling (cc)

130

130

170

280

380

410

Pump model

Intermediate shaft upper side bearing (g)

Intermediate shaft lower side bearing (g)

Bulkhead stuffing box (g)

(4) Gear oil amount

Pump model

8. STANDSTILL When there is a fear of freezing, drain the pump conrpletely after stopping.

In case of a long standstill, clean each

sliding part thoroughly and apply rust preventive where necessary.

cg SHINKO INb.Llb. C

)

Table 4.2 Gre85e (NLGI N0.2)

( ;ear Oi] (rso VG 680)

Name of Com pany

IDEMITSU KOSAN DAPHNE EPONEX EP2

EXXON R/!OBIL OIL

DAPnNE SUPER GEAR OIL 680

BEACON EP2 LISTAN EP2

SPARTAN EP 680 MOBIL UX 2 MOBIL PLEX 47

MOBIL GEAR 634 OR 636

NIPPON OIL

EPINOC GREASE AP2

BONNOCK M 680

CALTEX OIL

MULTIFAK EP2

~IEROPA LUBRICANT 680

JOMO

LISONIX GREASE EP2

REDUCTLJS 68,I

MITSUBISHI OIL

DIAMOND MIJLTIPURPOS N0.2 D[AMOND GEAR LUBE SP 680

CULF OIL

C.ULF CROWN GREASE N0.2

GL!LF EP LUBRICANT HD680

BP OIL

BP ENERCREASE MM-F.P-2

BP ENERCOL GR-XP 680

TEXACO OIL

MULTIPA K NO.2

TEXACO MEROPA 68Q

CASTROL

CASTROL ALPflA SP 680 St•HEEROL AP2 OR EPL2

COSMO OIL

COS*MO GEAR SE 680 COSMO C•REASI~ DAINAMAX N0.2 ALVANIA GREASE N0.2 ALVANIA CREASE EP2

SHOWA SHELL OIL

OMALA OIL 680 GENERAL S P GEAROL 680

GENERAL OIL

GEMICO GREASE MP-2

ELF

EPEXA 2 = EPONA Z680

CHEVRON

DURA-LITH GRF.ASE EP2 , NL GEAR COMPOUNl] 680 ** EP680

CLEARANCE AND LIMIT USE OF CHAPTER 5 STANDARD The bigger the clearance between impeller and mouth ring becomes, the more the counterflow from discharge side to suction side becomes, and consequently pump capacity decreases.

Unit :

Table 5.1

Model

Name of part

Length b

Standard clearance a

b a

Upper seal

Lower seal

O. 3

15.9

15.9

1

13

13

350

o. 3 3

15.9

15.9

1

13

13

400

o. 3 3

15.9

15.9

1

13

13

450-3

o. 3 8

15.9

l 5. 9

1

13

13

45 O-4

o. 3 8

16.5

1 5. 9

1

13.5

13

seal

500-2

o. 3 8

35

16.5

1

32

13.5

J

g

KV 300 Im p eller

c3

~3

and mouth ring

Floating seat of

b

Upper seal

m echanical

C

mm

Limit of use

New parts

SHINKO INO.LTD.

Lower seal

6 DISASSEMBLlNG AND ASSEMBLING CHAPTER 1 . DISASSEMBLING

Fig. 6.1

In order to replace impeller, ball bearing, mouth ring, etc., disassembling of pump is carried out as folbws.

34

1

1

20

7

9

l .1 Removal ofvolute cover (1) Remove the sealing pipe for the mechanical seal.

(2) Loosen the nut for the mechanical seal cover (146) until the mechanical seal cover moves

3 53

td

354

54

1

4

1

27 _'1~1'1

3B

/

2

I// l' /

and touches the flinger (48).

~\ L \ \ Ll

(3) Remove the volute cover nuts and move the volute cover (2) forward by using the two

j~

,l

t

t

l

' l ll l' l

lifting b olts.

L~

16

/

__.l

l9

1.2 Removal ofrotating element (1) Remove the coupling bolts.

70

5dB 18

Id 2

(2) Remove the bearing housing cap after removing

37 2

2

57

3

the nuts fastening the cap.

35

(3) Take out the rotating elements together with the bearing inner case (14), bearing covers

7

70

14 2

10

(9 & I O), bali bearing, etc. with paying attention

to the mouth ring (38) and mechanical seal.

l .3 Removal ofball bearing

(1) For the upper bearing, remove the coupling

1 .4 Removal ofmechanical seal Since the mechanical seal for this pump has a large spring compression allowance and force, the special tool provided must be used for re-

after removing the snap ring (70-1).

moving the mechanical seal and ball bearing

Remove the bearing cover (9).

from the shaft.

Make straight the rotation preventing piece on the washer (354) which is bent into one of the slots along the bearing nut (353) periphery and remove the bearing nut.

(1) As shown in Fig. 6.2 hold the tool in such a way that the spring force does not act upon the flinger (48), and maintain not to transmit directly to the mechanical seal the shock produced when the ball bearing is removed.

(2) For the lower bearing remove the bearing cover (1 O) and the snap ring (70-3).

(2) Remove the ball bearing and flinger from

(3) Compress the mechanical seal spring by using the special tool provided as shown in Fig. 6.2

and also mentioned in "Removal of mecha-

the shaft.

(3) Loosen the special tool bolts to reduce the spring force and remove the special tool as

nical seal".

shown in Fig. 6.3 .

(4) Since the ball bearing is pushed lightly onto the shaft, it can be removed with the inner

(4) Remove the mechanical seal from the shaft.

case by using puller. Fi9. 6.2

Fig. 6.3 SPECIAL TOO L ISUPPLIED)

COVER~ 2-"5cm

BALL BEARING

SPR I NC

STO PP E R RtNG

SET SCR EW SEAL RINC

LOAT I NG SEAT

FLING R

gD SuINKO INlo.L70. C

j

(2) Take care not to injure sliding face and "O"

1.5 Removal ofimpeller The impeller ~shaft _diameter where the impeller (16) is fitted is the largest and gets smaller toward either end. Fixing the impeller is by the impeller nut (27) at the upper side and by the split ring (70-2) at the lower side.

ring by hitting or scoring.

(3) When fitting be sure to apply lubricating oil to "O" ring .

(4) Referring to Fig. 6.2 the floating seat (54-1)

(carbon) must be inserted by hand until it

touches bottom of the cover (146) firmly

(1) Remove the setscrews on the impeller nut (27) and remove the impeller nut after re-

taking care not to injure sliding face.

(5) Place the stopper ring (54-7) against the shaft shoulder which forms fitting base and tighten

moving the ball bearing, the flinger and the mechanical seal.

it by the setscrew.

(2) Remove the impeller from the shaft. However, if it is difficult to remove the im-

(6) Confirm the winding direction of the spring

peller from the shaft, warm the hub of the

if it is suitable for the rotation direction of

impeller slightly to ease working.

the pump. Refer to Fig. 6.4.

(7) Fit rotating elements of the mechanical seal

2. ASSEMBLING

and the cover (146) onto the shaft.

Assembling can be carried out by reversing order of disassembling and attention must be paid to

(8) Afterward, apply the special tool and compress the spring evenly as shown in Fig. 6.2.

the followings.

(1) Clean each part thoroughly to remove rust

(9) Fit the flinger and the ball bearing onto the

and scale, and be sure there are not injury and

shaft, Ieaving the special tool as it is as shown

burr in fitting parts.

in Fig. 6.2 to compress the spring until the rotor is settled in the volute casing.

(2) Assemble fitting parts according to match

(10) After settling the rotor in the volute casing

marks if any.

remove the special tool.

(3) Turn nuts for rotating parts securely and fix anti-rotation device without fail. Fi9. 6.4

(4) Be sure to thoroughly cleanse the ball bearing

with pure kerosene taking care to keep off dust and foreign matter.

STOPPER RING

SEAL RING

SEAL R ING

2.1 Alignment Alignment is to be confirmed if it is within

/

the specified limit shown in Tables 2.1 and 2.2

l

in "ALIGNMENT" . 2.2 Assembly ofmechanical seal Use the special tool for assembling the mechanical seal as shown in Fig. 6.2 and 6.3. (1) Sliding face, "O" ring and "O" ring groove

Left-hand

winding

winding

IMPELLER SHAFT

off dust and other foreign matter.

SmNKO INO.LTD. )

l

R ight-hand

must be claned with leadless gasoline and wiped with soft cloth taking care to keep

C

STOPPER RING

IMPELLER

CHAPTER 7TROUBLE SHOOTING AND REMEDIES Pump can perform satisfactory function if properly handled and maintained.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest causes of trouble and suggested remedies.

Table 7.1

Troubles

Causes 1.

Remedies

Pump not completely or insufficiently

1.

Prime once more,

2,

4.

Check suction line. Check suction line, Check by suction gauge on suction side.

filled with liquid. 2.

3.

Pump cannot discharge

4. 5.

6.

Much air leakage in suction line. Air pocket in suction line. Suction lift too high. Wrong direction of rotation. Suction strainer and suction line clogged.

3.

5.

Check,

6.

Check interior of suction line,

7.

Speed too low.

7.

8.

Impeller clogged.

8.

Check by tachometer. Check pump interior.

1.

Air leakage.

l.

Check suction line and stuffing box,

2.

2.

3.

Speed too low. Discharge head too high.

4.

Suction lift too high.

4.

5.

Suction pipe bell-mouth not sufficiently

5.

Check by tachometer. Check by discharge gauge. Check by suction gauge. Check.

3.

submerged. Insufficient discharge

6.

Suction strainer and suction line clogged.

6,

Check interior of suction line.

7.

Impeller clogged. Wrong direction of rotation.

7.

Excessive clearance between impeller and mouth ring. Cavitation due to high liquid tempe-

9.

Check pump interior. Check. Replace mouth ring by new one.

8.

9.

1 O.

8,

1 O.

Check design.

rature or excessive viscosity of liquid.

Pump discharges liquid after starting, but soon fails to discharge

1.

Pump not sufficiently fmed with liquid

1.

2,

Air pocket in suction line. Much air leaks into suction line. Air leaks through stuffing box .

2.

3.

4.

1.

Speed too high (Power frequency too

3.

4.

Prime sufficiently. Check piping and if wrong correct it, Check suction side. Check if mechanical seal is incorrectly fitted or carbon is broken,

1.

Lower speed. (Frequency)

high.) 2.

Impeller touches mouth ring,

2.

Check state of installation and

3.

Rotating elements touch stationary element due to bent shaft. Casing deformed.

3.

alignment. Replace shaft by new one.

4.

5.

Liquid specific gravity or viscosity is

5.

Check if undue force is given by piping. Check design.

6.

greater than designed one. Voltage too low (Constant input, but

6.

Check power source,

Prime mover overload 4.

increase in current) in case of electric

motor driven.

g

SuINKO INb.LTo. C

)

Troubles

Causes

Remdeies

1.

Grease is too little.

1.

2.

Grease is too much. Grease has improper consistency or

2.

3.

3.

it is deteriorated.

Overheating of bearing

4.

4.

Misalignment is great.

5.

Shaft is bent.

5.

6.

Injury or too much wear in ball

6.

Supply grease up to specified level. Remove grease till specified level.

Replace old grease with specified

new grease, CorTect alignment of pump and driver. Replace with new shaft. Replace with new ball bearings.

bearing. 7.

Too much thrust force.

7.

Check if impeller is clogged and if

clearance between mouth ring and impeller becomes too much, and correct them if any.

Abnormal noise in

1.

Injury in balls or rolling face.

2.

Too much clearance due to abnormal

ball bearing

Replace with new ball bearing.

we ar . 3.

Abnormal wear in retainer.

1.

Misalignment.

1.

2.

Shaft bent. Impeller partially clogged with foreign

2.

3.

3.

Check alignment of pump and driver. Renew shaft. Check pump interior.

matter. 4.

Incorrect installation.

4.

Check state of installation.

5.

Weak foundation.

5.

Measure vibration up and down, right and left around pump's mounting on

Vibration in pump

foundation, if vibration is too great

reinforce foundation. 6.

Suction and discharge pipings not

6.

7.

1.

2.

3.

Rotating elements touch stationary elements.

7.

Injury or excessive wear down in rubbing faces. Foreign matter in rubbing faces. Insufficient tightening of mechanical

1.

Check pump alignment and bending of shaft.

Remove mechanical seal cover and check rubbing faces.

2.

Ditto.

3.

Check if cover bolts are evenly tightened. Check "O" rings for stationary and

seal cover.

Leakage in mechanical

Refer to "CAUTIONS FOR PIPING'*, and give necessary .

sufficiently secured.

4.

Break down of "O" ring.

4.

5.

Insufficient tightening of setscrew of stopper ring (54-7).

5.

Tighten sufficiently setscrew.

6.

Injury or wear down of part of shaft where rotary ring's "O" ring (54-5)

6.

Replace with new shaft.

7.

Disassemble and remove scale completely.

seal

rotary rings.

7.

s. Scale sticks in groove for "O" rmg (54-5), causing rotary ring to stick

and rubbing faces to open. 1.

Flushing is insufficient.

1.

Check if flushing pipe is clogged.

2.

Pump operated dry.

2.

Stop pump immediately.

Heating of mechanical seal (Sometimes

accompanied by abnormal noise)

c

J

g

SHINKO INO.LTb.

PART S CHAPTER 8 REPLACEMENT When ordering replacement parts, include the following information. 1 . Ship's name

2. Shipbuilder and hull number 3 . Service and model of the pump

4. Parts' numbers and names shown in this instruction manual

NAME OF PART

PART NO.

PREssuRE GAUGE

71 Io 71 1 1

PUMP SUCTION PUMP DISCHARGE

R EQ. 1 1

UJ

tD :) (g UJ cc :) Cl)

U) UJ o: CL

7221 TH ER MO-SW I TCH

7221 .1 1

( If fitted,

7222 7222-1 1

7223

7221 -1 1

7222.1 1

7223-1 1 7226-1 1

I o h ~ co o ~:

7223.1 1

7226 7226.1 1

PUMP CASING

INSTALL THREAD PUMP BEARING COUP.

INSTALL THREAD

1 set 1

1 set SIDE 1

PUMP BEARING END SIDE1 set 1 INSTALL THREAD 1 set BULKHEAD STUFFING BOX 1 INSTALL THREAD

a: UJ

I F

7221

7222 7223 7225

g

SHINKO INO.LTD. C

)

INSTRUCTION MANUAL FORTURBlNERX This instruction manual describes construction, caution for installation and piping, operation, maintenance, etc. As the life of turbine depends extremely on the correct installation and

handling and suitable maintenance, it is recommendable to carry out them according to this manual.

CONTENTS CHAPTER 1 CONSTRUCTION , . , . . . . . . . . . . .871 . General ,

Page 2 2

2. Exhaust casing . . . . . , . . . . .

2 2 2 2 3

3. Rotor disc . . . . . . .

4. Governorvalve . , . . . . . . . , , 5. Gland seal . . . , , . . . . . . . . .

6. Speed regulating governor 7. Emergency trip device , . . , . .

8. Lubrication system .

3

CHAPTER 2CAUTION FOR INSTALLATION AND PIPlNG . . . . . , , .87-

4 4 4 4 4

1 . Place ofinstallation and foundation . . .

2. Finishing ofturbine mounting seat . . 4. Alignment . . . , . , . . . . . . . ,

CHAPTER 3OPERATION . . . . , . , . . . . , . . . . . , . .87_

5

1. Check before operation . . . . . . .

5

2. Starting . . , . , . . . , . . . . , . .

3. Operation at various speeds

5

4, Stopping . , . , , . . , . , . . . . , . .

6 6 6

5. Emergency stopping . . . . . 6, Resetting of emergency trip , . .

CHAPTER 4MAlNTENANCE .

.87. 7

l . Maintenance check list for during operation .

8

2. Adjustment for accessories and emergency trip . . . 3 . Maintenance check list for regular inspection . . . . .

... 9

4. Lubricants . . . . . . . . . . . . . . . . . . . . . . .

. . 10

CHAPTER 5STANDARD CLEARANCE AND LIMIT OF USE. 87-1 1 CHAPTER 6DISASSEMBLlNG AND ASSEMBLlNG . 1. Disassembling . . . . .

2. Assembling .

. 87-1 2

. . . 12 14

CHAPTER 7TROUBLE SHOOTlNG AND REMEDIES

. 87-1 5

CHAPTER 8REPLACEMENT PARTS

. 87-1 8

C~g I snINKolNb.LTo.

C)

CHAPTER 1CONSTRUCTION 4. GOVERNOR VALVE

l . GENERAL The model RX steam turbine is a vertical Curtis

The governor valve is double seat type to prevent unbalance by the effect of steam pressure and also acts as an emergency stop valve so that this valve closses to stop the turbine when emergency trip

single stage with a reduction gear unit. Its construction is simple, strong and compact and

the safety device and the governing device are composed of simple mechanism.

devices work.

5. GLAND SEAL

2. EXHAUST CASING

The turbine gland is provided with labyrinth pack-

The exhaust casing is solid construction with an axial flow exhaust steam bore to lead steam flow smoothly to the exhaust steam piping for saving steam consumption.

ing.

3. ROTOR DISC The rotor disc is provided on the turbine shaft end

by shrinkage fit. The pinion and shaft are solid construction and teeth faces are grinded or shaved in order to operate in good effrciency and silently.

The outer circumference of rotor disc is provided with blads in two raws, and shroud rings are provided on the blads to prevent steam leakage.

Fig. I .2

Fig. I ,1

WITH UG8GOVERNOR TURBtNE SHAFT EXHAUST CASING ROTOR DISC LABYRINTH PACKING

BLADE

f=

~

[

C

rl

~- ~ ll ,

~ ~1J

GOVERNOR VALVE

J

~

Illl

~

,

/

J

c~g c

J

WITH PGDGOVERNOR

SHINKO IND.LTD.

6.

SPEED REGULATING COVERNOR Fig. I .3 For the speed regulating governor, Woodward governor is adopted and installed on the top of the reduction gear casing, driven by a gear at the output shaft end.

The speed regulations are as follows. SPEED GOVERNOR 7.

Momentary

:!: 9%

Steady state

~1%

EMERGENCY TRIP DEVICE For the purpose of safe turbine operation, the following emergency trips are provided. They actuate automatically

the governor valve, which is directly closed by linkage, MAIN

thus turbine is stopped. Lo pUMP Overspeed trip

1 13-1 1 5% of rated speed

Low L.O. pressure trip 0.5 kg/cm2g or below

High back pressure trip I .5 kg/cm2g r~:hr"~ Manual

Local hand trip

Electric or pneumatic ~~::

Remote stop

source

In case of driving pump, if the followings are provided .. _. __ their standard set values are as below to stop the turbine. ~~~r~'~., ~~~~~ _._ C trip Pump overpressure 1 10%80 ofrated dis.opress, Pump casing trip overheat . ,, ' dl iL :

Pump bearing overheatstuffing trip 800C (900C box for cargo ~ oil pump) Bulkhead f ~" ' 8 Oo C

overheat trip 8.

LUBRICATION SYSTEM Forced lubrication system by turbine driven L.O. pump is adopted. Namely, after L.O. pressure is adjusted at I .0-1.5 kg/cm2 g by adjusting valve, the L.O. is supplied to bearings, reduction gear, etc. through the L.O. cooler and strainer. And a part of L.O. is sent to solenoid valve, trip servomotor and actuates as control oil for various emergency trip devices. For the safe operation of turbine a motordriven priming L.O. pump is provided. Unless the pressure in the L.O. Iine reaches 0.2-0.3 kg/cm2g the interlock acts so that the turbine does not start even though the main steam valve is opened. Fig. I .4

P.S. FOR LOW LOP.S. FOR PRIM. LO PR ESS.

To triP deviCe

BEARINGS

PRESS. TR IP

t

,,

OIL JET FOR RE-

i jOLn~~:E~:~/D VALVE

DUCTION GEARING

LO PUMP

GAUGE

ll

~~

O L JET FOR GO-

VERNOR DAIVING GEARING OIL JET FOR MAIN LO PUMP DR IVING

GEARING

~

LO STRAINER PRESS.

t

AD J U ST I N G

VALVE

LO COOLER

L/'L~ ji~iE~~]

COOLINGWATER J [Ill]

~

CHECK VALVE

LO PUMP MAIN CHECK VALVE

PRIM.

COCHECK

LO PUMP

VALVE

LO TANK

~

cg SHINKO INb.LTb. C

)

CHAPTER 2CAUTION FORIN STALLATIONAND PIPlNG (b) Use of bellows type expansion t Bellows t is used in many cases. On the exhaust piping, the amount of elongation is

In order to prevent occurence of vibration and noise and to operate the turbine over long periods with best efficiency and safety the following points must be observed at the time of installation and piping.

small due to low temperature but outside

1 . PLACE OF INSTALLATION & FOUNDATION

force acting on the turbine is very great due to large bore of piping. Therefore, be sure to provide s where necessary.

(1) Size of the place of installation must be chosen in view of the turbine disassembly and inspection.

(2) Give consideration also to the movement of the steam inlet and exhaust flanges themselves on

A space necessary for disassembly is shown in the outside drawing.

the turbine under operation due to thermal

(2) The foundation must be strong enough to absorb

expansion of the turbine itself.

vibration of the turbine and to resist deformation against long use.

3.4 Drain separator, drain traps and drain valves

Special attention should be given not to send

2. FINISHING OF TURBINE MOUNTING SEAT (1) Chockliners must be welded on the foundation plate just under foundation bolt holes of the

drain to the turbine because most causes of turbine troubles are by the drain.

(1) Drain separator with drain trap for saturated steam

turbine baseplate and their faces must be planed by a surface plate so that the turbine lies on a

In order to remove the drain in the inlet steam be sure to provide a sufficient drain separator as near as possible to the turbine, with a drain

perfect plane.

(2) When the foundation bolts are tightened leaving

gaps between the liner faces and the turbine baseplate, deformation may be given to the

trap.

(2) Drain trap for superheated steam and saturated

turbine and besides vibration may result.

st e am

Provide drain traps at the low point of piping,

expansion t, upright pipe and the piping

3. PIPING

end to remove drain in inlet steam. (3) Drain valves

Deformation given to the turbine by outside force due to incorrect piping causes not only vibration but also turbine troubles. Therefore the followings must be considered.

Provide a drain valve each above 1 5 mm of bore just before the steam in]et valve and above 40 mm of bore just after the steam exhaust valve

(a) Matching piping flanges to turbine flanges. (b) Fitting to bear piping dead weight.

respectively to remove drain from the piping

(c) Avoiding effect of thermal expansion ofpipings.

before starting the turbine.

(d) Prevention of drain in pipings to turbine.

3.5 Others (1) Branch from main steam pipe

3.1 Matching pipe flanges to turbine flanges The pipe flanges connecting with the steam inlet

Take the branch from the top of the main

and exhaust flanges of the turbine must be co-

steam pipe and avoid the drain collection in case a bend is provided. In case drain collects in the piping be sure to provide a drain trap. (2) Flushing piping Before connecting the piping to the turbine be sure to do flushing so that no foreign matters such as dust, pipe scales, etc. do not enter the

rrectly matched.

3.2 Fitting and hanger Provide s and hangers to bear piping dead weight so that no bad effect caused by the piping dead weight will be given to the turbine.

turbine.

3.3 Effect ofthermal expansion of piping

(3) Special attention should be given to that pipe scales, welding beads, etc. may clog the drain trap especially at the initial operation after installation or repair of the turbine or the

(1) Thermal stress occurs when the pipe expands and contracts due to change of steam temperature and thus outside force is given to the turbine flanges, disturbing the alignment. In order to absorb the expansion ofpiping and decrease the outside force actingon the turbine, the following 2 methods are considered. (a) Use ofelasticity ofpipe

Provide 90'-bends, U-bends and double

piping.

4

ALIGNMENT

Refer to "ALIGNMENT" shown in the instruction

manual for the driven machine.

U-bends to absorb the thermal expansion of the steam inlet piping.

C

)

g

snINKO INO.LTO.

3 OPERATION CHAPTER 1 . CHECK BEFORE OPERATION

(1) Confirm if the driven machine is ready for so much steam as to start the turbine.

starting. Unless pulling the starting lever, if fitted, the

(2) Check by opening the drain valve or removing govemor does not function and the governor the plug if water is in the oil tank, Woodward valve remains closed. Moreover, unless L.O. pre-

governor, the L.O. cooler or the oil strainer. ssure is above 0.3 kg/cm2g by operating the (3) Check the oil level in the oil tank and the gover- Priming L.O. pump, the L.O. interlock acts and

nor. the governor valve can not be opened. (4) Check oil in the gear couplingbetween the turbine 2. STARTING and driven machine by removing the plugs on (1) Open the steam inlet valve gradually and start

the gear coupling. the turbine. Then keep its speed at 100 to 200 Supply of oil to the gear coupling is from the rpm to warm up the turbine for 25 minutes.

plugs. (2) During that time check if there is no abnormal

(5) Start the priming L.O, pump and confirm oil pre- noise or vibration in the turbine and the redu-

ssure reaches above 0.3 kg/cm2 g. ction gear.

In case any abnormal state is felt, stop the

(6) cooling water to the L.O. cooler, turbine immediately and trace the cause.

(cooling water is adjusted by throttling the (3) Close each drain valve on making sure that the cooling water outlet valve so that temperature

of the L.o. supplied is kept between 20 and drain has been completely discharged from

45'C during operation of the turbine.) each portion.

(7) Confirm all relating equipments, such as con- (4) Trip the turbine by operating the hand trip denser cooling water pump, condensate pump, knob to confirm that the governor valve closes

etc. are ready for starting the turbine. immediately. (8) Open fully the drain valves on the drain se- (5) After sufficient warm up, open the steam inlet parator, the governor valve, the exhaust casing valve further and gradually and raise the speed and the pipings and also on the pipings before up to the rated revolutions in about 5 minutes. the steam inlet valve and after the exhaust (6) When the governor is used t~or the first time,

valve. draw out air in the govemor oil by opening

(9) Open the exhaust valve fully. the needle valve on the governor and adjust (10) Turn the turbine together with the driven ma- the needle valve as described in the manual chine several revolutions by the turning bar to ofWoodward Governor.

confirm smooth turning. (7) Confirm if the emergency trip mechanism

(11) Set all trips on reset condition by the reset knob actuates surely always at the time of starting.

on the trip casing. Refer to Fig. 3.1. Also at the first operation after inspection or long standstill, confirm the actuation of over-

(12) Set the governor at the minimum speed by speed trip at the specifiedspeed. turning the adjusting knob counterclockwise

and fully. (8) When testing the overspeed trip for the turbi[]e,

(13) Supply the sealing steam to the turbine gland the pump must be disconnected and the test must be to the turbine only in order to avoid dry ru-

as follows ; (In case ofthe exlraust is vacuum). nning of mechanical seal fitted on the pump. Open the sealing steam valve gradually till the

sealing steam begins to slightly leak from the 3. OPERATION AT VARIOUS SPEEDS turbine gland where the turbine shaft pases (1) For remote control through. (The sealing steam pressure as an idea In the control room, operate the speed control

is 0.1 - 0.8 kglcm2 g. ) switch. (14) Open the steam inlet valve slightly to warm- For speed increase, turn the switch clockwise,

up the turbine. and vice versa. Pull the starting lever, if fitted, (2) For local control

to open the governor valve to supply a just suffi- For speed increase, turn the manual adjusting cient steam to the turbine for its warm-up, not knob clockwise, and vice versa.

9 1 SHIN!KOIN!O.LTO. C

)

5. EMERGENCY STOPPING

4. STOPPING

(1) Local stopping

(1) Decrease the turbine speed gradually.

Push the hand trip knob provided on the trip casing on the reduction grear casing so that the spindle moves downward and the governor valve closes through actuation of the trip mechanism and the turbine stops as shown in Fig.

(2) Close the steam inlet valve.

Also stopping is possible when the remote stop or the hand trip on the turbine is actuated.

(3) When speed decreases and oil pressure falls

below 0.45 kg/cm2g the priming L.O. pump

3.1 and 3.2.

starts automatically, keeping oil pressure above 0.3 kg/crn2g.

(2) Remote stopping Push the remote stop switch provided in the

(4) Stop the cooling water to the L.O. cooler.

remote control room so that the trip mechanism actuates to close the governor valve to stop the turbine as shown in Fig. 3.1 and 3.2.

(5) When the turbine has stopped, close the exhaust valve and open all drain valves on the turbine to discharge drain completely.

6. RESETTING OF EMERGENCY TRIP

(6) Keep the priming L.O. pump is in operation for more than 5 minutes after stopping the

Before resetting emergency trip, be sure to make the following conditions.

turbine. After stopping the priming L.O. pump, confrrm that the turbine bearing temperature

(a) The driven machine is at the minimum load, e.g. the pump discharge valve is fully closed.

does not rise above 80'C.

(b) The governor speed setting is at the minimum speed.

(c) The turbine steam inlet valve is fully closed.

Fig. 3.2

Fig. 3,1

RUNNING CONDITiON

WITH UG 8

GOVERNOR SPEED O SWITCH SETTE R

TRIP CONDITION WITH UG 8 GOVERNOR

SPEED REIMOTE STOP ADJUST. MOTOR

O o

Gov. LEVER o

GOV & EMERG STOP VALVE

SERVOMOTOR =

~

In et

close I '

TRIP

LOCAL

CONT.PAN E L

TACHOMETER o ~] RECEIVER Oo Q O~~

To nozzle

stea m

~~!:

ELECTRIC

SOU RC E

HAND

P.S. FOR LO TR IP

\'

R ESET

TRIP KNOBKNOB

P S. FOR

PRIM LO PUMP P.S. FOR

Press. oil

o

BACK PRESS. TRIP

To LO tank

SOL. VA LVE

(DE-ENERGIZED)

~ TRANSMITTER TACHOMETER

OVER SPEED~ TRIP LEVER WITHPGDGOVERNOR

c

J

-~

~

TRIP

WITH PGDGOVERNOR

g

SuINKO INO.LTO.

CHAPTER 4 MAINTENANCE In order to eliminate turbine troubles, to minimize parts consumption and repair and to maintain best efficiency over long periods the operator must aim at perfect maintenance of the turbine.

1 . MAINTENANCE CHECK LIST FOR DURlNG OPERATION Maintenance and check for the followings can extend a life of the turbine. Inspection procedure

Item Inlet steam pressure and temperature before governor valve

Remedy in case of trouble

Kcep constant as much as possible and record periodically.

Chcck everyday. 2 Keep between I and 1.5 kg/cm g and rccord periodically.

Refer tO"TROUBLE SHOOTlNG & REMEDIES ".

L.O. pressure

Chcck everyday. Keep between 20 and 45~C and record periodically.

L.O. temperature at L.O. cooler outlet

Discharge drain periodically by opening drain valve on drain separator and piping.

Drain in steam into turbine

Check everyday.

Vibration and noise

Check everyday.

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Turn its handle several times once a week to clean filter plate.

Oil strainer

Air in L.O. cooler and strainer

Draw out by vent valve or plug.

Check everyday by oil level gauge tbr oil tank and by sight glass for governor, and oil leakage from gear coupling.

Supply oil. Refer to "LUBRICANTS".

Oil level in oil tank, governor and gear coupling

In case of high vacuum (more than 600mmHg) , reduce the cooling water (S.W.) flow or driving steam pressure of ejector to keep the exilaust vacuum between design pressure and 600mlnH~, Check everyday and record periodically. (Exhaust pressure never exceeds 600mmHg-V)

Keep its switch in automatic operation always.

Priming L.O. pump Conrrrm at every initial starting of turbine if they work surely and smoothly.

When testing the overspeed trip for the turbine, the pump must be disconnected and the test must be to the turbine only in order to avoid dry ru- ' nning of mechanical seal fitted on the pump.

All trip devices

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Steam leakage from turbine gland

Check everyday.

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Bearing temperature

Check everyday and record periodically.

Corrosion protective piece on L.O. cooler

Corrosion protective piece (if fitted, the piece is shown in the spare list as its spare) is to be checked every 3 months and replaced if any.

g I SHINKOINlb.LTO. C

)

2. ADJUSTMENT FOR ACCESSORIES &

EMERGENCY TRIP

2.4 Electric tachometer

Turn the adjusting screw inside the adjusting nut at the back of the tachometer to adjust

As all parts of the turbine have been adjusted at the shop trial, it is important to avoid unnecessary

the reading.

readjustment.

Clockwise turn of the adjusting screw increases

However, if readjustment is required proceed as

the reading and vice versa.

follows ;

The tachometer pointer must be at zero point

2.1 Speed governor (Woodward governor) Refer to the separate instruction manual of Woodward governor.

However, the adjustment of the interior is very complicated and, therefore, must be done by expert.

Never open the sealed governor part for the adjustment.

when the turbine is at a standstill. Otherwise,

adjust by means of the zero point adjusting screw in the center of the tachometer front. 2.5 Mechanical overspeed trip ( I ) Remove the trip casing on the reduction gear

casing and remove from this opening the split pin for locking the trip ring and trip spindle of the overspeed trip.

Then draw out the trip spindle and spring from

2.2 L.O. pressure adjusting valve (Refer to Fig. 4.1)

Remove the plug and turn the adjusting screw to adjust lubricating oil pressure between 1.0

the trip ring by screw driver.

and 1.5 kg/cm2 g.

The adjusting liner is provided at the back of the spring in order to change as desired its

Clockwise turne of the adjusting screw increases

compressive load. By changing the thickness of this liner the overspeed trip actuating revo-

L.O, pressure and vice versa.

lutions can be changed. Every increase of

Fig. 4.1

0.5 mm in thickness of this liner means about

65rpm rise in revolutions of the overspeed trip and vice versa. Refer to Fig. 4.3.

P LU G

AD JU ST I NG

SC R EW i

~ SPR ING

ADJUSTING VALVE BODY ADJUSTING

(2) When testing the overspeed trip for the turbine, the pump must be disconnected and the test n:lust be to the turbine only in order to avoid drv running of mechanical seal fitted on the pump. Fig. 4.3

VALVE

TRIP CASI NG

2.3 Sentinel valve (Refer to Fig. 4.2)

Remove the cap and turn the adjusting screw to adjust the valve actuating pressure specified in the drawing. Clockwise turn of the adjusting

i l

R EDUCTION

screw increases the valve actuating pressure

GEAR CASING

and vice versa. Fig. 4.2

ADJUSTING SC R EW

LOCK NUT SPR I NG j': I:

VALVE BODY

OVERSPEED TRIP

ADJUSTING RING

VALVE SEAT

CLOSE-UP OVERSPEED TRIP TRIP SPINDLE

TRIP WEIGHT

ADJUSTING LINER SPR I NG

C

J

g

snINKO INO.LTO.

2.6 Electric overspeed trip

( I ) Adjust so that the actuating revolutions becomes 1 12 - 1 1 3% of the rated revolutions by tuming the adjusting screw at the head of the overspeed trip relay contained in the relay box. Clockwise turn of the adjusting screw increases the revolutions and vice versa. The adjusting range is between -5 and +1% of the preset revolutions. (2) when testing the overspeed trip for the turbine, the pump must be disconnected and the test must be to the tuFbine only in oFder to avoid dry running of mechanical seal fitted on the pump,

2.7 Pressure switCh (Refer tO Fig. 4.4 and 4.5)

Remove the plug and turn the adjusting screw clockwlse to decrease the actuating pressure and vice versa. For differential pressure adjustment, clockwise turn of the differential pressure adjusting screw widens pressure difference and vice versa. Fig.

Fig. 4.5

4.4

ADJUSTING

DIFFERENTIAL

P R ESSU R E

P LU G

ADJUSTING

P LU G

SCREW

ADJUSTING

SCR EW

SC R EW

~ ~~~_ _

L ~

l

2.8 Thermo-switch for overheat trip(If fitted)

An adjusting stem each for the contractor and the temperature reading is provided at the center of the front face and on the side respectively.

3. MAINTENANCE CHECK LIST FOR REGUIAR INSPECTION It is recommendable to perform the regular inspection to avoid accidental troubles.

3.1 Inspection every 3 months Procedure and inspection

Item

Item

Procedure and inspection Confirrn wear and damage on

Emergency trip device

Labyrinth packing and steam guard

labyrinth packing and steam guard. Suitable clearance between shaft and labyrinth packing is shown in standard clearance table.

Clean cooler interior and cooling tubes.

L.O. cooler

Confirm wear and damage on bearing. Suitable clearance is shown

3.2 Inspection every year

Item

Turbine blade and nozzle

in clearance table.

Procedure and inspection

Bearing metai

Check blades and nozzles for erosion, corrosion, damage and sticking scale. (Scale on blades causes vibration,

its seat and

parts

machined• fine. Thrust bearing clearance is adjusted with adjusting liner and its relating position is subject to clearance

between moving blades and nozzles.

abnormal steam thrust and insufficient output)

Governor valve,

No adjustment is required for radial bearing when fitting as they are

Confirm wear and rust on teeth

Check valve and valve seat for erosion, corrosion and wear. Check valve stem and guide bush for

Reduction gear

wear.

Dynamic balance

Dynamic balance to be carried

for turbine rotor

if rotor is damaged or repaired.

Main L.O. pump

faces. Ifthere is any indication of

rust immediately find cause and take proper measure.

Check clearance between casing and pumping gear and also axial clearance.

cg snINKO INIO.LTO. C

)

4

LUBRICANTS

4.2 Lubricants

ISO VG 68 (International Standard Organi-

4.1 Replacement of lubricating oil

The replacement interval of is based on deterioration or

the lubricating oil

contamination of

zation) for lubricating oil for the bearing, the reduction gear and the Woodward gover-

nor and ISO VG 460-VG680 for Gear

L.O. being used.

However Table 4.1 shows recommendable

Oi] for the gear coupling are recommendable.

interval of the replacement.

The brand names of the oils equivalent to the recommendable one are shown in Table 4.2.

Table 4.1

Replacement Location

L.O. tank

Norm al operation

After initial start

Within 3 months

Every I year

Woodward governor Gear coupling

If

ll

,l

Every 6 months

Table 4.2

Lubricating oil Gear oil BP ENERGOL GR-XP680,GR-EP680 BP ENERGOL THB68,77 CASTROL ALPHA SP680 PERFECTO T68 CASTROL COSMO GEAR SE680 COSMO TURBINE SUPER68 COSMO OIL SPARTAN EP680 EXXON TERESS068 SUPER GEAR OIL680 IDEMITSU KOSAN DAPHNE TURBlNE OIL68 KYOSEKI ES GEAR G680,M680 RIX TURBINE OIL 68 KYODO OIL DIAMOND GEAR LUBE SP680 HITSUBISHI OIL TURBINE OIL68, DIAMOND MARINE68 MOBIL DTE OIL HEAVY MOBIL DTE OIL HEAVY MEDlUM MOB I L MOBIL GEAR636

Name of company BP

NIPPON OIL CALTEX OIL

FBK68 REGAL OIL R & O 68

TURBO OIL T68 SHELL OIL SHOWA SHELL OILTURBO OIL T68,J-H OIL68 REGAL OIL R & O 68 TEXACO OIL

C

~

g

BONNOCK SP680 MEROPA LUBRICANT 680

SHELL OMARA OIL680 OMARA OIL680 TEXACO MEROPA 680

SHINKO INO.LTO.

LIMIT OF USE CHAPTER 5STANDARD CLEARANCE AND Fig. 5.1

17 1C_6

15 13 ,. 14 L-A 11

A B

13

o

13

(~) l* F~ l l I

~,,

D ETAI L-A

(~)

{

t

8

9

DETA IL-B L-B

Table 5.l

Unit ru :

NO.

2

l

o.

RXO Standard clearance

0.15-

RX1

RX1

Standard clearance Limit of

use

mm

7

8

9

0.2-0.3

0.45-0.55

0.25-0.35

0.25-0.30

0.4

0.65

0.45

0.4

17

Backlash

0.15-0.2 0.23 0.38

0.23

RXZ-2 0.28

NO.

6

5

15-0.2

0.3-0.35

RXO use

4

0.3-0.35

0.2

0.2~RX2-2 0.25

Limit of

3

0.23

0.38

lO

ll

t

12

14

13

15

16

0.25-0.30

0.20-0.50

0.20-0.25

2.2~2.8

0.4

0.65

0.35

1.5-3.5

0.28-0.63 (0.22-0.5D

The figures shown in Table 5.1 are for RX O , RX I . RX 2-2 ."Backlash" for RX O. And the figure in ( ) shows Backlash of Model RX O only.

SHlnKO InD.LTD. C

)

CHAPTER 6 DISASSEMBLING ANDASSEMBLING l .2 Disassembling ofexhaust casing (1) Remove the lagging on the casing.

1 . DISASSEMBLING 1.1 General caution

(1) Proceed with the work in good order by re-

('_) Remove the piece provided on the exhaust

ferring to the assembly drawing and thoroughly understanding the construction.

piping for disassembling.

(3) Remove the tightening bolts and taper bolts

(2) When removina* the fixing or fitting faces use

on the casing fiange.

lifting bolts provided on them.

(4) Separate the casing from the steam chest by

(3) When removing the rotating element, be careful

lifting bolts on the casing flange.

to avoid damage on,the sliding faces, the journals and machiried faces.

(5) Remove the casing vertically and axially from the steam chest.

(4) When removing the rotating parts from the shaft, remove them carefully after removing

This removal of the casing should be done carefully otherwise the casing may hit and

the rotation preventing device.

damage the rotor.

(5) In order to avoid mistake in assembling, mark suitable match marks as much as possible when disassembling.

Fig. 6.1

ADE ADE MOVING BLADE

~ EXHAUST CASING _-- EXH Ncz / MAII Top

NCZZLE

STATIONARY BLADE

MAIN LO PUMP

r : :~=E,~ t

c

TOP COVER

STEAM CHEST EST ING AFT EAR VER

G E,~ GEAR

WHEE L

LABYRINTH PACKING r~

TURBINE SHAFT

REDUCTION GEAR

CASING

.J

BOTTOM COVER

OUTPUT SHAFT OUT

~

c~ SHINKO IND.LTD. C

J

1

1.3 Disassembling of steam chest

(1) Disassembling of the steam chest should be carried out after disassembling of the exhaust casing mentioned before.

.6

(1)

(2)

Put the "Governor valve spring holding tool" to the threaded holes on both sides of the valve stem ing through the governor valve casing cover and screw down its nut so that the

(3) Separate the front half of the chest from the

spring coils touches closely.

rear half by lifting bolts on its vertical flange.

(3)

done carefully otherwise the rotating element,

the moving and the stationary blades may be damaged.

Remove the linkage betWeen the governor valve and the governor.

(2) Remove the bolts and taper bolts tightening the front and rear halves of the steam chest.

(4) Remove the front half of the steam chest. This removing of the steam chest should be

Opening of governor valve (Refer to Fig. 6.2)

Remove the bearing holder at the rod end of the valve stem frorn the valve stem after removing the split pin on the side and securing the valve stem.

(4 )

Remove the tightening bolts and taper bolts from the governor valve casing flange.

1 .4 Disassembling of reduction gear casing cover

(1) Remove the thermometers on the reduction

(5)

or injuring the valve stem.

gear casing.

(2) Remove the reduction gear casing top cover

Remove the cover vertically without bending

(6)

Screw 2 jack bolts of the governor valve seat pulling tool to the valve seat.

and the front half of the bottom cover.

Fix the holding plate to the casing by the

(3) Remove the piping, wiring, etc. disturbing

jack bolts.

the disassembling.

Refer to Fig. 6.3.

(4) Remove a bolt ning the front half of the L.O, pump casing flange and reduction gear casing cover.

(7)

out the valve seat from the casing.

(8)

(5) Separate the reduction gear casing cover from its casing by using the lifting bolts on the flange.

Tighten the nuts of the jack bolts as to pull

After removing the valve guide of the governor valve take out the governor valve toward the valve stem. (If the governor valve is an assembled one, remove the stop ring on the valve after removing the strainer and disassem-

(6) Pull the cover horinzontally.

ble the valve before taking it out.)

1.5 Opening of turbine rotor and reduction gear

(1) Disassemble the exhaust casing, the steam chest and the reduction gear casing cover in accordance with I .2, I .3 and 1.4 ofthis chapter.

(2) Using eyebolt into the hole on the turbine shaft end, put wire rope from the crane.

(3) Just lift up the turbine rotor a little gently

and draw it forward while taking care so as to avoid between the moving blads and nozzles, and labyrinth packing.

(4) Using eyebolt into the hole on the output shaft end, put wire rope from the crane.

(5) Just lift up the gear wheel a little gently and

draw it forward while taking care so as to avoid damage.

Gg snINKO INlb.LTo. c

)

Fig. 6.2

Fig. 6.3

WITH UG8 GOVERNOR BEARING COV E R HOLDER e

VALVE STEM

VALVE STEM

i~ !!i,l

JACK BOL BOLT

VALVE GUIDE

i,ij,1,

HOLDING PLATE

J

~•Til,

VALVE 1

VALVE SEAT

GOVERNOR VALVE CASING

AC Kl PAC Kl NG NG

WITH PGD GOVERNOR

RAINER STRAINER

~~

~:ii

r~

J -~

i:1 !il! I

~

'J~'

~

~

1

L*

2

ASSEMBLING Assembling can be carried out by reversing order (8) Clean thoroughly various bolts and nuts on the of disassembling and attention must be paid to the Steam side and apply seizure preventive (e.g.

follovving: Graphite) on them.

(1) Clean each part thoroughly with kerosene to (9) Before assembling apply seizure preventive (e.g. remove dust and foreign matter and correct if Graphite) on the sliding portion of the governor

injury is found. valve and on the valve and on the valve stem. (2) Turn nuts for rotating parts securely and fix (10) Assemble the positioning liners. split pins, set

anti-rotation device without fail. screws, spring washers, etc. of each part in the (3) Assemble fitting parts according to match same state as before. Never t~orget caulking where necessary.

marks ifany. (1 1) Check the clearance of each part in accordance (4) Before assembling apply sufficient lubricating with the clearance table. oil to the bearing portion and gear teeth. (12) Check the backlash of gear teeth. (5) Be careful to avoid one-sided tightening of

bolts. (13) Confirm that the position ofthe oil spray for the

(6) Before assembling confirm that no dust and reduction gear, the L.O. pump driving gear and the speed governor driving gear.

foreign matter exist inside the turbine casing, (14) Confirm alignment (Refer to "r:\;'STALLATION governor valve casing, reduction gear casing

and oil tank. AND PIPPING).

(7) Clean all the t faces and fitting faces and (15) Confirm the smooth turning ofthe rotor. apply heat resisting liquid packing (e.g. Hermetic) (16) When testing the overspeed trip for the turbine,

on the steam side and oil-proof liquid packing the pump must be disconnected and the test must

(e.g. Three Bond) on the oil side. be to the turbine only in order to avoid dry running of mechanical seal fitted on the pump.

Cg SHINKOIN!O LTO C

J

CHAPTER 7TROUBLE SHOOTlNG AND REMEDIES Turbines can perform satisfactory function if properly handled and maintened.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest causes of trouble and suggested remedies.

Table 7.1

Causes

Troubles

Remed ies

l.

Incorrect assembly.

1.

Check axial parallelism between shaft and bearing and correct. Check taper land of oil groove of thrust bearing and correct or replace.

2.

Abnormal misaJignment between

2.

Correct it within permissible value.

(Refer to "INSTALLATION AND PIPING" and "ALIGNMENT".

turbine and driven machine.

3.

Air, water or foreign matter mixed in

3.

sup p ly Refer to "Insufficient L.O. and pressure ,, mentioned later in this Table 7.1.

4.

Replace oil with correct one.

oil.

Overheating of bearing

4.

Incorrect selection of oil in oil tank.

(Refer to "LUBRICANTS")

5.

Shortage of oil in oil tank and of oil supply and of oil pressure by main

5.

L.O. pump. 6.

Refer to "Insufficient L.O. supply and ,, pressure mentioned later in this Table 7. l.

Vibratio n.

6.

Refer to "Vibration

,,

mentioned later

in this Table 7.1. 7.

Deterioration or pollution of L.O.

8.

High temperature of L.O. main L.O. pump.

supplied by

7.

Replace oil.

8.

Refer to "High temperature of L.O. ,, supplied by main L.O. pump

mentioned later in this Table 7. 1.

1.

Shortage of oil in oil tank.

1.

Add oil.

2.

Abnormai condition of main L.O.

2.

Check clearance between shaft and bearing of main L.O. pump and correct

pump.

it by replacing bearing if necessary.

Check axial thrust clearance between pumping gear and bearing of main L.O. pump and replace bearing if necessary. Insufficient L.O.

and pressure

supply 3.

Abnormal oil escape from L.O.

3.

pressure adjusting valve.

Increase oil pressure by adjusting valve.

(Refer to "ADJUSTMENT FOR

ACCESSORIES AND EMERGENCY TRIP") 4.

Air mixed in oil.

4.

Draw air from oil strainer and L.O. cooler by plug or vent valve. Repair part from where air invades into oil.

gl

St,!lNKO INO.LTO. C

)

Troubles

Causes

5. Water mixed in oil.

Remedies Draw water from oil tank, oil strainer

5.

and L.O. cooler by plug or drain valve. Check and repair cooling tube of L.O. cooler if necessary.

Insufficient L.O.

sup ply

Check steam leakage from turbine

and pressure

gland into reduction gear casing and replace labyrinth packing if necessary. 6. Foreign matter in oil.

Clean oil strainer by turning handle on

6.

oil strainer.

1. Foulling ofcooling tube of L.O.

1.

Clean cooling tube of L.O.

cooler.

cooler.

2. Insufficient cooling water flow to L.O. cooler.

2.

Increase cooling water by openin* cooling water inlet and outlet vaives for L.O. cooler and keep L.O.

High temperature of L.O. supplied by main L.O. pump

temperature between 20 and 45

o

C

suitable for correct bearing temperature.

3. Abnormal operation of L.O.

3.

Repair to work correctly.

4.

Decrease cooling water temperature.

1.

Adjust sealing steam adjusting valve provided on this line.

2.

Replace with new packing.

temperature control valve, if fitted.

4. High temperature of coolmg water to L.O. cooler.

1. Excess ofsealmg steam supply (In case of exhaust steam is

vacuum) Steam leakage from turbine gland

2. Excess of clearance between shaft and labyrinth packing.

1. Damage of bearing.

1.

Check bearing and replace if necessary.

2. Abnorrnalmisalignment between

2.

Correct it within permissible value.

(Refer to "INSTALLATION AND PIPlNG" and "ALIGNMENT")

turbine and generator.

Vibration

3. Excess of bearing clearance.

3.

Replace bearing.

4. Unbalance ofshaft due to damage

4.

Check and correct or replace with great consideration and dinamically rebalance.

5.

Correct or replace labyrinth packing.

6.

Check and correct. Warm-up sufficiently and turn turbine manually and sufficiently.

of blades or shrouds or bending of shaft.

5. Abnormal between shaft and labyrinth packing.

6. Thermal deformation of shaft or casing due to insufficient warming up or turning or excessive outside force, Iike incorrect piping.

C

J

g

SHINKO INO.LTD.

Troubles

Remedies

Causes 7.

Discharge drain by drain valve or plug. Clean drain separator and drain trap.

8.

Check and correct.

l.

of pinion and gear wheel, driving gear

Check and correct parallel between pinion and gear wheel, and driving

of main L.O. pump and governor.

gears.

7. Accumlated drain in exhaust casing and drain in inlet steam.

Vibration

8. Abnormal teeth of reduction gear and driving gear of main L.O.

pump and speed governor.

l. Abnormal or damage of teeth

Correct teeth by shaving or grinding machine, etc.

Noise 2. Insufficient oil spray to teeth of pinion, gear wheel or driving gear

2.

Clean oil spray to teeth.

1.

Check and correct to move smoothly

of main L.O. pump and governor.

1. Sticking in movement of governor valve, valve stem and valve guide.

2. Wear or sticking ofts and

or replace. 2.

Correct to move smoothly or replace.

pins of linkage.

Hunting in operation and difficulty of speed control caused by turbine itself

3. Incorrectselection of oil in

3.

Replace with correct oil.

(Refer to "LUBRICANTS")

govemor.

4. Deterioration or pollution of L.O. in governor.

4.

5. Incorrect operation ofgovernor.

5.

Replace oil.

Refer to manual of Woodward governor.

g

SuINKO INO.LTO. C

)

CHAPTER 8 REPLACEMENT PARTS This chapter introduces replacement parts information for the turbine RX. When ordering replacement parts, include the following information: 1 . Ship's name

2. Shipbuilder and hull number 3. Service and model of the turbine 4. Parts' numbers and names shown in the parts lists

1 440 ~

1414 \

/

1 402

1 461 ,

1521 ~

l(

1 oo 1

7008-1 4. 7065-7 7008-1 . 7065-1

7008-2 7065-1

1 089, 1 093

231 7

1 087 ~-~~~ 1 460,

t~r, ~

231 5

1 520 ll 1 050

~ 7008-3

// 1712

L

//~2115 _~/ 7128

1 002 / 1 003 l~

2 1 08

1012 1 020

1015 "

2101 2 1 07

~.,

2119 2 1 24

7 1 29

=~~

2113 7 1 26

1401

21 25

1 430

// 7053-27

2117

2114

L~:

7 1 27

~

2118 1 432

1433 /

C

J

21 1 6 2 1 20

g

SuINKO INO.LTO.

PART NO.

NAME OF PART

REQ.

1 set

2116 2117

TH RUST METAL

1 set

EXHAUST CASI NG

1 set

2113

1 002

STEAM CHEST

1 set

2114

1 003

PACKI NG CASE

1 set

21 1 5

1 ol 2

LABYR INTH PACKI NG

2 sets

1 O1 5

STEAM GUARD

1 set

1 020

SPRING

8

1 050

NOZZLE

1 087

STATIONARY B, SEAT

REQ.

BEARING METAL BEARING METAL BEARING METAL BEARING METAL

1 Ool

1 089

NAME OF PART

PART NO.

1 set 1 set 1 set

2118

TH R UST M ETAL

1 set

1 or 2

2119

THRUST METAL

1 set

1 or 2

2120

TH RUST M ETAL

1 set

STATIONARY BLADE

1 set or 2 sets

2124

1 set

1 093

SHROUD

1 set or 2 sets

1 40 1

TURBINE SHAFT ROTOR DISC

1 402

2125

OIL GUARD OIL GUARD

1

231 5

TACHOMETER ROTOR

1 set

1

231 7

1 set

7008-1

7008-2

TACHOMETE R TRANS. CAP SCREW CAP SCREW CAP SCREW CAP SCREW

1 41 4

KEY

1

1 430

TH R UST CO LLAR

1

1 432

BALANCE WEIGHT

1

1 433

TRIP SHAFT

1

7 008- 1 4

1 440

NUT

1

7053-27

1 460 1 461

1 520 1 521

KEY

Ist MOVING BLADE

1 set

7065-1

SPRING WASH ER

2nd MOVING BLADE

1 set

7065-7

SPRING WASHER

SHROUD SHROUD

1 set

TH E RM OM ETE R

1 set

7127

TH E RM OM ETE R

1

7 1 28

THERMOMETER THERMOMETER

1

DRIVING GEAR REDC. GEAR CASING

2107

WHEEL

1

2 1 08

WHEEL SHAFT

1

g

1

7 1 26

2101

1712

7008-3

1 set

1

1 set

7 1 29

1

1

SulNIKO INlb.L7b. C

~

COVERNOR VALVE

1 340 7061-29, 7051 -16

--••-•-~__

'~\\'

1 337

1317

\

1 341 =-1 304

\

\\\\ 1 730 1 753 706 1 -32,

6101. 7055-22 \

\.

1302 \_ 1 305 __

\\

\\

7051-10

\

\\

\+

1 752

1 306

7074-1 O

1 330 ---

1 331

1301 -__

1 333 1 335

__~~ 1 322 ~~/~~~~ ___/ 7074-1 2 ~ _~_/-

=.~ - 1203 =1 7074-2 /

\•;

/

\\-.

/

/

~'l

/

7008-24 /

PART NO. 1 203 1 301

1 302

1 304

V. CASING GOVERNOR V. COVER GOVERNOR lrl•,,,,~~ SPRING ~ - ,~-1 1

BUSH STEM

1317

1

1752

LEVER GOVERNOR HOLDER

1 753

BUSH

2

6101

STUD CAP SCREW SNAPRtNG SNAPRING

1

1 7 30

1

1

1

SPR t NG HOLDER

1

705 1 -1 6

1

7055-22

NUT

1

7 06 1 -29

PIN

1

706 1 -32

PIN

1

GASKET PACKI NG

1

P LU G

1 331

V. LtNER 1 IL 1 GOVERNOR

1 332

1 340

GUtDE GUIDE BUSH BUSH 8USH BALL BEARING

1341

LINER

1 337

R EO.

7051 -1 O

VALVE GOVERNOR

1 335

NAME OF PART

1

1 322

1 333

PART NO.

7008-24

1 330

1 334

J

* R E O.

STE AMSTRAINER

1 306

1 305

c

NAME OF PART

7074-2

2

1

7074- I O

GASKET PACKtNG

1

1

7074-1 1

GAS CET PACK,NC

1

1

7074-1 2

GASKET PACKING

1

1 1

1

g

2

SuINKO INO.LTO.

TR,P SERVO -MOTOR FOR UG 8 GOVERNOR

PART NO.

1721 7061-33, 7051 -6

> J m ~;

4750-2

LU

1 7 24

4750-1

1 721

LINK

1 724

CONNECTiNG BAR ASSEM B LY

1 set

1 830

CYLINDER

1

1831

COV E R

1

1832

BUSH

1

1 835

PISTON

1

1 836

SPINDLE

1

7061 -41 , 7051 -9

a:

1 837

1 837

ROD END NEEDLE BEARING

1

o H o ~:

1 842

SPR I NG

1

1 843

SPR I NG

1

3870-5

OIL SEAL

2

7051 -9

SNAP RING U-NUT

2

706 1 -4 1

PIN

1

7072- 1 8

1

4750-1

SEAT PACKI NG BALL T (L-TYPE)

47 50- 2

BALL JOtNT ( L-TYPE)

1

705 1 -6

SNAP RING

2

PIN

1

1

1 830

ROD END BALL BEARING ASSEMBLY CYLINDER

1 831

COV E R

1

1 832

BUSH

1

~~ UJ co co

1 835

P I STON

1

1 836

SPINDLE

1

a:

1 837

ROD END NEEDLE BEARING

1

SPRING SPRING

1

o > a: UJ co rL

a:

1 83 1

H

1 84 1

7057-7

7072-1 8 1 830 n' li,i[,

1 835 li

7057-7 l i,

1 843 1 842

7061 -33

1 755 1 758

FOR PGD GOVERNOR

C 1 830

> Joo

1 837~.

:l

1 836 \.

3870 5 \

1 755

1 832

lll I~

1 83 1 l _JL\~::JJJl' ' 7072-1 8

7061 -33,705 1 -1 7

1 758 I ~~,rH

1 830 1 835

T[ I 1,Il l ll

7057-7 1 843'

1 842

o H o :~

1841 1 842

1

1

1

1 set 1

1

1 843

UJ co CL

3870-5

OIL SEAL

2

7051 *9

SNAP RING U-NUT

2

7 061 -41

PIN

1

7 072-1 8

1

7051-17

SEAT PACKtNG SNAP RING

7 06 1 -33

PIN

h

7057-7

g

1

o > a: :c

.l

1

C 1 830

co

1 832

7061 -41 , 7051 -9

1

(1)

3870-5

1 84 1 ,..

RE(L

1 841

1 836

li

NAME OF PART

1

1

2 1

SlllINKO INb.LTO. C

)

PART NO.

MAINL.O. PUMP

NAME OF PART

R EO.

1 703

DRIVING SHAFT SPACER 1 709 BALL BEARING 1710 BALL BEARING

1

1 705

1

1 7 1:~ ;;~ijN~~n~bLLI~GGEAR

1

1 1

~1~~ L'I~~~~Gd~ E RNOR COY~LING_

8001

2054

C2051 ASSEMBLY

7057-9 3870-7

2064 >

2063

1711

2051

3530- 1

2059 2055

3540-1 1 709

7053-21

1 703

2057 2060 7053-22

1 705

1710 2129

-+

3870- I o

2 1 30

7053- 1 8

1713

l. ~

7053-23 7057- 1 2

J co ~ UJ co cl'

CL

~ D d J z-

~

2053 DRIVING SHAFT

1

2055 DRIVING GEAR 2057 FOLLOWING GEAR 2051}~91 BEA R I NG

- BEARING METAL 206,~__ 2060 2062 2063 2064 3870-7

set

1

set

1 set

1 set

BUSH BUSH

1

OIL SEAL

1

1

Ol L SEAL

1

7 05 3-2 1

KEY KEY KEY U-NUT U-NUT U-NUT DRIVING GEAR FOLLOWING GEAR BEARING NUT BEARING WASHER KEY SPEED GOVERNOR

1

7053-22 7053-23 7057-8 7057-9

2130 3530-1 3 540- 1

7053- 1 8

800 1

g

BEARING METAL

1

1

3870- I o

21 29

J

set 1

7057-1 2

c

1

2051 CASING~ ~~~~~

_ __ __2._054 FO L LOW_ I N G SHA FT

2061 7057-8

2062 2053

1

SuINKO INO.LTO.

1

1 1 1 1

1 1 1 1 1 1

PART NO.

TRIP DEVICE

1911

1 91 o

1 922

/

4020-2 1913

1 1

1 905

1 905

BUSH BUSH BUSH SPINDLE SPINDLE

1

1 90 1

1 906

> JtD ~ UJ

1 605 1 608 7061 -30, 7051 -1

'!'f

l~

\

\

1

1 set

COV E R

1 908 1 923

~\

ASS EM B LY

1

1 903

1 907 1 908

1 909

1910

UJ

1911

> D

1912 1913 1914

o

1434 \\

SPR I NG

1 91 2

co co

i

1 608

1

1 906

ll

1

1 605

ADJUSTING LINER TRIP LEVER

COV E R

3870-8

ll

1

1 450

1 set

CAS I N G

7057-15 -

1 450 1 436

SPR I NG

1 902

1920 ~

1 909

O.S.T. WEIGHT

1 901

~ 1 902

1 907 1 903

R EO.

1 436

C 1901

3870-6

1921 ---

1914

NAME OF PART

1 434

UJ 'L

tC

h

1 920

1921

1922 3870-6 3870-8 4020-2 7057-1 5

1

1 1

1

GRIP GRIP SPRING

1

SPR I NG

1

SPRING LINER

1

LEVER FULCRUM BOLT

1

OI L SEAL

1

1

1

1

1

OtL SEAL

1

B E L LOWS

1

U-NUT

1

1923

BRACKET

1

7051-1

SNAP RING

2

PIN

1

7061 -30

cg SulNIKO INIO.LTb. C

)

L . O.

NAME OF PART

PART NO.

COOLER

7 30 1

ASSEM B LY

R EO. 1

set

7301-6 l; 730 1 -5 / / 7301-9B ~~ 7301 -3

730 1 -2

INLET HEAD

1

730 1 -3

RETURN HEAD

1

730 1 -4

TUBE SHEET TUBE SHEET COOLtNG TUBE

730 1 -5

7301 -6

7301-9A 7301 -9B 7301 - 1 1

7301 -1 2

L.O. P R ESS. ADJUSTINC

V.

7801

1

set

CASING

1

780 1 -2

VALVE

1

780 1 -3

ADJUSTIN G SCR EW

1

7801 -4

SPRING

1

7801 -5

P LU G

1

780 1 -6

GASKET

1

ASSEM8LY

1

781 1-3

FILTER

1

781 1 -6

SPINDLE

1

781 1 -7

HANDLE

1

781 1 -8

PACKING AIR PLUG DRAINPLUG

1

ASSEMBLY ROTOR

1 se t

781 1

\

1

1

7801 -1

L.O. +\ \

781 1 -8

GASKET GASKET STU D &NUT BOLT &NUT ASSEMBLY

1 1

781 1 -9

781 1-1 O

se t

set

set 1

1

ll

PRIM. L.O. PUMP ( I f fitted ) _~_ 8301 _~~ 830 1 -~ 8301 ~_~= 8301 830 1 8301 83 o 1

8301 8301 -5 8301 -6

8ALL BEARING BALL BEARING

1

set 11

8301 -7 8301 - 1 6 --8301 - 1 5

830 1 -9 8301 - 1 1

FAN

1

IMPELLER FAN COVER

1

8301 - 1 3

1

8301 - 1 5

CRIMP TERMtNAL

3

8301 - 1 6

TERMINAL BOX OIL SEAL

1

8301 - 1 8

cg SHINKO INO.LTO. C

J

1

NAME OF PART

PART NO.

PRIM. L.O, PUMP (If fitted)

8302 8302-1

ASSEMBLY CAS I N G

CASING COVER DRIVING SHAFT 8302-4 FOLLOWtNG SHAFT

1 1

8302-7

8302-8 8302-9 8302- I O

8302-20 -___

..,\.-

8302-1 3 1 80-2

7 053-32

l,

3 1 90*2

8302-21

8302-1 9

8302-1 8 8302-1 5

7 008-62 // /~~/'/ 3530-3 l/'/ I l 8302-1 7

8302-3 l

8302-9 17053-33

8302-4 8302-1 O

8302-7

7053-34 8302-8

ll

/

1 set

PUMPING GEAR

1 set

BEARING METAL

1 set

BEARING METAL

1 set

8302-1 1

8302-1 2

BUSH 8302- 1 4 BUSH 8302- 1 5 SPACER d 8302-1 6 ADJUSTING LINER J ~ 8302-1 7 BALL BEARING oc tL 8302- 1 8 BEARING COVER 8302- 1 9 COUPLING 8302-20 COUPLING 8302- 1 3

8302*21 3 1 80-2

8302-6

8302-1 2,// ~

3 1 90-2

8302-1 1

OI L SEAL

COUPLING BOLT & NUT RING COUPLING BEARING NUT

8302- 1 3

3530-3

8302-1 4

\8302-1 6

7008-62

BO LT

7057-1 7

7057-1 6

7053-32

KEY KEY KEY

8302-2

7053-33 7053-34 7057-1 6 7057-1 7

ROTOR AXIAL MOV

. DETECT. (If fitted)

> J :o

BALANCE WEIGHT

:~

1 984

l I ~ I•lli~L

1 1 1 1 1 1 1 1

4 sets

4 1

2 1 1

1 1 1 1

MOTOR

1 set

ASSEMBLY

1 set

1 980

CASING

1 984

E LEM E NT

1 998

BRACKET

1

1 set 1

Jo XI

~

\

1 980

1

~UJcl) Ocod :~~

l

U-NUT U-NUT KEY ON MOTOR SHAFT

c 1 980

HEAD ASSEMBLY

1

PUMPING GEAR

oL :~ :) o*

8302-5

1

8302-2

8302'-6

:~ UJ co co

1 set

8302-3

8302-5

> J ao

R EQ.

f~ ~ I

J

, PINt~ ~ll

l

SET SCREW

__C. ~_~/

- -- I ~~

/

l ~J - J-~

Hh OUJ

QCo

-TJ l

'LL 1 998

g

snl'VKO INb.LTb. C

)

PART NO.

SENTINEL VALVE

>

741 1 -10

J co ~ UJ

741 1 -9

co co

741 1 -9 741 1 -1 o

ASS E M B L Y

RE(l 1

SPRING CAP

set 1

1

UJ

li

li

741 1

NAME OF PART

> J > J uJ Z H zuJ co

E LECTRIC TACHOMETER

231 5

R OTO R TACHOMETER

1

23 1 7

TACHO.TRANSMITTER RECEIVER TACHOMETER TACHOM E TE RECEtVER R

1

23 1 8

2325 {' !

701 0-37

23 1 5

1

1

FOR CONTROL ROOM S ETSC R EW

1

701 0-37 23 1 8

/

2325

23 1 7

_ Jj

7451

SOLENOID VALVE

7451 -3 745 1 -3 f' 7451-4 7451-10

>

J Co ~ UJ co co

/

7451 -8 uJ

7451~7

7451.6

J

> J > D o zUJ J o U)

J

Tl

C

J

g

7451 -4

ASSEMBLY SLEEVE SPOOL

1

set 1

1

745 1 -6

SPOOL SPR IN G

1

7451 -7

O- RING

6

745 1 -8

PUSHBUTTON

1

SOLENOID COI L

1

7451 -1 o

smNKO INO.LTO.

NAME OF PART

PART NO.

PREssuR E SWITCH

I o h ~ co UJ oC :) co U) UJ oC

R EQ.

7161

LOW L O PRESS. TRIP

1 set

7 1 63

LOW L.O. PRESS. ALARM PUMP DIS. OVER PRESS. TRIP

1 set

7 1 74

7181

HIGH BACK PRESS.

7 1 78

1 set

1 set ALARM

~

PREssuRE SWITCH

7178 1 7178 2 7178-3 7178

I

o h

~ (D

ASSEM B LY

1 set

7 1 78-1

PRIM L.O.PUMP

1 set

7 1 78.2

L.O. PRESS. INTERLOCK

1 set

7 1 78.3

HIGH BACK PRESS. TRIP

1 set

UJ oC

~~1 r~ --1 ~--l r~~~L----1 r --1 r--il I I t I : I I l i I

D

(1)

CD uJ

~

oC 'L

I

1

8458

OVERSPEED TRIP EMERGENCY TRIP

7101

tN LET STEAM

1

7 1 02

CHEST STEAM EXHAUST STEAM

1

8454

LtM IT SWITCH

I o H

~r~1 ~

1

~ H ~ J Cl)

@ PR ESSURE GAUGE

UJ

7 1 04

1

o :)

7 1 05

GLAND STEAM

1

o

7 1 08

L.O.

1

7110

PUMP SUCTION PUMP DISCHARGE

1

UJ oC :) (D (1)

UJ a: (L

7111

1

l

7 1 26

THERMOMETER

7127

FOR L.O. COOLER FOR TURBINE

7 1 28 7 1 29 a: uJ

h UJ :~

7 1 30

7131

TURBINE SHAFT UPPER SIDE

TURBINE SHAFT LOWER SIDE WHEEL SHAFT UPPER SIDE WHEEL SHAFT LOWER SI DE L.O. COOLER

L.O. INLET SIDE

L.O. COOLER L.O. OUTLET SIDE

1 1 1

1 1 1

O ~ CC UJ

I h

g

SNINKO IND.LTO. C

)

PART NO.

TH E RMO-SWI TCH ( tf fitted,

7 230 7230-1 1

7231

NAME OF PART TURB,NF_ SHAFT UPPER StDE

,NSTALL THREAD TURBINE SHAFT LOWER SIDE

,NSTALL THREAO SHAFT 7232 WHEEL UPPER SIDE 7232- 1 1 ,NSTALL THREAD

7231*1 1 :E

7230- 1 1 7231 -1 1 7232- 1 1 7233- 1 1

7230

u h ~ U' O :~

R EO. 1 sot 1

1 set 1

1 set 1

1 set 7233 WHEEL SHAFT LOWER S,DE

7233- 1 1

a:

tNSTALL THREAD

1

w I h

7231

7232 7233

PART NO.

QUICK EXHAUST VALVE 74 1-7

7481-6 7481-2 7481-3 748 1 - 5

LU

748 , -9

748 1 - 1

748 1 -8 EXH .

IN

FROM 1~_L MAiN LO PUMP

TO OIL TANK

> J

H ~ ~

(o :D

NAME OF PART BODY

1

7481-2

VALVE BODY

1

748 1 -3

DISC VALVE

1

7481-5

CHECK VALVE SEAT

1

7481~

CHECK VAKVE SPRING

1

748 1 -8

VALVE SEAT

1

748 1 -9

VALVE SEAT GASKET

1

748 1 -7

~'

g D o

hl :, O

TO TRIP SERVO-MOTOR

C

J

g

REQ.

7481.1

SHINKO INO.LTO.

1

INSTRUCTION MANUAL FOR DRAIN SEPARATOR FOR CARGO PUMP TURBINE 1 . Purpose for Drain Separator (1 ) The Drain Separator is intended to remove the drain in the steam coming into the

Steam Turbine to prevent not only a decrease of the Steam Turbine's performance but also damages of the moving blades and the bearing metals. (2) This Drain Sep~rator is so constructed that the steam coming, into the Drain Sep~rator circles in it and the Drain in the steam is gathered to the outer circle inside the Drain Separator and drained.

2. Installation of Drain Separator and Pipings A special attention is to be given for the installation of the Drain Separator and its

(1 ) The Drain S~parator is installed as low as possible to easily remove the Drain,and also near to the Steam Turbine. (2) The Drain Separator is securely fixed on its flat foundation with the bolts of M20, (3) The insulation is so constructed that the insulation is made thick enough to prevent as far as possible the steam in the Drain Separator becomes drain by radiation from the outside surrace of the Drain Separator. (4) The piping between the Drain Separator and the steam pipe is so connected that unreasonable force and moment do not effect as far as possible. (5) Special attention and consideration are sufriciently paid for the pipe s and the hangers not to give bad efrect for,the pipings,

3. Opefation Manual If the drain in the steam comes into the Steam Turbine it becomes th cause for several troubles. Therefore the drainage is to be carried out sutficiently before starting the Steam Turbine as follows;

(1 ) Warmihg up the steam pipings betwe~n the Boiler and the Drain Separator is ' sufficiently carried out by gradually opening the drain by - valve till no drain

comes out from the drain by - valve. , (2).After'confirming no drain coming out from the drain by - valve, the drain by valve is blosed and then the valve fitted on the Drain Trap Line is opened. (3) After sutficiently warming up th~ St~ani Turbine, the Steam Turbine is stared. (4) Dufing operating the Steam Turbine, no drain in the steam being supplied fs confirmed by opening the drain by - pa~s valve on the Drain Separator.

C~ I srnNKo IND. LTD.

c)

INSTRUCTION MANUAL FOR CENTRIFUGAL PUMP (CV) This instruction manual describes construction, operation, maintenance, disassembling and assembling, etc. of model CV pump.

CONTENTS Page

CHAPTER I CONSTRUCTION . . . . . . 82 - 2 2. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Pumpstuffingboxseal . . . . . . . . . . . . . . . . . . . . . . . . 3

6. Bulkhead stuffing box and intermediate shaft with gear coupling . . . . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 2 CAUTION FOR INSTALLATION AND PIPlNG . . . . . . . 82 - 4 1. Place of installation and foundation . , . . , . . . . . 4 2. Finishing ofpump mounting seat . . . . . . . . . . . . 4 3. Caution for piping . . . . . . . . . . . . . . . . . . . . . 4 4. Suction piping . . . . . . . . . . . . . . . . . . . . . . . . 4 5. Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Permissible deformation ofbellows . . . . . . . . . . 5 7. Fitting offloating shaft . . . . . . . . . . . . . . . . . . 5

CHAPTER 3 OPERATION . . . . . . . . . . . . . . . 82 - 6 l . Check before operation . . . . . . . . . . 6 2. Starting . . . . . . . . . . . . . . . . . . . . 6 3. Stopping . . . . . . . . . . . . . . . . . . . . 6

CHAPTER 4 MAlNTENANCE . . . . . . . . . . . . . . 82 - 7 1 . Caution during operation . . . . . . . . . . 7 2. Ball bearing . . . . . . . . . . . . . . . . . . . 7

CHAPTER 5 STANDARD CLEARANCE AND LIMIT OF USE . . . . . 82 -10

CHAPTER 6 DISASSEMBLlNG AND ASSEMBLlNG . . . . . . . 82 -11 1 . Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 1 1

2. Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CHAPTER 7 TROUBLE SHOOTlNG AND REMEDIES . . . . 82 -13

CHAPTER 8 REPLACEMENT PARTS . . . 82 -15

9 1 SHINKOINb.LTO.

C)

CHAPTER 1CONSTRUCTION 1 . GENERAL The model CV pump is of a vertical single-stage double-suction centrifugal type, and the pump and driver are connected with the flexible couplings through an intermediate shaft and a bulkhead stuffing box, the construction being simple for ease of handling, overhauling and caretaking.

2.ThePUMP CASING Fi9. I .1 volute casing is split into two halves along a vertical plane containing the axis. 70

Since the suction and discharge nozzles are provided on the rear half casing, the rotating element can be taken out by removing the front half casing (2) without

34

1

20 7

9

1

ld,8

353

1

54A

35d

disturbing the suction and discharge pipings.

4

1

1

A vent to be connected with the stripping

27

or priming line and an air valve are provided on the volute casing.

38

\\

/ /

2

lh

,~ ~

, ,

/

l

~LLI

a, ,1 ll

3. IMPELLER The impeller(16) is of the double-suction type and hydraulically balanced. It is so designed as to improve pump efficiency and

,

l

1t

suction performance. Moreover, the im-

19

\

,, , / / \

/

~~ ll

16

peller is statically and dinamically balanced.

,

,

L

/

54B

L~~~

t8

4. BEARING

3

57

7

35

10

R EO. FOR PUMP

(1) The ball bearing (34) at the coupling end

PAR T NO.

R EO. FOR PUMP

PART NO.

NAME OF PART

is secured in the housing by pressing its

38

NAME OF PART

MOUTH RING

outer race by means of the cover(9).

1

VOLUTE CASING

1

This serves to the weight of the

2

VOLUTE COVER

1

48-1

FLINGER

rotating element .

3

48.2

FLINGER

is not fixed axially in view of the thermal expansion of the shaft (1 8).

(3) Grease is used as lubricant for the ball bearing.

J

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2 1

PUMP BED

1

7- 1

BEARING HOUSING

1

54A MECHAN ICAL SEAL

1 SET

7.2

1 SET

(2) The ball bearing(35) at the bottom end

c

48

372

The rotating element is ed by ball bearings on both sides of the pump casing. The 6300 type ball bearing is fitted in the solid inner case (14) with the split type bearing housing (7) and can be taken out together with the rotating element if the cap of the bearing housing (7) is removed.

/

,,

/

BEARING HOUSING

1

54 B

9

BEARING COVER

1

57

10

MECHAN ICAL SEAL

1

PACK ING R ING

1

1

BEARING COVER

1

70-1

SNAP RING

141

BEARING INNER CASE

1

70-2

SPLIT RING

1 42

BEARiNG INNER CASE

1

70-3

SNAP RING

ISET 1

1 46- 1

MECHA. SEAL COVER

1

1 46.2

16

IMPELLER

1

18

IMPELLER SHAFT

1

MECHA. SEAL COVER

1

19

IMPELLER KEY

1

353

BEAR ING NUT

1

20

COUPLING KEY

1

354

BEAR ING WASH ER

1

27

IMPELLER NUT

1

37 2

PACKING A ING

1

34

BALL BEARING

1

35

BALL BEAR ING

1

SNINKO INO.LTD.

5. PUMP STUFFING BOX SEAL

Fig. 1.3

The stuffing box is so designed as to furnish the mechanical seal exclusively. Therefore there is no leakage of the liquid pumped and no air leaks into the pump. Moreover, the operation is very simple since no adjustment for the stuffing box during operation

~~~~~!l

f

_:~~!=

r

125 l

'16

12e

is required.

IZ1

426 I 411 l

401

Mechanical seal Unblanced type mechanical seal is fitted and flushed by pressure liquid led from discharge side.

441

'38 j

a4:

lo4

,II

Fi9. I .2

,02

40,

OHCX

t~Z~~]

13g a95 ,]s

52

1 31

5

~~

1

,oT

403

~)

lp

,15 4l9

5

Ito

4

lOO It2 13t

14,

12g

412

~~@

l05

5

1!a A

1:3

5

,T,

6

139

,8, ,1,

7'

5

ll, l

A

7

,3a

(?1

Close-up view of mechanical seai

541

F LOATING SEAT

542

PACKING RING

5lh3

PAC K I N G

544 545

SEAL R ING

546

SPR I NG

PACKING RING

430 lzo

CARBON RUBBER RUBBER STA I N LESS STEE L

RUBBER STA I N LESS STEE L

401

BEARING SUFPORT

STAI N LESS STE E L

REa. FOR PUM

PART NO.

NAME OF PAAT

402 BEARING CASE

STOPPER R ING & SET SCREW

5lh7

R Ea. FOR pUMP

PART NO.

1

423B

1

424

NAME OF PART

HU8

1

COUPLING BOLT & NUT

403 BEAR ING CASE

1

425

PACK ING R ING

1

426

PACKING R ING

1

For upper mechanical seal, A is attached, e.g. 54A-1

404 BEARING COVER 405 STUFFING BOX

1

427

PACKING RING

2

FLOATlNG SEAT, and tor lower one, e.g. 54B-1.

4 06

GL~ND

1

428

407

1

429

PACKING R ING PACKING R ING

2

430 COVER & PACKING

ISET

414

FLINGER COVER & PACKING DISTANCE RING DISTANCE RING BALL BEAAING BALL BEARfNG LANTERN RING PACKING RfNG

415

G LAND PACK ING

408

409 6. BULKHEAD STUFFING BOX & INTERMEDIATE 410 SHAFT WITH GEAR COUPLING (Standard)

A stuffimg box is provided where the intermediate shaft es through the bulkhead to prevent the gas in the pump room coming into the engine room. If non-standard arrangement is fitted, it will be shown later.

41 1

412

413

1 1

1 1

1

INTEAMEDIATE SHAFT 432 FLOATING SHAFT 433 COUPLtNG KEY 4 1 434 SNAP RING 431

1

1

1

435

BELLOWS

1

436

SEAT PACK ING

1

2

437

SEAT PACK I NG

1

416

1

438

1

417

1

439

1

SLEEVE SLEEVE 418A SLEEVE 418B SLEEVE 4l9 COUPLING FLANGE 4 20 COUPLiNG FLANGE

HUB HUB 423A HUB

c!D

1 SET

1

1

1

1 1

42 1

1

422

1

1

SPACER DOUBLING PLATE 440 PLUG

1

BEAR ING NUT 442 BEAR ING NUT 443 BEAR ING WASHE R 444 BEAR ING WASHER

1

441

1

1 1

1

SuINKO INO.LTO. C

)

2 CAUTIONFORIN STALLATIONANDPIPING CHAPTER In order to prevent occurrence periods with best efficiency and

of vibration and noise and to operate the pump over long safety the following points must be observed at the time

of installation and piping.

l . PLACE OF INSTALLATION & FOUNDATION4 SUCTION PIPING The piping on the suction side affects pump effi-

(1) Size of the place of installation must be chosen in view of the pump disassembly and inspection. A space necessary for disassembly is shown in the outside drawing.

ciency to a great degree and to avoid troubles arising there from the following points must be noted.

(1) No air pocket must be formed in the piping.

(2) The foundation must be strong enough to absorb pump vibration and to resist deformation against

(2) All fittings in the piping must be perfectly

10ng use.

tightened to prevent air invasion.

(3) The pump is placed on its foundation. The

(3) Care must be taken to prevent air leakage th-

driver with its bed is placed on its foundation with the bearing ( 401 ) complete fast-

rough glands of all valves in piping.

(4) The suction piping must be thoroughly cleansed

ened at the bottom of the driver's bed.

so that pipe scale, welding beads and other

In this case, confirm that the distance "E" shown in the outside drawing, between the end faces of

the coupling halves on the pump shaft end and the intermediate shaft bottom end must be as shown in the drawing. The permissible error of this distance "E" is :t2mm. (Refer to Fig. 2.2).

foreign matter do not remain, otherwise seizure and other troubles may result. 5

ALIGNMENT

Tables 2.1 and 2.2 show permissible errors in ali-

gument when the pump and driver are connected

2. FINISHING OF PUMP MOUNTING SEAT Chockliners must be welded on the foundation place just under the pump foundation bolt holes and their faces must be planed so that they lie in

a perfect plane. When the foundation bolts are tightened leaving gaps between the liner faces and

pump bed, deformation may be given to the pump and besides vibration may result.

through the intermediate shaft.

When installations of the pump and driver have been finished it is necessary to check the alignment

and if the errors exceed those shown in Tables 2.1

and 2.2 adjustment is needed. This work is also necessary when pipings for them have been finished.

When the alignment has been completed set the driver's bed and the pump bed on their foundation by driving the dowel pins.

3. CAUTION FOR PIPING Deformation given to the pump by outside force due to incorrect piping causes not only vibration but also pump troubles. Therefore, the pipe flanges connecting with the suction and discharge nozzles must be correctly matched. Be sure to avoid the

cases shown in Fig. 2.1 otherwise the pump may receive unreasonable force. Nor must the pump be directly given deformation due to the total weight of piping and thermal expansion.

Table 2,1 Between driver & intermediate shatt

Paranet misangnment A Angutar misalignrnent B at coupling (mm) at coupling (mm) Below O . 2 (Between centers)

Table 2.2

Between intermediate shaft & pump

Parallel misalignment A

at coupling (mm)

Below 0.4

(Between centers) Fig. 2.1

PIPING PUMP

Angular misalignment

C

J

Parallel m isa I ign ment

F Iange faces

do not touch

g

Below 0.2

suINKO INO.LTO.

Angular misalignment B at coupling (mm)

Below 0.4

5.1

(1)

5 .2 Between intermediate shaft and pump

Between driver and intermediate shaft

(1) Measurement of paranel and angular mis-

Measurement of parallel misalignment As shown in Fig. 2.2, fix a dial indicator on the coupling at the intermediate shaft upper end for the alignment so that its spindle rests on the periphery of the coupling on the driver.

alignments As shown in Fig. 2.2, fix dial indicators on the

temporary shaft to be provided for the alignment so that their spindles rest on the periphery and the face of the coupling half on the

Give one complete turn at the same time to both coupling halves on the driver and the intermedaite shaft and read the difference

intermediate shaft. Give one complete turn at the same time to both coupling halves on the pump and intermediate shaft and read the difference between the maximum and mini-

between the maximum and minimum readings on the indicator. (2)

Measurement of angular misalignment In the same way as above, give one complete turn to both coupling halves at the same time

measure the gap between the coupling faces (e.g. at each 90 deg.) using a feeler gauge, and

read the difference between the maximum and minimum measurements.

mum readings on the indicators.

6. PERMISSIBLE DEFORMATION OF BELOWS WHEN FITTED (1) Elongation or contract in vertical direction :!:lO mm.

(2) Angle deviation (Refer to Fig. 2.3) 5 deg.

(3) Perpendicular deviation (Refer to Fig. 2.4) Fig. 2.2

:!:8 mm. Driver

Fi9. 2.3 Fi9. 2.4

~ ~

50

,,,

~]

~r

FEELER GAUGE

'It,

li

tl

ll

Parallel

mi: misalignment

~8

A /

[

7. FITTING OF FLOATING SHAFT (LOWER INTERMEDIATE SHAFT) It is strictly prohibited to fit the floating shaft

( 432 ) upside-down due to an abnormal thrust

BE L LOWS Angu I ar m i$ m isa I ignment

force is given to the pump bearing. It is therefore special attention should be paid for that the floating

shaft with the coupling marked with "C" is to be

fitted up and the other side marked with "PC" down.

B~c

E

TEMPORARY SHAFT

Pum p

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SuINKO INO.LTD. C

)

CHAPTER 3OPERATION 1 . CHECK BEFORE OPERATION

2. STARTING

When operating for the first time after installation

(1) Close the discharge valve completely and open

or overhaul and assembly, it is necessary to do as

the suction valve fully.

(a) When the liquid level at the suction side is

foilows.

(1) Take off dust preventing tape placed on the part where the pump shaft es through and take care so that no foreign matter enters the clearance around the shaft.

(2) Give some oil to the mechanical seal. (Refer

to " MECHANICAL SEAL") (3) Give a few turns to the coupling by a turning

above the pump the liquid flows into the pump casing by gravity, so open the air vent valve on top of the volute casing to draw the air in the pump and close it when the liquid begins to flow out of it.

(b) When the liquid level at the suction side is below the pump draw the air in the pump and suction line through the gas vent on the volute

bar and see if it turns normally.

(4) Confirm if the rotation direction of the driver is correct.

(5) Confirm if the grease in the bearing housing and the oil in the gear coupling, if fitted, is within the specified amount. (6) Confirm if the driver is ready for the operation.

casing by means of stripping pump or some other extracting devices so that liquid can fill the pump inside. In this case keep the air vent

valve closed so that no air can enter the pump casing. Never neglect priming the pump.

(2) Start the driver gently and increase its speed gradually .

(3) When the discharge pressure has risen reasonablly, open the discharge valve gradually and fully .

3. STOPPING (1) Close the discharge valve.

(2) Stop the driver.

C

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SnINKO INo.LTb.

CHAPTER 4 MAINTENANCE In order to eliminate pump troubles, to minimize parts consumption and repair and to maintain best efficiency over long periods the operator must aim at perfect maintenance of the pump.

1 . CAUTION DURING OPERATION

(7) With lowering of the liquid level at suction side

(1) Never throttle the suction valve in any case during operation otherwise troubles may occur due to dry operation.

(2) Never operate the pump for over 3 minutes with discharge valve completely closed. When a centrifugal pump is operated without discharge, most of the power changes into heat and as a result temperature of the liquid in the pump casing rises to the boiling point causing seizure of the interior of the pump and accident

suction pressure approaches the vapor pressure

of liquid and vapor develops in the suction line and pump suction inlet and, moreover, air is sucked through the suction bell-mouth until pumping ability decreases to such extent that discharge stops.

In order to prevent this, vapor and air coming

into the pump inside must be drawn through the vent on the casing by means of stipping pump or some other extracting devices.

(8) When cavitation occurs even though the pump

may occur.

(3) Never operate the pump with dry condition. (4) Except that the driver is with the constant speed like electric motor, keep the discharge valve open in full and it is desirable to adjust discharge flow by changing speeds. The adjust-

ment of discharge flow by the degree of dis-

charge valve opening is not recommendable because of loss of driving energy.

(5) When operating more than 2 pumps in parallel be sure to keep the discharge pressure of each pump always equal. If the speed of some pump decreases during operation and its shut-off pressure drops below the discharge pressure of the remaining pumps, it is operated wlth zero flow even though its discharge valve is opened and thus the result will be the same as mentioned in (2) before in this chapter.

In such a case try to make the speed of the pump in question same as those of the remaining pumps, and if this is impossible stop that pump immediately.

(6) When operating the pump at the rated speed and with the discharge valve open in full available NPSH decreases as the liquid level at the suction side lowers and finally discharge becomes zero due to cavitation.

In such a case pumping ability can be restored if discharge is decreased, so for the reason

mentioned above lower the speed without throttling the discharge valve as the liquid level at the suction side drops.

g

speed becomes minimum, discharge must be decreased by throttling the discharge valve. If this remedy is ineffective stop the pump.

2. BALL BEARING (1) In consideration of lubricating ability of the

grease and running clearance of the bearing due to thermal expansion and liquid temperature pumped, the bearing temperature is so designed as to stand up to 900C.

However from viewpotnt 6f service life it is desirable to keep it below 750C. (2) For the lubrication of ball bearing grease is used.

The recommendable grease and the interval of replacement grease are shown in Tables 4.1 and 4.2.

(3) For supplying grease for the bottom ball bearing, take the grease drain plug away.

3. MECHANICAL SEAL (1) Cautions before starting and during standstill Care must be taken so that no dust enters part(a) in Fig. 4.1 .

Pouring lubricating oil in (a), when the pump is at a standstill , will prevent dust from sticking.

If dust accumulates here and sticks hard seal ring (544) may stick and sliding face (S) can not be tightened. When the pump is delivered, a strip of cloth tape is put over the gap around

the impeller shaft to prevent foreign matter from invading.

SnINKO INlo.LTb. C

)

Fig. 4.1

(a)

11

l

~~~ ~~~~ T i J / ~fjiUg A_

(~)

[i)lug ~

~ e m o v el Q) ci

L/~

ELo

>

\:~emove~

/ I LJ+- ---

r r~

U t/~

(b) Fill oil through an oil plug hole on the

T)

coupling by using pistol oiler till the oil

EL c]

~)

begins to flow out from the other oil plug

Ll

hole on the opposite side.

(3) Leaking from mechanical seal

Co u i) I i ng

Under normal operational conditions there is no leakage, but in case there is a leakage of over 30cc/h there must be some trouble inside,

A I ,' ga p Ov e "' f t ow

so a remedy must be taken as early as possible. (4) Heating of sliding parts and abnormal noise.

O-ring Gear oi ( so

vc}4so-~80)

Insufficient flushing to the sliding face causes

O rin~ CouJling

abnormal wear down of the carbon due to

heating and dry . If flushing temperature rises to more than 10~C above the liquid temperature being pumped, it is

(C)

C

o

'i

the coupling with Teflon seal tape on them.

When operated under the condition of dry

Apply several turns to the shaft so that

, abnormal sliding noise may occur.

the oil may reach the interior of the coupling. If too much oil is filled,

(1) Misalignment between pump and driver Since the gear coupling has sel~alignment action to some extent, small misalignment within the permissible values shown in Table 2.1 and 2.2 can be absorbed.

However the excessive misalignment causes t,oo much slip between the teeth and as a result

wear becomes excessive, vibration occurs and the coupling may be damaged. (2) Lubrication Lubrication oil has a very important function in

reducing friction and wear and in hydraulically

distributing pressure on the gear flanks by forming oil film in the gap between them.

The recommendable oils and the interval of replacement oil are shown in Tables 4.1 and 4.2.

(3) Filling lubricant oil

excessive oil may leak from the key way but this is acceptable because necessary oil is kept in the coupling.

5. BULKHEAD STUFFING BOX (Standard) (1) When operating for the first time after repacking the stuffimg box tighten once the gland firmly before starting, then loosen the gland nuts to such extent that the coupling can be turned lightly by turning bar.

(2) Supply grease to the gland packing for lubricating and to keep gas-tightness between the pump room and engine room. The recommendable greases and the interval of replacement grease are shown in Table 4.1 and 4.2.

(3) Start the pump and adjust the gland nuts gradually and evenly. If the gland is tightened suddenly or too much or unevenly there may be a danger of seizure of overheating.

(4) If the packing becomes deteriorated the

(a) Remove two oil plugs.

tightness can not be kept no matter how much the gland is tightened.

In such case renew the packing.

c

J

g

r

After the oil, puttwo twoluplugs backtoto After filling fillin the oil ut s back

necessary to trace the cause and remove it.

4. GEAR COUPLING (Standard)

e

SuINKO INO.LTO.

6. MAINTENANCE CHECK LIST Maintenance and check for the followings can extend a life of the pump.

Item Suction pressure

Remedy in case of trouble

Inspection procedure

Check every tinre if there is any

Stop pump immediately and check suction

abnormal pressure drop

line .

In the case of above ambient temperature Bearing temperature

plus 40~C or above 85~C, stop pump and

Check and record every time.

eliminate cause. Lubricating oil

Ball bearing

Check oil in gear coupling every time

Supply oil if necessary.

through oil hole on it.

If abnormal noise or overheating occurs, stop pump and eliminate cause, and renew

Check abnormal noise every time.

ball bearing if necessary.

Mechanical seal

Vibration

Check leakage, heating, noise every

Stop pump and remove cause.

t ilne .

Check alignment.

Check vibration every time.

7. LUBRICANTS (D Replacement oflubrication

Table 4.1

The replacement of the lubricants is based on deterioration or contamination of the lubricants

Replacement

being used. However, Table 4.1 shows

Location

recommendable replacement. (2) Lubricants

After initial start

Normal o peration

Within 3 months

Ball bearing

NLGI No. 2(National Lubricating Grease

Every year

Institute) for grease for the ball bearing on the

Every 6 months

Gear Coupling

pump and intermediate shaft and for its stuffing

box, and for the gear coupling, ISO VG 460680 gear oil are recommendable. The brand names of the lubrjcants equivalent to the recornmendable ones are shown in Table 4.2.

,, Every o peration

Every o peration

Bulkhead stuffing box.

(3) Grease amount

cV 350

CV 400-2

Cv 450

cV 500-2

Pump upper side bearing (g)

50

50

110

150

Pwnp lower side bearing (g)

30

30

70

110

70

70

110

150

70

70

110

150

240

240

280

300

cV 350

CV 400-2

CV 450

CV 500-2

180

180

180

310

130

130

130

190

130

130

130

190

Pump model

Intermediate shaft upper side bearing(g)

Intermediate shaft lower side bearing (g)

Bulkhead stuffing box (g)

(4) Gear oil amount

Pump model Turbine side gear coupling (cc) Intermediate shaft side gear cou pling(cc)

Pump side gear coupling (cc)

8. STANDSTILL When there is a fear of freezing, drain the pump completely after stopping.

In case of a long standstill, clean each

sliding part thoroughly and apply rust preventive where necessary.

g

SHINKO INb.LTO. c

)

Table 4.2 Gear Oil (fSO VC 680)

Crcase (*NLGI N0.2)

~lame of compan,_'

DAPtiNE SUPER CEAR O[L 680

IDEMITSU KOSAN DAPHNE EPONEX EP2 BEACON EP2 LISTAN EP2

Dxxorl

SPARTAN EP 680 MOBIL VX 2 MOBIL PLEX 47

MOBIL OIL

MOBIL CBAR 634 OR 636

NIPPO~' O]L

EPINOC GREASE AP2

BONNOCK M 680

CALTEX OIL

MLfLTIFAK EP2

MEROPA LUBRICAr,T 680

JoMo

LISONIX GREAS!~ EP2

REDUCTUS 680

MITSUB[SHI OIL

DIAMOND MULTIPURPOS N0.2l][AMOND GEAR LUBE SP 680

GULF OIL

CULF CROWN GREASE NO 2 CLILF EP LUBRICANT HD680

BP OIL

BP ENERGREASE MM-EP-2

BP ENERGOL CR-XP 680

TEXACO OIL

MLfLTIFAK N0.2

TEXACO MEROPA 6~O

CASTROL

SPHEEROL AP2 OR EPL2

CASTROL ALPtlA SP 680

COSMO OIL

COSMO CEAR SE 68(] COSMO C•REASE DAINAMAX N0.2 ALVANIA GREASE N0.2 AL1/A*NIA CREASE EP2

SHOWA SHELL OIL

O~IALA OIL 680 GENERAL SP CEAROL 680

GENERAL OrL

GEMICO GREASE MP-2

ELF

EPEXA 2

EPONA Z680

CHEVRON

DURA-LITH GREASE EP2

~L GEAR COMPOUND 680 or EP680

AND LIMIT OFUSE 5 STANDARD CLEARANCE CHAPTER The bigger the clearance between impeller and mouth ring becomes, the more the counterflow from discharge side to suction side becomes, and consequently pump capacity decreases. Unit :

Table 5.1

Model

Name of parts

New parts S t and ard

clearance a Im peller an d

el

d~~L

mouth ring

Floating seat

of mechanical seal

C

J

rb

a

b

15.9

1.5

13

400-2

0.35

15.9

1.5

13

450

0.40

15.9

1.5

13

0.40

15.9

1.5

13

! 5 OO*2

g

Length b

0.35

CV 350

a

Limit of use

SnINKO INO.LTD.

mm

6 DISASSEMBLING AND AssEMBLING CHAPTER 1.

DISASSEMBLING

Fig. 6.1

mouth

In order to replace impeller, ban bearing, ring, etc., disassembling of pump is carried

out as

follows.

1 .1 Removal ofvolute cover (1) Remove the sealing pipe for the mechanical seal.

(2) Loosen the nut for the mechanical seal cover (146) until the mechanical seal cover moves and touches the flinger (48).

(3) Remove the volute cover nuts and move the volute cover (2) forward by using the two

I I \ \ \\

lifting bolts. L1

l .2 Removal ofrotating element (1) Remove the coupling bolts.

(2) Remove the bearing housing cap after removing the nuts fastening the cap.

(3) Take out the rotating elements together with the bearing inner case (14), bearing covers (9 & I O), ball bearing, etc. with paying attention

to the mouth ring (38) and mechanical seal.

l.3 Removal ofball bearing

(1) For the upper bearing, remove the coupling

1 .4 Removal ofmechanical seal Since the mechanical seal for this pump has a large spring compression allowance and force, the special tool provided must be used for re-

after removing the snap ring (70-1).

moving the mechanical seal and ball bearing

Remove the bearing cover (9). Make straight the rotation preventing piece on the washer (354) which is bent into one of the slots along the bearing nut (353) periphery and remove the bearing nut.

from the shaft.

(1) As shown in Fig. 6.2 hold the tool in such a way that the spring force does not act upon the flinger (48), and maintain not to transmit directly to the mechanical seal the shock produced when the ball bearing is removed.

(2) For the lower bearing remove the bearing cover (1 O) and the snap dng (70-3).

(2) Remove the ball bearing and flinger from

(3) Compress the mechanical seal spring by using the special tool provided as shown in Fig. 6.2

and also mentioned m "Removal of mecha

the shaft .

(3) Loosen the special tool bolts to reduce the spdng force and remove the special tool as

nical seal".

shown in Fig. 6.3 .

(4) Since the ball bearing is pushed lightly onto the shaft, it can be removed wlth the inner

(4) Remove the mechanical seal from the shaft.

case by using puller. Fig. 6.3

Fi9' 6,2 SPEC,AL TOOL ,SUPPL,ED,

~ '."=" '

- 5cnl

BALL BEARINC

SPRINO STOPPE R,NG

ET SEAL SCREW RtNGFLOATfNG SEAT

FLING R

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snINKO INO.LTO. C

)

l .5 Removal ofimpeller The impeller shaft diameter where the impeller

(2) Take care not to injure sliding face and "O"

(16) is fitted is the largest and gets smaller to-

(3) When fitting be sure to apply lubricating oil

ward either end. Fixing the impeller is by the impeller nut (27) at the upper side and by the split ring (70-2) at

ring by hitting or scoring.

to "O" ring .

(4) Referring to Fig. 6.2 the floating seat (54-1)

the lower side.

(1) Remove the setscrews on the impeller nut (27) and remove the impeller nut after re-

(carbon) must be inserted by hand until it touches bottom of the cover (146) firmly taking care not to injure sliding face.

(5) Place the stopper ring (54-7) against the shaft

moving the ball bearing, the flinger and the

shoulder which forms fitting base and tighten

mechanical seal.

it by th*e setscrew.

(2) Remove the impeller from the shaft. However, if it is difficult to remove the im-

(6) Confirm the winding direction of the spring

peller from the shaft, warm the hub of the

if it is suitable for the rotation direction of

impeller slightly to ease working.

the pump. Refer to Fig. 6.4.

(7) Fit rotating elements of the mechanical seal

2. ASSEMBLING

and the cover (146) onto the shaft.

Assembling can be carried out by reversing order of disassemblirrg and attention must be paid to

(8) Afterward, apply the special tool and compress the spring evenly as shown in Fig. 6.2.

the followings.

(1) Clean each part thoroughly to remove rust

(9) Fit the flinger and the ball bearing onto the

and scale, and be sure there are not injury and

shaft, Ieaving the special tool as it is as shown

burr in fitting parts.

in Fig. 6.2 to compress the spring until the rotor is settled in the volute casing.

(2) Assemble fitting parts according to match

(lO) After settling the rotor in the volute casing

marks if any.

remove the special tool.

(3) Turn nuts for rotating parts securely and fix anti-rotation device without fail.

(4) Be sure to thoroughly cleanse the ball bearing

Fig. 6.4

with pure kerosene taking care to keep off dust and foreign matter.

STOPPER RING

2.1 Alignment Aligument is to be confirmed if it is within

STOPPER RING SEAL R ING

SEAL RING /

the specified limit shown in Tables 2.1 and 2.2

l

l

in " ALIGNMENT" . Right-hand winding

L eft -ha nd

winding

2.2 Assembly of mechanical seal

Use the special tool for assembling the mechanical seal as shown in Fig. 6.2 and 6.3.

IMPELLER SHAFT

(1) Slidmg face "O" rmg and "O" ring groove must be claned with leadless gasoline and wiped with soft cloth taking care to keep off dust and other foreign matter.

C

J

g

SHINKO INO.LTO.

IMPELLER

CHAPTER 7TROUBLE REMEDIES SHOOTING AND Pump can perform satisfactory function if properly handled and maintained.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest causes of trouble and suggested remedies.

Table 7.1

Troubles

Remedies

Causes 1.

Pump not completely or insufficiently

1.

Prirne once more,

2.

Check suction line. Check suction line. Check by suction gauge on suction side.

filled with liquid. 3.

Much air leakage in suction line. Air pocket in suction line.

3.

4.

Suction lift too high.

4,

2.

Pump cannot discharge

Wrong direction of rotation. 6. Suction strainer and suction line clogged. 7. Speed too low. 8. Impeller clogged, 5.

Check. Check interior of suction line.

7. 8.

Check by tachometer. Check pump interior.

1,

Air leakage.

1.

Check suction line and stuffing box,

2.

2.

3.

Speed too low. Discharge head too high.

3.

4.

Suction lift too high.

4. 5.

Check by tachometer. Check by discharge gauge. Check by suction gauge. Check.

6.

Check interior of suction line.

7.

Check pump interior. Check. Replace mouth ring by new one.

Suction pipe bell-mouth not sufficiently submerged , 6. Suction strainer and suction line clogged. 7. Impeller clogged. 8. Wrong direction of rotation. 9. Excessive clearance between impeller 5,

Insufficient discharge

5.

6.

8.

9.

and mouth ring. Pump discharges liquid after starting, but soon fails to discharge

Pump not sufficiently filled with liquid Air pocket in suction line.

2.

Much air leaks into suction line. Air leaks through stuffing box.

4.

Check suction side. Check if mechanical seal is incorrectly fitted or carbon is broken.

1.

Speed too high (Power frequency too

1.

Lower speed, (Frequency)

2.

high) Impeller touches mouth ring.

2.

Check state of installation and

3.

alignment. Replace shaft by new one.

4.

Check if undue force is given by piping.

5.

Check power source,

1.

2. 3.

4.

Prime mover overload

Rotating elements touch stationary element due to bent shaft. 4. Casing deformed. 5. Voltage too low (Constant input, but 3.

1.

3.

Prime sufficiently. Check piping and if wrong correct it.

increase in current) in case of electric

motor driven.

g

SHINKO INO.LTb. C

j

Troubles

Remedies

C auses 1.

Grease is too little.

1.

Supply grease.

2.

Grease is too much. Grease has improper consistency or

2.

Remove grease.

3.

Replace grease with specified new one.

3.

it is deteriorated.

Overheating of bearing

4.

Misalignment is great.

4.

5.

Shaft is bent.

5.

Injury or too much wear in ball

6.

Correct alignment of pump and driver. Replace with new shaft. Replace with new ball bearings.

7.

Check if impeller is clogged and if

6.

bear ing. 7.

Too much thrust force.

clearance between mouth ring and impeller becomes too much, and correct them if any.

Abnormal noise in

1.

Injury in balls or rolling face.

2.

Too much clearance due to abnormal

3.

wear. Abnormal wear in retainer.

1.

Misalignment.

1.

2.

Shaft bent. Impeller partially clogged with foreign

2.

ball bearing

3.

Replace with new ball bearing.

3.

Check alignment of pump and driver. Renew shaft. Check pump interior.

matter. 4.

Incorrect installation.

4.

Check state of installation.

5.

Weak foundation.

5.

Measure vibration up and down, right and lieft around pump's mounting on

Vibration in pump

foundation, if vibration is too great

reinforce foundation. 6.

Suction and discharge pipings not

6.

Rotating elements touch stationary elements.

7.

1.

Injury or excessive wear down in

1.

2.

rubbing faces. Foreign matter in rubbing faces. Insufficient tightening of mechanical

7.

3.

Remove mechanical seal cover and check rubbing faces.

2.

Ditto.

3.

Check if cover bolts are evenly tightened.

Break down of "O" ring.

4.

Leakage in mechanical seal

Check pump alignment and bending of sh af t.

seal cover. 4.

Refer to "CAUTIONS FOR PIPING", and give necessary .

sufficiently secured.

Check "O" rings for stationary and rotary rings.

s.

Insufficient tightening of setscrew for

5.

Tighten sufficiently setscrew.

6.

Replace with new shaft.

stopper ring (54.7). 6.

7.

Heating of mechanical seal (Sometimes

Injury or wear down of part of shaft s. Scale sticks in groove for "O" rmg (54-5), causing rotary ring to stick and rubbing faces to open.

7.

1.

Flushing is insufficient.

1.

Check if flushing pipe is clogged.

2.

Pump operated dry.

2.

Stop pump immediately.

accompanied by abnormal noise)

C

J

Disassemble and remove scale com pletely.

g

SuINKO INO.LTO.

PARTS CHAPTER 8 REPLACEMENT When ordering replacement parts, include the following information. 1 . Ship's name

2 . Shipbuilder and hull number

3 . Service and model of the pump

4. Parts' numbers and names shown in this instruction manual

NAME OF PART

PART NO.

PREssuRE GAUGE

71 IO l

71 1 1

l

R EQ.

PUMP SUCTICN PUMP DISCHARGE

1 1

UJ cg

l

::)

o LU a: :D

U' Q8 LU c::

If

t

l

7 22 1

TH ERMO-SW,TCH ( tf fitted)

7221 .1 1

PUMP CASING

1 set

INSTALL THREAD

1

1 set 7222 PUMP BEARING COUP. SIDE 7222- 1 1 ll

7223 !:

t

7221 -1 1

I 7222_1 1 7223.1 1 7225-1 1

o H ~ o 2 ~c

7223.1 1

INSTALL THREAD PUMP BEARING END

1

StDE 1 set

INSTALL THREAD

7226 BULKHEAD STU FFING

1

1 set BCX

Cl]

7226.1 1

INSTALL THREAD

1

uJ :E

H

7221 7 222 7 223

7226 l

,~5l

g

SNINKO IND.LTD. C

)

PISTONPUMP (KPH ) STEAM DRIVEN MANUAL OF INSTRUCTION

This instruction manual describes construction, installation maintenance, disassembling, assembling and trouble shooting of model KPH pump.

, operation, and remedies

CONTENTS Page

CHAPTER 1 CONSTRUCTION . . . . .

• 96A- 2

.2 .2 .2 .2 .2 .2

1. General . . . . . . .

2. Steam cylinder 3. Steam chest . . .

4. Liquid cylinder 5. Valve box . . . . . 6. Pump Valve . . . .

PIPING . . . CHAPTER 2 CAUTION FOR INSTALLATION AND

l. Place of installation and 2. Finishing of pump mounting

96A-3

foundat i on

3

seat . . . .

3. Cautions for piping . . . . . .

3 4

4. Suction piping . . . . . . . . . . .

CHAPTER 3OPERATION . . . 1. Preparation 2. Starting and

9 6A- S

for operation running . . . .

3. Stopping . . .

.S .S

4. Caution . . . .

S

CHAPTER 4MAINTENANCE AND INSPECTION l. Maintenance . . . . . . . . . . .

2. Normal inspection . . . . . 3. Lubricating oil . . .. .. .

ASSEMBLlNG CHAPTER S DISASSEMBLlNG AND l. Disassembling 2. Assembling .. .

ANDREMED I ES SHOOTING CHAPTER 6 TROUBLE

• • • • 96A-6

... 6 .... 6

... 6 . 96A-7 7 7

. 96A-8

• • • • • •, 96A-9 ADJUSTMENT OF • PISTON STRO

SUPPLEMENTATION

Cg I snlNIKolNo.LTo.

C)

CHAPTER lCONSTRUCTION l . GENERAL

The model KPH pump is a steam driven direct

action

p u mp

of the

worthington

t ype .

Fig. 1.l

2. STEAM CYLINDER The steam cylinder block has 2 cylinders.

'~~ (,1,

l 69

75

4 8

20

3. STEAM CHEST The steam chest block has 2 cylinders and distributes steam to the steam cylinder.

32

36

30

4. LIQUID CYLlNDER The liquid cylinder block has 2 cylinders which are provided

43

47

s.

76 171

T70

28

210

45

191

48

204

26

2oe

171

207

77

Ill

~'i~ 203

(1) The top and bottom valve boxes are cast separately and connect-

ed together on both sides by connecting pieces. (2) Both boxes are identical in construction and dimensions, and each contains suction and discharge valve chamber. (3) The suction valve chamber is divided into two chambers, each of which is open to the liquid cylinder. (4) Of both connecting pieces, one

serves as suction age and the other as discharge age,

with suction and discharge openings respectively. PUMP VALVE Both suction and discharge valves are of the flat type. The suction valve is fixed by pulling from the bottom by means of setscrew stay(208) and the discharge valve is fixed by pressing from the valve box cover by means

70

~~~20sA

.~ ~f",E ~,,1

.~/14 ~,~~ 11 ,

201

\Jl

208

PART NO.

AEQ NO

l PAR NAME OF PARTFOP PUMP NO.

l

STEAM CYLINOER

4

l STEAM CHEST STEAM CHEST LINER 2

8 ll

76

l

LfQUID CYLtNOER

77

20 STEAM PtSTON

NArnE OF PART

REQ NO FOR I puedP

STEAM PtSTON ROD2SETS GLANO PACX,NG LIQU,O PISTON ROO GLANO PACXING 2SETS

169 VALVE ROO TOP GLANO2 VALVE ROO 80TTOM 2

l 70

l

14 LIQUID CYLtNOER LINER 2

171

GLANO PISTou ROO GLANO

4

191

VALVE BOX

2

2SETS

23 STEAM P,STON R,NG 4

24

STEAM PfSTOW ROD 2

26

LtQUIO PISTON ROO

2

201 SUCTION VALVE SEAT8

28 FRONT COLUMN

l

30 BACK COLUMN 32 PtSTON VALVE

2

202 DELtVERY VALVE SEAT8 203 SUCTtON VALVE GUARD 8

2

204 DELIVERY VALVE GUARD8

35 PtSTON VALVE RING 3G VALVE ROO

8

205 VALVE

16

205A VALVE DISC

16

2 43 ROCKtNG LEVER SPINOLE

206 VALVE SPRING

16

45 ROCKING LEVER 47 CROSSHEAO

2 2

8 207 VALVE STEM 208 YA~ VALVE SETSCREW 8

48 CROSSHEAO PIN 7o UQUID PISTOfl

2

210 JACK 80LT

73 UQU,O P,STON Rt~3

2

GLANO PACXlrG

8

2SETS 4

241

ESCAPE VALVE OOX

RCO 80TTOM 74 VALVe 2 SETS 243 VALVE GLANO PACKI~3 VALVE aoO TOP 75 2SETS ~6 SPRt~G

g I snINKOINO.LTD. )

73

.J

chamber, suction valve chamber,,

of jack boltC210) .

74

/~~ ~/256 ~ 202

VALVE BOX

6.

' 24

35

with liners(14) .

C

~)

l 1

l

CHAPTER 2 CAUTIONS FOR INSTALLATION AND PIPING

In order to prevent occurrence of vibration and noise and to operate the pump over long periods with best efficiency and safety the following points~ must be observed at the time of installation and piping. l. PLACE OF INSTALLATIO\1 AND FOVNDATION

(1) Size of the place of installation must be chosen in view of the purnp's Space necessarY for disassembly is shown disassembly and inspection. in the outside drawing.

(2) The foundation must be strong enough to absorb pump's vibration and to resist deformation against long use. 2. FINISHING OF PUMP MOUNTING SEAT Chockliners must be welded on the foundation plate just under the puJnp'S foundation bolt holes and their faces must be planed using a surface plate so that they lie in a perfect plane. When the foundation bolts are tightened leaving gaps between the liner faces and liquid cylinder, deformation may be given to the pump and besides vibration may result. The same precaution is necessary in the case of fixing the steam cylinder to the bulkhead if any, for if fitted incorrectly pump alignment will be disturbed and premature wear of sliding faces and other trouble will occur. 3. CAUTIONS FOR PIPING

Deformation given to the pump bY outside force due to incorrect piping causes not only vibration but also pump troubles. Therefore, the pipe flanges connecting with the suction and discharge nozzles must be correctly matched. Be sure to avoid the cases shown in Fig. 2.l otherwise the pump may receive unreasonable force. Nor must the pump be directly given deformation due to the total weight of piping and thermal expan s ion .

Fig. 2.1

P ip in g

P ump

Angular misalignment

Para I I e l

mi sa I i gnment

Flange faces do not touch

g I SHINKOINO.LTD.

c)

4.

SUCTION PIPING The piping on the suction side affects pump efficiency to a degree and to avoid troubles arising therefrom the following must be noted.

great points

(1) No air pocket must be formed in the piping.

(2) All fittings in the piping must be perfectly tightened to prevent air invas ion .

(3) Care must be taken to prevent air leakage through glands of all valves in the piping. (4) The suction piping must be thoroughly cleansed so that pipe scale, welding beads and other foreign matter do not remain, otherwise seizure and other troubles may result.

cg SHINKO INO.LTO.

C)

CHAPTER 3 OPERATION 1. PREPARATION FOR OPERATION (1) Open each drain valve, exhaust valve, suction and discharge valve. (2) Pour oil where required. (3) Keep bolts and nuts perfectly tight.

2. STARTING AND RUNNING (1) Warm up the steam cylinder by opening the steam valve a little. (2) The pump will begin starting if the steam valve is opened further gradual I y .

(3) Wllen drain stops completely, close the drain valve. (4) Open the test valve provided on the valve box cover and expel air inside completely. (5) Open the steam valve gradually until the steam pressure reaches required pressure at required revolutions, and begin operation if no abnormal point is seen in the condition of running. (6) When steam or liquid leaks excessively from the glands, tighten the glands further and keep a tiny amount of liquid leaking from the pump gl ands .

(7) In case the extent of steam valve opening is kept constant during the operation the revolutions will rise or fall in accordance with the variation of the liquid end pressure, but the operation must be carried out at the rated revolutions by adjusting the extent of steam valve opening. In case the speed exceeds 12S"', of the rated revolutions there will be a fear of abnormal wear in the steam cylinder and piston rings. 3. STOPPING (1) Close the steam valve. (2) Open the drain valve to draw out the drain. (3) After the pump stops, close the exhaust valve, suction and discharge valves .

(4) Before stopping supply a small amount of oil and give attention to the means of preventing rust. 4. CAUTIONS

In case that the pump works as cargo oil stripping pump, a special attention is to be given to the followings; It may happen that discharge pressure of the pump is suddenly reduced due to an oil level in the cargo tank becomes lower and then gases and air come into the suction pipe, resulting that the pump speed becomes higher, the pump stroke length becomes shorter and shorter and finally the pump stops. Under the circumstances mentioned above, the pump does not work satisfactorily with its capability but also it cames abnormal wear out of the steam cylinder quickly. In case that gases and air mixtured in the cargo come into the pump, it is recomlnendable to operate the pump with a reduced speed, Iess than a half of the rated speed, and, if remote control devices are fitted, 10cal operation is preferable due to a difficulty of delicate control by the remote control devices.

SfJlINKO INO.LTO. C

)

AN D INSPECTION 4 MAINTENANCE CHAPTER

1. MAINTENANCE

(1) Since the service life of the pump depends greatly upon whether maintenance is good or not, it is important to observe what this booklet explains and. not to make mistakes in handling. (2) When stopping the pump, keep each moving part in good condition, and where rusting is feared apply rust preventing oil. (3) When stopping over long periods, open the steam cylinder and steam chest and remove the drain completely, and apply mineral oil on the inner surfaces after cleaning the interior. However this oil must be wiped off cleanly before using the pump again. The same proceduse is also applicable to the liquid cylinder. 2. NORMAL INSPECTION (1) During operation it is necessary to inspect from time to time the status of lubrication and the bolts and nuts which tend to loosen, especially the cap nuts for the pump valve setscrew stay at the bottom of the valve box and lock nuts need attention so that they do not drop off during operation. (2) It is desirable to inspect at least once a year the parts invisible from outside such as steam piston, Iiquid piston and pump valves, even though no trouble occurs during operation. Too much time and cost will be needed when the cylinder walls are found to have been injured due to the unexpectedly great wear or breakdown of piston rings. (3) It is imperative to inspect the pump valves once a year after overhauling the valve box. Especially, the valve discs made of synthetic resin should be replaced by spare ones when they are enlarged or deparated by reason of the weardown of the central holes.

3. LUBRICATING OIL For the lubrication for the crossstand and crosshead pin, oil of ISO VG68 (International Standard Organization) is used. The brand names of oil which is equivalent to ISO VG68 are shown in the right table.

Table 4.l

CO~dO OIL

GULP OIL IDEMITSU KOSAN

MOBIL OIL

NIPPON OIL, CALTEX OIL SHOWA SHELL OIL

TEXACO OIL

J

PERFECTO T68

COSMO TURBINE SUPER 68

ESSO STANDARD VACUUM

NITSUBISH:1 OIL

c

BP ENERGOL THB68,77

CASTRO L

KYODO OIL

g

LUBRICATING OIL

NAJVIE OP COMPANY

BRITISH PETROLEUVI

SHINKO INO.LTO.

TRESSO 68

GULF HARMONY 68

DAPHNI TUEBINE OIL N0.68 RIX68 TUEBINE OIL DIANOND MARINE68 TURBINE OIL68

MOBIL DTE OIL HEA~ MOBIL DTE OIL HEAVY MEDIUVl

PBK 68 REGAL OIL ReO 68

TURBO T OIL68

REAGAL OIL E (R~O)

CHAP TE R5

AN D ASSEMBLING DISASSEMBLING

l. DISASSEMBLING

Disassembling of the pump in case of replacing the parts with spares, maintenance and repair work will be done by following orders. (1) Remove all accessories. (2) Disconnect valve rod from valve rod link and remove valve rod link.

(3) Remove lever spindle nut and take off each lever spindle and at the same time remove rocking lever. (4) After drawing out bolt on the crosshead, disconnect stearn piston rod from crosshead. (S) Remove steam cylinder cover, Ioosen gland, and after fitting eye-bolt to top end of piston rod, Iift. piston rod together with piston. (6) Remove crosshead from liquid piston rod by turning it. (7) Remove gland for liquid cylinder and then remove liquid cylinder cover.

(8) Fit eye-bolt to top of liquid piston rod and lift piston rod together with piston. (9) Loosen glands for steam chest. (10) Remove steam chest covers. C11) Take out piston valve.

(12) After removing cotter, split pin and nut from piston rod, draw piston from piston rod.

(13) Remove cap nut from valve adjusting screw loosen screw remove valve box cover nuts, and remove cover. (14) Take out discharge valve.

(lS) Remove cap nut from suction valve setscrew stay at valve box bottom and take out suction valve. 2. ASSEMBLING

Assembling can be carried out attention must be paid to the

disassembling and

fo 1 Iowing .

assembled in accordance with matching

Cl) The fitting parts should be marks if any.

(2) At assembling care should be fitting parts. (3) Care should be taken so that securely fixed.

g

order of

by reversing

taken so that al l

bolts,

no undue

nut s ,

f o rce

is given to

screws and pins are

SHINKO INO.LTD.

C)

CHAPTER 6TROUBLE SHOOTrNG AND REMEDI'*S

can perform satisfactory function if properly handled trouble occur speedy remedies must be found for it. shows commonest causes of trouble and suggested remedies. Pump s

Shou I d

and maintained. Table 6.l

Table 6.l Caus e s

Troub I e s

(1) Ste~tm too muc~h.

Remidies

(1) Jump at start ot~ stroke is mostly cCluscd b), tOo much s~te(Im, so trace

and eliminate caus~e.

Too much vibra tion ~ noise

(2) Liquid temperature too high.

(~) 11'hen liquid temperature it;_- too

high, jump and noise will re_sult, so it must be reduced. (3) Examine gland, pipe fitting etc. , and make them t;~ompletely airtight.

(3) Air leak~~ge.

In reL:lproc~tlng pumps, increas.~e in

Speed too high.

spGed tends to caus~e long stroking and as a result piston strikes~ cylinder covers, so decrease spced by throttling steam valve.

Piston strikes cylinder covers

(1) Foreign matter lodges in valve.

(1) Remove valve box cover and examine valve and put it in good ordcr.

(2) Piston ring LYorn or damaged.

C2) Dismantle and examine. Renew rlng if necessary.

(1) Gland not enough tightened. (2) Packing deteriorated.

(1) Tighten gland properly. (2) Renew packlng

(3) Pis~ton rod worn.

(3) Renew piston rod.

Damage by over

(1) Incorrect alignment.

(1) Correct alignment.

heat

(2) Invasion of foreign matter.

(2) Prevent invasion of dust and sand.

Slide valve adjustment is not

Dlsconnect valve rod and link, then adjust valve position by turning valve rod. However, adjustmcnt of righthand stroke length is adJusted by left-hand valve rod.

Decrease in pump discharge

Too much leak from stut~fing box

Both stroke lengths are not

correc t .

equa l

Steam or/and liquid piston rings are not in good condition. Small vibration

too closely, sliding resistance Increases, causing often vibratio.n,

especially at low speed. In such case, remove piston rings and examine them.

c

J

g

SHINKO INO.LIO.

OFPISTONSTROKE SUPPLEMENTATIONAD JU STMENT The adjustment of the piston stroke is made as follows in case of that the cylinder top or bottom is knocked under the rated operation (the rated discharge pressure, the rated suction head, the rated exhaust steam pressure and the

rated number of stroke).

A) For "H" and lost motion The pump was adjusted and set at the shop test so that the pistons move in the middle of whole stroke under the rated operation.

Therefore if something happens on board the

l,

ship, Iike that the piston knocks the steam

VALVEROb

cylinder top or bottom under the rated

l

LOCK NUT

operation, it is necessary to confirm first as

AD JUST I NG

follows that the adjusted value marked at the

~~

NUT~

shop test is being kept as it was.

I

LOST MOTloN L = 3~m

::r ~

l

,

1) To confirm "H" between the valve rod

AD JUST I NG

and the valve rod t is correct and

NUTC

same as that set at the shop test.

SPLIT PIN

("H" was adjusted at the shop test and has

been marked on the side of front column

~~~

VALVE ROD Jo I NT

P,No. 28)

If "H" is incorrect compared with one marked on the front column, it is adjusted

by moving the adjusting nuts.

(When reassembling after overhauling, "H" is to be adjusted and set the original

one which has been marked on the front column.) 2) To confirm the lost Motion L=3mm is being kept.

If L of 3mm is not being kept, it is adjusted by moving

the adjusting nut (A) and set by the lock nut.

B) For adjustment for piston stroke If the piston stroke in operation is unsuitable even though the A) mentioned before is confirmed corrrect, the adjustment is carried out as follows;

1 ) Relation between piston and piston valve a) To change the left side piston stroke is made by moving the right side piston valve up or down. b) To change the right side piston stroke is made by moving the left side piston valve up or down.

!~c~

SHlnKO InD.LTb.

SW~~'uSSrui;::~:i:S,:::~S' , > * *, ;#="+. * + * ' ' ' "' '*** '* ' cl

2 ) Adjustment for piston stroke A necessity for the adjustment to get a suitable piston stroke is confirmed under the rated operation otherwise the piston stroke under other operation conditions is different.

a) In case of the left side piston moves partially up and down at lower position (like the piston knocks the cylinder bottom) : It is so adjusted that the lock nut on the right side valve rod is loosened and

the adJustlng nuts (A)(B) are screwed In to make "H" small, resulting that the piston stroke range is

moved upwards as a whole. However, the lost motion L=3mm is to be still kept.

b) In case of the left side piston moves partially up and down at upper position (like the piston knocks the cylinder top) : It is so adjusted that "H" becomes big.

However, the lost motion L=3mm is to be still kept.

c) In case of the right side piston moves partially up and down at lower position (like the piston knocks the cylinder bottom) : It is so adjusted that the lock nut on the left side valve rod is loosened and the

adJustlng nuts (A)(B) are loosened to make "H" big, resulting that the piston stroke range is moved

upwards as a whole. However, the lost motion L=3mm is to be still kept.

d) In case of the right side piston moves partially up and down at upper position (like the piston knocks the cylinder top) : It is so adjusted that "H" becomes small.

However the lost motlon L=3mm is to be still kept.

e) After the adjustment the "H" is to be set with the lock nut and the split pin.

C) References l) In operation on board the ship, the piston knocks the cylinder top or bottom sometimes.

However, almost of these abnormal operations are caused by too low discharge pressure or too low exhaust sieam pressure or the both, which makes too small reaction power to stop the piston at dead points of the top and the bottom of the piston stroke.

Therefore , it is absolutely necessry to confirm a necessity for the adjustment of the piston stroke before hand at the rated operation.

2) It is impossible, for example, to only adjust the piston stroke shortened towards downwards in case of the piston knocks the cylinder bottom. Therefore, in this case, do not shorten the piston stroke towards downwards but adjust the piston stroke

moving wholly upwards.

c~~

C]

SHIN!KO IN:D.LTD.

CONTROL SYSTEM INSTRUCTION MANUALREMOTE OF FOR STEAM DRIVEN PISTON PUMP (KSC 65-lOO) This Instruction service of each

operation and type of

Manual describes the construction , equipment of KSC 65 - lOO .

CONTENTS Page CHAPTER 1GENERAL

''e'''O ,

e

,

O

e

t

,

e

CHAPTER 2CONSTRUCTION ANDPLACE OFINSTALLATION

CHAPTER 3OPERATION 1. 2.

,

,

e

,

,

,

e

,

,

,

t

,

Stroke transmi tter Stroke converter . S troke

,

,

,

,

,

,

,

e

,

o

,

,

,

3 3

' e ' ' ' ' , 97-4 4 e

e

e

e

4 4

counter .

A ND REMEDIES CHAPTER 5TROUBLE SHOOTING

,

o t 97~2

Stroke number control Stroke counter

CHAPTER 4TYPE OFSERVICE OF EACHEQUIPMENT l. 2. 3.

,

l

o

,

,

e

,

,

e 97~6 ,

e

~~ 1 sHINIKOlnD.a:~i~!' ' '

C)

CHAPTER l GENERAL

KSC 65 - 100 is a system which controls the (hereinaf ter called ffstroke number") of the "pump") from the cargo control after called of the tanker and at the same control room

Generally, the control stroke

reciprocating stroke number reciprocating pump (hereinconsole provided in the cargo time monitors pump operation.

cargo control console is provided number and a stroke counter.

with a

speed setter to

(Refer to CHAPTER ANDPLACEOF INSTALLATION 2 CONSTRUCTION

3.1)

Control Valve (1)

l . Steam Th i s

Fig .

is installed

on the

s t eam

inlet

pipe in the

supply .

s t eam

pump room and regulates

Transmitter (7)

2 . Stroke This is

mounted on the pump and counts pump stroke number .

3. Stroke Converter (8) This is installed in counter 4 . S troke

the englne room an d outputs signals

to the

Counter (9)

This is installed stroke number .

on the cargo control

console and indicates

pump

5. Speed Setter (5) Thi s s t eam

is installed on control valve

the cargo control console, and operates and regulates pump stoke number

c~ Sl~NKO IHD.LTO.

c)

stroke

t^h.e

CHAPTER 3 OPERATION (Refer to Fig. 3 . I )

l . Regulating the stroke number

The steam supply is controlled by adjusting the opening of the steam control valve provided in the pump room, which can be done by changing pneumatic signals within the range of 0.2 to I .O kg/cm2 by the speed setter provided in the cargo control console. 2. Indicating the pump stroke number

2.1 The stroke transmitter provided on the pump counts the punrp stroke number, and supplies air to the stroke converter or dischargeS the air out. By repeating these actions, the transmitter outputs a pneumatic signal to the stroke converter provided in the englne room.

2.2 Pneumatic signal from the stroke transmitter is converted into an electric signal by the stroke converter provided in the engine room and then the electric signal is outputted to the stroke counter 2.3 An electric signal from the stroke converter is converted into stroke number by the stroke counter provided on the cargo control console and then the stroke number is digital-indicated on the stroke counter.

Flg. 3.l CARCOCONTROL ROOM

5

9

RUN. tN D.

AIR

ELEC SOURCE LA"IP C=_ J,-_D_PY_C_!!1_.2_5_W2 .(AC ,COINOV Of 2001~~fl

_j~~~~~l

Cd~O

(6~7 kg/cm2]

.. - --1

l

I

I

l t

O~2k TO 1.0k

I t

-t

5;*l l l

l

t,,CNl

r;~T;~Tr!~;;:71

r!;TIT7r;~ITl

i

~] ENGINE ROOM xt

PUMP ROOM

Ul

>,Ll

Pl

!,I

Ai F~

I

te~7 ~glcm2,

I

l l

6A

STEAM

8 l l

AtR

EXHAUST

(6N7 k9/cm2]

1 4k

t

i

l , l

-J STR I PPING

7

PUMP

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EQUIPMENT CHAPTER 4 TYPEOF SERVICEANDADJUSTMENT OF EACH l . Stroke

Transmitter

The three-way air valve is employed as the stroke transmitter. Vertical movements of the pumpfs valve rod changes over the air age in the stroke transmitter. When the valve rod is in the the upward stroke, air pressure is outputted to the stroke converter. When the valve rod is in the downward stroke, air is discharged through the exhaust port of stroke transmitter, and air pressure is removed. Thus, the stroke transmitter ,repeats the above actions corresponding to the pump stroke number, by which a pneumatic *-ignal is made and outputted to the stroke converter. 2 . Stroke

Converter

The stroke converter converts air pressure signals outputted from the stroke transmitter into an electric signal and outputs it to the stroke counter on the cargo control console. The pressure switch is preset to be ON when air pressure reaches 1.1 kglcm2 When confirming the preset value, set the supply air pressure through the filter regulator(6A) (pressure reducing valve) mounted on the pump to 1.1 kglcm2 Then force the roller of the stroke transmitter in and confirm that the operation indicating lamp provided on the head of the stroke converter goes ON. If not, adjust the setting by the pressure setting screw on the head of the stroke converter until the lamp goes ON. After confirmation, regulate supply air pressure to I .4 kg/cm through the filter regulator. 3 . Stroke

Counter (Refer to

Fig. 4.1)

3.l

The stroke counter calculates a value per minute inversely in the signals outputted from the stroke converter and cycle of electric digital-indicates the results on the stroke counter.

3.2

Confirm as foll ows

and adjust if

(1)

Press the power switch

(2)

While pressing the push button indicates 30 rpm. When adjustuent is necessary, (9), adjust the volume (8) by

necessary .

(5) .

(9), confirm that

while pressing the push button uslng a screw driver .

c~ SHINKO IND.LTD.

c)

the meter (1)

(3) While pressing the push button (ll) to confirm operating indication, confirm that the meter indicates 5 rpm. If adjustment is necessary, while pressing the push button (ll), adjust the volume (6) by using a screw driver. (4) When the optional overstroke indicator is provided, while pressing the push button (lO)p confirm that the meter (1) indicates 40 rpm. If adjustment is necessary9 while pressing the push button (10), adjust the volume (7) by using a screw driver. (5) After the above adjustment (3) or (4), press the push button ( 12) .

3 . 3 Others

(1) The stroke number counting operation of the stroke transmitter installed on the pump can be confirmed by the flickering lamp ( 13) .

(2)standard Theone. external terminal to indicate operation ON/OFF of the to indicate operation can be confirmed by the lamp (2). (3) The external ternrinal to indicate overstroke (14) is optional.

On theoperation unitcanwith thisbydevice, overstroke be confirmed the lamp (3). ONIOFF •of the

3.4 Stopping the Pump and Stroke Counter For twenty (20) s~conds after the pump stops, the stroke counter indicates the stroke number which have been made before the punrp stops, and after that, it indicates O rpm which means the pump is not running .

When no signals from the stroke converter are outputted to the stroke counter for more than twent~ (20) seconds,' the stroke counter indicates O rpm to show that the pump is not running. As the circuit of the stoke counter has been designed not to indicate 3 rpm or less, the pump is in a waiting state for twenty (20) seconds (3rpm), and during this period if no signals are inputted by the stroke converter tihe stoke number is judged to be less than 3 rpm and the circuit is reset and O ~pm is indicated. Fig .

~•ig. 4.2

4.l

ELECTRIC WtRtNG DiAGRA,R

rl~~I str::::1:lTrt: ~r I COINT o L l

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STRtPPING PUMP

STROKE COUNTER

1

L~IIFI-O

C @ 4 @A GND @B~z @c @ @A C @ 8~J PUT @ @ C C ~ @ o C C Ov @

I,1 PUT

,:

+1 2V

13

6

15

1tt I r'

T1 Wl~~'1

P2taND' - It"I ll" I l

PD"'iaV' II:I l

12

UI-

2

'uNO e l 1 Au~ e ~~~

10 18 f-CJIJL-~

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lI

OulrpuTt~,

g

ACa~~V Act ta,lOOv F

o --

a2av ~ t lav S :

@ @

8 ,aJIN

tlav p3

zo

11

3 7

INPuT P,

GND P2 OIJTPUTf t,

+ o UT

N'~s

5

,~

STROJ'~ couNTLn

stroke converter

4

8 n uN :Olb,

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: ELECT,NC WIRE FOR $troke CaRVerter

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CHAPTER 5TROUBLE ANDREMEDIES SHOOTING

This system can perform satisfactory function maintained. In case any trouble should occur, at once. The following table shows the conunonest causes

if

handled and should be remedied

properl y

it

of trouble

and suggested

remedies .

Possible Causes

Trouble Stroke counter does not indicate

l

e

2,

Remedies

Power wlrlng is not connected

,

Power is not ON

l

,

2,

e

Connect wiring to terminal (18) at t he back of stroke counter

e

Switch ON power switch (5) of stroke counter ,

3 o Wrong wlrlng

connection between stroke

3 , Correct the connection

between terminal codes P2 and P3 or Pl and P3, Ref er to Fig . 4 2 e

stroke converter and counter ,

e

During

l

,

o peration ,

indication of stroke counter is always O

Pressure setting

of strokeconverter

l

,

is impro per .

Set pressure switch sO that it wi I l be ON at l 1 kg/cm e Ref er to 2 Chapter 4 ,

2,

Stroke transmitter is not operating properly .

3 e Air pressure of stroke transmitter is insuf f icient

2,

,

,

Check the operation . Ref er tO l Chapter 4

,

,

,

3 e Adjust air pressure so as to be more than l , 4 kg/cm with f ilter

regulator 4 , Wrong wiring

connection between stroke

stroke converter and counter ,

c~ SHm,(O INBl.LTD.

C)

( 6A ) ,

4 , Correct the connections of terminal codes Pl an

P2

,

Ref er to Fig .

4 2 ,

e

Possible Causes

Trouble

During

l.

o per.ation ~

Push but.ton (12) is not pressed .

f or

Remedies

measurement

l.

Press the push button

Make pump stroke number more than 5 rpm.

e

l

indication of stroke counter is always 5

Operation indicating l amp does not goes ON

1 -e

Pumpstroke number is less than 5 rpm.

l.

2.

Stroke counter setting

2. Set stroke counter to 5 rpm . Ref er to 3.2 (3) Chapter 4.

is . not

proper .

c~ SHIN:KO IN:D.LTD.

C~

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SHIN:XiOlno. L70. Head Office & Factory

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